r2r manufacturing of organic pv using gravure and rotary...

R2R Manufacturing of Organic PV Using

Gravure – and Rotary Screen Printing

Techniques

Plastic Electronics 2012, 9th October 2012, Dresden

J. Hast, P. Apilo, M. Välimäki, M. Ylikunnari, M.

Tuomikoski, R. Suhonen, S. Rousu

VTT Technical Research Centre of Finland

2 10/10/2012

© VTT 2012 – All rights reserved

Contents

VTT in brief

VTT printed electronics and R2R pilot facilities

Printing and OPV developments at VTT

Up-scaling from cell to module level

R2R printing of conventional and inverted structure OPV modules

ITO free printed OPV cells using Ag-nanowires as transparent

electrode

R2R printed OPV cells on flexible glass substrate

OPV demonstrators

Summary & Acknowledgements

3 10/10/2012


Customer sectors - Biotechnology,

pharmaceutical and food industries

- Electronics - Energy - ICT - Real estate and

construction - Machines and vehicles - Services and logistics - Forest industry - Process industry and

environment

Focus areas of research - Applied materials - Bio- and chemical

processes - Energy - Information and

communication technologies

- Industrial systems management

- Microtechnologies and electronics

- Services and the built environment

- Business research

VTT’s operations - Research and

Development - Strategic Research - Business Solutions - Business Development - Group Services

VTT’s companies - VTT Expert Services Ltd

(incl. Labtium Ltd, Enas Ltd)

- VTT Ventures Ltd - VTT International Ltd

(incl. VTT Brasil LTDA) - VTT Memsfab Ltd

VTT Group in brief

Turnover 307 M€ (2011) • Personnel 3,187 (31.12.2011)

Read more at:

www.vtt.fi

http://www.vtt.fi/

4 10/10/2012


Brussels,

Belgium

VTT on map

São Paulo,

Brazil

Shanghai,

China

Saint Petersburg,

Russia

Seoul,

South Korea

Tokyo,

Japan

• • •

•

•

Tampere

Oulu

Jyväskylä

Helsinki • • Turku Rajamäki

• Raahe

• Kajaani

Kuopio •

Finland

Lappeenranta

• Sodankylä

• Rovaniemi

Outokumpu •

Espoo •

Berkeley and

Washington,

USA

5 10/10/2012


Printed electronics examples at VTT

Printed components integrated on web or foils to form printed functional systems (~ 100 persons)

Organic PV, bio fuel cells, super capacitors, batteries

OLED displays and - signage

Memory devices: WORM, FeRAM

Nano-imprinted holographs and diffractive optics

Printed TFT circuits, passive components and multilayer electronic circuits – sensors

Electrical and optical codes

Gravure printed

organic solar cells

Printed

disposable bio

fuel cell

Passive electrical

components OLED

signage

Optical

codes for

linking

physical and

digital media

Processing tools for

nanoparticle sintering Optical effects for

packaging

www.vttprintedintelligence.fi

http://www.vttprintedintelligence.fi/

6 10/10/2012


Roll-To-Roll Facilities at VTT

2 gravure printing units

Hot embossing unit

Corona unit

Lamination unit

Drying units (air, UV,IR)

Max. web width 200mm

Max. web velocity 100 m/min

PICO 2003

4 interchangeable printing

units forward and reverse

gravure, rotary screen and

flexography

Corona/plasma

pretreatment

Lamination unit

Drying units (air, UV, IR)

Web width 300mm

Max. web velocity 10m/min

ROKO 2007

4 interchangeable printing unit slots forward and reverse gravure, rotary

screen, flexography

Slot die coating

Hot embossing unit

Plasma substrate treatment unit

Lamination unit

Rotary die cut unit

Drying units (air, UV)

Automatic registration system



MAXI 2012

7 10/10/2012


NITROGEN ATMOSPHERE

2 interchangeable printing unit

slots forward gravure, rotary screen

Lamination unit

Drying units (IR)

Manual registration system

Printing, curing and lamination

made in nitrogen atmosphere

(O2 level <0.1%)



NICO 2011 R2R EVAPORATOR

Thin film metal evaporation

Ag, Al, Au, Ca..

5 thermal evaporation sources

Max. web width 320 mm

Max. web velocity 2 m/min

Different laser systems

available for R2R testing of

various applications

Ps-Fs-ablation, IR-diode,

CO2, NdYAG, fiber lasers

LASER PROCESSING

R2R test line

Electrical and optoelecltronic

characterization

Yield analysis

Stop-and-go process

Roll-To-Roll Facilities at VTT

8 10/10/2012


R2R facilities for hybrid integration

Datacon R2R assembly & bonding line Engel Victory injection moulding machine

A pilot lines for hybrid in-mould integration:

• enables seamless integration of novel optical, electrical, and mechanical features

into 3D plastic products

• component assembly and bonding of various types of components (chips – sheets)

on flexible substrates

• continuous WEB Stop & Go process as well as over-moulding of the assembled

foils

9 10/10/2012


Modeling and simulation of the

R2R manufacturing process

Improving the runnability and

productivity of the R2R process

Novel on-line measurement and

characterization techniques

Other supporting activities in R2R environment

Long way from table top printers

to real R2R production!

10 10/10/2012


Printed electronics vs. traditional graphical printing

MODIFICATIONS

Separated dots High uniformity requirements

P. Kopola et al., Solar Energy Materials and Solar Cells. Vol. 94 (2010) No: 10, 1673 - 1680

P. Kopola et al., Thin Solid Films. Vol. 517 (2009) No: 19, 5757 - 5762 0 1 2 3 4 5 6 7 8 9 10

0

1

2

3

4

5

Curr

ent

den

sity [

mA

/cm

2]

Voltage [V]

PEDOT

Modified PEDOT

11 10/10/2012


OPV process step development in printing

Layer specificationsThickness, roughness, dimensions of patterning

Ink propertiesSolid conc., solvents,

rheological properties, surface properties

Printability testPrinting method, cylinder/plate, printing parameters,

pre-treatments and post-treatments

Process step developmentIntegration of material printing into R2R process

R2R pilot fabrication of OPVProcess step integration into R2R process

OPV device testsEvaluation of printed structures

OPV device testsProcess step evaluation

12 10/10/2012


Development of printed OPV at VTT

Printo (TEKES)

Investigate the possibilities to fabricate passive and active electrical, optical and optoelectrical elements using roll-to-roll processes

Proof-of-concept of printable OPV

FP7-FACESS (EU), PrinDemo (TEKES)

R2R manufacturing technology for flexible OPV devices

Integration of OPV devices to application demonstrators

FP7-ROTROT (EU), Autosys (TEKES)

R2R process development

Novel device structures (ITO free, tandem OPV)

Projects (VTT, customers, TEKES, EU)

Novel R2R processes and machinery developments

Up-scaling

Application demonstrators

13 10/10/2012


CONVENTIONAL STRUCTURE

Single junction OPV device structures for R2R

Ca

PEDOT:PSS

ITO

P3HT:PCBM

PET

Ag or Al

PEDOT:PSS

ZnO

ITO

P3HT:PCBM

PET

Ag

INVERTED STRUCTURE

14 10/10/2012


Up-scaling in laboratory from cell to module level

Integrated system OPV+battery+circuit

4 printed organic solar modules

PCE 2.3%, 15.5 cm2, Voc 4.6V, Jsc 8.8

mA/cm2

Printed rechargeable Li battery

• 36 mAh @ 36 cm2

Thinned control transistor chip

• 30 µm thick flip chip bonded

Rotary screen printed backplane

Patterned (screen printing) ITO-PET

Gravure printed PEDOT:PSS

Gravure printed P3HT:PCBM

Evaporated cathode Ca/Ag

Patterned ITO-PET

Gravure printed PEDOT:PSS

Gravure printed P3HT:PCBM

Evaporated cathode Ca/Ag

NOTE: commercial P3HT:PCBM blend system used

Laboratory scale printed

cell

Laboratory scale printed

module (8 cells in series)

PCE = 3.1 %

Voc = 0.6 V

Jsc = 10.2 mA/cm2

FF = 0.54

Active area= 18 mm2

Active area PCE = 2.9%

Voc = 4.9 V

Jsc = 9.9 mA/cm2

FF = 0.47

Active area = 15 cm2 (one cell 1.9 cm2)

15 10/10/2012


R2R printing of conventional structure OPV modules

Average module performance

(8 cells in series, module area 15 cm2):

NOTE: commercial P3HT:PCBM blend system used as photoactive material

+ sheet evaporated

electron contact

16 10/10/2012


R2R printing of conventional structure OPV modules

17 10/10/2012


Lifetime of R2R printed conventional

P3HT:PCBM OPV modules

t [hours] PCE [%] Voc [V] J [mA] FF

0 2.49 4.30 17.7 0.45

5000 0.51

(21%)

3.65

(85%)

6.5

(37%)

0.31

(69%)

-1 0 1 2 3 4 5-20

-15

-10

-5

0

5

10

15

Fresh module

After 7 month

Voltage [V]

Curr

ent

[mA

]

Commercial barrier (WVTR 10-2) +

PSA lamination

Voc still 85% of initial value

Still capable to drive voltage controlled

systems

Electro chromic displays

Electro phoretic displays

…

18 10/10/2012


R2R manufacturing of inverted structure OPV films

ITO patterning Buffer layer gravure printing

In co-operation with

Photoactive layer gravure printing

PEDOT:PSS rotary screen printing Ag anode rotary screen printing Barrier film lamination

19 10/10/2012


R2R manufacturing of inverted structure OPV films

R2R printed OPV module driving LCD clock

IV-curves of typical R2R printed inverted

structure OPV devices

-1.0 -0.5 0.0 0.5 1.0

-0.002

-0.001

0.000

0.001

DO_6_3a

DO_6_3b

DO_6_3c

DO_6_3a_illuminated

DO_6_3b_illuminated

DO_6_3c_illuminated

Isc[m

A]

U[V]

Module efficiency around 1% at area 12 cm2

In co-operation with

20 10/10/2012


R2R printed Ag-nanowires as ITO free transparent electrode

Voc

[V]

Isc

[mA/cm2)

FF PCE

[%]

Cell area

[mm2]

Ag-NW 0.60 10.78 0.54 3.3 27

ITO-

PET

0.57 10.30 0.51 3.1 18

R□ ~10 Ω/□

OC50

21 10/10/2012


Ca

PEDOT:PSS

ITO

P3HT:PCBM

GLASS

Ag

10x10 cm Willow glass

sheet on a PET carrier

R2R processing of OPV cells on 100mm Corning®

Willow™ Glass

22 10/10/2012


R2R processing of OPV cells on 100mm Corning®

Willow™ Glass

Cells after cathode evaporation

Voc

[V]

Isc

[mA/cm2)

FF PCE

[%]

Cell area

[mm2]

Glass 0.60 13.30 0.56 3.9 18

ITO-

PET

0.57 10.30 0.51 3.1 18

NOTE: commercial P3HT:PCBM blend system used as photoactive material

23 10/10/2012


Printed OPV demonstrators

Electrochrome display driven by printed

OPV module under indoor lighting

“BIPV” – dollhouse’s LED lighting powered via printed OPV

24 10/10/2012


Summary

VTT offers unique R2R pilot facility environment for printed

electronics pilot manufacturing

R2R pilot printing processes were demonstrated OPV modules

Conventional and inverted structures

ITO free gravure printed cells with Ag-NW transparent electrode

R2R printed cells on flexible glass

We are actively looking for new research and industry partners to

join our research projects

25 10/10/2012


ACKNOWLEDGEMENTS

TEKES and EU FP6 & FP7 for financial support

Research partners & Industrial collaborators

Printed Optoelectronics Components – team and

co-workers throughout VTT working on

developing printed intelligence

More information on www.vttprintedintelligence.fi

http://www.vttprintedintelligence.fi/

26 10/10/2012


Thank you for your

attention!

Contact information:

[email protected]

mailto:[email protected]

27 10/10/2012


VTT - 70 years of

technology for business

and society

r2r manufacturing of organic pv using gravure and rotary...

Documents