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Flex Europe Conference 2016 | Dr Solenn Berson
M. Manceau, M. Matheron, N. lemaitre, S. Cros and S. Berson
LIFETIME STUDY OF FLEXIBLE ENCAPSULATED
ORGANIC PHOTOVOLTAIC MODULES:
OPTIMIZATION OF DEVICE ARCHITECTURE AND
SELECTION OF ENCAPSULATION MATERIALS
| 2FOR 154 F - INES Flex Europe Conference 2016 | Dr Solenn Berson
Lightweight<1kg/m²
PolychromaticColoration blue, green, purple
Ultra Thin<1 mm
Semi-Transparent Silver NWs top electrode, PCE 3% (P3HT:PCBM)
T 50%, PCE 6% (Heliatek)
FlexibleRadius < 5 cm
CustomizedDimensions, shapes, voltage, current
ORGANIC PHOTOVOLTAIC MODULE TECHNOLOGY
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ORGANIC PHOTOVOLTAIC MODULE TECHNOLOGY
Best performances of OPV modules :
• World record lab efficiency 13% (Heliatek)
• Modules from R2R production at 6 % (Heliatek)
• Flexible modules up to 7000h at 85°C/85%RH (Heliatek)
• Production lines: Heliatek (DE), Belectric (DE), Armor (FR), Eigth19 (UK), Mitsubishi (JP)
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LMPO: LABORATORY OF ORGANIC PHOTOVOLTAIC MODULES
- Transparent Conducting Electrode (Oxyde, NWs Ag)
- N layer (ZnO, TiOx)
- Active layer (Polymers, Organometallic Materials)
- P layer (PEDOT:PSS, WO3)
- Top electrode (Silver, Aluminium, NWs Ag)
Flexible and stable cell: NIP architecture, formulations compatible with production
Active MaterialsDevices
(conditions)substrate Active Area (cm²) Efficiency (%)
Polymer:PC60BM Cell (lab.) PET 0,13 > 9%
Perovskites Cell (lab.) Glass 0,13 >18%
Adjust the printing process :
• Tuning of ink formulation
• Get defect-free printed layers
Labscale cell Pilot scale module
Optimization of the design of the module:
• Design of the cell
• Series connection
Selection of materials and optimization of architecture for flexible PV devices
Flex Europe Conference 2016 | Dr Solenn Berson
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© CEA – 7,5 cm x 1 m
Conformability,
lightweight, semi-
transparence, coloration
Improvment of the
integration – Design on
demand
S2S Inkjet, digital
Small to medium surface
Design on demand
R2R Coating designed by
ARMOR
Large volume & surface
Standard Design
15cmx15cm
7,5cmx100cm
S2S coating + laser, digital
Small to medium surface
Design on demand5cmx5cm 10cmx10cm
PCE=4,3%
PCE=5,2%
FRONT END PROCESS
Development of printing processes with the highest Geometrical Fill Factor (GFF)
Design
on-demand
Design
on-demand
OPV module
Flex Europe Conference 2016 | Dr Solenn Berson
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What is the stability of CEA flexible OPV devices?
Next step: determination of extrinsic stability with “real” flexible protection.
Devices aged in sealed bags with ultra-low water and oxygen transmission rates.
0 1000 2000 3000 4000 50000
20
40
60
80
100
Time under continuous illumination AM 1,5 (h)
No
rma
lize
d P
CE
Cell
Cell
Cell
Module - 5 cmx 5 cm substrate
Light stabilityHeat stability
0 200 400 600 800 1000 1200
0,0
0,2
0,4
0,6
0,8
1,0
1,2
No
rma
lize
d e
ffic
ien
cy
Ageing time at 85°C (vacuum) (h)
Flex Europe Conference 2016 | Dr Solenn Berson
FRONT END: INTRINSIC STABILITY
1st step: determination of intrinsic stability with a « perfect » encapsulation
| 7FOR 154 F - INES Flex Europe Conference 2016 | Dr Solenn Berson
Development and optimization of flexible encapsulation:
Elaboration and selection of high barrier films
Elaboration and selection of barrier adhesive
Improvement of interface adhesion and design of electrical connections
Permeation and degradation can occur along 3 major pathways:
Orthogonal (through the barrier film)
Lateral (in the plane of the device)
• In the bulk adhesive
• Along the interface between the adhesive
and the barrier film and along the electrical
connections
H2O
H2O
H2O
H2O
+ -
Prevent water and oxygen from entering the encapsulated printed PV device
Development of materials and processes for high stability
BACK END: EXTRINSIC STABILITY
| 8FOR 154 F - INES Flex Europe Conference 2016 | Dr Solenn Berson
BACK END: EXTRINSIC STABILITY
Development of materials to limit orthogonal permeation
Barrier stability characterization and correlation to device lifetime
• He Transmission Rate increase ~ barrier degradation
0 500 1000 1500 2000 2500
0,0
0,2
0,4
0,6
0,8
1,0
1,2
No
rma
lize
d p
ow
er
co
nve
rsio
n e
ffic
ien
cy (
%)
Aging time at 85°C/85RH (h)
OPV modules + barrier film 1
OPV modules + barrier film 2
OPV modules + barrier film 3
0,1
1
10
100
1000
3 days
85°C/85%RHT
0
Barrier film 1
Barrier film 2
Barrier film 3
He
TR
va
ria
tio
n fa
cto
r
3 days
65°C/85%RH1000 h
at 65°C 85% RH1000 h
at 85°C 85% RHT0
Ageing time at 85°C 85% RH (h)
He
TR
va
ria
tio
n fa
cto
r
No
rma
lize
dP
CE
of m
od
ule
s (
%)
Helium measurements Rapid control of barrier ageing.
Correlation btw barrier film stability and encapsulated device lifetime.
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Device stability at 65°C/85%RH
0 h 30 h 68 h1 h
5 c
m
0 h 30 h 68 h1 h
No wiring
PSA
Process A
Wiring
PSA
Process A
Wiring
Thermoplastic
Process B
0,0
20,0
40,0
60,0
80,0
100,0
0 50 100 150 200N
orm
aliz
ed
PC
E (
%)
Time of stabilty test at 65°C/85%RH (h)
cellule 1
celllule 2
cellule 4
L10467_C 1
L10467_C 2
Série6
Série7
Série8
Série9
Ca test characterization – 65°C/85%RH
• Electrical connections may induce additional permeation pathways.
• Adhesive selection should take into account the whole ‘back-end’ process.
Process A
Process B
Comparison of water ingress for 2 adhesives, with / without electrical connections
Stable barrier (10-4 g/m²/d)
68 h
BACK END: EXTRINSIC STABILITY
Development of materials and design to limit lateral permeation
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DAMP HEAT & THERMAL CYCLING STABILITY
Flex Europe Conference 2016 | Dr Solenn Berson
T80 > 200 cyclesT80 > 2000 h
85°C 85% RH - ISOS-D-3
T80 > 1000 hT80 > 2000 h
1 sun, ambient T & RH - ISOS-L-1
1 sun, 65°C, 50% RH - ISOS-L-3 Thermal cycles -40°C +85°C, ambient RH
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CONCLUSIONS AND FUTURE WORK
• Digital printing processes:
• Fully design on demand OPV modules
• GFF>90%
• PV Efficiencies >5%
• Development of design and encapsulation processes:
• Flexible OPV modules with stability:
T80 > 1000 h at 85°C 85% RH.
T80 > 1000 h at 65°C, 50%Rh, 1 sun
T80 > 200 cylces (-40°C + 85°C)
T80 > 1000 h ambient T°C, RH, 1sun
• Future work
• Pilot line development for digital process
• Reliability for specific applications and uses
Flex Europe Conference 2016 | Dr Solenn Berson
Commissariat à l’énergie atomique et aux énergies alternatives
Alternative Energies and Atomic Energy Commission 17 av des martyrs F-38000 GRENOBLE France
http://liten.cea.fr
Établissement public à caractère industriel et commercial
Public establishment with commercial and industrial character
RCS Paris B 775 685 019
INES Site
Institut National de l’Energie Solaire
National Solar Energy Institute
50 avenue du lac Léman
F-73375 Le Bourget-du-Lac France
+33 4 79 79 20 00
THANK YOU
FOR YOUR ATTENTION
ACKNOWLEDGEMENTS
CEA - Laboratory of Organic
Photovoltaic Modules
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FRENCH CAMPUS FOR SOLAR TECHNOLOGY DEVELOPMENT
Buildings : 22 000 m²
People : 450-500
Annual budget : 60M€
Equipments : 140M€
Capacity
400 Active patents (+70 per year)
40 Publications per year
200 Industrial partners :
Results
Flex Europe Conference 2016 | Dr Solenn Berson
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Adhesive
Thickness
% permeation
Ortho
% permeation
Bulk
% permeation
Interface
Lateral
permeation rate
(µg/day)
100 µm 54% 11% 35% 13.6
250 µm 38% 27% 35% 17.7
• Thicker adhesive increase of permeation.
• Lateral permeation is a significant source of water.
• Interfacial permeation is as important as through the bulk adhesive.
65°C/85%RH
Grayscale changes orthogonal permeation
Changes in deposit size lateral permeation
• Characterization of lateral permeation by optical calcium test
• Influence of adhesive thickness
Flex Europe Conference 2016 | Dr Solenn Berson
BACK END: EXTRINSIC STABILITY – LATERAL PERMEATION
Quantification of water ingress for PSA / barrier (~10-4 g/m²/d)
