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Abstract We applied complementary imaging methods to investigate processing failures of roll-to-roll solution processed polymer solar modules based on polymer:fullerene bulk heterojunctions. For investigation of processing deficiencies in solar modules we employed dark lock-in thermography (DLIT), electroluminescence (ELI) and photoluminescence/reflection imaging (PLI/RI) complemented by optical imaging (OI). The combination of all high resolution images allowed us to allocate the origin of processing errors to a specific deposition process, i.e. the insufficient coverage of an electrode interlayer. The investigation can be divided into a fast DLIT overview of the module and a successive more detailed analysis of the suspicious region by all imaging methods.

Accurate characterization and reporting of organic photovoltaic (OPV) device performance reniains one of the important challenges in the field. The large spread among the efficiencies of devices with the same structure reported by different groups is significantly caused by different procedures and equipment used during testing. The presented article addresses this issue by offering a new method of device testing using "suitcase sample" approach combined with outdoor testing that limits the diversity of the equipment, and a strict measurement protocol. A round robin outdoor characterization of roll-to-roll coated OPV cells and modules conducted among 46 laboratories worldwide is presented, where the samples and the testing equipment were integrated in a compact suitcase that served both as a sample transportation tool and as a holder and test equipment during testing. In addition, an internet based coordination was used via plasticphotovoltaics.org that allowed fast and efficient communication among participants and provided a controlled reporting format for the results that eased the analysis of the data. The reported deviations among the laboratories were limited to 5% when compared to the Si reference device integrated in the suitcase and were up to 8% when calculated using the local irradiance data. Therefore, this method offers a fast, cheap and efficient tool for sample sharing and testing that allows conducting outdoor measurements of OPV devices in a reproducible manner. (C) 2014 Elsevier B.V. All rights reserved.

The investigation of degradation of seven distinct sets (with a number of individual cells of n $ 12) of state of the art organic photovoltaic devices prepared by leading research laboratories with a combination of imaging methods is reported. All devices have been shipped to and degraded at Risø DTU up to 1830 hours in accordance with established ISOS-3 protocols under defined illumination conditions. Imaging of device function at different stages of degradation was performed by laser-beam induced current (LBIC) scanning; luminescence imaging, specifically photoluminescence (PLI) and electroluminescence (ELI); as well as by lock-in thermography (LIT). Each of the imaging techniques exhibits its specific advantages with respect to sensing certain degradation features, which will be compared and discussed here in detail. As a consequence, a combination of several imaging techniques yields very conclusive information about the degradation processes controlling device function. The large variety of device architectures in turn enables valuable progress in the proper interpretation of imaging results—hence revealing the benefits of this large scale cooperation in making a step forward in the understanding of organic solar cell aging and its interpretation by state-of-the-art imaging methods.

Polymer solar cells were prepared in large numbers using roll-to-roll methods and were subsequently integrated into the Organic Electronics Association (OE-A) demonstrator in the year 2011 and presented as a small credit card sized lamp with a flat outline. The lamp comprised the polymer solar cell together with printed circuitry, discrete components and flexible lithium polymer batteries. The number of discrete steps required for the manufacture of the lamp was 35 and more than 10000 units of the demonstrator was manufactured. We describe the efforts towards increasing the technical yield which was 89% overall and discuss the compromises that had to be made to achieve the high technical yield for a process that was as automated as possible. All the steps in the preparation of the solar cell, the circuitry and the overlays were performed using full roll-to-roll methods. The mounting of the discrete components, such as LED, diode and Zener diode, was performed in sheets of 15 units using a fully automated SMD mounting machine. The mounting of the batteries, contacts and final testing was done manually. The lamination into the final lamp and the final laser cutting into the discrete lamps were performed using automated systems. © 2011 The Royal Society of Chemistry.

Abstract Fully roll-to-roll processed polymer solar cell modules were prepared, characterized, and laminated. Cell modules were cut from the roll and matched pairs were selected, one module with exposed cut edges, the other laminated again with the same materials and adhesive sealing fully around the cut edges. The edge sealing rim was 10 mm wide. Cell modules were characterized by periodic measurements of IV curves over extended periods in a variety of conditions, as well as by a variety of spatial imaging techniques. Data show significant stability benefits of the edge sealing process. The results of the imaging experiments show that the ingress of atmospheric reactants from the edges leads to degradation. In the case of edge sealed devices the same effects are observed but significantly slowed down. In particular, the fast nonlinear degradation is eliminated.