challenges of vacuum roll-to-roll processing of organic solar cells … · 2018-10-08 ·...

Challenges of vacuumroll-to-roll processing of organic solar cells and encapsulation processesEritt, Michael; Falkenberg, Christiane; Wichtendahl, Ralph

Heliatek GmbH

CONFIDENTIAL / 2016 June 2nd© Heliatek GmbH www.heliatek.com

Agenda

AIMCAL 2016 2

1. HeliaFilm® – motivation and benefits

2. Current processes for OPV

3. Upscaling – from pilot to production

4. Summary and outlook

AIMCAL 2016 3

HeliaFilm®

Motivation and benefits

CONFIDENTIAL / 2016 June 2nd© Heliatek GmbH www.heliatek.com 4

The urban landscape of the futureBuildings will have active façades and cars will be emission free

AIMCAL 2016

HELIAFILM®

CONFIDENTIAL / 2016 June 2nd© Heliatek GmbH www.heliatek.com 5

Key material features of HeliaFilm®The freedom of possibilities

Flexible Exhibiting minimum radius of 10 cm

Ultra-lightWith an extremely low weight of 500g/m²

TransparentAchieving up to 50% transmission

Light with 6 % efficiency

Ultra-thinLess than 1 mm thin solar film

Numerous colorspossible in shades

of grey, blue and green

Custom-designedFlexible dimensions

in lengths

AIMCAL 2016


Physics: p-i-n tandem devices

6

Stack design and engineering

TCO front electrode

-

+

p

n

p

n

Organic vacuum deposited layers:

Total thickness 250 nm

Plastic substrate

+ + + + + + + + + + + + + + +

Organic absorber 1

- - - - - - - - - - - - - - -+ + + + + + + + + + + + + + +

Organic absorber 2

- - - - - - - - - - - - - - -Metal back electrode

d

Optical engineering:

Absorber layers are placed in the respective interference maxima.

AIMCAL 2016


Efficiency Development

AIMCAL 2016 7

0

2

4

6

8

10

12

14

16

2007 2008 2009 2010 2011 2012 2013 2014 2015 2016 2017 2018 2019 2020

Roadmap

Actual

Continuous progress towards higher efficiencies

Effic

ienc

y [%

]

10.7%9.8%

8.3%

World Record13.2%

12%


HeliaFilm®

8

First pilot line implementing vacuum roll-to-roll production

AIMCAL 2016


HeliaFilm®: Enabling partner innovation

9

Concrete

GlassPolymer

sheetsFoils

PVC membrane

AIMCAL 2016

Steel Aluminum

AIMCAL 2016 10

Current processes for OPV


Process tools for OPV manufacturing

1) Substrate structuring

at Heliatek

laser

nitrogen

vacuum

curinglamination

Encapsulationcassette

lasers

2) Vacuum deposition

org. stack

back electrode

back film

Pilot line

300 mm film with


Unique R2R vacuum vapor process

12

Precise and homogenous production process for little upscaling losses

Roll-to-roll processContinuous process500 m long rolls300 mm wide web

Vapor depositionLinear sourcesHomogenous depositionMulti-layer stackLow temperature (120 °C)

Laser structuringPrecise processUltra narrow scribes Minimum area losses

Heliatek Company Presentation

CONFIDENTIAL / 2016 June 2nd© Heliatek GmbH www.heliatek.com 14AIMCAL 2016

Manufacturing Process – front endSequential processes

Cross section: Module out of the front end

TCO coated PET substrate

Substrate, PETTCO



P1Cross section: Module out of the front end

P1 – scribing of the front contact

SubstrateTCO



P1Cross section: Module out of the front end

Evaporation of the organic multi-layer stack

Substrate, PET

Tandem absorberTCO



P1P2Cross section: Module out of the front end

P2 – scribing of the organic

Substrate, PET

Tandem absorberTCO



P1P2Cross section: Module out of the front end

Evaporation of the transparent or opaque back contact

Substrate, PET

Tandem absorberBack contact

TCO



P1P2P3Substrate, PET


TCO


P3 – patterning of the back contact





TCO

Back film


Back film lamination





TCO

Back filmactive areaactive area


Functional principle of HeliaFilm

Series interconnection of diodes


Transfer from vacuum tool

Contacting with metal stripe

Adhesive application front and back side

Lamination process

Curing step

22AIMCAL 2016

Atmosphere

Inert atmosphere

R2R-encapsulation system

Adhesive

Metal stripe

Back filmBacksheet

Cross section: Module out of the back end

FrontsheetSubstrate, PET

Manufacturing Process – back endSequential processes

Protect active OPV film against moisture/oxygen

AIMCAL 2016 23

Upscaling – from pilot to production


Challenges for (pilot) production

AIMCAL 2016 24

Pilot manufacturing line

- Material based on polyester film

- Flexible film material and HeliaFilm product

- 300 mm film width

Front end

- vacuum processes

- film handling without surface contact

Back end

- encapsulation in inert atmosphere


Vacuum processing

AIMCAL 2016 25

Organic stack and metal electrode deposition in high vacuum continuously

Structuring by laser processes

- Organic stack

- Metal electrode

Transport without contact of deposited film surface

- film handling

- defined temperature control

Deposition tool

- Laser process in vacuum

- Clean process no shorts by re-deposited particles

- Handling in pilot tool ~ 50 m (w/o surface contact)

- Homogeneous substrate heating


Encapsulation process

AIMCAL 2016 26

Film handling and process in inert atmosphere

Material transfer via cassette

Gas flow

- conditioning: nitrogen flooding

- process: N2+pre-treatment exhaust

Critical parameter: oxygen

- tracking the oxygen concentration encapsulation tool

cassettew/substrate

N2inlets

barrierfilm

valve

encaps.HeliaFilm

lamination

pre-treatment

curing

exhaust


Encapsulation process – inert atmosphere

AIMCAL 2016 27

Base level of oxygen concentration 100 ppm

- w/o process

Start of pre-treatment process exhaust open

- immediate increase of oxygen level

Root cause

- Leakage of chambers – contamination w/ air

Optimized process: slight increase but stable

optimization

process start


Encapsulation process – inert atmosphere

AIMCAL 2016 28

Encapsulation of 250 modules

Barrier film material exchange after 150 modules

Short interruption of N2 atmosphere

Lead to decrease of Gsext until #170

After recovery of N2 atmosphere normal Gsext

O2 concentration

cha

nge

of

ba

rrier

film


From ramp up to current production

29

curve of best module out of current production

PCE is 7,7%

Fill factor is 66.4%

transfer of lab results successfulI-V-curve from a module out of the production

present results

Industrialization the patterning of organic solar cells

0.0

0.2

0.4

0.6

0.8

1.0

1.2

0 10 20 30 40 50

I in

A

V in V

aggregated data

VOC 41.15 VISC 1113.5 mAFF 66.4%

Vmpp 31.89 VImpp 953.6 mAPmpp 30.409 W


Summary

AIMCAL 2016 30

Results proven in pilot line

- Transfer from lab to R2R manufacturing – film handling / deposition /encapsulation

- Complete roll-to-roll process for OPV manufacturing

- Lifetime capabilities of R2R process

- Highest power conversion efficiency (PCE) of active area 7,7%

First pilot projects together with partners installed


Realized pilot installations

AIMCAL 2016 31

HeliaFilm

glass facade

… on PVC membrane … on concrete

http://upload.wikimedia.org/wikipedia/commons/3/33/Reckli.gif

http://upload.wikimedia.org/wikipedia/commons/3/33/Reckli.gif


Outlook

32

Next generation of manufacturing tools

AIMCAL 2016

Upscaling of pilot line processes to mass production project Fab2 started

Requirements

- current pilot line with 300 mm film width upscaling to 1200 mm

- accurate film handling / deposition equipment – defined temperature regime

- sequencing of proven laser patterning across wider web

- improved encapsulation process

- flexible product layout in width and length of the solar film

Next gen of OPV production tools will be deployed in Dresden

Thank youfor your attentionwww.heliatek.com

Title of presentation 33

Dr. Michael ErittManager Back End

Heliatek GmbHTreidlerstraße 301139 Dresden, GermanyT (+49-351) 213 034-432F (+49-351) 213 034-40

[email protected]

Title of presentation 34

challenges of vacuum roll-to-roll processing of organic solar cells … · 2018-10-08 ·...

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