Organic photovoltaics (OPVs) are an emerging technology for providing renewable energy. However, translation from lab scale to low cost roll-to-roll manufacturing of OPVs on a commercial scale requires significant research. This presentation will highlight work to overcome challenges such as the use of non-halogenated solvents for reduced toxicity formulations, all-solution processed OPVs, and reduced processing temperatures for compatibility with flexible plastic substrates in roll-to-roll coating. The use of ZnO nanoparticle electron transport layers will be discussed as a method for generating uniform films with sufficiently low work functions (< 3.7eV) for generating high performing OPVs using low temperatures that do not deform plastic substrates and enable roll-to-roll coating. Combining these advances, pilot scale OPV modules were fabricated, reaching 6.3% power conversion efficiency.
Advancement of organic photovoltaic (OPV) technology towards commercial products requires the development of materials that are amenable to large area print manufacturing. This manuscript will highlight efforts by the OPV program at Phillips 66 to solve issues related to material scale-up, through material design combining good processability and high photovoltaic performance. An internally developed polymer/phenyl-C71-butyric acid methyl ester (PC70BM) blend that combines these critical parameters achieved a certified power conversion (PCE) of 12.14% in 2017.