Combining Printing, Coating, and Vacuum Deposition on the Roll-to-Roll Scale: A Hybrid Organic Photovoltaics Fabrication

The potential for organic electronic technologies to produce low-cost energy at large scales is often cited as the most attractive feature of these materials. Such aspirations depend on the ability of materials to be printed from solution at high speeds across large areas using roll-to-roll (R2R) processing. However, progressing the technology from the laboratory environment into the industrial manufacturing arena is highly challenging. Closing the gap between exciting laboratory scale insights and the industrial scale potential requires a new focus on upscaling existing technology. Some recent progress in this area is discussed, concentrating on the need to pursue research across several different scales simultaneously in order to most effectively optimize large-scale fabrication efforts. These discussions are placed in the context of a design philosophy that combines printing, coating, and vacuum-based procedures. The challenges associated with selecting, and subsequently synthesizing, the optimal materials for device construction at large scales are considered. Case histories that highlight the unique challenges encountered during printing, coating, and sputtering at the R2R scale are presented. Developing testing and characterization procedures that can interrogate organic photovoltaic device (OPV) structures in real time is also discussed, and the opportunity for new tools to probe device photophysics is highlighted. The collection of innovative approaches to R2R fabrication challenges discussed here highlights the exciting progress toward efficient OPV modules becoming a commercial reality.