Large-area organic photovoltaic module—Fabrication and performance

Here we describe the fabrication of the largest (233 cm² total area) organic photovoltaic (OPV) module (polymer:fullerene) to be certified by the National Renewable Energy Laboratory (NREL). OPV solar cells were fabricated at Plextronics by spin coating a blend of poly 3-hexylthiophene-2,5 diyl (P3HT) and [6,6] phenyl C₆₁ butyric acid methyl ester (PCBM) on top of our hole transport layer (HTL), Plexcore^® OC. In laboratory-scale devices (0.09 cm²), this system routinely exhibits power conversion efficiencies exceeding 3.7%. This P3HT:PCBM active layer and HTL ink system was used to scale up to the larger area module (15.2 cm×15.2 cm module size, i.e. 233 cm² total area; 108 cm² active area), which was certified by NREL as having 1.1% total area efficiency (3.4% active area efficiency).     

High-performance polymer photovoltaic devices with inverted structure prepared by thermal lamination

Use of a lamination process for the introduction of Au electrode, instead of conventional metal evaporation, improved the power conversion efficiency (PCE) of inverted-structure photovoltaic devices from 1.6% to 2.6% based on a bulk heterojunction of poly(3-hexylthiophene) (P3HT) and (6,6)-phenyl C₆₁ butyric acid methyl ester (PCBM). X-ray photoelectron spectroscopy indicated that a thin layer of P3HT is spontaneously formed at the air/polymer blend layer interface during the spin-coating process. It is suggested that the vacuum-evaporated gold could destroy the surface-segregated thin layer of P3HT, while the lamination process preserves the surface structure working as an electron-blocking layer. The insertion of a PEDOT:PSS layer, between the metal electrode and polymer layer, in the lamination process further improved the PCE to 3.3% with a short-circuit current density of 9.94 mA cm⁻², an open-circuit voltage of 0.60 V, and a fill factor of 55% under AM1.5 100 mW cm⁻² irradiation.     

Effect of electrode geometry on the photovoltaic performance of dye-sensitized solar cells

Effect of electrode geometry on the photovoltaic performance of dye-sensitized solar cell (DSSC) has been investigated to optimize the device geometry for reliable energy conversion efficiency assessment. Mesoporous TiO₂ layers with an identical active area (0.40 cm²) and different dimension are prepared on FTO glass substrate by the screen printing method and used as photoanodes for DSSCs. Under 1 sun illumination (AM 1.5G, 100 mW cm⁻²), both the open-circuit voltage and the short-circuit current density are independent of electrode geometry whereas the fill factor and hence energy conversion efficiency show strong dependency. Electrochemical impedance spectroscopy analysis indicates that the distance between active layer and ohmic contact directly contributes to internal series resistance and influence photovoltaic performance.     

ITO-free flexible inverted organic solar cell modules with high fill factor prepared by slot die coating

We report on the fabrication of inverted ITO-free P3HT:PCBM solar cell modules on glass and PET foil as substrate where the organic functional layers are deposited with slot die coating, a reel to reel compatible coating technique. The active layers have been processed in ambient atmosphere, which will be of advantage in a future production and is especially remarkable as the metallic cathode is already deposited on the substrate at this stage of fabrication. The modules comprise two busses of 11 cell elements connected in series each. The series connection leads to an open circuit voltage of up to 6.88 V on glass substrate, which translates to 625 mV per cell element, a very competitive value for P3HT:PCBM based solar cells on glass. Although the designated area is as large as 41 cm² and the active area 26.4 cm², we obtain fill factors of up to 65% for these modules, which again is a typical value for small area laboratory cells. Remarkably the values for PET foil as substrate with an open circuit voltage of 6.5 V and a fill factor of 64% are very close to the results on glass and to our knowledge the highest fill factors for flexible organic solar cells, even if compared to small area devices. The short circuit current densities and therefore efficiencies are also comparable to small area devices, if only the photoactive area is accounted for. Therefore we have demonstrated that the scale up of organic solar cells can be achieved with a suited circuitry scheme.     

Thin film solar cells of CdS/PbS chemically deposited by an ammonia-free process

A new type of solar cell with structure glass/ITO/CdS/PbS/conductive graphite was constructed and studied. Both window (CdS) and absorption (PbS) layers were deposited by means of the chemical bath deposition (CBD) technique. The maximum temperature employed during the solar cell processing was 70 °C and it did not include any post-treatment. In case of the CdS window layer, complexing agents alternative to ammonia were employed in the CBD process and their effects on the CdS films properties were studied. The solar cells are photosensitive in a large spectral range (all visible and near infrared regions); the cell with the area of 0.16 cm² without any special treatment has shown the values of open-circuit voltage V_oc of 290 mV and short circuit current J_sc of 14 mA/cm² with the efficiency η=1.63% (fill factor FF is 0.36) under illumination intensity of 900 W/m². It was found that the CBD-made PbS layer has a certain degree of porosity, which favorably affects its applicability in solar cell construction. The possible ways of device optimization, and in particular, the effect of the PbS grain size on its performance are discussed.     

High performance metal-supported intermediate temperature solid oxide fuel cells fabricated by atmospheric plasma spraying

The LSGM(La_0.8Sr_0.2Ga_0.8Mg_0.2O₃) electrolyte based intermediate temperature solid oxide fuel cells (ITSOFCs) supported by porous nickel substrates with different permeabilities are prepared by plasma spray technology for performance studies. The cell having a porous nickel substrate with a permeability of 3.4 Darcy, an LSCM(La_0.75Sr_0.25Cr_0.5Mn_0.5O₃) interlayer on the nickel substrate, a nano-structured LDC(Ce_0.55La_0.45O₂)/Ni anode functional layer, an LDC interlayer, an LSGM/LSCF(La_0.58Sr_0.4Co_0.2Fe_0.8O₃) cathode interlayer and an LSCF cathode current collector layer shows remarkable electric output power densities such as 1270 mW cm⁻² (800 °C), 978 mW cm⁻² (750 °C) and 702 mW cm⁻² (700 °C) at 0.6 V cell voltage under 335 ml min⁻¹ H₂ and 670 ml min⁻¹ air flow rates. SEM, TEM, EDX, AC impedance, voltage and power data with related analyses are presented here to support this high performance. The durability test of the cell with the best power performance shows a degradation rate of about 3% kh⁻¹ at the test conditions of 400 mA cm⁻² constant current density and 700 °C. Results demonstrate the success of APS technology for fabricating high performance metal-supported and LSGM based ITSOFCs.     

Thin crystalline silicon solar cells based on epitaxial films grown at 165 °C by RF-PECVD

We report on heterojunction solar cells whose thin intrinsic crystalline absorber layer has been obtained by plasma enhanced chemical vapor deposition at 165 °C on highly doped p-type (1 0 0) crystalline silicon substrates. We have studied the effect of the epitaxial intrinsic layer thickness in the range from 1 to 2.5 μm. This absorber is responsible for photo-generated current whereas highly doped wafer behave like electric contact, as confirmed by external quantum efficiency measurements and simulations. A best conversion efficiency of 7% is obtained for a 2.4 μm thick cell with an area of 4 cm², without any light trapping features. Moreover, the achievement of a fill factor as high as 78.6% is a proof that excellent quality of the epitaxial layers can be produced at such low temperatures.     

Experimental study of commercial size proton exchange membrane fuel cell performance

Commercial sized (16 × 16 cm² active surface area) proton exchange membrane (PEM) fuel cells with serpentine flow chambers are fabricated. The GORE-TEX® PRIMEA 5621 was used with a 35-μm-thick PEM with an anode catalyst layer with 0.45 mg cm⁻² Pt and cathode catalyst layer with 0.6 mg cm⁻² Pt and Ru or GORE-TEX® PRIMEA 57 was used with an 18-μm-thick PEM with an anode catalyst layer at 0.2 mg cm⁻² Pt and cathode catalyst layer at 0.4 mg cm⁻² of Pt and Ru. At the specified cell and humidification temperatures, the thin PRIMEA 57 membrane yields better cell performance than the thick PRIMEA 5621 membrane, since hydration of the former is more easily maintained with the limited amount of produced water. Sufficient humidification at both the cathode and anode sides is essential to achieve high cell performance with a thick membrane, like the PRIMEA 5621. The optimal cell temperature to produce the best cell performance with PRIMEA 5621 is close to the humidification temperature. For PRIMEA 57, however, optimal cell temperature exceeds the humidification temperature.     

A microfabricated low cost enzyme-free glucose fuel cell for powering low-power implantable devices

In the past decade the scientific community has showed considerable interest in the development of implantable medical devices such as muscle stimulators, neuroprosthetic devices, and biosensors. Those devices have low power requirements and can potentially be operated through fuel cells using reactants present in the body such as glucose and oxygen instead of non-rechargeable lithium batteries. In this paper, we present a thin, enzyme-free fuel cell with high current density and good stability at a current density of 10 μA cm⁻². A non-enzymatic approach is preferred because of higher long term stability. The fuel cell uses a stacked electrode design in order to achieve glucose and oxygen separation. An important characteristic of the fuel cell is that it has no membrane separating the electrodes, which results in low ohmic losses and small fuel cell volume. In addition, it uses a porous carbon paper support for the anodic catalyst layer which reduces the amount of platinum or other noble metal catalysts required for fabricating high surface area electrodes with good reactivity. The peak power output of the fuel cell is approximately 2 μW cm⁻² and has a sustainable power density of 1.5 μW cm⁻² at 10 μA cm⁻². An analysis on the effects of electrode thickness and inter electrode gap on the maximum power output of the fuel cell is also performed.     

Effect of unsintered gadolinium-doped ceria buffer layer on performance of metal-supported solid oxide fuel cells using unsintered barium strontium cobalt ferrite cathode

In this study, a Gd_0.1Ce_0.9O_1.95 (GDC) buffer layer and a Ba_0.5Sr_0.5Co_0.8Fe_0.2O_3−δ (BSCF) cathode, fabricated without pre-sintering, are investigated (unsintered GDC and unsintered BSCF). The effect of the unsintered GDC buffer layer, including the thickness of the layer, on the performance of solid oxide fuel cells (SOFCs) using an unsintered BSCF cathode is studied. The maximum power density of the metal-supported SOFC using an unsintered BSCF cathode without a buffer layer is 0.81 W cm⁻², which is measured after 2 h of operation (97% H₂ and 3% H₂O at the anode and ambient air at the cathode), and it significantly decreases to 0.63 W cm⁻² after 50 h. At a relatively low temperature of 800 °C, SrZrO₃ and BaZrO₃, arising from interaction between BSCF and yttria-stabilized zirconia (YSZ), are detected after 50 h. Introducing a GDC interlayer between the cathode and electrolyte significantly increases the durability of the cell performance, supporting over 1000 h of cell usage with an unsintered GDC buffer layer. Comparable performance is obtained from the anode-supported cell when using an unsintered BSCF cathode with an unsintered GDC buffer layer (0.75 W cm⁻²) and sintered GDC buffer layer (0.82 W cm⁻²). When a sintered BSCF cathode is used, however, the performance increases to 1.23 W cm⁻². The adhesion between the BSCF cathode and the cell can be enhanced by an unsintered GDC buffer layer, but an increase in the layer thickness (1-6 μm) increases the area specific resistance (ASR) of the cell, and the overly thick buffer layer causes delamination of the BSCF cathode. Finally, the maximum power densities of the metal-supported SOFC using an unsintered BSCF cathode and unsintered GDC buffer layer are 0.78, 0.64, 0.45 and 0.31 W cm⁻² at 850, 800, 750 and 700 °C, respectively.     

Solid oxide fuel cell with compositionally graded cathode functional layer deposited by pressure assisted dual-suspension spraying

In this work, the benefit of compositionally grading a cathode functional layer (CFL) for solid oxide fuel cells (SOFCs) is explored. Cells are prepared wherein either a standard cathode functional layer (SCFL) or a linearly compositionally graded cathode functional layer (CGCFL) is placed between the cell electrolyte and cathode current collecting regions. The electrochemical performance of these cells is compared with a SOFC cell containing no CFL. All cells are fabricated using a pressurized dual-suspension spraying system. Electrolytes, cathode functional layer, and cathode current collecting materials are deposited on a powder compacted anode support. SEM and EDAX area maps are taken to study the resulting micro-structures and to verify that the desired CFL profiles are produced. The EDAX area map verifies that a compositionally graded CFL and a SCFL are obtained. The cells are analyzed using impedance spectroscopy to evaluate the electrochemical performances of each cell. The open circuit voltage (OCV) and peak power densities of all three cells are 1.04 V with 80 mW cm⁻², 1.12 V with 108 mW cm⁻², and 1.08 V with 193 mW cm⁻² at 850 °C for the SCFL cell, the cell without a CFL, and the compositionally graded CFL cell respectively. The results show that this approach is a viable means for producing SOFC functional layers with unique composition and interfacial properties.     

Dicyanovinyl substituted oligothiophenes: Thermal stability, mobility measurements, and performance in photovoltaic devices

A series of dicyanovinyl-oligothiophenes are investigated concerning their thermal stability, absorption in thin film, and hole mobility. Due to very high extinction coefficients, these materials are interesting for application as donor in solar cells. The quinquethiophene DCV₂-5T, which shows a hole mobility of 2.2×10^-5 cm²/Vs, is used as donor material in a flat heterojunction organic small molecule solar cells. Despite a very thin donor layer of only 6 nm, these devices exhibit in a planar heterojunction with 15 nm C₆₀ an efficiency of up to 2.8% with a fill factor of up to 58%, a short circuit current density of 5.2 mA/cm², an open circuit voltage of 1.03 V, and an external quantum efficiency of 30% in the green spectral range.     

Comparison of solar cell performance of conducting polymer dyes with different functional groups

Conductive polymer precursors, including carboxylic acid, cyano groups, amino groups, 5,2′:5′,2″-terthiophene-3′-carboxylic acid (TTCA), 3′-cyano-5,2′:5′,2″-terthiophene (CTT), and 3′,4′-diamino-2,2′:5′,2″-terthiophene (DATT) are synthesized. Electrochemically polymerized films of the precursors on a nanocrystalline TiO₂ layer are examined as photo sensitizers, and the cell performance is compared. The photovoltaic cells are assembled with a polymer-coated TiO₂ layer treated with TiCl₄ as an anode and a Pt layer as a cathode in a propionitrile solution containing an iodide ion-based redox electrolyte. The charge-transfer processes of polymer-dyed cells are studied using impedance spectroscopy. The polymer dyes on the TiO₂ surfaces are characterized by scanning electron microscope (SEM), atomic force microscope (AFM), transmission electron microscope (TEM), and X-ray photoelectron spectroscopy (XPS). XPS results show that the conducting polymer dye, bearing a carboxylic acid group, is more strongly bound to the TiO₂ layer in comparison with other groups. Various experimental parameters affecting the cell efficiency are optimized, including the scan rate, number of potential cycles, and terthiophene monomer concentration. Of these polymers, the best cell efficiency is attained for poly-TTCA containing a carboxylic acid group. The optimized cell with the poly-TTCA dye shows a short-circuit current of 6.78 mA cm⁻², an open-circuit voltage of 0.54 V, and a fill factor of 63.6. An energy conversion efficiency of 2.32% is obtained with a cell area of 0.24 cm² under an air mass 1.5 solar simulated light irradiation of 100 mW cm⁻².     

Effect of carbon fiber paper made from carbon felt with different yard weights on the performance of low temperature proton exchange membrane fuel cells

This study employed fuel cell gas diffusion layers (GDLs) consisting of carbon fiber paper made from carbon fiber felt with different yard weights in proton exchange membrane fuel cells (PEMFCs), and investigated the relationship between the yard weight of the carbon fiber paper and the fuel cell performance and thickness of the gasket. In this paper we discuss the relationship between carbon fiber felt with different yard weights and fuel cell performance and also explore the effect of carbon fiber paper thickness, air permeability, surface resistivity, and structural study. We focused on the material used for the gas diffusion layer in this study. Carbon fiber paper made in-house in this study contained 10 wt% (all percentages are by weight unless otherwise noted) phenolic resin. When the tested area was 25 cm², the test temperature was 40 °C, the gasket thickness was 0.06 mm, and the yard weight 70 g m⁻², fuel cell current density was 1968 mA cm⁻² at a load 0.3 V. When the gasket thickness was 0.36 mm and yard weight was 190 g m⁻², fuel current density was 1710 mA cm⁻² at a load of 0.3 V.     

High efficiency flexible dye-sensitized solar cells by multiple electrophoretic depositions

A multiple electrophoretic deposition (EPD) of binder-free TiO₂ photoanode has been developed to successfully fill the crack occurring after air-drying on the first EPD-TiO₂ film surface. With the slow 2nd EPD, high quality TiO₂ thin films are acquired on flexible ITO/PEN substrates at room temperature and the device efficiency of the dye-sensitized solar cell achieved 5.54% with a high fill factor of 0.721. Electrochemical impedance spectroscopy measurements analyze the great enhancement of the photovoltaic performance through multiple EPD. The electron diffusion coefficient improved by about 1 order of magnitude in crack-less multiple-EPD TiO₂ films. With the scattering layer, the device reveals a high conversion efficiency of up to 6.63% under AM 1.5 G one sun irradiation, having a short circuit current density, open circuit voltage, and filling factor of 12.06 mA cm⁻², 0.763 V and 0.72, respectively.     

Mass transfer layer for liquid fuel cells

Performance of a new type of mass transfer layer (MTL) compared to a commercial material has been shown in single fuel cell testing. GRAFCELL^® natural graphite MTL is used as a cathode diffusion media along with carbon cloth. Its chemically modified permeable structure is diffusion limited at high current densities, independent of temperature, while perforated structure provides temperature dependent performance increases. The impact of open area variation in perforated mass transfer layer (PMTL) is demonstrated at high current densities and shows advantages over commercial material at room temperature operation. Performance reaches about 25 mW cm⁻² at room temperature testing with maximum current density around 250 mA cm⁻². Better performance is attributed to large openings for liquid transfer with PMTL compare to ELAT. Being able to design perforations on expanded graphite material may also play role in developing passive fuel supply systems for future liquid fuel power sources.     

An abiotically catalyzed glucose fuel cell for powering medical implants: Reconstructed manufacturing protocol and analysis of performance

Although the first abiotically catalyzed glucose fuel cells have already been developed as sustainable power supply for medical implants in the 1970s, no detailed information concerning the fabrication of these devices has been published so far. Here we present a comprehensive manufacturing protocol for such a fuel cell, together with a detailed analysis of long-term performance in neutral buffer containing physiological amounts of glucose and oxygen. In air saturated solution a power density of (3.3 ± 0.2) μW cm⁻² is displayed after 10 days of operation that gradually decreases to a value of (1.0 ± 0.05) μW cm⁻² in the course of 224 days. A novelty of this work is the characterization of fuel cell performance with individually resolved electrode potentials. Using this technique, we can show that the major part of performance degradation originates from a positive shift of the anode potential, indicating that a more poisoning-resistant glucose oxidation catalyst would improve the degradation behavior of the fuel cell. As further factors influencing performance an incomplete reactant separation and a mass transfer governed cathode reaction under the relatively low oxygen partial pressures of body tissue have been identified. Consequently we propose an oxygen depleting electrode interlayer and the application of more effective oxygen reduction catalysts as promising strategies to further improve the fuel cell performance under physiological concentrations of glucose and oxygen.     

The influence of gas diffusion layer wettability on direct methanol fuel cell performance: A combined local current distribution and high resolution neutron radiography study

The influence of the anode and cathode GDL wettability on the current and media distribution was studied using combined in situ high resolution neutron radiography and locally resolved current distribution measurements. MEAs were prepared by vertically splitting either the anode or cathode carbon cloth into a less hydrophobic part (untreated carbon cloth ‘as received’) and a more hydrophobic part (carbon cloth impregnated by PTFE dispersion). Both parts were placed side by side to obtain a complete electrode and hot-pressed with a Nafion membrane. MEAs with partitioned anode carbon cloth revealed no difference between the untreated and the hydrophobised part of the cell concerning the fluid and current distribution. The power generation of both parts was almost equal and the cell performance was similar to that of an undivided MEA (110 mW cm⁻², 300 mA cm⁻², 70 °C). In contrast, MEAs with partitioned cathode carbon cloth showed a better performance for the hydrophobised part, which contributed to about 60% of the overall power generation. This is explained by facilitated oxygen transport especially in the hydrophobised part of the cathode gas diffusion layer. At an average current density of 300 mA cm⁻², a pronounced flooding of the cathode flow field channels adjacent to the untreated part of GDL led to a further loss of performance in this part of the cell. The low power density of the untreated part caused a significant loss of cell performance, which amounted to less than 40 mW cm⁻² (at 300 mA cm⁻²).     

Comparison of infiltrated ceramic fiber paper and mica base compressive seals for planar solid oxide fuel cells

Solid oxide fuel cells using non-glass sealants have become increasingly common. In this paper, fumed silica infiltrated ceramic fiber paper with pre-compression was compared with plain and pre-compressed at 10 MPa hybrid mica as compressive seals. Leakage tests were measured under a 0.1–1.0 MPa compressive load with the pressure gradient varying from 2 to 15 kPa. The results demonstrated that the leakage rate of infiltrated fiber paper was 0.04 sccm cm⁻¹ for a 10 kPa gradient, under 1.0 MPa compressive load, while for mica it was 0.60 and 0.63 sccm cm⁻¹ which indicated that the infiltrated ceramic fiber paper showed a much lower leakage than mica. Long-term thermal cycling tests demonstrated that although the leakage of fumed silica infiltrated fiber paper was slightly higher than that of hybrid mica, it remained stable after 20 thermal cycles and no interlayer was needed. The mass loss of the fiber paper was 1.7 × 10⁻² mg cm⁻² h⁻¹ in a hydrogen environment at 1073 K for 200 h. The leakage of infiltrated fiber paper remained about 0.06 sccm cm⁻¹ after reduction.     

Bulk and contact resistance in P3HT:PCBM heterojunction solar cells

In this paper, the series resistance of poly(3-hexylthiophene-2,5-diyl) (P3HT) and [6,6]-phenyl C61-butyric acid methyl ester (PCBM) bulk heterojunction (BHJ) organic solar cells (OSC) has been studied. The series resistance of thermal annealed and un-annealed devices with different active layer thicknesses was measured. The series resistance of the organic solar cells consists of the bulk resistance of the active layer itself and the specific contact resistance between the active layer and the electrode. The bulk resistance and contact resistance were extracted from the measured series resistance using the vertical transmission line model (TLM) method. By fabricating solar cell devices with different active layer thicknesses, a relationship of the series resistance with thickness was established from which bulk and contact resistances were derived. We have also found that thermal annealing helps reduce both contact resistance and bulk resistance significantly; the contact resistance dropped by a factor of 2, while the bulk resistance decreased by a factor of 8. Results have shown that for an annealed P3HT:PCBM device that has an active layer thickness of 85 nm (optimum thickness for high efficiency), 17% of the total series resistance was due to the contact resistance, and bulk resistance contributed the rest 83%. The bulk resistance value for thermal annealed organic solar cell device with an active area of 0.1 cm² was found to be 150 Ω, and the measured specific contact resistance was 3.1 Ω cm². The measured bulk and contact resistance values are much higher as compared to the high efficiency silicon solar cells. Bulk resistance and contact resistance need to be further decreased in order to achieve higher organic solar cell efficiency.