protection of organic solar cells for long lifetime · etfe pvdf pvf pp pfa pc pvdc lcp ectfe 0,01...
TRANSCRIPT
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Plessing A. K., Depiné N., Erler B., Feichtner M., Gradwohl J., Krumlacher W., Muckenhuber, H., Reininger A., Reisinger F., Ruplitsch A., Seitler E.,
Skringer A., Spanring J.
International Symposium towards Organic PhotovoltaicsLinz, Johannes Kepler Universität
2008, February, 6-8
Protection of Organic Solar Cells forLong Lifetime
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Outline1. Overview
Historical backgroundStandard Isovolta products for the PV industry
2. Encapsulation Material for Flexible Solar Cells
RequirementsState of the artConceptsToday`s results
3. Automated encapsulation
4. Summary
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Isovolta AG
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Werndorf Plant2005
competence center
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Lebring Plantopened 2005expanded 2008
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Wr. Neudorf Plant & Headquarters
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Locations•Isovolta Werndorf, AT 1949•Isovolta Wr.Neudorf, AT 1962•Isovolta India, IND (40%) 1984•Skyline, USA (100%) 1989•Isovolta Hong Kong, CN (76%) 1990•Teinser, E (60%) 1992•Changzhou Isovolta, CN (70%) 1995•Nippon Rika Isovolta, JP (34%) 1996•Isovolta S.A., RO (99%) 1998•Micafil Glimmer-Aktivitäten, CH (100%) 1999•Isovolta di Mexico, MX (60%) 2000•Gatex, DE (100%) 2001•Isoma, BG (100%) 2002•Skylife spol. s.r.o., SK (100%) 2003•Isovolta Inc./US Samica, USA (100%) 2003•Changzhou Olong, CN (40%) 2004•Changzhou T C , CN (70%) 2005•Lebring, AT (100%) 2005•Deglarges, F (60%) 2006
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Isovolta AG
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High Voltage
Low Voltage & Transformers
Rigid Laminates
ISOVOLTA GROUP
Photovoltaics
Composite Materials
Aircraft
Div
isio
nM
arke
t
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Production
R & D International
Process Technology
CompetenceCompetence Center Center WerndorfWerndorf
> 340 employes
work.70%
empl.15%
R & D15%
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PV Module
Encapsulation material forStandard crystalline cellsThin film cellsSpecial encapsulation application solutions
Laminated film
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Laminated Film
Fluoropolymer(PVF, PVDF)
• weather resistance
Polyester• electrical insulation
• mechanical stabilisty
• H2O vapor barrier
Adhesive
Adhesive
Laminated Film
23 years of experience25 years guaranteed lifetime+30 years lifetime
Fluoropolymer, Primer, EVA• adhesion to EVA,TPU, PVB
outside
inside
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Long Term Stability of Encapsulating Materials
WeatherabilityDamp-Heat Test @ 85 °C/ 85% r.h.: 2000 h – 3500 hUV-Stability: IEC 61730
Evaluation Adhesion between layersDiscolouration
Crystalline solar cells
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stand-alone integrated
ISOVOLTA AG, Wr. Neudorf (A) Headquarters PV-facade
PV-facility, New Mexicco (USA)(Shell Solar Industries LP)
thin film
transparent
a-Si thin film modules(Kaneka Corporation)
Floriade(Siemens Nederland N.V.)solar park
Mercedes solar roof, D(Webasto Systemkomponenten GmbH & Co. KG)
Solarpark Mühlhausen,D35820 modules, ~ 6,3 Mw
Application of Laminated Films
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Encapsulation Material for Flexible Solar Cells
© Konarka
© Fraunhofer ISE
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weatherability
high transparency
flexibility
UV-stability - low yellowing
no brittleness
adhesion
cost efficiency
availability
barrier properties (water vapour, oxygen)
Requirements on Encapsulation Materials for Flexible Solar Cells
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Barrier Requirements for Different Product Sectors
Water Vapour Transmission (WVTR):
Standard material today: 2 g.m-².d-1
Goal: High Barrier Laminates 10-5 g.m-².d-1 and lower
WVTR OTR Lifetime[g.m-2.d-1] [cm3.m-2.d-1.atm-1] [a]
amorphous Si < 100 < 100 > 20CIS < 10-3 < 10-3 > 10Organic Solar Cells < 10-3 < 10-3 > 5OLEDs < 10-6 < 10-5 > 2
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PEN PANPA 6PET
PSU
PCTFE
ETFE
PVDFPVF
PP
PFA
PC
PVDC
LCP
ECTFE
0,01
0,1
1
10
100
1000
10000
0,01 0,1 1 10 100
water vapor transmittance / g / m2 dox
ygen
tran
smitt
ance
/ cm
3 / m
2 d b
arO
TR [c
m3 /m
2d
bar]
WVTR [g/m2 d]
Barrier properties of technical polymers
Permeability, normalized to 100 µm thickness
Oxygen transmission (DIN 53 380): 23°C, 50% r.h.Water vapor transmission (DIN 53 122):23°C, 85% r.h. to 0% r.h.
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0,01
0,1
1
10
100
1000
0,01 0,1 1 10 100
OTR
[cm
³/m² d
bar
]
BOPP/PE
PET-PEN/PE, laminates with SiOx (PVD)
PET/PE EVOH-laminates
PA/PE
PET/PVDC
PET/PE
WVTR [g/m² d]
aluminum-film-laminates
OTR: (DIN 53 380: 23°C, 50% r.h.)WVTR: (DIN 53 122: 23°C, 85% r.h.)
Barrier properties oflaminates and composite materials
(PVD: physical vapordeposition)
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Flexible Encapsulation Materials: State of the Art (1)
PML®-ProcessPolymer Multi Layer Process (by Vitex Systems, Inc.)
alternating coating systems acrylates & inorganic barrier layers
Burrows, P.E. et al.; MRS spring Meeting 2002, Boston, USA
BARIXTM encapsulation
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©Vitex Systems
PML® process
Barrier stack ( alternating coatingof acrylates and inorganic barrierlayers)
Teonex® PEN substrate
direct deposition on OLED, OSC substrateflexibleformats: 7-9 in wide, up to 100 ft long
Vitex, Inc.
Flexible Encapsulation Materials: State of the Art (2)
Barrier propertiesWVTR: 10-5 g/m2*dOTR: 10-5 cm3/m2*d(Ca test)
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SABIC (former GE Plastics)
Scheme of the graded inorganic / organic barrierlayers:
The moisture rate of a PC substrate with the ultra high barrier (UHB) coating measured by the Ca corrosion test is less than 1 x 10-5 g/m2.d.
Flexible Encapsulation Materials: State of the Art (3)
J. Vac. Sci. Technol. A, Vol. 23, No. 4, Jul/Aug 2005
Application: 24 x 24 in OLED display (cooperation withKonika Minolta)
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Flexible Encapsulation Materials: State of the Art (4)
Nova Plasma, Canadadevelopement of new encapsulation technology for
OLEDsinorganic / organic PEVCD coating deposition on
polymer substratesone-step multilayerflexible, transparent excellent T resistanceOTR & WVTR rates: below the sensitivity limit of
standard Mocon instrument (< 0.005 g/cm2 *day)
United Solar Ovonic, USAworld leader in thin-film amorphous PV technology & applicationsmanufacture of a-Si cells & R2R vacuum deposition on substrate(substrate: rollable stainless steel)flexible Building-Integrated photovoltaic solar energy systemsdimensions: 1.5 miles long, 14 in wide
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Flexible Encapsulation Materials: State of the Art (5)
University and Related InstitutesIMRE, Singapore (Institute of Materials Research and
Engineering):flexible barrier developmentdevelpment of measurement system (> 10-6 g/ m2*d)
Fraunhofer Gesellschaft, D (FhG): development of flexible tailor made barrier layers (organic / inorganic hybrid materials)
Film Manufacturers – Barrier FilmsDuPont Teijin, worldwide
Teonex® Q65FA Melinex® ST 506/504
Honeywell, USAAclar ® (PCTFE)OxyShield® (PVdC coex. Nylon: moisture & O2 barrier )
Vacumet, USA (metallized polymer films, e.g. BARRIER-MET®)Pliant Engineered Films, USA (SynergyTM: hybrid moisture barrier)
heat stabilized, optical clear, planarized
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Isovolta Concepts for High Barrier Materials
Multilayer materials with inorganic coatings
Multilayer structures with inorganic coatings and sealants
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Substrates
PET 1 PET 2
PET 3 PEN 1
Influence of surface roughness before PEVCD !
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MeOx – vacuum deposition, PEVD
© Applied Materials
Schematic set-up
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Multilayer Materials with Inorganic Coatings (1)
Schematic drawing of a 4 layer PET/MeOx composite
(thickness approximately 100 µm)
Adhesive
PET
PET
Adhesive
Adhesive
PET
PET
MeOx
MeOx
MeOx
MeOx
Adhesive
PET
PET
Adhesive
Adhesive
PET
PET
MeOx
MeOx
MeOx
MeOx
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PET
PET
AdhesiveSiOx
Multilayer Materials with Inorganic Coatings (2)
TEM picture of a two layer composite, 26kx
TEM picture, 52kx
Inorganic Coating defects decrease in barrier coating properties
Sealants close defects
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Barrier Properties of Multilayer Materials with Inorganic Coatings (3)
MeOx layers WVTR
[g.m-2.d-1]2 layers 0,404 layers 0,108 layers 0,03
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Transmission of Transparent BarrierLaminates
0
20
40
60
80
100
120
0 200 400 600 800 1000 1200
λ [nm]
Tran
smis
sion
[%]
> 85% light transmission !
2 layers4 layers 8 layers
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Multilayer Structures with Inorganic Coatings and Sealants
MeOx layers WVTR
[g.m-2.d-1]
4 layers 0,06
PET/MeOx with sealant, recoated with MeOx
Sealant
Sealant
PET
Adhesive
PET
MeOx
MeOx
MeOx
MeOxSealant
Sealant
PET
Adhesive
PET
MeOx
MeOx
MeOx
MeOx
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SiOxSiOx
PET PET
Org. Sealant
Adhesive
Film material
Thickness[µm]
WVTR 1[g/m²d]
WVTR 2[g/m²d]
WVTR 3[g/m²d]
PET 36 5.9 6.0 -PET-SiOx 36.08 0.4 0.6 0.6Multilayer 102.32 0.063 0.057 -
Barrier values of a 4 layer material
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Multilayer Structures with Inorganic Coatings and Improved Sealants
PET
PET
SiOx
SiOxAdhesive
Sealant
PET
Sealant
SiOx
Adhesive
TEM picture, 4,4kxTEM picture, 42kx
New sealants further improved barrier properties
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Best Barrier Properties of Multilayer Material with Inorganic Coatings
and Improved Sealants
MeOx layers WVTR OTR
[g.m-2.d-1] [cm3.m-2.d-1.atm-1]
2 layers < 0,01 < 0,05
Barriers of 10-4 g.m-2.d-1 could be achieved on laboratory samples in cooperation with FraunhoferGesellschaft.
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Results Up to Now
Both, hydrolysis and UV stability tests demonstrate good stability!
MeOx layers WVTR
[g.m-2.d-1]0,400,10
2 layers4 layers8 layers 0,03
0,064 layers
2 layers < 0,01
inorganic layers
inorganic layers, improved sealants
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Further Developments in Progress
Up-scaling of encapsulation material with 10-2 g.m-2.d-1 WVTR and 10-2
cm3.m-2.d-1.atm-1 OTR (cooperation with Fraunhofer Gesellschaft). Introduction into the market by end of 2008
Improved sealants & MeOx-substrates target values: < 10-6 for WVTR & OTR
R2R encapsulation process
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R2R Encapsulation Process (1)
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R2R encapsultion process (2)
Encapsulant
Thin film solar cellson flexiblesubstrate
encapsulatedsolar cells
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Applications for Flexible Solar Cells
©Brunton, SolarRolls™ ©Konarka
©Flexcell
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Summary
Organic solar cells require high barrier materials for encapsulation.
Laboratory results of barriers in the range of 10-2 to 10-4 (FraunhoferGesellschaft) could be achieved.
Encapsulation material, which fulfils all requirements has to be developed for industrial production processes.
Automated encapsulation processes have to be developed.
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