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The comparison of solution processed organic photovoltaics with two roll-to-roll coated electron transport layers (ETL), as well as printed grid or solid back electrodes provides insight into the future of R2R fabricated architectures. The variation in performance of the R2R slot-die coated zinc oxide (ZnO) versus the tin oxide (SnO2), showed a clear dependence on the spectrum of the illumination source. It was found that under indoor light conditions (200–1000 lux LED and fluorescent sources) the SnO2 outperformed the ZnO with highest efficiencies near 13% and 10% respectively. This is in contrast to results obtained under 1 Sun (AM 1.5) in which the cells fabricated with a ZnO ETL had a higher power conversion efficiency than those prepared with SnO2. The results also confirm the significance of the layout of the printed silver back contact; in which cells with the grid structure outperformed those with full coverage by approximately 35% for ZnO and just under 10% for SnO2 (all light conditions). The combination of a R2R coating and S2S printing process to prepare modules with 8 cells in series (PET/ITO/SnO2/PV2001:PCBM/PEDOT:PSS/silver grid) resulted in a PCE of 13.4% under indoor office light conditions.

Understanding the phenomena at interfaces is crucial for producing efficient and stable flexible organic solar cell modules. Minimized energy barriers enable efficient charge transfer, and good adhesion allows mechanical and environmental stability and thus increased lifetime. We utilize here the inverted organic solar module stack and standard photoactive materials (a blend of poly(3-hexylthiophene) and [6,6]-phenyl C61 butyric acid methyl ester) to study the interfaces in a pilot scale large-area roll-to-roll (R2R) process. The results show that the adhesion and work function of the zinc oxide nanoparticle based electron transport layer can be controlled in the R2R process, which allows optimization of performance and lifetime. Plasma treatment of zinc oxide (ZnO) nanoparticles and encapsulation-induced oxygen trapping will increase the absolute value of the ZnO work function, resulting in energy barriers and an S-shaped IV curve. However, light soaking will decrease the zinc oxide work function close to the original value and the S-shape can be recovered, leading to power conversion efficiencies above 3%. We present also an electrical simulation, which supports the results. Finally, we study the effect of plasma treatment in more detail and show that we can effectively remove the organic ligands around the ZnO nanoparticles from the printed layer in a R2R process, resulting in increased adhesion. This postprinting plasma treatment increases the lifetime of the R2R printed modules significantly with modules retaining 80% of their efficiency for ∼3000 h in accelerated conditions. Without plasma treatment, this efficiency level is reached in less than 1000 h.