Ultimate form freedom in thin film solar cells by postmanufacture laser-based processing

Abstract. Thin film photovoltaics can be beneficial for specific applications like building integrated photovoltaics. To fully exploit the differentiator of form freedom, the interconnections in thin film modules can be tuned depending on the required module output. Traditionally, an alternation of coating and scribing steps is applied, determining the form from the start. Here, we present a set of techniques to define the module design from a master substrate with homogeneously coated electroactive layers. By applying subtractive and additive laser-based processes, the size and form of the module are only fixed after the manufacturing of the whole solar cell stack. By laser-induced forward transfer, an isolating dielectric material and a conductive top electrode are deposited in laser ablated scribes to enable the interconnection between two adjacent cells. After optimization of the laser settings for ablation and forward transfer, the optimal annealing time and temperature for the curing of the silver top electrode were determined. The proof of principle was demonstrated by constructing a 4-cell organic solar module of 1.0% efficiency on an area of over 3  cm2 showing the anticipated short-circuit current and open-circuit voltage.