Roll-to-roll fabrication of bulk heterojunction plastic solar cells using the reverse gravure coating technique

The roll-to-roll reverse gravure (RG) coating technique was used to produce thin homogeneous films (∼100 nm) for organic bulk heterojunction solar cells. The conducting polymer poly(3,4-ethylenedioxythiophene):poly(styrene sulfonate) (PEDOT:PSS) and the active layer regioregular poly(3-hexylthiophene- 2,5-diyl):[6,6]-phenyl-C₆₁-butyric acid methyl ester (P3HT:PCBM) were successfully subsequently RG coated on an ITO covered plastic substrate in ambient air. Working solar cells were achieved after annealing and thermal evaporation of the top contact. The AM1.5 power conversion efficiency (PCE) of the RG coated organic solar cells was determined to 0.74% (at 100 mW/cm ²). This was very similar to the results of a reference device that was spin coated on a glass substrate in a nitrogen glove box.