Advancement of organic photovoltaic (OPV) technology towards commercial products requires the development of materials that are amenable to large area print manufacturing. This manuscript will highlight efforts by the OPV program at Phillips 66 to solve issues related to material scale-up, through material design combining good processability and high photovoltaic performance. An internally developed polymer/phenyl-C<sub>71</sub>-butyric acid methyl ester (PC<sub>70</sub>BM) blend that combines these critical parameters achieved a certified power conversion (PCE) of 12.14% in 2017.
Solution processable polymer-based organic photovoltaics offer tremendous opportunities for applications requiring flexible, translucent or aesthetically pleasing designs, with potential for low-cost roll-to-roll mass production. However, progress in moving the organic photovoltaic technology from lab-scale to commercial applications has been slow, generating skepticism around the commercial viability of the technology. Organic photovoltaic research is often carried out on small-area research cells fabricated under inert conditions using techniques such as spin coating that do not translate to mass production. While high research cell performance can be achieved, the materials selected or conditions used for fabrication are typically not amenable to scale-up. This paper will focus on solving some of the technical challenges associated with scaling polymer-based bulk heterojunction organic photovoltaics to high-performance large-area modules. Efforts to develop materials that are stable to fabrication in air, have good solubility, and enable deposition of thick (>300 nm) photoactive layers are described, leading to organic photovoltaic modules reaching 8% power conversion efficiency (PCE).