A 16.10% efficiency organic solar module with ultra-narrow interconnections fabricated via nanosecond ultraviolet laser processing

Scaling organic solar cells (OSCs) for commercial use is challenging. High-quality and precise scribing is needed to bridge lab-scale cells and large-area OSC modules, but the research lags significantly. Here, we demonstrate a cost-effective patterning approach using a 355-nm ultraviolet nanosecond pulsed laser for performing all scribing processes, including P1, P2, and P3, in the fabrication of OSC modules. Optimized laser processing enables an 80-μm interconnection width, comparable with femtosecond laser methods, and broadens the process window of P2 layer patterning, making OSC module performance less impacted by indium tin oxide damage. With ultraviolet nanosecond laser scribing, the OSC module yields an impressive geometric fill factor of 98% and a certified power conversion efficiency of 15.43% with an aperture area of 11.30 cm2, making it one of the top-performing OSC modules reported. This study delivers an efficient, repeatable laser patterning method for high-quality OSC modules.