Cold isostatic pressing technique for producing highly efficient flexible dye‐sensitised solar cells on plastic substrates

One of the biggest challenges for making dye‐sensitised solar cells (DSCs) on plastic substrates is the difficulty in making good quality nanoporous TiO₂ films with both good mechanical stability and high electrical conductivity. Cold isostatic pressing (CIP) is a powder compaction technique that applies an isostatic pressure to a powder sample in all directions. It is particularly suitable for making thin films on plastic substrates, including non‐flat surfaces. Cold isostatically pressed nanocrystalline TiO₂ electrodes with excellent mechanical robustness were prepared on indium tin oxide (ITO)‐coated polyethylene naphthalate (PEN) substrates in the absence of organic binders and without heat treatment. The morphology and the physical properties of the TiO₂ films prepared by the CIP method were found to be very compatible with requirements for flexible DSCs on plastics. This room‐temperature processing technique has led to an important technical breakthrough in producing high efficiency flexible DSCs. Devices fabricated on ITO/PEN films by this method using standard P‐25 TiO₂ films with a Ru‐complex sensitiser yielded a maximum incident photon‐to‐current conversion efficiency of 72% at the wavelength of 530 nm and showed high conversion efficiencies of 6.3% and 7.4% for incident light intensities of 100 and 15 mW cm⁻², respectively, which are the highest power conversion efficiencies achieved so far for any DSC on a polymer substrate using the widely used, commercially available P‐25 TiO₂ powder. Copyright © 2011 John Wiley & Sons, Ltd.