The ORION consortium project, funded under the German research grant FKZ 03EE1075, focused on the integration of organic photovoltaic (OPV) modules into greenhouse film systems and the long‑term monitoring of these modules once installed. The German partner ASCA GmbH i. L. carried out the majority of the technical work, contributing 42 person‑months of effort. Key collaborators included Israeli partners who supplied OPV modules for testing and the German research institute TRDC, which performed life‑time tests and monitored module performance in greenhouse conditions. The project was executed within the framework of the ORION consortium’s work packages 1 and 3, with no new equipment required beyond the existing climate chambers, solar simulators, and lamination facilities.
Technically, the project achieved several milestones. First, ASCA developed and refined three variants of electrical connection points for OPV modules: (A) injection‑molded contact caps, (B) pre‑formed caps glued onto the module, and (C) flat, tape‑fixed contacts. The glued variant proved most suitable for integration into greenhouse film tunnels, as it maintained mechanical integrity and prevented delamination under airflow. Second, a seamless integration process was established, laminating OPV modules between two polyethylene greenhouse films using a suitable ethylene‑vinyl acetate (EVA) interlayer. This EVA layer did not adversely affect module lifetime, confirming its compatibility with the OPV encapsulation.
A critical advancement was the use of novel barrier films with low water‑vapor permeability to encapsulate the OPV modules. These barrier layers significantly extended module lifetime compared to earlier designs, as demonstrated in accelerated aging tests. The modules were fabricated with different spectral characteristics tailored to greenhouse applications, and their electrical and optical designs were optimized for the specific light environment inside a greenhouse.
To support long‑term monitoring, ASCA designed a custom printed circuit board equipped with sensors for voltage, current, and temperature. Data from the board were transmitted to an online interface, enabling real‑time analysis of module performance. TRDC installed the modules in both greenhouse and laboratory settings and conducted life‑time tests. While most modules remained stable, the blue‑colored modules exhibited a rapid decline in power output during some tests. The tests suggested that applying an electrical load and maintaining low system voltage during aging slowed degradation, indicating that operational conditions influence module longevity. Despite mixed results, the overall stability of the modules was confirmed, and the monitoring system proved effective for capturing performance trends.
In summary, the ORION project delivered a robust integration method for OPV modules in greenhouse films, advanced connection technologies, and a reliable monitoring platform. The collaboration between ASCA, Israeli partners, and TRDC, supported by German research funding, enabled the successful development of modules with extended lifetimes and demonstrated the feasibility of deploying OPV technology in controlled agricultural environments. Further life‑time testing is planned to resolve remaining uncertainties and to validate the long‑term performance of the developed modules under diverse greenhouse conditions.