Scalable Deposition Methods for Large-area Production of Perovskite Thin Films

In the last decade, the power conversion efficiency (PCE) of solution-processed perovskite solar cells (PSCs) in the lab-scale has reached an incredible level of 25.5%. Generally, PSCs are composed of a stack consisting of a perovskite thin-film sandwiched between an electron transporting layer (ETL) and a hole transporting layer (HTL). Although the quality of the ETL and HTL interfaces with the perovskite thin-film is important, the quality of the perovskite thin-film is also critical to achieving high-performance PSCs. Low-temperature deposition of organic–inorganic perovskite thin-films by simple solution processes is one of the significant advantages of PSCs compared to other well-developed semiconductors for manufacturing solar cells. However, growing highly uniform and crystalline solution-processed perovskite thin-films is very challenging due to multiple phenomena during film formation, including solvent evaporation, wetting effects, inhomogeneous film stress and uncontrolled nucleation and growth. Therefore, understanding the different stages of perovskite crystallization is critical for achieving high-quality films and realizing higher PCEs. On the other hand, switching to large-scale solar modules leads to a substantial loss in performance, decreasing the chance of commercialization of this technology. Therefore, developing large-scale deposition techniques for reliable perovskite crystallization is very vital for scaling up PSCs. So far, several solution-processed methods such as anti-solvent and two-step processes have been developed for lab-scale perovskite thin-films deposition. However, these methods are not applicable for large-scale perovskite deposition. This review explores various scalable solution-processed perovskite deposition techniques. Moreover, different solvent quenching techniques as the most critical step of large-scale perovskite crystallization are discussed to provide a comprehensive view for achieving high-quality perovskite thin-films with large areas. Finally, the existing challenges and opportunities to push forward the commercialization of PSCs are discussed.

Solution-processed perovskite thin-films: the journey from lab- to large-scale solar cells

To make perovskite solar cells an industrially relevant technology large area deposition techniques are needed and one of the most promising is slot-die coating. This review article details the progress reported in the literature where slot-die coating has been used for the deposition of both the perovskite layer and other layers in the perovskite solar cell device stack. An overview of the methods used to adapt the coating process, materials and drying conditions in order to create high quality layers and devices is given and an outlook on future research directions in this field is made.

https://cronfa.swan.ac.uk/Record/cronfa52964/Download/52964__16040__f0edea3933a14d3aa6995029c18d157a.pdf

Slot-die coating of perovskite solar cells: An overview

Efficient perovskite solar mini-modules fabricated via bar-coating using 2-methoxyethanol-based formamidinium lead tri-iodide precursor solution

Enhancing the open circuit voltage of the SnS based heterojunction solar cell using NiO HTL

Roll-to-roll coating of all active layers is demonstrated for a P–I–N perovskite solar cell stack, using a single step perovskite ink with an acetonitrile solvent system and flexible plastic substrate. A slot-die coating roll-to-roll process (with a common coating speed for all layers) is developed by using appropriate length meniscus guides as part of the coating head for each ink rheology. High performance devices are demonstrated with four roll-to-roll slot-die coated layers and evaporated top electrode. The drying conditions of the perovskite layer are optimized and found to be critical to achieving good performance. Multi solvent blend systems for the electron collection layer are developed that are more industrially compatible than the commonly used chlorobenzene solvent system and make use of a gradient of solvent volatilities to give both good macro film formation and rapid drying. A stabilised power conversion efficiency of 12.2% is demonstrated, that is the highest reported to date for devices with all layers other than the top electrode deposited roll-to-roll. This work demonstrates the feasibility of a roll-to-roll fabrication process for perovskite solar cells that could be transferred to a fully inline roll-to-roll process with all coating and drying stages made sequentially on one line running at a common coating speed and further demonstrates the potential to produce high efficiency photovoltaics using roll-to-roll fabrication methods.

/pdf/roll-to-roll-slot-die-coated-p-i-n-perovskite-solar-cells-2v21krdsu7.pdf

Roll-to-roll slot-die coated P–I–N perovskite solar cells using acetonitrile based single step perovskite solvent system

Thin films of polycrystalline NiO were deposited by Flame Assisted Chemical Vapour Deposition, which is an ideal process for in-line, atmospheric pressure deposition of wide area coatings. This, along with the ability to use aqueous salts rather than organic precursors or solvents makes it well suited for industrial integration. To establish the capability of FACVD deposited NiO for use as a low cost, commercially viable option planar perovskite cells were fabricated under ambient conditions. The resulting cells showed the importance of both the flame composition and NiO thickness. A continuous NiO Hole Transport Layer (HTL) was achieved for ca. 36 nm thick film, which showed a maximum higher efficiency of 12.3% over that of the control (11.8%) which used a spin coated HTL. This was mainly driven by the large improvement in the current density from 16.6 mA/cm2 to 19.0 mA/cm2.

/pdf/flame-assisted-chemical-vapour-deposition-of-nio-hole-x84eva4rx3.pdf

Flame Assisted Chemical Vapour Deposition of NiO hole transport layers for planar perovskite cells

Roll-to-roll slot-die coating with a meniscus guide is used to deposit several layers in a P-I-N perovskite solar cell stack, including the perovskite layer. The use of various length meniscus guides as part of the slot-die head allows controlled coating of these layers at a common coating speed. The length of meniscus guide used is optimised and related to the rheology of the coated ink and appropriate choice of meniscus guide length provides a way to avoid flooding of the coated area and improve coating definition. Initial coating trial results suggest the low-flow limit of slot-die coating is still applicable when using a meniscus guide, which is an important and previously unreported observation, application of this theory to meniscus guide coating provides a useful tool for rapidly determining the appropriate coating conditions that can be used as part of a manufacturing process. This is further explored through the deposition of perovskite solar cells by roll-to-roll slot-die coating. The perovskite layer is deposited using a sequential slot-die deposition process using a low toxicity dimethyl sulfoxide ink for the lead iodide layer, it is found that increasing the drying oven temperature and air flow rate can be used to improve the uniformity of the layer but this can also result in deformation of the plastic substrate. Functioning perovskite solar cells are demonstrated using this technique, but a large variation is found between device performances which is attributed to the poor uniformity of the perovskite layer and damage caused to the substrate by excessive heating.

Meniscus Guide Slot-Die Coating For Roll-to-Roll Perovskite Solar Cells

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Papers

Roll-to-roll slot-die coated P–I–N perovskite solar cells using acetonitrile based single step perovskite solvent system

Flame Assisted Chemical Vapour Deposition of NiO hole transport layers for planar perovskite cells

Meniscus Guide Slot-Die Coating For Roll-to-Roll Perovskite Solar Cells