Inkjet technology for crystalline silicon photovoltaics

Challenges in the Synthesis and Processing of Hydrosilanes as Precursors for Silicon Deposition

Hydrosilanes are highly attractive compounds, which can be processed as liquids with printing technology to amorphous silicon films on nearly any solid substrate. The silicon layers can be processed for electronic devices like transistors or thin-film solar cells. The endothermic character of hydrosilanes with their positive enthalpies of formation results in favorable properties for processing. The larger the molecules, the lower their decomposition temperature and the higher their photoactivity. Cyclic hydrosilanes such as cyclopentasilane and cyclohexasilane can be easily deposited. The branched neopentasilane is more difficult to deposit but yields better-quality films after processing. The key challenge is the complex synthesis of the precursors and the hydrosilanes. The available preparative methods are presented in this review and their advantages and disadvantages are evaluated. The following synthesis methods are presented and discussed in this article: Wurtz coupling and other reductive coupling processes, dehydrogenative coupling of silanes, plasma synthesis of chlorinated polysilanes, amine- or chloride-induced disproportionations, and transformation of monosilane to higher silanes. Plasma synthesis is already carried out today as a continuous industrial process. The most effective synthesis methods in the laboratory are currently amine- and chloride-induced disproportionations. There is a great need to further optimize the syntheses of hydrosilanes and to develop new simple synthesis variants.

Mask and plate: a scalable front metallization with low-cost potential for III-V-based tandem solar cells enabling 31.6 % conversion efficiency

Low-cost approaches for mass production of III-V-based photovoltaics are highly desired today. For the first time, this work presents industrially relevant mask and plate for front metallization of III-V-based solar cells replacing expensive photolithography. Metal contacts are fabricated by nickel (Ni) electroplating directly onto the solar cell's front using a precisely structured mask. Inkjet printing offers low-cost and high-precision processing for application of an appropriate plating resist. It covers the solar cell's front side with narrow openings for subsequent electroplating. The width of the resulting Ni contacts is as low as (10.5 ± 0.8) µm with sharp edges and homogenous shape. The 4 cm2-sized champion III-V-on-silicon triple-junction solar cell with mask and plate front metallization reaches a certified conversion efficiency η of (31.6 ± 1.1) % (AM1.5 g spectrum). It performs just as well as the reference sample with photolithography-structured evaporated front contacts, which reaches η = (31.4 ± 1.1) %.

The solvent effect on the morphology and molecular ordering of benzothiadiazole-based small molecule for inkjet-printed thin-film transistors

A small molecule organic semiconductor, D(D'-A-D')₂ comprising benzothiadiazole as an acceptor, 3-hexylthiophene, and thiophene as donors, was successfully synthesized. X-ray diffraction and atomic force microscopy were used to investigate the effect of a dual solvent system with varying ratios of chloroform and toluene on film crystallinity and film morphology via inkjet printing. The film prepared with a chloroform to toluene ratio of 1.5 : 1 showed better performance with improved crystallinity and morphology due to having enough time to control the arrangement of molecules. In addition, by optimizing ratios of CHCl₃ to toluene, the inkjet-printed TFT based on 3HTBTT using a CHCl₃ and toluene ratio of 1.5 : 1 was successfully fabricated and exhibited a hole mobility of 0.01 cm² V^-1 s^-1 due to the improved molecular ordering of the 3HTBTT film.

Capillary instability in screen-printed micropatterns

Screen printing (SP) has been extensively studied owing to its widespread industrial applications; however, only a few studies have focused on the substrate effect. Herein, we demonstrate that a screen-printed line can undergo a broadening effect or lateral undulation, which is determined by the substrate and printed dimensions. The degree of spreading was systematically investigated by employing 1D and 2D geometrical parameters. Based on the liquidity of the ink, we developed a simple inviscid theory with imposed perturbation to analyze the instability of screen-printed lines. The dispersion relation was derived to estimate the geometry of the laterally undulated lines and compared with the experimental results. The proposed argument is particularly applicable to a regime in which SP inks have greater liquidity. The screen-printed patterns exhibited unique undulated shapes and were utilized as photomasks for the facile fabrication of raccoon-type microchannels.

High-Frequency Rheological and Piezo-Voltage Waveform Characterization of Inkjet-Printed Polymer-Based Dopant-Source Inks

This work focuses on developing an understanding of the rheological properties of polymer-based dopant-source inks at the timescales relevant to inkjet printing and their corresponding roles in determining the production of defect-free droplets. Ink-specific optimization of printing processes for phosphorus and boron dopant-source inks with different compositions is demonstrated. Rheological flow curves measured by a piezo axial vibrator (PAV) were used to study the changes in complex viscosity (η*) and in the elastic (G') and viscous (G″) components of the shear modulus (G*) with respect to changes in frequency (from f_min = 1 kHz to f_max = 10 kHz) to obtain an insight into the high-frequency behaviour of inks, as well as the effects of temperature (25 °C and 45 °C) and the natural aging time of the inks. Inks demonstrating complex viscosity η*_min ≥ 2 mPas to η*_max ≤ 20 mPas and an elastic modulus G' ≤ 20 Pa, produced droplets with negligible defects. Of the three rheological parameters (η*, G' and G″), the elastic component (G') of the shear modulus was observed to have the greatest significance in determining the stability and homogeneity of ink droplets, thus dictating the quality of the printed structures. The reliability and stability of droplet formation were further investigated through voltage waveform simulation using an oscilloscope.

Manipulating Single-Walled Carbon Nanotube Arrays for Flexible Photothermoelectric Devices

Flexible photothermoelectric (PTE) devices possess great application prospects in the field of light energy and thermoelectric energy harvesting which are some of the cornerstones of modern green renewable energy power generation. However, the low efficiency of PTE materials and lack of suitable manufacturing processes remain an impediment to restrict its rapid development. Here, we designed a flexible PTE device by printing a highly integrated single-walled carbon nanotubes (SWCNTs) array at intervals that were surface-functionalized with poly(acrylic acid) and poly(ethylene imine) as p-n heterofilms. After the introduction of a mask to give a selective light illumination and taking advantage of the photothermal effect of SWCNTs, a remarkable temperature gradient along the printed SWCNTs and a considerable power density of 1.3 μW/cm² can be achieved. Meanwhile, both experimental data and COMSOL theoretical simulations were adopted to optimize the performance of our device, showing new opportunities for new generation flexible PTE devices.

Facile fabrication of self-assembled nanostructures of vertically aligned gold nanorods by using inkjet printing

We demonstrated that the vertically aligned gold nanorods (AuNRs) were quickly and easily formed by using inkjet printing when aqueous dispersion of AuNRs containing a small amount of ethylene glycol (EG) was employed as an ink. It was observed that the content of EG in water suppressed rapid drying and convection in the droplets, which is favorable for the formation of the nanostructures.

Slow evaporation of a droplet of water/ethylene glycol (EG) mixture allows the fabrication of vertically aligned gold nanorods using inkjet printing.

Ink Processing for Thermoelectric Materials and Power-Generating Devices

The growing concern over the depletion of hydrocarbon resources, and the adverse environmental effects associated with their use, has increased the demand for renewable energy sources. Thermoelectric (TE) power generation from waste heat has emerged as a renewable energy source that does not generate any pollutants. Recently, ink-based processing for the preparation of TE materials has attracted tremendous attention because of the simplicity in design of power generators and the possibility of cost-effective manufacturing. In this progress report, recent advances in the development of TE inks, processing techniques, and ink-fabricated devices are reviewed. A summary of typical formulations of TE materials as inks is included, as well as a discussion on various ink-based fabrication methods, with several examples of newly designed devices fabricated using these techniques. Finally, the prospects of this field with respect to the industrialization of TE power generation technology are presented.

Inkjet Printing in Liquid Environments

Inkjet printing (IJP) is an old but still vivifying technique for flexible and cost-effective printing of various kinds of functional inks. Normally, IJP can only work in gaseous environments. Here, it is shown that traditional piezoelectric IJP can be performed in liquid environments with a totally different droplet dispensing and manipulating mechanism. With the same piezoelectric nozzle, the volume of the droplets printed in a carrier liquid can be thousands of times smaller than those printed in air. Therefore, this work demonstrates a working mode of traditional IJP with a highly improved resolution opening possibilities for novel applications of the IJP technique.

Inkjet printable-photoactive all inorganic perovskite films with long effective photocarrier lifetimes

Photoactive perovskite quantum dot films, deposited via an inkjet printer, have been characterized by x-ray diffraction and x-ray photoelectron spectroscopy. The crystal structure and bonding environment are consistent with CsPbBr₃ perovskite quantum dots. The current-voltage (I-V) and capacitance-voltage (C-V) transport measurements indicate that the photo-carrier drift lifetime can exceed 1 ms for some printed perovskite films. This far exceeds the dark drift carrier lifetime, which is below 50 ns. The printed films show a photocarrier density 10⁹ greater than the dark carrier density, making these printed films ideal candidates for application in photodetectors. The successful printing of photoactive-perovskite quantum dot films of CsPbBr₃, indicates that the rapid prototyping of various perovskite inks and multilayers is realizable.

The fabrication of highly conductive and flexible Ag patterning through baking Ag nanosphere-nanoplate hybrid ink at a low temperature of 100 °C

With the aim of developing highly conductive ink for flexible electronics on heat-sensitive substrates, Ag nanospheres and nanoplates were mixed to synthesize hybrid inks. Five kinds of hybrid ink and two types of pure ink were written to square shape on Epson photo paper using rollerball pens, and sintered at a low temperature (100 °C). The microstructure, electrical resistivity, surface porosity, hardness and flexibility of silver patterns were systematically investigated and compared. It was observed that the optimal mixing ratio of nanospheres and nanoplates was 1:1, which equipped the directly written pattern with excellent electrical and mechanical properties. The electrical resistivity was 0.103 μΩ · m, only 6.5 times that of bulk silver. The enhancement compared to pure silver nanospheres or nanoplates based ink was due to the combined action of nanospheres and nanoplates. This demonstrates a valuable way to prepare Ag nanoink with good performance for printed/written electronics.

Inkjet Printing of Functional Materials for Optical and Photonic Applications

Inkjet printing, traditionally used in graphics, has been widely investigated as a valuable tool in the preparation of functional surfaces and devices. This review focuses on the use of inkjet printing technology for the manufacturing of different optical elements and photonic devices. The presented overview mainly surveys work done in the fabrication of micro-optical components such as microlenses, waveguides and integrated lasers; the manufacturing of large area light emitting diodes displays, liquid crystal displays and solar cells; as well as the preparation of liquid crystal and colloidal crystal based photonic devices working as lasers or optical sensors. Special emphasis is placed on reviewing the materials employed as well as in the relevance of inkjet in the manufacturing of the different devices showing in each of the revised technologies, main achievements, applications and challenges.

Digital Printing of Titanium Dioxide for Dye Sensitized Solar Cells

Silicon solar cell manufacturing is an expensive and high energy consuming process. In contrast, dye sensitized solar cell production is less environmentally damaging with lower processing temperatures presenting a viable and low cost alternative to conventional production. This paper further enhances these environmental credentials by evaluating the digital printing and therefore additive production route for these cells. This is achieved here by investigating the formation and performance of a metal oxide photoelectrode using nanoparticle sized titanium dioxide. An ink-jettable material was formulated, characterized and printed with a piezoelectric inkjet head to produce a 2.6 µm thick layer. The resultant printed layer was fabricated into a functioning cell with an active area of 0.25 cm² and a power conversion efficiency of 3.5%. The binder-free formulation resulted in a reduced processing temperature of 250 °C, compatible with flexible polyamide substrates which are stable up to temperatures of 350 ˚C. The authors are continuing to develop this process route by investigating inkjet printing of other layers within dye sensitized solar cells.

Suppressing the Coffee-Ring Effect in Semitransparent MnO2 Film for a High-Performance Solar-Powered Energy Storage Window

We introduce a simple and effective method to deposit a highly uniform and semitransparent MnO2 film without coffee-ring effect (CRE) by adding ethanol into MnO2 ink for transparent capacitive energy storage devices. By carefully controlling the amount of ethanol added in the MnO2 droplet, we could significantly reduce the CRE and thus improve the film uniformity. The electrochemical properties of supercapacitor (SC) devices using semitransparent MnO2 film electrodes with or without CRE were measured and compared. The SC device without CRE shows a superior capacitance, high rate capability, and lower contact resistance. The CRE-free device could achieve a considerable volumetric capacitance of 112.2 F cm(-3), resulting in a high volumetric energy density and power density of 10 mWh cm(-3) and 8.6 W cm(-3), respectively. For practical consideration, both flexible SC and large-area rigid SC devices were fabricated to demonstrate their potential for flexible transparent electronic application and capacitive energy-storage window application. Moreover, a solar-powered energy storage window which consists of a commercial solar cell and our studied semitransparent MnO2-film-based SCs was assembled. These SCs could be charged by the solar cell and light up a light emitting diode (LED), demonstrating their potential for self-powered systems and energy-efficient buildings.

Stereocomplex Film Using Triblock Copolymers of Polylactide and Poly(ethylene glycol) Retain Paxlitaxel on Substrates by an Aqueous Inkjet System

The stereocomplex formation of poly(L,L-lactide) (PLLA) and poly(D,D-lactide) (PDLA) using an inkjet system was expanded to the amphiphilic copolymers, using poly(ethylene glycol) (PEG) as a hydrophilic polymer. The diblock copolymers, which are composed of PEG and PLLA (MPEG-co-PLLA) and PEG and PDLA (MPEG-co-PDLA), were employed for thin-film preparation using an aqueous inkjet system. The solvent and temperature conditions were optimized for the stereocomplex formation between MPEG-co-PLLA and MPEG-co- PDLA. As a result, the stereocomplex was adequately formed in acetonitrile/water (1:1, v/v) at 40 °C. The aqueous conditions improved the stereocomplex film preparation, which have suffered from clogging when using the organic solvents in previous work. The triblock copolymers, PLLA-co-PEG-co-PLLA and PDLA-co-PEG-co-PDLA, were employed for square patterning with the inkjet system, which produced thin films. The amphiphilic polymer film was able to retain hydrophobic compounds inside. The present result contributed to the rapid film preparation by inkjet, retaining drugs with difficult solubility in water, such as paclitaxel within the films.

Organic-inorganic-hybrid-polymer microlens arrays with tailored optical characteristics and multi-focal properties

Plano-convex microlens arrays of organic-inorganic polymers with tailored optical properties are presented. The fine-tuning of each microlens within an array is achieved by confining inkjet printed drops of the polymeric ink onto pre-patterned substrates. The lens optical properties are thus freely specified, and high numerical apertures from 0.45 to 0.9 and focal lengths between 10 μm and 100 μm are demonstrated, confirming theoretical predictions. Combining nanoimprint lithography approaches and inkjet printing enables using the same material for the microlenses and their substrates, improving the optical performances. Microlens arrays with desired specifications are printed reaching yields up to 100% and high lens reproducibility with standard deviations of the apparent contact angle under 1° and of the numerical apertures and focal lengths under 6%. Microlens arrays involving lenses with different characteristics, e.g. multi focal length, and thus focal planes separated by only few microns are printed with the same reproducibility.