Perovskite solar cells in N-I-P structure with four slot-die-coated layers

Continuous roller nanoimprinting: next generation lithography

Nanoimprint lithography (NIL) is a cost-effective and high-throughput technique for replicating nanoscale structures that does not require expensive light sources for advanced photolithography equipment. NIL overcomes the limitations of light diffraction or beam scattering in traditional photolithography and is suitable for replicating nanoscale structures with high resolution. Roller nanoimprint lithography (R-NIL) is the most common NIL technique benefiting large-scale, continuous, and efficient industrial production. In the past two decades, a range of R-NIL equipment has emerged to meet the industrial needs for applications including biomedical devices, semiconductors, flexible electronics, optical films, and interface functional materials. R-NIL equipment has a simple and compact design, which allows multiple units to be clustered together for increased productivity. These units include transmission control, resist coating, resist curing, and imprinting. This critical review summarizes the hitherto R-NIL processes, their typical technical problems, and corresponding solutions and gives guidelines for developing advanced R-NIL equipment.

Recent Developments in Upscalable Printing Techniques for Perovskite Solar Cells

Just over a decade, perovskite solar cells (PSCs) have been emerged as a next-generation photovoltaic technology due to their skyrocketing power conversion efficiency (PCE), low cost, and easy manufacturing techniques compared to Si solar cells. Several methods and procedures have been developed to fabricate high-quality perovskite films to improve the scalability and commercialize PSCs. Recently, several printing technologies such as blade-coating, slot-die coating, spray coating, flexographic printing, gravure printing, screen printing, and inkjet printing have been found to be very effective in controlling film formation and improving the PCE of over 21%. This review summarizes the intensive research efforts given for these printing techniques to scale up the perovskite films as well as the hole transport layer (HTL), the electron transport layer (ETL), and electrodes for PSCs. In the end, this review presents a description of the future research scope to overcome the challenges being faced in the printing techniques for the commercialization of PSCs.

Solution-processed two-dimensional materials for next-generation photovoltaics

In the ever-increasing energy demand scenario, the development of novel photovoltaic (PV) technologies is considered to be one of the key solutions to fulfil the energy request. In this context, graphene and related two-dimensional (2D) materials (GRMs), including nonlayered 2D materials and 2D perovskites, as well as their hybrid systems, are emerging as promising candidates to drive innovation in PV technologies. The mechanical, thermal, and optoelectronic properties of GRMs can be exploited in different active components of solar cells to design next-generation devices. These components include front (transparent) and back conductive electrodes, charge transporting layers, and interconnecting/recombination layers, as well as photoactive layers. The production and processing of GRMs in the liquid phase, coupled with the ability to "on-demand" tune their optoelectronic properties exploiting wet-chemical functionalization, enable their effective integration in advanced PV devices through scalable, reliable, and inexpensive printing/coating processes. Herein, we review the progresses in the use of solution-processed 2D materials in organic solar cells, dye-sensitized solar cells, perovskite solar cells, quantum dot solar cells, and organic-inorganic hybrid solar cells, as well as in tandem systems. We first provide a brief introduction on the properties of 2D materials and their production methods by solution-processing routes. Then, we discuss the functionality of 2D materials for electrodes, photoactive layer components/additives, charge transporting layers, and interconnecting layers through figures of merit, which allow the performance of solar cells to be determined and compared with the state-of-the-art values. We finally outline the roadmap for the further exploitation of solution-processed 2D materials to boost the performance of PV devices.

Polymer-Assisted Single-Step Slot-Die Coating of Flexible Perovskite Solar Cells at Mild Temperature from Dimethyl Sulfoxide

The industrialization of perovskite solar cells relies on solving intrinsic-to-material issues. To reach record efficiencies perovskite deposition needs to be finely adjusted by multi-step processes, in a humidity free glove-box environment and by means of hardly scalable techniques often associated with toxic solvents and anti-solvent dripping/bath. Herein, the use of polymeric material is proposed to deposit perovskite layers with easy processability. To the scope, a starch-polymer/perovskite composite is developed to suit slot-die coating technique requirement, allowing the deposition of hybrid halide perovskite material in a single straightforward step without the use of toxic solvents, and in uncontrolled humid environment (RH up to 70 %). The starch-polymer increases the viscosity of the perovskite precursor solutions and delays the perovskite crystallization that results in the formation of perovskite films at mild temperature (60 °C) with good morphology. These innovative inks enables the fabrication of flexible solar cells with p-i-n configuration featured by a power conversion efficiency higher than 3 %. . Overall, this approach can be exploited in the future to massively reduce perovskite manufacturing costs related to keeping the entire fabrication line at high-temperature and under nitrogen or dry conditions.

Simple Method for Efficient Slot-Die Coating of MAPbI3 Perovskite Thin Films in Ambient Air Conditions

Scalable methods for deposition of lead halide perovskite thin films are required to enable commercialization of the highly promising perovskite photovoltaics. Here, we have developed a slot-die coating process under ambient conditions for methylammonium lead iodide (MAPbI3) perovskite on heated substrates (about 90 °C on the substrate surface). Dense, highly crystalline perovskite films with large grains (100-200 μm) were obtained by careful adjustment of the deposition parameters, using solutions that are similar but more dilute than those used in typical spin-coating procedures. Without any further after treatments, such as antisolvent treatment or vapor annealing, we achieved power conversion efficiencies up of 14.5% for devices with the following structure: conducting tin oxide glass (FTO)/TiO2/MAPbI3/spiro-MeOTAD/Au. The performance was limited by the significant roughness of the deposited films, resulting from the hot-casting method, and the relatively high deposition temperature, which led to a defect-rich surface due to loss of MAI.

Coated and Printed Perovskites for Photovoltaic Applications

Hybrid organic-inorganic metal halide perovskite semiconductors provide opportunities and challenges for the fabrication of low-cost thin-film photovoltaic devices. The opportunities are clear: the power conversion efficiency (PCE) of small-area perovskite photovoltaics has surpassed many established thin-film technologies. However, the large-scale solution-based deposition of perovskite layers introduces challenges. To form perovskite layers, precursor solutions are coated or printed and these must then be crystallized into the perovskite structure. The nucleation and crystal growth must be controlled during film formation and subsequent treatments in order to obtain high-quality, pin-hole-free films over large areas. A great deal of understanding regarding material engineering during the perovskite film formation process has been gained through spin-coating studies. Based on this, significant progress has been made on transferring material engineering strategies to processes capable of scale-up, such as blade coating, spray coating, inkjet printing, screen printing, relief printing, and gravure printing. Here, an overview is provided of the strategies that led to devices deposited by these scalable techniques with PCEs as high as 21%. Finally, the opportunities to fully close the shrinking gap to record spin-coated solar cells and to scale these efficiencies to large areas are highlighted.

Acetonitrile based single step slot-die compatible perovskite ink for flexible photovoltaics

Low viscosity rapid drying perovskite formulations designed to give high quality solar films when slot-die coated on flexible roll-to-roll compatible substrates are developed .

Perovskite Photovoltaic Modules: Life Cycle Assessment of Pre-industrial Production Process

Photovoltaic devices based on perovskite materials have a great potential to become an exceptional source of energy while preserving the environment. However, to enter the global market, they require further development to achieve the necessary performance requirements. The environmental performance of a pre-industrial process of production of a large-area carbon stack perovskite module is analyzed in this work through life cycle assessment (LCA). From the pre-industrial process an ideal process is simulated to establish a benchmark for pre-industrial and laboratory-scale processes. Perovskite is shown to be the most harmful layer of the carbon stack module because of the energy consumed in the preparation and annealing of the precursor solution, and not because of its Pb content. This work stresses the necessity of decreasing energy consumption during module preparation as the most effective way to reduce environmental impacts of perovskite solar cells.

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LCA of a pre-industrial process of a carbon stack perovskite module

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Laboratory, pre-industrial, and extrapolated ideal scenarios are compared

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The pre-industrial process shows a significant improvement in environmental impact

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Energy consumption is the main cause of the environmental impacts, not the Pb

Major Impediment to Highly Efficient, Stable and Low-Cost Perovskite Solar Cells

Organic–inorganic hybrid perovskite solar cells (PSCs) have made immense progress in recent years, owing to outstanding optoelectronic properties of perovskite materials, such as high extinction coefficient, carrier mobility, and low exciton binding energy. Since the first appearance in 2009, the efficiency of PSCs has reached 23.3%. This has made them the most promising rival to silicon-based solar cells. However, there are still several issues to resolve to promote PSCs’ outdoor applications. In this review, three crucial aspects of PSCs, including high efficiency, environmental stability, and low-cost of PSCs, are described in detail. Recent in-depth studies on different aspects are also discussed for better understanding of these issues and possible solutions.

Sequential Slot-Die Deposition of Perovskite Solar Cells Using Dimethylsulfoxide Lead Iodide Ink

This work demonstrates a sequential deposition of lead iodide followed by methylammonium iodide using the industrially compatible slot-die coating method that produces homogeneous pin-hole free films without the use of the highly toxic dimethylformamide. This is achieved through the careful selection and formulation of the solvent system and coating conditions for both the lead iodide layer and the methylammonium iodide coating. The solvent system choice is found to be critical to achieving good coating quality, conversion to the final perovskite and for the film morphology formed. A range of alcohols are assessed as solvent for methylammonium iodide formulations for use in slot-die coating. A dimethylsulfoxide solvent system for the lead iodide layer is shown which is significantly less toxic than the dimethylformamide solvent system commonly used for lead iodide deposition, which could find utility in high throughput manufacture of perovskite solar cells.