Roll-to-roll gravure-printed flexible perovskite solar cells using eco-friendly antisolvent bathing with wide processing window.

Driven by recent improvements in efficiency and stability of perovskite solar cells (PSCs), upscaling of PSCs has come to be regarded as the next step. Specifically, a high-throughput, low-cost roll-to-roll (R2R) processes would be a breakthrough to realize the commercialization of PSCs, with uniform formation of precursor wet film and complete conversion to perovskite phase via R2R-compatible processes necessary to accomplish this goal. Herein, we demonstrate the pilot-scale, fully R2R manufacturing of all the layers except for electrodes in PSCs. Tert-butyl alcohol (tBuOH) is introduced as an eco-friendly antisolvent with a wide processing window. Highly crystalline, uniform formamidinium (FA)-based perovskite formation via tBuOH:EA bathing was confirmed by achieving high power conversion efficiencies (PCEs) of 23.5% for glass-based spin-coated PSCs, and 19.1% for gravure-printed flexible PSCs. As an extended work, R2R gravure-printing and tBuOH:EA bathing resulted in the highest PCE reported for R2R-processed PSCs, 16.7% for PSCs with R2R-processed SnO2/FA-perovskite, and 13.8% for fully R2R-produced PSCs.

Slot-Die Coated Perovskite Films Using Mixed Lead Precursors for Highly Reproducible and Large-Area Solar Cells.

Recently, many kinds of printing processes have been studied to fabricate perovskite solar cells (PeSCs) for mass production. Among them, slot-die coating is a promising candidate for roll-to-roll processing because of high-throughput, easy module patterning, and a premetered coating system. In this work, we employed mixed lead precursors consisting of PbAc2 and PbCl2 to fabricate PeSCs via slot-die coating. We observed that slot-die-coated perovskite films based on the mixed lead precursors exhibited well-grown and uniform morphology, which was hard to achieve by using only a single lead source. Consequently, PeSCs made with this precursor system showed improved device performance and reproducibility over single PbAc2. Lastly, a large-area module with an active area of 10 cm2 was fabricated with a power conversion efficiency of 8.3%.

Small-Molecule Organic Photovoltaic Modules Fabricated via Halogen-Free Solvent System with Roll-to-Roll Compatible Scalable Printing Method.

For the first time, the photovoltaic modules composed of small molecule were successfully fabricated by using roll-to-roll compatible printing techniques. In this study, blend films of small molecules, BTR and PC71BM were slot-die coated using a halogen-free solvent system. As a result, high efficiencies of 7.46% and 6.56% were achieved from time-consuming solvent vapor annealing (SVA) treatment and roll-to-roll compatible solvent additive approaches, respectively. After successful verification of our roll-to-roll compatible method on small-area devices, we further fabricated large-area photovoltaic modules with a total active area of 10 cm2, achieving a power conversion efficiency (PCE) of 4.83%. This demonstration of large-area photovoltaic modules through roll-to-roll compatible printing methods, even based on a halogen-free solvent, suggests the great potential for the industrial-scale production of organic solar cells (OSCs).

One-Step Printable Perovskite Films Fabricated under Ambient Conditions for Efficient and Reproducible Solar Cells.

Despite the potential of roll-to-roll processing for the fabrication of perovskite films, the realization of highly efficient and reproducible perovskite solar cells (PeSCs) through continuous coating techniques and low-temperature processing is still challenging. Here, we demonstrate that efficient and reliable CH3NH3PbI3 (MAPbI3) films fabricated by a printing process can be achieved through synergetic effects of binary processing additives, N-cyclohexyl-2-pyrrolidone (CHP) and dimethyl sulfoxide (DMSO). Notably, these perovskite films are deposited from premixed perovskite solutions for facile one-step processing under a room-temperature and ambient atmosphere. The CHP molecules result in the uniform and homogeneous perovskite films even in the one-step slot-die system, which originate from the high boiling point and low vapor pressure of CHP. Meanwhile, the DMSO molecules facilitate the growth of perovskite grains by forming intermediate states with the perovskite precursor molecules. Consequently, fully printed PeSC based on the binary additive system exhibits a high PCE of 12.56% with a high reproducibility.

Differentially pumped spray deposition as a rapid screening tool for organic and perovskite solar cells.

We report a spray deposition technique as a screening tool for solution processed solar cells. A dual-feed spray nozzle is introduced to deposit donor and acceptor materials separately and to form blended films on substrates in situ. Using a differential pump system with a motorised spray nozzle, the effect of film thickness, solution flow rates and the blend ratio of donor and acceptor materials on device performance can be found in a single experiment. Using this method, polymer solar cells based on poly(3-hexylthiophene) (P3HT):(6,6)-phenyl C61 butyric acid methyl ester (PC61BM) are fabricated with numerous combinations of thicknesses and blend ratios. Results obtained from this technique show that the optimum ratio of materials is consistent with previously reported values confirming this technique is a very useful and effective screening method. This high throughput screening method is also used in a single-feed configuration. In the single-feed mode, methylammonium iodide solution is deposited on lead iodide films to create a photoactive layer of perovskite solar cells. Devices featuring a perovskite layer fabricated by this spray process demonstrated a power conversion efficiencies of up to 7.9%.

Toward large scale roll-to-roll production of fully printed perovskite solar cells.

Fully printed perovskite solar cells are demonstrated with slot-die coating, a scalable printing method. A sequential slot-die coating process is developed to produce efficient perovskite solar cells and to be used in a large-scale roll-to-roll printing process. All layers excluding the electrodes are printed and devices demonstrate up to 11.96% power conversion efficiency. It is also demonstrated that the new process can be used in roll-to-roll production.