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Scalable sheet-to-sheet slot die coating processes have been demonstrated for perovskite solar cells and modules. The processes have been developed on 6 in. × 6 in. glass/ITO substrates for two functional layers: the perovskite photo-active layer and the Spiro-OMeTAD hole transport layer. Perovskite solar cells produced using these slot die coating processes demonstrate device performances identical to the spin coated devices. All manufactured devices illustrate a high level of reproducibility. The developed slot die coating processes were also used for the manufacturing of perovskite PV modules. Large area modules of 12.5 × 13.5 cm2 were realized by slot die coating on 6 in. × 6 in. substrates in combination with newly developed laser ablation processes for conventional P1-P2-P3 monolithic cell interconnections. The modules demonstrate power conversion efficiencies above 10%, with a power output of 1.7 W. This achievement is an important milestone in the development of up-scalable manufacturing technologies for perovskite PV modules.

This paper reports on the analysis and comparison of mechanical and laser patterning in the fabrication of perovskite thin-film photovoltaic modules. Besides stability, device upscaling and module fabrication is a key challenge for the commercialization of perovskite photovoltaics. Here, the focus is on the optimization of the P2 interconnection that represents the electrical connection between serially connected cells in a module. The specific contact resistivity for P2 interconnection is determined by using an enhanced transmission line method. Mechanical or laser patterning are used to fabricate 4 cm $^{2}$ modules with aperture area efficiencies of up to 15.3% and geometrical fill factors as high as 94%. With the application of a simulation program with an integrated circuit emphasis-based electrical device model, the interconnection losses are quantified, and optimal designs for perovskite modules are presented.

In order to commercialize the perovskite solar cells (PSC) technology, efficient and industrial deposition methods over large areas have to be adopted, and the device architectures have to provide long term stability. In this work we combine several upscalable deposition methods to develop a stable semitransparent PSC. The control of the uniformity of perovskite crystallization by tailoring the ink formulation and the drying process was pursued in order to drastically reduce the efficiency losses over an area increase of 3 orders of magnitude (from 0.04 to 100 cm2). When adopting sputtered ITO as top electrode, the stack retains up to 90% of the initial performance after 1000hrs at 85 °C. The use of laser patterning to define P1 P2 and P3 scribes for series interconnected modules enables the fabrication of thermally stable minimodule (4cm2) and large module (100cm2). Finally an outlook on the use of the perovskite device as top cell in a 4T tandem architecture with commercial c-Si cells will be provided.

The industrialization of perovskite solar cells (PSC) require processes to efficiently deposit the constituent layers over large areas. In this work we optimized the use of slot die coating process for both sheet-to-sheet (S2S) and roll-to-roll (R2R) manufacturing. Particular focus have been put on the control of the uniformity of perovskite crystallization by tailoring the ink formulation and the drying process in order to avoid any efficiency losses over an area increase of 3 orders of magnitude (from 0.09 to 144 cm2). In this way we were able to fabricate 144 cm2 modules with 13.8% stabilized efficiency on aperture area on glass (14.5% on active area). At the same time, by developing the R2R slot die deposition process of the perovskite layer, we demonstrated 160 cm2 flexible module with 10.1 % stabilized efficiency on aperture area (11.0% on active area). In addition, fully R2R coated cells exhibit up to 16% efficiency. An outlook on how to upscale more stable perovskite cells (i.e. with pin structure) will be given. These results prove how to optimize the upscaling process towards large area manufacturing of perovskite solar modules on both rigid and flexible substrate.

© 2018 The Royal Society of Chemistry. Thin film perovskite photovoltaic devices combine high power conversion efficiencies with low weight, large area, high speed production capabilities and high versatility in form factor. With this paper, an additional feature is added to the device property portfolio: optical transparency. Results on translucent perovskite modules with selectively tuned levels of transparency are reported by applying the industrially established fabrication process of partial area ablation to high efficiency opaque devices. After process completion, the final devices consist of opaque areas that absorb the light, and transparent areas that permit neutral light transmission. We compare the effectiveness of using two active area removal techniques: mechanical scribing and laser ablation, and determine the factors that limit the maximum transparency and power conversion efficiency. Moreover, we show how the choice of the ablation method and design of the active area removal pattern affect and limit the maximum light utilization efficiency ratio that can be achieved with this fabrication process. The resulting 4 cm2 translucent modules cover a range of visible light transparency from 7 to 37% with a corresponding power conversion efficiency of 5 to 13%. ispartof: JOURNAL OF MATERIALS CHEMISTRY C vol:6 issue:12 pages:3034-3041 status: published

The proper long term operation of organic electronic devices like organic photovoltaics OPV depends on their resistance to environmental influences such as permeation of water vapor. Major efforts are spent to encapsulate OPV. State of the art is sandwich-like encapsulation between two ultra-barrier foils. Sandwich encapsulation faces two major disadvantages: high costs (∼1/3 of total costs) and parasitic intrinsic water (sponge effects of the substrate foil). To fight these drawbacks, a promising approach is to use the OPV substrate itself as barrier by integration of an ultra-barrier coating, followed by alternating deposition and structuring of OPV functional layers. In effect, more functionality will be integrated into less material, and production steps are reduced in number. All processing steps must not influence the underneath barrier functionality, while all electrical functionalities must be maintained. As most reasonable structuring tool, short and ultrashort pulsed lasers USP are used. Laser machining applies to three layers: bottom electrode made of transparent conductive materials (P1), organic photovoltaic operative stack (P2) and top electrode (P3). In this paper, the machining of functional ∼110...250 nm layers of flexible OPV by USP laser systems is presented. Main focus is on structuring without damaging the underneath ultra-barrier layer. The close-to-process machining quality characterization is performed with the analysis tool "hyperspectral imaging" (HSI), which is checked crosswise with the "gold standard" Ca-test. It is shown, that both laser machining and quality controlling, are well suitable for R2R production of OPV.

We present the development of laser processes for flexible OPV on roll-to-roll (RR2R) produced thin film barrier with indium tin oxide (ITO) as transparent conductive (TC) bottom electrode. Direct laser structuring of ITO on such barrier films (so-called P1 process) is very challenging since the layers are all transparent, a complete electrical isolation is required, and the laser process should not influence the barrier performance underneath the scribes. Based on the optical properties off the SiN and ITTO, ultra-short pulse lasers inn picosecond and femtosecond regime with standard infrared (IR) wavelength as well as lasers with new a wavelength (22 μm regime) are tested for this purpose. To determine a process window for a specific laser a fixed methodology is adopted. Single pulse ablation tests were followed by scribing experiments where the pulse overlap was tuned by varying laser pulse fluence, writing speed and frequency. To verify that the laser scribing does not result inn barrier damage underneath, a new test method was developed based on the optical Ca-test. This method shows a clear improvement in damage analysis underneath laser scribes over normal optical inspection methods (e.g. microscope, optical profiler, SEM). This way clear process windows can be obtained for IR TC patterning. © (2017) COPYRIGHT Society of Photo-Optical Instrumentation Engineers (SPIE). Downloading of the abstract is permitted for personal use only.

Organometallic halide perovskite solar cells (PSCs) are extremely promising novel materials for thin-film photovoltaics, exhibiting efficiencies over 22% on glass and over 17% on foil 1, 2. First, a sheet-to-sheet (S2S) production of PSCs and modules on 152x152 mm2 substrates was established, using a combination of sputtering, e-beam evaporation, slot die coating and thermal evaporation (average PCE of 14.6 ± 1.3 % over 64 devices, more than 10% initial PCE on modules). Later the steps towards a roll-to-roll production will be investigated, starting from the optimization of the stack to make it compatible with a faster production at low temperature. A water based SnOx nanoparticles dispersion was used as solution processable ETL, and the deposition process was scaled-up from spin coating to R2R slot die coating on a 300 mm wide roll of PET/ITO. R2R production is often carried out in ambient atmosphere and involve the use of large volumes of materials, thus a first point is the development of a green solvent and precursor system for the perovskite layer to prevent the emission of toxic compound in the environment. The first results on device fabrication are encouraging, which allow partial R2R manufacturing of flexible PSC (R2R coating of SnOx and perovskite, S2S for Spiro-OMeTAD and gold) with stabilized PCE of 12.6%, a remarkable value for these novel devices. This result can be considered an important milestone towards the production of efficient, low cost, lightweight, flexible PSC on large area.

Local laser ablation of the cathode of OLEDs has been applied to create a population of pinholes of the same size. This enables the direct comparison at different conditions of black spots and grey spots in the emission of OLEDs as a result of water ingress into the device. We confirmed earlier observations on the operational effect of black spot growth as determined in a sequential test on particle induced pinholes. Furthermore, we measured the operational effect in parallel, providing data that are test independent. With the same population of pinholes we studied the operational effect of grey spot growth. The observed larger operational effect of grey spot growth with respect to that of black spot growth is attributed to a lateral flow of protons to the centre of the black spot. In this part of the black spot a depletion region is present which is created by transport of H3O+ to the cathode under the influence of the applied electric field. This proposal is supported by the observation of black and grey spot growth in polymer LEDs on basis of PEDOT:PSS with increased pH.

To protect organic flexible devices from the ambient, they have to be encapsulated. Depending on the application in mind (OLED lighting, PV) different thin-film encapsulation methodology can be chosen. Each encapsulation process has different requirements and fabrication process freedom might be restricted, for example by mechanical reliability requirements or the total cost of the end product. Here we will show our recent investigations into different thin-film barriers with respect to their application and the route to production.