Humidity‐Tolerant Roll‐to‐Roll Fabrication of Perovskite Solar Cells via Polymer‐Additive‐Assisted Hot Slot Die Deposition

Heating‐assisted deposition is an industry‐friendly scalable deposition method. This manufacturing method is employed together with slot die coating to fabricate perovskite solar cells via a roll‐to‐roll process. The feasibility of the method is demonstrated after initial testing on a rigid substrate using a benchtop slot die coater in air. The fabricated solar cells exhibit power conversion efficiencies (PCEs) up to 14.7%. A nonelectroactive polymer additive is used with the perovskite formulation and found to improve its humidity tolerance significantly. These deposition parameters are also used in the roll‐to‐roll setup. The perovskite layer and other solution‐processed layers are slot die‐coated, and the fabricated device shows PCEs up to 11.7%, which is the highest efficiency obtained from a fully roll‐to‐roll processed perovskite solar cell to date.     

A universal roll‐to‐roll slot‐die coating approach towards high‐efficiency organic photovoltaics

This work develops a combinational use of solvent additive and in‐line drying oven on the flexible organic photovoltaics to improve large‐area roll‐to‐roll (R2R) slot‐die coating process. Herein, addition of 1,8‐diiodooctane (DIO) in the photoactive layer is conducted to yield a performance of 3.05% based on the blending of poly(3‐hexylthiophene) (P3HT) and [6,6]‐phenyl C₆₁‐butyric acid methyl ester (PC₆₁BM), and a very promising device performance of 7.32% based on the blending of poly[[4,8‐bis[(2‐ethylhexyl)oxy] benzo[1,2‐b:4,5‐b’] dithiophene‐2,6‐diyl] [3‐fluoro‐2‐[(2‐ethylhexyl)carbonyl]thieno[3,4‐b]thiophenediyl]] (PTB7) and [6,6]‐phenyl C₇₁‐butyric acid methyl ester (PC₇₁BM). Based on this R2R slot‐die coating approach for various polymers, we demonstrate the high‐performance result with respect to the up‐scaling from small high‐PCE cell to large‐area module. This present study provides a route for fabricating a low‐cost, large‐area, and environmental‐friendly flexible organic photovoltaics.     

Non‐destructive lateral mapping of the thickness of the photoactive layer in polymer‐based solar cells

Non‐destructive lateral mapping of the thickness of the photoactive layer in poly(3‐hexyl‐thiophene) : 1‐(3‐methoxy‐carbonyl)propyl‐1‐phenyl‐(6,6)C₆₁ (P3HT : PCBM) solar cells is demonstrated. The method employs a spatially resolved (XY) recording of ultraviolet‐visible spectra in reflection geometry at normal incidence, using a dense raster defined by a circular probe spot of 800‐µm diameter. The evaluation of the thickness of the photoactive layer at each raster point employs an algorithm‐driven comparison of the measured absorption spectrum with spectral features, as compiled from the corresponding simulated spectrum. For the robustness of the applied algorithm toward noise in the recorded absorption data to be increased, a new minimum finder algorithm is described and implemented. The thickness evaluation relies on the correct assignment of extrema in the experimental absorption spectra to the corresponding extrema in the simulated absorption spectra, and a new algorithm for this is also implemented and described. For a level of confidence for the method to be established, first thickness mapping is performed for a set of reference samples consisting of P3HT : PCBM spin‐coated on indium tin oxide‐coated float glass substrates. After this, two application examples for solar cells processed either by spin coating or slot die coating of the P3HT : PCBM layer follow. The spin‐coated solar cells have glass as the substrate with the P3HT : PCBM spun at different spinning speeds. The slot die‐coated solar cells were processed on polyethylene terephthalate foil in a roll‐to‐roll experiment involving a continuously changing P3HT : PCBM concentration along the printing direction. Copyright © 2011 John Wiley & Sons, Ltd.     

Control of Crystal Growth toward Scalable Fabrication of Perovskite Solar Cells

With the impressive record power conversion efficiency (PCE) of perovskite solar cells exceeding 23%, research focus now shifts onto issues closely related to commercialization. One of the critical hurdles is to minimize the cell‐to‐module PCE loss while the device is being developed on a large scale. Since a solution‐based spin‐coating process is limited to scalability, establishment of a scalable deposition process of perovskite layers is a prerequisite for large‐area perovskite solar modules. Herein, this paper reports on the recent progress of large‐area perovskite solar cells. A deeper understanding of the crystallization of perovskite films is indeed essential for large‐area perovskite film formation. Various large‐area coating methods are proposed including blade, slot‐die, evaporation, and post‐treatment, where blade‐coating and gas post‐treatment have so far demonstrated better PCEs for an area larger than 10 cm². However, PCE loss rate is estimated to be 1.4 × 10^?2% cm^?2, which is 82 and 3.5 times higher than crystalline Si (1.7 × 10^?4% cm^?2) and thin film technologies (≈4 × 10^?3% cm^?2) respectively. Therefore, minimizing PCE loss upon scaling‐up is expected to lead to PCE over 20% in case of cell efficiency of >23%.     

Roll‐to‐roll gravure printing of organic photovoltaic modules—insulation of processing defects by an interfacial layer

Gravure printing as direct patterning roll‐to‐roll (R2R) production technology can revolutionize the design of thin‐film organic photovoltaic (OPV) devices by allowing feasible manufacturing of arbitrary‐shaped modules. This makes a distinction to coating methods, such as slot die coating, in which the pattern is limited to continuous stripes. Here, we analyze the thin‐film formation and its influence on OPV module performance as the gravure printing of hole transport and photoactive layers are transferred from laboratory to R2R pilot production environment. Insertion of a 0.8‐nm layer of lithium fluoride (LiF) as an interfacial layer between the active layer and the electron contact provided insulation against the detrimental pinholes formed in the R2R printing process. Using this device configuration, we produced well‐performing R2R‐printed monolithic modules with a mean efficiency of 1.7%. In comparison, reference modules with an efficiency of 2.2% were fabricated using laboratory‐scale bench top sheet‐level process. Surface energy and tension measurements together with optical microscopy were used to analyze the printability of the materials. The pinhole insulation was investigated in detail by processing R2R‐printed OPV modules with different interfacial layer materials and performing electrical measurements under dark and AM1.5 illumination conditions. Furthermore, we analyzed the LiF distribution using X‐ray photoelectron spectroscopy. The insulating nature of the LiF layer to improve module performance was confirmed by manufacturing lithographically artificial pinholes in device structures. The results show the possibility to loosen the production environment constraints and the feasibility of fabricating well‐performing thin‐film devices by R2R gravure printing. Copyright © 2014 John Wiley & Sons, Ltd.     

Sequential Deposition of High‐Quality Photovoltaic Perovskite Layers via Scalable Printing Methods

Sequential deposition is demonstrated as an effective technology for preparation of high‐performance perovskite solar cells based on lab‐scale spin coating. However, devices fabricated by scalable methods are lagging far behind their state‐of‐the‐art spin‐coated counterparts, largely due to the difficulty in obtaining high‐quality thin films of perovskites crystallized from printed precursors. Here, a generic strategy that allows sequential deposition of dense and uniform perovskite films via two‐step blade coating is reported. The rational selection of solvent combined with a mild vacuum extraction process enables us to produce uniform lead iodide (PbI₂) films over large areas. Significantly, the resulting PbI₂ films possess a mesoporous structure that is highly beneficial for the insertion reaction with methylammonium iodide (MAI). It is further identified that the deposition temperature of MAI plays an important role in determining the morphology and crystallinity of the perovskite films. Solar cells using these sequentially bladed perovskite layers yield efficiencies over 16% with high fill factors up to 78%. These results represent important progress toward the large‐scale deposition of perovskite thin films for practical applications.     

Roll‐to‐Roll Printed Silver Nanowire Semitransparent Electrodes for Fully Ambient Solution‐Processed Tandem Polymer Solar Cells

Silver nanowires (AgNWs) and zinc oxide (ZnO) are deposited on flexible substrates using fast roll‐to‐roll (R2R) processing. The AgNW film on polyethylene terephthalate (PET) shows >80% uniform optical transmission in the range of 550–900 nm. This electrode is compared to the previously reported and currently widely produced indium‐tin‐oxide (ITO) replacement comprising polyethylene terephthalate (PET)|silver grid|poly(3,4‐ethylenedioxythiophene):poly(styrenesulfonate) (PEDOT:PSS)|ZnO known as Flextrode. The AgNW/ZnO electrode shows higher transmission than Flextrode above 490 nm in the electromagnetic spectrum reaching up to 40% increased transmission at 750 nm in comparison to Flextrode. The functionality of AgNW electrodes is demonstrated in single and tandem polymer solar cells and compared with parallel devices on traditional Flextrode. All layers, apart from the semitransparent electrodes which are large‐scale R2R produced, are fabricated in ambient conditions on a laboratory roll‐coater using printing and coating methods which are directly transferrable to large‐scale R2R processing upon availability of materials. In a single cell structure, Flextrode is preferable with active layers based on poly‐3‐hexylthiophene(P3HT):phenyl‐C61‐butyric acid methylester (PCBM) and donor polymers of similar absorption characteristics while AgNW/ZnO electrodes are more compatible with low band gap polymer‐based single cells. In tandem devices, AgNW/ZnO is more preferable resulting in up to 80% improvement in PCE compared to parallel devices on Flextrode.     

Mapping Morphological and Structural Properties of Lead Halide Perovskites by Scanning Nanofocus XRD

Scanning nanofocus X‐ray diffraction (nXRD) performed at a synchrotron is used to simultaneously probe the morphology and the structural properties of spin‐coated CH₃NH₃PbI₃ (MAPI) perovskite films for photovoltaic devices. MAPI films are spin‐coated on a Si/SiO₂/poly(3,4‐ethylenedioxythiophene):polystyrene sulfonate (PEDOT:PSS) substrate held at different temperatures during the deposition in order to tune the perovskite film coverage. The films are then investigated using nXRD and scanning electron microscopy (SEM). The advantages of nXRD over SEM and other techniques are discussed. A method to visualize, selectively isolate, and structurally characterize single perovskite grains buried within a complex, polycrystalline film is developed. The results of nXRD measurements are correlated with solar cell device measurements, and it is shown that spin‐coating the perovskite precursor solution at elevated temperatures leads to improved surface coverage and enhanced solar cell performance.     

Hydrothermally Treated SnO2 as the Electron Transport Layer in High‐Efficiency Flexible Perovskite Solar Cells with a Certificated Efficiency of 17.3%

Perovskite solar cells (PSCs) are one of the most promising solar energy conversion technologies owing to their rapidly developing power conversion efficiency (PCE). Low‐temperature solution processing of the perovskite layer enables the fabrication of flexible devices. However, their application has been greatly hindered due to the lack of strategies to fabricate high‐quality electron transport layers (ETLs) at the low temperatures (≈100 °C) that most flexible plastic substrates can withstand, leading to poor performances for flexible PSCs. In this work, through combining the spin‐coating process with a hydrothermal treatment method, ligand‐free and highly crystalline SnO₂ ETLs are successfully fabricated at low temperature. The flexible PSCs based on this SnO₂ ETL exhibit an excellent PCE of 18.1% (certified 17.3%). The flexible PSCs maintained 85% of the initial PCE after 1000 bending cycles and over 90% of the initial PCE after being stored in ambient air for 30 days without encapsulation. The investigation reveals that hydrothermal treatment not only promotes the complete removal of organic surfactants coated onto the surface of the SnO₂ nanoparticles by hot water vapor but also enhances crystallization through the high vapor pressure of water, leading to the formation of high‐quality SnO₂ ETLs.     

High efficiency arrays of polymer solar cells fabricated by spray‐coating in air

We present bulk heterojunction organic solar cells fabricated by spray‐casting both the PEDOT:PSS hole‐transport layer (HTL) and active PBDTTT‐EFT:PC₇₁BM layers in air. Devices were fabricated in a (6 × 6) array across a large‐area substrate (25 cm²) with each pixel having an active area of 6.45 mm². We show that the film uniformity and operational homogeneity of the devices are excellent. The champion device with spray cast active layer on spin cast PEDOT:PSS had an power conversion efficiency (PCE) of 8.75%, and the best device with spray cast active layer and PEDOT:PSS had a PCE of 8.06%. The impacts of air and light exposure of the active layer on device performance are investigated and found to be detrimental. Copyright © 2015 John Wiley & Sons, Ltd.     

Self‐Doping Fullerene Electrolyte‐Based Electron Transport Layer for All‐Room‐Temperature‐Processed High‐Performance Flexible Polymer Solar Cells

To achieve high‐performance large‐area flexible polymer solar cells (PSCs), one of the challenges is to develop new interface materials that possess a thermal‐annealing‐free process and thickness‐insensitive photovoltaic properties. Here, an n‐type self‐doping fullerene electrolyte, named PCBB‐3N‐3I, is developed as electron transporting layer (ETL) for the application in PSCs. PCBB‐3N‐3I ETL can be processed at room temperature, and shows excellent orthogonal solvent processability, substantially improved conductivity, and appropriate energy levels. PCBB‐3N‐3I ETL also functions as light‐harvesting acceptor in a bilayer solar cell, contributing to the overall device performance. As a result, the PCBB‐3N‐3I ETL‐based inverted PSCs with a PTB7‐Th:PC₇₁BM photoactive layer demonstrate an enhanced power conversion efficiency (PCE) of 10.62% for rigid and 10.04% for flexible devices. Moreover, the device avoids a thermal annealing process and the photovoltaic properties are insensitive to the thickness of PCBB‐3N‐3I ETL, yielding a PCE of 9.32% for the device with thick PCBB‐3N‐3I ETL (61 nm). To the best of one's knowledge, the above performance yields the highest efficiencies for the flexible PSCs and thick ETL‐based PSCs reported so far. Importantly, the flexible PSCs with PCBB‐3N‐3I ETL also show robust bending durability that could pave the way for the future development of high‐performance flexible solar cells.     

Transparent,Double‐Sided,ITO‐Free,Flexible Dye‐Sensitized Solar Cells Based on Metal Wire/ZnO Nanowire Arrays

Transparent, double‐sided, flexible, ITO‐free dye‐sensitized solar cells (DSSCs) are fabricated in a simple, facile, and controllable way. Highly ordered, high‐crystal‐quality, high‐density ZnO nanowire arrays are radially grown on stainless steel, Au, Ag, and Cu microwires, which serve as working electrodes. Pt wires serve as the counter electrodes. Two metal wires are encased in electrolyte between two poly(ethylene terephthalate) (PET) films (or polydimethylsiloxane (PDMS) films) to render the device both flexible and highly transparent. The effect of the dye thickness on the photovoltaic performance of the DSSCs as a function of dye‐loading time is investigated systematically. Shorter dye‐loading times lead to thinner dye layers and better device performance. A dye‐loading time of 20 min results in the best device performance. An oxidation treatment of the metal wires is developed effectively to avoid the galvanic‐battery effect found in the experiment, which is crucial for real applications of double‐metal‐wire DSSC configurations. The device shows very good transparency and can increase sunlight use efficiency through two‐sided illumination. The double‐wire DSSCs remain stable for a long period of time and can be bent at large angles, up to 107°, reversibly, without any loss of performance. The double‐wire‐PET, planar solar‐cell configuration can be used as window stickers and can be readily realized for large‐area‐weave roll‐to‐roll processing.     

Understanding How Processing Additives Tune the Nanoscale Morphology of High Efficiency Organic Photovoltaic Blends: From Casting Solution to Spun‐Cast Thin Film

Adding a small amount of a processing additive to the casting solution of photoactive organic blends has been demonstrated to be an effective method for achieving improved power conversion efficiency (PCE) in organic photovoltaics (OPVs). However, an understanding of the nano‐structural evolution occurring in the transformation from casting solution to thin photoactive films is still lacking. In this report, the effects of the processing additive diiodooctane (DIO) on the morphology of the established blend of PBDTTT‐C‐T polymer and the fullerene derivative PC₇₁BM used for OPVs are investigated, starting in the casting solution and tracing the effects in spun‐cast thin films by using neutron/X‐ray scattering, neutron reflectometry, and other characterization techniques. The results reveal that DIO has no observable effect on the structures of PBDTTT‐C‐T and PC₇₁BM in solution; however, in the spun‐cast films, it significantly promotes their molecular ordering and phase segregation, resulting in improved PCE. Thermodynamic analysis based on Flory‐Huggins theory provides a rationale for the effects of DIO on different characteristics of phase segregation due to changes in concentration resulting from evaporation of the solvent and additive during film formation. Such information may help improve the rational design of ternary blends to more consistently achieve improved PCE for OPVs.     

Highly Efficient Indoor Organic Photovoltaics with Spectrally Matched Fluorinated Phenylene‐Alkoxybenzothiadiazole‐Based Wide Bandgap Polymers

The unique electro‐optical features of organic photovoltaics (OPVs) have led to their use in applications that focus on indoor energy harvesters. Various adoptable photoactive materials with distinct spectral absorption windows offer enormous potential for their use under various indoor light sources. An in‐depth study on the performance optimization of indoor OPVs is conducted using various photoactive materials with different spectral absorption ranges. Among the materials, the fluorinated phenylene‐alkoxybenzothiadiazole‐based wide bandgap polymer—poly[(5,6‐bis(2‐hexyldecyloxy)benzo[c][1,2,5]thiadiazole‐4,7‐diyl)‐alt‐(5,50‐(2,5‐difluoro‐1,4‐phenylene)bis(thiophen‐2‐yl))] (PDTBTBz‐2F_anti)‐contained photoactive layer—exhibits a superior spectrum matching with indoor lights, particularly a light‐emitting diode (LED), which results in an excellent power absorption ratio. These optical properties contribute to the state‐of‐the‐art performance of the PDTBTBz‐2F_anti:[6,6]‐phenyl‐C₇₁ butyric acid methyl ester (PC₇₁BM)‐based OPV with an unprecedented high power‐conversion efficiency (PCE) of 23.1% under a 1000 lx LED. Finally, its indoor photovoltaic performance is observed to be better than that of an interdigitated‐back‐contact‐based silicon photovoltaic (PCE of 16.3%).     

Solution‐Processable Perovskite Solar Cells toward Commercialization: Progress and Challenges

In the last few years, organometal halide perovskites (OHPs) have emerged as a promising candidate for photovoltaic (PV) applications. A certified efficiency as high as 23.7% has been achieved, which is comparable with most of the well‐established PV technologies. Their good solubility due to the ionic nature enables versatile low‐temperature solution processes, including blade coating, slot‐die coating, etc., most of which are scalable and compatible with roll‐to‐roll large‐scale manufacturing processes. The low cost, high efficiency, and facile processable features make perovskite solar cells (PSCs) a very competitive PV technology. Despite the great progress, long‐term durability concerns, toxicity issues of both materials and manufacturing process, and lack of robust high‐throughput production technology for fabricating efficient large‐area modules are major obstacles toward commercialization. In this review, the recent progress of commercially available process of PSCs is surveyed, the underlying determinants for upscaling high‐quality PSCs from hydrodynamic characteristics and crystallization thermodynamic mechanism are identified, the influence of external stress factors on stability of PSCs and intrinsic instability mechanism in OHPs themselves is revealed, and the environmental impact and sustainable development of PSC technology are analyzed. Strategies and opportunities for large‐scale production of PSCs are suggested to promote the development of PSCs toward commercialization.     

High‐speed atmospheric atomic layer deposition of ultra thin amorphous TiO2 blocking layers at 100 °C for inverted bulk heterojunction solar cells

Ultrafast, spatial atmospheric atomic layer deposition, which does not involve vacuum steps and is compatible with roll‐to‐roll processing, is used to grow high quality TiO₂ blocking layers for organic solar cells. Dense, uniform thin TiO₂ films are grown at temperatures as low as 100 °C in only 37 s (~20 nm/min growth rate). Incorporation of these films in P3HT‐PCBM‐based solar cells shows performances comparable with cells made using TiO₂ films deposited with much longer processing times and/or higher temperatures. Copyright © 2013 John Wiley & Sons, Ltd.     

Room‐Temperature Meniscus Coating of >20% Perovskite Solar Cells: A Film Formation Mechanism Investigation

Perovskite solar cells (PSCs) are ideally fabricated entirely via a scalable solution process at low temperatures to realize the promise of simple manufacturing, low‐cost processing, compatibility with flexible substrates, and perovskite‐based tandem solar cells. However, high‐quality photoactive perovskite thin films under those processing conditions is a challenge. Here, a laminar air‐knife‐assisted room‐temperature meniscus coating approach that enables one to control the drying kinetics during the solidification process and achieve high‐quality perovskite films and solar cells is devised. Moreover, this approach offers a solid model platform for in situ UV–vis and microscopic investigation of the perovskite film drying kinetics, which provide rich insights correlating the degree of supersaturation, the nucleation, and growth rate during the kinetic drying process, and ultimately, the film morphology and performance of the solar cell devices. Manufacturing friendly, antisolvent‐free room‐temperature coating of hysteresis‐free PSCs with a power conversion efficiency of 20.26% for 0.06 cm² and 18.76% for 1 cm² devices is demonstrated.     

A Versatile Fluoro‐Containing Low‐Bandgap Polymer for Efficient Semitransparent and Tandem Polymer Solar Cells

The versatility of a fluoro‐containing low band‐gap polymer, poly[2,6‐(4,4‐bis(2‐ethylhexyl)‐4H‐cyclopenta[2,1‐b;3,4‐b’]dithiophene)‐alt‐4,7‐(5‐fluoro‐2,1,3‐benzothia‐diazole)] (PCPDTFBT) in organic photovoltaics (OPVs) applications is demonstrated. High boiling point 1,3,5‐trichlorobenzene (TCB) is used as a solvent to manipulate PCPDTFBT:[6,6]‐phenyl‐C₇₁‐butyric acid methyl ester (PC₇₁BM) active layer morphology to obtain high‐performance single‐junction devices. It promotes the crystallization of PCPDTFBT polymer, thus improving the charge‐transport properties of the active layer. By combining the morphological manipulation with interfacial optimization and device engineering, the single‐junction device exhibits both good air stability and high power‐conversion efficiency (PCE, of 6.6%). This represents one of the highest PCE values for cyclopenta[2,1‐b;3,4‐b’]dithiophene (CPDT)‐based OPVs. This polymer is also utilized for constructing semitransparent solar cells and double‐junction tandem solar cells to demonstrate high PCEs of 5.0% and 8.2%, respectively.     

Printable and Large‐Area Organic Solar Cells Enabled by a Ternary Pseudo‐Planar Heterojunction Strategy

Bulk heterojunction (BHJ) processing technology has had an irreplaceable role in the development of organic solar cells (OSCs) in the past decades due to the significant advantages in achieving high‐power conversion efficiency (PCE). However, the difficulty in exploring and regulating morphology makes it inadequate for upscaling large‐area OSCs. In this work, printable high‐performance ternary devices are fabricated by a pseudo‐planar heterojunction (PPHJ) strategy. The fullerene derivative indene‐C₆₀ bisadduct (ICBA) is incorporated into PM6/IT‐4F system to expand the vertical phase separation and facilitate an obvious PPHJ structure. After the addition of ICBA, the IT‐4F enriches on the surface of active layer, while PM6 is accumulated underneath. Furthermore, it increases the crystallinity of PM6, which facilitates exciton dissociation and charge transfer. Accordingly, 1.05 cm² devices are fabricated by blade‐coating with an enhanced PCE of 14.25% as compared to the BHJ devices (13.73%). The ternary PPHJ strategy provides an effective way to optimize the vertical phase separation of organic semiconductor during scalable printing methods.     

Synergistic Roll‐to‐Roll Transfer and Doping of CVD‐Graphene Using Parylene for Ambient‐Stable and Ultra‐Lightweight Photovoltaics

A roll‐to‐roll (R2R) transfer technique is employed to improve the electrical properties of transferred graphene on flexible substrates using parylene as an interfacial layer. A layer of parylene is deposited on graphene/copper (Cu) foils grown by chemical vapor deposition and are laminated onto ethylene vinyl acetate (EVA)/poly(ethylene terephthalate). Then, the samples are delaminated from the Cu using an electrochemical transfer process, resulting in flexible and conductive substrates with sheet resistances of below 300 Ω sq^?1, which is significantly better (fourfold) than the sample transferred by R2R without parylene (1200 Ω sq^?1). The characterization results indicate that parylene C and D dope graphene due to the presence of chlorine atoms in their structure, resulting in higher carrier density and thus lower sheet resistance. Density functional theory calculations reveal that the binding energy between parylene and graphene is stronger than that of EVA and graphene, which may lead to less tear in graphene during the R2R transfer. Finally, organic solar cells are fabricated on the ultrathin and flexible parylene/graphene substrates and an ultra‐lightweight device is achieved with a power conversion efficiency of 5.86%. Additionally, the device shows a high power per weight of 6.46 W g^?1 with superior air stability.