Two-stage photoluminescence detection method and apparatus for perovskite battery assembly production

Abstract

This invention provides a two-stage photoluminescence detection method and apparatus for perovskite solar cell module production, aiming to solve the problem that existing technologies cannot perform step-by-step photoluminescence (PL) detection and quantify inter-layer matching of the perovskite core layer and the transport layer after core layer preparation. The apparatus includes production line adaptation, two-stage PL detection, data processing and analysis, and control and feedback modules. The production line adaptation module fixes the semi-finished products and assigns them unique identifiers; the two-stage PL detection module has two independent and identical first and second PL detection units, which collect data after the core layer and transport layer are prepared, respectively; the data processing and analysis module quantifies the data to determine the qualification of the semi-finished products and establishes and updates the matching database; the control and feedback module is connected to the production line control system, alarms and intercepts non-conforming products, and outputs process adjustment signals to improve production stability and module efficiency.

Description

Technical Field

[0001] This invention belongs to the field of perovskite photovoltaic cell preparation and testing technology, specifically to a two-stage photoluminescence detection method and device for perovskite cell module production. Background Technology

[0002] Perovskite solar cells are a key representative of third-generation photovoltaic technology and have received significant attention from academia and industry in recent years. Utilizing perovskite-type organometal halide semiconductors as light-absorbing materials, their photoelectric conversion efficiency has climbed from 3.8% to over 26% in laboratory certification over the past decade, approaching the theoretical limit of traditional crystalline silicon cells. Furthermore, perovskite cells offer advantages such as solution-based fabrication, low cost, and flexible production, making them promising for applications in building-integrated photovoltaics, wearable devices, vehicle-mounted photovoltaics, and large-scale ground-mounted power plants. The perovskite light-absorbing core layer is the core of photoelectric conversion, where photons excite electron-hole pairs (charge carriers). Its crystal quality, grain uniformity, and defect density directly determine the carrier generation efficiency and recombination loss, affecting the cell's short-circuit current and open-circuit voltage. After the core layer is fabricated, a transport layer needs to be prepared. Its carrier extraction efficiency, interfacial contact quality, and interlayer energy level matching determine the charge separation and collection effect, thus affecting the cell's fill factor and overall efficiency. The quality of the core layer and transport layer defines the performance ceiling of the module.

[0003] However, scaling up this technology for mass production presents significant challenges in process control and defect detection. Currently, most production lines rely primarily on finished module testing (such as IV curve testing and efficiency calibration) for quality assessment. Performance compliance can only be determined after all cell processes are completed and the cells are packaged. This post-production inspection model suffers from significant delays: if uneven grain size, pinholes, or impurities occur in the core layer crystallization, these issues are masked by subsequent transport and electrode layers. When finished product testing reveals low efficiency, it's difficult to trace the root cause, necessitating batch scrapping or downgrading, resulting in wasted raw materials and time. Furthermore, when module efficiency fails to meet standards, the lack of step-by-step data from intermediate processes prevents technicians from determining whether the problem lies in core layer crystallization, carrier extraction in the transport layer, or poor interface contact. Process adjustments rely on trial and error based on experience, leading to long cycles and high costs.

[0004] To address the issues of detection lag and difficulty in localization, existing technologies have been explored. Photoluminescence (PL) detection, due to its sensitivity to defects, non-contact nature, and high speed, has become a powerful tool for online quality monitoring of perovskite solar cells. Some institutions and manufacturers have introduced it into production lines for rapid screening of finished or semi-finished products; other solutions characterize perovskite thin films in the laboratory using PL, assessing film quality through luminescence intensity, peak position, and other indicators. Some researchers focus on nodes after the core layer and transport layer are fabricated, attempting to infer the carrier extraction effect of the transport layer by comparing changes in PL signals at different stages—theoretically, effective charge extraction will cause predictable quenching or shifting of the PL signal, which can be used as a criterion for transport layer function.

[0005] Despite positive attempts to apply PL (Label Layer) inspection technologies, there are still significant shortcomings in online step-by-step inspection for mass production. First, PL inspection is mostly limited to single measurements in the laboratory, where the environment differs greatly from the production line and is not linked to the production line's cycle time, making it difficult to adapt to high-speed continuous production. Second, even when PL equipment is installed on the production line, it is mostly used for final inspection of finished products, lacking independent inspection stations for core layers only and core layer + transport layer, making it impossible to obtain step-by-step quantitative data. Third, existing equipment lacks specific designs adapted to step-by-step inspection on the production line, making it difficult to maintain stable and consistent inspection parameters, resulting in poor data comparability and an inability to reliably establish the matching relationship between the core layer and the transport layer. Finally, when general-purpose inspection equipment is used on the production line, due to inspection redundancy, inaccurate positioning, or cycle time mismatch, inspection is slow, the false positive rate is high, and the production pace is slowed down. In summary, the industry has not yet developed a mature online step-by-step PL inspection solution for production lines. Defects in intermediate processes are difficult to capture in a timely manner, and inter-layer matching data cannot be accumulated, restricting the mass production yield and performance stability of components. Summary of the Invention

[0006] To address the limitations of existing technologies in performing stepwise photoluminescence (PL) testing on the perovskite core layer and the transport layer after core layer fabrication, and in quantifying interlayer compatibility, this invention provides a two-stage photoluminescence detection method and apparatus for perovskite solar cell module production. By conducting a first PL test after the core layer is completed and a second PL test on the transport layer after the core layer, the quality of the two layers can be determined and compared stepwise, quickly locating process defects, accumulating matching data, and improving production stability and module efficiency.

[0007] To achieve the above objectives, the present invention provides the following technical solution: a two-stage PL detection device for the production process of perovskite solar cell modules, comprising a production line adaptation module, a two-stage PL detection module, a data processing and analysis module, and a control and feedback module; The production line adapter module is used to fix the perovskite core layer semi-finished product and transmit it synchronously with the production line, and assign a unique identifier to each semi-finished product to be tested. The dual-stage PL detection module includes two independent and identical first and second PL detection units. The first PL detection unit is arranged after the core layer is prepared and before the transport layer is prepared to collect core layer PL detection data. The second PL detection unit is arranged after the transport layer is prepared to collect transport layer PL detection data. The data processing and analysis module receives and stores the unique identifier of the fixed perovskite core layer semi-finished product, the core layer PL detection data, and the transport layer PL detection data. It quantifies the PL image brightness uniformity and PL intensity attenuation rate, determines whether the semi-finished product is qualified, and transmits it to the control and feedback module. At the same time, it establishes and updates the perovskite layer-transport layer matching database based on historical relevant data. The control and feedback module is electrically connected to the production line control system, receives the results of the semi-finished product qualification judgment, synchronously detects and monitors the production process, alarms and intercepts unqualified semi-finished products, and calls the matching perovskite layer-transmission layer matching database data to output process adjustment signals to the production line.

[0008] Furthermore, the production line adaptation module includes a liftable test platform and a conveyor track. The test platform is synchronized with the production line conveyor speed, with a synchronization speed range of 0.5-2m / min. The test platform switches its fixing mode according to the type of semi-finished product.

[0009] Furthermore, the unique identifier adopts a QR code encoding format, and the identifier binding is achieved through a scanning module.

[0010] Furthermore, the optical path height, excitation angle, and acquisition parameters of the first PL detection unit and the second PL detection unit are completely identical; both the first PL detection unit and the second PL detection unit contain an excitation light source, a high-sensitivity imaging component, and a spectral analysis unit.

[0011] Furthermore, the excitation source is a tunable laser with a wavelength of 405-532nm and a power adjustable range of 0.5-10mW / cm². 2 The excitation wavelength is selected based on the band gap of the perovskite material; the high-sensitivity imaging component is a CMOS camera with ≥20 million pixels, a spectral response range of 400-900nm, and an adjustable integration time of 100ms-1s; the spectral analysis unit has a wavelength resolution of <1nm and is used to simultaneously acquire PL peak position and full width at half maximum (FWHM) data.

[0012] This invention also provides a two-stage PL detection method for the perovskite solar cell module manufacturing process, based on the aforementioned two-stage PL detection device for the perovskite solar cell module manufacturing process, comprising the following steps: The production line adapter module assigns a unique identifier and fixes it to the semi-finished perovskite core layer molding product. After the core layer is prepared and annealed, the first PL detection unit acquires the PL image and spectral data of the core layer, and determines the quality of the core layer based on the brightness uniformity of the PL image and the PL intensity. After the core layer of qualified semi-finished products completes the preparation of the transport layer, the second PL detection unit uses the same parameters as the first stage to collect PL images and spectral data of the same area, calculates the PL intensity attenuation rate, and determines the quality of the transport layer. The data from the two tests, production process parameters, and test results are linked and stored in the perovskite layer-transport layer matching database of the data processing and analysis module, and the semi-finished products are graded and disposed of according to the test results. By statistically analyzing the two-stage detection data in the perovskite-transport layer matching database, a range of perovskite-transport layer matching parameters is established to guide the optimization of preparation parameters in the production line. The performance indicators of the finished components are correlated with the two-stage detection data to reversely correct the judgment threshold and matching parameter range in the perovskite-transport layer matching database, forming a closed-loop optimization.

[0013] Furthermore, the core layer quality judgment criteria are as follows: if the PL image brightness uniformity CV ≤ 5% and the PL intensity ≥ preset standard threshold, the core layer quality is deemed qualified; if the PL image brightness uniformity CV > 5% or the PL intensity is lower than the preset standard threshold, the core layer quality is deemed unqualified, the control and feedback module will alarm and intercept, prohibiting it from entering the transport layer preparation process.

[0014] Furthermore, the formula for calculating the PL intensity attenuation rate is as follows: Attenuation rate = (first stage PL intensity) (Second stage PL intensity) / First stage PL intensity × 100% The pass / fail criteria for the transmission layer are as follows: if the attenuation rate is ≥30%, the transmission layer is considered to be of acceptable quality; if the attenuation rate is <15%, the transmission layer is considered to be of unacceptable quality; and if the attenuation rate is between 15% and 30%, a re-inspection process will be initiated.

[0015] Furthermore, the graded handling rules are as follows: if both the core layer and the transmission layer are qualified, the product proceeds to the next process; if the core layer is qualified but the transmission layer is unqualified, it is marked and isolated, and the transmission layer process is investigated; if the core layer is unqualified, the product is directly intercepted and scrapped or reworked; after confirmation and re-inspection, the product is handled according to the corresponding results.

[0016] Furthermore, the perovskite layer-transport layer matching parameter range represents the correspondence between the core layer PL intensity, brightness uniformity, and the optimal attenuation rate of the transport layer; the performance indicators of the finished module include conversion efficiency, fill factor, and maximum power.

[0017] Compared with the prior art, the present invention has at least the following beneficial effects: This invention provides a two-stage PL (Plastic Layer) detection device for the production process of perovskite solar cell modules. By integrating a production line adaptation module, a two-stage PL detection module, a data processing and analysis module, and a control and feedback module, it achieves step-by-step online detection of the perovskite core layer and transport layer. The detection targets are clear and the judgment is direct. The quality of the two layers can be intuitively determined by the change in PL brightness. The brighter the core layer, the better the crystallization quality. The darker the transport layer after preparation, the better the carrier extraction efficiency. This is consistent with the physical mechanism of perovskite carriers, is easy for workers to understand, and is easy to implement on the production line. The detection process is completed online and quickly without interrupting the production cycle. It can achieve early detection, early alarm, and early adjustment, with minimal impact on the overall efficiency of the production line. At the same time, it can accurately bind the unique identifier of semi-finished products, realize the traceability of detection data, and promptly intercept unqualified products, reducing the waste of raw materials and labor time. By establishing and updating the inter-layer matching database to accumulate inter-layer matching data, it provides accurate data support for the adjustment of the production line process, helping to improve the conversion efficiency and yield of the modules. The device has a high degree of integration, is adapted to the production workshop environment, avoids damage or degradation of semi-finished products during the detection process, and meets the stability and reliability requirements of industrial production.

[0018] Furthermore, the liftable testing platform and conveyor track of the production line adaptation module of this invention can synchronize with the production line speed of 0.5-2 m / min, further ensuring that the testing cycle time matches the production cycle time and reducing the impact on production efficiency. Simultaneously, the fixing method can be switched according to the type of semi-finished product, adapting to different types of semi-finished products, avoiding damage to semi-finished products during testing, ensuring accurate testing data, and improving the adaptability and practicality of the device. Furthermore, the unique identifier of this invention adopts a QR code encoding form and is bound through a scanning module, enabling rapid and accurate binding of semi-finished products with the unique identifier. This further ensures that two testing data points accurately correspond to the same semi-finished product, eliminating data misalignment, improving the convenience and accuracy of data traceability, and providing a reliable guarantee for the accumulation of inter-layer matching data. Furthermore, the optical path height, excitation angle, and acquisition parameters of the two PL detection units in this invention are completely identical, ensuring good comparability of detection data between the core layer and the transport layer. This provides a guarantee for the accurate calculation of PL intensity attenuation rate, thereby improving the accuracy of the determination of transport layer carrier extraction efficiency. The invention also specifies that each detection unit includes an excitation light source, a high-sensitivity imaging component, and a spectral analysis unit, ensuring the comprehensiveness and reliability of detection data acquisition, reducing the false positive rate, and meeting the actual detection needs of the production line. Furthermore, this invention specifies the specific parameters of the excitation light source, the high-sensitivity imaging component, and the spectral analysis unit. The excitation light source can be selected with a corresponding wavelength according to the band gap of the perovskite material, ensuring stable excitation effect and adapting to the detection needs of different types of perovskite materials. The parameter settings of the high-sensitivity imaging component and the spectral analysis unit can clearly capture the details of the PL emission image and accurately acquire spectral data, improving the quantitative accuracy of parameters such as PL image brightness uniformity and PL intensity, providing reliable data support for semi-finished product quality determination, and further reducing the false positive rate.

[0019] This invention provides a two-stage PL (Plastic Layer) detection method for the production process of perovskite solar cell modules. Based on the aforementioned device, the detection process is clear and orderly, realizing step-by-step detection, data association and storage, and closed-loop optimization of the perovskite core layer and transport layer. Continuing the advantages of the device, the detection process is completed online without interrupting the production cycle. While minimizing the impact on production speed, it increases the precision of the production process, which is beneficial for improving the production quality of perovskite solar cells. The quality of the two layers can be intuitively determined using PL brightness changes and attenuation rates, with clear judgment standards that are easy for workers to master and easy to implement on the production line. By accumulating two-stage PL comparison data, an inter-layer matching parameter range is established, providing precise guidance for production line process optimization. Simultaneously, through closed-loop iteration, the detection standards and process parameters are continuously optimized, and inter-layer matching data is accumulated, significantly improving module conversion efficiency and yield. This provides reliable data support for large-scale production and adapts to the needs of industrial mass production.

[0020] Furthermore, this invention clarifies specific criteria for judging the quality of the core layer (PL image brightness uniformity CV ≤ 5% and PL intensity ≥ preset standard threshold), making the core layer quality judgment more targeted and operable, avoiding misjudgments caused by ambiguous judgment criteria. Simultaneously, it clarifies interception measures for unqualified core layers, enabling timely interception of unqualified core layer semi-finished products and preventing them from entering the transport layer preparation process, further reducing subsequent waste of raw materials and labor, lowering production costs, and achieving the advantages of early detection and early interception. Furthermore, this invention clarifies the calculation formula for the PL intensity attenuation rate and specific criteria for judging the quality of the transport layer, making the judgment of transport layer carrier extraction efficiency more accurate and standardized, aligning with the core logic of judging transport layer quality based on PL brightness changes. The invention also establishes a re-inspection process, which can eliminate the influence of detection errors on the judgment of transport layer quality, improve the reliability of detection results, ensure that the transport layer quality meets production requirements, and provide assurance for the overall performance of the component. Furthermore, this invention clarifies the grading and disposal rules for semi-finished products, and formulates corresponding disposal plans for different test results. This enables refined management of semi-finished products, preventing qualified core layers from being wasted due to unqualified transport layers, while reducing the inflow of unqualified semi-finished products into subsequent processes. This further improves production efficiency, reduces production costs, ensures module production quality, and aligns with the needs of refined production line management. Furthermore, this invention clarifies the specific meaning of the perovskite layer-transport layer matching parameter range and the core performance indicators of finished modules, making interlayer matching modeling more targeted. This provides more precise guidance for production line process optimization and clear correction criteria for closed-loop optimization, helping to continuously accumulate interlayer matching data, further improving module conversion efficiency and mass production stability, and providing stronger data support for large-scale production. Attached Figure Description

[0021] Figure 1 This is a schematic diagram of the two-stage PL testing device, showing the integration relationship between the device and the production line, the composition of the two sets of PL testing units and the connection logic of each module. The first PL testing unit is located after the core layer is prepared, and the second PL testing unit is located after the transmission layer is prepared after the core layer. Figure 2 This is a flowchart of a two-stage PL inspection method, showing the complete process of core layer inspection, inspection of the first transport layer after the core layer, data storage, matching analysis, and process feedback. Detailed Implementation

[0022] The present invention will be further described below with reference to the accompanying drawings and specific embodiments.

[0023] like Figure 1 As shown, this invention provides a two-stage PL (Power Layer) inspection device for the perovskite solar cell module production process. This device is integrated into the perovskite solar cell module production line to achieve step-by-step online inspection of the core layer and the transport layer, adapting to the needs of industrial mass production. Its specific structure is as follows: Production line adaptation module: Includes a liftable testing platform and conveyor rail. The testing platform's conveyor speed is synchronized with the production line (0.5-2m / min). The fixing method can be switched according to the type of semi-finished product: rigid semi-finished products are fixed with snap-fit ​​mechanisms, while flexible semi-finished products are fixed with flexible adsorption, avoiding substrate deformation or damage. Simultaneously, this module assigns a unique identifier to each semi-finished product to be tested, and the identifier is bound via a barcode scanning module, ensuring that two test data points accurately correspond to the same component and the same testing area, preventing data misalignment.

[0024] Further restrictions are imposed: the flexible adsorption fixation method used for the flexible semi-finished product has a contact pressure ≤0.1N; and the unique identifier adopts a QR code encoding format.

[0025] The dual-stage PL inspection module comprises two independent PL inspection units with identical parameters: a first PL inspection unit and a second PL inspection unit. These units are respectively positioned after the core layer preparation station and before the transport layer preparation station (first inspection station), and after the transport layer preparation station (second inspection station). The two units are synchronized with the production line cycle, ensuring uninterrupted production flow. Each inspection unit includes: Excitation source: tunable laser with wavelength 405-532nm, power 0.5-10mW / cm² 2 It is adjustable, and the excitation wavelength can be selected according to the band gap matching of the perovskite material to ensure stable excitation effect.

[0026] To further specify, commonly used perovskite materials include MAPbI3 and FA. 0.85 Cs 0.15 For PbI3 and CsPbI3, the corresponding excitation wavelength can be selected based on the band gap characteristics of the aforementioned materials.

[0027] High-sensitivity imaging components: ≥20 million pixel CMOS camera, spectral response range 400-900nm, resolution ≤0.1μm, integration time adjustable from 100ms to 1s, which can clearly capture the brightness distribution details of PL luminescent images; Spectroscopic analysis unit: wavelength resolution <1nm, capable of simultaneously acquiring PL peak position and full width at half maximum (FWHM) data to assist in determining the crystal quality and defect density of materials.

[0028] The optical path height, excitation angle, and acquisition parameters (integration time, power, wavelength) of the two detection units are kept completely consistent to ensure that the two detection data are comparable and to provide a reliable basis for subsequent calculation of PL intensity attenuation rate.

[0029] The data processing and analysis module includes a storage unit, an image analysis unit, and a matching database. The image analysis unit quantifies the brightness uniformity (coefficient of variation, CV) and peak intensity of the perovskite (PL) image, accurately calculating the PL intensity attenuation rate between two tests. The storage unit associates and stores the unique identifier of the semi-finished product, core layer PL parameters (CV value, PL intensity, peak position), transport layer PL parameters (PL intensity, peak position), attenuation rate, and corresponding production process parameters (coating speed, annealing temperature, transport layer deposition thickness). The matching database establishes a perovskite layer-transport layer matching parameter model through statistical analysis of a large amount of two-stage detection data, forming a correspondence between core layer parameters and the optimal attenuation rate of the transport layer.

[0030] Control and Feedback Module: Electrically connected to the production line control system, it synchronously detects and monitors the production cycle time in real time, ensuring that the detection speed matches the production line conveyor speed (single detection ≤20s, impact on overall production line efficiency ≤3%). When a defective semi-finished product is detected, an alarm signal is immediately issued and the defect is intercepted. At the same time, targeted process adjustment signals are output (e.g., adjusting coating speed and annealing temperature when the core layer is defective; adjusting deposition thickness and coating pressure when the transfer layer is defective), achieving early detection, early alarm, and early adjustment.

[0031] like Figure 2 As shown, this invention also provides a two-stage PL (Layered Detection) method for the production process of perovskite solar cell modules. Based on the above-mentioned device, it can effectively solve the problems of detection lag, difficulty in defect localization, and inability to accumulate interlayer matching data in the prior art. The specific steps are as follows: Step 1: Identification and Positioning of Semi-finished Products Before the perovskite core layer molding semi-finished product (core layer molding part) enters the first inspection station, the production line adapter module assigns it a unique identifier. After the identifier is bound, it is fixed on the test platform. The height and angle of the test platform are adjusted to ensure that the inspection area is aligned with the optical path of the PL inspection unit, laying the foundation for the alignment of the same area in two inspections.

[0032] Step 2: First-stage testing (after core layer preparation) After the perovskite core layer is prepared and annealed, the semi-finished product enters the first detection station via a conveyor track; the control and feedback module starts the first PL detection unit, sets the excitation parameters according to the band gap of the core layer material, and collects PL emission images and spectral data.

[0033] Further specifying, the core layer is an ABX3 type light-absorbing layer; different core layer materials correspond to different excitation parameters, for example, MAPbI3 corresponds to an excitation wavelength of 780nm and a power of 5mW / cm. 2 CsPbI3 corresponds to an excitation wavelength of 453 nm and a power of 3 mW / cm. 2 .

[0034] The criteria for judging the quality of the core layer are: if the uniformity of PL image brightness CV is ≤5% and the PL intensity is ≥ the preset standard threshold, the core layer is judged to have uniform crystallization, low defect density, and qualified preparation quality.

[0035] Furthermore, the preset standard threshold is based on the calibration of standard qualified samples, and the threshold varies for different materials.

[0036] If the test result is CV>5% or PL intensity is below the threshold, the core layer is deemed unqualified. The control and feedback module will immediately alarm and intercept the semi-finished product, prohibiting it from entering the transport layer preparation process to avoid subsequent waste of raw materials and time. At the same time, it will output a process adjustment signal to the production line to optimize the core layer coating and annealing parameters.

[0037] Step 3: Second-stage detection (after the transport layer is prepared) The semi-finished products that pass the first stage of testing enter the transmission layer preparation process along the production line; after the transmission layer preparation is completed, the semi-finished products enter the second testing station, where they are bound with a unique identifier to ensure that they are the same semi-finished products tested in the first stage.

[0038] Further defining the transport layer, it is divided into electron transport layer (ETL) and hole transport layer (HTL) based on the battery structure. Commonly used electron transport layers include TiO2 and C. 60 Commonly used hole transport layers include Spiro-OMeTAD.

[0039] The second PL detection unit uses the exact same excitation parameters, imaging parameters, and acquisition parameters as the first stage to perform PL detection on the same detection area and acquire PL emission images and spectral data. Calculate the PL intensity attenuation rate: Attenuation rate = (PL intensity in the first stage) (Second stage PL intensity) / First stage PL intensity × 100%; The pass / fail criteria for the transport layer are as follows: if the attenuation rate is ≥30%, the carrier extraction efficiency of the transport layer is good; if the attenuation rate is <15%, the transport layer has poor interface contact, energy level mismatch or film formation defects; if the attenuation rate is between 15% and 30%, it is in a pending confirmation state, and a re-inspection process is initiated to eliminate detection errors before making a final judgment.

[0040] Further, when the attenuation rate is ≥30%, the carriers are rapidly extracted to the transport layer, which will cause the PL signal to be quenched. This allows for a direct assessment of the carrier extraction efficiency.

[0041] Step 4: Tiered processing and data storage The data processing and analysis module associates the unique identifier of the semi-finished product, the core layer PL parameters, the transmission layer PL parameters, the attenuation rate, the corresponding production process parameters, and the test results (qualified / unqualified / pending confirmation) of the semi-finished product with the matching database. Tiered handling rules: Core layer qualified + transport layer qualified → proceed to subsequent electrode preparation and packaging processes; Core layer qualified + transport layer unqualified → mark and isolate, and only investigate the transport layer preparation process (such as deposition thickness, coating pressure) to avoid wasting qualified core layers; Core layer unqualified → directly intercept and scrap or rework; after confirming product re-inspection, handle according to the corresponding results.

[0042] Step 5: Interlayer compatibility analysis and process guidance The data processing and analysis module performs statistical analysis on a large amount of two-stage detection data in the matching database, extracts the correlation between the core layer PL intensity, brightness uniformity and the optimal attenuation rate range of the transport layer, and establishes the matching parameter range between the perovskite layer and the transport layer.

[0043] To further define the optimal range, a typical example of the matching parameters is: when the core layer PL strength is ≥8000 a.u. and CV is ≤4%, the optimal attenuation rate of the transport layer is 35%-45%.

[0044] When the dual-stage PL parameters of the newly tested semi-finished product deviate from the matching range, the control and feedback module predicts the component performance risk in advance, automatically outputs process adjustment signals to the production line, optimizes the core layer or transmission layer preparation parameters, and improves the interlayer energy level matching degree.

[0045] Step 6: Product Verification and Closed-Loop Iteration Once encapsulated, the perovskite modules enter the finished product testing phase, where core performance indicators of the modules are tested. The finished product performance indicators are then correlated with the corresponding two-stage PL test data and production process parameters of the module, and the judgment thresholds and interlayer matching parameter ranges in the matching database are corrected in reverse.

[0046] Further, the core performance indicators include component conversion efficiency, fill factor, and maximum power; the judgment thresholds include CV threshold, PL intensity threshold, and attenuation rate threshold.

[0047] Through multiple iterations, we continuously optimize testing standards and process parameters, forming a closed loop of testing, analysis, adjustment, and verification, thereby continuously improving component conversion efficiency and mass production yield.

[0048] The following examples further illustrate the implementation effects of the present invention. Parameters not explicitly described in each example are all set according to the standard settings of the specific embodiments described above.

[0049] Example 1: Two-stage PL testing of rigid perovskite modules (for large-scale ground power plants) Test object: A rigid perovskite module measuring 1.6m × 1.0m, which consists of 10 sub-cells connected in series, with a core layer of FA. 0.85 Cs 0.15The PbI3 light-absorbing layer, followed by the electron transport layer (ETL) after the core layer, is designed for large-scale ground-mounted power plants, requiring high module efficiency and yield.

[0050] In this embodiment, the electron transport layer (ETL) is made of TiO2 material, which is the preferred electron transport layer material for perovskite modules used in large-scale ground power plants. It can effectively improve carrier extraction efficiency and is suitable for complex outdoor working conditions.

[0051] Device parameters: Excitation source: 453nm laser, power 5mW / cm 2 The spot diameter is 100μm; Imaging components: 20-megapixel CMOS camera, integration time 500ms, spectral response range 400-900nm; Test platform: transmission speed 1m / min, using snap-fit ​​fixing, optical path height fixed at 50cm; Judgment thresholds: Core layer CV≤5%, PL intensity≥6000a.u.; Transmission layer attenuation rate≥30% is qualified, <15% is unqualified.

[0052] Testing process: 1. After the core layer is prepared and annealed (annealing temperature 150℃, time 10min), the semi-finished product enters the first inspection station, is assigned a unique QR code, and is fixed after scanning and binding; the first PL detection unit is started to collect PL images and spectral data, and the brightness uniformity CV=3.2% and PL intensity=8500a.u. are analyzed and found to meet the qualified standards. The core layer is judged to be qualified and enters the transport layer preparation process.

[0053] 2. After the transport layer (TiO2) is prepared, the semi-finished product enters the second detection station, where a unique identifier is bound by a barcode. Using the same detection parameters as in the first stage, PL images and spectral data of the same area are collected. The measured PL intensity is 5100 a.u., and the attenuation rate is calculated as (8500-5100) / 8500×100%=40%, which meets the qualification standard. Therefore, the carrier extraction efficiency of the transport layer is determined to be good.

[0054] 3. The identification, two-stage PL parameters, decay rate, annealing temperature (150℃), and coating speed (0.8m / min) of the semi-finished product are associated and stored in the matching database; the semi-finished product then proceeds to the subsequent packaging process.

[0055] 4. Batch testing of 100 components in this batch, importing all dual-stage test data into the matching database, and statistical analysis showed that when the core layer CV ≤ 4% and PL strength ≥ 8000 a.u., the optimal attenuation rate of the transmission layer is 35%-45%. Subsequent production processes will adjust the process parameters according to this matching range.

[0056] Test results: The average conversion efficiency of this batch of components reached 23.2%, with a yield of 92%. Compared with the batch that did not use this method (average efficiency 22.1%, yield 86%), the efficiency improved by 1.1% and the yield improved by 6%, meeting the application requirements of large-scale ground power plants. No unqualified core layer products flowed into the transmission layer preparation process, and raw material waste was reduced by 30%.

[0057] Example 2: Two-stage PL detection of flexible perovskite components (for wearable devices) Test object: A flexible perovskite module with dimensions of 0.5m × 0.5m. The module has a structure of 6 sub-cells connected in series. The core layer is a CsPbI3 light-absorbing layer, and the transmission layer behind the core layer is an electron transport layer (ETL). It is intended for use in wearable electronic devices. The module is required to be thin, flexible, and has high requirements for substrate protection during the test.

[0058] In this embodiment, the electron transport layer (ETL) adopts C 60 The material is lightweight, thin, and highly compatible, making it suitable for the fabrication of flexible components. It avoids damage to the flexible substrate while ensuring carrier extraction performance.

[0059] Device parameters: Excitation source: 405nm laser, power 3mW / cm², spot diameter 80μm.

[0060] In this embodiment, the excitation light source power is reduced to 3mW / cm. 2 This is to prevent the perovskite material of flexible components from degrading due to overheating, protect the flexible substrate from damage, and adapt to the thin and light characteristics of wearable device components.

[0061] Imaging components: 20-megapixel CMOS camera, integration time 400ms, spectral response range 400-900nm; Test platform: conveying speed 0.8m / min, using flexible adsorption fixation, contact pressure 0.08N, to avoid deformation of the flexible substrate; Judgment thresholds: Core layer CV≤5%, PL intensity≥5500a.u.; Transmission layer attenuation rate≥30% is qualified, <15% is unqualified.

[0062] Testing process: 1. After the core layer is prepared and annealed (annealing temperature 130℃, time 8min), the semi-finished product enters the first inspection station, is assigned a unique QR code, and is flexibly adsorbed and fixed. Then, the first PL detection unit is started to collect data. Among them, the CV of 3 components is 6.8% (>5%) and PL strength is 5200 a.u. (<5500 a.u.). The core layer is judged to be unqualified, the control module alarms and intercepts, and at the same time outputs an adjustment signal to adjust the coating blade speed from 0.6m / min to 0.5m / min. After the adjustment, the CV of the core layer of subsequent components is ≤4.5%, and the PL strength is ≥5800 a.u.

[0063] 2. Qualified core layer semi-finished products enter the transmission layer (C) 60 After the preparation process is completed, the components enter the second testing station, where the barcode is scanned and the identification is bound. Data from the same area is collected using the testing parameters from the first stage. Two components were found to have an attenuation rate of 12% (<15%), indicating that the transmission layer was unqualified. The investigation revealed that the coating thickness of the transmission layer was uneven (local thickness deviation >0.1μm). The coating pressure was adjusted from 0.3MPa to 0.25MPa. After the adjustment, the attenuation rate of the transmission layer of subsequent components was improved to over 30%.

[0064] 3. Link and store the test data and process parameters of all components to establish a dedicated matching database for flexible components. It is found that when the core layer CV ≤ 4.5% and PL strength ≥ 5800 a.u., the optimal attenuation rate of the transmission layer is 32%-42%.

[0065] Test results: After process optimization, the average conversion efficiency of this batch of components increased by 4.8%, the defect rate decreased from 8% to 2.5%, the flexible substrate was undeformed and undamaged, and fully met the application requirements of wearable devices; the testing process did not affect the production line cycle time, the single test time was 18 seconds, and the impact on production efficiency was only 2.5%.

[0066] Example 3: Two-stage PL testing for mass-produced perovskite modules (for building-integrated photovoltaics, BIPV) Test object: Rigid perovskite module with dimensions of 2.0m×1.2m. The module has a 12-cell series structure, with a MAPbI3 light-absorbing layer as the core layer and a hole transport layer (HTL) as the transport layer behind the core layer. It is intended for building-integrated photovoltaics (BIPV) and requires good batch stability, small efficiency fluctuations, and compatibility with large-scale mass production.

[0067] In this embodiment, the hole transport layer (HTL) uses Spiro-OMeTAD material, which has good energy level matching and high carrier mobility, making it suitable for the mass production requirements of BIPV modules and ensuring batch stability of the modules.

[0068] Device parameters: Excitation source: 532nm laser, power 8mW / cm 2 The spot diameter is 120μm; Imaging components: 30-megapixel CMOS camera, integration time 600ms, spectral response range 400-900nm.

[0069] In this embodiment, a 30-megapixel CMOS camera is selected to improve imaging resolution, thereby meeting the detection requirements of a large-size 2.0m×1.2m BIPV module, ensuring that the PL luminescence details in different areas of the module can be clearly captured, and avoiding missed detections.

[0070] Test platform: transmission speed 2m / min, snap-fit ​​fixing, optical path height can be automatically adjusted.

[0071] In this embodiment, the optical path height is set to be automatically adjustable in order to adapt to the detection area of ​​the 2.0m×1.2m large-size component, ensure that the optical path is always aligned with the area to be detected during the detection process, guarantee the accuracy of the detection data, and adapt to the cycle time requirements of mass production.

[0072] Judgment thresholds: Core layer CV≤5%, PL strength≥7000a.u.; transmission layer attenuation rate≥30% is qualified, <15% is unqualified; in mass production, if 3 consecutive modules show the same type of unqualified, emergency process adjustment is initiated.

[0073] Testing process: 1. After the core layer is prepared and annealed (annealing temperature 140℃, time 12min), the semi-finished products enter the first inspection station, and a unique QR code is assigned to each batch. Fixing and inspection are completed simultaneously. In the first stage of inspection, no unqualified core layer products were found. The CV of all components was ≤4.8%, and the PL strength was ≥7200a.u., and they successfully entered the transport layer preparation process.

[0074] 2. After the transport layer (Spiro-OMeTAD) is prepared, the semi-finished product enters the second testing station for batch scanning and binding, and data is collected using the testing parameters from the first stage. During the testing process, three consecutive modules were found to have an attenuation rate of 13% (<15%), indicating that the transport layer was unqualified. The control module immediately initiated emergency adjustments, and the problem was found to be a deviation in the concentration of the transport layer solution. The concentration was adjusted from 0.02 mol / L to 0.025 mol / L. After the adjustment, the attenuation rate of the transport layer in subsequent modules stabilized at 33%-48%.

[0075] 3. Batch testing of 500 modules in this batch, correlation between dual-stage testing data, process parameters and finished product efficiency, reverse correction of matching database, adjustment of core layer PL strength threshold to 7200 a.u., adjustment of optimal attenuation rate range of transmission layer to 33%-48%, after optimization, the accuracy of detection judgment is improved to 99.2%.

[0076] 4. In the finished product testing phase, the component conversion efficiency is correlated with the two-stage PL data to form a closed-loop iteration. The efficiency fluctuation of subsequent batches of components is controlled within ±0.3%, which meets the stability requirements for large-scale BIPV applications.

[0077] Test results: The average conversion efficiency of this batch of components reached 22.8%, and the yield was 93.5%. Compared with the batch that did not use this method, the yield improved by 7.5%, and the waste of raw materials in mass production was reduced by 35%. The testing cycle was perfectly matched with the production line, with a single testing time of 20 seconds and an impact on production efficiency of 3%, which is fully adapted to the needs of large-scale mass production.

Claims

1. A two-stage PL detection device for the perovskite solar cell module manufacturing process, characterized in that, This includes a production line adaptation module, a two-stage PL detection module, a data processing and analysis module, and a control and feedback module; The production line adapter module is used to fix the perovskite core layer semi-finished product and transmit it synchronously with the production line, and assign a unique identifier to each semi-finished product to be tested. The dual-stage PL detection module includes two independent and identical first and second PL detection units. The first PL detection unit is arranged after the core layer is prepared and before the transport layer is prepared to collect core layer PL detection data. The second PL detection unit is arranged after the transport layer is prepared to collect transport layer PL detection data. The data processing and analysis module receives and stores the unique identifier of the fixed perovskite core layer semi-finished product, the core layer PL detection data, and the transport layer PL detection data. It quantifies the PL image brightness uniformity and PL intensity attenuation rate, determines whether the semi-finished product is qualified, and transmits it to the control and feedback module. At the same time, it establishes and updates the perovskite layer-transport layer matching database based on historical relevant data. The control and feedback module is electrically connected to the production line control system, receives the results of the semi-finished product qualification judgment, synchronously detects and monitors the production process, alarms and intercepts unqualified semi-finished products, and calls the matching perovskite layer-transmission layer matching database data to output process adjustment signals to the production line.

2. The dual-stage PL detection device for the perovskite solar cell module production process according to claim 1, characterized in that, The production line adaptation module includes a liftable test platform and a conveyor track. The test platform is synchronized with the production line conveyor speed, with a synchronization speed range of 0.5-2m / min. The test platform switches its fixing mode according to the type of semi-finished product.

3. The dual-stage PL detection device for the perovskite solar cell module production process according to claim 2, characterized in that, The unique identifier is in the form of a QR code, and the identifier is bound through a scanning module.

4. The dual-stage PL detection device for the perovskite solar cell module production process according to claim 1, characterized in that, The first PL detection unit and the second PL detection unit have the same optical path height, excitation angle, and acquisition parameters; both the first PL detection unit and the second PL detection unit contain an excitation light source, a high-sensitivity imaging component, and a spectral analysis unit.

5. The dual-stage PL detection device for the perovskite solar cell module production process according to claim 1, characterized in that, The excitation source is a tunable laser with a wavelength of 405-532nm and a power adjustable range of 0.5-10mW / cm². 2 The excitation wavelength is selected based on the band gap of the perovskite material; the high-sensitivity imaging component is a CMOS camera with ≥20 million pixels, a spectral response range of 400-900nm, and an adjustable integration time of 100ms-1s; the spectral analysis unit has a wavelength resolution of <1nm and is used to simultaneously acquire PL peak position and full width at half maximum (FWHM) data.

6. A two-stage PL detection method for the perovskite solar cell module manufacturing process, characterized in that, The two-stage PL detection device for the perovskite solar cell module production process according to any one of claims 1-5 includes the following steps: The production line adapter module assigns a unique identifier and fixes it to the semi-finished perovskite core layer molding product. After the core layer is prepared and annealed, the first PL detection unit acquires the PL image and spectral data of the core layer, and determines the quality of the core layer based on the brightness uniformity of the PL image and the PL intensity. After the core layer of qualified semi-finished products completes the preparation of the transport layer, the second PL detection unit uses the same parameters as the first stage to collect PL images and spectral data of the same area, calculates the PL intensity attenuation rate, and determines the quality of the transport layer. The data from the two tests, production process parameters, and test results are linked and stored in the perovskite layer-transport layer matching database of the data processing and analysis module, and the semi-finished products are graded and disposed of according to the test results. By statistically analyzing the two-stage detection data in the perovskite-transport layer matching database, a range of perovskite-transport layer matching parameters is established to guide the optimization of preparation parameters in the production line. The performance indicators of the finished components are correlated with the two-stage detection data to reversely correct the judgment threshold and matching parameter range in the perovskite-transport layer matching database, forming a closed-loop optimization.

7. The two-stage PL detection method for the perovskite solar cell module production process according to claim 6, characterized in that, The core layer quality judgment criteria are as follows: if the PL image brightness uniformity CV ≤ 5% and the PL intensity ≥ preset standard threshold, the core layer quality is deemed qualified; if the PL image brightness uniformity CV > 5% or the PL intensity is lower than the preset standard threshold, the core layer quality is deemed unqualified, the control and feedback module will alarm and intercept, and prohibit it from entering the transport layer preparation process.

8. The two-stage PL detection method for the perovskite solar cell module production process according to claim 6, characterized in that, The formula for calculating the PL intensity attenuation rate is: Attenuation rate = (first stage PL intensity) (Second stage PL intensity) / First stage PL intensity × 100% The pass / fail criteria for the transmission layer are as follows: if the attenuation rate is ≥30%, the transmission layer is considered to be of acceptable quality; if the attenuation rate is <15%, the transmission layer is considered to be of unacceptable quality; and if the attenuation rate is between 15% and 30%, a re-inspection process will be initiated.

9. A two-stage PL detection method for the perovskite solar cell module production process according to claim 8, characterized in that, The graded handling rules are as follows: if both the core layer and the transmission layer are qualified, the product proceeds to the next process; if the core layer is qualified but the transmission layer is unqualified, it is marked and isolated, and the transmission layer process is investigated; if the core layer is unqualified, the product is directly intercepted and scrapped or reworked; after confirmation and re-inspection, the product is handled according to the corresponding results.

10. A two-stage PL detection method for the perovskite solar cell module production process according to claim 6, characterized in that, The perovskite layer-transport layer matching parameter range represents the correspondence between the core layer PL intensity, brightness uniformity, and the optimal attenuation rate of the transport layer; the performance indicators of the finished module include conversion efficiency, fill factor, and maximum power.

Images