Perovskite Thin-Film Coating for Dual-Substrate Manufacturing
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Solution Overview
Problem
Current methods for manufacturing perovskite solar cells are limited by poor manufacturability, requiring precise adjustments and only producing one film at a time, which hinders scalability and commercial viability.
Innovation Solution
The face-to-face planar contact (PCD) process allows for the simultaneous fabrication of two uniform perovskite films by sandwiching perovskite ink between two substrates, which are then pulled apart and dried, enabling the production of multiple films in a single round of coating with controlled thickness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If blade coating or screen printing is used to manufacture perovskite solar cells, then coating quality can be controlled, but only one film can be produced at a time and precise adjustments are required
Solution Approach 1:
The patent combines multiple substrates (first substrate and second substrate) into a single coating system where both substrates are coated simultaneously in one coating round. The coating head applies coating solution to both substrates at the same time, merging what would traditionally be separate coating operations into one unified process, thereby doubling productivity without requiring additional precision adjustments.
Solution Approach 2:
The coating system is designed to handle multiple substrates with potentially different requirements (different sizes, materials, or coating specifications) using a single coating head and one coating process. The system achieves multi-functionality by coating different substrates simultaneously, allowing one coating operation to serve multiple production needs without requiring separate precision-adjusted coating stations.
2Loss of substance
If traditional coating methods are used, then manufacturing process is simple, but material usage is inefficient and energy consumption is high
Solution Approach 1:
The patent merges the coating of two substrates into a single simultaneous operation, allowing the same amount of perovskite material to be distributed across two substrates instead of one. This effectively doubles material utilization efficiency without complicating the manufacturing process, as the coating head and coating solution delivery system remain fundamentally the same as traditional single-substrate coating.
3Productivity
If single-substrate coating is used, then process control is straightforward, but production yield is limited
Solution Approach 1:
The patent combines two coating operations into one simultaneous process where a single coating head deposits coating solution on both substrates at the same time. This merging approach maintains consistent coating conditions (solution flow rate, deposition speed, environmental parameters) for both substrates, ensuring uniformity while doubling the number of films produced per coating round.
Solution Approach 2:
The coating system allows for local optimization by enabling different substrates to receive appropriate coating conditions tailored to their specific requirements (different substrate sizes, materials, or desired coating thicknesses) while still being processed simultaneously. The coating head can be positioned or adjusted to provide locally optimized coating parameters for each substrate zone.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method increases product yield, reduces material usage, and allows for the production of films with varying thicknesses, enhancing the manufacturing process by enabling the production of semitransparent and tandem devices while reducing energy consumption and improving smoothness and flatness tolerances.
Implementation Method 1
a capillary action or surface tension may be used to deposit the perovskite precursor solution on the substrate
Implementation Method 2
a capillary action or surface tension may be used to deposit the perovskite precursor solution on the substrate
Implementation Method 3
drying the first coating and the second coating, thereby concomitantly manufacturing at least two thin-film devices
Data Source
AI summary
A method of concomitantly manufacturing at least two thin-film devices is provided, the method comprising: applying a solution on a first surface of a first planar substrate; positioning a second surface of a second planar substrate proximate to the first surface of the first planar substrate to provide parallelly disposed adjacent substrates, such that the first surface and the second surface are in contact with the solution; sliding the parallelly disposed adjacent substrates over one another such that the solution is drawn over the first surface and the second surface, which when the parallelly disposed adjacent substrates slide passed one another, provide a first coating on a first surface and a second coating on the second surface; and drying the first coating and the second coating, thereby concomitantly manufacturing at least two thin-film devices.