Multi-Cation Perovskite Layer Manufacturing via Gas Sweeping
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Solution Overview
Problem
Current methods for depositing perovskite layers on an industrial scale face challenges such as nonhomogeneous films, difficulty in crystallization, and the use of toxic solvents, which limit the scalability and stability of photovoltaic devices.
Innovation Solution
A method involving the deposition of a precursor solution with specific molar ratios of CsX, FAY, and PbZ2, including an FACI additive, followed by a gas flow of at least 120 m/s and heat treatment between 25°C to 80°C, to achieve high-quality crystalline perovskite layers on large surfaces without significant thermal annealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If spin coating method is used to deposit perovskite layer, then high optoelectronic quality and covering films are obtained, but nonhomogeneous wet film is produced when used over large surface
Solution Approach 1:
The patent replaces the mechanical spin coating system with a blade coating system that uses a moving blade to deposit precursor solution. This substitution eliminates the centrifugal force limitations of spin coating, enabling uniform film deposition over large substrate areas while maintaining controlled film formation through the blade's linear motion rather than rotational mechanics
Solution Approach 2:
The patent introduces a gas flow system (pneumatic element) to blow dry air or inert gas across the wet film during deposition. This pneumatic approach controls solvent evaporation and promotes uniform crystallization across the entire substrate surface, overcoming the area limitations of spin coating while maintaining film homogeneity
2Area of stationary object
If blade coating or slot die coating is used for industrial scale deposition, then large surface coverage is achieved, but difficulty in obtaining crystallization of perovskite film occurs
Solution Approach 1:
The patent employs a gas flow system that blows dry air or inert gas across the wet film at controlled speeds (1-100 cm/s). This pneumatic intervention promotes uniform solvent evaporation and triggers controlled crystallization across the entire large substrate area, solving the crystallization difficulty inherent in blade and slot die coating methods while maintaining industrial scalability
Solution Approach 2:
The patent modifies the evaporation rate parameter by controlling gas flow speed and introducing heat treatment (25-80°C). These parameter changes promote uniform crystallization across large areas by controlling the solvent removal rate, transforming the crystallization process from a problematic outcome to a controlled and uniform result across the entire substrate
3Manufacturing precision
If anti-solvent method based on centrifugal effect is used, then nucleation of perovskite is initiated, but the method is not suitable for large substrates and requires toxic solvents
Solution Approach 1:
The patent replaces the centrifugal force mechanism with a linear blade coating system combined with gas flow. This substitution eliminates the area limitations of centrifugal methods while maintaining controlled nucleation through the coordinated action of blade deposition and gas-induced solvent evaporation, enabling uniform nucleation across large substrate areas without requiring toxic anti-solvents
Solution Approach 2:
The patent introduces gas flow (dry air or inert gas) as an intermediary medium to control the crystallization process. This gas mediator promotes uniform solvent evaporation and nucleation across large areas without requiring the toxic anti-solvent chemicals needed in traditional centrifugal methods, replacing chemical mediation with physical gas-phase control
4Productivity
If implementation under air is used for industrial application, then scalability is improved, but device performances are limited
Solution Approach 1:
The patent allows the option of using inert gas (nitrogen or argon) instead of air during deposition and gas flow treatment. This creates an inert environment that prevents oxidation and degradation of the perovskite film, maintaining high device performance while still enabling industrial scalability through the blade coating and gas flow system that can operate in either air or inert atmosphere
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 produces perovskite layers with excellent crystalline quality and efficiency comparable to spin coating, while reducing the presence of PbCl2 peaks and enabling industrial-scale production with reduced manufacturing costs and environmental hazards.
Implementation Method 1
sweeping an exposed surface of the wet film by a flow of dry air or inert gas having a speed greater than or equal to 120 m/s so as to crystallize the multi-cation perovskite layer
Implementation Method 2
the method further comprising the application of a heat treatment to the substrate so that the deposition face has a temperature ranging from about 25° C. to at least 80° C. during step b)
Data Source
AI summary
A method for manufacturing a multi-cation perovskite layer, including: a) supply of a substrate having a deposition face, b) deposition of a precursor solution including precursors comprising CsX, FAY, PbZ2, with X, Y and Z = I, Br, and an FAC1 additive, the molar ratio of cesium to lead is between approximately 4 % and 22%, the molar ratio of FAC1 relative to lead between 0.1% and 5%, and the perovskite layer has an empirical formula of the type CsxFA(1-x+w)Pb(IyBr(1-y))3 with x between 0.04 and 0.22, y between 0 and 1 and w between 0.001 and 0.05, c) sweeping of the wet film by an inert gas to crystallize the perovskite layer, and heat treatment so that the deposition face has a temperature ranging from about 25° C. to 80° C. C at least during step b).