Perovskite Solar Module Coating for Scalable Sub-Cell Interconnection
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Solution Overview
Problem
There is a need for scalable manufacturing methods to produce large-area perovskite solar cell modules with high efficiency, as existing methods like spin coating are not suitable for uniform coating over large substrates, leading to challenges in integrating multiple sub-cells and achieving commercial-scale production.
Innovation Solution
The use of spray pyrolysis for depositing a TiO2 electron transport layer and blade coating for the perovskite and hole transport layers, optimizing layer thicknesses and compositions to achieve efficient interconnections between sub-cells, resulting in a 4-cell perovskite module with an aperture PCE of 15.6% and a geometrical fill factor of 87.3%, demonstrating a fully scalable manufacturing method for perovskite module fabrication.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If spin coating is used to deposit perovskite layers, then uniform coating and high efficiency can be achieved on small substrates, but the method is not suitable for large-area substrates and scalable manufacturing
Solution Approach 1:
The patent replaces the mechanical spin coating process with a solution-based deposition method that does not rely on high-speed rotation. The perovskite precursor solution is deposited onto the substrate and then annealed to form the perovskite layer, eliminating the scalability limitations of spin coating while maintaining coating quality.
Solution Approach 2:
The patent changes the processing parameters from spin coating (high-speed mechanical rotation) to solution deposition followed by thermal annealing. This parameter change enables the process to be applied to large-area substrates while maintaining the formation of high-quality perovskite layers with appropriate crystallinity and uniformity.
2Productivity
If multiple sub-cells are integrated to form large-area modules, then commercial-scale production can be achieved, but interconnection resistance and parasitic losses increase
Solution Approach 1:
The patent merges multiple sub-cells into a single integrated module structure where the perovskite layer and charge transport layers are continuous across cell boundaries. This merging reduces the number of interfaces and interconnections required, thereby reducing interconnection resistance and parasitic losses while maintaining high module area.
Solution Approach 2:
The patent uses the perovskite layer and charge transport layers as intermediary materials that facilitate efficient charge transport across cell boundaries. These intermediary layers provide low-resistance pathways for charge carriers, reducing parasitic losses at the interfaces between sub-cells.
3Manufacturing precision
If layer thicknesses are optimized for high efficiency, then power conversion efficiency improves, but manufacturing complexity increases
Solution Approach 1:
The patent optimizes the thickness parameters of each layer (perovskite, electron transport layer, hole transport layer) to achieve high power conversion efficiency. By carefully controlling these thickness parameters during the solution deposition and annealing process, the patent achieves optimal charge generation and transport while maintaining manufacturability.
Solution Approach 2:
The patent performs preliminary optimization of layer thicknesses and compositions during the module fabrication process. By establishing optimal thickness parameters in advance and maintaining consistent processing conditions, the patent achieves high efficiency while reducing the complexity of real-time thickness control during manufacturing.
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 approach enables the production of high-efficiency perovskite solar modules with improved interconnection resistance and reduced parasitic losses, achieving one of the highest efficiencies for scalable deposition methods, paving the way for commercial adoption of perovskite solar cells.
Implementation Method 1
an electron transfer layer that includes TiO2 and having a second thickness between 1 nm and 10 μm
Implementation Method 2
an active layer that includes the perovskite and having a third thickness
Implementation Method 3
a hole transfer layer that includes spiro-OMeTAD and having a fourth thickness
Data Source
Figure 1A
Figure 1B
Figure 1C
AI summary
The present disclosure relates to a perovskite-containing solar cell module that includes a glass substrate; a first cell; and a second cell, where each cell includes, in order, a first contact layer that includes fluorine-doped tin oxide, positioned on the substrate, and having an outside surface and a first thickness; an electron transfer layer that includes TiO2 and having a second thickness between 1 nm and 10 µm; an active layer that includes the perovskite and having a third thickness; a hole transfer layer that includes spiro-OMeTAD and having a fourth thickness; and a second contact layer that includes copper and having a fifth thickness. In addition, the first cell and the second cell are electrically connected by a first gap filled with the copper, and the first gap passes through the third thickness, the fourth thickness, and substantially through the second thickness to terminate at the outside surface.