Perovskite Thin Film Spray Coating for Large-Area Patterned Deposition

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Solution Overview

Problem

Current methods for forming perovskite thin films face challenges such as difficulty in producing large-area films and pattern formation, with issues like deposition source degradation in thermal evaporation and limited scalability in spin coating.

Innovation Solution

A method involving a dual nozzle system where a first and second perovskite compound precursor solutions are sprayed onto a substrate, reacting to form a perovskite compound solution, which is then used to create a thin film by evaporating the solvent, allowing for large-area and patterned film formation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If thermal evaporation is used to form thin films, then deposition can be performed, but deposition source degradation occurs over long periods and deposition source losses are huge

Engineering Contradiction:

Improvedeposition capabilityVSAvoiddeposition source loss

Core Design Contradiction:

ProductivityVSLoss of substance

Solution Approach 1:

The patent replaces the thermal evaporation method (thermal field) with a spray coating method (mechanical field). The dual nozzle system sprays precursor solutions onto the substrate, forming perovskite thin films through chemical reaction and solvent evaporation rather than thermal decomposition, thereby eliminating deposition source degradation and material loss associated with thermal evaporation

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the deposition parameters by using solution-based precursors sprayed at controlled rates rather than thermal evaporation at high temperatures. The spray coating process operates at lower temperatures with controlled solution flow rates, transforming the deposition mechanism from thermal decomposition to solution deposition followed by solvent evaporation

Inventive Principle:

Principle #35Parameter changes

2Manufacturing precision

If spin coating is used to form thin films, then film formation is achieved, but large-area film formation and pattern formation are difficult

Engineering Contradiction:

Improvefilm formation qualityVSAvoidfilm area

Core Design Contradiction:

Manufacturing precisionVSArea of stationary object

Solution Approach 1:

The patent divides the film formation process into two separate spray operations: first spraying one precursor solution, then spraying the second precursor solution. This segmented approach allows precise control over film composition and enables pattern formation by controlling the spray trajectories and timing, while also facilitating large-area coverage

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent uses a dual nozzle spray coating system that utilizes pneumatic spray mechanisms to deposit precursor solutions. The spray nozzles can be positioned and moved to cover large substrate areas, enabling both large-area film formation and pattern formation through controlled spray deposition

Inventive Principle:

Principle #29Pneumatics and hydraulics

3Ease of manufacture

If conventional spray coating is used, then film formation is possible, but solvent aggregation occurs and film uniformity deteriorates

Engineering Contradiction:

Improvefilm formation processVSAvoidfilm uniformity

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The patent performs preliminary action by first spraying one precursor solution and allowing it to form a uniform layer, then spraying the second precursor solution on top. This sequential deposition prevents solvent aggregation by ensuring proper layer formation and chemical reaction before complete solvent evaporation, maintaining film uniformity throughout the process

Inventive Principle:

Principle #10Preliminary action

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 formation of high-quality perovskite thin films with improved coverage and uniformity, enhancing the efficiency and lifespan of light-emitting devices by minimizing solvent aggregation and maintaining film integrity.

Implementation Method 1

spraying a first solution of a first perovskite compound precursor through the inner nozzle of a dual nozzle including an inner nozzle and an outer nozzle, spraying a second solution of a second perovskite compound precursor through the outer nozzle

Methodology Applied

Scientific EffectAerosol: Aerosol

Implementation Method 2

forming a perovskite compound solution by reacting the first solution of the first perovskite compound precursor and the second solution of the second perovskite compound precursor

Methodology Applied

Scientific EffectChemical reaction: Chemical Bonding