Scalable Fabrication of High Efficiency Hybrid Perovskite Solar Cells by Electrospray

Perovskite solar cells have attracted much attention both in research and industrial domains. An unprecedented progress in development of hybrid perovskite solar cells (HPSCs) has been seen in past few years. The power conversion efficiencies of HPSCs has been improved from 3.8% to 24.2% in less than a decade, rivaling that of silicon solar cells which currently dominate the solar cell market. Hybrid perovskite materials have exceptional opto-electrical properties and can be processed using cost-effective solution-based methods. In contrast, fabrication of silicon solar cells requires high-vacuum, high-temperature, and energy intensive processes. The combination of excellent opto-electrical properties and cost-effective manufacturing makes hybrid perovskite a winning candidate for solar cells.

As power conversion efficiencies of HPSCs improves beyond that of the established solar cell technology and their long-term stability increases, one of the crucial hurdles in the path to commercialization remaining to be adequately addressed is the cost-effective scalable fabrication. Spin-coating is the prevailing method for fabrication of HPSCs in laboratories. However, this technique is limited to small areas and results in excessive material waste. Two types of scalable manufacturing methods have been successfully demonstrated to fabricate HPSCs: (i) meniscus-assisted coating such as doctor-blade coating and slot-die coating; and (ii) dispersed deposition based on the coalescence of individual droplets, such as inkjet printing and spray coating. Electrospray printing belongs to the second category with advantages of high material utilization rate and patterning capability along with the scalability and roll-to-roll compatibility.

In Chapter 3 of this dissertation, electrospray printing process is described for manufacturing of HPSCs in ambient conditions below 150 C. All three functional layers were printed using electrospray printing including perovskite layer, electron transport layer, and hole transport layer. Strategies for successful electrospray printing of HPSCs include formulation of the precursor inks with solvents of low vapor pressures, judicial choice of droplet flight time, and tailoring the wetting property of the substrate to suppress coffee ring effects. Implementation of these strategies leads to pin-hole free, low surface roughness, and uniform perovskite layer, hole transport layer and electron transport layer. The power conversion efficiency of the all electrospray printed device reached up to 15.0%, which is among the highest to date for fully printed HPSCs.

The most efficient HPSCs rely on gold and organic hole-transport materials (HTMs) for achieving high performance. Gold is also chosen for its high stability. Unfortunately, the high price of gold and high-vacuum along with high-temperature processing requirements for gold film is not suitable for the large-scale fabrication of HPSCs. Carbon is a cheap alternative electrode material which is inert to hybrid perovskite layer. Due to the ambipolar transport property of hybrid perovskite, perovskite itself can act as a hole conductor, and the extra hole transport layer can be left out. Carbon films prepared by doctor-blade coating method have been reported as the top electrode in HPSCs. The efficiencies of these devices suffer from the poor interface between the doctor-blade coated carbon and the underlying perovskite layer. In Chapter 4, electrospray printing was applied for the fabrication of carbon films and by optimizing the working distance during electrospray printing, the interface between carbon and the underlying perovskite layer was greatly improved compared to the doctor-blade coated carbon film. The resulting HPSCs based on the electrospray printed carbon electrode achieved higher efficiency than that based on doctor-blade method and remarkably, this performance is close to that of gold based devices.

In Chapter 5, preliminary results are provided on the laser annealing of hybrid perovskite films to further advance their scalable manufacturing. All layers of HPSCs require thermal annealing at temperature over 150 C for about half an hour or longer. The time-consuming conventional thermal annealing complicates the fabrication process and is not suitable for continuous production. High temperature over150 C is also not compatible with flexible substrates such as PET. Laser annealing is a promising method for overcoming these issues. It has several other advantages including compatibility with continuous roll-to-roll printing, minimal influence on non-radiated surrounding area, and rapid processing. Laser annealing can be integrated with the electrospray process to realize the continuous fabrication of hybrid perovskite film. Rapid laser annealing process with optimized power density and scanning pattern is demonstrated here for annealing perovskite films. The resulting hybrid perovskite film is highly-crystalline and pin-hole free, similar to that obtained from conventional thermal annealing.