Presentation Details
| Scalable Process Development for Large-Area and Flexible Perovskite Modules using Integrated Slot-Die Coating and Drying Technologies Katsumi Araki. Alpha Precision Systems Inc, Mckinney, TX, USA |
Abstract
Perovskite solar cells have attracted significant attention as next-generation photovoltaic technologies due to their high efficiency potential and low-temperature processing. However, the transition from laboratory-scale devices to large-area, manufacturable modules—particularly on flexible substrates—remains a key technical challenge. This work reports a manufacturing-oriented full-process development strategy for large-area rigid and flexible perovskite modules, focusing on scalable coating and drying technologies. All core manufacturing equipment, including slot-die coating systems, vacuum drying units, and thermal drying equipment, were developed in-house to ensure precise control over film formation and drying behavior. Two pilot lines with substrate formats of 300 × 300 mm² and 1200 × 600 mm² were established to enable systematic process optimization and scale-up validation. The smaller line was used for device structure development and rapid process tuning, while the larger line was dedicated to evaluating coating uniformity, process stability, and manufacturability on rigid and flexible substrates. Using the 300 × 300 mm² pilot line, reproducible power conversion efficiencies of approximately 22% were achieved on rigid substrates. On the 1200 × 600 mm² pilot line, both rigid and flexible modules demonstrated efficiencies exceeding 20%, confirming successful scale-up of the developed processes. In addition, comparative studies between conventional C60-based electron transport layers and simplified C60-free device architectures were conducted. The C60-free devices exhibited competitive efficiencies while enabling reduced process complexity, indicating advantages for large-area manufacturing. Coating uniformity across the 1200 × 600 mm² substrates was evaluated and showed stable, uniform film formation without critical thickness variations leading to performance degradation. These results demonstrate that the developed process platform provides a viable and scalable manufacturing approach for large-area and flexible perovskite photovoltaics.
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No part of this publication may be reproduced, distributed, or transmitted in any form or by any means, including photocopying, recording, or other electronic or mechanical methods, without the prior written permission of the author.
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