Jon E. Carlé | infinityPV ApS: Why is trying to jump directly from lab-scale spin coating to large-scale roll-to-roll a recipe for failure in printed electronics?
00:08:49 - 00:09:54
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Summary of the clip:
Why is trying to jump directly from lab-scale spin coating to large-scale roll-to-roll a recipe for failure in printed electronics?
The speaker argues that for flexible solar cells, the vision of roll-to-roll (R2R) manufacturing requires a more pragmatic development path. To effectively transfer the knowledge and optimizations gained in the lab to industrial-scale production, the initial development must happen on a platform that mimics the final process. This is where lab-scale R2R systems become indispensable as a bridge technology.
Drawing on past experience with organic photovoltaics (OPV), the speaker highlights how difficult it is to translate results from spin-coating on glass directly to a large R2R line. A lab-scale R2R coater acts as a crucial intermediate step. While not identical to a massive production line, it gets much closer, making the final technology transfer significantly faster, cheaper, and easier.
A key advantage of this approach is resource efficiency. Contrary to what one might assume, lab-scale R2R does not require huge investments in materials. Expensive substrates like ITO-coated PET and complex inks can be tested with very small quantities—on the order of a few hundred microliters—making it a cost-effective platform for rapid iteration and process optimization.
In this short video, you can learn:
* The necessity of using a scalable platform (like lab-scale R2R) for initial R&D.
* The historical difficulty of transferring spin-coating processes directly to large-scale R2R.
* How lab-scale R2R enables cost-effective development with minimal material consumption.
📋 **Clip Abstract** Jumping from lab spin-coaters to industrial roll-to-roll (R2R) lines is a major challenge that often fails. This clip explains the strategic importance of using lab-scale R2R systems as an intermediate step to de-risk and accelerate technology transfer while minimizing material costs.
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This is a highlight of the presentation:
Innovations in Processing Techniques for Perovskite Solar Cells
More Highlights from the same talk.
00:04:45 - 00:06:33
How do we translate record-breaking lab efficiencies for perovskite solar cells into a scalable, industrial manufacturing process?
How do we translate record-breaking lab efficiencies for perovskite solar cells into a scalable, industrial manufacturing process?
The speaker highlights a critical disconnect in perovskite PV development. While most record-efficiency devices are fabricated on small, rigid glass substrates in a lab, these processes are not easily transferable to the large-scale, industrial manufacturing required for commercial viability. This "lab-to-fab" gap is a major hurdle for the entire industry, and success hinges on developing processes that are inherently scalable from the outset.
To address this challenge, infinityPV has launched a video series aimed at demystifying the roll-to-roll (R2R) processing of perovskite solar cells. The series breaks down the entire device stack, layer by layer, starting from substrate preparation, which is crucial for flexible devices. It will cover each functional layer in detail, providing practical guidance on how to deposit and treat materials in a continuous, scalable manner.
The initiative goes beyond just coating, also planning to cover critical downstream processes like encapsulation and lamination, which are essential for protecting the sensitive perovskite layers and ensuring long-term device stability. The series will also include performance checks and practical tips, creating a comprehensive resource for researchers and engineers looking to scale up their work from the lab to a pilot line.
In this short video, you can learn:
* The primary challenge of scaling perovskite PV from glass substrates to industrial roll-to-roll.
* A breakdown of the key layers in a perovskite device stack for R2R processing.
* The importance of substrate preparation and encapsulation for flexible solar cells.
📋 **Clip Abstract** Most high-efficiency perovskite solar cells are made on small glass substrates, a process that doesn't scale. This clip introduces a new initiative to create a public, baseline recipe for roll-to-roll manufacturing, breaking down the process layer-by-layer.
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#PerovskiteSolarCells, #RollToRollProcessing, #LabToFabScaling, #FlexiblePV, #PrintedElectronics, #FlexibleElectronics
00:07:23 - 00:08:41
What are the most critical, and often overlooked, variables when processing highly sensitive perovskite inks for roll-to-roll manufacturing?
What are the most critical, and often overlooked, variables when processing highly sensitive perovskite inks for roll-to-roll manufacturing?
Processing perovskite solar cells is notoriously tricky due to their extreme sensitivity to the environment. The speaker emphasizes the huge difference between processing in an ambient atmosphere versus an inert gas environment like a glovebox. This choice fundamentally impacts the film quality, device performance, and the feasibility and cost of the manufacturing line.
Beyond the atmosphere, the choice of deposition and drying technology is critical. While slot-die coating is a versatile option for depositing the thin films, the subsequent drying step offers a wide array of methods. These include gas or air knives, IR heating, vacuum ovens, and even directional drying (from above or below), each interacting differently with the perovskite precursor film to influence crystallization and final device efficiency.
The ultimate goal of this detailed process exploration is to create a baseline recipe for the community. By establishing and sharing a standardized set of procedures for a scalable process, the field can move forward more efficiently. This allows brilliant minds worldwide to build upon a solid foundation rather than reinventing the wheel, accelerating the path to commercialization.
In this short video, you can learn:
* The critical impact of the processing environment (ambient vs. inert gas) on perovskite films.
* An overview of different coating and drying techniques for R2R, including slot-die, air knives, and IR ovens.
* The strategic value of establishing a baseline "recipe" to accelerate community-wide R&D.
📋 **Clip Abstract** Perovskite processing is highly sensitive to environmental conditions and the specific coating and drying methods used. This clip details these critical variables and explains the mission to establish a baseline recipe to help standardize and accelerate scalable manufacturing.
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#PerovskiteInks, #RollToRollManufacturing, #SlotDieCoating, #ControlledAtmosphereProcessing, #PerovskitePhotovoltaics, #PrintedElectronics