Grooved perovskite PV panel for roll to roll production
Power Roll in the UK and the University of Sheffield have developed a grooved perovskite photovoltaic panel that can be made on a high volume roll-to-roll process.
This uses a perovskite material on a flexible, grooved plastic substrate for high volume production and cheaper to produce than existing solar cells based on monocrystalline or polycrystalline silicon. Significantly, the devices do not contain any expensive or scarce rare earth elements such as indium, so the technology can be both sustainable and low-cost.
The team at Sheffield built the back-contact perovskite solar cell based on 1.5 μm-width grooves that are embossed into a plastic film whose opposing “walls” are selectively coated with either n- or p-type contacts.
A perovskite precursor solution is then deposited into the grooves, creating individual photovoltaic devices. Each groove device is series-connected to its neighbours, creating minimodules consisting of hundreds of connected grooves.
The groove-based devices using slot-die coating to deposit the perovskite precursor and explore the structure of the perovskite in the grooves using a range of microscopy and spectroscopy techniques.
The work, published in Applied Energy Materials, can produce lightweight, flexible solar films that can be used on surfaces such as rooftops and other unconventional surfaces that could not normally stand the weight of solar panels. Together with their anticipated low cost, this could significantly enhance the roll out of solar, particularly in developing countries.
“This partnership demonstrates the potential of combining cutting-edge research with industrial innovation to deliver transformative solutions in renewable energy,” said Dr Nathan Hill, Research Scientist at Power Roll and lead author of the paper. “Previously, we have worked with the University’s Department of Physics and Astronomy to further develop our solar designs, which not only reduced manufacturing costs but also enhanced solar efficiency.”
Regular perovskite devices use a sandwich structure composed of a number of layers deposited in a specific order. The back-contact cells have all the electrical contacts on the back of the device making it easier and cheaper to manufacture, with the potential for high efficiency.
To check the structure and composition of the solar cells a Hard X-ray nanoprobe microscope at Diamond Light Source in Oxfordshire, was used to take very detailed images of the solar cells. These also helped to spot hidden problems like empty spaces, flaws and the boundaries between tiny crystals within the semiconductor material. This was the first time this type of analysis had been used on this kind of solar cell.
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The embossing process was undertaken at high volume under a commercial contract with Power Roll in Durham, where the grooves have a U-shaped cross-section that are easier to emboss with high fidelity. This embossed roll was then loaded into a vacuum deposition chamber on a spool and was passed at a web speed of 5–15 mm/s in front of a series of deposition sources.
“A key advantage of these flexible films is that the panel can be stuck onto any surface. In the UK, you currently have to think twice about adding thick solar panels onto relatively fragile roofs of warehouses that are not really designed to be load-bearing. With this lightweight solar technology, you could essentially stick it anywhere. This could be a gamechanger for solar energy in low and middle income countries,” said Professor David Lidzey, from the School of Mathematical and Physical Sciences at the University of Sheffield.
“We’ve partnered with Power Roll for over 10 years, combining our expertise in materials science and advanced imaging techniques with their focus on manufacturing and this collaboration has been very successful, resulting in this exciting new product.”
The next phase of the work on this project will be to further develop the use of X-ray microscopy in characterising these materials. New experiments are scheduled this summer, at the Diamond Light Source, to help understand key aspects of device operation, particularly device stability.
www.powerroll.solar; www.sheffiled.ac.uk
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