Controlling Thin Film Morphology Formation during Gas Quenching of Slot-Die Coated Perovskite Solar Modules

Transferring record power conversion efficiency (PCE) >25% of spin coated perovskite solar cells (PSCs) from the laboratory scale to large-area photovoltaic modules requires significant advances in scalable fabrication techniques. In this work, we demonstrate the fundamental interrelation between drying dynamics of slot-die coated precursor solution thin films and the quality of resulting slot-die coated gas-quenched polycrystalline perovskite thin films. Well-defined drying conditions are established using a temperature-stabilized, movable table and a flow-controlled, oblique impinging slot nozzle purged with nitrogen. The accurately deposited solution thin film on the substrate is recorded by a tilted CCD camera, allowing for in situ monitoring of the perovskite thin film formation. With the tracking of crystallization dynamics during the drying process, we identify the critical process parameters needed for the design of optimal drying and gas quenching systems. In addition, defining different drying regimes, we derive practical slot jet adjustments preventing gas backflow and demonstrate large-area, homogeneous, and pinhole-free slot-die coated perovskite thin films that result in solar cells with PCEs of up to 18.6%. Our study reveals key interrelations of process parameters, e.g., the gas flow and drying velocity, and the exact crystallization position with the morphology formation of fabricated thin films, resulting in a homogeneous performance of corresponding 50 × 50 mm2 solar minimodules (17.2%) with only minimal upscaling loss. In addition, we validate a previously developed model on the drying dynamics of perovskite thin films on small-area slot-die coated areas of ≥100 cm2. The study provides methodical guidelines for the design of future slot-die coating setups and establishes a step forward to a successful transfer of solution processes towards industrial-scale deposition systems beyond brute force optimization.