All-inkjet-printed thin-film transistors: manufacturing process reliability by root cause analysis

We report on the detailed electrical investigation of all-inkjet-printed thin-film transistor (TFT) arrays focusing on TFT failures and their origins. The TFT arrays were manufactured on flexible polymer substrates in ambient condition without the need for cleanroom environment or inert atmosphere and at a maximum temperature of 150 degrees C. Alternative manufacturing processes for electronic devices such as inkjet printing suffer from lower accuracy compared to traditional microelectronic manufacturing methods. Furthermore, usually printing methods do not allow the manufacturing of electronic devices with high yield (high number of functional devices). In general, the manufacturing yield is much lower compared to the established conventional manufacturing methods based on lithography. Thus, the focus of this contribution is set on a comprehensive analysis of defective TFTs printed by inkjet technology. Based on root cause analysis, we present the defects by developing failure categories and discuss the reasons for the defects. This procedure identifies failure origins and allows the optimization of the manufacturing resulting finally to a yield improvement

Scalable, ambient atmosphere roll-to-roll manufacture of encapsulated large area, flexible organic tandem solar cell modules

Inline printing and coating methods have been demonstrated to enable a high technical yield of fully roll-to-roll processed polymer tandem solar cell modules. We demonstrate generality by employing different material sets and also describe how the ink systems must be carefully co-developed in order to reach the ambitious objective of a fully printed and coated 14-layer flexible tandem solar cell stack. The roll-to-roll methodologies involved are flexographic printing, rotary screen printing, slot-die coating, X-ray scattering, electrical testing and UV-lamination. Their combination enables the manufacture of completely functional devices in exceptionally high yields. Critical to the ink and process development is a carefully chosen technology transfer to industry method where first a roll coater is employed enabling contactless stack build up, followed by a small roll-to-roll coater fitted to an X-ray machine enabling in situ studies of wet ink deposition and drying mechanisms, ultimately elucidating how a robust inline processed recombination layer is key to a high technical yield. Finally, the transfer to full roll-to-roll processing is demonstrated

Perovskite solar cells: An integrated hybrid lifecycle assessment and review in comparison with other photovoltaic technologies

Solar cells are considered as one of the prominent sources of renewable energy suitable for large-scale adoption in a carbon-constrained world and can contribute to reduced reliance on energy imports, whilst improving the security of energy supply. A new arrival in the family of solar cells technologies is the organic-inorganic halide perovskite. The major thrust for endorsing these new solar cells pertains to their potential as an economically and environmentally viable option to traditional silicon-based technology. To verify this assertion, this paper presents a critical review of some existing photovoltaic (PV) technologies in comparison with perovskite-structured solar cells (PSCs), including material and performance parameters, production processes and manufacturing complexity, economics, key technological challenges for further developments and current research efforts. At present, there is limited environmental assessment of PSCs and consequently, a methodologically robust and environmentally expansive lifecycle supply chain assessment of two types of PSC modules A and B is also undertaken within the context of other PV technologies, to assess their potential for environmentally friendly innovation in the energy sector. Module A is based on MAPbX3 perovskite structure while module B is based on CsFAPbX3 with improved stability, reproducibility and high performance efficiency. The main outcomes, presented along with sensitivity analysis, show that PSCs offer more environmentally friendly and sustainable option, with the least energy payback period, as compared to other PV technologies. The review and analysis presented provide valuable insight and guidance in identifying pathways and windows of opportunity for future PV designs towards cleaner and sustainable energy production