Emerging strategies for the large-scale fabrication of perovskite solar modules: from design to process

Abstract

Perovskite solar cells (PSCs), recognized as a promising third-generation thin-film photovoltaic technology, offer notable advantages including low-cost production, high power conversion efficiency, and tunable bandgap characteristics. Despite these advancements, scaling up PSCs to large-area perovskite solar modules (PSMs) presents substantial challenges. To overcome the obstacles, alternative deposition methods such as solution-based blade coating, slot-die coating, spray coating, inkjet printing, and screen printing, as well as solvent-free methods like chemical vapor deposition and physical vapor deposition, are being explored to eliminate film inhomogeneity and defects when applied to a larger area. These emerging strategies aim to enhance film quality, uniformity, and scalability, which are essential for large-area applications. This comprehensive review systematically summarizes the manufacturing status of PSMs from fundamental theoretical principles to practical applications in processing, discussing various deposition techniques, and simultaneously exploring strategies to enhance PSM performance in terms of solvent, additive and interface engineering. Additionally, it delves into the stability challenges faced by large-scale manufacturing of commercial products, analyzing and summarizing the latest scribing processing and encapsulation technologies, and providing prospects for module development.