Scalable Full Back-Contacted Roll-to-Roll Perovskite Photovoltaic Modules Utilising a Commercial 3D Embossed Substrate

Background:
Power Roll Ltd is a technology development company based in the North East of England. It is developing an innovative thin film photovoltaic (PV) technology that is based on 3D patterned substrate suitable for high throughput roll-to-roll (R2R) manufacturing. As part of its scale up development, it is looking to develop R2R deposition of Perovskite into its patented architecture. PRL technology has been demonstrated at +10% using spin coated perovskite into its flexible mini-module platform but is now in the process of scaling all process parameters to R2R.

The project, located within SPECIFIC will involve working as part of Professor Trystan Watson's research group at Swansea. SPECIFIC is a National Innovation and Knowledge Centre led by Swansea University, working collaboratively with Universities across the UK. SPECIFIC has significant capability and expertise across its team and facilities; capabilities at SPECIFIC relate to the printing, coating and lifetime testing of functional materials and the development of enabling technologies that support the transition from laboratory bench to factory floor. The SPECIFIC PV scale-up and stability research activity is carried out in purpose-built facilities which include a new stability testing and cleanroom printing facility.

Project Aims:
During the 4 years, the project will involve;
- Characterisation of Power Roll architecture structure including electrode and transport materials positions, thickness and properties.
- Optimising perovskite formulation to match material architecture of PRLs substrates utilising standard spin coating deposition techniques.
- Assisting the PRL team to develop optimised material architecture based on analysis form IV data.
- Developing a process for scale up printing of perovskite to adequately fill PRL microgrooves architecture.
- Developing optimised post processing of perovskite to accommodate variations in perovskite thickness.
- Demonstrating scalability of printing process on large R2R format.
- Transfering knowledge to PRL and assisting in purchase of equipment suitable for PRL scale up.

The CDT will produce 50 graduates with doctoral level knowledge and research skills focussed on the development and manufacture of functional industrial coatings. Key impact areas are:

Knowledge
- The development of new products and processes to address real scientific challenges existing in industry and to transfer this knowledge into partnering companies. The CDT will enable rapid knowledge transfer between academia and industry due to the co-created projects and co-supervision.
- The creation of knowledge sharing network for partner companies created by the environment of the CDT.
- On average 2-3 publications per RE. Publications in high impact factor journals. The scientific scope of the CDT comprises a mixture of interdisciplinary areas and as such a breadth of knowledge can be generated through the CDT. Examples would include Photovoltaic coatings - Journal of Materials Chemistry A (IF 8.867) and Anti-corrosion Coatings - Corrosion Science (IF 5.245), Progress in Organic Coatings (IF 2.903)
- REs will disseminate knowledge at leading conferences e.g. Materials Research Society (MRS), Meetings of the Electrochemical Society, and through trade associations and Institutes representing the coatings sector.
- A bespoke training package on the formulation, function, use, degradation and end of life that will embed the latest research and will be available to industry partners for employees to attend as CPD and for other PGRs demonstrating added value from the CDT environment.

Wealth Creation
- Value added products and processes created through the CDT will generate benefits for Industrial partners and supply chains helping to build a productive nation.
- Employment of graduates into industry will transfer their knowledge and skills into businesses enabling innovation within these companies.
- Swansea University will support potential spin out companies where appropriate through its dedicated EU funded commercialisation project, Agor IP.

Environment and society
- Functionalised surfaces can potentially improve human health through anti-microbial surfaces for health care infrastructure and treatment of water using photocatalytic coatings.
- Functionalised energy generation coatings will contribute towards national strategies regarding clean and secure energy.
- Responsible research and innovation is an overarching theme of the CDT with materials sustainability, ethics, energy and end of life considered throughout the development of new coatings and processes. Thus, REs will be trained to approach all future problems with this mind set.
- Outreach is a critical element of the training programme (for example, a module delivered by the Ri on public engagement) and our REs will have skills that enable the dissemination of their knowledge to wide audiences thus generating interest in science and engineering and the benefits that investments can bring.

People
- Highly employable doctoral gradates with a holistic knowledge of functional coatings manufacture who can make an immediate impact in industry or academia.
- The REs will have transferable skills that are pertinent across multiple sectors.
- The CDT will develop ethically aware engineers with sustainability embed throughout their training
- The promotion of equality, diversity and inclusivity within our cohorts through CDT and University wide initiatives.
- The development of alumni networks to grow new opportunities for our CDT and provide REs with mentors.