Japanese company devises low-temperature plasma approach for producing perovskite materials

In a groundbreaking development, Japan's Sumitomo Heavy Industries (SHI) has announced a new method for creating the electron transport layer (ETL) in perovskite solar cells. This innovative approach is set to revolutionise the solar industry, making perovskite technology more accessible for mass production and bringing it closer to commercial rollout.

The new method, named Reactive Plasma Deposition (RPD), is a form of Physical Vapor Deposition (PVD). Unlike conventional methods, RPD deposits ultra-thin tin oxide (SnO2) ETLs at low temperatures, enabling low-temperature mass production with minimal substrate damage. This is a significant advantage as current methods often involve high-energy particles, high-temperature environments, or toxic gases, which can damage the perovskite material, increase costs, or pose safety risks.

Tin dioxide, an inorganic compound also known as stannic oxide, is the main ore of tin (cassiterite). It is a low-cost metal oxide known for its excellent electrical conductivity when deposited using PVD. In the new method, the ETL acts as a "highway" for electrons generated in the perovskite to travel to the electrode.

One of the biggest bottlenecks in manufacturing perovskite solar cells cheaply, safely, and at scale has been addressed by SHI's advancement. The new method is reportedly 200 times faster than current methods and costs around 0.5% of current ETL manufacturing costs. Moreover, this method is compatible with other solar cell layers and can be done continuously alongside transparent Indium Tin Oxide (ITO) electrodes.

The cost-effectiveness and efficiency of this new method are not its only advantages. It also prioritises safety and environmental friendliness. The new method uses non-hazardous gases, making it safer and more environmentally friendly than traditional methods.

SHI's development aligns with Japan's goal of achieving 20 GW of perovskite solar capacity by 2040. As the technology advances globally, the next development stage of mass production for perovskite solar cells introduced by Sumitomo Heavy Industries focuses on addressing two critical challenges: economic viability and scalability. The implementation of this process is expected in the near future as the technology continues to evolve.

Manufacturers are actively exploring chemical film deposition methods due to the limitations of conventional methods. The success of SHI's new method is a promising step towards overcoming these challenges and paving the way for the widespread adoption of perovskite solar cells.