Liz Josephson will be presenting at TechBlick on Oct 22-23 in Berlin.
Flexible Roll-to-Roll Platform Providing Lightweight Sputtered Coatings Including Environmental Barrier and Transparent Conductors for Perovskite Solar Cell Manufacturing
By: Liz Josephson, Mike Simmons, Dr. Robert Malay, Intellivation LLC
A key obstacle to the commercial success of flexible perovskite solar cells (PSCs) is the long-term stability of the perovskite layer. This layer is vulnerable to several degradation mechanisms, such as moisture, oxygen, and UV-catalyzed reactions which make barrier films essential for boosting reliability, lifetime, and overall performance of these devices. Barrier films act as protective layers, shielding the sensitive components of PV devices from environmental factors, while allowing for increased incident light transmission in the photoactive regime. Another key layer in perovskite solar cells is the current collector, which is often a sputtered transparent conductive metal oxide layer. The current collector should maximize light transmission and minimize sheet resistance for maximum power conversion efficiency (PCE). Lightweight polymer films such as PET, combined with sputtered thin film coatings, can offer excellent environmental barrier and current collector properties while preserving necessary optical effects that can elevate the PCE. Utilizing Roll-to-Roll manufacturing processes for these films also further reduces production costs and facilitates scalability. By reducing the impact of environmental stressors, barrier films play a vital role in protecting flexible PSCs, enabling more reliable, sustainable solar energy solutions and broader market adoption of perovskite technology.
Please join us at V2025 Oct 13-16 in Dresden. Liz Josephson will be presenting “Process development of multi-layer dielectric and barrier solutions for energy and sustainable applications“.
The development of multi-layer dielectric and barrier solutions play a key role in the advancement of sustainable and renewable energy technologies. Using vacuum coating processes, multi-layer structures and barrier coatings enable unique material properties for applications in energy storage, electronic devices, aerospace and environmental protection. Key methodologies include precision layer deposition, advanced patterning capabilities, in-situ capabilities for improved analysis of a wider range of materials, and scalable manufacturing processes. Applications span across thin-film photovoltaics, multi-layer optical film stacks, high-performance capacitors, protective coatings for renewable energy systems, barriers for multiple applications, including OLED’s and insulation or shielding technologies that enhance device longevity, efficiency and performance. These solutions contribute to the evolution of sustainable energy systems and environmentally friendly solutions.
This summer we had the pleasure of hosting brothers for summer internships; John Hebert has spent 3 summers with us now and continues to grow his engineering skills and contributions. This year his brother Steven Hebert joined us prior to heading off to college to also study engineering. “This summer, I worked as an intern in the engineering room. I worked alongside other engineers to assist in completing and releasing projects that would later be assembled and implemented on R2R coating machines. Through this experience, I learned about the processes and machines at Intellivation and gained valuable experience with programs, tools, and procedures used industry wide. I have enjoyed meeting and working with the engineers at Intellivation and am very grateful for this opportunity! John“
“This summer, I had the amazing opportunity to intern alongside the engineers at Intellivation. From day one, I was thrown right into the flow of things, helping the engineers with small tasks. I learned a lot very quickly and got to a point where I could work through projects on my own. I spent most of my time working on CAD: updating parts, detailing drawings, and creating new components. I also spent time cataloging parts, checking inventory, and purchasing materials. Overall, it has been a great experience—I’ve learned so much, and I hope to be back next summer! Steven”
We wish both well in their studies and look forward to seeing how they can implement what they learned at Intellivation into their engineering classes and future endeavors.
Vacuum coating technologies for flexible substrates unlock a wide range of industrial applications, enabling advancements across sectors like electronics, energy, aerospace, packaging and more.
The flexibility, versatility and precision deposition of the different vacuum technologies allows for simple single layer stacks up to multi-layer, multi-pass complex materials which can provide optical, electrical or mechanical properties depending on the end use.
Mike Simmons will be presenting in Dresden at Pro Flex 2025 on May 6th.
Intellivation will be participating in the 2025 Pro Flex event in Dresden May 6-7th. Mike Simmons will present on Advanced Roll-to-Roll PVD Technology: Transforming High -Volume Production of Precision Multi-Layer Devices.
Physical Vapor Deposition (PVD) technology is a critical process in the fabrication of a variety of devices, including high-precision, multilayer sensors and by using roll-to-roll (R2R) sputtering it is easily scalable to high-volume production for these devices. The R2R sputtering is a continuous process involving depositing thin films onto flexible substrates, enhancing production efficiency and scalability. By implementing the ability to pattern layers into these R2R vacuum systems it allows for precise control of sensor fabrication. Optical monitoring of the film with in-situ variable wavelength spectrophotometers ensures the integrity and performance of the deposited layers. This monitoring enables real-time adjustments and quality control, which are crucial for upholding the stringent standards necessary for sensor manufacturing. Controlling uniformity in cross and down web directions is also essential for sensor controls, this can be accomplished for multiple materials including metals, magnetics, oxides and nitrides. The integration of these advanced features in R2R PVD technology not only allows for scalable production but also ensures highly reliable and sophisticated multilayer devices for various applications.
The primary challenge in commercial adoption of perovskite solar cells (PSCs) is the long-term stability of the perovskite layer. These layers have multiple degradation pathways, and barrier films play a crucial role in enhancing the durability and performance of these devices. Barrier films act as protective layers, shielding the sensitive components of PV devices from environmental factors such as moisture, oxygen, and UV-catalyzed volatilization. The encapsulation of PSCs with high-quality barrier films significantly improves stability, enabling them to maintain high efficiency even under prolonged exposure to degradation conditions. PET and other polymer films with sputtered optical coatings allow for lightweight, high performance barrier properties while still allowing optical effects that can improve the power conversion efficiency (PCE) of the solar device. These films also enable Roll-to-Roll manufacturing and integration, further reducing the cost. This presentation will discuss various encapsulation methods, their respective barrier properties, common challenges for each method, and current work on the addition of functionality to barrier films with the use of sputtered coatings. By mitigating the adverse effects of environmental variables, barrier films contribute to the protection of PSCs, allowing for more reliable and sustainable solar energy solutions and wider market adoption of PS technology.
By Mike Simmons, Mark George and Liz Josephson, Intellivation LLC
Producing multilayer dielectric coatings via reactive magnetron sputtering on a large-area web is efficient but challenging due to the need for precise reactive gas distribution and concentration control. Ensuring excellent cross-web and down-web uniformity of the layers is essential for high-tech applications. By using in-situ precision optical methods, cross-web uniformity of reactively deposited dielectric coatings can be measured and adjusted quickly; this is crucial for producing high-performance multilayer coatings.
Characterization of the sputtered layers is done in a roll-to-roll (R2R) sputter vacuum coater by fine-tuning the reactive sputter controller, achieving baseline properties of each single layer. Transitioning to R2R deposition and using in-situ optical measurements ensures satisfactory cross-web uniformity for each single layer, which then sequentially are deposited to form a complex multilayer coating. Validating these processes in-situ accelerates the development of new dielectric materials and multilayer designs.
Intellivation LLC is honored to have been awarded the Technology of the Year Award from the Association of Roll-To-Roll Convertors (ARC) for our unique and innovative solution to measure Mid-IR Reflectance In-Situ with Spectrometry in our R2R Vacuum Sputter Coaters. “We are excited to introduce the first production solution using spectrometry to measure in-situ in this spectral range in a vacuum R2R coating system. As requirements and applications use broader spectral ranges and become more sophisticated, we see increase demand for monitoring sputtered multi-layers in-situ,” says Mike Simmons, President & CEO of Intellivation. “Our customers are redefining the standards for end use requirements and we are extremely proud to be a part of the solution. Receiving this Award from ARC, which represents the entire industry of Roll-to-Roll converting and manufacturing processes, is an incredible honor, and we are so appreciative.”
The ability to expand the spectral range to reach the Mid-Infrared (Mid IR) spectrum can create new opportunities and applications for sputtered thin film use. The integration of a Mid IR Tunable Quantum Cascade Laser (QCL) based reflectance spectrometer into a Roll-to-Roll (R2R) Sputter Coater offers enhanced spectral resolution and tunability, allowing for precise and selective analysis of Infrared optical materials during the coating process. Integrating this advanced spectrometer into a R2R Sputter Vacuum Coater enables real-time monitoring and control of thin film deposition, facilitating improved process optimization. The ability to monitor reflection beyond the current UV and visible ranges, into the Mid IR wavelength (8 to 13 microns) contributes to the development of a much wider range of functional layer materials and provides a versatile and efficient manufacturing platform for high-throughput production of coated materials with tailored optical properties, offering new possibilities for applications in various industries.
Coatings and multi-layers in the Mid IR range can provide optical functions that enable environmental protection for devices and systems from light, humidity, and stress that can be induced by the environment and outside influences. These coatings can extend the life and/or improve durability of components in a wide range of applications and industries, many of which are just being developed.
In-situ Mid IR reflection monitoring of vacuum roll-to-roll coatings improves development and production yield of highly complex and multi-functional layer stacks used in high tech industries and applications.
We are looking forward to seeing the R2R community at the 2024 ARC Conference in Charlotte later this month. Visit our booth to discuss our latest innovations and hear Mike Simmons speak on Weds at 11:00 AM about our Multi-Layer Dielectric coating achievements made possible by cutting edge in-situ monitoring.
