A hermetic encapsulation is required to protect perovskite solar cells (PSCs) from the most relevant sources of degradation – humidity and oxygen. According to the IEC61646 PV standard test, commercial photovoltaic devices must be stable from - 40°C to 85°C and relative humidity of 85%. Therefore, to achieve the previously mentioned requirements, the PSCs should be fabricated with thermally stable layers and protected by a long-term stable hermetic encapsulation. Previously, we reported a laser-assisted glass frit encapsulation that successfully achieved long-term stability for PSCs with n-i-p and HTM-free structures. An advanced dual laser beam glass frit sealing process was previously developed and optimized to hermetically encapsulate n-i-p PSCs at 65 ± 5°C for a short processing time of < 60 s. In contrast, printable HTM-Free perovskite solar cells have been reported to be sealed with a single laser beam at 100°C for a long processing time of ca. 35 min. Therefore, this work aims to use the dual laser sealing process to hermetically encapsulate HTM-Free PSCs and mini-modules. Moreover, a 100 x 100 cm² panel (ca. 234 cm²) was manufactured using dual laser-sealed mini-modules (ca. 6 cm²). The novel sealing process had no impact on the performance of the encapsulated devices, since the power conversion efficiency (PCE) of both small-area PSCs and mini-modules slightly increased from (8.27 ± 0.83)% to (10.75 ± 1.41)% and from (6.08 ± 0.32)% to (6.61 ± 0.49)%, respectively. After sealing 39 mini-modules in series and in parallel, the assembled panel delivered an average PCE of 4.71% when exposed to 789 W m^-2 solar irradiation. In conclusion, this study indicates that dual laser sealing has a low impact on the performance of lab-scale devices and mini-modules, and it also reinforces that this sealing procedure can be suitable for encapsulating large-area PSCs.

Perovskite Solar Cells, Hermetically Laser-Assisted Glass Frit Encapsulation, Stability, Scalability