Precision Coating Solutions

ASAHI SUNAC New Components Division > Solutions > Precision Coating Solutions

Example Application for Precision Spray Coater (PCS)

Example Application for Solar Cell Manufacturing Process

Generally, vacuum-based deposition and film systems were used as conventional deposition systems in antireflective coating applications. However, from a cost perspective, these systems were extremely expensive in solar cell manufacturing, and there has been an increasing market demand for a non-vacuum based method.
In this example, we presented a solution using our spray coating technology and conducted testing and validation in conjunction with the customer.

Review of spray technology for antireflective coating

A lot of glass is used for the front panels in solar cells. Yet, in order to improve the processing efficiency of the solar energy all the way through to the power generation layer, the glass reflection must be controlled and as much of the solar energy (light) as possible must pass through. Here is where the antireflective coating or film is applied, which aims to prevent reflection on the glass substrate surface. The antireflective film has various effects depending on the coating conditions and properties. However, the coating generally improves the light transmittance around 3-5% more. Specifically, our review shows that the following results when the antireflective film is applied using a spray coating method.

1. Coating Quality

2. Consistent and Evenly Distributed Film Thickness

3. Productivity Improvement

4. Improving the Efficiency of Material Use

Our system configuration

1. Coating Quality

When spraying with an antireflective coating application, an improvement in the total light transmittance for spray coated glass was confirmed when compared to untreated glass.

In addition, the wavelength of the light transmitted can be controlled by using the relationship between the thickness of the antireflective coating and its refractive index.
With regard to this control, the film thickness produced by our spray coater can be easily adjusted by controlling the gun feed speed and the amount of the antireflective coating that is discharged.

2. Consistent and Evenly Distributed Film Thickness

Using a low pressure atomizing spray gun minimizes the particle size variation in the spray pattern, and by increasing the total number of coats, it produces an evenly distributed and consistent result.

3. Productivity Improvement

To coat large size substrates, using a multi-gun system increases the target area that can be coated at one time.
In order to provide film coating for line or continuous production needs, our systems offer complete support from the coating process to the drying process.
(Roll to roll coating system)

4. Improving the Efficiency of Material Use

The inductive charging system spray gun is used, which offers improved coating efficiency for insulated substrates, such as glass.
The inductive charging system spray gun does not generate an electric field, and therefore it helps minimize the damage caused by electrostatic discharge for solar cells and electric circuits.

Our testing and development facilities verify the ideal coating conditions. (NC Technology Center) We can construct a system that optimizes the equipment to meet your requirements, such as work material, workpieces, and film thickness conditions. Feel free to contact us today.

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