Search Results (56)

LED polymer multilayer films offer clear advantages over single-layer coatings, such as minimized particle settling, finer control over particle distribution, and more precise spectral tuning. However, the standard “coat–dry–coat” process for these multilayer systems often traps air bubbles, degrading film quality and uniformity. This study investigates the air entrainment mechanism in multilayer film formation. Bubbles form when the cured bottom layer exhibits a low contact angle, which destabilizes the advancing liquid front. High-speed microscopy captured these interfacial dynamics, and contact-angle measurements quantified the wetting behavior. Numerical simulations further demonstrated that reduced wettability and vortex formation drive air entrainment. To mitigate air entrainment, a semi-cured slot die coating approach was proposed to modify the surface wettability and suppress the flow instabilities. Incorporating temperature-dependent viscosity into the simulation model improved its predictive accuracy, cutting the error in predicted coating-gap limits from 11.49% to 4.99%. This combined strategy delivers reliable, bubble-free multilayer films and paves the way for more consistent, high-quality LED polymer applications. Full article

Perovskite, as a promising candidate for the next generation of photovoltaic materials, has attracted extensive attention. To date, the power conversion efficiency (PCE) of perovskite solar cells (PSCs) has reached 26.7%, which is competitive with that of commercial silicon cells. However, high PCE is usually achieved in devices with a small surface area fabricated by the spin-coating method. Perovskite thin films, as the most important layer, suffer from poor uniformity and crystallization caused by the large-area fabrication process, which leads to a dramatic drop in efficiency and exhibits poor reproducibility. Here, we summarize common architectures of PSC and perovskite solar modules (PSMs), as well as analyzing the reasons for efficiency loss on the modules. Subsequently, the review describes the mechanism of perovskite growth in detail, and then sums up recent research on small-to-large-area perovskite devices. Large-area fabrication methods mainly include blade coating, slot-die coating, spray-coating, inkjet printing, and screen printing. Moreover, we compare the advantages and disadvantages of each method and their corresponding mechanisms and research progress. The review aims to provide potential logical conclusions and directions for the commercial large-area perovskite fabrication process. Full article

Slot-die coating is widely used in the preparation of negative electrodes for lithium batteries. The thickness of the negative electrode has a significant influence on the battery performance and lifespan, and different manufacturers have different requirements for its thickness. In order to reduce the waste caused by trial and error in the electrode preparation process, a prediction model for the negative electrode thickness was established and verified through simulation and experiments. Based on the Landau–Levich film equation and the Ruschak model, a high-precision prediction model was constructed by taking into account the influence of factors’, such as temperature and slurry, spreading characteristics on the coating thickness. The minimum coating thickness and its influencing factors were explored. Meanwhile, the simulation analysis of the coating thickness was performed, and the theoretical values of three common process parameters were compared with the simulation results, showing a deviation of only 2.9%. An experiment on predicting the thickness of the negative electrode of lithium batteries was conducted. Thickness measurements were performed on the samples prepared through the experiment and compared with theoretical values. The accuracy rate of this thickness prediction model can reach 98.75%. Full article

Silver nanowire transparent conductive films (AgNW TCFs), as the novel transparent electrode materials replacing ITO, are anticipated to be applied in numerous optoelectronic devices, and slot-die coating is currently acknowledged as the most suitable method for the mass production of large-sized AgNW TCFs. In this study, sodium carboxymethyl cellulose (CMC) and polyvinyl alcohol (PVA), as film-forming aids, and AgNWs, as conductive materials, were utilized to prepare a specialized AgNW ink, and a slot-die coating is employed to print and prepare AgNW TCFs. The optoelectrical properties of AgNW TCFs are optimized by adjusting the compositions of AgNW ink and the process parameters of slot-die coating. The suitable compositions of AgNW ink and the optimal parameters of slot-die coating are a CMC type of V, a PVA volume of 1 mL, a AgNW volume of 1.5 mL, a volume ratio of 30 and 45 nm AgNWs (2:1), and a coating height of 400 μm. The resultant AgNW TCFs achieve excellent comprehensive optoelectronic performance, with a sheet resistance of less than 50 Ω/sq, a visible light transmittance exceeding 92%, and a haze below 1.8%. This research provides a valuable approach to producing AgNW TCFs on a large scale via the slot-die coating. Full article

Perovskite solar cells (PSCs) offer a number of key advantages over silicon solar cells. These include their low-cost materials, high efficiency, simplicity of fabrication, and inexpensive manufacturing techniques. To commercialize PSCs, there are many methods to develop the quality of the cells, one of them being printing techniques. Different printing techniques deposition have been developed for the perovskite solar cell, such as blade coating, slot die coating, inkjet printing, screen printing, spray coating, flexographic printing, and gravure printing. These techniques have a substantial impact on the performance of PSCs and controlling film formation to commercialize PSCs. This review summarizes a comprehensive overview of various deposition printing techniques used to fabricate PSCs during different years and different techniques, such as using different preparation methods, novel drying techniques, and ink engineering. In addition, the challenges that are faced by using these, such as material stability, reproducibility of printing processes, and cost-effectiveness techniques, are reviewed. Future research should focus on optimizing printing techniques to improve the stability and scalability of PSCs. Exploring novel perovskite materials, deposition techniques, and innovative fabrication methods may further enhance the PSCs and facilitate their commercialization. Full article

Perovskite photovoltaic technology carries immense opportunity for the solar industries because of its remarkable efficiency and prospect for cost-effective production. However, the successful deployment of perovskite solar modules (PSMs) in the solar market necessitates tackling stability-based obstacles, scalability, and environmental considerations. This paper unveils a comprehensive examination of the cutting-edge advancements in the manufacturing of perovskite solar cells (PSCs) and modules, with an emphasis on high-speed, large-area printing. The paper underscores the substantial progress achieved in printed PSCs and PSMs, demonstrating promising electrical performance and long-term device durability. This review paper categorizes printing techniques compatible with large-area high-speed manufacturing into three distinct families: blade coating, slot die coating, and screen printing, as these common printing practices offer precise control, scalability, cost-effectiveness, high resolution, and efficient material usage. Additionally, this paper presents an in-depth investigation and comparison of superior PSCs and PSMs fabricated by printing on power conversion efficiency (PCE), stability, and scalability. Full article

In-depth analysis of the pressure profile of coating beads of slot die coating is helpful to better understand the behavior of the flow field in a coating bead and to better obtain a stable coating bead. In this study, ANSYS Fluent 19.2 was used to simulate slot die coating. The simulation results clearly show the influence of various operating parameters on the state of the coating bead and the pressure profile in the coating bead. The results show that the pressure profile can be clearly changed by changing the flow rate, substrate speed, and downstream die lip length. Simultaneously increasing the substrate speed from 0.08 to 0.12 m/s and the average inlet velocity from 0.02672 to 0.04 m/s results in an increase in maximum pressure from 298 to 538 Pa. Increasing only the substrate speed, from 0.12 to 0.16 m/s, causes the maximum pressure to decrease from 538 to 195 Pa. Increasing only the average inlet flow velocity, from 0.027 to 0.04 m/s, leads to an increase in maximum pressure from 167 to 745 Pa. Extending the downstream die lip length from 0.4 mm to 1 mm results in an increase in maximum pressure from 189 to 471 Pa. Reducing the upstream coating gap from 0.3 to 0.1 mm results in significant changes in the pressure profile in the upstream direction. Changing the contact angle can affect the pressure profile in the coating bead, but this is not clear. Changing the coating liquid density at a Reynolds number less than 1.733 has less effect on the pressure profile. Full article

In recent years, third-generation solar cells have experienced a remarkable growth in efficiency, making them a highly promising alternative energy solution. Currently, high-efficiency solar cells often use top electrodes fabricated by thermal evaporation, which rely on high-cost and high energy-consumption vacuum equipment, raising significant concerns for mass production. This study develops a method for fabricating silver electrodes using the screen-printing process, aiming to achieve solar cell production through an all-solution coating process. By selecting appropriate blocking-layer materials and optimizing the process, we have achieved device efficiencies for organic photovoltaics (OPVs) with screen-printed silver electrodes comparable to those with silver electrodes fabricated by thermal evaporation. Furthermore, we developed a method to cure the silver ink using near-infrared (NIR) annealing, significantly reducing the curing time from 30 min with hot air annealing to just 5 s. Additionally, by employing sheet-to-sheet (S2S) slot-die coating, we scaled up the device area and completed module development, successfully verifying stability in ambient air. We have also extended the application of screen-printed silver electrodes to perovskite solar cells (PSCs). Full article

Perovskite solar cells (PSCs) are gaining prominence in the photovoltaic industry due to their exceptional photoelectric performance and low manufacturing costs, achieving a significant power conversion efficiency of 26.4%, which closely rivals that of silicon solar cells. Despite substantial advancements, the effective area of high-efficiency PSCs is typically limited to about 0.1 cm² in laboratory settings, with efficiency decreasing as the area increases. The limitation poses a major obstacle to commercialization, as large-area, high-quality perovskite films are crucial for commercial applications. This paper reviews current techniques for producing large-area perovskites, focusing on slot-die coating, a method that has attracted attention for its revolutionary potential in PSC manufacturing. Slot-die coating allows for precise control over film thickness and is compatible with roll-to-roll systems, making it suitable for large-scale applications. The paper systematically outlines the characteristics of slot-die coating, along with its advantages and disadvantages in commercial applications, suggests corresponding optimization strategies, and discusses future development directions to enhance the scalability and efficiency of PSCs, paving the way for broader commercial deployment. Full article

Perovskite solar cells (PSCs) are the most rapidly advancing photovoltaic technology in terms of power conversion efficiency. An efficiency of 26.1% was achieved in a decade, which is on par with the efficiency of very mature silicon panels. However, PSC commercialisation is partly hindered by the difficulty of scaling these devices without efficiency loss, mostly due to the increasing sheet resistance of the transparent conductive layer substrates and the nonuniformity of the layers when deposited across large areas. Therefore, it is crucial for the commercialisation of PSCs to implement easily scalable deposition processes with low material waste and compatibility with roll-to-roll (R2R) processes to reduce manufacturing costs. Slot-die coating can meet all these requirements, allowing for great uniformity over large areas. The most recent developments in PSC upscaling using slot-die coating as the main deposition process, along with its extension to the R2R process, are reviewed, including a thorough discussion of the slot-die coating process and the theory behind its operating limits. In fact, R2R coating is a very promising strategy for PSC industrialisation, since all processing steps use low-cost materials and scalable processes at temperatures lower than 120 °C, allowing the cost-effective and high-throughput production of PSC devices. Full article

Roll-to-roll (R2R) manufacturing depends on a system’s capability to deposit high-quality coatings with precise thickness, width, and uniformity. Therefore, consistent maintenance requires the immediate and accurate detection of coating defects. This study proposes a primary color selection (PCS) method to detect edge defects in R2R systems. This method addresses challenges associated with training data demands, complexity, and defect adaptability through a vision data-centric approach, ensuring precise edge coating defect detection. Using color information, high accuracy was achieved while minimizing data capacity requirements and processing time. Precise edge detection was facilitated by accurately distinguishing coated and noncoated regions by selecting the primary color channel based on color variability. The PCS method achieved superior accuracy (95.8%), outperforming the traditional weighted sum method (78.3%). This method is suitable for real-time detection in manufacturing systems and mitigates edge coating defects, thus facilitating quality control and production optimization. Full article

In fabricating functional layers, including thin-film transistors and conductive electrodes, using roll-to-roll (R2R) processing on polymer-based PET film, the instability of the slot-die coating meniscus under a high-speed web impedes functional layer formation with the desired thickness and width. The thickness profiles of the functional layers significantly impact the performance of the final products. In this study, we introduce an electrohydrodynamic (EHD)-based voltage application module to a slot-die coater to ensure the uniformity of the cross-machine direction (CMD) thickness profile within the functional layer and enable a stable, high-speed R2R process. The module can effectively control the spreadability of the meniscus by utilizing variations in the surface tension of the ink. The effectiveness of the EHD module was experimentally verified by applying a high voltage to a slot-die coater while keeping other process variables constant. As the applied voltage increases, the CMD thickness deviation reduces by 64.5%, and the production rate significantly increases (up to 300%), owing to the formation of a stable coated layer. The introduction of the EHD-based application module to the slot-die coater effectively controlled the spreadability of the meniscus, producing large-area functional layers. Full article

We reported the comparative studies of the optimization of solution-processable tungsten trioxide (WO₃) as a hole transporting layer (HTL) in inverted organic photovoltaics (OPVs) using spin coating, slot-die coating, and spray coating technologies for scaling-up applications. To facilitate the technology’s transition into commercial manufacturing, it is necessary to explore the role of scalable technologies for low-cost and efficient device fabrication. We investigated the role of diluting WO₃ with isopropanol as an HTL in inverted OPVs to solve the issue of poor wettability of the hydrophobic surface of the PBDB-T: ITIC bulk heterojunction layer. The optimal dilution ratios of WO₃ with isopropanol were 1:4, 1:4 and 1:8 with spin coating, slot-die coating and spray coating techniques, respectively. We evaluated the device performance by conducting a current density–voltage (J-V) analysis, incident photon-to-current conversion efficiency (IPCE) measurements, and ultraviolet–visible (UV-Vis) absorbance spectra for various WO₃ concentrations. The J-V characteristics revealed that slot-die coating resulted in the highest performance, followed by the spray coating technology. We further investigated the impact of the annealing temperature on device performance for both slot-die- and spray-coated diluted WO₃. The highest device performance was achieved at an annealing temperature of 120 °C for both coating technologies. This research offers valuable insights into the scalable fabrication of inverted OPV devices, paving the way for cost-effective and efficient large-scale production. Full article

The mixing process is the basis of the electrode microstructure, which defines key cell performance indicators. This work investigated the effects of varying the energy input within the mixing procedure on slurry rheology, coating behavior, mechanical and electrical properties of dry electrodes and electrochemical performance of cells fabricated from these negative electrodes. Energy input differences were achieved by varying the solids content within the mixing procedure; however, the final total solids content of the slurries was always the same. The slurries, produced with graphite and silicon oxide as active materials and carboxymethylcellulose (CMC) and styrene-butadiene rubber as binders, showed large differences in flow behavior which were explained by changes in CMC adsorption and mechanical degradation because of increasing energy input. Low shear viscosity and the degree of shear thinning decreased with increasing energy input, resulting in a narrower stability window for slot-die coating. The resistance between the electrode and current collector decreased as more CMC was adsorbed on the active material. Electrode adhesion drastically dropped at the highest energy input, presumably due to a change in SBR distribution. Despite these variations, all fabricated pouch cells demonstrated excellent electrochemical performance and a slight trend of increased charge capability was observed in cells prepared with higher energy input. Full article

Poly(3,4-ethylenedioxythiophene):poly(styrenesulfonate) (PEDOT:PSS) has emerged as a promising conductive polymer for constructing efficient hole-transport layers (HTLs) in perovskite solar cells (PSCs). However, conventional fabrication methods, such as spin coating, spray coating, and slot-die coating, have resulted in PEDOT:PSS nanofilms with limited performance, characterized by a low density and non-uniform nanostructures. We introduce a novel 3D-printing approach called electrically assisted direct ink deposition with ultrasonic vibrations (EF-DID-UV) to overcome these challenges. This innovative printing method combines programmable acoustic field modulation with electrohydrodynamic spraying, providing a powerful tool for controlling the PEDOT:PSS nanofilm’s morphology precisely. The experimental findings indicate that when PEDOT:PSS nanofilms are crafted using horizontal ultrasonic vibrations, they demonstrate a uniform dispersion of PEDOT:PSS nanoparticles, setting them apart from instances involving vertical ultrasonic vibrations, both prior to and after the printing process. In particular, when horizontal ultrasonic vibrations are applied at a low amplitude (0.15 A) during printing, these nanofilms showcase exceptional wettability performance, with a contact angle of 16.24°, and impressive electrical conductivity of 2092 Ω/square. Given its ability to yield high-performance PEDOT:PSS nanofilms with precisely controlled nanostructures, this approach holds great promise for a wide range of nanotechnological applications, including the production of solar cells, wearable sensors, and actuators. Full article