Abstract
Spraying of solution-processable materials such as organic molecules, polymers, nanoparticles, and quantum dots is a viable candidate for the coating process and fabrication of thin film solar cells and other similar semiconductor devices. Spray coating, similar to spray painting in the automotive industry, is a fast process and can be scaled up and used for the roll-to-roll fabrication of solar panels. In this paper, attempts are made to understand various steps of the process and develop a simple model as a design tool. The model equations are solved numerically for the spray coating of a P3HT-PCBM active layer in a polymer solar cell using ultrasonic atomization to investigate the effect of process parameters on the thin film characteristics, such as the film thickness and heat consumption needed to vaporize the solvent. It is concluded that when using spray coating with a small thermal budget, large areas with desired submicron- and nanometer-sized thicknesses can be made in a fast process. Cost of thermal energy and materials decreases with an increase in the substrate speed and nozzle-substrate distance.
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