Ultrasonic Spray Coating Machine for Solar Cells

Ultrasonic Spray Coating Machine for Solar Cells

Against the backdrop of global energy transition and green, low-carbon development, solar cells, as the core device for converting solar energy into electricity, have become a core support for the development of the photovoltaic industry due to their core advantages of permanence, cleanliness, and flexibility. They are widely used in diverse scenarios such as ground-mounted photovoltaic power stations, distributed photovoltaics, building-integrated photovoltaics, rooftop photovoltaics for new energy vehicles, and flexible photovoltaics in aerospace. The core of a solar cell is converting solar energy into electrical energy through the photoelectric effect. Its structure includes components such as tempered glass, EVA, solar cells, and backsheets. The coating quality of key structures such as the anti-reflective coating and electrode coating directly determines the photoelectric conversion efficiency and lifespan of the cell. As a crucial step in solar cell manufacturing, the spray coating process bears the heavy responsibility of accurately coating anti-reflective coatings and electrode materials. Cheersonic ultrasonic spray coating machines, with their core advantages of high precision, low loss, and high adaptability, perfectly meet the spray coating needs of solar cells, providing core equipment support for their large-scale mass production and performance upgrades.

The diverse types and high-performance requirements of solar cells impose extremely stringent standards on the spray coating process, deeply binding its photoelectric conversion efficiency with the quality of the spray coating. Currently, mainstream solar cells mainly include crystalline silicon solar cells and perovskite solar cells. Whether it’s the preparation of antireflective coatings for crystalline silicon cells or the coating of precursors for perovskite cells, both place clear requirements on the spraying process. The core spraying requirements focus on three main aspects: First, high-uniformity coating, requiring precise control of coating thickness and distribution to adapt to the structural requirements of different types of solar cells, with a deviation ≤ ±0.05μm and uniformity exceeding 98%. This avoids defects such as pinholes and coating buildup, ensuring the antireflective coating reduces solar reflection and improves light absorption efficiency, while simultaneously protecting the electrodes. The coating process requires several key considerations: first, high conductivity; second, low-damage adaptation. Solar cells (especially flexible perovskite cells) are fragile and easily damaged, and cannot withstand high pressure and high temperature. The entire spraying process must be conducted under low pressure and without high temperature to avoid damaging the cell structure and photoelectric properties, while ensuring strong adhesion between the coating and the substrate to prevent coating peeling and performance degradation during long-term outdoor use; third, high utilization adaptation. Solar cell coating materials (such as perovskite precursors and nano-quartz coatings) are relatively expensive, requiring improved material utilization and reduced waste, while also adapting to the needs of large-area spraying, aligning with the trend of large-scale mass production in the photovoltaic industry.

Currently, in the field of solar cell spraying, traditional spraying processes (spin coating, air spraying, slot coating) have many shortcomings, making it difficult to adapt to the high-performance and large-scale manufacturing requirements, becoming a bottleneck restricting the improvement of quality and efficiency in the photovoltaic industry. While spin coating can achieve high-quality coating over small areas, it suffers from low efficiency and material utilization of less than 40%, making it unsuitable for the mass production needs of large-area solar cells. Air spraying relies on high-pressure airflow, which easily leads to uneven droplet distribution, resulting in inconsistent coating thickness. High-pressure impacts can also damage the cells, and the high-pressure airflow can introduce impurities, affecting photoelectric conversion efficiency. Slit coating, while suitable for large-area spraying, is prone to uneven solution flow and film thickness deviations, affecting product quality consistency. Furthermore, its equipment adaptability is poor, making it difficult to meet the spraying needs of different types of cells, such as crystalline silicon and perovskite.

Cheersonic ultrasonic spraying machine addresses the characteristics and spraying pain points of solar cells. Leveraging its core high-frequency atomization technology and combining it with key aspects of solar cell manufacturing processes, it creates customized solutions that completely break through the bottlenecks of traditional processes. The equipment converts industrial frequency electricity into a 40-150kHz high-frequency electrical signal via an ultrasonic generator. This signal is then converted into high-frequency mechanical vibration by a piezoelectric ceramic transducer. Utilizing the ultrasonic cavitation effect, the coating material is atomized into fine droplets of 0.01-3 microns, effectively preventing particle agglomeration and ensuring a uniform and delicate coating. This perfectly adapts to different coating needs, such as anti-reflective coatings for crystalline silicon solar cells and precursors for perovskite solar cells. The atomization process is low-pressure and high-temperature-free throughout. The droplets are gently deposited on the surface of the solar cell using only a small amount of carrier gas, without damaging the cell structure or photoelectric properties. This maximizes the photoelectric conversion efficiency of the solar cell and also accommodates low-temperature spraying requirements, meeting the process requirements of online coating for photovoltaic glass, enabling integrated production of the original wafer and coating processes.

For the spraying needs of solar cells, Cheersonic ultrasonic spraying machines demonstrate four core advantages, helping photovoltaic companies improve mass production quality and efficiency. First, high-precision coating with a uniformity exceeding 98% and a deviation of ≤±1% ensures even distribution of the anti-reflective coating and electrode coating, improving solar absorption efficiency and conductivity, and helping to overcome bottlenecks in solar cell photoelectric conversion efficiency.
Second, low-damage protection with low-pressure gentle atomization technology avoids damage to the cells, adaptable to various types of solar cells such as crystalline silicon, perovskite, and flexible solar cells, balancing coating adhesion and device performance.
Third, high material utilization, reaching over 95%, significantly reduces coating material waste and lowers solar cell manufacturing costs, especially suitable for high-priced perovskite precursors and nano-quartz coatings.
Fourth, excellent mass production adaptability, supporting automated continuous spraying and cleanroom adaptation, seamlessly integrating into large-scale solar cell production lines, suitable for large-area cell spraying, and allowing flexible parameter adjustments to meet the battery manufacturing needs of different scenarios such as ground-mounted power stations and building-integrated photovoltaics, solving the problems of low efficiency, high loss, and poor consistency of traditional processes.

Currently, Cheersonic ultrasonic spraying machines are widely used in solar cell spraying applications, covering core areas such as the preparation of antireflective films for crystalline silicon cells, coating of perovskite cell precursors, and spraying of nano-coatings for photovoltaic glass. This helps companies solve problems such as low photoelectric conversion efficiency and low yield rates caused by traditional spraying processes, achieving breakthroughs in high-quality solar cell preparation and large-scale mass production. As a leading company in the field of ultrasonic electronic equipment, Cheersonic Ultrasonic has been deeply involved in the photovoltaic spraying field for many years, keeping abreast of solar cell technology development trends. It can provide customized spraying solutions, covering the entire process from equipment selection and process parameter optimization to coating adaptation for different types of solar cells, helping customers fully leverage the core advantages of solar cells.

In the future, Cheersonic Ultrasonic will continue to optimize equipment performance to meet the needs of solar cells upgrading towards higher efficiency, thinner profiles, and greater flexibility, injecting strong momentum into the high-quality development of the photovoltaic industry and the global energy transition.

About Cheersonic

Cheersonic is the leading developer and manufacturer of ultrasonic coating systems for applying precise, thin film coatings to protect, strengthen or smooth surfaces on parts and components for the microelectronics/electronics, alternative energy, medical and industrial markets, including specialized glass applications in construction and automotive.

Our coating solutions are environmentally-friendly, efficient and highly reliable, and enable dramatic reductions in overspray, savings in raw material, water and energy usage and provide improved process repeatability, transfer efficiency, high uniformity and reduced emissions.

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