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Automated spray coating process for the fabrication of large-area artificial opals on textured substrates

Alexander N. Sprafke, Daniela Schneevoigt, Sophie Seidel, Stefan L. Schweizer, and Ralf B. Wehrspohn

Open Access Open Access

Abstract

3D photonic crystals, such as opals, have been shown to have a high potential to increase the efficiency of solar cells by enabling advanced light management concepts. However, methods which comply with the demands of the photovoltaic industry for integration of these structures, i. e. the fabrication in a low-cost, fast, and large-scale manner, are missing up to now. In this work, we present the spray coating of a colloidal suspension on textured substrates and subsequent drying. We fabricated opaline films of much larger lateral dimensions and in much shorter times than what is possible using conventional opal fabrication methods.

© 2013 Optical Society of America

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Figures (8)
Fig. 1
Fig. 1 Schematic illustration of the fabrication process of an artificial opal by spray coating.

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Fig. 2
Fig. 2 Course of the drying sequence on a glass substrate. In this example, an approximately 10 × 15cm2 opal has formed after 70 min. on a 15 × 21cm2 glass substrate.

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Fig. 3
Fig. 3 (a) Reflectance spectra of the spray coating deposited opaline film from the inner (full line) and outer region of the substrate which is presented in Fig. 2. SEM cross-sectional views: Cross-section of the (a) inner region (5000x magnification) and (b) outer region (7500x magnification).

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Fig. 4
Fig. 4 Cracks in the opaline structure: (a) Optical microscope image in reflection (200x magnification), (b) SEM image (10000x magnification).

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Fig. 5
Fig. 5 Samples prepared with different concentrations of the colloidal dispersion: (a) 19%, (b) 10% and (c) 5% by weight.

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Fig. 6
Fig. 6 (a) Reflectance and (b) thickness of the opaline films prepared with colloidal dispersions of varying solid content.

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Fig. 7
Fig. 7 Artificial opal deposited onto aluminium foil: (a) SEM top view (300x magnification), (b) SEM cross-sectional view (13000x magnification).

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Fig. 8
Fig. 8 Possible implementations of a backside foil on solar cells. The backside foil is applied to the backside of the absorber. (a) Photonic crystal structure (here: inverted opal) consists of a electrically conducting material and the foil acts as a large scale backside contact. (b) Photonic crystal structure (here: opal) is isolating, electrical contacts are laser-fired into the absorber material.

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Tables (1)

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Table 1 Surface tension and vapor pressure of several solvents.

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