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SONO-TEK

FUEL CELL | SOLAR CELL

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ULTRASONIC ATOMIZATION - Using high-frequency sound vibrations, ultrasonic nozzles create a soft spray without bounceback from the substrate, unlike pressure nozzles. When combined with low-pressure air (typically 1 psi), the atomized spray can be shaped in a variety of fan-shaped or conical spray patterns. The type of air shaping method used is dictated by the specific needs of each process. Capability to coat unlimited widths with multiple nozzle systems.

Wet Process Ultrasonic Nozzle Systems
for Solar Cell Manufacturing

Sono-Tek offers ultrasonic coating equipment for wet processing of both thin film (flexible and non-flexible, including CIGs solar cells, CdTe solar cells and CZTs based solar cells) and silicon solar cell manufacturing. Sono-Tek coating systems offer significant cost savings over conventional vapor deposition processing in many solar cell coating applications.

Selective fluxing of solder bus lines on photovoltaic Si cells
Precise, targeted deposition and controlled velocity of the flux spray confines the flux to solder bus areas without overspray onto other areas of the cell. The ultrasonic vibration of the SelectaFlux nozzle makes it impossible for the nozzle to clogg, with only a monthly cleaning recommended. The SelectaFlux system is easily installed on existing Tabber Stringer lines.

Nanocoatings onto thin film solar cells
Sono-Tek ultrasonic coating systems are ideal for R&D applications spraying thin film nanosuspensions for active layers, TCO coating, PEDOT and anti-reflection layers, silver nanowire deposition, buffer layers (absorber layers) and quantum dots. The ultrasonic vibration of the nozzle breaks apart agglomerated particles (a common problem with nanosuspensions), creating highly uniform coatings from several microns to nanolayer thicknesses. Systems are available for both high temp and low temp processes and ultrasonic spray pyrolysis techniques.

Sono-Tek nozzles are also proven effective for spraying uniform coatings of carbon nanotubes, and are particularly effective in breaking apart agglomerations for the highest degree of uniformity and desirable coating morphologies for CNT coatings.

Examples of solutions sprayed onto flexible and non-flexible base substrates such as glass, stainless steel, conductive foils and other films:

Copper Indium Gallium Selenide (CIGS)
Cadmium Telluride (CdTe)
Cadmium Sulphide (CdS)
Gallium Arsenide (GaAs)
Indium Tin Oxides (ITO)
Cu2ZnSnS4 (CZTS)

Uniform coatings of liquid dopant solgel solutions, phosphoric acid solutions, titanium and zinc oxides for N-type and P-type silicon wafers
Sono-Tek offers several options for scalable doping processes, from fully enclosed R&D systems such as the ExactaCoat SC to inline systems such as our HyperSonic high speed reciprocating system for continuous high volume production. Advantages over traditional POCl3 batch doping processes:

Reduced cycle time with continuous inline process
Uniform thin films readily adhere to silicon surface
High speed reciprocator optimized for doping processes

Anti-reflection coatings for reducing surface reflection and maximizing cell efficicency
Sono-Tek ultrasonic nozzles are used to apply thin film and nanocoatings such as Silicon Monoxide (SiO) to reduce surface reflection and increase cell efficiencies.

Sono-Tek ultrasonic nozzles feature:

Up to 80% reduction in material consumption
Reduced wasteful overspray and atmospheric contamination
Minimal servicing and downtime
Spray patterns that are easily shaped for precise coating applications
Highly controllable spray that produces reliable, consistent results
Non-clogging
No moving parts to wear out
Ultra-low flow rate capabilities, intermittent or continuous

HyperSonic

HyperSonic is used to coat silicon wafers with uniform layers of phosphoric acid nanosuspensions (up to 85% concentration) for inline phosphoric doping emitter processes to create the emitter prior to furnace diffusion of PV cells. The system easily integrates with existing PV manufacturing lines and is fabricated from phosphoric resistant materials. Ultrasonic nozzle technology creates uniform thin films for cost effective phosphoric doping of silicon cells in high volume photovoltaic manufacturing

SelectaFlux Retrofit for Solar Cell Solder Bus Fluxing

The SelectaFlux Retrofit system for solar cell fluxing offers ultrasonic accuracy and precise control for targeted selective flux coatings onto solder bus lines in Tabber Stringer machines. Fluxing and soldering electrical contacts in the Tabber Stringer process is crucial as it ensures that the connections between the silicon crystal and the conductive electrical contacts are optimal for electricity to flow between them properly. Durability of solder bus joints is key to ensuring the module's quality and longevity.

EXACTACOAT SC

ExactaCoat SC is ideal for R&D thin film solar cell coating applications for spraying solutions, suspensions, and nanosuspensions such as carbon nanotubes, organic polymer coatings for organic solar cell manufacturing, TCO layer coatings, CIGS thin film solar cell coatings, anti-reflection coatings and quantum dots. Ultrasonic wet process spray systems drastically reduce equipment costs with very high effective material usage, compared to CVD and sputtering machines.
Ideal for R&D or low-volume production, the ExactaCoat SC is easily configured with Sono-Tek ultrasonic nozzles to customize spray patterns for your specific application. Spray patterns range from 0.08 - 2" wide (2 - 50 mm).