Multi-Spray Head Coating for Organic Electronics

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Solution Overview

Problem

Existing methods for producing organic electronic devices, such as solar cells and photodetectors, are limited by the requirement that materials must be soluble in the same solvent to form bulk heterojunctions, restricting the production of thicker layers and multilayer systems, and often result in thin layers due to solvent re-dissolution issues.

Innovation Solution

An apparatus and method utilizing multiple spray heads with different or the same solvents to apply layers simultaneously on a substrate, allowing for variable layer thicknesses and the production of bulk heterojunctions without the need for materials to be soluble in the same solvent, using a system with atomizers and flexible supply lines for efficient roll-to-roll processing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Quantity of substance

If conventional spray coating methods are used with single solvent systems, then materials can be applied to substrates, but the layer thickness is limited and materials must be soluble in the same solvent

Engineering Contradiction:

Improvelayer thicknessVSAvoidsolvent compatibility

Core Design Contradiction:

Quantity of substanceVSAdaptability or versatility

Solution Approach 1:

The single spray head is divided into multiple spray heads (first spray head, second spray head, etc.), each capable of delivering different solvents or material solutions. This segmentation allows independent control of each spray head to deposit layers with different thicknesses and material compositions, enabling thicker cumulative layers and compatibility with materials that require different solvents.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The spray coating apparatus is designed with multi-functionality to handle both single-layer and multi-layer coating processes. The system can selectively activate different spray heads based on the required material properties and layer specifications, making it universally applicable to various organic electronic device structures including bulk heterojunctions, multilayers, and tandem devices.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Ease of manufacture

If multiple layers are stacked using conventional methods with the same solvent, then layer-by-layer construction is possible, but the underlying layer re-dissolves causing defects

Engineering Contradiction:

Improvelayer stacking capabilityVSAvoidlayer integrity

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The coating process is segmented into distinct stages with different spray heads active at different times. The first spray head deposits the initial layer, then the second spray head deposits subsequent layers. This temporal and spatial segmentation prevents solvent from subsequent layers from re-dissolving previous layers, maintaining layer integrity while enabling multi-layer construction.

Inventive Principle:

Principle #1Segmentation

3Quantity of substance

If thicker layers are produced using conventional spray methods, then more material can be deposited, but solvent re-dissolution issues limit the maximum achievable thickness

Engineering Contradiction:

Improvelayer thicknessVSAvoidsolvent re-dissolution

Core Design Contradiction:

Quantity of substanceVSObject-affected harmful factors

Solution Approach 1:

The first layer is deposited and allowed to partially dry or set before the second layer is applied. This preliminary action reduces the solvent content in the first layer, minimizing the re-dissolution effect when the second layer's solvent is applied. The segmented spray head activation ensures proper timing between layers to achieve optimal thickness without defects.

Inventive Principle:

Principle #10Preliminary action

4Adaptability or versatility

If materials not soluble in the same solvent are used, then broader material selection is possible, but conventional bulk heterojunction formation becomes impossible

Engineering Contradiction:

Improvematerial selection rangeVSAvoidbulk heterojunction formation

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The bulk heterojunction formation process is segmented into separate deposition steps using different spray heads. Instead of mixing incompatible materials in a single solvent, the first spray head deposits one material layer, and the second spray head deposits the complementary material layer. This segmented approach enables bulk heterojunction formation with materials that are not mutually soluble, expanding material selection while maintaining manufacturing feasibility.

Inventive Principle:

Principle #1Segmentation

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

Enables the production of organic electronic devices with thicker, high-efficiency layers and multilayer systems, increasing absorption and reducing dark currents, while allowing for flexible substrate use and low-cost, high-throughput fabrication processes.

Implementation Method 1

an atomizer, a reservoir and a holder

Methodology Applied

Scientific EffectAtomization: Aerosol

Data Source

PatentUS8975112B2Device for spraying, method therefor, and organic electronic construction element

Publication Date: 2015.03.10 SIEMENS HEALTHINEERS AG

AI summary

The embodiments relate to a device and a method for spraying coatings of organic construction elements. The embodiments relate, in particular, to the spraying of coatings made up of components that do not dissolve in the same solvent, for example, and/or the spraying of a plurality of coatings one after the other. A plurality of spray heads is used, for example one after the other and/or next to one another.