Optimized design for anti-reflection coating process in roll-to-roll slot-die coating system

• The anti-reflection coating process is studied using roll-to-roll slot-die coating.
• Coating speed and solid content are parameters governing the coating performance.
• A method for mass-producing a coating product with high accuracy is developed.
• Optimal coating speed and solid content are <3 m/min and <3.3 wt%, respectively.
• A high performance of transmittance is achieved using the optimization results.

This study investigated the application of the anti-reflection (AR) coating technology by using the roll-to-roll (R2R) slot-die coating process. To simulate the coating phenomenon, we investigated governing parameters in the slot-die coating process by using a viscocapillary model. Results of using this model revealed that the coating speed and solid content are two dominant factors affecting transmittance, which is an important parameter for the AR coating process. As the design of experiment methodology, response surface design was used to observe parameter interactions and establish a meta model for obtaining optimum process conditions. Further, to enhance the accuracy of analysis of the coating performance, the light wavelength was divided into visible and IR wavelength regions. In addition, the average and standard deviation values of transmittance were determined by a statistical correlation. An improvement of approximately 5% of the transmittance was observed in comparison to that of an uncoated (bare) substrate. The optimum conditions of process parameters for the AR coating process were determined through the established meta model and guidelines for performing the AR slot-die coating process were suggested.

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