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For the manufacturing of thin films of solution-processable organicsemiconductors, e.g. for organic photovoltaics (OPV), meniscus guided-coatingtechniques are the method of choice for large-scale industrial applications.However, the process requires an in-depth understanding of the respective fluiddynamics to control the resulting film thickness. In this article, we derive ananalytical expression to describe the layer thickness of coatings manufacturedwith a trapezoidal-shaped applicator as a function of various fluid and processparameters. The analytical calculations are compared with results fromcomputational fluid dynamics (CFD) simulations and experimental data for anindustrially relevant OPV active material system. The analytical calculationsare compared with results from computational fluid dynamics (CFD) simulationsand experimental data for an industrially relevant OPV active material system.The good agreement of all three approaches demonstrates the potential of theanalytical and simulative methods to reduce time- and resource-consumingexperiments to a minimum. Furthermore, our theoretical model can be used toenhance the homogeneity of large-area coatings by means of an accelerationprofile of the applicator that can compensate the liquid loss during thecoating process. The respective analytical expression is validated by simulatedand experimentally obtained data for long-distance coatings. Finally, thisapproach is used to fabricate a large-area OPV module with new world recordefficiency.

On the theoretical framework for meniscus-guided manufacturing of large-area OPV modules