Foam-core meniscus coating is being used to retrofit 100 nm-scale sol–gel anti-reflective coatings (ARCs) onto in-field solar panels through the deposition, evaporation, and curing of wet films. Advantages of this technique include the means to control fluid flow relative to substrate motion and the ability to conform to large, warped substrates. While simple in practice, no models exist for predicting critical outcomes such as film thickness. In this paper, preliminary experiments are used to identify important process parameters, and an analytical model is developed and validated for predicting the thickness of silica sol–gel films deposited on solar glass.

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