Development of a Synthetic Optical Coating for Efficient UV Light Conversion and Enhanced Transmittance

Photovoltaic modules require efficient sunlight modulation, including enhanced visible transmittance and conversion of unused ultraviolet light. This study develops a synthetic optical coating that achieves both functions by integrating down-conversion BAM (BaMgAl10O17:Eu2+, Mn2+) nanophosphors into a silica anti-reflection sol. The key novelty lies in a synergistic surface engineering strategy that decouples dispersion stabilization from luminescence protection. Five dispersants are systematically compared under combined ball and sand milling. The polyester-modified acrylic long-chain dispersant (DK062) yields a stable nanodispersion with an average particle size of 228 nm and a Zeta potential of −7.61 mV, effectively suppressing re-agglomeration while retaining high photoluminescence. Subsequent surface modification with KH570 grafts a dense silane passivation layer via Si–O–M covalent bonds, further increasing the photoluminescence intensity by 1.39-fold. The optimized nanophosphors are incorporated into a commercial anti-reflection sol and dip-coated onto photovoltaic glass. At a doping concentration of 2‰ and a withdrawal speed of 8 mm/s, the resulting DCSAR coating exhibits an average transmittance of 91.16%—slightly higher than that of the pure anti-reflection coating (90.96%)—while showing strong green emission at 515 nm. Industrial on-site testing further demonstrates an average transmittance of 94.20%–94.31% with uniform green emission. This work provides a scalable route to fabricate highly transparent, light-converting anti-reflection coatings by combining dispersant-assisted milling and silane passivation.