JP2005142085A - Electrode board for dye-sensitized solar cell, its manufacturing method and dye-sensitized solar cell - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide an electrode board for a dye-sensitized solar cell, capable of easily obtaining a plurality of porous semiconductor electrodes formed. <P>SOLUTION: In manufacturing an electrode board 20 for a dye-sensitized solar cell provided with a transparent base material 1, a transparent electrode 3 formed on one face of the transparent base material, a porous semiconductor electrode 7 formed on the transparent electrode with the use of a large number of semiconductor fine particles, and dyes 9 supported on the surface of the semiconductor fine particles 7a forming the porous semiconductor electrode, a photocatalyst-containing layer 5 with wettability augmented relatively in a region which is to be a foundation of the porous semiconductor is provided between the transparent electrode and the porous semiconductor electrode prior to forming of the porous semiconductor electrode. <P>COPYRIGHT: (C)2005,JPO&NCIPI

Description

  The present invention relates to an electrode substrate for a dye-sensitized solar cell, a method for producing the same, and a dye-sensitized solar cell.

  The use of solar power generation systems is increasing today because the load on the surrounding environment is small compared to power generation systems using fossil fuels and nuclear fuel, and it is easy to save resources.

  The solar cell used in the photovoltaic power generation system is a photoelectric conversion element that can directly convert light energy into electrical energy. This solar cell includes a silicon solar cell, a compound semiconductor solar cell (gallium arsenide solar cell, Indium phosphide solar cells, CIS (copper indium selenium) solar cells, etc.), dye-sensitized solar cells, and the like. Among these solar cells, silicon solar cells are already widely used as consumer solar cells. In recent years, attention has been focused on dye-sensitized solar cells that can be easily reduced in cost and weight as compared with silicon solar cells.

FIG. 7 is a schematic view showing a cross-sectional structure of a typical dye-sensitized solar cell (Gretzel cell). Dye-sensitized solar cell 250 ^shown, _I ^- / I ₃ - is a wet solar cell with an electrolyte solution 205 was sandwiched between a pair of electrode substrates 220 and 230 structure containing a redox couple.

  The electrode substrate 220 includes a transparent glass substrate 211, a transparent electrode (fluorine-doped tin oxide film) 213 formed on one surface thereof, and a semiconductor electrode (porous titanium oxide thin film) 215 formed thereon. The semiconductor electrode 215 functions as a photoelectrode. The semiconductor electrode 215 is formed by a sol-gel method, and is a sintered body of a large number of anatase-type titanium oxide fine particles. The surface of the semiconductor electrode 215 is adsorbed with a dye 217 made of one of ruthenium (Ru) complexes. The absorption wavelength range of the dye 217 extends to a longer wavelength side than the absorption wavelength range of titanium oxide. Yes. The energy level of electrons when the dye 217 is photoexcited is higher than the position of the conduction band edge of titanium oxide. In FIG. 7, the dye 217 is drawn as one layer for convenience. On the other hand, the electrode substrate 230 includes a transparent glass substrate 221, a transparent conductive film (fluorine-doped tin oxide film) 223 formed on one surface thereof, and a platinum thin film 225 formed thereon. The film 223 and the platinum electrode 225 function as a counter electrode. The transparent electrode 213 in the electrode substrate 220 and the transparent conductive film 223 in the electrode substrate 230 are connected to the load 240 by lead wires 235a and 235b.

When the dye-sensitized solar cell 250 is irradiated with light within the absorption wavelength range of the dye 217, the dye 217 is excited, and photoexcited electrons (e ⁻ ) are injected into the semiconductor electrode 215. Electronic (e ^-) dye 217 lost in, ^I in the electrolyte solution 205 - / _{I 3} ^- from redox pairs deprive electrons (I ^- reacts with _{I 3} ^- to occur), return to the original state . On the other hand, the electrons (e ⁻ ) injected into the semiconductor electrode 215 move to the transparent electrode 213 and further reach the electrode substrate 230 via the lead wire 235a, the load 240, and the lead wire 235b and react with I ₃ ^−. , I ⁻ . Therefore, a closed circuit is formed in the dye-sensitized solar cell 250 by the light irradiation. When this closed circuit is formed, the dye-sensitized solar cell 250 generates power constantly. By using the dye 217, it is possible to generate power using light having a longer wavelength than the light in the absorption wavelength region of the semiconductor electrode 215, so that the photoelectric conversion efficiency can be increased. Incidentally, the platinum thin film 225, the serving other to increase the conductivity of the electrode substrate _{^{230, I - / I 3 -}} I 3 of the redox pair ^- is I ^- also serves as a catalyst as it is reduced to.

  Because the sheet resistance of the transparent electrode is relatively high, in order to obtain a dye-sensitized solar cell with a large operating current, the structure is a structure in which a plurality of relatively small cells are electrically connected in parallel. It is preferable to make it. Further, in order to obtain a dye-sensitized solar cell having a high operating voltage, it is preferable that the structure is a structure in which a plurality of relatively small cells are electrically connected in series. The term “cell” as used herein means that an electrolyte layer is interposed between a pair of electrodes composed of at least one photoelectrode and at least one counter electrode, and this cell alone can be used as a dye-sensitized solar cell. Function.

  From the viewpoint of obtaining a dye-sensitized solar cell having a structure in which a plurality of cells are electrically connected in parallel or in series at low cost, a porous semiconductor electrode functioning as a photoelectrode is formed on one transparent substrate. It is preferable to form a plurality on one side.

  For example, Patent Document 1 discloses a photoelectric device in which a plurality of porous semiconductor electrodes are formed by applying a suspension containing a particulate inorganic semiconductor material to a desired portion by screen printing, drying, solidifying, and firing. A conversion element (solar cell) is described.

Further, Patent Document 2 discloses that a coating film is formed by applying a dispersion of a semiconductor fine particle, a colloidal liquid, and the like, and then the semiconductor fine particles are sintered by selectively irradiating the coating with electromagnetic waves. A method of manufacturing a semiconductor electrode is described in which a porous semiconductor electrode patterned into a desired shape is obtained by removing the bonded portion by washing or the like. The irradiation of electromagnetic waves by this method is for accelerating the sintering of the semiconductor fine particles. Preferably, the sintering is performed by using the irradiation of electromagnetic waves and heating by another method in combination.
JP 2002-319689 (No. 0025-0051, especially No. 0032-0033) JP 2002-134435 (Nos. 0005 to 0030, in particular, No. 0021, No. 0027, and No. 0029)

  However, in the formation of the porous semiconductor electrode using screen printing as described in Patent Document 1, it is necessary to increase the viscosity of the suspension as a material. Along with this, the semiconductor fine particles in the suspension are easily aggregated, and there is a problem that it is difficult to form a porous semiconductor electrode having a desired shape.

  Further, when the porous semiconductor electrode is formed by the method described in Patent Document 2, in order to prevent the sintered portion from locally peeling or dropping when the unsintered portion is removed, the sintering is performed. The condensation temperature must be relatively high. For this reason, for example, if a plurality of porous semiconductor electrodes are formed at once on a transparent resin film having relatively low heat resistance, there is a problem that it is difficult to form a porous semiconductor electrode having a desired shape.

  The present invention has been made to solve the above-mentioned problems, and a first object of the present invention is for a dye-sensitized solar cell in which a plurality of porous semiconductor electrodes can be easily obtained. The object is to provide an electrode substrate.

  In addition, a second object of the present invention is to provide a method for producing a dye-sensitized solar cell electrode substrate in which it is easy to obtain a dye-sensitized solar cell electrode substrate on which a plurality of porous semiconductor electrodes are formed. It is to provide.

  A third object of the present invention is to provide a dye-sensitized solar cell that is easy to obtain having a plurality of porous semiconductor electrodes.

  The electrode substrate for a dye-sensitized solar cell of the present invention that achieves the first object described above uses the transparent base material, the transparent electrode formed on one side of the transparent base material, and a large number of semiconductor fine particles. An electrode substrate for a dye-sensitized solar cell, comprising: a porous semiconductor electrode formed on a transparent electrode; and a dye supported on the surface of semiconductor fine particles forming the porous semiconductor electrode, wherein the transparent substrate A wettability changing layer is interposed between the electrode and the porous semiconductor electrode, and the wettability in the region of the surface of the wettability changing layer that is the base of the porous semiconductor electrode is relatively high. It is characterized by being.

  Here, the “wetting property changing layer” in the present specification means a layer capable of relatively improving the wettability of the surface by light irradiation.

  The wettability changing layer is formed so as to cover at least a part of the surface of the transparent electrode and so that at least a part of the surface becomes a formation region in a plan view of the porous semiconductor electrode. If the wettability in a region corresponding to the formation region of the porous semiconductor electrode in a plan view in the surface of the wettability changing layer is relatively increased in advance, the following technical effect is obtained.

  That is, when a coating solution for forming a semiconductor electrode containing a large number of semiconductor fine particles is applied onto the wettability changing layer, substantially only on the region where the wettability is relatively enhanced. A coating film can be formed. And a porous semiconductor electrode can be formed by drying this coating film. At this time, the viscosity of the coating solution for forming a semiconductor electrode need not be so high.

  Therefore, according to the dye-sensitized solar cell electrode substrate of the present invention, it is easy to obtain a substrate on which a plurality of porous semiconductor electrodes are formed.

  The method for producing a dye-sensitized solar cell electrode substrate of the present invention that achieves the second object described above comprises a transparent substrate, a transparent electrode formed on one side of the transparent substrate, and a large number of semiconductor fine particles. A method for producing an electrode substrate for a dye-sensitized solar cell, comprising: a porous semiconductor electrode formed on the transparent electrode, and a dye supported on the surface of semiconductor fine particles forming the porous semiconductor electrode A preparation step of preparing a transparent substrate having a transparent electrode formed on one side, and a wettability changing layer capable of changing the wettability of the surface by light irradiation, at least a part of the surface of the transparent electrode And the wettability changing layer forming step of forming the wettability changing layer so that at least a part of the surface of the wettability changing layer is a formation region in plan view of the porous semiconductor electrode, and the wettability Of the surface of the change layer A selective exposure step of selectively exposing a region corresponding to a formation region of the porous semiconductor electrode in plan view to relatively increase the wettability of the region, and the selection among the surfaces of the wettability changing layer Porous semiconductor electrode for forming a porous semiconductor electrode by forming a coating film by a coating solution for forming a semiconductor electrode containing a large number of semiconductor fine particles on a region selectively exposed in an exposure step, and drying the coating film And a dye carrying step for carrying a dye on the surface of the semiconductor fine particles forming the porous semiconductor electrode (hereinafter, this production method is referred to as “Production Method I”). is there.).

  According to the production method I of the present invention, the above-described electrode substrate I of the present invention can be easily obtained.

  In the production method I of the present invention, (A) in the selective exposure step, a photomask having a photocatalyst-containing layer is used, and the photocatalyst-containing layer is positioned on the surface side of the wettability changing layer. A mask is disposed, and the surface of the wettability changing layer is selectively exposed (hereinafter, this manufacturing method may be referred to as “manufacturing method II”), and (B) in the porous semiconductor electrode forming step. The coating solution for forming a semiconductor electrode is applied by an ink jet method or an electric field jet method to form the coating film (hereinafter, this production method may be referred to as “production method III”), or (C ) Further including a non-exposed portion removing step performed after the porous semiconductor electrode forming step, and the non-exposed portion removing step leaves the region corresponding to the formation region of the porous semiconductor electrode in plan view. sex Layer is removed (hereinafter, this production method may be referred to as "production method IV.") It is preferable.

  According to the production method II of the present invention, the selective exposure step is performed using a photomask having a photocatalyst-containing layer, so that the desired exposure can be achieved in a shorter time than when a photomask not having a photocatalyst-containing layer is used. It is possible to perform the exposure process.

  According to the production method III of the present invention, since the coating solution for forming a semiconductor electrode is applied by an ink jet method or an electric field jet method, it becomes easy to form a coating film only at a necessary portion. As a result, it becomes easy to obtain a porous semiconductor electrode having a desired shape.

  According to the production method III of the present invention, since the wettability changing layer in the portion not forming the porous semiconductor electrode is removed, when obtaining a dye-sensitized solar cell in which a plurality of cells are electrically connected in series In addition, it becomes easy to electrically connect the electrode substrate for the dye-sensitized solar cell of the present invention and the counter electrode disposed to face the electrode substrate in series and under a low resistance.

  The dye-sensitized solar cell of the present invention that achieves the third object described above includes a first electrode substrate having a porous semiconductor electrode having a dye supported on the surface, and facing the first electrode substrate. A dye-sensitized solar cell comprising: a second electrode substrate disposed; and an electrolyte layer interposed between the first electrode substrate and the second electrode substrate, wherein the first electrode The substrate is the electrode substrate for a dye-sensitized solar cell of the present invention described above.

  According to the dye-sensitized solar cell of the present invention, since the above-described electrode substrate for the dye-sensitized solar cell of the present invention is used, it is easy to obtain one having a plurality of porous semiconductor electrodes. become.

  According to the electrode substrate for a dye-sensitized solar cell of the present invention, it is easy to obtain a substrate on which a plurality of porous semiconductor electrodes are formed. Therefore, a plurality of cells are electrically connected in parallel or in series. It becomes easy to obtain a dye-sensitized solar cell having a different structure.

  In addition, the method for producing a dye-sensitized solar cell electrode substrate of the present invention makes it easy to obtain a dye-sensitized solar cell electrode substrate on which a plurality of porous semiconductor electrodes are formed. It is easy to obtain a dye-sensitized solar cell having a structure in which the cells are electrically connected in parallel or in series.

  And according to the dye-sensitized solar cell of the present invention, it becomes easy to obtain one having a plurality of porous semiconductor electrodes, so that a plurality of cells are electrically connected in parallel or in series. It becomes easy to obtain a dye-sensitized solar cell having a structure.

  Hereinafter, the dye-sensitized solar cell electrode substrate, the method for producing the dye-sensitized solar cell electrode substrate, and the respective forms of the dye-sensitized solar cell according to the present invention will be sequentially described with reference to the drawings as appropriate. .

<Dye-sensitized solar cell electrode substrate and manufacturing method thereof (first embodiment)>
FIG. 1 is a schematic view showing an example of a basic cross-sectional structure of an electrode substrate for a dye-sensitized solar cell of the present invention. The illustrated dye-sensitized solar cell electrode substrate 20 (hereinafter referred to as “electrode substrate 20”) is used to obtain a dye-sensitized solar cell in which a plurality of cells are electrically connected in parallel. It is something that can be done.

  In this electrode substrate 20, one transparent electrode 3 is formed on one side of the transparent base material 1, and a plurality of wettability changing layers 5 are formed in parallel on the transparent electrode 3. The surface of each wettability changing layer 5 is partially partially at a relatively high wettability, and the porous semiconductor electrode 7 is formed on each of the regions with relatively high wettability. . As a result, one porous semiconductor electrode 7 is formed on each wettability changing layer 5. Each porous semiconductor electrode 7 is formed using a large number of semiconductor fine particles, and a dye 9 is supported on the surface of the semiconductor fine particles 7 a forming the porous semiconductor electrode 7. A plurality of lead wires 11 are formed on the transparent electrode 3 so as to correspond to one porous semiconductor electrode 7 one by one, and a protective layer 13 is provided on the outer surface of each lead wire 11. ing. In FIG. 1, for convenience, the dye 9 supported on each semiconductor fine particle 7a is drawn as one layer. Hereinafter, the electrode substrate 20 and the manufacturing method thereof will be described in detail.

(1) Transparent base material The transparent base material 1 transmits light of a desired wavelength region in the wavelength region ranging from the ultraviolet region to the infrared region in an average value of approximately 85% or more, and has desired light resistance and weather resistance. It is preferable to use an inorganic material or an organic material, and if necessary, various additives can be used in combination to form the film by various methods. The “desired wavelength range” can be appropriately selected in consideration of the absorption wavelength ranges of the porous semiconductor electrode 7 and the dye 9.

  Specifically, an inflexible transparent rigid material such as a quartz glass plate, a Pyrex (registered trademark) glass plate, or a synthetic quartz plate can be used as the transparent substrate 1, but the electrode substrate 20 can be used. From the viewpoint of enhancing flexibility, it is preferable to use a transparent glass sheet or a transparent resin film, and it is particularly preferable to use a transparent resin film.

  Examples of the transparent resin film include biaxially stretched polyethylene terephthalate (PET) film, ethylene / tetrafluoroethylene copolymer film, polyethersulfone (PES) film, polyetheretherketone (PEEK) film, and polyether. An imide (PEI) film, a polyimide (PI) film, a polyester naphthalate (PEN) film, a polycarbonate (PC) film, a cyclic polyolefin film, or the like can be used. From the viewpoint of reducing the manufacturing cost of the electrode substrate 20, a transparent resin film formed of a relatively inexpensive resin material is used rather than a transparent resin film formed of a relatively expensive resin material such as engineering plastic. It is preferable to use it. When a transparent resin film is used as the transparent substrate 1, the film thickness can be appropriately selected within a range of about 15 to 500 μm depending on the use of the dye-sensitized solar cell produced using the electrode substrate 20. It is.

  In addition, since the temperature of the transparent substrate 1 is also increased when forming the porous semiconductor electrode 7, it is preferable to consider the heat resistance when selecting the material and thickness of the transparent substrate 1.

(2) Transparent electrode The transparent electrode 3 receives carriers (electrons) from each porous semiconductor electrode 7 formed thereon when the dye-sensitized solar cell is irradiated with light of a desired wavelength range. Alternatively, carriers (holes) are transmitted to each porous semiconductor electrode 7 formed thereon, and can be formed using various conductive materials.

  In consideration of light transmittance and conductivity, the transparent electrode 3 is preferably formed of indium tin oxide (ITO), fluorine-doped tin oxide, indium zinc oxide (IZO), zinc oxide (ZnO) or the like, and particularly fluorine-doped. It is preferable to form with tin oxide or ITO. The film thickness of the transparent electrode 3 can be appropriately selected within a range of about 0.1 nm to 500 nm, and the sheet resistance is preferably as low as possible, generally about 15Ω / □ or less.

  In manufacturing the electrode substrate 20, first, a preparation process for preparing the transparent base material 1 on which the transparent electrode 3 is formed on one side is performed. Such a transparent base material 1 may be produced by itself, or may be purchased by others.

  When the transparent electrode 3 is formed on one side of the transparent substrate 1, the transparent electrode 3 may be formed by a physical vapor deposition method (PVD method) such as a vacuum deposition method, a sputtering method, or an ion plating method. it can. From the viewpoint of suppressing the manufacturing cost, it is preferable to form the transparent electrode 3 by an ion plating method or a sputtering method.

(3) Wettability changing layer The wettability changing layer 5 is used to control the formation position of the porous semiconductor electrode 7 when the porous semiconductor electrode 7 is formed using a semiconductor electrode forming coating liquid described later. Is. This wettability changing layer 5 can relatively improve the wettability of the surface by light irradiation, and also moves carriers (electrons) from the porous semiconductor electrode 7 to the transparent electrode 3 or is porous from the transparent electrode 3. Formed of a material that allows carriers (holes) to move to the porous semiconductor electrode 7.

  In order to control the formation position of the porous semiconductor electrode 7 as accurately as possible by the wettability changing layer 5, the wettability changing layer 5 is in a state where the surface wettability is not changed (irradiates light in a predetermined wavelength region). The contact angle with a liquid with a surface tension of 40 mN / m under the following condition is 10 ° or more, and the liquid with a surface tension of 40 mN / m is irradiated with light. Those that can improve the wettability of the surface until the contact angle becomes 9 ° or less are preferred. A more preferable wettability changing layer 5 has a contact angle with a liquid with a surface tension of 30 mN / m in the initial state of 10 ° or more, and a contact angle with a liquid with a surface tension of 50 mN / m by light irradiation is 10 ° or less. The wettability changing layer 5 can improve the surface wettability until the contact angle with a liquid having a surface tension of 20 mN / m in the initial state is 10 ° or more, and the surface tension is 60 mN by light irradiation. The wettability of the surface can be increased until the contact angle with the liquid of / m becomes 10 ° or less.

  In addition, the contact angle with the liquid here is a contact angle measuring device (Kyowa Interface Science Co., Ltd. CA-) with a contact angle with a liquid having various surface tensions (wet index standard solution manufactured by Junsei Co., Ltd.). (Z type) was used to measure (30 seconds after dropping a droplet from a microsyringe), and the result was obtained or the result was graphed.

  A region with relatively high wettability (hereinafter referred to as “hydrophilic region”) and a region with relatively low wettability (hereinafter referred to as “water-repellent region”) are distributed on the surface of the wettability changing layer 5. In this case, when a coating solution for forming a semiconductor electrode is applied onto the wettability changing layer 5, a coating film can be formed substantially only on the hydrophilic region. The coating solution for forming a semiconductor electrode coated on the water-repellent region has a low adhesion to the wettability changing layer 5 and can be easily removed. Moreover, it is suppressed that the coating liquid for semiconductor electrode formation coated on the hydrophilic region flows onto the hydrophobic region.

  The material of the wettability changing layer 5 is not particularly limited as long as the material can form a layer capable of relatively improving the wettability of the surface by light irradiation. Specific examples of the material of the wettability changing layer 5 include, for example, (i) organopolysiloxane obtained by hydrolysis and polycondensation of chlorosilane, alkoxysilane, etc. by sol-gel reaction, etc., and (ii) water repellency and oil repellency. And (iii) a self-assembled film exhibiting water repellency using a fluoroalkylsilane and the like.

As a material of the above (i), the general formula _{Y n SiX (4-n)} ( wherein, Y represents an alkyl group, fluoroalkyl group, vinyl group, amino group, phenyl group, or epoxy group, X is An alkoxyl group, an acetyl group, or a halogen atom, where n is an integer of 0 to 3.) One or two or more hydrolyzed condensates or cohydrolyzed condensates of a silicon compound represented by Polysiloxane is preferred. In addition, it is preferable that carbon number of the group shown by Y in said general formula exists in the range of 1-20, and the alkoxy group shown by X is a methoxy group, an ethoxy group, a propoxy group, a butoxy group. It is preferable that In particular, polysiloxanes containing fluoroalkyl groups can be preferably used, and those generally known as fluorine-based silane coupling agents can be used.

  In manufacturing the electrode substrate 20, following the preparation step described above, a wettability changing layer (hereinafter referred to as “precursor layer”) that is the basis of the wettability changing layer 5 is used as at least one surface of the transparent electrode 3. A wettability changing layer forming step is performed in which a part is covered so that at least a part of the surface of the precursor layer becomes a formation region of the porous semiconductor electrode 7 in plan view. Further, following this wettability changing layer forming step, a region corresponding to the formation region in the plan view of the porous semiconductor electrode 7 in the surface of the precursor layer is selectively exposed to thereby improve the wettability of this region. A relatively high selective exposure process is performed. By performing this selective exposure step, the precursor layer can be the wettability changing layer 5.

  For example, the precursor layer is prepared by dispersing the material of the wettability changing layer 5 in a solvent to prepare a coating liquid (hereinafter referred to as “wetting liquid changing layer forming coating liquid”). It can form by apply | coating the said coating liquid for wettability change layer formation on the formed transparent base material 1 and forming this coating film, and drying this coating film. The wettability changing layer forming coating liquid may contain a desired additive as required. The thickness of the precursor layer is preferably in the range of approximately 0.001 μm to 1 μm, particularly in the range of approximately 0.005 to 0.1 μm, from the viewpoint of forming the hydrophilic region described above in the shortest possible time. It is preferable that

  In selectively exposing the surface of the precursor layer, a photomask having a photocatalyst-containing layer may be used, and the photomask may be arranged so that the photocatalyst-containing layer is located on the surface side of the precursor layer. preferable.

  The above photomask may be in any form as long as it has at least a photocatalyst-containing layer and a mask pattern. Usually, a thin photocatalyst-containing layer is formed so as to cover the mask pattern. If necessary, the photocatalyst-containing layer may be patterned into a desired shape. The configuration of the photomask excluding the photocatalyst-containing layer can be, for example, a configuration in which a mask pattern is formed on one side of a transparent substrate such as a glass plate with metal chromium or the like. In printing applications, a photocatalyst-containing layer formed at a predetermined location such as a plate-making film can also be used as the photomask.

  The photocatalyst-containing layer can be formed, for example, by dispersing a photocatalyst in a binder. In order to prevent the binder from being decomposed when the photocatalyst is photoexcited, it is preferable to use a material having sufficient resistance to the photooxidation action of the photocatalyst.

Examples of the photocatalyst include titanium oxide (TiO ₂ ), zinc oxide (ZnO), tin oxide (SnO ₂ ), strontium titanate (SrTiO ₃ ), fermented tungsten (WO ₃ ), oxidation, which are known as photo semiconductors. Examples thereof include those made of metal oxides such as bismuth (Bi ₂ O ₃ ) and iron oxide (Fe ₂ O ₃ ), and titanium oxide is particularly preferable. Titanium oxide has a high bandgap energy, is chemically stable, has no toxicity, and is easily available. Either anatase type or rutile type titanium oxide can be used, but anatase type titanium oxide is preferred. When anatase-type titanium oxide is used as a photocatalyst, a photocatalytic reaction occurs more efficiently when the particle size is smaller, so it is preferable to use a material having a smaller particle size. Specifically, those having an average particle diameter of 50 nm or less are preferable, and those having an average particle diameter of 20 nm or less are more preferable. Specific examples of such anatase type titanium oxide include, for example, hydrochloric acid peptizer type anatase type titania sol (STS-02 manufactured by Ishihara Sangyo Co., Ltd., average crystallite diameter 7 nm), nitrate peptizer type anatase type titania sol (Nissan) TA-15 manufactured by Chemical Co., Ltd. and an average crystallite diameter of 12 nm).

  As the above-mentioned binder, those having a high binding energy such that the main skeleton of the binder is not decomposed by photoexcitation of the above-mentioned photocatalyst are preferable, and examples thereof include organopolysiloxane.

  In the case of using an organoalkoxysilane as the binder layer, it is more preferable to use a material in which at least 10 to 30% by mass is composed of a bifunctional silicone precursor (for example, dialkoxydimethylsilane). When an organoalkoxysilane is used in a sol-gel method or the like, the crosslink density can be improved by using a trifunctional silicone precursor such as trialkoxymethylsilane as a main component.

An amorphous silica precursor can also be used as a binder. Examples of the amorphous silica precursor include a silicon compound represented by the general formula SiX ₄ (wherein X represents a halogen atom, a methoxy group, an ethoxy group, or an acetyl group), and a hydrolyzate of this silicon compound. A certain silanol or polysiloxane having an average molecular weight of 3000 or less is preferable. Specific examples include tetraethoxysilane, tetraisopropoxysilane, tetra-n-propoxysilane, tetrabutoxysilane, tetramethoxysilane and the like. When forming a photocatalyst-containing layer using an amorphous silica precursor as a binder, for example, an amorphous silica precursor and photocatalyst particles are uniformly dispersed in a non-aqueous solvent to prepare a coating solution. And this coating liquid is apply | coated on a base material, and a coating film is formed. Thereafter, a hydrolysis reaction proceeds in the coating film by moisture in the air to form silanol. Thereafter, dehydration condensation polymerization is performed at room temperature. Thereby, a photocatalyst containing layer can be formed. If dehydration condensation polymerization of silanol is performed at 100 ° C. or higher, the degree of polymerization of silanol increases and the strength of the film surface can be improved. Amorphous silica precursors can be used alone or in admixture of two or more, like other binders.

  In the photocatalyst-containing layer containing at least one of organosiloxane and amorphous sill force and a photocatalyst, the amount of the photocatalyst is preferably in the range of approximately 5% by mass to 60% by mass, and approximately 20% by mass to 40% by mass. More preferably.

  The photocatalyst-containing layer containing the binder is prepared by dispersing and dissolving the photocatalyst and the binder in a solvent to prepare a coating liquid (hereinafter referred to as “photocatalyst coating agent”), and the coating formed by the photocatalyst coating agent. It can be formed by drying the membrane. Examples of the solvent used for the photocatalyst coating agent include alcohol-based organic solvents such as ethanol and isopropanol. Further, if necessary, a titanium-based, aluminum-based, zirconium-based or chromium-based coupling agent can be used in combination. The photocatalyst coating agent can be applied to the photomask by a method such as spray coating, dip coating, roll coating, or bead coating. In addition, when an ultraviolet curable component is contained as a binder, the photocatalyst-containing layer can be formed on the substrate by irradiating the coating film with ultraviolet rays and performing a curing treatment.

  The photocatalyst-containing layer can be formed of a photocatalyst alone (for example, titanium oxide alone) without using a binder. For example, a photocatalyst-containing layer can be formed of titanium oxide alone by forming amorphous titanium oxide on a substrate and then changing the phase to crystalline titanium oxide by firing.

  The above amorphous titanium oxide can be obtained by, for example, (i) hydrolyzing and dehydrating and condensing an inorganic salt of titanium such as titanium tetrachloride and titanium sulfate, or (ii) tetraethoxy titanium, tetraisopropoxy titanium, tetra It can be obtained by hydrolyzing and dehydrating and condensing an organic titanium compound such as -n-propoxy titanium, tetrabutoxy titanium, and tetramethoxy titanium in the presence of an acid. When this amorphous titanium oxide is baked at about 400 ° C. to 500 ° C., it can be transformed into anatase type titanium oxide, and when baked at about 600 ° C. to 700 ° C., it can be transformed into rutile type titanium oxide.

  Also, a photocatalyst-containing layer consisting only of a photocatalyst can be formed by a vacuum film forming method such as a sputtering method, a CVD method, or a vacuum vapor deposition method. By forming the photocatalyst-containing layer by a vacuum film forming method, it is possible to obtain a uniform photocatalyst-containing layer containing only the photocatalyst. Using a photomask having such a photocatalyst-containing layer to selectively expose the surface of the precursor layer, which is the basis of the wettability changing layer, uniformly improves the wettability of a desired region on the surface of the precursor layer. Becomes easier. In addition, since the photocatalyst-containing layer is composed only of the photocatalyst, it is easy to efficiently improve the wettability of the desired region on the surface of the precursor layer as compared with the photocatalyst-containing layer containing the binder.

  The selective exposure of the surface of the precursor layer using a photomask having a photocatalyst-containing layer is performed using a light source that can photoexcite the photocatalyst. For example, since the anatase-type titanium oxide has an excitation wavelength of 380 nm or less, when the photocatalyst contained in the photocatalyst-containing layer is anatase-type titanium oxide, the precursor layer surface is selectively exposed using a light source that emits ultraviolet rays. It is necessary. Specific examples of the light source that emits ultraviolet light include a mercury lamp, a metal halide lamp, a xenon lamp, an excimer lamp, an excimer laser, a YAG laser, and the like.

Here, the reason why the wettability of the surface of the precursor layer becomes relatively high by exposure will be briefly described by taking the case where the precursor layer is made of fluorine-based silicone as an example. In this case, the wettability is low because the surface of the precursor layer before exposure is covered with CF ₃ groups. That is, the surface of the precursor layer at this stage is a water-repellent region throughout. When the surface of the precursor layer is selectively exposed using a photomask having a photocatalyst-containing layer, a hydroxyl group (OH group) is generated in the exposure light irradiation region by the action of the photocatalyst, and this hydroxyl group becomes CF _{3 on the} precursor layer surface. It is considered that the bonding is performed instead of the group, and only the region of the surface of the precursor layer is exposed to change into the hydrophilic region. Although the mechanism of action of the photocatalyst is not always clear, the carrier generated by light irradiation reacts directly with nearby compounds, or depending on the active oxygen species generated in the presence of oxygen and water, It is thought to change the chemical structure.

  By performing exposure through a photomask having a photocatalyst-containing layer, the wettability change reaction on the surface of the precursor layer is greatly accelerated as compared with exposure through a photomask not having a photocatalyst-containing layer. Therefore, the wettability change reaction can be completed with a short exposure. In a relatively short time, the precursor layer can be the wettability changing layer 5.

  In addition, the size of the wettability changing layer 5 in plan view can be the same as the size of the porous semiconductor electrode 7 in plan view, and as shown in FIG. It can also be larger than the size in plan view. In any case, the size of the precursor layer that is the basis of the wettability changing layer 5 is set to be equal to or larger than the size of the target wettability changing layer 5 in plan view. When the size of the precursor layer in plan view is larger than the target wettability changing layer 5, for example, after performing the porous semiconductor electrode forming step described later, the plan view of the porous semiconductor electrode 27 is shown. It is preferable to perform a non-exposed portion removing step of removing a wettability changing layer (a portion of the wettability changing layer that has not been exposed in the selective exposure step) located outside the formation region.

  The method for removing the unnecessary portion of the wettability changing layer can be appropriately selected according to the material of the wettability changing layer. For example, when the material of the wettability changing layer is silicone, unnecessary portions are selectively etched away using an alkaline developer or the like. By removing unnecessary portions of the wettability changing layer, the wettability changing layer 5 having a desired shape can be obtained.

(4) Porous semiconductor electrode The porous semiconductor electrode 7 is for receiving carriers (electrons) from the photoexcited dye 9 or for transmitting carriers (holes) to the photoexcited dye 9. . The porous semiconductor electrode 7 can be a single component layer or a mixture layer. Furthermore, it can also be set as the laminated body of a some porous semiconductor film. The conductivity type of the porous semiconductor electrode 7 is usually N-type.

  Examples of the material of the porous semiconductor electrode 7 include titanium oxide, zinc oxide, tin oxide, indium tin oxide, zirconium oxide, silicon oxide, magnesium oxide, aluminum oxide, cesium oxide, bismuth oxide, manganese oxide, yttrium oxide, and oxide. Fine particles of a metal oxide semiconductor such as tungsten, tantalum oxide, niobium oxide, or lanthanum oxide can be used. These metal oxide semiconductor fine particles are suitable for forming a porous semiconductor electrode, and are preferable because they can improve the energy conversion efficiency of the dye-sensitized solar cell and reduce the cost. Considering the durability of the dye-sensitized solar cell using the electrode substrate 20 and the safety and economy when manufacturing the electrode substrate 20, titanium oxide fine particles are preferable as the material of the porous semiconductor electrode 7, In particular, anatase type titanium oxide fine particles are preferable. The “semiconductor fine particles” referred to in the present invention include not only fine-particle-shaped semiconductors but also amorphous micro-semiconductors and fine-powder semiconductors.

  From the viewpoint of increasing the photoelectric conversion efficiency of the dye-sensitized solar cell, it is preferable to make the porous semiconductor electrode 7 a mesoscopic porous material that exhibits a quantum size effect. In FIG. 1, the porous semiconductor electrode 7 is depicted as a porous body formed by a large number of semiconductor fine particles 7a.

  In manufacturing the electrode substrate 20, following the selective exposure step described above, a semiconductor electrode containing a large number of semiconductor fine particles on the surface of the wettability changing layer 5 selectively exposed in the selective exposure step. A porous semiconductor electrode forming step is performed in which a coating film is formed by the forming coating solution, and the coating film is dried to obtain the porous semiconductor electrode 7.

  The porous semiconductor electrode 7 can be formed by, for example, a sol-gel method. However, when the sol-gel method is used, a sintering process at a relatively high temperature is required. If it is low, it is not suitable. If the above-described coating solution for forming a semiconductor electrode is used, the porous semiconductor electrode 7 can be formed even if the heat resistance of the transparent substrate 1 is relatively low.

  If necessary, the coating liquid for forming a semiconductor electrode can contain fine particles that function as a light scattering center (not shown) in the porous semiconductor electrode 7. By incorporating these fine particles into the porous semiconductor electrode 7, the amount of light contributing to the photoexcitation of the dye 9 can be increased, and as a result, the photoelectric conversion efficiency of the dye-sensitized solar cell can be improved. Specific examples of the fine particles functioning as the light scattering center include titanium oxide fine particles having a particle diameter of approximately 50 to 200 nm.

  The above-mentioned coating solution for forming a semiconductor electrode is, for example, (i) a method in which semiconductor fine particles are precipitated as crystallized fine particles in a predetermined solvent to form a sol solution, or (ii) the semiconductor fine particles are ball mill, sand mill, roll mill, etc. It can be prepared by a method of mixing with an appropriate dispersion medium and dispersing it in a dispersion medium using a known dispersing machine such as a kneader, a homogenizer, or a planetary mixer. In preparing the coating solution for forming a semiconductor electrode by the method (ii) above, if the semiconductor fine particles to be used are agglomerated, an appropriate time in the process until obtaining the dispersion, for example, before mixing with the dispersion medium Alternatively, it is preferable to loosen the agglomerated semiconductor fine particles in the process of mixing with the dispersion medium or after mixing with the dispersion medium. The coating solution for forming a semiconductor electrode can also be prepared by mixing the sol solution (i) and the dispersion liquid (ii).

  When the heat resistance of the transparent substrate 1 is relatively low, examples of the dispersion medium in the coating solution for forming a semiconductor electrode include (a) a chlorine-based dispersion medium such as chloroform, methylene chloride, dichloroethane, and (b) tetrahydrofuran. Ether-based dispersion media, (c) aromatic hydrocarbon-based dispersion media such as toluene and xylene, (d) ketone-based dispersion media such as acetone and methyl ethyl ketone, (e) esters such as ethyl acetate, butyl acetate, and ethyl cellosolve acetate (F) alcohol dispersion media such as isopropyl alcohol (IPA), ethyl alcohol, methyl alcohol, butyl alcohol, etc. (g) other (N-methyl-2-pyrrolidone, pure water, etc.) Is preferred. When the below-described binder is contained in the semiconductor electrode forming coating liquid, a dispersion medium capable of dissolving the binder is used.

  In order to improve the adhesion between the porous semiconductor electrode 7 and the wettability changing layer 5 and the mechanical strength of the porous semiconductor electrode 7 itself, the coating solution for forming the semiconductor electrode contains a binder made of a polymer material. Can be dissolved. For example, a cellulose resin, a polyester resin, a polyamide resin, a polyacrylate resin, a polycarbonate resin, a polyurethane resin, a polyolefin resin, a polyvinyl acetal resin, a fluorine resin, a polyimide resin, or a polyethylene glycol Such polyhydric alcohols can be used as a binder. The content of the binder in the coating solution for forming a semiconductor electrode is preferably as small as possible. Specifically, the ratio of the binder to the total solid content contained in the coating solution for forming a semiconductor electrode is preferably 0.5% by mass or less, and more preferably 0.2% by mass or less.

  In addition, various additives can be contained in the coating solution for forming a semiconductor electrode in order to improve the coating suitability. As this additive, for example, a surfactant, a viscosity adjusting agent, a dispersion aid, a pH adjusting agent and the like can be used. For example, nitric acid, hydrochloric acid, acetic acid, dimethylformamide, ammonia or the like can be used as a pH adjuster.

From the viewpoint of controlling the formation position of the coating film as accurately as possible and forming the porous semiconductor electrode 7 having a desired film thickness by one coating, the viscosity of the coating solution for forming a semiconductor electrode is described in, for example, JIS Z8803. More preferably, the viscosity is approximately 1 × 10 ^{−5 to} 100 N · s / m ² , more preferably approximately 1 × 10 ^{−4 to} 10 N. -It is desirable to adjust so that it may become in the range of s / m < ² >.

  Coating of coating solution for semiconductor electrode formation is electric field jet method, ink jet, die coating, gravure coating, gravure reverse coating, roll coating, reverse roll coating, bar coating, blade coating, knife coating, air knife coating, slot die coating, slide die coating. , Dip coating, micro bar coating, micro bar reverse coating, screen printing (rotary method), spray coating, and the like. From the viewpoint of forming a coating film of the coating solution for forming a semiconductor electrode only in a necessary portion as much as possible, it is preferable to apply the coating solution for forming a semiconductor electrode by an electric field jet method or an inkjet method.

  A region of the surface of the wettability changing layer 5 where the porous semiconductor electrode 7 is to be formed is a region (hydrophilic region) that is selectively exposed and relatively wettable as described above. . Therefore, when the coating solution for forming a semiconductor electrode is applied onto the wettability changing layer 5 by the above method, a coating film is generally formed only on a region (hydrophilic region) where the porous semiconductor electrode 7 is to be formed. The By setting the viscosity of the coating solution for forming a semiconductor electrode within the above range, it is possible to form a coating film on the desired region more accurately and to form a coating film having a relatively high shape retention ability. it can.

  Thereafter, the porous semiconductor electrode 7 can be obtained by drying the coating film. It is necessary to dry the coating film at a temperature lower than the heat resistant temperature of the transparent substrate 1. Specifically, it is preferable to heat and dry within a temperature range of approximately 100 ° C. or more and not more than the heat resistant temperature of the transparent substrate 1.

  In addition, when the heat resistance of the transparent base material 1 is comparatively high, the porous semiconductor electrode 7 can also be obtained by baking or sintering a coating film at about 400-600 degreeC. In this case, the portion of the wettability changing layer 5 that has not been exposed in the selective exposure step (the surface that has not been exposed and its lower portion) is thermally decomposed and removed during firing or sintering.

(5) Dye Dye 9 is for sensitizing porous semiconductor electrode 7. As this dye 9, (A) the absorption wavelength region extends to a longer wavelength side than the absorption wavelength region of the porous semiconductor electrode 7, and (B) the porous semiconductor electrode 7 is an N-type semiconductor. In the case where the energy level of electrons when photoexcited is higher than the position of the conduction band edge of the porous semiconductor electrode 7, (C) when the porous semiconductor electrode 7 is an N-type semiconductor, It is preferable that the time required to inject carriers (electrons) into the semiconductor electrode 7 is shorter than the time required to recapture carriers (electrons) from the porous semiconductor electrode 7.

  For example, when the porous semiconductor electrode 7 is formed of anatase-type titanium oxide, it is preferable to use a ruthenium complex represented by the following formula (I) as the dye 9.

  From the viewpoint of obtaining a dye-sensitized solar cell with high photoelectric conversion efficiency using the electrode substrate 20, among the ruthenium complexes represented by the above formula (I), X is NCS (thiocyanate) (cis-di). It is particularly preferred to use (thiocyanate) -N, N′-bis (2,2′-bipyridyl-4,4′-dicarboxylic acid) ruthenium (II).

  Of course, metal complex dyes other than the ruthenium complex described above and organic dyes can also be used. Specific examples of the organic dye include acridine dyes, azo dyes, indigo dyes, quinone dyes, coumarin dyes, merocyanine dyes, and phenylxanthene dyes. Of these organic dyes, coumarin dyes are preferable.

  In manufacturing the electrode substrate 20, subsequent to the porous semiconductor electrode forming step described above, a dye supporting step of supporting the above-described dye 9 on the surface of the semiconductor fine particles 7 a forming the porous semiconductor electrode 7 is performed. From the viewpoint of obtaining a dye-sensitized solar cell with high photoelectric conversion efficiency, it is preferable to support the dye 9 on as many semiconductor fine particles 7a as possible, and in particular, each of the semiconductor fine particles 7a forming the porous semiconductor electrode 7. It is preferable to support the dye 9 on the surface.

  For this purpose, it is preferable to support the dye 9 on the porous semiconductor electrode 7 by a method capable of adsorbing the dye 9 to the inner surface of the pores of the porous semiconductor electrode 7. For example, (A) a dye solution (hereinafter referred to as “dye-supporting coating solution”) is prepared, and the transparent substrate 1 formed up to each porous semiconductor electrode 7 is immersed in the dye-supporting coating solution. Then, a method of drying, or (B) a method of contacting and infiltrating each porous semiconductor electrode 7 by a method such as coating, spraying or spraying of a dye-supporting coating solution, and then drying, etc. According to the above, it is possible to adsorb the dye 9 up to the inner surfaces of the pores of the respective porous semiconductor electrodes 7 and to support the dye 9 on the surface of each of the semiconductor fine particles 7a.

  The dye-supporting coating liquid is prepared by appropriately selecting either an aqueous solvent or an organic solvent according to the type of the dye used. As necessary, the transparent substrate 1 formed up to each porous semiconductor electrode 7 is immersed in the dye-supporting coating liquid, or the coating of the dye-supporting coating liquid on each porous semiconductor electrode 7 is sprayed. Or spraying etc. can be performed in multiple times. When the immersion, coating, spraying, or spraying is performed in a plurality of times, drying of the coating solution that has adhered to and penetrated each porous semiconductor electrode 7 completes the required number of times of immersion, coating, spraying, or spraying. It is preferable to carry out at the end without performing until. Moreover, when performing the said immersion, application | coating, spraying, or spraying in multiple steps, the pigment | dye density | concentration in the pigment | dye supporting coating liquid, the liquid temperature of a coating liquid, etc. can be changed suitably on the way.

  In order to obtain a dye-sensitized solar cell with high photoelectric conversion efficiency, it is preferable to support the dye 9 on the semiconductor fine particles 7a in a monomolecular film state. For that purpose, an extra dye supported on the semiconductor fine particles 7a 9 is preferably removed by washing with a solvent that can be used for the preparation of the dye-carrying coating solution. When the immersion, coating, spraying, or spraying is performed in a plurality of times, excess dye 9 can be removed by washing at a desired time, but it is preferable to perform it every time.

  By subjecting each porous semiconductor electrode 7 to surface treatment in advance, it is possible to increase the moving speed of carriers (electrons) from the dye 9 to the porous semiconductor electrode 7. After the dye 9 is supported on each porous semiconductor electrode 7, the porous semiconductor electrode 7 and the dye 9 are subjected to a predetermined treatment, for example, the porous semiconductor electrode 7 is formed of titanium oxide, and the dye 9 is made of the ruthenium complex described above. In some cases, it is possible to improve the photoelectric conversion efficiency of the dye-sensitized solar cell using the electrode substrate 20 by performing a treatment with a base such as t-butylpyridine.

(6) Lead wire and protective layer The lead wire 11 is for collecting the electrons moved from the porous semiconductor electrode 7 to the transparent electrode 3 and outputting them in parallel electrically. 7 are arranged in the vicinity of the corresponding porous semiconductor electrode 7 so as to correspond one by one. Each lead wire 11 extends in a direction substantially parallel to the extending direction of the corresponding porous semiconductor electrode 7.

  These lead wires 11 are single metals or alloys having higher conductivity than the transparent electrode 3, such as copper (Cu), iron (Fe), nickel (Ni), chromium (Cr), aluminum (Al), gold (Au ), Silver (Ag), stainless steel, titanium (Ti), molybdenum (Mo), etc. Among these metals or alloys, copper, nickel, stainless steel, titanium, etc., which are highly conductive materials, can be used. It is preferable to form by using. From the viewpoint of reducing the manufacturing cost of the electrode substrate 20, it is preferable to use copper, nickel, and stainless steel, which are inexpensive conductive materials.

  Each lead wire 11 is formed, for example, on a transparent electrode 3 by forming a large vapor-deposited film (meaning a film formed by physical vapor deposition or chemical vapor deposition (CVD)). The deposited film is etched into a desired shape using, for example, an etching mask formed by a photolithography method, or the deposited film is formed by physical vapor deposition or chemical vapor deposition using a mask having a predetermined shape. It can be formed by forming a film. The formation of each lead wire 11 can be performed at any time before and after the wettability changing layer forming step described above, but it is preferable that the lead wire 11 be formed before the wettability changing layer forming step. 11 is easy to form.

  On the other hand, the protective layer 13 is for protecting the lead wire 11 from the electrolyte when a dye-sensitized solar cell is produced using the electrode substrate 20. Therefore, the protective layer 13 includes, for example, (i) nitrides such as silicon nitride and aluminum nitride, (ii) nickel (Ni), zinc (Zn), gold (Au), platinum (Pt), chromium (Cr), Aluminum (Al), Cadmium (Cd), Tungsten (W), Tin (Sn), Cobalt (Co), Iron (Fe), Titanium (Ti), Manganese (Mn), Zirconium (Zr), Molybdenum (Mo), etc. (Iii) a material having corrosion resistance to the electrolyte, such as an alloy composed of two or more of the above-mentioned single metals.

  The protective layer 13 is formed by, for example, forming a large vapor-deposited film isotropically so as to cover each lead wire 11 and anisotropically using an etching mask formed by, for example, a photolithography method. Or a vapor deposition film of a desired material is formed on the outer surface (upper surface and each side surface) of each lead wire 11 by physical vapor deposition or chemical vapor deposition using a mask having a predetermined shape. Thus, it can be formed. Furthermore, it can be formed by electroplating, electroless plating, or chemical conversion treatment. If necessary, the protective layer 13 can be subjected to a surface treatment such as a chromate treatment. When the protective layer 13 is formed by electroless plating, a plating layer is also formed at a place other than the outer surface of the lead wire 11, so that the plating formed at an unnecessary place by a method such as etching or lift-off. Remove the layer.

  In order to protect the lead wire 11 from the electrolyte of the dye-sensitized solar cell, it is preferable to make the protective layer 13 as dense as possible. Even when the heat resistance of the transparent substrate 1 is relatively low, a relatively dense protective layer 13 can be obtained by forming the protective layer 13 by electroplating, electroless plating, or chemical conversion treatment.

  The protective layer 13 can be formed at any time before and after the wettability changing layer forming step described above. However, the protective layer 13 is preferably formed before the wettability changing layer forming step. Is easy to form.

(7) Arbitrary member A gas barrier layer, an auxiliary electrode, etc. can be formed in the electrode substrate 20 as needed. Hereinafter, these optional members will be described.

(A) Gas barrier layer The gas barrier layer is formed by allowing oxygen or moisture to enter the dye-sensitized solar cell through the electrode substrate 20 when the dye-sensitized solar cell is manufactured using the electrode substrate 20, and the dye This is for preventing the electrolyte used in the sensitized solar cell from evaporating to the outside through the electrode substrate 20, and is provided between the transparent substrate 1 and the transparent electrode 3 or the back surface of the transparent substrate 1 (transparent It means a surface opposite to the surface on which the electrode 3 is formed.

The oxygen permeability of the gas barrier layer is preferably about 1 cc / m ² / day · atm (about 10 ml / m ² / day / MPa) or less, and the water vapor permeability is about 1 g / m ² / day or less. It is preferable. Such a gas barrier layer can be formed by a deposited film or film of a desired organic material, or by a deposited film of a desired inorganic material.

  By preventing oxygen from entering the dye-sensitized solar cell, deterioration of the dye 9 and the electrolyte is suppressed, so that a decrease in the performance of the dye-sensitized solar cell over time can be suppressed. In addition, by suppressing the intrusion of moisture, for example, even when the transparent electrode 3 is formed of a material that is relatively easily deteriorated by moisture, such as ITO, the deterioration of its performance over time is suppressed. A decrease in battery performance over time can be suppressed.

(B) Auxiliary electrode The auxiliary electrode is for increasing the conductivity of the electrode substrate 20 and is provided between the transparent substrate 1 and the transparent electrode 3 so as to be in contact with the transparent electrode 3. As a material for the auxiliary electrode, various metals or alloys having higher conductivity than the transparent electrode 3 can be used. The shape of the auxiliary electrode in plan view is preferably a shape in which a large number of fine lines are combined, such as a lattice shape, a mesh shape, or a parallel stripe shape, from the viewpoint of suppressing a decrease in the amount of light incident on the dye 9 as much as possible. .

  Such an auxiliary electrode is formed by, for example, providing a large vapor-deposited film on the transparent substrate 1 or the gas barrier layer, and etching the vapor-deposited film into a desired shape using an etching mask formed by, for example, a photolithography method. Or by forming a vapor deposition film of a desired material on the transparent substrate 1 or the gas barrier layer by physical vapor deposition or chemical vapor deposition using a mask having a predetermined shape. Can do. Furthermore, a desired metal foil is bonded onto the transparent substrate 1 or the above gas barrier layer using an adhesive, and the metal foil is etched into a desired shape using an etching mask formed by, for example, a photolithography method. Can also be formed.

(C) Corrosion prevention layer The corrosion prevention layer is for preventing the auxiliary electrode from being corroded by the electrolyte of the dye-sensitized solar cell when the above-mentioned auxiliary electrode is provided. Similarly to the layer 13, it is formed so as to cover at least the outer surface of the auxiliary electrode. If necessary, a corrosion prevention layer can also be formed on a region of the surface of the layer serving as the base of the auxiliary electrode that is not covered by the auxiliary electrode.

  Since the electrode substrate 20 described above is one of the electrode substrates for dye-sensitized solar cells of the present invention described above, it has been described in the description of the electrode substrate for dye-sensitized solar cells of the present invention. Has a technical effect.

<Dye-sensitized solar cell electrode substrate and manufacturing method thereof (second embodiment)>
FIG. 2 is a schematic view showing another basic cross-sectional structure of the electrode substrate for a dye-sensitized solar cell of the present invention. The illustrated dye-sensitized solar cell electrode substrate 30 (hereinafter referred to as “electrode substrate 30”) is used to obtain a dye-sensitized solar cell in which a plurality of cells are electrically connected in series. It is something that can be done.

  This electrode substrate 30 has (1) a point in which a plurality of transparent electrodes 23 are formed on one side of the transparent base material 21, and (2) a wettability change layer 25 is formed on each transparent electrode 23 one by one, In addition, a region 23a where the wettability changing layer 25 is not formed is present at a predetermined edge of the upper surface of each transparent electrode 23, and (3) the lead wire 11 and the protective layer 13 are formed. This is different from the electrode substrate 20 of the first embodiment described above.

  Since the other configuration except for the differences (1) to (3) is the same as the configuration of the electrode substrate 20, among the members shown in FIG. 2, the members shown in FIG. About the thing, the reference code which added 20 to the numerical value of the reference code used in FIG. 1 is attached | subjected, and the description is abbreviate | omitted.

  The electrode substrate 30 can be manufactured in the same manner as the electrode substrate 20 except that the plurality of transparent electrodes 23 are formed on the transparent base material 21 and the lead wires 11 and the protective layer 13 are not formed.

  The plurality of transparent electrodes 23 are formed, for example, by forming a large vapor-deposited film with a desired material on one surface of the transparent substrate 21, and etching the vapor-deposited film into a desired shape using an etching mask formed by, for example, a photolithography method. Or by forming a vapor deposition film of a desired material on one surface of the transparent substrate 21 by physical vapor deposition or chemical vapor deposition using a mask having a predetermined shape.

  In order to obtain a dye-sensitized solar cell in which a plurality of cells are electrically connected in series, it is necessary to electrically connect adjacent cells by wiring. There is a region 23a in which the property change layer 25 is not formed.

  The region 23a is formed by not forming the wettability changing layer 25 on the region 23a from the beginning, or after forming a large wettability changing layer that covers the region 23a, in the wettability changing layer. It can be provided by removing the region located on 23a.

  In the case where the region 23a is provided by removing the unnecessary portion after the large wettability changing layer is once formed, it has been described in the description of the dye-sensitized solar cell electrode substrate 20 of the first embodiment. After performing the porous semiconductor electrode forming step, the wettability changing layer located outside the formation region of the porous semiconductor electrode 27 in plan view, that is, the portion of the wettability changing layer that has not been exposed in the selective exposure step It is preferable to perform a non-exposed portion removing step for removing the film.

  A method for removing an unnecessary portion of the wettability changing layer can be appropriately selected according to the material of the wettability changing layer. For example, when the material of the wettability changing layer is silicone, unnecessary portions are selectively etched away using an alkaline developer or the like. By removing unnecessary portions of the wettability changing layer, the wettability changing layer 25 having a desired shape can be obtained, and the region 23 a can be provided in the transparent electrode 23.

  Since the electrode substrate 30 described above is also a kind of the electrode substrate for the dye-sensitized solar cell of the present invention, like the electrode substrate 20 of the first embodiment, the electrode for the dye-sensitized solar cell of the present invention is used. The technical effects described in the description of the substrate are obtained.

  In the electrode substrate 20 of the first form and the electrode substrate 30 of the second form described above, only one porous semiconductor electrode 7, 27 is formed on one wettability changing layer 5, 25. It is also possible to obtain a dye-sensitized solar cell electrode substrate by forming a plurality of porous semiconductor electrodes on two wettability changing layers.

<Dye-sensitized solar cell (first embodiment)>
FIG. 3 is a schematic view showing the basic principle of the dye-sensitized solar cell of the present invention. In the illustrated dye-sensitized solar cell 100, the electrode substrate 20 of the first form described above is used as the first electrode substrate, and one first conductive film 44 and a plurality of second conductive materials are provided on one side of the transparent base material 42. A dye-sensitized solar cell electrode substrate 50 (hereinafter referred to as “electrode substrate 50”) in which each 46 is formed is used as the second electrode substrate.

  Since the configuration of the electrode substrate 20 has already been described, the description thereof is omitted here. Moreover, as the transparent base material 42 and the 1st electrically conductive film 44 in the electrode substrate 50, since the same thing as the transparent base material 1 or the transparent electrode 3 in the electrode substrate 20 mentioned above can be used, respectively, these transparent base materials are used. The description of the material 42 and the first conductive film 44 is also omitted here.

  Each second conductive film 46 formed on the first conductive film 44 is for improving the conductivity of the electrode substrate 50, and one second conductive film is formed on one porous semiconductor electrode 7 on the electrode substrate 20. The films 46 are arranged in parallel on the first conductive film 44 so as to correspond. One porous semiconductor electrode 7 and the second conductive film 46 corresponding to the porous semiconductor electrode 7 substantially overlap each other in plan view.

  The second conductive film 46 is formed by appropriately selecting a conductive material having corrosion resistance to the electrolyte according to the type of electrolyte used in the dye-sensitized solar cell using the electrode substrate 50. The material of the second conductive film 46 is most preferably platinum (Pt), but the second conductive film 46 can also be formed of carbon, a conductive polymer, or the like. From the viewpoint of obtaining a dye-sensitized solar cell with high photoelectric conversion efficiency using the electrode substrate 50, one ionic species constituting a redox pair in the electrolyte of the dye-sensitized solar cell reacts with a carrier during light irradiation. The second conductive film 46 is preferably formed of a metal (for example, platinum (Pt)) that can function as a catalyst when generating the other ionic species.

  Each of the second conductive films 46 is formed by, for example, providing a large deposited film on the first conductive film 44 and etching the deposited film into a desired shape using an etching mask formed by, for example, a photolithography method, or A vapor deposition film of a desired material can be formed on the first conductive film 44 by physical vapor deposition or chemical vapor deposition using a mask having a desired shape. The film thickness of the second conductive film 46 can be appropriately selected within a range of approximately 1 to 500 nm. From the viewpoint of suppressing the manufacturing cost of the electrode substrate 50, it is preferable to form each second conductive film 46 by a sputtering method using a mask having a desired shape.

  The electrode substrate 20 and the electrode substrate 50 are disposed so that the porous semiconductor electrode 7 in the electrode substrate 20 and the second conductive film 46 in the electrode substrate 50 face each other. A plurality of spacers 48 are disposed between the adjacent porous semiconductor electrodes 7 and between the adjacent second conductive films 46. The lead wire 11 and the protective layer 11 are covered with a spacer 48. An electrolyte layer 90 is interposed between each porous semiconductor electrode 7 and the second conductive film 46 corresponding to the porous semiconductor electrode 7. Although not shown, in the dye-sensitized solar cell 100, the periphery of the electrode substrates 20 and 50 is sealed with a sealing agent in order to prevent the electrolyte forming the electrolyte layer 90 from leaking out. Sealed.

  Each spacer 48 is formed of a material having corrosion resistance with respect to the electrolyte, such as glass or resin, for example, and maintains a distance between the electrode substrates 20 and 50 at a predetermined distance to prevent a short circuit. The individual spacers 48 can be formed in advance on one of the electrode substrates 20 and 50, or are used by being fixed to at least one of the electrode substrates 20 and 50 when the dye-sensitized solar cell 100 is assembled. You can also. The spacer 48 can also serve as a sealant.

  The electrolyte layer 90 is located between the electrode substrate 10 and the electrode substrate 20 and is reduced by the photoexcited dye 9, while being oxidized by carriers (electrons) supplied via the electrode substrate 20, A closed circuit including the substrate 10 and the electrode substrate 20 can be formed.

  As the material of the electrolyte layer 90, various electrolytes used in a dye-sensitized solar cell containing at least a redox pair contributing to carrier transport can be used, and the form thereof is liquid, solid, and It may be any gel. From the viewpoint of improving the durability and stability of the dye-sensitized solar cell 100, it is preferable to use a room temperature molten salt electrolyte or a gel electrolyte.

The redox couple is not particularly limited as long as it is used for an electrolyte. Examples of the combination of raw materials include a combination of iodine and iodide, or a combination of bromine and bromide. It is done. For example, specific examples of combinations of iodine and iodide include metal iodides such as lithium iodide (LiI), sodium iodide (NaI), potassium iodide (KI), calcium iodide (CaI ₂ ), and iodine. A combination with (I ₂ ) can be mentioned. Specific examples of combinations of bromine and bromide include lithium bromide (LiBr), sodium bromide (NaBr), potassium bromide (KBr), calcium bromide (CaBr ₂ ), and the like, and bromide (Br). ₂ ) and a combination thereof.

  When a gel electrolyte is used as the material of the electrolyte layer 90, the electrolyte may be a physical gel or a chemical gel. A physical gel is gelled near room temperature due to physical interaction, and a chemical gel is a gel formed by a chemical bond such as a crosslinking reaction. The physical gel can be prepared by using a gelling agent such as polyacrylonitrile or polymethacrylate, and as the chemical gel, an acrylic ester-based or methacrylic ester-based one can be used.

  When a solid electrolyte is used as the material of the electrolyte layer 90, it is preferable to use a conductive polymer having a high hole transporting property such as copper iodide (CuI), polypyrrole, or polythiophene as the electrolyte.

  Although the thickness of the electrolyte layer 90 can be selected as appropriate, the total thickness of the electrolyte layer 90 and the porous semiconductor electrode 7 corresponding to the electrolyte layer 90 is within a range of approximately 2 μm to 100 μm, and of these, approximately 2 μm. It is preferable to select the thickness of the electrolyte layer 90 so as to be in the range of ˜50 μm. If the thickness of the electrolyte layer 90 is thinner than the above range, the porous semiconductor electrode 7 and the second conductive film 46 are likely to come into contact with each other, causing a short circuit. Moreover, when the thickness of the electrolyte layer 90 is thicker than the above range, the internal resistance of the dye-sensitized solar cell 100 increases, and the performance of the dye-sensitized solar cell 100 decreases.

  The electrolyte layer 90 described above can be formed by various methods depending on the material. As a specific example of the method for forming the electrolyte layer 90, a method for forming the electrolyte layer 90 by applying an electrolyte layer forming coating solution so as to cover the porous semiconductor electrode 7 and drying it (hereinafter referred to as “coating method”). Or the electrode substrates 20 and 50 are arranged so that the porous semiconductor electrode 7 and the second conductive film 46 have a predetermined distance, and the electrode substrate 20 and the electrode substrate 50 are separated from each other. Examples thereof include a method of forming the electrolyte layer 90 by injecting a coating solution for forming an electrolyte layer into the gap (hereinafter sometimes referred to as “injection method”). Hereinafter, these “coating method” and “injection method” will be described.

(I) Coating Method The coating method is a method mainly used for forming the solid electrolyte layer 90, and at least a redox pair and this redox pair are used as the coating liquid for forming the electrolyte layer used in this coating method. It is preferable to contain a polymer that holds Moreover, it is preferable that a crosslinking agent, a photopolymerization initiator, and the like are added to the electrolyte layer forming coating solution.

  The coating solution for forming the electrolyte layer can be applied by die coating, gravure coating, gravure reverse coating, roll coating, reverse roll coating, bar coating, blade coating, knife coating, air knife coating, slot die coating, slide die coating, dip coating, and micro bar. It can be performed by various methods such as coating, microbar reverse coating, and screen printing (rotary method).

  When the above-mentioned photopolymerization initiator is contained in the electrolyte layer forming coating solution, the electrolyte layer 90 is formed by exposing the photopolymerization initiator to light after applying this electrolyte layer forming coating solution. Can do.

(II) Injection Method The injection method is a method used for forming a liquid, gel, or solid electrolyte layer. When the electrolyte layer 90 is formed by this method, the spacer 48 described above is used. It is preferable to hold the electrode substrate 20 and the electrode substrate 50 at a desired interval in advance. Injection | pouring of the coating liquid for electrolyte layer formation can be performed using a capillary phenomenon, for example. In the case of forming a gel-like or solid electrolyte layer 90, a two-dimensional or three-dimensional crosslinking reaction is performed by, for example, performing temperature adjustment, ultraviolet irradiation, electron beam irradiation, etc. after injecting the electrolyte layer forming coating solution. Give rise to

  In the dye-sensitized solar cell 100 having the above-described configuration, one porous semiconductor electrode 7, one dye 9 corresponding to the porous semiconductor electrode 7, the electrolyte layer 90, and the second conductive film 46 are provided. Configure the cell. The transparent electrode 3 and the first conductive film 44 correspond to all cells.

  Although not shown in FIG. 3, the lead wires 11 are connected in series to a load (external load) in a state of being connected in parallel to each other, and the second conductive films 46 are also connected in parallel to each other. Connected in series to the load. Carriers (electrons) generated in each cell by photoelectric conversion are collected by the transparent electrode 3 and then taken out from the transparent electrode 3 in parallel by the lead wires 11.

  Since the dye-sensitized solar cell 100 described above is one of the dye-sensitized solar cells of the present invention described above, the technical description described in the description of the dye-sensitized solar cell of the present invention is provided. There is an effect.

<Dye-sensitized solar cell (second form)>
FIG. 4 is a schematic view showing another basic principle of the dye-sensitized solar cell of the present invention. In the illustrated dye-sensitized solar cell 110, (1) a dye-sensitized solar cell electrode substrate 60 (hereinafter referred to as "electrode substrate 60") is used as the second electrode substrate; 2) It differs greatly from the dye-sensitized solar cell 100 of the first embodiment described above in that the electrolyte layer 90 is interposed between the electrode substrate 20 and the electrode substrate 60 without being divided by the plurality of spacers 48. Since the other configuration is the same as the configuration of the dye-sensitized solar cell 100, the description of the common configuration is omitted here.

  In the electrode substrate 60 used as the second electrode substrate, one first conductive film 54, a plurality of second conductive films 56, and a plurality of lead wires 58 are formed on one surface of the transparent base 52, and each lead wire 58 is formed. Is covered with a protective layer 59.

  The transparent substrate 52 and the first conductive film 54 can be formed in the same manner as the transparent substrate 42 or the transparent electrode 44 in the dye-sensitized solar cell 100 of the first embodiment, respectively. Each of the second conductive films 56 can also be formed using the same material as that of the second conductive film 46 in the dye-sensitized solar cell 100 of the first embodiment, but these second conductive films 56 are adjacent to each other. The two porous semiconductor electrodes 7 are arranged in parallel on the first conductive film 54 so as to correspond to each other. Each of the second conductive films 56 covers a gap between the two porous semiconductor electrodes 7 corresponding to the second conductive film 56 in a plan view, and each of the corresponding two porous semiconductor electrodes 7 has a plan view. Overlap partially.

  Each lead wire 58 is for supplying carriers (electrons) to the first conductive film 54, and corresponds to one second conductive film 56 one by one so that the corresponding second conductive film 56 Located in the vicinity. Each lead wire 58 extends in a direction substantially parallel to the extending direction of the corresponding second conductive film 56. These lead wires 58 can be formed in the same manner as the lead wires 11 in the dye-sensitized solar cell 100 of the first embodiment.

  The protective layer 59 covering the lead wire 58 is for protecting the lead wire 58 from the electrolyte, and can be formed in the same manner as the protective layer 11 in the dye-sensitized solar cell 100 of the first embodiment. it can.

  In the dye-sensitized solar cell 110 having the above-described configuration, one second conductive film 56, two porous semiconductor electrodes 7 corresponding to the second conductive film 56, and the two porous semiconductor electrodes 7 respectively. The dye 9 supported on the surface of each constitutes one cell. The transparent electrode 3, the first conductive film 54, and the electrolyte layer 90 correspond to all cells.

  Although not shown in FIG. 4, each lead wire 11 is connected in series to a load (external load) in a state of being connected in parallel to each other, and each lead wire 58 is also connected to the load in a state of being connected in parallel to each other. Connected in series. Carriers (electrons) generated in each cell by photoelectric conversion are collected by the transparent electrode 3 and then taken out from the transparent electrode 3 in parallel by the lead wires 11.

  Since the dye-sensitized solar cell 110 described above is a kind of the dye-sensitized solar cell of the present invention, like the dye-sensitized solar cell 100 of the first embodiment described above, the dye-sensitized solar cell of the present invention. The technical effect described in the description of the solar cell is obtained.

<Dye-sensitized solar cell (third embodiment)>
FIG. 5 is a schematic view showing still another basic principle of the dye-sensitized solar cell of the present invention. In the illustrated dye-sensitized solar cell 120, the electrode substrate 30 of the second form described above is used as the first electrode substrate, and a plurality of first conductive films 64 and a plurality of second conductors are provided on one side of the transparent base material 62. A dye-sensitized solar cell electrode substrate 70 (hereinafter, referred to as “electrode substrate 70”) formed with 66 is used as the second electrode substrate.

  Since the configuration of the electrode substrate 30 has already been described, the description thereof is omitted here. Moreover, as the transparent base material 62 in the electrode substrate 70, the 1st electrically conductive film 64, and the 2nd electrically conductive film 66, respectively, the transparent base material 42 in the dye-sensitized solar cell 100 of the 1st form mentioned above, and the 1st. A conductive film similar to the conductive film 44 or the second conductive film 46 can be used. However, a plurality of first conductive films 64 are formed in parallel on one side of the transparent substrate 62, and the second conductive film 66 is formed on each of the first conductive films 64 one by one.

  The plurality of first conductive films 64 are formed, for example, by providing a large vapor-deposited film on the transparent substrate 62 and etching the vapor-deposited film into a desired shape using, for example, an etching mask formed by photolithography. A vapor deposition film of a desired material can be formed on the transparent substrate 62 by physical vapor deposition or chemical vapor deposition using a mask having a shape. The plurality of second conductive films 66 can be formed in a similar manner.

  The electrode substrate 30 and the electrode substrate 70 are arranged so that the porous semiconductor electrode 27 in the electrode substrate 30 and the second conductive film 66 in the electrode substrate 70 face each other. In between, the spacers 68 and the wirings 69 are arranged so as to correspond to one transparent electrode 23 one by one. An electrolyte layer 90 is interposed between each porous semiconductor electrode 27 and the second conductive film 66 corresponding to the porous semiconductor electrode 27.

  One end of each spacer 68 (one end in the thickness direction of the dye-sensitized solar cell 120) is joined to the region 23a (see FIG. 2) of the corresponding transparent electrode 23, and the other end (dye sensitization) of each spacer 68. The other end in the thickness direction of the sensitive solar cell 120 is bonded to the surface of the transparent base material 62 exposed from between the corresponding second conductive film 66 and the adjacent second conductive film 66.

  Each wiring 69 has one end (one end in the thickness direction of the dye-sensitized solar cell 120) connected to the region 23a (see FIG. 2) in the corresponding transparent electrode 23, and next to the corresponding second conductive film 66. The other end (one end in the thickness direction of the dye-sensitized solar cell 120) is connected to the second conductive film 66, and one surface of the corresponding spacer 68 (opposite to the surface in contact with the porous semiconductor electrode) Side surface).

  Although not shown, in the dye-sensitized solar cell 120, the periphery of the electrode substrates 30 and 70 is sealed with a sealant in order to prevent the electrolyte forming the electrolyte layer 90 from leaking out. Sealed.

  Each spacer 68 described above can be formed, for example, in the same manner as the spacer 48 (see FIG. 3) in the dye-sensitized solar cell 100 of the first embodiment described above. Each wiring 69 is formed of a conductive material having corrosion resistance to the electrolyte. Similar to the spacer 48 described above, the spacer 68 can also serve as a sealant.

  Since the electrolyte layer 90 can be formed by the same method using the same material as the electrolyte layer 90 in the dye-sensitized solar cell 100 of the first embodiment described above, the reference numerals used in FIG. 3 are used here. The same reference numerals as those in FIG.

  In the dye-sensitized solar cell 120 having the above-described configuration, one transparent electrode 23, the porous semiconductor electrode 27 corresponding to the transparent electrode 23, the dye 29, the electrolyte layer 90, the second conductive film 66, and the first The conductive film 64 constitutes one cell. Adjacent cells are electrically connected in series by wiring 69.

  Although not shown in FIG. 5, the transparent electrode 23 in one cell located at the end of the series connection among the cells connected in series electrically is in series with the load (external load). This load is connected in series to the first conductive film 64 in one cell located at the end of the series connection among the cells electrically connected in series. Carriers (electrons) generated in each cell by photoelectric conversion are electrically extracted from each cell in series.

  Since the dye-sensitized solar cell 120 described above is one of the dye-sensitized solar cells of the present invention described above, the technical description described in the description of the dye-sensitized solar cell of the present invention is provided. There is an effect.

<Dye-sensitized solar cell (fourth embodiment)>
FIG. 6 is a schematic view showing still another basic principle of the dye-sensitized solar cell of the present invention. In the illustrated dye-sensitized solar cell 130, (1) a dye-sensitized solar cell electrode substrate 80 (hereinafter referred to as "electrode substrate 80") is used as the second electrode substrate; 2) It differs greatly from the dye-sensitized solar cell 120 of the third embodiment described above in that the wiring 69 has a structure sandwiched by two spacers 68a and 68b. Since the other configuration is the same as the configuration of the dye-sensitized solar cell 120, the description of the common configuration is omitted here.

  In the electrode substrate 80, as shown in the figure, a plurality of first conductive films 74 are formed on one surface of the transparent base material 72, and each one of the first conductive films 74 is separated from the first conductive film 74. A small second conductive film 76 is formed. As the transparent base material 72, the first conductive film 74, and the second conductive film 76, the transparent base material 62, the first conductive film 64, or the first conductive film in the dye-sensitized solar cell 120 of the third embodiment described above, respectively. The same material as the two conductive films 66 can be used.

  Each spacer 68a has one end (one end in the thickness direction of the dye-sensitized solar cell 130) joined to the region 23a (see FIG. 2) in the corresponding transparent electrode 23, and from between adjacent first conductive films 74. The other end (the other end in the thickness direction of the dye-sensitized solar cell 130) is joined to the exposed surface of the transparent base material 72, and corresponds to one porous semiconductor electrode 27 one by one. And is arranged.

  Each wiring 69 is formed on the surface of the corresponding spacer 68 a opposite to the surface in contact with the porous semiconductor electrode 27. One end of each wiring 69 (one end in the thickness direction of the dye-sensitized solar cell 130) is connected to the region 23a (see FIG. 2) in the corresponding transparent electrode 23, and the other end (the dye-sensitized solar cell 130). Is connected to the first conductive film 74 adjacent to the corresponding first conductive film 74.

  Each spacer 68b is formed on the surface of the corresponding wiring 69 opposite to the surface in contact with the spacer 68a. One end of each spacer 68b (one end in the thickness direction of the dye-sensitized solar cell 130) is on the surface of the transparent substrate 21 exposed from between the corresponding transparent electrode 23 and the adjacent transparent electrode 23. The other end (the other end in the thickness direction of the dye-sensitized solar cell 130) is joined to the first conductive film 74 adjacent to the corresponding first conductive film 74.

  In the dye-sensitized solar cell 130 having the above-described configuration, similarly to the dye-sensitized solar cell 120 of the third embodiment, one transparent electrode 23, a porous semiconductor electrode 27 corresponding to the transparent electrode 23, a dye 29, the electrolyte layer 90, the second conductive film 76, and the first conductive film 74 constitute one cell. Adjacent cells are electrically connected in series by wiring 69.

  Although not shown in FIG. 6, the transparent electrode 23 in one cell located at the end of the serial connection among the cells electrically connected in series is in series with the load (external load). This load is connected in series to the first conductive film 74 in one cell located at the end of the series connection among the respective cells electrically connected in series. Carriers (electrons) generated in each cell by photoelectric conversion are electrically extracted from each cell in series.

  The dye-sensitized solar cell 130 described above is one of the dye-sensitized solar cells of the present invention, similar to the dye-sensitized solar cell 120 of the third embodiment described above, and therefore the dye-sensitized solar cell of the present invention. The technical effect described in the description of the solar cell is obtained.

  In addition, instead of the spacer 68 and the corresponding wiring 69 shown in FIG. 5, or instead of the spacer 68a and the corresponding wiring 69 and spacer 68b shown in FIG. 6, it has corrosion resistance to the electrolyte. It is also possible to use one conductive material layer.

<Example 1>
[Production of dye-sensitized solar cell electrode substrate]
(Preparation process)
First, a 125 μm-thick PET film (A4100 manufactured by Toyobo Co., Ltd .; total light transmittance 90.9%) was prepared as a transparent substrate, and this PET film was surface-supported by a glass substrate having a thickness of 1.1 mm. The surface support of the PET film by the glass substrate is performed until the dye supporting step described later is completed.

Next, the above PET film was placed in the chamber of the ion plating apparatus, and a mask having a predetermined shape was placed on the evaporation source side surface of the PET film. Then, indium tin oxide (ITO) as a sublimation material is deposited on the PET film under the conditions of a film formation pressure of 1.5 × 10 ⁻¹ Pa, an argon gas flow rate of 18 sccm, an oxygen gas flow rate of 28 sccm, and a film formation current value of 60 A. Thus, a plurality of transparent electrodes made of an ITO film having a thickness of 150 nm were formed in a line. The size and shape of each transparent electrode in plan view is a rectangle of 8 cm × 1 cm, and the interval between adjacent transparent electrodes is 2 mm.

(Wettability change layer forming process)
First, 0.5 g of organosiloxane (TSL8113 manufactured by Toshiba Silicone), 0.3 g of fluoroalkoxysilane (MF-160E manufactured by Tochem Products) and 0.2 g of 0.1 N hydrochloric acid were mixed and stirred for 24 hours. Thus, a coating solution for forming a wettability changing layer was obtained.

  Next, this coating solution for forming a wettability changing layer was applied on each transparent electrode (ITO film) by a spin coating method to form a coating film on the entire surface of the transparent electrode. This was dried, hydrolyzed and polycondensed to obtain a transparent wettability changing layer having a thickness of 30 nm.

(Selective exposure process)
First, a photomask (ultraviolet mask) having a mask pattern in which a plurality of openings of 8 cm × 0.8 cm are formed in parallel at intervals of 4 mm is prepared, and a photocatalytic coating agent is applied so as to cover the mask pattern. Thus, a coating film was formed. The photocatalyst coating agent is prepared by mixing 15 g of ethyl alcohol, 15 g of isopropyl alcohol, and 30 g of an aqueous titanium oxide dispersion (ST-K01 manufactured by Ishihara Sangyo Co., Ltd.), and mixing and stirring for 20 minutes at a liquidity of 40 ° C. Prepared. Subsequently, said coating film was dried and the photocatalyst containing layer with a film thickness of 0.2 micrometer which covers a mask pattern was obtained.

  Next, the above-described photomask is formed so that the distance between the transparent electrode (ITO film) and the surface of the photocatalyst containing layer is 30 μm, and the photocatalyst containing layer is opposed to the wettability changing layer. It arranged on the PET film formed to the wettability change layer.

Next, using a mercury lamp as a light source, the wettability changing layer is selectively exposed under conditions of an irradiation intensity of 70 mW / cm ² and an irradiation time of 180 seconds to relatively wet the surface of the wettability changing layer. A plurality of regions (hydrophilic regions) with improved properties were formed. These hydrophilic regions correspond to a porous semiconductor electrode formation region described later in plan view.

  It was 7 degrees when the contact angle of the water droplet in each hydrophilic area | region was measured using the contact angle measuring device (Kyowa Interface Science Co., Ltd. product CA-Z). On the other hand, when the contact angle of the water droplet at the non-exposed portion in the wettability changing light was measured under the same conditions as described above, it was 118 °.

(Porous semiconductor electrode formation process)
First, as a coating solution for forming a semiconductor electrode for forming a porous semiconductor electrode, titanium oxide (TiO ₂ ) fine particles (F-6 manufactured by Showa Denko KK) having a primary particle size of 15 nm are mixed with water and polypropylene glycol monomethyl ether. A paste containing 20.5% by mass of the TiO ₂ fine particles was prepared by dispersing in a mixture of isopropyl alcohol and isopropyl alcohol using a homogenizer. The viscosity of the paste was measured with a Brookfield viscometer (manufactured by Brookfield) under the conditions of a liquid temperature of 20 ° C. and a rotation speed of 12 rpm, and was 120 mN · s / m ² . Moreover, when the electrical conductivity of the paste agent was measured, it was 2.6 × 10 ⁻⁶ / Ω · m.

  Next, the above paste agent is sequentially applied to each hydrophilic region formed on the surface of the wettability changing layer in the selective exposure step by the electric field jet method to form one coating film on each hydrophilic region. did.

The coating machine used at this time was provided with a total of ten Teflon (registered trademark) discharge sections each having a discharge opening with an inner diameter of 500 μm, and these discharge sections had a discharge opening interval of 500 μm. It is arranged to be. In addition, the coating of the paste agent is a rectangular wave having an amplitude of 7 kV and a frequency of 600 Hz applied to the electrode provided around each discharge unit while applying a negative pressure of ² kg / cm ² to the paste agent container in the coating machine. While applying a pulsed AC voltage, each discharge part was moved at a speed of 35 mm / second in a state where the distance between the coated surface and the tip of the discharge part was kept at 0.75 mm. The design size and shape when each coating film was viewed in plan was a rectangle of 8 cm × 0.8 cm.

  The coating film formed in this manner was substantially formed only on each hydrophilic region, and was not formed at other locations. Moreover, the shape retention ability of each coating film was high, and the deformation after coating did not substantially occur.

  Next, each coating film was dried at 100 ° C. for 15 minutes. Thereby, a porous semiconductor electrode having a film thickness of 12 μm was formed on the hydrophilic region one by one. Each porous semiconductor electrode was formed without protruding on the area of the surface of the wettability changing layer that was not exposed in the selective exposure step.

(Non-exposed part removal process)
An etching mask having a predetermined shape is formed so as to cover each porous semiconductor electrode, and the wettability changing layer located outside the formation region in a plan view of the porous semiconductor electrode by selective etching using an alkali developer. Was removed. Thereafter, each porous semiconductor electrode layer was washed with ethanol.

(Dye support process)
First, a ruthenium complex (manufactured by Kojima Chemical Co., Ltd.) as a sensitizing dye was dissolved in ethyl alcohol so that its concentration was 3 × 10 ⁻⁴ mol / l to prepare a dye-supporting coating solution.

Next, the PET film formed up to the above-described porous semiconductor electrode was immersed in a dye-carrying coating solution, and allowed to stand for 1 hour at a liquid temperature of 40 ° C. Thereafter, the PET film was lifted from the dye-supporting coating solution, and the dye-supporting coating solution adhering to each porous semiconductor electrode was dried using nitrogen gas. Thus, the surface of the semiconductor particles forming the porous semiconductor electrode (TiO ₂ fine particles) The above dye is carrying.

  Thereafter, the above glass substrate supporting the PET film was removed to obtain a dye-sensitized solar cell electrode substrate having the same structure as the electrode substrate 30 shown in FIG.

<Example 2>
[Manufacture of dye-sensitized solar cells]
From the electrode substrate for the dye-sensitized solar cell obtained in Example 2, a substrate having a length of 9 cm and a width of 1.4 cm including the porous semiconductor electrode portion carrying the dye (hereinafter referred to as “electrode substrate A”). "). In the electrode substrate A, there are regions where the porous semiconductor electrodes are not formed at both ends in the width direction. The surface of the transparent electrode has a 9 cm long and 0.17 cm wide area that is exposed without being covered by the porous semiconductor electrode.

  Separately, a transparent electrode (ITO electrode) is formed on one side of a 9 × 1.4 cm PET film under the same conditions as in the preparation step of Example 1, and platinum is formed on the transparent electrode. A thin film (thickness 50 nm) was formed by a sputtering method to obtain a dye-sensitized solar cell electrode substrate (hereinafter referred to as “electrode substrate B”). In the electrode substrate B, the transparent electrode corresponds to the first conductive film, and the platinum thin film corresponds to the second conductive film.

  Next, the electrode substrate A and the electrode substrate B described above are bonded together using a 20 μm thick heat-sealing film (Surlin (trade name) manufactured by DuPont) and pressurized at 140 ° C. for 10 minutes to form an electrode. The substrate A and the electrode substrate B were bonded to each other, and when the two electrode substrates A and B were bonded together, the long sides (two in total) in plan view of the electrode substrates A and B were respectively The heat-fusible film was arranged along one of the short sides (two in total) in plan view of the electrode substrates A and B.

  After that, after filling the gap between the two electrode substrates A and B with the microsyringe from the place where the heat-fusible film is not disposed, the above-mentioned heat-fusible film is filled. The part which did not arrange | position was sealed with the epoxy adhesive, and the dye-sensitized solar cell was obtained.

  The electrolyte layer forming coating solution is methoxyacetonitrile, 0.1 mol / l lithium iodide, 0.05 mol / l iodine, 0.3 mol / l dimethylpropylimidazolium iodide, and tertiary. A solution in which butylpyridine was dissolved at a rate of 0.5 mol / l was used.

In measuring the performance of the obtained dye-sensitized solar cell, the current-voltage characteristics when using artificial sunlight (AM1.5, irradiation intensity 100 mW / cm ² ) as a light source are shown as a source measure unit (Keutley Model 2400). Determined by As a result, the battery characteristics of the single cell were a short-circuit current density of 8.26 mA / cm ² , an open-circuit voltage of 0.71 V, a fill factor of 0.68, and a conversion efficiency of 3.99%.

It is the schematic which shows an example of the basic cross-section of the electrode substrate for dye-sensitized solar cells of this invention. It is the schematic which shows the other basic cross-section of the electrode substrate for dye-sensitized solar cells of this invention. It is the schematic which shows an example of the basic cross-section of the dye-sensitized solar cell of this invention. It is the schematic which shows the other basic cross-section of the dye-sensitized solar cell of this invention. It is the schematic which shows the other basic cross-section of the dye-sensitized solar cell of this invention. It is the schematic which shows the other basic cross-section of the dye-sensitized solar cell of this invention. It is the schematic which shows the cross-section of the conventional dye-sensitized solar cell.

Explanation of symbols

1, 21 Transparent base material 3, 23 Transparent electrode 5, 25 Wetting change layer 7, 27 Porous semiconductor electrode 7a, 27a Semiconductor fine particle 9, 29 Dye 20, 30 Dye-sensitized solar cell electrode substrate (first Electrode substrate)
50, 60, 70, 80 Dye-sensitized solar cell electrode substrate (second electrode substrate)
90 Electrolyte layer 100, 110, 120, 130 Dye-sensitized solar cell

Claims (6)

A transparent base material, a transparent electrode formed on one side of the transparent base material, a porous semiconductor electrode formed on the transparent electrode using a large number of semiconductor fine particles, and the porous semiconductor electrode are formed A dye-sensitized solar cell electrode substrate having a dye supported on the surface of semiconductor fine particles,
A wettability changing layer is interposed between the transparent electrode and the porous semiconductor electrode, and the wettability in the region of the surface of the wettability changing layer that is the base of the porous semiconductor electrode is relatively An electrode substrate for a dye-sensitized solar cell, characterized in that A transparent base material, a transparent electrode formed on one side of the transparent base material, a porous semiconductor electrode formed on the transparent electrode using a large number of semiconductor fine particles, and the porous semiconductor electrode are formed A method for producing a dye-sensitized solar cell electrode substrate having a dye supported on the surface of semiconductor fine particles,
Preparing a transparent substrate with a transparent electrode formed on one side; and
A wettability changing layer capable of changing the wettability of the surface by light irradiation so as to cover at least a part of the surface of the transparent electrode, and at least a part of the surface of the wettability changing layer is the porous A wettability changing layer forming step to be formed so as to be a formation region in a plan view of the crystalline semiconductor electrode;
A selective exposure step of selectively exposing a region corresponding to a formation region of the porous semiconductor electrode in a plan view of the surface of the wettability changing layer to relatively increase the wettability of the region;
On the surface of the wettability changing layer, a coating film is formed by using a coating solution for forming a semiconductor electrode containing a large number of semiconductor fine particles on a region selectively exposed in the selective exposure step, and the coating film is dried. A porous semiconductor electrode forming step to obtain a porous semiconductor electrode; and
A dye carrying step of carrying a dye on the surface of the semiconductor fine particles forming the porous semiconductor electrode;
The manufacturing method of the electrode substrate for dye-sensitized solar cells characterized by including this.   In the selective exposure step, a photomask having a photocatalyst-containing layer is used, and the photomask is disposed so that the photocatalyst-containing layer is located on the surface side of the wettability changing layer. The method for producing a dye-sensitized solar cell electrode substrate according to claim 2, wherein the surface is selectively exposed.   The dye-sensitized dye according to claim 2 or 3, wherein, in the porous semiconductor electrode forming step, the coating film is formed by applying the coating solution for forming a semiconductor electrode by an ink jet method or an electric field jet method. Of manufacturing electrode substrate for solar cell.   The method further includes a non-exposed portion removing step performed after the porous semiconductor electrode forming step, and the non-exposed portion removing step removes the wettability changing layer located outside the formation region in plan view of the porous semiconductor electrode. The manufacturing method of the electrode substrate for dye-sensitized solar cells of any one of Claims 2-4 characterized by the above-mentioned. A first electrode substrate having a porous semiconductor electrode having a dye supported on the surface; a second electrode substrate disposed opposite to the first electrode substrate; the first electrode substrate; and the second electrode substrate. A dye-sensitized solar cell comprising an electrolyte layer interposed between the electrode substrate and the electrode substrate,
The dye-sensitized solar cell, wherein the first electrode substrate is the electrode substrate for a dye-sensitized solar cell according to claim 1.

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