JP5002926B2 - Film-like solar cell - Google Patents

Description

  The present invention relates to a solar cell using a film as a base material. More specifically, the present invention relates to a solar cell with excellent conversion efficiency in which a thin film that hardly peels off when a photoelectric conversion layer is stacked is formed.

Solar cells are manufactured by laminating photoelectric conversion layers and the like on various substrates. Many proposals have been made to use various polymer films as the substrate in view of heat resistance and flexibility.
It is disclosed that polybenzazole polymer, which is a rigid polymer, exhibits excellent strength, elastic modulus, and heat resistance, and its oriented film has extremely high mechanical strength (see Patent Document 1). However, when the film is formed with a solution exhibiting optical anisotropy, the molecular chain is excessively oriented in the ejection direction, so that the resulting film is easily fibrillated, which is also referred to as the film forming direction (MD direction, film flow direction, machine direction). ) And width direction (TD direction, direction perpendicular to MD direction, also referred to as transverse direction), it is difficult to balance the mechanical properties, and the film thickness direction is easily delaminated. Yes.
U.S. Pat. No. 4,973,442

As a method for solving the problems related to the balance of mechanical properties, a film forming method is disclosed in which the process up to die extrusion is carried out in an optically anisotropic phase, and after die extrusion, the phase transition is made optically isotropic by composition change or temperature change. (See Patent Document 2). In addition, the polybenzazole solution having optical anisotropy is cast on a support and then changed to a state in which it is optically isotropic. A polybenzazole-based film is disclosed (see Patent Document 3). However, none of the above methods solves the problem of easy delamination. Furthermore, it cannot be said that the balance between the mechanical properties in the MD direction and the TD direction has been sufficiently solved.
Kumar et al. Have attempted to improve the mechanical properties in the MD and TD directions by introducing a methyl group into the dicarboxylic acid component and causing intermolecular crosslinking to improve the tensile strength in the TD direction. However, although intermolecular cross-linking was successful, it has not been possible to obtain performance that is satisfactory in practical use (for example, see Non-Patent Document 1).
See JP-A-9-118758 See JP 2000-273214 A J. et al. Appl. Polym. Sci. 73, 305-314, (1999)

  The present invention has been made to solve such problems, and the object of the present invention is to laminate a photoelectric conversion layer such as a silicon thin film by using a specific film on a substrate of a solar cell. It is an object of the present invention to provide a substrate film suitable for forming a thin film that is less likely to be peeled off and is excellent in conversion efficiency with less peeling and a solar cell module that is improved in conversion efficiency using the film.

As a result of intensive studies, the present inventors have found that a high-quality and uniform solar cell can be obtained by using a heat-resistant polybenzazole film having a specific linear expansion coefficient as a substrate, and the present invention has been completed. I let you.
That is, this invention consists of the following structures.
1. A film-like solar cell in which a laminate including a photoelectric conversion layer made of a semiconductor is formed on a film substrate, wherein the film substrate is a polybenzazole film and is perpendicular to the flow direction and the flow direction of the film A film-like solar cell having a linear expansion coefficient in the direction of −10 to 16 ppm / ° C.
2. The film substrate is a polybenzazole film in which polybenzazole having a substituent in at least a part of the benzazole ring is subjected to intermolecular crosslinking treatment, and has a thickness of 3 to 200 μm, and the tensile strength ratio of the film (Tensile rupture strength in the flow direction of the film / tensile rupture strength in the direction perpendicular to the flow direction) has an isotropic property of 0.85 to 1.20, and the tensile rupture strength of the film is 300 MPa or more. . The film-like solar cell described.
3. 1. Laminate has thin film silicon layer Or 2. The film-like solar cell described.
4). 1. The laminate has an amorphous silicon layer ~ 3. The film-shaped solar cell as described in any one of these.
5. 1. Laminate has a polycrystalline silicon layer ~ 3. The film-shaped solar cell as described in any one of these.
6). 1. The laminated body has a thick film semiconductor layer. Or 2. The film-like solar cell described.

  In the present invention, a film used as a substrate film is a polybenzazole film, and a benzazole polymer in which a substituent (side chain) is introduced into a benzazole ring is formed into a film and replaced by heating or irradiation with active energy rays. Crosslinks are made between the groups to balance the mechanical properties in the MD direction and TD direction of the film, and the drawbacks of easy delamination are eliminated. Further, the film has a linear expansion coefficient in the direction perpendicular to the flow direction and the flow direction of −10 to 16 ppm / ° C., is heat resistant, and has a high film forming temperature such as a silicon thin film as a photoelectric conversion layer. However, since the CTE (Linear Expansion Coefficient) is in a certain range even at high temperatures, the influence of stress etc. is small on the silicon thin film as the photoelectric conversion layer (because it does not have a large difference from the linear expansion coefficient of the silicon thin film). ) There is no peeling. In addition, since a silicon thin film that is a photoelectric conversion layer with good conversion efficiency can be obtained and flexible, it is possible to obtain an excellent solar cell at low cost.

The polybenzazole film according to the present invention is a film composed of a polybenzazole polymer having a functional group in the azole ring, and is a polybenzazole composed of a repeating unit represented by the general formula 1 in a molecular chain.
The present invention is a polybenzazole film characterized in that a polymer having the following general formula 1 is formed into a film and crosslinked between side chains by heating or irradiation with active energy rays, for example, light irradiation. In addition, the isotropic tensile strength ratio and delamination resistance are excellent.

但し、ｎはポリマー中のモル分率であり、０以上１未満の実数である。ＸはＳ、Ｏ原子又はＮＨ基を示す。アゾール環においてＮ原子とＸ原子／基はトランス位であってもシス位であっても良い。繰り返し単位（１）におけるＹは下記化２で表される。

However, n is a mole fraction in the polymer, and is a real number from 0 to less than 1. X represents an S, O atom or NH group. In the azole ring, the N atom and the X atom / group may be trans or cis. Y in the repeating unit (1) is represented by the following chemical formula 2.

で表され、これらが単独、又は１〜ｎの範囲内でこれらの繰り返し単位が任意の割合で共重合していてもよい。また、Ｒはハロゲン原子、炭素原子数１〜６のアルキル基のうちの少なくとも１種である。
本発明におけるホモポリマーおよび共重合ポリマーとしては下記のものが挙げられる。共重合ポリマーはランダム共重合ポリマー、ブロック共重合ポリマー、交互共重合ポリマーいずれでも構わない。

And these may be copolymerized in an arbitrary ratio within a range of 1 to n. R is at least one of a halogen atom and an alkyl group having 1 to 6 carbon atoms.
The following are mentioned as a homopolymer and a copolymer in the present invention. The copolymer may be any of a random copolymer, a block copolymer, and an alternating copolymer.

等が挙げられる。もちろん本発明はこれら具体例に限定されるものではない。

Etc. Of course, the present invention is not limited to these specific examples.

In the copolymer of the present invention, the ratio between the repeating structure having a substituent and the repeating structure not having a substituent can be appropriately selected depending on the desired degree of polymerization and degree of crosslinking. The molar fraction of the repeating structure having a substituent is preferably 0.8 to 0.3, more preferably 0.7 to 0.5. Outside this range, the degree of polymerization increases but the number of cross-linking sites decreases, the degree of cross-linking is low, and it is difficult to obtain desired physical properties, or the degree of polymerization does not increase and only low physical properties can be obtained. Prone.
Since the degree of polymerization tends to increase and a high physical property film can be obtained, the polymer copolymerization ratio is preferably 20 to 70% (mol% based on the total R group-containing units in Chemical Formula 1), more preferably 30 to 50%. It is. Outside this range, the degree of polymerization increases but the desired physical properties cannot be obtained, and high physical properties can be expected, but the degree of polymerization is difficult to increase.
The polybenzazole film is produced from a dope containing a polybenzazole polymer, and suitable solvents for preparing the dope include cresol and a non-oxidizing acid capable of dissolving the polymer. Examples of suitable non-oxidizing acids include polyphosphoric acid, methanesulfonic acid and high concentrations of sulfuric acid or mixtures thereof. Of these, polyphosphoric acid and methanesulfonic acid, particularly polyphosphoric acid are preferred.

The polymer concentration in the dope is preferably at least about 7% by weight, more preferably at least 10% by weight. The maximum concentration is limited by practical handling properties such as polymer solubility and dope viscosity. Due to their limiting factors, the polymer concentration usually does not exceed 20% by weight.
In the present invention, suitable polymers or copolymers and dopes are synthesized by known methods. For example, US Pat. No. 4,533,693 to Wolfe et al., US Pat. No. 4,772,678 to Sybert et al., US Pat. No. 4,847,350 to Harris, or US Pat. No. 5,089,591. In summary, suitable monomers are heated in a non-oxidizing, dehydrating acid solution at a stepwise or constant rate of heating from about 60 ° C. to 230 ° C. under high-speed stirring and high shear conditions in a non-oxidizing atmosphere. It is made to react by raising.

Next, a method for producing a film will be described. The film is made by extruding the dope from a slit die and further stretching. The stretching process is relatively simple in that it is extruded from a circumferential slit die and blow-stretched. For example, in blow stretching described in US Pat. No. 4,898,924, biaxial stretching is achieved by drawing down in the discharge direction and expanding the discharged tube in the circumferential direction. At this time, it is more preferable to form a film by putting a coagulating liquid inside the tube.
As another stretching method suitable for thin stretching, a method in which a dope extruded from a slit die and a support film are integrated using a flexible polymer as a support film and the support film is sandwiched and stretched by a tenter clip is also preferable. The support film may be integrated on both sides of the dope, or only one side may be bonded. When both surfaces are bonded together, it is necessary to peel off the flexible film on one side before solidification. Examples of flexible polymers suitable for this method include polyesters such as polyethylene terephthalate, polyethylene isophthalate, and polyethylene naphthalate, polyolefins such as polyethylene and polypropylene, fluororesins such as polytetrafluoroethylene, and multilayers thereof. A molded film or the like can be used.
The stretched dope is solidified by contact with a non-solvent. The non-solvent may be a liquid phase or a gas phase. Further, the solvent may be evaporated or extracted to be solidified. As a medium used for coagulation and extraction, an aqueous solution of mineral acid, an organic solvent such as alcohol or glycol can be used. A preferred coagulant is water or a mixture of water and mineral acid. As the extraction of the solvent in the dope proceeds, the stretched dope undergoes a volume change. In order to prevent a film defect occurring at this time, as described in US Pat. No. 5,302,334, it is necessary to perform tentering and limited shrinkage while solidification proceeds. It is preferable to sufficiently extract the solvent subsequent to the coagulation. It is also possible to add a base for the purpose of neutralizing the mineral acid of the residual solvent.

When the non-solvent is dried from the water-washed or water-washed / neutralized or resin-impregnated composite, the volume changes more than in the solvent extraction. Therefore, it is preferable to use a fixing method such as US Pat. No. 5,445,779. Drying may be carried out with dry air at room temperature, but in an industrial process, a hot air system is preferred. Moreover, since it may cause a micro crack defect inside when rapidly dried with high temperature gas, it is preferable to dry over time. The dried film becomes a strong film having a high elastic modulus, but it can also be heat-treated at a temperature of 350 ° C. or higher in order to arrange the internal molecules. When heat-treated, changes in film properties such as an increase in density, an increase in elastic modulus, and a decrease in equilibrium moisture content occur.
On the other hand, there are also the following film production methods. The obtained dope is pressed in a state of being sandwiched between polytetrafluoroethylene sheets by a heat press. The obtained film dope is fixed to a metal frame and washed. The term “cleaning” as used herein refers to removing the acid solvent from the dope by immersing the film in a liquid that is compatible with the mineral acid in which the polybenzazole polymer is dissolved and is not a solvent for the polybenzazole polymer. is there. Suitable cleaning liquids include water and mixtures of water and acid solvents. The residual mineral acid concentration is preferably washed to 8000 ppm or less, more preferably 5000 ppm or less. Thereafter, the film is dried at 80 ° C. for 1 hour.
The film thus obtained is cross-linked by treating it under an inert gas. The treatment here means heating at 300 to 600 ° C. or irradiating light with a wavelength of 210 to 330 nm, a deuterium lamp, a mercury lamp, or a xenon lamp. Nitrogen, argon, etc. are generally used as the inert gas.
Hereinafter, the present invention will be described in detail with reference to examples. However, the present invention is not limited by the following examples, and may be implemented with appropriate modifications within a range that can meet the gist of the preceding and following descriptions. Of course, it is also possible, and they are all included in the technical scope of the present invention.

In the above polybenzazole film, a lubricant is added to the polybenzazole to add fine irregularities to the film surface to improve the slipperiness of the film (especially the surface opposite to the surface providing the surface irregular structure). You can also
As the lubricant, inorganic or organic fine particles having an average particle diameter of about 0.03 μm to 3 μm can be used. Specific examples include titanium oxide, alumina, silica, calcium carbonate, calcium phosphate, calcium hydrogen phosphate, and calcium hydrogen pyrophosphate. , Magnesium oxide, calcium oxide, clay mineral and the like.

As described above, a polybenzazole film having a linear expansion coefficient of −10 to 16 ppm / ° C. in the flow direction of the film and in the direction perpendicular to the flow direction can be obtained.
The film-like solar cell of the present invention uses the polybenzazole film described above as a base material, and a laminate including a photoelectric conversion layer made of a semiconductor is formed on the film base material. The said laminated body has a photoelectric converting layer which converts the energy of sunlight into an electrical energy as an essential structure, and usually further has an electrode layer etc. for taking out the obtained electrical energy.
Hereinafter, a laminated structure in which a photoelectric conversion layer is sandwiched between a pair of electrode layers will be described as a typical example of the laminated body formed so as to constitute a film-like solar cell. However, the laminated structure formed in the present invention is not limited to the embodiment described below, and the structure of the laminated body of the solar cell of the prior art may be referred to as appropriate, and a protective layer and known auxiliary means are added. Is also good.
One electrode layer (hereinafter also referred to as a back electrode layer) of the pair of electrode layers is preferably formed on one main surface of the film substrate. The back electrode layer is obtained by laminating a conductive inorganic material by a method known per se, for example, a CVD (Chemical Vapor Deposition) method or a sputtering method. Examples of conductive inorganic materials include metal thin films such as Al, Au, Ag, Cu, Ni, and stainless steel, and In ₂ O ₃ , SnO ₂ , ZnO, Cd ₂ SnO ₄ , ITO (adding Sn to In ₂ O ₃ Oxide semiconductor-based conductive materials and the like. The thickness of the back electrode layer is not particularly limited, and is usually about 30 to 1000 nm. Preferably, the back electrode layer is a metal foil film.

The photoelectric conversion layer that converts sunlight energy into electrical energy is a layer made of a semiconductor, and is usually a layer made of a silicon-based semiconductor. Examples of the silicon-based semiconductor include a thin film silicon layer, an amorphous silicon layer, and a polycrystalline silicon layer. The photoelectric conversion layer may be a laminate having a plurality of layers made of different semiconductors.
The thin film silicon layer is a silicon layer obtained by a plasma CVD method, a thermal CVD method, a sputtering method, a cluster ion beam method, a vapor deposition method, or the like.
The amorphous silicon layer is a layer made of silicon having substantially no crystallinity. The lack of crystallinity can be confirmed by not giving a diffraction peak even when irradiated with X-rays. Means for obtaining an amorphous silicon layer are known, and examples of such means include a plasma CVD method and a thermal CVD method.
The polycrystalline silicon layer is a layer made of an aggregate of microcrystals made of silicon. The above amorphous silicon layer is distinguished by giving a diffraction peak by irradiation with X-rays. Means for obtaining a polycrystalline silicon layer are known, and such means include means for heat-treating amorphous silicon.

The photoelectric conversion layer used in the present invention is not limited to a silicon-based semiconductor layer, and may be, for example, a thick film semiconductor layer. The thick film semiconductor layer is a semiconductor layer formed from a paste of titanium oxide, zinc oxide, copper iodide or the like.
The means for constituting the semiconductor material as the photoelectric conversion layer may refer to a known method as appropriate. For example, an a-Si (n layer) of about 20 nm is formed by performing high-frequency plasma discharge in a gas in which phosphine (PH ₃ ) is added to SiH ₄ at a temperature of 200 to 500 ° C., followed by SiH _4. An a-Si (i layer) of about 500 nm can be formed with gas alone, and then diborane (B ₂ H ₆ ) can be added to SiH ₄ to form a p-Si (p layer) of about 10 nm. .
Of the pair of electrode layers sandwiching the photoelectric conversion layer, an electrode layer (hereinafter also referred to as a current collecting electrode layer) provided on the side opposite to the film substrate is formed by solidifying a conductive paste containing a conductive filler and a binder resin. It may be an electrode layer or a transparent electrode layer. As the transparent electrode layer, an oxide semiconductor material such as In ₂ O ₃ , SnO ₂ , ZnO, Cd ₂ SnO ₄ , ITO (In ₂ O ₃ added with Sn) can be preferably used. Further, by laminating ZnO containing Zn (ZnO: Ga), SnO2, or the like on the ITO film, the stability of the film can be increased. These methods may be appropriately combined with known methods.
Thus, a transparent electrode / p-type a-Si / i-type a-Si / n-type a-Si / metal electrode / polyimide benzoxazole film having a surface concavo-convex structure surface, which is a preferred embodiment of the present invention, are laminated in this order. A film-like solar cell is obtained. Alternatively, the p layer may be a-Si, the n layer may be polycrystalline silicon, and a thin and doped a-Si layer may be inserted between them. In particular, when an a-Si / polycrystalline silicon hybrid type is used, the sensitivity to the sunlight spectrum is improved.

In manufacturing a solar cell, an antireflection layer, a surface protective layer, or the like may be added in addition to the above structure. For example, as an antireflection layer (antireflection film) material, an Si ₃ N ₄ film, a TiO ₂ film, an SiO ₂ film, an MgO film, an ITO film, an SnO ₂ film, a ZnO film, or the like can be used. The thickness is appropriately selected depending on the material, and realizes the non-reflection condition for incident light (if the refractive index of the material is n and the wavelength of the spectral region to be non-reflection is λ, (λ / n) / 4 = d is set. D to satisfy is the optimum film thickness of the antireflection film). For example, in the case of a commonly used Si ₃ N ₄ film (n = about 2), if the non-reflection target wavelength is 600 nm, the film thickness may be about 75 nm.
As a manufacturing method, a PECVD method, a vapor deposition method, a sputtering method, or the like is used, and the film is formed at a temperature of about 400 to 500 ° C. The antireflection film is patterned in a predetermined pattern in order to form a surface electrode. As a patterning method, an etching method (wet or dry) used for a mask such as a resist, or a method in which a mask is formed in advance at the time of forming the antireflection film and then removed after the formation of the antireflection film can be used.

EXAMPLES Hereinafter, although an Example and a comparative example are shown and this invention is demonstrated more concretely, this invention is not limited by a following example. In addition, the evaluation method of the physical property in a following example and a comparative example is as follows.
1. Intrinsic viscosity The viscosity of a polymer solution prepared at a concentration of 0.5 g / l using methanesulfonic acid as a solvent was measured and calculated in an oven at 25 ° C using an Ostwald viscometer.
2. Confirmation of cross-linking The ¹³ C solid-state NMR of the film before treatment and the dried film was measured to confirm the presence or absence of cross-linking.
In the case of having a methyl group, the signal based on the methyl group decreased and a new signal based on the methylene group was observed. In the case of having an ethyl group, the signal based on the ethyl group decreased, and a signal of a methylene group different from the methylene group of the ethyl group was observed. In the case of having a halogen group, a high magnetic field shift of the carbon signal to which the halogen group was bonded was observed.
3. Tensile Breaking Strength and Tensile Strength Ratio of Film Base Material A base material film to be measured was cut into strips of 100 mm × 10 mm in the MD direction and the TD direction, respectively, as test pieces. Using a tensile tester (manufactured by Shimadzu Corporation, autograph model name AG-5000A), the tensile strength and the tensile strength ratio were measured for each of the MD direction and the TD direction under the conditions of a tensile speed of 50 mm / min and a distance between chucks of 40 mm. .
4). Coefficient of linear expansion (CTE) of film substrate
With respect to the film substrate to be measured, the stretch rate in the MD direction and the TD direction is measured under the following conditions, and the stretch rate / temperature at intervals of 30 ° C. to 45 ° C., 45 ° C. to 60 ° C.,. Then, this measurement was performed up to 300 ° C., and the average value of all measured values was calculated as CTE. The meanings of the MD direction and the TD direction are as described above.
Device name: TMA4000S manufactured by MAC Science
Sample length; 20mm
Sample width: 2 mm
Temperature rise start temperature: 25 ° C
Temperature rising end temperature: 400 ° C
Temperature increase rate: 5 ° C / min
Atmosphere: Argon 5. Photoelectric conversion characteristics Measured with an Oriel solar simulator whose conversion efficiency was adjusted to AM = 1.

Example 1
6.9 g of 4,6-diaminoresorcin dihydrochloride, 0.6 g of 2-methyl-4,6-diaminoresorcin dihydrochloride, 0.6 g of terephthalic acid, 5 g 8.1 g of phosphorus oxide was added, and the mixture was stirred and mixed at 70 ° C. for 15 minutes in the reactor. Further, the temperature was raised to 120 ° C., mixed with stirring for 3.5 hours to remove hydrochloric acid, heated to 135 ° C. and stirred for 16 hours to oligomerize. Thereafter, the temperature was raised to 200 ° C. to polymerize to obtain a PBO polymer dope in which 10 mol% of a methyl group-substituted benzazole ring was copolymerized. The color of the polymer dope was yellow and the intrinsic viscosity was 21 dl / g.
The obtained dope was sandwiched between polytetrafluoroethylene sheets and pressed with a heat press machine at a press plate temperature of 170 ° C. and a pressure of 150 kgf / cm ² . The taken-out dope sheet was peeled off from the polytetrafluoroethylene sheet, immersed in 1 L of distilled water for 15 hours to extract phosphoric acid, fixed on a metal frame having a side of 10 cm, and dried at 80 ° C. for 1 hour. The obtained film was heat-treated at 500 ° C. for 1 hour under a nitrogen stream. Table 1 shows the results of the evaluation of the tensile strength ratio and delamination resistance.

(Example 2)
116% polyphosphoric acid 27.1 g under nitrogen stream, 4,6-diaminoresorcinol dihydrochloride 3.8 g, 2-methyl-4,6-diaminoresorcinol dihydrochloride 1.7 g, terephthalic acid 4.2 g and five 8.0 g of phosphorus oxide was added, and the mixture was stirred and mixed at 70 ° C. for 15 minutes in the reactor. Further, the temperature was raised to 120 ° C., mixed with stirring for 3.5 hours to remove hydrochloric acid, heated to 135 ° C. and stirred for 19 hours to oligomerize. Then, it heated up at 200 degreeC and superposed | polymerized and the PBO polymer dope by which 30 mol% of methyl group substituted benzazole rings were copolymerized was obtained. The color of the polymer dope was yellow and the intrinsic viscosity was 21 dl / g.
The obtained dope was sandwiched between polytetrafluoroethylene sheets and pressed with a heat press machine at a press plate temperature of 170 ° C. and a pressure of 150 kgf / cm ² . The taken-out dope sheet was peeled off from the polytetrafluoroethylene sheet, immersed in 1 L of distilled water for 15 hours to extract phosphoric acid, fixed on a metal frame having a side of 10 cm, and dried at 80 ° C. for 1 hour. The obtained film was heat-treated at 500 ° C. for 1 hour under a nitrogen stream. Table 1 shows the results of the evaluation of the tensile strength ratio and delamination resistance.

(Example 3)
In 27.2 g of 116% polyphosphoric acid, 2.7 g of 4,6-diaminoresorcin dihydrochloride, 2.8 g of 2-methyl-4,6-diaminoresorcin dihydrochloride, 4.1 g of terephthalic acid and five 7.9 g of phosphorus oxide was added, and the mixture was stirred and mixed at 70 ° C. for 15 minutes in the reactor. The temperature was further raised to 120 ° C., stirred and mixed for 3.5 hours to remove hydrochloric acid, heated to 135 ° C. and stirred for 20 hours to oligomerize. Thereafter, the temperature was raised to 200 ° C. to polymerize to obtain a PBO polymer dope in which 50 mol% of a methyl group-substituted benzazole ring was copolymerized. The color of the polymer dope was yellow and the intrinsic viscosity was 22 dl / g.
The obtained dope was sandwiched between polytetrafluoroethylene sheets and pressed with a heat press machine at a press plate temperature of 170 ° C. and a pressure of 150 kgf / cm ² . The taken-out dope sheet was peeled off from the polytetrafluoroethylene sheet, immersed in 1 L of distilled water for 15 hours to extract phosphoric acid, fixed on a metal frame having a side of 10 cm, and dried at 80 ° C. for 1 hour. The obtained film was heat-treated at 500 ° C. for 1 hour under a nitrogen stream. Table 1 shows the results of the evaluation of the tensile strength ratio and delamination resistance.

Example 4
116% polyphosphoric acid 27.3 g under nitrogen flow, 1.6 g of 4,6-diaminoresorcin dihydrochloride, 3.9 g of 2-methyl-4,6-diaminoresorcin dihydrochloride, 4.1 g of terephthalic acid and five 7.8 g of phosphorus oxide was added, and the mixture was stirred and mixed at 70 ° C. for 15 minutes in the reactor. The temperature was further raised to 120 ° C., mixed with stirring for 3.5 hours, dehydrochlorination was performed, and the temperature was raised to 135 ° C. and stirred for 24 hours to oligomerize. Thereafter, the temperature was raised to 200 ° C. for polymerization to obtain a PBO polymer dope in which 70 mol% of a methyl group-substituted benzazole ring was copolymerized. The color of the polymer dope was yellow and the intrinsic viscosity was 20 dl / g.
The obtained dope was sandwiched between polytetrafluoroethylene sheets and pressed with a heat press machine at a press plate temperature of 170 ° C. and a pressure of 150 kgf / cm ² . The taken-out dope sheet was peeled off from the polytetrafluoroethylene sheet, immersed in 1 L of distilled water for 15 hours to extract phosphoric acid, fixed on a metal frame having a side of 10 cm, and dried at 80 ° C. for 1 hour. The obtained film was heat-treated at 500 ° C. for 1 hour under a nitrogen stream. Table 1 shows the results of the evaluation of the tensile strength ratio and delamination resistance.

(Example 5)
Under nitrogen flow, 5.5 g of 2-methyl-4,6-diaminoresorcin dihydrochloride, 4.0 g of terephthalic acid and 7.6 g of phosphorus pentoxide were added to 27.5 g of 116% polyphosphoric acid. Stir and mix at 15 ° C. for 15 minutes. The temperature was further raised to 120 ° C., mixed with stirring for 3.5 hours to remove hydrochloric acid, heated to 135 ° C. and stirred for 30 hours to oligomerize. Then, it heated up at 200 degreeC and superposed | polymerized and obtained the PBO polymer dope. The color of the polymer dope was yellow and the intrinsic viscosity was 18 dl / g.
The obtained dope was sandwiched between polytetrafluoroethylene sheets and pressed with a heat press machine at a press plate temperature of 170 ° C. and a pressure of 150 kgf / cm ² . The taken-out dope sheet was peeled off from the polytetrafluoroethylene sheet, immersed in 1 L of distilled water for 15 hours to extract phosphoric acid, fixed on a metal frame having a side of 10 cm, and dried at 80 ° C. for 1 hour. The obtained film was heat-treated at 500 ° C. for 1 hour under a nitrogen stream. Table 1 shows the results of the evaluation of the tensile strength ratio and delamination resistance.

(Comparative Examples 1-3)
To 67.1 g of 116% polyphosphoric acid, 13.7 g of 4,6-diaminoresorcin, 10.6 g of terephthalic acid and 20.4 g of phosphorus pentoxide were added in a nitrogen stream, and the mixture was stirred and mixed at 70 ° C. for 15 minutes. . Further, the temperature was raised to 120 ° C., mixed with stirring for 3.5 hours to remove hydrochloric acid, heated to 135 ° C. and stirred for 16 hours to oligomerize. Then, it heated up at 200 degreeC and superposed | polymerized and obtained the PBO polymer dope. The color of the polymer dope was yellow and the intrinsic viscosity was 22 dl / g.
The obtained dope was sandwiched between polytetrafluoroethylene sheets and pressed with a heat press machine at a press plate temperature of 170 ° C. and a pressure of 150 kgf / cm ² . The taken-out dope sheet was peeled off from the polytetrafluoroethylene sheet, immersed in 1 L of distilled water for 15 hours to extract phosphoric acid, fixed on a metal frame with a side of 10 cm, and dried under various conditions. Each obtained film was heat-treated at 500 ° C. for 1 hour under a nitrogen stream. Table 2 shows the results of evaluations such as the tensile strength ratio and the linear expansion coefficient.

(Manufacture of film-like solar cells)
Sputtering-plasma CVD Each device has an independent thin film deposition chamber and can transport a substrate without breaking the vacuum inside the chamber. Using a stainless steel target, a stainless steel layer having a thickness of 900 nm is sputtered on each film. Formed. Next, a film in which a stainless steel layer was formed was placed between the counter electrode and the support electrode in the vacuum reactor, and the inside of the reactor was once evacuated to 10 ⁻⁵ Torr, and the temperature of the support electrode was raised to 350 ° C. Thereafter, while applying a high frequency voltage of 13.56 MHz of 30 W to the counter electrode and the support electrode, argon gas was introduced into the reactor and presputtered in an argon atmosphere of 3 mTorr, and then diluted to 10% with hydrogen gas. SiH ₄ and a PH ₃ gas diluted to 1% with hydrogen gas were simultaneously introduced to form a 25 nm n-type amorphous silicon layer on the stainless steel layer by plasma CVD under an atmosphere of 1 Torr. Next, only SiH ₄ is introduced by plasma CVD, an i-type amorphous silicon layer having a thickness of 500 nm is laminated on the n-type amorphous silicon layer, and 1% B ₂ H _{6 in} SiH ₄ gas. A p-type amorphous silicon layer having a thickness of 25 nm was formed on the i-type amorphous silicon layer.

Next, the film on which this pin type amorphous silicon layer is formed is moved to another thin film production chamber without breaking the vacuum in the chamber, and a 50 nm thick indium tin oxide layer and then a SnO ₂ film of 25 nm are deposited by sputtering. Thus, a hetero electrode layer was obtained. Finally, a 100 nm palladium layer was vacuum-deposited in a comb shape on it. The film-like solar cell of each Example and the comparative example was obtained as mentioned above.
In the production process of the film-like solar cell of each example, there was no problem that the film substrate was deformed by heat or wrinkles were produced, and a solar cell with excellent flatness was obtained. Comparative Examples In the production process of the film-like solar cell in each example, there were problems that the film base material was deformed by heat and wrinkles were generated, and the film was peeled off from the laminated thin film. The results of the conversion efficiency of the film-like solar cell in each example are shown in Tables 1 and 2.

表中、ＭＤ；フィルムの流れ方向（長さ方向）、ＴＤ；流れ方向と直角の方向（幅方向）をそれぞれ示す。

In the table, MD represents the film flow direction (length direction), and TD represents the direction perpendicular to the flow direction (width direction).

表中、ＭＤ；フィルムの流れ方向（長さ方向）、ＴＤ；流れ方向と直角の方向（幅方向）をそれぞれ示す。

In the table, MD represents the film flow direction (length direction), and TD represents the direction perpendicular to the flow direction (width direction).

  As described above, by cross-linking a polybenzazole film having a structural unit having a halogen atom, a methyl group or an ethyl group introduced on the benzene ring constituting the heterocyclic ring, it is excellent in isotropic property and the linear expansion coefficient is within a predetermined range. It can be seen that the solar cell using the film is excellent in performance.

  According to the present invention, not only flexibility, high strength, high elastic modulus, high heat resistance, but also the performance of using a polybenzazole film having a linear expansion coefficient within a predetermined range and having an excellent tensile strength ratio as a substrate. Therefore, it is possible to provide a solar cell that is excellent in performance, and the effect of enhancing practicality and expanding the field of use is tremendous.

Claims (5)

A film-like solar cell in which a laminate including a photoelectric conversion layer made of a semiconductor is formed on a film base material , wherein the film base material is a molecule of polybenzazole having a substituent on at least a part of the benzazole ring It is a polybenzazole film that has been subjected to interchain crosslinking treatment , has a thickness of 3 to 200 μm, and has a linear expansion coefficient of −30 to 300 ° C. in the flow direction of the film and in the direction perpendicular to the flow direction. 10 to 16 ppm / ° C. , and the film has an isotropic strength ratio (tensile breaking strength in the flow direction of the film / tensile breaking strength in the direction perpendicular to the flow direction) of 0.85 to 1.20, A film-like solar cell, wherein the film has a tensile strength at break of 300 MPa or more . The laminate has a thin film silicon layer. The film-like solar cell described. Film-like solar cell according to any one of claim 1 to 2, the laminate having an amorphous silicon layer. Film-like solar cell according to any one of claim 1 to 2, the laminate has a polycrystalline silicon layer. The laminate has a thick semiconductor layer. The film-like solar cell described.