JP5970796B2 - 太陽電池基板用鋼箔およびその製造方法、並びに太陽電池基板、太陽電池およびその製造方法 - Google Patents
太陽電池基板用鋼箔およびその製造方法、並びに太陽電池基板、太陽電池およびその製造方法 Download PDFInfo
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- 229910000831 Steel Inorganic materials 0.000 title claims description 67
- 239000010959 steel Substances 0.000 title claims description 67
- 239000011888 foil Substances 0.000 title claims description 50
- 239000000758 substrate Substances 0.000 title claims description 46
- 238000004519 manufacturing process Methods 0.000 title claims description 19
- 238000005096 rolling process Methods 0.000 claims description 21
- 238000010438 heat treatment Methods 0.000 claims description 14
- 238000000137 annealing Methods 0.000 claims description 13
- 238000005097 cold rolling Methods 0.000 claims description 11
- 238000010924 continuous production Methods 0.000 claims description 11
- 229910000859 α-Fe Inorganic materials 0.000 claims description 10
- 229910052804 chromium Inorganic materials 0.000 claims description 8
- 238000000034 method Methods 0.000 claims description 8
- 239000000203 mixture Substances 0.000 claims description 6
- 238000004544 sputter deposition Methods 0.000 claims description 6
- 238000005554 pickling Methods 0.000 claims description 5
- 239000012535 impurity Substances 0.000 claims description 4
- 239000011261 inert gas Substances 0.000 claims description 4
- 229910052799 carbon Inorganic materials 0.000 claims description 3
- 229910052758 niobium Inorganic materials 0.000 claims description 3
- 229910052757 nitrogen Inorganic materials 0.000 claims description 3
- 229910052719 titanium Inorganic materials 0.000 claims description 3
- 238000004140 cleaning Methods 0.000 claims description 2
- 229910052802 copper Inorganic materials 0.000 claims description 2
- 229910052750 molybdenum Inorganic materials 0.000 claims description 2
- 229910052720 vanadium Inorganic materials 0.000 claims description 2
- 229910052748 manganese Inorganic materials 0.000 claims 2
- 229910052698 phosphorus Inorganic materials 0.000 claims 2
- 229910052721 tungsten Inorganic materials 0.000 claims 1
- 238000005260 corrosion Methods 0.000 description 16
- 230000007797 corrosion Effects 0.000 description 16
- 239000007789 gas Substances 0.000 description 8
- 229910001220 stainless steel Inorganic materials 0.000 description 7
- 230000037303 wrinkles Effects 0.000 description 6
- 239000010935 stainless steel Substances 0.000 description 5
- 230000000694 effects Effects 0.000 description 4
- 239000010409 thin film Substances 0.000 description 4
- 230000015572 biosynthetic process Effects 0.000 description 3
- 239000000463 material Substances 0.000 description 3
- QGZKDVFQNNGYKY-UHFFFAOYSA-N Ammonia Chemical compound N QGZKDVFQNNGYKY-UHFFFAOYSA-N 0.000 description 2
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 2
- 238000005452 bending Methods 0.000 description 2
- 238000005238 degreasing Methods 0.000 description 2
- 239000013067 intermediate product Substances 0.000 description 2
- 230000007774 longterm Effects 0.000 description 2
- 229910052759 nickel Inorganic materials 0.000 description 2
- 229910052761 rare earth metal Inorganic materials 0.000 description 2
- 150000002910 rare earth metals Chemical class 0.000 description 2
- 238000009864 tensile test Methods 0.000 description 2
- 229910052726 zirconium Inorganic materials 0.000 description 2
- 238000003483 aging Methods 0.000 description 1
- 229910021529 ammonia Inorganic materials 0.000 description 1
- 238000013459 approach Methods 0.000 description 1
- QZPSXPBJTPJTSZ-UHFFFAOYSA-N aqua regia Chemical compound Cl.O[N+]([O-])=O QZPSXPBJTPJTSZ-UHFFFAOYSA-N 0.000 description 1
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 1
- 229910001566 austenite Inorganic materials 0.000 description 1
- 239000010960 cold rolled steel Substances 0.000 description 1
- 230000000052 comparative effect Effects 0.000 description 1
- 239000002131 composite material Substances 0.000 description 1
- 238000000354 decomposition reaction Methods 0.000 description 1
- 230000003247 decreasing effect Effects 0.000 description 1
- 238000000151 deposition Methods 0.000 description 1
- 230000008021 deposition Effects 0.000 description 1
- 238000005530 etching Methods 0.000 description 1
- 239000011521 glass Substances 0.000 description 1
- 229920000592 inorganic polymer Polymers 0.000 description 1
- 238000009413 insulation Methods 0.000 description 1
- 230000031700 light absorption Effects 0.000 description 1
- 229910000734 martensite Inorganic materials 0.000 description 1
- 150000001247 metal acetylides Chemical class 0.000 description 1
- 150000004767 nitrides Chemical class 0.000 description 1
- 229910052760 oxygen Inorganic materials 0.000 description 1
- 239000001301 oxygen Substances 0.000 description 1
- 239000000377 silicon dioxide Substances 0.000 description 1
- 238000005728 strengthening Methods 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- 238000007740 vapor deposition Methods 0.000 description 1
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- B21B1/40—Metal-rolling methods or mills for making semi-finished products of solid or profiled cross-section; Sequence of operations in milling trains; Layout of rolling-mill plant, e.g. grouping of stands; Succession of passes or of sectional pass alternations for rolling foils which present special problems, e.g. because of thinness
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- B21B3/00—Rolling materials of special alloys so far as the composition of the alloy requires or permits special rolling methods or sequences ; Rolling of aluminium, copper, zinc or other non-ferrous metals
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- C21D8/0236—Cold rolling
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- C21D8/00—Modifying the physical properties by deformation combined with, or followed by, heat treatment
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Description
本発明において、基材として使用する鋼箔については、太陽電池の基板で必要とされる耐食性を有する限り特段の制約は無い。ただし、Cr量が7質量%未満では長期使用時の耐食性が不足しており、基板の腐食の問題があり、40質量%を超えると鋼箔製造における中間製品である熱延鋼板の靭性が著しく低下し、製造ラインを通板することができなくなるという問題がある。そのため、Cr量は7〜40質量%にする必要がある。こうした鋼としては、SUS430(17%Cr鋼)、SUS447J1(30%Cr-2%Mo鋼)、9%Cr鋼、20%Cr-5%Al鋼、SUS304(18%Cr-8%Ni鋼)などを挙げられる。
Cは、鋼中のCrと結合して、耐食性の低下をもたらすため、低いほど望ましいが、0.12%以下であれば耐食性を著しく低下させることはない。このため、0.12%以下が好ましく、より好ましくは0.04%以下である。
Siは、脱酸に用いる元素であるが、過剰に含有されると、延性の低下をもたらすため、2.5%以下が好ましい。より好ましくは1.0%以下である。
Mnは、Sと結合してMnSを形成し、耐食性を低下させるため、1.0%以下が好ましい。より好ましくは0.8%以下である。
上述したとおり、Sは、Mnと結合してMnSを形成し、耐食性を低下させるため、0.030%以下が好ましい。より好ましくは0.008%以下である。
Pは、延性の低下をもたらすため、低いほど望ましいが、0.050%以下であれば延性を著しく低下させることはない。このため、0.050%以下が好ましく、より好ましくは0.040%以下である。
Cr量が7%未満では長期使用時の耐食性が不足しており、基板の腐食の問題があり、40%を超えると鋼箔製造における中間製品である熱延鋼板の靭性が著しく低下し、製造ラインを通板することができなくなるという問題がある。そのため、Cr量は7%以上40%以下にする必要がある。
Nb、Ti、Zrはいずれも、鋼中のC、Nを炭化物や窒化物、あるいは炭窒化物として固定し、耐食性を改善するのに有用な元素である。ただし、1.0%を超えて含有すると延性の低下が顕著となるので、これらの元素は単独添加または複合添加いずれの場合も1.0%以下に限定する。なお、これらの元素の添加効果を十分に発揮させるには、0.02%以上含有させることが好ましい。
Alは、脱酸に用いられる元素であるが、過剰に含有されると延性の低下をもたらすため、0.20%以下が好ましい。より好ましくは、0.15%以下である。
Nは、鋼中のCrと結合して、耐食性の低下をもたらすため、低いほど望ましいが、0.05%以下であれば耐食性を著しく低下させることはない。このため、0.05%以下が好ましい。より好ましくは0.015%以下である。
Moは、鋼箔の耐食性、特に局部腐食性を改善するのに有効な元素であり、この効果を得るためには、0.02%以上含有させることが好ましい。一方、4.0%を超えて含有すると延性の低下が顕著となるので、上限は4.0%が好ましい。より好ましくは2.0%以下である。
本発明である太陽電池基板用鋼箔は、Crを7〜40質量%含み、厚さ1mm以下の光輝焼鈍後または焼鈍し、酸洗後の鋼板を、圧下率50%以上で冷間圧延することによって製造できる。これは、図1に示すように、SUS430などでは圧下率を50%以上にすれば930MPa以上の引張強度が得られるためである。圧下率を70%以上にすれば1000MPa以上の引張強度が得られる。
Claims (15)
- 質量%で、C:0.12%以下、Si:2.5%以下、Mn:1.0%以下、S:0.030%以下、P:0.050%以下、Crを7〜40%を含有し、残部がFeおよび不可避的不純物からなる成分組成を有し、
圧延方向に直角方向の引張強度が930MPa以上であり、
0〜100℃における線膨張率が12.0×10 -6 /℃以下であることを特徴とする太陽電池基板用鋼箔。 - 質量%で、C:0.12%以下、Si:2.5%以下、Mn:1.0%以下、S:0.030%以下、P:0.050%以下、Crを7〜40%を含有し、残部がFeおよび不可避的不純物からなる成分組成を有し、
圧延方向に直角方向の引張強度が930MPa以上であり、ミクロ組織がフェライト組織を主体とする組織であることを特徴とする太陽電池基板用鋼箔。 - 質量%で、さらに、Nb、Ti、Zrのうちから選ばれる少なくとも一種を合計で1.0%以下含有することを特徴とする請求項1または2に記載の太陽電池基板用鋼箔。
- 質量%で、さらに、Al:0.20%以下、N:0.05%以下、Mo:0.02〜4.0%のうちから選ばれる少なくとも1種を含有することを特徴とする請求項1〜3のいずれか一項に記載の太陽電池基板用鋼箔。
- 質量%で、さらに、Ni:1.0%以下、Cu:1.0%以下、V:1.0%以下、W:1.0%以下、Ca:0.1%以下、Mg:0.1%以下、REM:0.1%以下、B:0.1%以下のうちから選ばれる少なくとも1種を含有することを特徴とする請求項1〜4のいずれか一項に記載の太陽電池基板用鋼箔。
- 圧延方向に直角方向の引張強度が1000MPa以上であることを特徴とする請求項1〜5のいずれか一項に記載の太陽電池基板用鋼箔。
- ミクロ組織が圧延組織のままであることを特徴とする請求項1〜6のいずれか一項に記載の太陽電池基板用鋼箔。
- 請求項1〜7のいずれか一項に記載の太陽電池基板用鋼箔の製造方法であり、厚さ1mm以下の光輝焼鈍後または焼鈍し、酸洗後の鋼板を、圧下率50%以上で冷間圧延することを特徴とする太陽電池基板用鋼箔の製造方法。
- 圧下率70%以上で冷間圧延することを特徴とする請求項8に記載の太陽電池基板用鋼箔の製造方法。
- フェライト組織を有する光輝焼鈍後または焼鈍し、酸洗後の鋼板を用いることを特徴とする請求項8または9に記載の太陽電池基板用鋼箔の製造方法。
- 冷間圧延後、不活性ガス雰囲気中で400〜700℃の熱処理を施すことを特徴とする請求項8〜10のいずれか一項に記載の太陽電池基板用鋼箔の製造方法。
- 請求項1〜7のいずれか一項に記載の太陽電池基板用鋼箔を用いたことを特徴とする太陽電池基板。
- 請求項12に記載の太陽電池基板を用いたことを特徴とする太陽電池。
- 請求項12に記載の太陽電池基板を用いてRoll-to-Roll方式の連続プロセスにより製造することを特徴とする太陽電池の製造方法。
- Roll-to-Roll方式の連続プロセスが、クリーニング-バック電極スパッタリング-太陽電池処理-セレン化処理-バッファー層形成-トップ電極スパッタリング-電極形成-スリットの工程を含むことを特徴とする請求項14に記載の太陽電池の製造方法。
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