TW201403832A - Laminate for a thin film solar cell and manufacturing method of a thin film solar cell by using the same - Google Patents

Abstract

Laminate for a thin film solar cell 3 according to the present invention is provided with a substrate 30, a transparent conductive layer 31, a photoelectric conversion layer 32 and a transparent electrode layer 33 in this order. The transparent electrode layer 33 contains transparent conductive oxide particles such as indium tin oxide particles and antimony-doped oxidized tin particles and so on and a light-transmissive binder such as hydrolyzate of a silicon alkoxide, polystyrene and acrylic resin. The transparent electrode layer 33 has an adherence capability so that a metal foil or a metal film formed on a substrate can be bonded thereto.

Description

Laminate for thin film solar cell, and manufacturing method of thin film solar cell using the same

The present invention relates to a laminate for a thin film solar cell and a method of producing the thin film solar cell using the same.

At present, based on the standpoint of environmental protection, research and development and practical use of clean energy have progressed, and solar cells have attracted attention because of their inexhaustible sunlight as energy sources and pollution-free. In the past, solar cells used monocrystalline or polycrystalline silicon solar cells. However, since bulk solar cells have high manufacturing costs and low productivity, it is urgent to develop solar cells that are as economical as possible.

Therefore, development of a thin film solar cell using a semiconductor such as an amorphous germanium having a thickness of, for example, 0.3 to 2 μm is being actively carried out. Since the thin film solar cell has a structure in which a semiconductor layer required for photoelectric conversion is formed on a glass substrate or a heat-resistant plastic substrate, it is thin, light in weight, low in cost, and easy to have a large area.

The thin film solar cell has a super-straight-type structure and a sub-straight-type structure, and the ultra-straight structure is usually incident on the light-transmitting substrate side, so it is usually as shown in FIG. The structure is formed in the order of the substrate 201 - the transparent conductive layer 202 - the photoelectric conversion layer 203 - the back electrode layer 204. In the conventional method for producing a thin film solar cell, a transparent conductive layer or a back electrode layer is conventionally formed by a vacuum film formation method such as sputtering. The ultra-straight thin film solar cell 200 is formed by vacuum forming a transparent conductive layer 202, a photoelectric conversion layer 203, and a back electrode layer 204 on a substrate 201. Here, a vacuum is required, and a large vacuum is required. The film forming apparatus generally requires a considerable cost for introduction, maintenance, and operation of a large vacuum film forming apparatus. In order to improve this, it has been disclosed that a composite film composed of a transparent conductive film and a conductive reflective film is formed by a wet coating method using a composition for a transparent conductive film and a composition for a conductive reflective film by a cheaper manufacturing method. Technology of (back electrode layer) (Patent Document 1).

Next, Fig. 2 is a schematic view showing a cross section of a conventional ultra-straight thin film solar cell manufactured by a wet coating method. The ultra-straight type thin film battery 100 manufactured by the wet coating method includes the substrate 110, the transparent conductive layer 103, the photoelectric conversion layer 102, the transparent conductive film 101, and the conductive reflective film 104 in this order, and sunlight is incident from the substrate 110 side. Most of the incident sunlight is reflected by the conductive reflective film 104 and returned to the photoelectric conversion layer 102 to improve conversion efficiency. Here, the reflection of sunlight is also caused at the interface between the transparent conductive film 101 and the photoelectric conversion layer 102. Accordingly, the transparent conductive film 101 and the photoelectric conversion layer 102 are made by lowering the refractive index of the transparent conductive film 101. The difference in refractive index becomes large, which can increase the reflected light at the interface and improve the power generation efficiency of the thin film solar cell.

However, in the above-described wet coating method, since the composition for a transparent conductive film and the composition for a conductive reflective film are directly coated on the photoelectric conversion layer, and then fired, the number of manufacturing steps of the thin film solar cell is increased. Become more. Accordingly, it is desirable to shorten and simplify the number of manufacturing steps. Further, the transparent conductive film of the conventional transparent conductive film formed by the above wet coating method does not have adhesiveness. Therefore, in order to form a conductive reflective film, a heat treatment step of applying a composition for a conductive reflective film onto a transparent conductive film and then baking is performed, so that the heat treatment step may cause damage to the photoelectric conversion layer.

[Previous Technical Literature] [Patent Literature]

[Patent Document 1] Japanese Patent Laid-Open Publication No. 2009-88489

The subject of the present invention is to simplify the process and the efficiency of the manufacturing process of the back electrode of the thin film solar cell, so that the metal foil of the conductive reflective film or the metal film formed on the substrate can be bonded together, and further, by omitting The heat treatment process in the manufacturing step of the conductive reflective film improves the conversion efficiency of the thin film solar cell.

The present invention relates to a laminate for a thin film solar cell, a method for producing a thin film solar cell, and a thin film solar cell, which solve the above problems by the configuration shown below.

The laminating system for a thin film solar cell of the present invention is sequentially provided with a substrate, a transparent conductive layer, a photoelectric conversion layer, and a transparent electrode layer, wherein the transparent electrode layer contains tin oxide particles doped with indium tin oxide particles At least one of transparent conductive oxide particles selected from the group consisting of particles, aluminum-doped zinc oxide particles, and gallium-doped zinc oxide particles, and hydrolyzate from decane oxide, colloidal cerium oxide, polyphenylene a light-transmitting adhesive selected from the group consisting of ethylene, polyurethane, polyamide, polymethyl methacrylate and acrylic resin, and having a conformable metal foil or formed on a substrate The adhesion of the metal film on it.

The laminated system for a thin film solar cell according to another aspect of the present invention is provided with a substrate, a transparent conductive layer, a photoelectric conversion layer, and a transparent electrode layer, wherein the transparent electrode layer is provided with a transparent electrode film sequentially from the side of the photoelectric conversion layer. And the adhesive layer, the transparent electrode film comprising at least one transparent conductive oxide selected from the group consisting of indium tin oxide, antimony-doped tin oxide, aluminum-doped zinc oxide, and gallium-doped zinc oxide. The foregoing layer is composed of a hydrolyzate of decane oxide, colloidal cerium oxide, polyurethane, polyamine, polyvinyl acetate, polyolefin, poly At least one selected from the group consisting of vinyl alcohol and acrylic resin, and having adhesion to a metal foil or a metal film formed on the substrate.

A method of manufacturing a thin film solar cell according to the present invention comprises bonding a metal foil or a metal film formed on a substrate to a thin film solar energy having a substrate, a transparent conductive layer, a photoelectric conversion layer, and a transparent electrode layer in this order. The step of the transparent electrode layer of the laminate for a battery.

A thin film solar cell of the same state of the present invention comprises the above laminate for a thin film solar cell.

According to the laminate for a thin film solar cell of the present invention, since the manufacturing steps of the thin film solar cell are simplified and efficient, the metal foil of the conductive reflective film or the metal foil formed on the substrate can be bonded together. Since the heat treatment process in the manufacturing step of the conductive reflective film of the thin film solar cell is omitted, the conversion efficiency of the thin film solar cell is improved by suppressing deterioration of the photoelectric conversion layer.

According to the method for manufacturing a thin film solar cell of the present invention, the manufacturing process of the thin film solar cell can be simplified and streamlined by bonding a metal foil or a metal film formed on the substrate, thereby improving the thin film solar cell. Conversion efficiency.

1, 2, 3, 4 ‧ ‧ laminates for thin film solar cells

10, 0, 30, 40‧‧‧ substrates

11, 21, 31, 41‧‧‧ transparent conductive layer

12, 22, 32, 42‧‧‧ photoelectric conversion layer

13, 23, 33, 43‧‧‧ transparent electrode layer

13a, 23a‧‧‧ heated transparent electrode layer

14.24‧‧‧Metal foil or metal film formed on a substrate

25‧‧‧Transparent conductive film

5‧‧‧Metal film formed on a substrate

50‧‧‧Metal film

51‧‧‧Substrate

100‧‧‧Super straight thin film solar cell

110‧‧‧Substrate

101‧‧‧Transparent conductive film

102‧‧‧ photoelectric conversion layer

103‧‧‧Transparent conductive layer

104‧‧‧ Conductive reflective film

200‧‧‧Super straight thin film solar cell

201‧‧‧Substrate

202‧‧‧Transparent conductive layer

203‧‧‧ photoelectric conversion layer

204‧‧‧Back electrode layer

431‧‧‧Transparent electrode film

432‧‧‧Next layer

Fig. 1 is a schematic view showing a cross section of a conventional ultra-straight thin film solar cell.

Fig. 2 is a schematic view showing a cross section of a conventional ultra-thin thin film solar cell manufactured by a wet coating method.

Fig. 3A is a schematic view showing an example of a method of manufacturing a thin film solar cell of the present invention.

Fig. 3B is a schematic view showing an example of a method of manufacturing the thin film solar cell of the present invention.

Fig. 3C is a schematic view showing an example of a method of manufacturing the thin film solar cell of the present invention.

Fig. 4 is a schematic cross-sectional view showing a laminate for a thin film solar cell in the case where the transparent electrode layer of the present invention itself has an adhesive property.

Fig. 5 is a schematic cross-sectional view showing a laminate for a thin film solar cell in the case where an adhesive layer is formed on the surface of the transparent electrode film of the present invention.

Fig. 6 is a schematic cross-sectional view showing a metal film formed on a substrate.

Fig. 7A is a schematic view showing an example of a method of manufacturing a thin film solar cell of the present invention.

Fig. 7B is a schematic view showing an example of a method of manufacturing the thin film solar cell of the present invention.

Fig. 7C is a schematic view showing an example of a method of manufacturing the thin film solar cell of the present invention.

Hereinafter, the present invention will be specifically described based on the embodiments. Further, the % in the present specification is % by mass unless otherwise specified.

The laminate for a thin film solar cell of the present invention (hereinafter referred to as a laminate) is provided with a laminate of a substrate, a transparent conductive layer, a photoelectric conversion layer, and a transparent electrode layer in this order. The transparent electrode layer is characterized by comprising at least one selected from the group consisting of indium tin oxide particles, antimony-doped tin oxide particles, aluminum-doped zinc oxide particles, and gallium-doped zinc oxide particles. The oxide particles are selected from the group consisting of hydrolyzate of decane oxide, colloidal cerium oxide, polystyrene, polyurethane, polyamine, polymethyl methacrylate, and acrylic resin. A light-transmitting adhesive having adhesion to a metal foil or a metal film formed on a substrate. The transparent electrode layer in this case is referred to as type (1). Here, the adhesive bondability refers to a layer having a transparent electrode layer after bonding a metal foil or a metal film formed on the substrate by applying an external force to the transparent electrode layer provided on the laminate. The metal foil formed on the substrate or the metal foil is not removed, and the metal foil or the metal film formed on the substrate is not peeled off from the transparent electrode layer.

Further, the laminate system of the present invention is provided with a laminate of a substrate, a transparent conductive layer, a photoelectric conversion layer and a transparent electrode layer, and the transparent electrode layer is provided with a transparent electrode film and an adhesive layer in this order from the side of the photoelectric conversion layer, and is transparent. The electrode layer is a transparent electrode film of at least one selected from the group consisting of indium tin oxide, antimony-doped tin oxide, aluminum-doped zinc oxide, and gallium-doped zinc oxide, followed by a transparent conductive oxide. The layer is at least one selected from the group consisting of hydrolyzate of decane oxide, colloidal cerium oxide, polyurethane, polyamine, polyvinyl acetate, polyolefin, polyvinyl alcohol, and acrylic resin. And has a conformable metal foil or is formed on The adhesion of the metal film on the substrate. The transparent electrode layer at this time is referred to as a type (2).

These laminates can be used in a variety of thin film solar cells, particularly for ultra-straight thin film solar cells.

3A to 3C are schematic views showing an example of a method of manufacturing a thin film solar cell using a laminate. First, as shown in FIG. 3A, a laminate 1 including a substrate 10, a transparent conductive layer 11, a photoelectric conversion layer 12, and a transparent electrode layer 13, and a metal foil or a metal film 14 formed on a substrate are prepared in this order. Next, as shown in FIG. 3B, after the metal foil or the metal film 14 formed on the substrate is bonded to the transparent electrode layer 13, the transparent electrode layer 13 is heated. Thereby, as shown in FIG. 3C, a thin film solar cell in which a metal foil or a metal film 14 formed on a substrate is bonded to the transparent electrode layer 13a can be manufactured.

The substrate, the transparent conductive film, and the photoelectric conversion layer are not particularly limited as long as they are available to a thin film solar cell. Further, the method of curing the transparent electrode layer 13 may be appropriately selected depending on the type of the transparent electrode layer.

[Transparent electrode layer]

The transparent electrode layer has an adhesiveness. When the transparent electrode layer is of the (1) type, the transparent electrode layer itself has an adhesive property, and when it is of the (2) type, the adhesive layer formed on the surface of the transparent electrode film has an adhesive property. Here, the adhesion of the transparent electrode layer is (A) utilizing the adhesion of the transparent electrode laminate itself or the adhesive layer of the surface of the transparent electrode film itself to the metal foil or formed on the substrate. The metal film (hereinafter also referred to as a metal foil or the like) is attached (hereinafter referred to as (A) type), and the (B) transparent laminate itself or the adhesive layer on the surface of the transparent electrode film itself does not have adhesiveness, but overlaps the metal foil. After that, the person who exhibits adhesion by heating (hereinafter referred to as (B) type). In the case of the type (A), the metal foil or the like is bonded to the transparent electrode layer by the adhesion of the transparent electrode layer, and then heated to cure the transparent electrode layer. In the case of the (B) type, after the metal foil or the like is superposed on the transparent electrode layer, it is heated and bonded to a metal foil or the like. Here, FIG. 4 shows a cross-sectional schematic view of a laminate for a thin film solar cell in which the transparent electrode layer itself has an adhesive property, and FIG. 5 shows a film in which an adhesive layer is formed on the surface of the transparent electrode film. A schematic view of a cross section of a laminate for a solar cell. As shown in FIG. 4, when the transparent electrode layer itself has adhesiveness, the thin film solar cell laminate 3 includes the substrate 30, the transparent conductive layer 31, the photoelectric conversion layer 32, and the transparent electrode layer 33 in this order. Further, as shown in FIG. 5, when the adhesive layer is formed on the surface of the (2) transparent electrode film, the thin film solar cell laminate 4 includes the substrate 40, the transparent conductive layer 41, the photoelectric conversion layer 42, and the transparent electrode in this order. A transparent electrode layer 43 of the adhesion layer 432 is formed on the surface of the layer 431.

"(1) type: the case where the transparent electrode layer itself has an adhesion" In the case of (A) type, the adhesion of the transparent electrode layer itself is followed by the metal foil or the like.

When the transparent electrode layer of the type (A) is a super-straight thin film solar cell, a substrate in which a transparent conductive layer and a photoelectric conversion layer are sequentially formed is prepared in advance. Connect The composition for a transparent electrode layer is applied onto the photoelectric conversion layer by a wet coating method to form a coating film for a composition for a transparent electrode layer, and then the coating film is semi-dried to produce a transparent electrode layer. Here, since the composition for a transparent electrode layer contains a transparent conductive oxide particle and a light-transmitting adhesive, it is suitable for a wet coating method.

The transparent conductive oxide particles impart conductivity to the cured transparent electrode layer. The transparent conductive oxide particles are made of indium tin oxide (ITO) particles, antimony-doped tin oxide (ATO) particles, aluminum-doped zinc oxide (AZO) particles, and gallium-doped zinc oxide (GZO) particles. At least one selected from the group consisting of. Further, the average particle diameter of the transparent conductive oxide particles is preferably in the range of 10 to 100 nm in order to maintain stability in the dispersion medium. Here, the average particle diameter is measured by the BET method of measuring the specific surface area by AQUNTACHROME AUTOSORB-1.

When the light-transmitting adhesive used in the type (A) is at least one selected from the group consisting of hydrolyzate of decane oxide, colloidal cerium oxide, polyurethane, polyamide, and acrylic resin, It is preferred that the adhesion of the transparent electrode layer itself is high. It is preferred that the hydrolyzate of the decane oxide and the colloidal cerium oxide have less change with time in the transparent electrode layer after hardening. Polystyrene, polymethyl methacrylate, and acrylic resin are preferred thermoplastic resins which are formed at a lower temperature and are more suitable for the operation surface. A representative of a polyurethane and a polyamine-based solid binder is preferred in terms of ease of use.

100 parts by mass of the solid component (transparent conductive oxide grain) in the composition for a transparent electrode layer with respect to the composition for a transparent electrode layer The seed, the binder, and the like) preferably contain 98 to 50 parts by mass of the transparent conductive oxide particles. The reason is that when the amount is more than 98 parts by mass, the adhesion is lowered, and when the amount is less than 50 parts by mass, the conductivity is lowered.

The composition for a transparent electrode layer preferably contains a dispersion medium in order to form a film. The dispersion medium is exemplified by alcohols such as water, methanol, ethanol, isopropanol and butanol, or ketones such as acetone, methyl ethyl ketone, cyclohexanone and isophorone, or toluene, xylene and hexane. Hydrocarbons such as cyclohexane, or guanamines such as N,N-dimethylformamide, N,N-dimethylacetamide, or anthraquinones such as dimethyl hydrazine, or ethylene glycol. Glycols, glycol ethers such as ethyl cellosolve, and the like. The content of the dispersion medium is preferably from 80 to 99 parts by mass based on 100 parts by mass of the composition for the transparent electrode layer in order to obtain good film formability.

The composition for a transparent electrode layer may further contain a filler, a stress relieving agent, a low-resistance agent, a water-soluble cellulose derivative, other additives, etc., as needed within the range not impairing the object of the present invention.

The composition for a transparent electrode layer can be produced by mixing a transparent conductive oxide particle and a light-transmitting adhesive by mixing a desired component with a coating shaker, a ball mill, a sand mill, a Centrimill, a triaxial roll, or the like by a usual method. . Of course, it is also possible to manufacture a composition for a transparent electrode layer by a usual stirring operation.

Next, the composition for a transparent electrode layer is applied onto the photoelectric conversion layer of the substrate by a wet coating method, and by semi-drying, a transparent electrode layer having an adhesive property can be produced.

The wet coating method is preferably a spray coating method or a cloth coating method. Any one of a method, a spin coating method, a knife coating method, a slit coating method, an inkjet coating method, a screen printing method, a lithography method, or a die coating method, but is not limited thereto. All methods are available

The step of allowing the substrate having the coating film for the composition of the transparent electrode layer to be kept in the atmosphere or semi-drying in an inert gas atmosphere such as nitrogen or argon is as long as the thickness of the transparent electrode layer is operable, and the composition of the transparent electrode layer is used. The conditions of the residual adhesiveness of the object can be carried out. For example, it is preferable to semi-dry the volatilization of about 1/2 to 2/3 of the dispersion medium in the composition for the transparent electrode layer, but since the residual dispersion medium becomes a cause of generation of bubbles after bonding, It is preferred that the adhesive is semi-dried to a small extent in the range of adhesion. One of the conditions for semi-drying the coating film of the composition for a transparent electrode layer is 30 to 40 ° C for 10 to 30 minutes. Here, it is preferable that the thickness of the composition for the transparent electrode layer after the semi-drying is in the range of 0.03 to 0.5 μm. When the thickness of the composition for a transparent electrode layer after semi-drying is less than 0.03 μm, the uniformity of the film is lowered and the adhesion is lowered. When the thickness exceeds 0.5 μm, the transparency and conductivity are lowered.

In the type (B), the transparent electrode layer itself does not have adhesiveness, but after being overlapped with a metal foil or the like, the adhesion is exhibited by heating.

In the case of a super-straight-type thin film solar cell, the transparent electrode layer of the type (B) is prepared in advance to form a substrate of a transparent conductive layer and a photoelectric conversion layer in this order. Then, the transparent electrode layer composition is applied onto the photoelectric conversion layer by a wet coating method to form a coating film for the composition for a transparent electrode layer, and then the coating film is dried, whereby a transparent electrode layer can be produced. Here, in addition to making transparent electricity The step of drying the coating film of the composition for the electrode layer is the same as in the case of the above (A) type. One example of the conditions for drying the coating film of the composition for the transparent electrode layer is in an inert gas atmosphere at 40 to 50 ° C for 5 to 10 minutes. Here, the transparent conductive oxide particles used in the type (B) are the same as those in the above (A) type.

The light-transmitting adhesive used in the type (B) is at least one selected from the group consisting of polystyrene, polyurethane, polyamide, and polymethyl methacrylate, since the transparent electrode is used. Since the layer is completely hardened once and can be heated by heating, it is preferable in terms of the operation surface. Further, the light-transmitting adhesive is preferably the emulsion type.

"(2) type: formation of an adhesive layer on the surface of a transparent electrode film"

The transparent electrode film contains a transparent conductive oxide that imparts conductivity to the transparent electrode film. The transparent conductive oxide is at least one selected from the group consisting of indium tin oxide, antimony-doped tin oxide, aluminum-doped zinc oxide, and gallium-doped zinc oxide. In the above-mentioned (1) type, the transparent electrode film is not only dried or cured by the composition for the transparent electrode layer of the type (A) or (B), but also by sputtering, MBE, PLD, or vapor deposition. A film formed by a vacuum film formation method or a spray pyrolysis method, such as indium tin oxide, antimony-doped tin oxide, aluminum-doped zinc oxide, or gallium-doped zinc oxide. Further, in the type (1), one of the conditions for curing the composition for the transparent electrode layer of the (A) type or the (B) type is in the atmosphere or in an inert gas atmosphere such as nitrogen or argon at 130 to 200 ° C. It lasted 5~60 minutes. The thickness of the transparent electrode film is preferably from 0.001 to 10 μm, which is better in terms of transparency, resource saving, and step. 0.01~0.5μm. Further, the thickness of the subsequent layer is preferably from 0.001 to 1 μm. The reason for this is that it has adhesion while maintaining contact with the photoelectric conversion layer. The layer can be formed on the surface of the transparent electrode film by a wet coating method or the like.

The layer is then at least one selected from the group consisting of hydrolyzate of decane oxide, colloidal cerium oxide, polyurethane, polyamine, polyvinyl acetate, polyolefin, polyvinyl alcohol, and acrylic resin. .

In the case of the type (A), the adhesion of the adhesive layer itself on the surface of the transparent electrode film is followed by the metal foil or the like.

Next, the layer can be applied onto the transparent electrode film by a wet coating method to form a coating film of the composition for the subsequent layer, and then the coating film is semi-dried to be produced. As the composition for the layer, the composition for a transparent electrode layer of the type (A) in the above (1) type can be used.

In the case of the type (B), the adhesive layer on the surface of the transparent electrode film itself does not have adhesiveness, but after bonding with a metal foil or the like, the adhesion is exhibited by heating.

Next, the layer can be produced by applying a composition for an adhesive layer on a transparent electrode film by a wet coating method to form a coating film of a composition for an adhesive layer, and then drying the coating film. When the light-transmitting adhesive used in the type (B) is a polyurethane, a polyamide, a polyvinyl acetate, a polyolefin, or a polyvinyl alcohol, the adhesive layer can be heated by being completely hardened once. Therefore, it is preferable in terms of the operation surface. Further, the light-transmitting adhesive is also preferably the emulsion type.

[Metal foil, metal film formed on a substrate]

The metal foil refers to an electrolytic metal produced by electroplating, and a rolled metal is formed into a thin plate. The metal foil is exemplified by a silver foil, an aluminum foil, a copper foil, a gold foil, or the like. When the thickness of the metal foil is 0.1 to 50 μm, it is preferable from the viewpoint of workability and cost of the metal foil.

Further, the metal film formed on the substrate refers to a film made of a metal which is produced by a method other than plating and rolling on the substrate, and is exemplified as a metal deposited film formed on the substrate, or is sputtered on the substrate. A metal film formed by a method or an ion plating method. The metal vapor deposition film is a metal thin film formed on a substrate by vaporizing or sublimating by heating a metal under vacuum. The metal film is exemplified by a silver vapor deposition film, an aluminum vapor deposition film, a copper vapor deposition film, a gold vapor deposition film, a silver sputtering film, a silver ion plating film, or the like. When the thickness of the metal film is 0.1 to 50 μm, it is preferable from the viewpoint of cost. The substrate is exemplified by a PET film, a polyimide film, or the like. When the thickness of the substrate is 50 to 250 μm, it is preferable from the viewpoint of workability. Fig. 6 is a schematic cross-sectional view showing a metal film formed on a substrate. As shown in FIG. 6, the metal film 5 formed on the substrate has a substrate 51 and a metal film 50 formed thereon.

Further, in the metal foil and the metal film formed on the substrate, when a transparent conductive film is formed on the surface to which the laminate is bonded, the transparent electrode layer and the transparent conductive film which are hardened from the sunlight incident on the substrate The reflected light at the interface increases. Thereby, the conversion efficiency of the thin film solar cell can be improved, which is preferable. This transparent conductive film is the same as the transparent conductive film of the laminate for a thin film solar cell of the above (2) type.

[Manufacturing method of thin film solar cell]

The method for producing a thin film solar cell of the present invention is characterized in that the metal foil or the metal film formed on the substrate is bonded to the thin film solar energy having a substrate, a transparent conductive layer, a photoelectric conversion layer, and a transparent electrode layer in this order. The step of the transparent electrode layer of the laminate for a battery. 7A to 7C are schematic views showing an example of a method of manufacturing a thin film solar cell in the case where the metal foil or the metal film formed on the substrate has a transparent conductive film. First, as shown in FIG. 7A, a laminate 2 including a substrate 20, a transparent conductive layer 21, a photoelectric conversion layer 22, and a transparent electrode layer 23, and a metal foil having a transparent conductive film 25 or formed on a substrate are prepared. Metal film 24. Next, as shown in FIG. 7B, after the metal foil or the transparent conductive film 25 of the metal film 24 formed on the substrate is bonded to the transparent electrode layer 23, by heating the transparent electrode layer 23, it can be manufactured as shown in the figure. Thin film solar cell shown in 7C. An example of the condition for heating the transparent electrode layer 23 is in the case of the type (A) or the type of the type (B) in an atmosphere of an inert gas such as nitrogen or argon at 130 to 200 ° C for 5 to 60 minutes.

[Examples]

The invention will be described in detail below by way of examples, but the invention is not limited thereto. Further, the evaluation of the present invention uses an ultra-straight thin film tantalum solar cell, but the thin film solar cell to which the present invention can be applied is not limited to these. The conversion efficiency was determined by the following. For the evaluation of the electrode after the fabrication of the film 矽 solar cell, the wire was wired on the substrate after the wire processing of the solar cell element, and a solar simulator and a digital current-voltage measuring instrument were used to obtain AM: 1.5, and irradiation of 100 mM/cm ^{2 .} Time IV (current-voltage) curve. Next, the current value (I) in the obtained IV (current-voltage) curve was divided by the surface area of the thin film solar cell element, and JV (current density-voltage) was obtained. In the JV curve, the axis of the voltage and the axis of the current density are set to two sides, and the output of the area where the area of the rectangle drawn by the point on the origin and the JV curve is maximized is set to the highest output density (mW/cm). ² ), [maximum output density (mW/cm ² )] / [100 (mW/cm ² )] × 100 was used as the conversion efficiency (%). Tables 1~3 show these results.

In the case of Examples 1 to 22, as shown in Fig. 3A, a glass substrate having a SiO ₂ layer (not shown) having a thickness of 50 nm was formed as a substrate 10 on one main surface. A surface electrode layer (SnO ₂ film) having a surface having a concave-convex pattern and having a thickness of 800 nm doped with F (fluorine) was formed as the transparent conductive layer 11 on the SiO ₂ layer. The transparent conductive layer 11 is patterned into a matrix by a laser processing method, and these are electrically connected to each other to form a wiring. Next, the photoelectric conversion layer 12 is formed on the transparent conductive layer 11 by a plasma CVD method. In this embodiment, the photoelectric conversion layer 12 is sequentially laminated from the side of the substrate 10 by p-type a-Si:H (amorphous germanium), i-type a-Si:H (amorphous germanium), and n. A film formed by a type of μc-Si:H (microcrystalline germanium). The above-described photoelectric conversion layer 12 is patterned using a laser processing method. The solar cell element which has been actively formed into a film is used in the evaluation of the laminate for thin film solar cells shown in the examples. Similarly, in the case of the embodiments 23 to 35, as shown in FIG. 7A, the transparent conductive layer 21 and the photoelectric conversion layer 22 are formed on the substrate 20, and as the solar cell element which has been actively formed into a film, it is used in the embodiment. Evaluation of laminates for thin film solar cells.

In the case of Examples 1 to 22, as shown in FIG. 3A, a transparent electrode layer 13 was formed on the photoelectric conversion layer 12 of the solar cell element which has been actively formed into a film, as shown in Table 1 and Table 2, and a film was formed. Laminated body 1 for solar cells. On the formed transparent electrode layer 13, as shown in FIG. 3B, a metal foil patterned by laser or mechanical drawing, etching, or the like, or a metal film 14 formed on the substrate is bonded. Similarly, in the case of Examples 23 to 35, as shown in Fig. 7A, a transparent electrode layer 23 was formed on the photoelectric conversion layer 22 of the solar cell element which had been actively formed into a film, and a thin film solar cell was fabricated. Use laminate 2. On the formed transparent electrode layer 23, a transparent conductive film 25 formed on a metal foil or a metal film 24 formed on a substrate is bonded as shown in FIG. 7B. Here, in the column of "treatment method after bonding" in Tables 1 to 3, "hot" indicates the case of (A) type, and "hot melt" indicates the case of type (B).

Next, when the power generation efficiency of the solar cell element was evaluated, a reinforcing film was formed on the metal foil or the metal film formed on the substrate. Specifically, a composition for a reinforcing film is applied to a solar cell element in which a metal foil is actively formed or a metal film is formed on a substrate, by a die coating device. Then, the solvent is removed from the coating film for a reinforcing film by vacuum drying, and the solar cell element is held in a hot air drying furnace to thermally harden the coating film for the reinforcing film. Thereby, a reinforcing film is obtained.

a photoelectric conversion layer of the solar cell element, a transparent electrode layer formed thereon, a metal foil or a metal film formed on the substrate, and The reinforced film is patterned by a laser processing method as needed, thereby producing a film solar cell for evaluation.

<Example 1>

A method of forming a transparent electrode layer, a metal foil, a metal film formed on a substrate, and a reinforcing film will be described. The composition for a transparent electrode layer used for forming a transparent electrode layer was prepared as follows. By mixing 70 parts by mass of gallium-doped zinc oxide (GZO) having an atomic ratio of Ga/(Ga+Zn)=0.02 as a transparent conductive oxide particle, and isopropanol as a dispersion medium, The whole is set to 100 parts by mass. The mixture was dispersed in a Dyno Mill (horizontal bead mill) by using a 0.3 mm diameter zirconia ball for 2 hours to disperse the GZO powder in the mixture. Polystyrene as a binder was mixed in the dispersion in a mass ratio of GZO powder: polystyrene = 7:3. Then, the dispersion liquid was diluted with ethanol so that the GZO powder became 2 parts by mass with respect to 100 parts by mass of the composition for the transparent electrode layer, and a composition for a transparent electrode layer was obtained. The composition for the transparent electrode layer was applied to the photoelectric conversion layer of the solar cell element which had been actively formed by a die coater so as to have a film thickness of 50 nm after heat treatment, and dried. Transparent electrode layer. On the other hand, on a PET film (stretched film, heat-resistant: 200 ° C) having a thickness of 100 μm used as a substrate, a silver film was formed by sputtering as a metal film, and the silver film was patterned by mechanical drawing. Chemical. After the silver film formed on the PET film was bonded to the transparent electrode layer, heat treatment was performed at 180 ° C for 10 minutes, and the silver film formed on the PET film was bonded to the transparent electrode layer. Connect A cerium oxide sol gel (SB-10A manufactured by Mitsubishi Materials Co., Ltd.) was applied onto a PET film by a die coating apparatus so that the film thickness after the heat treatment was 1 μm, and heat treatment was performed at 120 ° C. In minutes, a reinforcing film is formed.

<Examples 2 to 14>

Except that the conditions shown in Table 1 were used, the test was carried out in the same manner as in Example 1. Here, the cerium oxide-soluble gel used as the hydrolyzate containing a decane oxide used in Example 5 or the like is SB-10A manufactured by Mitsubishi Materials Corporation. Further, in the wet coating method used in Example 7 or the like, an Ag nano ink obtained by dispersing an Ag colloid having an average particle diameter of 0.03 μm in an ethanol solvent was used. The composition of the Ag nano ink used was 10 parts by mass of Ag colloid and 90 parts by mass of ethanol. Further, the ratio of the transparent conductive oxide particles in Table 1 (the transparent conductive oxide particles in the solid content, unit: % by mass) means {(the mass of the transparent conductive oxide particles) / [(transparent conductive oxidation) The mass of the particles) + (mass of the binder)] × 100}. Further, the adhesive layers of Examples 6, 11, and 13 were produced by drying, and the adhesive layers of Examples 2 to 5, 7 to 10, 12, and 14 were produced by semi-drying.

<Example 15>

A method of forming a transparent electrode layer, a metal foil, or a metal film formed on a substrate and a reinforcing film will be described. On the photoelectric conversion layer of the solar cell element which has been actively formed into a film, indium tin having an atomic ratio of Sn/(Sn+In)=0.05 is used. An oxide (ITO) target was formed into a film of an ITO thin film as a transparent electrode film by molecular beam epitaxy (MBE). Polyimine was applied to the formed transparent electrode film by a die coating device, and an adhesive layer was formed by drying. On the other hand, on a PET film (stretched film, heat-resistant: 200 ° C) having a thickness of 100 μm used as a substrate, a titanium film was formed by sputtering as a metal film, and the titanium film was applied as a laser line. Modeling. The titanium film formed on the PET film was bonded to the adhesive layer, and then heat-treated at 180 ° C for 5 minutes to bond the titanium film formed on the PET film to the transparent electrode layer. Next, methylcellulose was applied onto a PET film by a die coating apparatus so that the film thickness after the heat treatment was 1 μm, and heat treatment was performed at 120 ° C for 10 minutes to form a reinforcing film.

<Examples 16 to 22>

Except that the conditions shown in Table 2 were set, the test was carried out in the same manner as in Example 15. Here, the cerium oxide-soluble gel used in Example 16 or the like was SB-10A manufactured by Mitsubishi Materials Corporation. Further, in the wet coating method used in Example 18 or the like, an Ag nano ink obtained by dispersing an Ag colloid having an average particle diameter of 0.03 μm in an ethanol solvent was used. The composition of the Ag nano ink used was 10 parts by mass of Ag colloid and 90 parts by mass of ethanol. The adhesive layers of Examples 19 and 21 were prepared by drying, and the subsequent layers of Examples 16 to 18, 20 and 22 were produced by semi-drying.

<Example 23>

A method of forming a transparent electrode layer, a metal foil, or a metal film formed on a substrate and a reinforcing film will be described. On a PET film (stretched film, heat-resistant: 200 ° C) having a thickness of 100 μm used as a substrate, a titanium film was formed by sputtering as a metal film, and an atomic ratio of Sn/(Sn+In)=0.05 was used. The ITO target was formed by sputtering a ITO thin film as a transparent conductive film on the formed titanium thin film, and the ITO thin film was patterned by a laser line. On the other hand, on the photoelectric conversion layer of the solar cell element which has been actively formed, an ITO target having an atomic ratio of Sn/(Sn+In)=0.05 was used, and a transparent electrode film was formed by a sputtering method. Polyimine was applied to the formed transparent electrode film by a die coating device and dried to form an adhesive layer. The ITO film formed on the titanium film formed on the PET film was bonded to the adhesive layer, and then heat-treated at 180 ° C for 5 minutes to bond the titanium film formed on the PET film to the adhesive layer. . Next, methylcellulose was applied onto a PET film by a die coating apparatus so that the film thickness after the heat treatment became 1 μm, and heat treatment was performed at 120 ° C for 10 minutes to form a reinforcing film.

<Examples 24 to 35>

Except that the conditions shown in Table 3 were set, the test was carried out in the same manner as in Example 23. Here, the cerium oxide-soluble gel used in Example 25 or the like was SB-10A manufactured by Mitsubishi Materials Corporation. Further, in the wet coating method used in Example 30 or the like, an Ag nano ink obtained by dispersing an Ag colloid having an average particle diameter of 0.03 μm in an ethanol solvent was used. The composition of the Ag nano ink used is 10 parts by mass of the Ag colloid. Ethanol was 90 parts by mass. The adhesive layers of Examples 24, 31, 33, and 34 were prepared by drying, and the adhesive layers of Examples 25 to 30, 32, and 35 were prepared by semi-drying.

<Comparative Example 1>

A coated back electrode is used in place of the transparent electrode layer, the metal foil, and the like. A method of forming a coated back electrode will be described. The coated back surface electrode is made of a transparent conductive film or a reflective electrode layer. First, a composition for a transparent conductive film used for forming a transparent conductive film on the back side is prepared as follows. 1.0 part by mass of ITO powder having an atomic ratio of Sn/(Sn+In)=0.1, an average particle diameter of 0.03 μm, and 0.05 parts by mass of the transparent conductive oxide particles as a light-transmitting adhesive The cerium oxide sol gel (SB-10A, manufactured by Mitsubishi Materials Corporation) and 98.95 parts by mass of ethanol as a dispersion medium were mixed, and the whole was set to 100 parts by mass.

This mixture was obtained by running a Dyno Mill (horizontal bead mill) for 2 hours using a 0.3 mm diameter zirconia ball to disperse the fine particles in the mixture to obtain a composition for a transparent conductive film.

Then, the composition for the transparent conductive film to be prepared is applied onto the photoelectric conversion layer of the solar cell element which has been actively formed by a spin coating method so that the film thickness after firing is 80 nm, and the coating film is formed. It was baked at 200 ° C for 30 minutes, thereby forming a transparent conductive film. The film thickness after firing was measured by photographs on the SEM photographing cross section. The ratio of the transparent conductive oxide particles to the light-transmitting adhesive in the transparent conductive film obtained by firing is 2/1 of the ratio of the transparent conductive oxide particles/translucent adhesive. Again, off The temperature at the time of firing was measured at a temperature of 4 o'clock on the corner of a glass plate of 10 cm square, and the average value fell within ±5 ° C of the set temperature.

Further, Ag nano ink was applied onto the formed transparent conductive film so as to have a film thickness after firing of 200 nm by a spin coating method, and the coating film was fired at 200 ° C for 30 minutes to form a conductive film. Reflective film. Further, the Ag nano ink used was obtained by dispersing an Ag colloid having an average particle diameter of 0.03 μm in an ethanol solvent, and the composition was 10 parts by mass of Ag colloid and 90 parts by mass of ethanol. A cerium oxide sol gel (SB-10A manufactured by Mitsubishi Materials Co., Ltd.) was applied onto a conductive reflective film layer by a die coating apparatus so that the film thickness after the heat treatment was 1 μm, and heat treatment was performed at 120 ° C. After 10 minutes, a reinforcing film was formed.

As shown in Tables 1-3, the conversion efficiencies of all of Examples 1 to 35 are as high as 8.2 to 9.8%. On the other hand, in Comparative Example 1, although it was produced in a more complicated procedure than in Examples 1 to 35, the conversion efficiency was lower than that of Examples 1 to 35. It is considered that in Examples 1 to 35, since the heat treatment process in the production step is shortened and the temperature is lowered, the conversion efficiency is high.

As described above, by using the laminate for a thin film solar cell of the present invention, since the manufacturing process of the thin film solar cell is simplified and efficient, the metal foil as the conductive reflective film or the metal film formed on the substrate can be attached. Combined with the transparent electrode layer, the conversion efficiency of the thin film solar cell can be further improved.

3‧‧‧Layer for thin film solar cells

30‧‧‧Substrate

31‧‧‧Transparent conductive layer

32‧‧‧ photoelectric conversion layer

33‧‧‧Transparent electrode layer

Claims (4)

A laminate for a thin film solar cell, which is provided with a laminate for a thin film solar cell having a substrate, a transparent conductive layer, a photoelectric conversion layer, and a transparent electrode layer, wherein the transparent electrode layer contains doped tin oxide particles and is doped At least one of transparent conductive oxide particles selected from the group consisting of tin oxide particles, aluminum-doped zinc oxide particles, and gallium-doped zinc oxide particles, and hydrolyzate and colloidal dioxide by decane oxide a light-transmitting adhesive selected from the group consisting of ruthenium, polystyrene, polyurethane, polyamido, polymethyl methacrylate, and acrylic resin, and having a conformable metal foil or The adhesion of the metal film formed on the substrate. A laminate for a thin film solar cell, which is provided with a laminate for a thin film solar cell having a substrate, a transparent conductive layer, a photoelectric conversion layer, and a transparent electrode layer, wherein the transparent electrode layer is sequentially transparent from the side of the photoelectric conversion layer An electrode film and an adhesive layer, wherein the transparent electrode film contains at least one transparent conductive oxide selected from the group consisting of indium tin oxide, antimony-doped tin oxide, aluminum-doped zinc oxide, and gallium-doped zinc oxide. The foregoing adhesive layer is selected from the group consisting of hydrolyzate of decane oxide, colloidal cerium oxide, polyurethane, polyamine, polyvinyl acetate, polyolefin, polyvinyl alcohol and acrylic resin. At least one of them has an adhesion to a metal foil or a metal film formed on the substrate. A method of manufacturing a thin film solar cell comprising a metal foil Or a metal film formed on the substrate is bonded to the transparent electrode layer of the laminate for a thin film solar cell according to claim 1 or 2, which is provided with a substrate, a transparent conductive layer, a photoelectric conversion layer, and a transparent electrode layer. step. A thin film solar cell comprising the laminate for a thin film solar cell according to claim 1 or 2.