TW201808461A - Die coater and method of manufacturing dye-sensitized solar cell - Google Patents

Abstract

The present application provides a die coater 3 including a first block 31 having a liquid chamber 3a that accommodates an electrolysis solution 15, a second block that is disposed so as to face the first block 31, and a shim 30 that is held between the first block 31 and the second block and has a projected discharging section 33 that projects toward the discharging side from a part of the width direction W and discharges the electrolysis solution 15 in the liquid chamber 3a, wherein the shim 30 includes a projected discharging section 33 that projects toward the discharging direction from the distal end surface 30a of a side from which the electrolysis solution 15 is discharged and a slit 35a that communicates a discharging outlet 33a of the projected discharging section 33 and a liquid chamber 3a.

Description

Mold coater, manufacturing device of dye-sensitized solar cell, and method of manufacturing battery

The present invention relates to a mold coater, a manufacturing apparatus of a dye-sensitized solar cell, and a method of manufacturing a battery.

The present application claims priority based on Japanese Patent Application No. 2016-153700, filed on Jan.

In the dye-sensitized solar cell, for example, a structure including a transparent conductive layer, a semiconductor electrode, a counter electrode substrate, a counter electrode, a sealing material, an electrolyte layer (electrolyte), and a collector electrode is known as disclosed in Patent Document 1. In such a dye-sensitized solar cell, continuous production by a roll-to-roll method (hereinafter referred to as RtoR method) has been put into practical use.

In the manufacturing step of the dye-sensitized solar cell, for example, a step of applying an electrolytic solution (coating liquid) between the semiconductor electrode and the counter electrode is known to have a discharge port serving as a coating liquid at the tip end portion. The die coater of the slit is one of the coating devices. For example, as described in Patent Document 2, a die coater supplies a coating liquid to a manifold formed inside, and extrudes a coating liquid from a manifold to a slit, and brings a film-like substrate close to the slit. Relative movement, thereby utilizing surface tension A coating liquid is applied to the surface of the substrate. Then, when adjusting the thickness of the coating liquid applied to the substrate, the interval between the die coater and the substrate, the slit width of the die coater, etc., or the change of the coating liquid from the manifold can be changed. The amount of extrusion of the slit or the extrusion speed is adjusted to become a coating film having a uniform thickness.

Further, in the die coater used in the production of the dye-sensitized solar cell using the RtoR method, the electrolyte used as the coating liquid is a material having a lower viscosity than the sealing material, so that the mold coater is erected. When the electrolytic solution is applied to the substrate conveyed in the substantially horizontal direction, a predetermined amount or more of the electrolytic solution is dropped by the own weight and applied to the substrate. Therefore, in order to apply such a low-viscosity electrolyte well, the following method is adopted, that is, the transfer direction of the substrate is folded back in the vertical direction and the die coater is made to make the discharge port horizontal. The method is directed to the horizontal direction, and the electrolyte is applied from the horizontal direction to the substrate conveyed in the substantially vertical direction.

In such a die coater, a predetermined gap is provided between the discharge port extending in the width direction of the substrate and the substrate, and the gap is used to eject the slit from the slit communicating with the discharge port by surface tension. The liquid is applied to the surface of the substrate.

[Patent Document 1] Japanese Patent Laid-Open Publication No. 2012-174596

[Patent Document 2] Japanese Patent Laid-Open Publication No. 2009-18227

However, in the case of a conventional die coater used in the production of a dye-sensitized solar cell by the RtoR method, a predetermined gap is provided between the discharge port extending in the width direction of the substrate and the substrate, and the gap is utilized. The electrolyte ejected from the slit is applied to the surface of the substrate by surface tension. However, even if the mold coater is oriented horizontally as described above When it is necessary to increase the coating amount of the electrolyte and apply it thickly, it is necessary to extrude a large amount of electrolyte from the slit portion of the die coater, but at this time, the electrolyte ejected from the slit may be due to surface tension. And expanding along the discharge port in the width direction.

In this case, there is a case where the electrolyte overflows the predetermined coating width on the substrate and is applied with a wide width, and the predetermined coating film thickness cannot be ensured.

The present invention has been made in view of the above problems, and it is an object of the invention to provide a mold which can be applied with a predetermined coating width or a coating film thickness accurately even in the case of a coating liquid having a low viscosity. A coating machine, a manufacturing apparatus of a dye-sensitized solar cell, and a method of manufacturing a battery.

In order to solve the above problems, the present invention achieves the related object and adopts the following aspects.

(1) A mold coater according to an aspect of the present invention, comprising: a spray body for applying a coating liquid to a surface of a substrate, wherein: the discharge body has: a liquid chamber: a coating liquid; a plurality of convexities; a discharge portion that protrudes in a discharge direction from a front end surface on which the coating liquid is discharged, and is provided at intervals in a width direction of the base material; and a discharge flow path that discharges the discharge portion of the convex discharge portion The liquid chamber is in communication; the protruding end of the convex discharge portion has a dimension in the width direction of 30% or more and 100% or less of a width dimension of the coated region in the substrate to which the coating liquid is applied.

In the present invention, by separating the gap between the convex discharge portion and the substrate The discharge main body is disposed in a state in which the coating liquid ejected from the discharge port of the convex discharge portion can be applied to the coated region of the substrate by the surface tension generated in the gap. The coating liquid contained in the liquid chamber discharged into the body is extruded by a pump or the like to a discharge flow path formed in the discharge body, and is ejected from the discharge port through the discharge flow path.

At this time, since the convex discharge portion protrudes from the front end surface of the discharge body on the side where the coating liquid is discharged, regardless of the viscosity of the coating liquid, the region where the surface tension is generated in the coating liquid discharged from the discharge port becomes a convex discharge. The range of width dimensions of the part. That is, even in the case where the application amount of the coating liquid is increased, the region in which the surface tension acts is not enlarged over the entire width direction of the end surface before the ejection body, and the coating width, that is, the coating region, can be kept constant. Further, since the width of the convex discharge portion is 30% or more and 100% or less of the width of the coated region in the substrate to which the coating liquid is applied, the coating accuracy can be improved. For example, by using a die coater of the present invention, a coating liquid is applied to a substrate constituting a dye-sensitized solar cell to be coated as a coating liquid, whereby the coating width of the electrolytic solution can be set with a desired precision. The film thickness is applied.

(2) The die coater according to (1) above, wherein the discharge body has a thickness of 1 cm or more and 20 cm or less.

In this case, since the discharge body has a thickness of 1 cm or more and 20 cm or less, the liquid chamber can be provided in the discharge body itself, or the discharge flow path can be processed in the discharge body using a drilling tool such as a drill.

By setting the discharge body to a thickness of 1 cm or more and 20 cm or less, it is convenient to suppress deformation by the rigidity of the metal. In particular, when the thickness is less than the lower limit of 1 cm, the liquid chamber having a sufficient capacity cannot be provided, and if the aperture ratio of the convex discharge portion is not adjusted, the application amount in the width direction is difficult to be stabilized. When the thickness exceeds the upper limit of 20 cm, there is a disadvantage that the amount of metal increases. It becomes heavier, has poor workability, and becomes expensive.

(3) The mold coater according to the above (1) or (2), wherein the projecting length of the convex discharge portion is preferably 0.1 mm or more and 30 mm or less.

(4) The above (1) to (3) according to any one of the die coater, preferably wherein the discharge opening of the convex portion of 0.00015mm ² or more and an area of 0.375mm ² or less.

According to this configuration, regardless of the viscosity of the coating liquid, the region where the surface tension is generated in the coating liquid ejected from the ejection port becomes the range of the width dimension of the convex ejection portion, and the above-described energy can be further improved. The coating width and coating film thickness of the coating liquid are set to the desired accuracy.

In this case, when the protruding length of the convex discharge portion is less than 0.1 mm, it is difficult to concentrate the surface tension only on the convex discharge portion, and when the protruding length of the convex discharge portion exceeds 30 mm, the viscosity is high. Since the pressure loss is easily distinguished, it is preferably in the range of 0.1 mm or more and 30 mm or less.

(5) The mold coater according to any one of the above (1) to (4), wherein the surface roughness of the portion in contact with the coating liquid is preferably an arithmetic mean roughness Ra of 0.025 to 1.6. And the maximum height roughness Rz is 0.1 to 6.3.

In this case, since the portion in contact with the coating liquid is mirror-polished or more, even in the case of using a coating liquid having a small viscosity and being liable to corrode the metal, the coating liquid may be contacted. The progress of corrosion of the above portion is suppressed to a small extent.

(6) The die coater according to any one of (1) to (5), wherein the discharge body includes: a first block having the liquid chamber; a second block: disposed opposite to the first block; and a shim: being sandwiched between the first block and the second block, and having a portion from the width direction toward the above The convex discharge portion of the coating liquid in the liquid chamber is protruded in a direction, and the discharge flow path is formed.

In this case, by arranging the spacer in a state in which a gap is formed between the convex discharge portion and the member to be coated (first base material), the surface tension generated in the gap can be self-convex discharge portion. The coating liquid sprayed from the discharge port is applied to a predetermined coating region of the member to be coated. The coating liquid contained in the liquid chamber in the die coater is extruded by a pump or the like to a discharge flow path formed in the gasket, and is ejected from the discharge port through the discharge flow path.

At this time, since the convex discharge portion protrudes from the front end surface on the side where the coating liquid is discharged from the gasket, the region where the surface tension is generated in the coating liquid discharged from the discharge port becomes the width of the convex discharge portion of the gasket. In the range, the area where the surface tension acts is not enlarged over the entire width direction of the front end surface of the gasket, and the coating width, that is, the coating area, can be kept constant.

(7) The mold coater according to (6) above, wherein the spacer comprises: a first backing plate: laminated on the first block, and having an opening communicating with the liquid chamber; and a second pad a plate that is laminated on the first pad, and has a slit-shaped discharge flow path that communicates from the discharge port to the opening; and a third pad that is sandwiched between the second pad and the second block The discharge flow path is covered from the side opposite to the first pad.

In this case, a gasket having a discharge flow path that communicates with the liquid chamber can be formed by laminating three sheets of the first mat, the second mat, and the third mat in a liquid-tight manner. In this situation When the first pad and the third pad are sandwiched and covered from both sides, the discharge path of the second pad is sandwiched and fixed to the first block and the second block of the discharge flow path. In contrast, the coating liquid is less likely to leak out of the discharge passage.

In the present invention, a plurality of convex discharge portions are provided at intervals in the width direction, and concave portions are formed between adjacent convex discharge portions, so that they are not adjacent to the convex discharge portions. The coating liquid is brought into contact with each other by the surface tension generated between the substrates, and the coating liquid can be surely applied to the substrate at a predetermined interval in the width direction.

(8) A device for producing a dye-sensitized solar cell according to another aspect of the present invention, which is continuously conveyed in a predetermined direction using a die coater according to any one of the above (1) to (7) The first base material on which the semiconductor electrode is formed is bonded to the second base material to produce a dye-sensitized solar cell; and the die coater is used in the convex discharge portion and the semiconductor substrate of the first base material A gap is formed therebetween, and the coating liquid ejected from the ejection port of the convex ejection portion is applied to the first base by a surface tension acting between the gap and the first substrate. The above semiconductor electrode of the material.

(9) A method of producing a battery according to another aspect of the present invention, wherein the first substrate continuously conveyed in a predetermined direction is used in the mold coater according to any one of the above (1) to (7) The second substrate is bonded to the battery for manufacturing the battery; the method includes the steps of: arranging the die coater so as to form a gap between the convex discharge portion and the first substrate; and The coating liquid discharged from the discharge port of the discharge portion is applied to the first base material by a surface tension acting between the gap and the first base material.

According to various aspects of the present invention, a mold coater, a dye-sensitized solar cell manufacturing apparatus, and a battery manufacturing method can apply a prescribed width even in the case of a coating liquid having a low viscosity. Or the coating film thickness is applied with high precision.

1‧‧‧ manufacturing equipment

3, 3A‧‧‧Mold coating machine

3a‧‧‧ liquid room

10‧‧‧Dye-sensitized solar cells

11‧‧‧Semiconductor electrodes

12‧‧‧ opposite electrode

13‧‧‧1st substrate

14‧‧‧2nd substrate

15‧‧‧ electrolyte (coating solution)

16‧‧‧Conducting materials

17‧‧‧ Sealing material

30‧‧‧shims

30a‧‧‧ front face

31‧‧‧1st block

32‧‧‧ Block 2

33‧‧‧ convex ejector

33a‧‧‧Spray outlet

33b‧‧‧ prominent front end

34‧‧‧1st pad

34a‧‧‧ openings

35‧‧‧2nd pad

35a‧‧‧slit

36‧‧‧3rd pad

E‧‧‧ direction

H‧‧‧ Thickness direction

P1‧‧‧Transfer direction

W‧‧‧Width direction

Fig. 1 is a side view schematically showing a manufacturing apparatus of a dye-sensitized solar cell according to a first embodiment of the present invention.

Fig. 2 is a cross-sectional view showing a schematic configuration of the dye-sensitized solar cell shown in Fig. 1.

Fig. 3 is a perspective view showing the overall configuration of the mold coater shown in Fig. 1.

4 is a perspective view showing a state in which a first pad is placed in a first block in a die coater.

Fig. 5 is a perspective view showing a state in which a second pad is placed on a first pad in a die coater.

Fig. 6 is a perspective view showing a state in which a third pad is placed on a second pad in a die coater.

Fig. 7 is an enlarged perspective view showing a convex discharge portion of the gasket from the discharge port side.

FIG. 8 is a plan view showing a state in which an electrolytic solution is applied to a semiconductor electrode of a first substrate by a die coater, and shows a state of a second pad.

Fig. 9 is an enlarged perspective view showing a state of application of the convex discharge portion formed by the die coater shown in Fig. 8.

Fig. 10 is a perspective view showing the overall configuration of a mold coater according to a second embodiment.

Hereinafter, a mold coater, a dye-sensitized solar cell manufacturing apparatus, and a battery manufacturing method according to embodiments of the present invention will be described based on the drawings. The drawings used in the following description are schematic drawings, and the ratios, structures, and the like of the length, the width, and the thickness are not limited to the actual ones, and may be appropriately changed.

(First embodiment)

As shown in Fig. 1, the die coater 3 of the present embodiment is provided in a manufacturing apparatus 1 for producing a film-type dye-sensitized solar cell 10.

As shown in FIG. 2 , the dye-sensitized solar cell 10 includes a first base material 13 , a second base material 14 , a semiconductor electrode 11 , a counter electrode 12 , an electrolytic solution 15 (coating liquid), and a conductive material 16 .

The semiconductor electrode 11 includes a transparent conductive film 111 laminated on the first base material 13 and a porous semiconductor layer 112 laminated on the transparent conductive film 111.

The counter electrode 12 includes an opposite conductive film 121 laminated on the second base material 14 and a catalyst layer 122 laminated on the opposite conductive film 121.

In order to form a series structure, an insulating portion is required, and therefore, an insulating treatment may be appropriately performed as needed.

Sealing materials 17, 17 are disposed on both sides of the conductive material 16 of the dye-sensitized solar cell 10.

The electrodes (i.e., between the semiconductor electrode 11 and the counter electrode 12) are followed by the conductive material 16 and the sealing material 17. On the other hand, a sealing material is disposed in a direction intersecting the extending direction X1 of the conductive material 16 (the battery width direction X2), or is continued by means of ultrasonic welding or the like. Take In this manner, the cells having the semiconductor layer 112 are each liquid-tightly sealed. Further, a gap is formed in the thickness direction between the semiconductor electrode 11 and the counter electrode 12 by the conductive material 16, and the electrolytic solution 15 is sealed in the gap.

The transparent conductive film 111 and the opposite conductive film 121 of the adjacent cells are divided into a plurality of portions by the patterning portion, thereby forming patterns of the plurality of transparent conductive films 111 and the opposite conductive films 121.

In each of the divided units, the opposite conductive film 121 of the counter electrode 12 and the transparent conductive film 111 constituting the semiconductor electrode 11 adjacent to another unit of one unit are electrically connected by the conductive material 16. connection.

The material of the first base material 13 and the second base material 14 is not particularly limited, and examples thereof include an insulator such as a resin, a semiconductor, a metal, and glass. Examples of the resin include poly(meth)acrylate, polycarbonate, polyester, polyimine, polystyrene, polyvinyl chloride, and polyamine. From the viewpoint of producing a thin and lightly soft dye-sensitized solar cell 10, the substrate is preferably made of a transparent resin, more preferably a polyethylene terephthalate (PET) film or polyethylene naphthalate. (PEN) membrane.

The type or material of the transparent conductive film 111 and the counter conductive film 121 is not particularly limited, and a known conductive film for a dye-sensitized solar cell can be applied, and examples thereof include a film made of a metal oxide. Examples of the metal oxide include tin-doped indium oxide (ITO), fluorine-doped tin oxide (FTO), aluminum-doped zinc oxide (ATO), indium oxide/zinc oxide (IZO), and gallium-doped zinc oxide (GZO).

The semiconductor layer 112 is composed of a material capable of receiving electrons from the adsorbed photosensitizing dye, and is generally preferably porous. The material constituting the semiconductor layer 112 is not particularly limited. A material of the known semiconductor layer 112 can be applied, and examples thereof include metal oxide semiconductors such as titanium oxide, zinc oxide, and tin oxide.

The photosensitizing dye to be carried on the semiconductor layer 112 is not particularly limited, and examples thereof include known dyes such as organic dyes and metal complex dyes. Examples of the organic dye include a coumarin system, a polyene system, a cyanine system, a hemicyanine system, and a thiophene system. As the metal complex dye, for example, a ruthenium complex or the like can be preferably used.

The electrolyte solution 15 is applied by the die coater 3 of the present embodiment, and examples thereof include an electrolyte solution in which iodine and sodium iodide are dissolved in an organic solvent and the viscosity is as small as water.

Examples of the electrolytic solution 15 include a solution in which an organic solvent such as acetonitrile, dimethylpropylimidazolium iodide or butyl iodide oxime or an ionic liquid is mixed with a supporting electrolyte such as lithium iodide and iodine. Wait.

The surface of the semiconductor layer 112 that is in contact with the electrolytic solution 15 including the inside of the porous interior is adsorbed with a known photosensitizing dye (not shown).

Next, a manufacturing apparatus 1 for manufacturing the dye-sensitized solar cell 10 of the above configuration will be specifically described with reference to Fig. 1 .

The manufacturing apparatus 1 includes a semiconductor electrode forming portion (not shown): a semiconductor electrode 11 is formed in a predetermined region on the surface of the first substrate 13; and an electrolyte coating portion (die coater 3): at least the electrolyte 15 is applied The semiconductor electrode 11 is formed on a predetermined region of the first substrate 13; the sealing material application portion 4 is disposed downstream of the mold coater 3 in the transport direction P1, and the sealing material 17 (see FIG. 2) is applied. Applied to the region of the first substrate 13 where the electrolyte 15 is not applied Field; wiring forming portion 5: wiring is formed between the sealing materials 17 (conducting material 16 shown in FIG. 2); substrate bonding portion 6 (6A, 6B): a catalyst layer 122 is formed on the surface (refer to the figure) 2) The second base material 14 is bonded to the first base material 13; and the heating unit 7: the first base material 13 and the second base material 14 which are bonded together by the base material bonding portion 6 are fixed to each other; And an insulating treatment portion (not shown): the predetermined position of the battery sheet to which the first base material 13 and the second base material 14 are bonded is subjected to an insulation treatment.

In the manufacturing apparatus 1, the semiconductor electrode 11 is formed in the most upstream portion in the transport direction P1, and the roller portion 10A in which the surface of the first base material 13 is wound up in the radial direction on the outer side in the radial direction is provided. The first conveyance roller 21 that lifts and conveys the first base material 13 obliquely upward is disposed downstream of the conveyance direction P1 that extends substantially horizontally from the installation position of the roller portion 10A.

A die coater 3 that is disposed in a horizontal position with the discharge port 33a oriented in the lateral direction is disposed at a position opposed to the first transfer roller 21 via the first base material 13 . The discharge port 33a of the die coater 3 is directed to a position where the electrolyte 15 can be applied to the semiconductor electrode 11 wound around the first base material 13 of the first transfer roller 21.

In the manufacturing apparatus 1 of the present embodiment configured as described above, the second base material 14 is bonded to the first base material 13 which is continuously conveyed in the transport direction P1 and in which the semiconductor electrode 11 is formed in a predetermined region on the surface. A dye-sensitized solar cell 10 is produced. The method for producing the dye-sensitized solar cell 10 at this time includes an electrolyte application step of applying the electrolytic solution 15 to the semiconductor electrode 11 of the first substrate 13 and applying a sealing material to the die coater 3. Step, which is tied to After the electrolyte application step, the sealing material 17 is applied to the surface of the first substrate 13 on the surface of the first substrate 13 where the electrolyte 15 is not applied, and the wiring forming step is applied to the sealing material. After the application step, wiring (conducting material 16) is formed between the sealing materials 17 in the wiring forming portion 5, and a substrate bonding step is performed after the wiring forming step, and the substrate bonding portion 6 is to be The second base material 14 on which the catalyst layer 122 is formed is bonded to the first base material 13 . The dye-sensitized solar cell 10 is produced by such a manufacturing method.

Next, a specific configuration of the die coater 3 for applying the electrolytic solution 15 to the semiconductor electrode 11 formed in a predetermined region on the surface of the first substrate 13 will be described.

As shown in FIG. 3, the die coater 3 includes a first block 31 having a liquid chamber 3a for accommodating the electrolytic solution 15 (see FIG. 4), and a second block 32 disposed opposite to the first block 31; And the gasket 30 is sandwiched between the first block 31 and the second block 32, and has a convex discharge portion that protrudes from the width direction W toward the discharge direction and ejects the electrolyte 15 in the liquid chamber 3a. 33.

Here, the first block 31, the second block 32, and the spacer 30 correspond to the discharge body of the present invention.

Here, as shown in FIG. 4, the first block 31, the spacer 30, and the second block 32 are laminated, and the lamination direction is referred to as a thickness direction H. The direction orthogonal to the thickness direction H when viewed in the direction along the width direction W is referred to as the front-rear direction E. The width of the die coater 3 is approximately equal to the width dimension of the dye-sensitized solar cell 10.

The width of the die coater 3 may be set to a size such that the electrolyte 15 can be applied to the semiconductor electrode 11 formed in a predetermined region on the surface of the first substrate 13. A plurality of convex discharge portions 33.

As shown in FIG. 4, in the first block 31, the upper surface 31a of the spacer 30 is formed in a plane in the thickness direction H, and is formed in the width direction W at a position substantially in the center of the front surface E in the upper surface 31a. The liquid chamber 3a is formed in a groove shape extending. In the liquid chamber 3a, a supply hole 3b for supplying the electrolytic solution 15 by a pump or the like (not shown) is formed. In the second block 32, the lower surface 32a of the spacer 30 is formed in a plane in the thickness direction H. Further, the upper surface 31a of the first block 31 and the lower surface 32a of the second block 32 are opposed to each other in a state in which the plate-like spacers 30 are sandwiched. The first block 31 and the second block 32 are detachably fixed by a fixing means such as a bolt or the like (not shown) in a state in which the spacer 30 is sandwiched.

The first block 31 and the second block 32 are formed with inclined surfaces 31b and 32b in front of the front and rear direction E, and the inclined surfaces 31b and 32b gradually approach the spacer 30 in the thickness direction H as they go forward. The positions of the front end faces 31c and 32c (see FIG. 9) of the first block 31 and the second block 32 in the front and rear directions substantially coincide with each other.

As shown in FIG. 5, a discharge flow path (the following slit 35a) that connects the liquid chamber 3a and the discharge port 33a of the convex discharge portion 33 is formed in the gasket 30.

Specifically, as shown in FIGS. 4 to 7 , the spacer 30 includes a first pad 34 that is laminated on the first block 31 and has an opening 34 a that communicates with the liquid chamber 3 a. The second pad 35 is laminated. In the first pad 34, a slit 35a (a discharge flow path) that communicates from the discharge port 33a to the opening 34a is formed; and the third pad 36 is sandwiched between the second pad 35 and the second block 32 (refer to the figure). 3) The slit 35a is covered from the opposite side of the first pad 34.

The first pad 34, the second pad 35, and the third pad 36 are each made of a metal foil. It is formed in the same outer shape when viewed from the direction H.

The convex discharge portions 33 are provided in plural (here, four) in the width direction W with an interval therebetween.

As shown in FIG. 7 and FIG. 8, the width of the protruding end 33b of the convex discharge portion 33 is set to be coated with the semiconductor electrode 11 (coated portion) of the first base material 13 to which the electrolytic solution 15 is applied. The width dimension of the region is 30% or more and 100% or less. Here, the "coated region" is a region where the liquid (electrolyte 15) exists after the first base material 13 and the second base material 14 are bonded together, that is, when the production of the battery is completed.

Further, the protruding length L of the convex discharge portion 33 protruding from the front end surface 30a can be set, for example, to about 2 mm, but is preferably 0.1 mm or more and 30 mm or less, more preferably 0.5 mm or more and 10 mm or less, and further preferably 0.8 mm. Above and below 5mm.

As shown in FIG. 4, the first pad 34 is formed with an opening 34a having substantially the same shape as the liquid chamber 3a, and a first convex portion 34b constituting one of the convex discharge portions 33.

As shown in FIG. 5, the second pad 35 is formed with a plurality of slits 35a extending from the discharge port 33a in the front-rear direction E to at least a position overlapping the opening 34a of the first pad 34, and a convex discharge portion 33. A part of the second convex portion 35b.

As shown in FIG. 6, the third pad 36 is formed with a third convex portion 36b constituting one of the convex discharge portions 33.

As described above, the surface roughness of the portion in contact with the electrolytic solution 15 is such that the viscosity of the electrolytic solution 15 is small in the present embodiment, and the corrosiveness of the liquid contact portion in contact with the electrolytic solution 15 is high. The arithmetic mean roughness Ra is set to a range of 0.025 to 1.6, and the maximum height roughness Rz is set to a range of 0.1 to 6.3. Moreover, the surface roughness of the spacer 30 is preferably an arithmetic mean The roughness Ra is about 0.8 to 1.6. In particular, the important portion (the liquid-repellent portion or the like) has a higher surface roughness, and the arithmetic mean roughness Ra is set to 0.1 to perform finishing.

The geometric tolerance of the portion of the die coater 3 that is in contact with the electrolytic solution 15 (that is, the convex discharge portion 33 or the liquid contact portion, etc.) is preferably, for example, a parallelism of 0.003 mm, a flatness of 0.003 mm, and a straightness. Finishing is performed at 0.003 mm and a straight angle of 0.01 mm.

In the case of the spacer 30, a grinding method by, for example, a melting treatment using an etching liquid can be employed. The portion of the die coater 3 other than the spacer 30 may be subjected to mirror polishing.

Next, the function of the above-described mold coater 3 and the manufacturing apparatus 1 of the dye-sensitized solar cell 10 will be described in detail using a drawing.

In the present embodiment, as shown in FIG. 8 and FIG. 9, the spacer 30 is placed in a state in which the gap S is formed between the convex discharge portion 33 and the first base material 13 of the dye-sensitized solar cell 10. The electrolytic solution 15 discharged from the discharge port 33a of the convex discharge portion 33 can be applied to a predetermined coating region of the first base material 13 by the surface tension generated in the gap S. As shown in Fig. 5, the electrolytic solution 15 accommodated in the liquid chamber 3a in the die coater 3 is extruded by a pump or the like into a slit 35a formed in the gasket 30, and further passes through the slit 35a from the discharge port 33a. ejection.

At this time, since the convex discharge portion 33 protrudes from the front end surface 30a on the side where the electrolytic solution 15 is discharged from the gasket 30, the surface tension region is generated in the electrolytic solution 15 ejected from the discharge port 33a regardless of the viscosity of the electrolytic solution 15. (the surface tension portion of the symbol 15a shown in FIGS. 8 and 9) is a range of the width dimension of the convex discharge portion 33. That is, even in the case where the application amount of the electrolytic solution 15 is increased, the area where the surface tension acts is not enlarged over the entire width direction of the front end surface 30a of the spacer 30, and the coating width, that is, the coating area can be maintained. For fixing. Specifically, even when the electrolyte 15 is excessively ejected from the gasket 30, the liquid is biased to be located. The first pad 34, which is lower than the second spacer 35, is dropped without affecting the coating width.

As described above, by setting the width dimension of the convex discharge portion 33 in accordance with the width dimension of the semiconductor electrode 11 of the first base member 13, the coating accuracy can be improved. For example, as in the present embodiment, the electrolyte solution 15 is applied to the first base material 13 constituting the dye-sensitized solar cell 10 by the die coater 3, whereby the coating width of the electrolytic solution 15 can be set with a desired accuracy. And coating film thickness.

Since the spacer 30 of the present embodiment is configured to be easily divided together with the first block 31 and the second block 32, the replacement of the spacer 30 can be performed efficiently in a short time. Further, for example, it is possible to apply different conditions only by replacing the spacers having different shapes and numbers of the convex discharge portions 33.

In the present embodiment, the three pads of the first pad 34, the second pad 35, and the third pad 36 are laminated in a liquid-tight manner to form the slit 35a that communicates with the liquid chamber 3a. Shim 30. In this case, the slit 35a of the second pad 35 is sandwiched and covered by the first pad 34 and the third pad 36 from both sides, so that the slit 35a is formed by the first block 31. The electrolyte 15 is less likely to leak out of the slit 35a than when the second block 32 is sandwiched and fixed.

In the present embodiment, since the concave portions are formed between the adjacent convex discharge portions 33 and 33, the surface generated between the adjacent convex discharge portions 33 and 33 and the first base material 13 is not caused. The electrolyte solution 15 is brought into contact with each other by the tension, and the electrolyte solution 15 can be surely applied to the first base material 13 at a predetermined interval in the width direction W.

In the present embodiment, the width dimension of the convex discharge portion 33 is set to match the width dimension of the semiconductor electrode 11 of the first base member 13, whereby the coating accuracy can be improved.

(Second embodiment)

The die coater 3A of the second embodiment shown in Fig. 10 has a configuration in which only one of the spacers 35 of the spacer 30 of the first embodiment described above is used. That is, the first pad 34 and the third pad 36 are omitted. In this case, the second pad 35 is directly sandwiched between the first block 31 and the second block 32.

In the die coater 3A of the second embodiment, the electrolytic solution 15 is ejected from the discharge port 33a of the convex discharge portion 33 by the power of the pump.

At this time, surface tension is generated between the discharge port 33a and the slit 35a, whereby the electrolyte 15 can be promoted in the front-rear direction E, and the liquid before the discharge of the electrolyte 15 reaches the first substrate 13 can be prevented. Drops in the thickness direction H.

From the viewpoint of surface tension, the opening 33 by the discharge area of the convex portion is set to 0.375mm ² 0.00015mm ² or more and less, regardless of how the electrolytic solution viscosity 15 can discharge from the discharge port 33a with good precision. Therefore, the region where the surface tension is generated in the discharged electrolytic solution 15 becomes the range of the width dimension of the convex discharge portion 33, and the effect of providing the coating width and the coating film thickness of the electrolytic solution 15 with a desired precision can be further improved.

In the above, the embodiment of the mold coater, the dye-sensitized solar cell manufacturing apparatus, and the battery manufacturing method of the present invention has been described. However, the present invention is not limited to the above embodiment, and the present invention can be omitted. Make appropriate changes within.

For example, in the above-described embodiment, the configuration of the spacer 30 is a configuration in which three pads (the first pad 34, the second pad 35, and the third pad 36) are laminated, but Limited to this. In short, as long as the convex discharge portion 33 that protrudes from the front end surface 30a of the gasket 30 in the discharge direction is provided, and the discharge flow path that connects the discharge port 33a of the convex discharge portion 33 to the liquid chamber 3a is provided, it may not be The composition of a padded layer.

In the present embodiment, the width dimension of the convex discharge portion 33, the number or position in the width direction W of the entire gasket 30, and the amount of protrusion L from the front end surface 30a of the spacer 30 in the die coater 3 are used. The configuration of the first embodiment is not limited to the above embodiment, and can be appropriately set depending on the form of the portion to be coated or the conditions of the coating liquid. Further, the configuration of the first block 31 or the second block 32 is not limited to the configuration of the embodiment, and may be appropriately sized and shaped.

In the present embodiment, the coated portion to which the coating liquid is applied by the die coater 3 is applied to the dye-sensitized solar cell 10, and the die coater 3 is applied to the roll-to-roll method. The apparatus 1 is manufactured, but is not limited to such a coated portion and a manufacturing apparatus.

In the above embodiment, each of the pads 34, 35, and 36 of the spacer 30 is formed of a metal foil, but the member is not limited to a metal foil. For example, the thickness of the gasket is not limited to a thin plate such as a metal foil, and may be, for example, a member made of a resin such as polytetrafluoroethylene or polypropylene (PP).

In the present embodiment, the configuration of the die coater 3 is not limited to the provision of the spacer 30.

For example, the spacer member itself may be omitted, and may be manufactured by using a perforating tool such as a drill to a variety of metals such as stainless steel, iron, aluminum, titanium, or various alloys having a thickness of about 10 cm. After the plate member (discharge body) forms a hole, a plurality of convex discharge portions are processed.

The thickness of the discharge body is preferably 1 cm or more and 20 cm or less. By setting it as such a thickness range, deformation can be suppressed by the rigidity of the metal. When the thickness is less than the lower limit of 1 cm, a liquid chamber having a sufficient capacity cannot be provided, and if the aperture ratio of the convex discharge portion is not adjusted, the application amount in the width direction is difficult to stabilize. When the thickness exceeds the upper limit of 20 cm, there is a disadvantage that the amount of metal increases and becomes heavy, workability is poor, and it becomes expensive.

In the above-described embodiment, the dye-sensitized solar cell 10 is used as a battery manufactured by using the method of manufacturing the mold coater 3, but the dye-sensitized solar cell 10 is not limited thereto, and for example, it can also be used. A battery such as a secondary battery.

Further, the constituent elements in the above-described embodiments may be appropriately replaced with well-known constituent elements without departing from the gist of the invention.

[Industrial availability]

According to the mold coater, the dye-sensitized solar cell manufacturing apparatus, and the battery manufacturing method of the present invention, even in the case of a coating liquid having a low viscosity, a coating width or a coating film can be applied in a prescribed manner. The coating is applied with good precision.

Claims (9)

A die coater having a spray body for applying a coating liquid to a surface of a substrate; wherein the discharge body has: a liquid chamber: containing a coating liquid; and a plurality of convex discharge portions: self-spraying the coating a front end surface of the liquid side protrudes toward the discharge direction, and is disposed at intervals in the width direction of the base material; and a discharge flow path that communicates the discharge port of the convex discharge portion with the liquid chamber; the convex discharge portion The size of the protruding front end in the width direction is 30% or more and 100% or less of the width dimension of the coated region in the substrate to which the coating liquid is applied. The mold coater of claim 1, wherein the discharge body has a thickness of 1 cm or more and 20 cm or less. The mold coater according to claim 1 or 2, wherein the projecting length of the convex discharge portion is 0.1 mm or more and 30 mm or less. Patent application range as 1 to 3 die coater according to any one of, wherein the opening area of the convex portion of the ejection 0.00015mm ² or more and less 0.375mm ^2. The die coater according to any one of claims 1 to 4, wherein the surface roughness of the portion in contact with the coating liquid has an arithmetic mean roughness Ra of 0.025 to 1.6 and a maximum height roughness. Rz is 0.1~6.3. The mold coater of any one of claims 1 to 5, wherein the discharge body comprises: a first block: having the liquid chamber; a second block: opposite to the first block; and a shim: being sandwiched between the first block and the second block, and having a portion from the width direction toward the discharge The convex discharge portion of the coating liquid in the liquid chamber is protruded in a direction, and the discharge flow path is formed. The mold coater of claim 6, wherein the gasket comprises: a first backing plate: laminated in the first block, forming an opening communicating with the liquid chamber; and a second backing plate: layered on The first pad is formed with a slit-shaped discharge flow path that communicates from the discharge port to the opening; and the third pad is sandwiched between the second pad and the second block. The opposite side of the first pad covers the discharge flow path. A manufacturing apparatus for a dye-sensitized solar cell, which is bonded to a first substrate on which a semiconductor electrode is continuously conveyed in a predetermined direction, using a die coater according to any one of claims 1 to 7. a second substrate for manufacturing a dye-sensitized solar cell; wherein the die coater is configured to form a gap between the convex discharge portion and the semiconductor electrode of the first substrate The coating liquid ejected from the ejection port of the convex ejection portion is applied to the semiconductor electrode of the first substrate by a surface tension acting between the gap and the first substrate. A method for producing a battery, in which a second substrate is bonded to a first substrate continuously conveyed in a predetermined direction by using a die coater according to any one of claims 1 to 7 Manufacturing a battery; characterized in that the mold is disposed such that a gap is formed between the convex discharge portion and the first base material And a coating liquid sprayed from the discharge port of the convex discharge portion is applied to the first base material by a surface tension acting between the gap and the first base material.