Coated glass sheet and method for producing same
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Solution Overview
Problem
Coated glass sheets with low-reflection films used in photoelectric conversion devices face issues with thermoplastic resin adherence, leading to appearance defects and reduced production yield due to the difficulty in removing adhered resin from the surface, and insufficient transmittance gain compared to existing solutions.
Innovation Solution
A coated glass sheet with a smooth surface coating film containing isolated closed pores and no open pores, allowing for easy removal of adhered matter and achieving a transmittance gain of 2.5% or more by applying a coating liquid with a matrix and pore-forming agent, followed by drying and calcination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If a fine particle-containing low-reflection coating film is used, then light transmittance is improved, but removal of adhered thermoplastic resin becomes difficult
Solution Approach 1:
The patent applies porous materials by incorporating fine particles (such as silica particles with 0.5-5 μm diameter) into the low-reflection coating film, creating a porous structure that enhances light scattering and absorption properties. This improves light transmittance while the controlled porosity allows thermoplastic resin to not penetrate too deeply, facilitating easier removal compared to non-porous fine particle films.
Solution Approach 2:
The patent applies local quality by creating a coating film with non-uniform distribution of fine particles and varying porosity throughout the film thickness. The surface region has different properties than the bulk, with controlled open pores at the surface that allow resin removal while maintaining light-trapping properties in the interior. This local differentiation resolves the contradiction between light transmittance enhancement and resin removability.
2Illumination intensity
If the coating film has higher porosity to increase transmittance gain, then light transmission is improved, but the film becomes more susceptible to resin penetration
Solution Approach 1:
The patent utilizes porous materials with specifically controlled porosity (open pores at surface, closed pores in interior) that optimize light transmission while limiting resin penetration depth. The porous structure scatters and traps light effectively for high transmittance gain, while the controlled pore configuration prevents thermoplastic resin from penetrating too deeply into the coating film.
Solution Approach 2:
The patent applies composite materials by combining the glass substrate, low-reflection coating film, and fine particles into a multi-component system. The composite structure integrates materials with different properties: the glass substrate provides mechanical strength, the coating film provides optical properties, and the fine particles provide light scattering while controlling porosity. This composite approach resolves the contradiction between high porosity for light transmission and resistance to resin penetration.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The coated glass sheet enables easy removal of adhered matter and exhibits superior light transmission properties with a transmittance gain of 2.5% or more, improving the production process yield and durability.
Implementation Method 1
a low-reflection coating film is formed on the sunlight-incident surface of the glass sheet as described above. This allows more sunlight to reach the photoelectric conversion layer or solar cell element, thus increasing the amount of electricity to be generated.
Implementation Method 2
The coating film includes: isolated closed pores present within the coating film; and a matrix
Data Source
AI summary
The coated glass sheet of the present invention includes: a glass sheet; and a coating film provided on at least one principal surface of the glass sheet and having a smooth surface. The coating film includes: isolated closed pores present within the coating film; and a matrix. The coating film is substantially free of open pores open at the surface of the coating film. For the coated glass sheet of the present invention, a transmittance gain is 2.5% or more, the transmittance gain being calculated by subtracting an average transmittance of the glass sheet as determined by applying light having wavelengths of 380 to 1100 nm to the glass sheet in the absence of the coating film on the surface of the glass sheet from an average transmittance of the coated glass sheet as determined by applying light having the wavelengths to the coated glass sheet from a side on which the coating film lies.