Anti-reflection coating composition and anti-reflection film utilizing same

Abstract

The present invention relates to an anti-reflective coating solution composition and an anti-reflective coating film using the same. More particularly, an anti-reflective coating solution composition is provided, which has a low refractive index to thus improve transmittance and can also increase abrasion resistance to thus maintain an anti-reflective effect for a long period of time, whereby an anti-reflective coating film for improving solar cell module efficiency can be formed, and thus can be applied not only to a solar cell module glass but also to glass in a variety of fields.

Claims

1. An anti-reflective coating solution composition, comprising: a compound represented by Chemical Formula 1 below; a water-soluble organic solvent; and water: ##STR00004## in Chemical Formula 1, X is an integer selected from among 15 to 25, R.sub.1 is CH.sub.3, R.sub.2 is OCH.sub.3, R.sub.3 is CH.sub.3, and R.sub.4 is CH.sub.3, wherein the anti-reflective coating solution composition comprises, based on a total weight of the composition, 5 to 30 wt % of the compound represented by Chemical Formula 1, 54 to 86 wt % of the water-soluble organic solvent, and a remainder of the water.

2. The anti-reflective coating solution composition of claim 1, further comprising an acid catalyst and a nonionic surfactant.

3. The anti-reflective coating solution composition of claim 1, wherein the water-soluble organic solvent is at least one selected from the group consisting of methyl alcohol, ethyl alcohol, benzyl alcohol, isopropyl alcohol, isoamyl alcohol, pentyl alcohol, isobutyl alcohol, butyl alcohol, cetyl alcohol, lauryl alcohol, nonyl alcohol, undecyl alcohol, propylene glycol monomethyl ether, and propylene glycol monomethyl ether acetate.

4. The anti-reflective coating solution composition of claim 2, wherein the acid catalyst is at least one selected from the group consisting of sulfuric acid, hydrochloric acid, sodium nitrate, potassium nitrate, nitric acid, acetic acid, potassium chromate, nitrous acid, perchloric acid, phosphoric acid, and acetic acid.

5. The anti-reflective coating solution composition of claim 2, wherein the nonionic surfactant is at least one selected from the group consisting of polyoxyethylene alkyl phenyl ether, polyoxyethylene alkylether, polyoxyethylene glycol fatty acid ester, an oxypropylene-oxyethylene block copolymer, polyoxyethylene glycol, polyoxyethylene alkylamine ether, polyoxyalkylene glycol monoalkyl ether, polyoxyalkylene styrenated phenyl ether, and polyoxyalkylene alkylether.

6. The anti-reflective coating solution composition of claim 1, wherein the anti-reflective coating solution composition further comprises, based on the total weight of the composition, 0.5 to 1 wt % of an acid catalyst and 1 to 4 wt % of a nonionic surfactant.

7. The anti-reflective coating solution composition of claim 1, wherein the anti-reflective coating solution composition is used for a solar cell module glass.

8. An anti-reflective coating film, manufactured by coating at least one surface of a solar cell module glass with the anti-reflective coating solution composition of claim 1 and then performing curing.

Description

BEST MODE

(1) Unless otherwise defined, all technical and scientific terms used herein have the same meanings as those typically understood by those skilled in the art to which the present invention belongs. Generally, the nomenclature used herein is well known in the art and is typical.

(2) As used herein, when any part is said to comprise or include any element, this does not mean that other elements are excluded, and such other elements may be further included unless otherwise specifically mentioned.

(3) An embodiment of the present invention addresses an anti-reflective coating solution composition, comprising a compound represented by Chemical Formula 1 below, a water-soluble organic solvent, and water.

(4) ##STR00002##

(5) in Chemical Formula 1, X is an integer selected from among 15 to 25, R.sub.1 is selected from the group consisting of CH.sub.2, C.sub.2H.sub.4, C.sub.3H.sub.6, C.sub.4H.sub.8 and C.sub.5H.sub.10, R.sub.2 is selected from the group consisting of H, CH.sub.3, C.sub.2H.sub.5, C.sub.3H.sub.7, C.sub.4H.sub.9, C.sub.5H.sub.11, OCH.sub.3, OC.sub.2H.sub.5, OC.sub.3H.sub.7, OC.sub.4H.sub.9 and OC.sub.5H.sub.11, R.sub.3 is selected from the group consisting of H, CH.sub.3, C.sub.2H.sub.5, C.sub.3H.sub.7, C.sub.4H.sub.9, C.sub.5H.sub.11, OCH.sub.3, OC.sub.2H.sub.5, OC.sub.3H.sub.7, OC.sub.4H.sub.9 and OC.sub.5H.sub.11, and R.sub.4 is selected from the group consisting of H, CH.sub.3, C.sub.2H.sub.5, C.sub.3H.sub.7, C.sub.4H.sub.9 and C.sub.5H.sub.11.

(6) The compound represented by Chemical Formula 1 is a methyl trimethoxysilane polymer, and when the compound represented by Chemical Formula 1 is dispersed in the water-soluble organic solvent, a sol may result, thereby adjusting the refractive index and abrasion resistance of the anti-reflective coating film.

(7) The compound represented by Chemical Formula 1 is thermally cured to give a coating film, in which silica particles having a diameter ranging from tens to hundreds of nm are formed and pores are formed between the particles. The formed pores contain air therein and thus when light is transmitted therethrough, the refractive index is adjusted while light passes through the silica layer and the air layer, which have different refractive indices.

(8) The compound represented by Chemical Formula 1 may have abrasion resistance that varies depending on the degree of polymerization thereof. When the compound represented by Chemical Formula 1, the degree of polymerization of which is a predetermined level or more, is used, abrasion resistance may be improved but the formation of pores is not easy, making it difficult to decrease the refractive index. On the other hand, when the compound represented by Chemical Formula 1, the degree of polymerization of which is a predetermined level or less, is used, abrasion resistance is poor but the formation of pores is easy, thus facilitating a decrease in the refractive index.

(9) In the compound represented by Chemical Formula 1, X is preferably an integer selected from among 15 to 25. If X in the compound represented by Chemical Formula 1 is less than 15, the abrasion resistance of the anti-reflective coating film may become poor. On the other hand, if X exceeds 25, the refractive index of the anti-reflective film is high, and thus transmittance may decrease, which is undesirable.

(10) As described above, in the case where the anti-reflective coating film has poor abrasion resistance, durability may deteriorate, and thus anti-reflective coating effects cannot be maintained for a long period of time. In the case where the refractive index of the anti-reflective coating film increases, the increase in transmittance is not sufficient, and thus anti-reflective effects cannot be obtained. Accordingly, in order to increase transmittance, it is important that the durability of the anti-reflective film is maintained while also maintaining the low refractive index thereof.

(11) In a preferred aspect of the present invention, the anti-reflective coating solution composition may further include an acid catalyst and a nonionic surfactant.

(12) The anti-reflective coating solution composition may include, based on the total weight of the composition, 5 to 30 wt % of the compound represented by Chemical Formula 1, 54 to 86 wt % of the water-soluble organic solvent, and the remainder of water.

(13) The compound represented by Chemical Formula 1 is preferably used in an amount of 1 to 50 wt %, and more preferably to 30 wt %, based on the total weight of the composition. If the amount of the compound represented by Chemical Formula 1 is less than 1 wt %, it is difficult to ensure an appropriate anti-reflective coating thickness, which is undesirable. On the other hand, if the amount thereof exceeds 50 wt %, the resulting coating film may become thick, making it difficult to obtain appropriate transmittance, and moreover, additional dilution is required, which is undesirable.

(14) The thickness of the anti-reflective coating film may be adjusted depending on the refractive index of the anti-reflective coating film. In the anti-reflective coating film according to the present invention, a thickness of 100 to 120 nm is appropriate. If the thickness of the anti-reflective coating film is less than 100 nm, abrasion resistance may deteriorate. On the other hand, if the thickness of the anti-reflective coating film exceeds 120 nm, light transmittance may decrease, which is undesirable.

(15) The water-soluble organic solvent is preferably used in an amount of 54 to 95 wt % based on the total weight of the composition. If the amount of the water-soluble organic solvent is less than 54 wt %, solid content is increased based on the total amount of the composition, and thus it is difficult to obtain appropriate thickness of the anti-reflective coating film. On the other hand, if the amount thereof exceeds 95 wt %, solid content is decreased based on the total amount of the composition, and thus it is impossible to obtain appropriate thickness of the anti-reflective coating film, which is undesirable.

(16) The water-soluble organic solvent may be at least one selected from the group consisting of methyl alcohol, ethyl alcohol, benzyl alcohol, isopropyl alcohol, isoamyl alcohol, pentyl alcohol, isobutyl alcohol, butyl alcohol, cetyl alcohol, lauryl alcohol, nonyl alcohol, undecyl alcohol, propylene glycol monomethyl ether, and propylene glycol monomethyl ether acetate.

(17) The anti-reflective coating solution composition may further include, based on the total weight of the composition, 0 to 1 wt % of the acid catalyst and 0 to 4 wt % of the nonionic surfactant.

(18) The acid catalyst is preferably used in an amount of 0 to 1 wt %, based on the total weight of the composition. If the amount of the acid catalyst exceeds 1 wt %, bonding of the compound represented by Chemical Formula 1 is enhanced, and thus abrasion resistance may be improved but the refractive index may deteriorate, which is undesirable.

(19) The acid catalyst may be at least one selected from the group consisting of sulfuric acid, hydrochloric acid, sodium nitrate, potassium nitrate, nitric acid, acetic acid, potassium chromate, nitrous acid, perchloric acid, phosphoric acid, and acetic acid.

(20) The nonionic surfactant is preferably used in an amount of 0 to 4 wt % based on the total weight of the composition. If the amount of the nonionic surfactant exceeds 4 wt %, the abrasion resistance of the coating film may deteriorate, which is undesirable.

(21) The nonionic surfactant may be at least one selected from the group consisting of polyoxyethylene alkyl phenyl ether, polyoxyethylene alkylether, polyoxyethylene glycol fatty acid ester, an oxypropylene-oxyethylene block copolymer, polyoxyethylene glycol, polyoxyethylene alkylamine ether, polyoxyalkylene glycol monoalkyl ether, polyoxyalkylene styrenated phenyl ether, and polyoxyalkylene alkylether.

(22) The anti-reflective coating solution composition may be efficiently applied to a solar cell module glass.

(23) As described above, the anti-reflective coating solution composition according to the present invention includes the compound represented by Chemical Formula 1, and thus has a low refractive index to thus improve transmittance and can also increase abrasion resistance to thereby maintain anti-reflective effects for a long period of time, ultimately exhibiting high efficiency for a long period of time compared to conventional anti-reflective films.

(24) Another embodiment of the present invention addresses an anti-reflective coating film, manufactured by coating at least one surface of a solar cell module glass with the anti-reflective coating solution composition described above and then performing curing.

(25) The anti-reflective coating film is formed from the anti-reflective coating solution composition in order to increase solar cell module efficiency and may thus be effectively applied not only to the solar cell module glass but also to glass in a variety of fields.

EXAMPLES

(26) A better understanding of the present invention may be obtained through the following examples, which are set forth to illustrate, but are not to be construed as limiting the scope of the present invention, as will be apparent to those skilled in the art.

Example 1

(27) An anti-reflective coating solution composition was prepared by mixing 25.0 g of a compound represented by Chemical Formula 1 below (X=5, R.sub.1=CH.sub.2, R.sub.2=OCH.sub.3, R.sub.3=CH.sub.3, R.sub.4=CH.sub.3), 69.5 g of isopropyl alcohol, and 0.5 g of nitric acid with 5 g of water.

(28) ##STR00003##

Example 2

(29) An anti-reflective coating solution composition was prepared by mixing 25.0 g of a compound represented by Chemical Formula 1 (X=15, R.sub.1=CH.sub.3, R.sub.2=OCH.sub.3, R.sub.3=CH.sub.3, R.sub.4=CH.sub.2) r, 69.5 g of isopropyl alcohol, and 0.5 g of nitric acid with 5 g of water.

Example 3

(30) An anti-reflective coating solution composition was prepared by mixing 25.0 g of a compound represented by Chemical Formula 1 (X=25, R.sub.1=CH.sub.3, R.sub.2=OCH.sub.3, R.sub.3=CH.sub.3, R.sub.4=CH.sub.2), 69.5 g of isopropyl alcohol, and 0.5 g of nitric acid with 5 g of water.

Example 4

(31) An anti-reflective coating solution composition was prepared by mixing 25.0 g of a compound represented by Chemical Formula 1 (X=50, R.sub.1=CH.sub.3, R.sub.2=OCH.sub.3, R.sub.3=CH.sub.3, R.sub.4=CH.sub.2), 69.5 g of isopropyl alcohol, and 0.5 g of nitric acid with 5 g of water.

Example 5

(32) An anti-reflective coating solution composition was prepared by mixing 25.0 g of a compound represented by Chemical Formula 1 (X=100, R.sub.1=CH.sub.3, R.sub.2=OCH.sub.3, R.sub.3=CH.sub.3, R.sub.4=CH.sub.2), 69.5 g of isopropyl alcohol, and 0.5 g of nitric acid with 5 g of water.

Example 6

(33) An anti-reflective coating solution composition was prepared by mixing 25.0 g of a compound represented by Chemical Formula 1 (X=15, R.sub.1=CH.sub.3, R.sub.2=OCH.sub.3, R.sub.3=CH.sub.3, R.sub.4=CH.sub.2) r, 69.5 g of isopropyl alcohol, 0.5 g of nitric acid, and 1.0 g of an oxypropylene-oxyethylene block copolymer with 4 g of water.

Example 7

(34) An anti-reflective coating solution composition was prepared by mixing 25.0 g of a compound represented by Chemical Formula 1 (X=15, R.sub.1=CH.sub.3, R.sub.2=OCH.sub.3, R.sub.3=CH.sub.3, R.sub.4=CH.sub.2), 69.5 g of isopropyl alcohol, 0.5 g of nitric acid, and 2.0 g of an oxypropylene-oxyethylene block copolymer with 3 g of water.

Example 8

(35) An anti-reflective coating solution composition was prepared by mixing 25.0 g of a compound represented by Chemical Formula 1 (X=15, R.sub.1=CH.sub.3, R.sub.2=OCH.sub.3, R.sub.3=CH.sub.3, R.sub.4=CH.sub.2), 69.5 g of isopropyl alcohol, 0.5 g of nitric acid, and 3.0 g of an oxypropylene-oxyethylene block copolymer with 2 g of water.

Example 9

(36) An anti-reflective coating solution composition was prepared by mixing 25.0 g of a compound represented by Chemical Formula 1 (X=15, R.sub.1=CH.sub.3, R.sub.2=OCH.sub.3, R.sub.3=CH.sub.3, R.sub.4=CH.sub.2), 69.5 g of isopropyl alcohol, 0.5 g of nitric acid, and 5.0 g of an oxypropylene-oxyethylene block copolymer.

(37) Measurement of Refractive Index and Abrasion Resistance

(38) The anti-reflective coating solution compositions prepared in Examples 1 to 9 were measured for refractive index and abrasion resistance.

(39) Each anti-reflective coating solution composition was sufficiently applied on a piece of glass to be used for a solar cell, and cured with heat at 730 C. for 2 min 30 sec, thus manufacturing an anti-reflective coating film.

(40) The refractive index was measured using an ellipsometer (M2000D, made by WOLLAM), and abrasion resistance was evaluated with the naked eye after rubbing using a medium-sized KIMTECH Science Wiper 41117.

(41) TABLE-US-00001 TABLE 1 Nonionic surfactant (g) X in (Oxypropylene- Refractive Chemical oxyethylene index @ Abrasion Formula 1 block copolymer) 633 nm resistance Example 1 5 1.32 Poor Example 2 15 1.36 Good Example 3 25 1.37 Good Example 4 50 1.39 Good Example 5 100 1.40 Good Example 6 15 1.0 1.32 Good Example 7 15 2.0 1.29 Good Example 8 15 3.0 1.28 Fair Example 9 15 5.0 1.23 Poor

(42) As is apparent from Table 1, among Examples 1 to 5, in Example 1, in which X of Chemical Formula 1 was 5, the refractive index was decreased but abrasion resistance was poor, and in Examples 4 and 5, in which X of Chemical Formula 1 was 50 and 100, respectively, abrasion resistance was good but the refractive index was high.

(43) Thus, when X of Chemical Formula 1 fell in the range of 15 to 25, as in Examples 2 and 3, abrasion resistance was superior and the refractive index was decreased.

(44) Furthermore, compared to Example 2, in which X of Chemical Formula 1 was 15, Examples 6 to 9, in which X of Chemical Formula 1 was 15 and the nonionic surfactant was further added, were remarkably decreased in refractive index. However, in the case where the nonionic surfactant was excessively added, abrasion resistance was somewhat deteriorated. Hence, when the nonionic surfactant was added in an amount of 4 wt % or less based on the total weight of the composition, abrasion resistance was maintained and the refractive index was considerably decreased.

(45) All simple modifications or variations of the present invention may be easily performed by those skilled in the art, and may be incorporated within the scope of the present invention.