EP2286463A2 - Photovoltaic modules containing plasticized interlayer films having a high volume resistance and good penetration resistance - Google Patents
Photovoltaic modules containing plasticized interlayer films having a high volume resistance and good penetration resistanceInfo
- Publication number
- EP2286463A2 EP2286463A2 EP09742148A EP09742148A EP2286463A2 EP 2286463 A2 EP2286463 A2 EP 2286463A2 EP 09742148 A EP09742148 A EP 09742148A EP 09742148 A EP09742148 A EP 09742148A EP 2286463 A2 EP2286463 A2 EP 2286463A2
- Authority
- EP
- European Patent Office
- Prior art keywords
- polyvinyl acetal
- plasticizer
- photovoltaic module
- film
- ppm
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Withdrawn
Links
- 230000035515 penetration Effects 0.000 title description 7
- 239000011229 interlayer Substances 0.000 title description 2
- 229920002554 vinyl polymer Polymers 0.000 claims abstract description 37
- DHKHKXVYLBGOIT-UHFFFAOYSA-N acetaldehyde Diethyl Acetal Natural products CCOC(C)OCC DHKHKXVYLBGOIT-UHFFFAOYSA-N 0.000 claims abstract description 26
- 229910001413 alkali metal ion Inorganic materials 0.000 claims abstract description 11
- 229910052784 alkaline earth metal Inorganic materials 0.000 claims abstract description 9
- 229910021645 metal ion Inorganic materials 0.000 claims abstract description 8
- HCHKCACWOHOZIP-UHFFFAOYSA-N Zinc Chemical compound [Zn] HCHKCACWOHOZIP-UHFFFAOYSA-N 0.000 claims abstract description 7
- 150000001342 alkaline earth metals Chemical class 0.000 claims abstract description 7
- 229910052782 aluminium Inorganic materials 0.000 claims abstract description 7
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims abstract description 7
- 229910052725 zinc Inorganic materials 0.000 claims abstract description 7
- 239000011701 zinc Substances 0.000 claims abstract description 7
- 125000002777 acetyl group Chemical class [H]C([H])([H])C(*)=O 0.000 claims abstract 10
- 239000004065 semiconductor Substances 0.000 claims description 26
- 239000004014 plasticizer Substances 0.000 claims description 22
- 229920002451 polyvinyl alcohol Polymers 0.000 claims description 14
- 239000004372 Polyvinyl alcohol Substances 0.000 claims description 12
- 238000004519 manufacturing process Methods 0.000 claims description 10
- 229910052799 carbon Inorganic materials 0.000 claims description 5
- 229910004298 SiO 2 Inorganic materials 0.000 claims description 4
- 150000001875 compounds Chemical class 0.000 claims description 4
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 claims description 3
- 229910052760 oxygen Inorganic materials 0.000 claims description 3
- 229910052739 hydrogen Inorganic materials 0.000 claims description 2
- 125000004435 hydrogen atom Chemical group [H]* 0.000 claims description 2
- 239000011118 polyvinyl acetate Substances 0.000 claims description 2
- 229920002689 polyvinyl acetate Polymers 0.000 claims description 2
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 claims 1
- 238000009413 insulation Methods 0.000 claims 1
- 239000001301 oxygen Substances 0.000 claims 1
- 239000010408 film Substances 0.000 description 64
- 150000001241 acetals Chemical class 0.000 description 28
- 239000010410 layer Substances 0.000 description 26
- 229920002037 poly(vinyl butyral) polymer Polymers 0.000 description 26
- 239000011521 glass Substances 0.000 description 22
- 235000019422 polyvinyl alcohol Nutrition 0.000 description 13
- 150000003839 salts Chemical class 0.000 description 10
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 10
- 239000000853 adhesive Substances 0.000 description 7
- 238000000034 method Methods 0.000 description 7
- 239000000203 mixture Substances 0.000 description 7
- 238000006359 acetalization reaction Methods 0.000 description 6
- 230000001070 adhesive effect Effects 0.000 description 6
- -1 alkaline earth metal salts Chemical class 0.000 description 6
- 239000002131 composite material Substances 0.000 description 6
- 239000005340 laminated glass Substances 0.000 description 6
- 239000005336 safety glass Substances 0.000 description 6
- 238000007740 vapor deposition Methods 0.000 description 6
- 239000002253 acid Substances 0.000 description 5
- 125000001931 aliphatic group Chemical group 0.000 description 5
- 150000002148 esters Chemical class 0.000 description 5
- 239000010409 thin film Substances 0.000 description 5
- ZTQSAGDEMFDKMZ-UHFFFAOYSA-N Butyraldehyde Chemical compound CCCC=O ZTQSAGDEMFDKMZ-UHFFFAOYSA-N 0.000 description 4
- RTZKZFJDLAIYFH-UHFFFAOYSA-N Diethyl ether Chemical compound CCOCC RTZKZFJDLAIYFH-UHFFFAOYSA-N 0.000 description 4
- 239000011888 foil Substances 0.000 description 4
- 238000005259 measurement Methods 0.000 description 4
- 238000002360 preparation method Methods 0.000 description 4
- ZIBGPFATKBEMQZ-UHFFFAOYSA-N triethylene glycol Chemical compound OCCOCCOCCO ZIBGPFATKBEMQZ-UHFFFAOYSA-N 0.000 description 4
- PYGXAGIECVVIOZ-UHFFFAOYSA-N Dibutyl decanedioate Chemical compound CCCCOC(=O)CCCCCCCCC(=O)OCCCC PYGXAGIECVVIOZ-UHFFFAOYSA-N 0.000 description 3
- KWYUFKZDYYNOTN-UHFFFAOYSA-M Potassium hydroxide Chemical class [OH-].[K+] KWYUFKZDYYNOTN-UHFFFAOYSA-M 0.000 description 3
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 3
- HEMHJVSKTPXQMS-UHFFFAOYSA-M Sodium hydroxide Chemical compound [OH-].[Na+] HEMHJVSKTPXQMS-UHFFFAOYSA-M 0.000 description 3
- XTXRWKRVRITETP-UHFFFAOYSA-N Vinyl acetate Chemical compound CC(=O)OC=C XTXRWKRVRITETP-UHFFFAOYSA-N 0.000 description 3
- 150000001299 aldehydes Chemical class 0.000 description 3
- 125000004432 carbon atom Chemical group C* 0.000 description 3
- 150000001735 carboxylic acids Chemical class 0.000 description 3
- 239000003054 catalyst Substances 0.000 description 3
- KRKNYBCHXYNGOX-UHFFFAOYSA-N citric acid Chemical compound OC(=O)CC(O)(C(O)=O)CC(O)=O KRKNYBCHXYNGOX-UHFFFAOYSA-N 0.000 description 3
- 238000000151 deposition Methods 0.000 description 3
- 230000008021 deposition Effects 0.000 description 3
- 238000009863 impact test Methods 0.000 description 3
- 229920003023 plastic Polymers 0.000 description 3
- 239000004033 plastic Substances 0.000 description 3
- CXMXRPHRNRROMY-UHFFFAOYSA-N sebacic acid Chemical class OC(=O)CCCCCCCCC(O)=O CXMXRPHRNRROMY-UHFFFAOYSA-N 0.000 description 3
- MCAHWIHFGHIESP-UHFFFAOYSA-L selenite(2-) Chemical compound [O-][Se]([O-])=O MCAHWIHFGHIESP-UHFFFAOYSA-L 0.000 description 3
- 239000011734 sodium Substances 0.000 description 3
- 238000004544 sputter deposition Methods 0.000 description 3
- 239000000126 substance Substances 0.000 description 3
- HGBOYTHUEUWSSQ-UHFFFAOYSA-N valeric aldehyde Natural products CCCCC=O HGBOYTHUEUWSSQ-UHFFFAOYSA-N 0.000 description 3
- 238000005406 washing Methods 0.000 description 3
- GCDUWJFWXVRGSM-UHFFFAOYSA-N 2-[2-(2-heptanoyloxyethoxy)ethoxy]ethyl heptanoate Chemical compound CCCCCCC(=O)OCCOCCOCCOC(=O)CCCCCC GCDUWJFWXVRGSM-UHFFFAOYSA-N 0.000 description 2
- SSKNCQWPZQCABD-UHFFFAOYSA-N 2-[2-[2-(2-heptanoyloxyethoxy)ethoxy]ethoxy]ethyl heptanoate Chemical compound CCCCCCC(=O)OCCOCCOCCOCCOC(=O)CCCCCC SSKNCQWPZQCABD-UHFFFAOYSA-N 0.000 description 2
- QTBSBXVTEAMEQO-UHFFFAOYSA-M Acetate Chemical compound CC([O-])=O QTBSBXVTEAMEQO-UHFFFAOYSA-M 0.000 description 2
- IRIAEXORFWYRCZ-UHFFFAOYSA-N Butylbenzyl phthalate Chemical compound CCCCOC(=O)C1=CC=CC=C1C(=O)OCC1=CC=CC=C1 IRIAEXORFWYRCZ-UHFFFAOYSA-N 0.000 description 2
- CURLTUGMZLYLDI-UHFFFAOYSA-N Carbon dioxide Chemical compound O=C=O CURLTUGMZLYLDI-UHFFFAOYSA-N 0.000 description 2
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 2
- 239000004971 Cross linker Substances 0.000 description 2
- LFQSCWFLJHTTHZ-UHFFFAOYSA-N Ethanol Chemical compound CCO LFQSCWFLJHTTHZ-UHFFFAOYSA-N 0.000 description 2
- VZCYOOQTPOCHFL-OWOJBTEDSA-N Fumaric acid Chemical compound OC(=O)\C=C\C(O)=O VZCYOOQTPOCHFL-OWOJBTEDSA-N 0.000 description 2
- 229910019142 PO4 Inorganic materials 0.000 description 2
- FAPWRFPIFSIZLT-UHFFFAOYSA-M Sodium chloride Chemical compound [Na+].[Cl-] FAPWRFPIFSIZLT-UHFFFAOYSA-M 0.000 description 2
- GTVWRXDRKAHEAD-UHFFFAOYSA-N Tris(2-ethylhexyl) phosphate Chemical compound CCCCC(CC)COP(=O)(OCC(CC)CCCC)OCC(CC)CCCC GTVWRXDRKAHEAD-UHFFFAOYSA-N 0.000 description 2
- 150000007513 acids Chemical class 0.000 description 2
- 239000000654 additive Substances 0.000 description 2
- WNLRTRBMVRJNCN-UHFFFAOYSA-N adipic acid Chemical compound OC(=O)CCCCC(O)=O WNLRTRBMVRJNCN-UHFFFAOYSA-N 0.000 description 2
- 230000000181 anti-adherent effect Effects 0.000 description 2
- SAOKZLXYCUGLFA-UHFFFAOYSA-N bis(2-ethylhexyl) adipate Chemical compound CCCCC(CC)COC(=O)CCCCC(=O)OCC(CC)CCCC SAOKZLXYCUGLFA-UHFFFAOYSA-N 0.000 description 2
- BJQHLKABXJIVAM-UHFFFAOYSA-N bis(2-ethylhexyl) phthalate Chemical compound CCCCC(CC)COC(=O)C1=CC=CC=C1C(=O)OCC(CC)CCCC BJQHLKABXJIVAM-UHFFFAOYSA-N 0.000 description 2
- 238000007906 compression Methods 0.000 description 2
- 230000006835 compression Effects 0.000 description 2
- 230000001143 conditioned effect Effects 0.000 description 2
- 229910052802 copper Inorganic materials 0.000 description 2
- 239000010949 copper Substances 0.000 description 2
- 230000007797 corrosion Effects 0.000 description 2
- 238000005260 corrosion Methods 0.000 description 2
- HBGGXOJOCNVPFY-UHFFFAOYSA-N diisononyl phthalate Chemical compound CC(C)CCCCCCOC(=O)C1=CC=CC=C1C(=O)OCCCCCCC(C)C HBGGXOJOCNVPFY-UHFFFAOYSA-N 0.000 description 2
- VJHINFRRDQUWOJ-UHFFFAOYSA-N dioctyl sebacate Chemical compound CCCCC(CC)COC(=O)CCCCCCCCC(=O)OCC(CC)CCCC VJHINFRRDQUWOJ-UHFFFAOYSA-N 0.000 description 2
- 239000005329 float glass Substances 0.000 description 2
- HHLFWLYXYJOTON-UHFFFAOYSA-N glyoxylic acid Chemical compound OC(=O)C=O HHLFWLYXYJOTON-UHFFFAOYSA-N 0.000 description 2
- 239000012535 impurity Substances 0.000 description 2
- 229910052738 indium Inorganic materials 0.000 description 2
- APFVFJFRJDLVQX-UHFFFAOYSA-N indium atom Chemical compound [In] APFVFJFRJDLVQX-UHFFFAOYSA-N 0.000 description 2
- 150000002500 ions Chemical class 0.000 description 2
- 238000003475 lamination Methods 0.000 description 2
- OJXOOFXUHZAXLO-UHFFFAOYSA-M magnesium;1-bromo-3-methanidylbenzene;bromide Chemical compound [Mg+2].[Br-].[CH2-]C1=CC=CC(Br)=C1 OJXOOFXUHZAXLO-UHFFFAOYSA-M 0.000 description 2
- 239000000463 material Substances 0.000 description 2
- 229910052751 metal Inorganic materials 0.000 description 2
- 239000002184 metal Substances 0.000 description 2
- 230000007935 neutral effect Effects 0.000 description 2
- 235000021317 phosphate Nutrition 0.000 description 2
- 150000003013 phosphoric acid derivatives Chemical class 0.000 description 2
- XNGIFLGASWRNHJ-UHFFFAOYSA-N phthalic acid Chemical compound OC(=O)C1=CC=CC=C1C(O)=O XNGIFLGASWRNHJ-UHFFFAOYSA-N 0.000 description 2
- 235000011118 potassium hydroxide Nutrition 0.000 description 2
- 230000005855 radiation Effects 0.000 description 2
- 229920005989 resin Polymers 0.000 description 2
- 239000011347 resin Substances 0.000 description 2
- 229940082569 selenite Drugs 0.000 description 2
- 229910052708 sodium Inorganic materials 0.000 description 2
- 235000011121 sodium hydroxide Nutrition 0.000 description 2
- 239000000243 solution Substances 0.000 description 2
- 239000000758 substrate Substances 0.000 description 2
- KDYFGRWQOYBRFD-UHFFFAOYSA-N succinic acid Chemical compound OC(=O)CCC(O)=O KDYFGRWQOYBRFD-UHFFFAOYSA-N 0.000 description 2
- ZUHZGEOKBKGPSW-UHFFFAOYSA-N tetraglyme Chemical compound COCCOCCOCCOCCOC ZUHZGEOKBKGPSW-UHFFFAOYSA-N 0.000 description 2
- OLAQBFHDYFMSAJ-UHFFFAOYSA-L 1,2-bis(7-methyloctyl)cyclohexane-1,2-dicarboxylate Chemical compound CC(C)CCCCCCC1(C([O-])=O)CCCCC1(CCCCCCC(C)C)C([O-])=O OLAQBFHDYFMSAJ-UHFFFAOYSA-L 0.000 description 1
- DLZBUNUDESZERL-UHFFFAOYSA-N 1-o-heptyl 6-o-nonyl hexanedioate Chemical compound CCCCCCCCCOC(=O)CCCCC(=O)OCCCCCCC DLZBUNUDESZERL-UHFFFAOYSA-N 0.000 description 1
- ZMWRRFHBXARRRT-UHFFFAOYSA-N 2-(benzotriazol-2-yl)-4,6-bis(2-methylbutan-2-yl)phenol Chemical compound CCC(C)(C)C1=CC(C(C)(C)CC)=CC(N2N=C3C=CC=CC3=N2)=C1O ZMWRRFHBXARRRT-UHFFFAOYSA-N 0.000 description 1
- WTTWSMJHJFNCQB-UHFFFAOYSA-N 2-(dibenzylamino)ethanol Chemical compound C=1C=CC=CC=1CN(CCO)CC1=CC=CC=C1 WTTWSMJHJFNCQB-UHFFFAOYSA-N 0.000 description 1
- OBETXYAYXDNJHR-UHFFFAOYSA-N 2-Ethylhexanoic acid Chemical class CCCCC(CC)C(O)=O OBETXYAYXDNJHR-UHFFFAOYSA-N 0.000 description 1
- GWQRPOCMBMQBTK-UHFFFAOYSA-N 2-[2-(2-ethylhexanoyloxy)ethoxy]ethyl 2-ethylhexanoate Chemical compound CCCCC(CC)C(=O)OCCOCCOC(=O)C(CC)CCCC GWQRPOCMBMQBTK-UHFFFAOYSA-N 0.000 description 1
- WPMUZECMAFLDQO-UHFFFAOYSA-N 2-[2-(2-hexanoyloxyethoxy)ethoxy]ethyl hexanoate Chemical compound CCCCCC(=O)OCCOCCOCCOC(=O)CCCCC WPMUZECMAFLDQO-UHFFFAOYSA-N 0.000 description 1
- FZWOQNIYLGAJOA-UHFFFAOYSA-N 2-[2-[2-(7-methyloctanoyloxy)ethoxy]ethoxy]ethyl 7-methyloctanoate Chemical compound CC(C)CCCCCC(=O)OCCOCCOCCOC(=O)CCCCCC(C)C FZWOQNIYLGAJOA-UHFFFAOYSA-N 0.000 description 1
- JCZWSBFREPCATE-UHFFFAOYSA-N 2-cyclohexyl-2-hexylhexanedioic acid Chemical compound CCCCCCC(CCCC(O)=O)(C(O)=O)C1CCCCC1 JCZWSBFREPCATE-UHFFFAOYSA-N 0.000 description 1
- OIUGWVWLEGLAGH-UHFFFAOYSA-N 6-nonoxy-6-oxohexanoic acid Chemical class CCCCCCCCCOC(=O)CCCCC(O)=O OIUGWVWLEGLAGH-UHFFFAOYSA-N 0.000 description 1
- 229910002014 Aerosil® 130 Inorganic materials 0.000 description 1
- 239000004803 Di-2ethylhexylphthalate Substances 0.000 description 1
- NEHDRDVHPTWWFG-UHFFFAOYSA-N Dioctyl hexanedioate Chemical compound CCCCCCCCOC(=O)CCCCC(=O)OCCCCCCCC NEHDRDVHPTWWFG-UHFFFAOYSA-N 0.000 description 1
- VGGSQFUCUMXWEO-UHFFFAOYSA-N Ethene Chemical compound C=C VGGSQFUCUMXWEO-UHFFFAOYSA-N 0.000 description 1
- IMROMDMJAWUWLK-UHFFFAOYSA-N Ethenol Chemical compound OC=C IMROMDMJAWUWLK-UHFFFAOYSA-N 0.000 description 1
- 239000005977 Ethylene Substances 0.000 description 1
- IAYPIBMASNFSPL-UHFFFAOYSA-N Ethylene oxide Chemical compound C1CO1 IAYPIBMASNFSPL-UHFFFAOYSA-N 0.000 description 1
- GYHNNYVSQQEPJS-UHFFFAOYSA-N Gallium Chemical compound [Ga] GYHNNYVSQQEPJS-UHFFFAOYSA-N 0.000 description 1
- DGAQECJNVWCQMB-PUAWFVPOSA-M Ilexoside XXIX Chemical compound C[C@@H]1CC[C@@]2(CC[C@@]3(C(=CC[C@H]4[C@]3(CC[C@@H]5[C@@]4(CC[C@@H](C5(C)C)OS(=O)(=O)[O-])C)C)[C@@H]2[C@]1(C)O)C)C(=O)O[C@H]6[C@@H]([C@H]([C@@H]([C@H](O6)CO)O)O)O.[Na+] DGAQECJNVWCQMB-PUAWFVPOSA-M 0.000 description 1
- CGSLYBDCEGBZCG-UHFFFAOYSA-N Octicizer Chemical compound C=1C=CC=CC=1OP(=O)(OCC(CC)CCCC)OC1=CC=CC=C1 CGSLYBDCEGBZCG-UHFFFAOYSA-N 0.000 description 1
- 229920001744 Polyaldehyde Polymers 0.000 description 1
- XBDQKXXYIPTUBI-UHFFFAOYSA-N Propionic acid Chemical class CCC(O)=O XBDQKXXYIPTUBI-UHFFFAOYSA-N 0.000 description 1
- UCKMPCXJQFINFW-UHFFFAOYSA-N Sulphide Chemical compound [S-2] UCKMPCXJQFINFW-UHFFFAOYSA-N 0.000 description 1
- YSMRWXYRXBRSND-UHFFFAOYSA-N TOTP Chemical compound CC1=CC=CC=C1OP(=O)(OC=1C(=CC=CC=1)C)OC1=CC=CC=C1C YSMRWXYRXBRSND-UHFFFAOYSA-N 0.000 description 1
- ATJFFYVFTNAWJD-UHFFFAOYSA-N Tin Chemical compound [Sn] ATJFFYVFTNAWJD-UHFFFAOYSA-N 0.000 description 1
- FRQDZJMEHSJOPU-UHFFFAOYSA-N Triethylene glycol bis(2-ethylhexanoate) Chemical compound CCCCC(CC)C(=O)OCCOCCOCCOC(=O)C(CC)CCCC FRQDZJMEHSJOPU-UHFFFAOYSA-N 0.000 description 1
- DTQVDTLACAAQTR-UHFFFAOYSA-N Trifluoroacetic acid Chemical class OC(=O)C(F)(F)F DTQVDTLACAAQTR-UHFFFAOYSA-N 0.000 description 1
- 239000012963 UV stabilizer Substances 0.000 description 1
- 150000001242 acetic acid derivatives Chemical class 0.000 description 1
- 239000003377 acid catalyst Substances 0.000 description 1
- 239000002313 adhesive film Substances 0.000 description 1
- 239000012790 adhesive layer Substances 0.000 description 1
- WNLRTRBMVRJNCN-UHFFFAOYSA-L adipate(2-) Chemical compound [O-]C(=O)CCCCC([O-])=O WNLRTRBMVRJNCN-UHFFFAOYSA-L 0.000 description 1
- 239000001361 adipic acid Substances 0.000 description 1
- 235000011037 adipic acid Nutrition 0.000 description 1
- 239000003513 alkali Substances 0.000 description 1
- 229910052783 alkali metal Inorganic materials 0.000 description 1
- 238000004458 analytical method Methods 0.000 description 1
- 239000012736 aqueous medium Substances 0.000 description 1
- 159000000032 aromatic acids Chemical class 0.000 description 1
- 238000001479 atomic absorption spectroscopy Methods 0.000 description 1
- 239000002585 base Substances 0.000 description 1
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- 229910052790 beryllium Inorganic materials 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- HORIEOQXBKUKGQ-UHFFFAOYSA-N bis(7-methyloctyl) cyclohexane-1,2-dicarboxylate Chemical compound CC(C)CCCCCCOC(=O)C1CCCCC1C(=O)OCCCCCCC(C)C HORIEOQXBKUKGQ-UHFFFAOYSA-N 0.000 description 1
- 238000007664 blowing Methods 0.000 description 1
- 150000004648 butanoic acid derivatives Chemical class 0.000 description 1
- 229910052792 caesium Inorganic materials 0.000 description 1
- 229910052791 calcium Inorganic materials 0.000 description 1
- 238000004364 calculation method Methods 0.000 description 1
- 239000001569 carbon dioxide Substances 0.000 description 1
- 229910002092 carbon dioxide Inorganic materials 0.000 description 1
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- 125000003178 carboxy group Chemical group [H]OC(*)=O 0.000 description 1
- 238000005266 casting Methods 0.000 description 1
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- 150000003841 chloride salts Chemical class 0.000 description 1
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- 238000004132 cross linking Methods 0.000 description 1
- 239000003431 cross linking reagent Substances 0.000 description 1
- 230000007423 decrease Effects 0.000 description 1
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- 150000002170 ethers Chemical class 0.000 description 1
- 229920001038 ethylene copolymer Polymers 0.000 description 1
- 239000005038 ethylene vinyl acetate Substances 0.000 description 1
- 150000004675 formic acid derivatives Chemical class 0.000 description 1
- 238000009472 formulation Methods 0.000 description 1
- 229910052730 francium Inorganic materials 0.000 description 1
- 239000001530 fumaric acid Substances 0.000 description 1
- 230000004927 fusion Effects 0.000 description 1
- 229910052733 gallium Inorganic materials 0.000 description 1
- 239000007789 gas Substances 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- 125000003187 heptyl group Chemical group [H]C([*])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])[H] 0.000 description 1
- 230000007062 hydrolysis Effects 0.000 description 1
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- 229910052500 inorganic mineral Inorganic materials 0.000 description 1
- 239000011810 insulating material Substances 0.000 description 1
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- 239000002346 layers by function Substances 0.000 description 1
- 229910052744 lithium Inorganic materials 0.000 description 1
- 229910052749 magnesium Inorganic materials 0.000 description 1
- 238000000691 measurement method Methods 0.000 description 1
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- 239000011707 mineral Substances 0.000 description 1
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- 150000002823 nitrates Chemical class 0.000 description 1
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- 235000005985 organic acids Nutrition 0.000 description 1
- 230000003647 oxidation Effects 0.000 description 1
- 238000007254 oxidation reaction Methods 0.000 description 1
- 125000004430 oxygen atom Chemical group O* 0.000 description 1
- 239000000049 pigment Substances 0.000 description 1
- 229920003229 poly(methyl methacrylate) Polymers 0.000 description 1
- 229920001223 polyethylene glycol Polymers 0.000 description 1
- 239000004848 polyfunctional curative Substances 0.000 description 1
- 229920000642 polymer Polymers 0.000 description 1
- 238000006116 polymerization reaction Methods 0.000 description 1
- 239000004926 polymethyl methacrylate Substances 0.000 description 1
- 229910052700 potassium Inorganic materials 0.000 description 1
- 238000010248 power generation Methods 0.000 description 1
- 238000003825 pressing Methods 0.000 description 1
- 239000013615 primer Substances 0.000 description 1
- 239000002987 primer (paints) Substances 0.000 description 1
- 230000001698 pyrogenic effect Effects 0.000 description 1
- 229910052701 rubidium Inorganic materials 0.000 description 1
- 229940116351 sebacate Drugs 0.000 description 1
- 238000010008 shearing Methods 0.000 description 1
- 239000005368 silicate glass Substances 0.000 description 1
- 239000000377 silicon dioxide Substances 0.000 description 1
- 239000011780 sodium chloride Substances 0.000 description 1
- 229910001415 sodium ion Inorganic materials 0.000 description 1
- 239000003381 stabilizer Substances 0.000 description 1
- 229910052712 strontium Inorganic materials 0.000 description 1
- 239000001384 succinic acid Substances 0.000 description 1
- 150000003467 sulfuric acid derivatives Chemical class 0.000 description 1
- 230000003746 surface roughness Effects 0.000 description 1
- 238000003786 synthesis reaction Methods 0.000 description 1
- 229920001897 terpolymer Polymers 0.000 description 1
- UWHCKJMYHZGTIT-UHFFFAOYSA-N tetraethylene glycol Chemical compound OCCOCCOCCOCCO UWHCKJMYHZGTIT-UHFFFAOYSA-N 0.000 description 1
- 229920001187 thermosetting polymer Polymers 0.000 description 1
- VZCYOOQTPOCHFL-UHFFFAOYSA-N trans-butenedioic acid Natural products OC(=O)C=CC(O)=O VZCYOOQTPOCHFL-UHFFFAOYSA-N 0.000 description 1
- DQWPFSLDHJDLRL-UHFFFAOYSA-N triethyl phosphate Chemical compound CCOP(=O)(OCC)OCC DQWPFSLDHJDLRL-UHFFFAOYSA-N 0.000 description 1
Classifications
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
- C08K5/00—Use of organic ingredients
- C08K5/04—Oxygen-containing compounds
- C08K5/10—Esters; Ether-esters
- C08K5/101—Esters; Ether-esters of monocarboxylic acids
- C08K5/103—Esters; Ether-esters of monocarboxylic acids with polyalcohols
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B17/00—Layered products essentially comprising sheet glass, or glass, slag, or like fibres
- B32B17/06—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material
- B32B17/10—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin
- B32B17/10005—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing
- B32B17/1055—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing characterized by the resin layer, i.e. interlayer
- B32B17/10688—Adjustment of the adherence to the glass layers
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B17/00—Layered products essentially comprising sheet glass, or glass, slag, or like fibres
- B32B17/06—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material
- B32B17/10—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin
- B32B17/10005—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing
- B32B17/1055—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing characterized by the resin layer, i.e. interlayer
- B32B17/10761—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing characterized by the resin layer, i.e. interlayer containing vinyl acetal
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L31/00—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
- H01L31/04—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof adapted as photovoltaic [PV] conversion devices
- H01L31/042—PV modules or arrays of single PV cells
- H01L31/048—Encapsulation of modules
- H01L31/0481—Encapsulation of modules characterised by the composition of the encapsulation material
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02B—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO BUILDINGS, e.g. HOUSING, HOUSE APPLIANCES OR RELATED END-USER APPLICATIONS
- Y02B10/00—Integration of renewable energy sources in buildings
- Y02B10/10—Photovoltaic [PV]
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
- Y02E10/00—Energy generation through renewable energy sources
- Y02E10/50—Photovoltaic [PV] energy
Definitions
- the invention relates to the production of photovoltaic modules using plasticized films based on polyvinyl acetal with increased volume resistance and good penetration resistance
- Photovoltaic modules consist of a photosensitive semiconductor layer, which is provided to protect against external influences with a transparent cover.
- a photosensitive semiconductor layer monocrystalline solar cells or polycrystalline, thin semiconductor layers can be used on a support.
- Thin-film solar modules consist of a photosensitive semiconductor layer deposited on a substrate such as a substrate. a transparent plate or a flexible carrier sheet e.g. by vapor deposition, vapor deposition, sputtering or wet deposition is applied.
- Both systems are often placed between a sheet of glass and a rigid, rear cover plate, e.g. laminated from glass or plastics using a transparent adhesive.
- the transparent adhesive must completely enclose the photosensitive semiconductor layer and its electrical connection lines, be UV-stable and insensitive to moisture and be completely bubble-free after the lamination process.
- Curing resins or crosslinkable systems based on ethylene-vinyl acetate (EVA) are frequently used as transparent adhesives, as disclosed, for example, in DE 41 22 721 C1 or DE 41 28 766 A1. These adhesive systems can be set in the uncured state so low viscosity that they surround the solar cell units bubble-free. After adding a hardener or crosslinking agent, a mechanically resistant adhesive layer is obtained.
- a disadvantage of these adhesive systems is that during the curing process often aggressive substances such as acids are released, which can destroy the photosensitive semiconductor layers, in particular thin-film modules.
- some casting resins tend after some years to blistering or delamination by UV radiation.
- thermosetting adhesive systems are the use of plasticized films based on polyvinyl acetals, such as polyvinyl butyral (PVB) known from the manufacture of laminated glass.
- PVB polyvinyl butyral
- Photovoltaic modules are subjected to a multitude of tests according to IEC 61215 (damp heat test, wet leakage current test) in order to reduce the leakage currents of the modules.
- Solar cells in particular photosensitive semiconductor layers of thin-film solar modules, e.g. based on CIS (Copper / indium / (di) selenite) or
- Copper / indium / gallium / sulphide / selenite (CIGS) or the thin conductive layers (TCO) are chemically susceptible to corrosion, so the encapsulant must be chemically inert and free from aggressive chemicals Additives such as crosslinkers, crosslinkers or primers, and the presence of water, alkali metal ions or traces of acid should be avoided.
- plastics commonly used in photovoltaic modules are generally known as electrically good insulating materials, however, have Restleit refineen, which are as a rule due to impurities such as water, ionic catalyst residues or salts.
- impurities such as water, ionic catalyst residues or salts.
- the interaction of ionic impurities with diffusing water which is always to be expected in the case of ambient humidities typical for use, has a considerable share in the residual conductivity.
- the salt content of the film depends firstly on the salt content of the PVB polymer, which from the manufacturing process depending on the quality of the washing process used there, salts of Mineral acids such as NaCl, KCl, NaNO 3 , KNO 3 , Na 2 SO 4 or K 2 SO 4 typically in amounts between 20-300 ppm.
- alkali and alkaline earth metal salts are often added to the usual PVB films as so-called anti-adhesion agents to increase the penetration resistance of the glass / film / glass composites in amounts of about 20-500 ppm. These salts are required to set a sufficiently low level of adhesion of the film to the glass. If a photovoltaic module produced with PVB film is therefore also to have the safety properties of a laminated safety glass in addition to high power generation, for example because the module is part of a glass façade, the problem arises that the anti-adhesive agent combinations and quantities normally used to reduce adhesion impair the electrical resistance can also increase the corrosion of the semiconductor layers.
- the safety properties of a glass component on laminated glass are generally considered to be sufficient if the component in the pendulum impact test according to EN 12600 at least Class 3B for which a 50 kg double tire pendulum from a height of 190 mm is levitated against the glass , If the pendulum does not break through the glass component or if there is no large opening and no Sharp-edged splinters detach, the test is passed.
- laminated glass also has the pendulum impact test at significantly greater deflection heights, in particular 1200 mm, which then achieves the highest resistance class 1 B.
- the PVB film should have a not too high adhesion to the glass or the adjacent functional layers.
- Object of the present invention was therefore, plasticizer-containing films based on polyvinyl acetal with high volume resistance and provide good penetration resistance in conjunction with glass layers for the manufacture of photovoltaic modules.
- the present invention therefore relates to photovoltaic modules comprising a laminate of a) a transparent front cover b) one or more photosensitive semiconductor layers c) at least one plasticizer-containing polyvinyl acetal-based film and d) a back cover wherein the plasticizer-containing polyvinyl acetal-based Film c) has more than 10 ppm of metal ions selected from the group of alkaline earth metals, zinc and aluminum and less than 150 ppm of alkali metal ions.
- concentrations refer to the respective sums of the individual concentrations, i. E. to the total concentrations of alkali metal ions or polyvalent metal ions.
- the film used according to the invention c) contains more than 15 ppm, preferably more than 20 ppm, preferably more than 30 ppm, preferably more than 50 ppm, preferably more than 75 ppm, preferably more than 100 ppm, preferably more than 125 ppm and more preferably more than 150 ppm ions of the alkaline earth metals (Be, Mg, Ca, Sr, Ba, Ra), zinc or aluminum.
- Be, Mg, Ca, Sr, Ba, Ra the alkaline earth metals
- not more than 1000 ppm of said polyvalent metals should be present.
- the content of alkali metal ions (Li, Na, K, Rb, Cs, Fr) in the plasticizer-containing polyvinyl acetal-based film should be as low as possible.
- the film contains less than 100 ppm, preferably less than 75 ppm, preferably less than 50 ppm, preferably less than 25 ppm, preferably less than 15 ppm, preferably less than 10 ppm and more preferably less than 5 ppm alkali metal ions.
- Alkali metal ions are added to the film mixture in the form of the salts of mono- or polyvalent inorganic or mono- or polyvalent organic acids.
- counterions are e.g. Salts of organic carboxylic acids such as formates, acetates, trifluoroacetates, propionates, butyrates, benzoates, 2-ethylhexanoates, etc., preferably carboxylic acids having less than 10 C atoms, preferably less than 8, preferably less than 6, preferably less than 4 and especially preferably be used with less than 3 C-atoms.
- inorganic counterions are chlorides, nitrates, sulfates, phosphates.
- the films used in the invention in a
- Ambient humidity of 85% RH at 23 ° C a resistivity of at least 1E + 11 ohms * cm, preferably at least 5E + 11 ohms * cm, 1E + 12 ohms * cm, 5E + 12 ohms * cm, 1E + 13 , 5E + 13 ohms * cm or 1E + 14 ohms * cm.
- polyvinyl alcohol is dissolved in water and acetalized with an aldehyde such as butyraldehyde with the addition of an acid catalyst.
- the precipitated polyvinyl acetal is separated, washed neutral, optionally suspended in an alkaline aqueous medium, then washed neutral again and dried.
- the acid used for the acetalization must be neutralized again after the reaction.
- a low level of alkali metal ions can be achieved inter alia in the synthesis of the polyvinyl acetal by dispensing with the sodium or potassium hydroxides or carbonates usually used to neutralize the catalyst or by thoroughly washing the polyvinyl acetal obtained in the acetalization become.
- the catalyst acid can be neutralized from the acetalization step, for example by blowing in carbon dioxide or ethylene oxide.
- the polyvinyl alcohol content of the polyvinyl acetal can be adjusted by the amount of aldehyde used in the acetalization.
- Aldehydes having 2-10 carbon atoms e.g., valeraldehyde.
- the films based on plasticized polyvinyl acetal preferably contain uncrosslinked polyvinyl butyral (PVB), which is obtained by acetalization of polyvinyl alcohol with butyraldehyde.
- PVB polyvinyl butyral
- crosslinked polyvinyl acetals in particular crosslinked polyvinyl butyral (PVB) is also possible.
- Suitable crosslinked polyvinyl acetals are e.g. in EP 1527107 B1 and WO 2004/063231 A1 (thermal self-crosslinking of polyvinyl acetals containing carboxyl groups), EP 1606325 A1 (polyvinyl acetals crosslinked with polyaldehydes) and WO 03/020776 A1 (polyvinyl acetals crosslinked with glyoxylic acid).
- EP 1527107 B1 and WO 2004/063231 A1 thermal self-crosslinking of polyvinyl acetals containing carboxyl groups
- EP 1606325 A1 polyvinyl acetals crosslinked with polyaldehydes
- WO 03/020776 A1 polyvinyl acetals crosslinked with glyoxylic acid
- terpolymers of hydrolyzed vinyl acetate / ethylene copolymers can also be used as the polyvinyl alcohol. These compounds are typically hydrolyzed to greater than 98 mole percent and contain from 1 to 10 weight percent ethylene based units (e.g., "Exceval" type from Kuraray Europe GmbH).
- hydrolyzed copolymers of vinyl acetate and at least one further ethylenically unsaturated monomer can also be used within the scope of the present invention.
- polyvinyl alcohols can be used in the context of the present invention purely or as a mixture of polyvinyl alcohols with different degree of polymerization or degree of hydrolysis.
- Polyvinyl acetals still contain in addition to the acetal units
- the polyvinyl acetals used according to the invention preferably have a polyvinyl alcohol content of less than 22% by weight, 20% by weight or 18 % By weight, less than 16% by weight or 15% by weight and in particular less than 14% by weight. A polyvinyl alcohol content of 12% by weight should not be exceeded.
- Polyvinyl acetal is preferably less than 5% by weight, less than 3% by weight or less than 1% by weight, particularly preferably less than 0.75% by weight, very preferably less than 0.5% by weight and in particular less than 0.25% by weight.
- the degree of acetalization can be determined by calculation.
- the films have a plasticizer content of at most 40% by weight, 35% by weight, 32% by weight, 30% by weight, 28% by weight, 26% by weight, 24% by weight, 22% by weight. , 20 wt.%, 18 wt.%, 16 wt.%, Wherein a plasticizer content of 15 wt.% For reasons of processability of the film should not be exceeded (in each case based on the total film formulation).
- Inventive films or photovoltaic modules may contain one or more plasticizers.
- suitable plasticizers for the films used according to the invention are one or more compounds selected from the following groups:
- Esters of polyhydric aliphatic or aromatic acids e.g. Dialkyladipates such as Dihexyladipat, Dioctyladipat, Hexylcyclohexyladipat, mixtures of heptyl and nonyl adipates, Diisononyladipat, heptylnonyl adipate and esters of adipic acid with cycloaliphatic or ether-containing ester alcohols, dialkyl sebacates such as dibutyl sebacate and esters of sebacic acid with cycloaliphatic or ether-containing ester alcohols, esters of phthalic acid such as butyl benzyl phthalate or bis-2-butoxyethyl phthalate
- esters of di-, tri- or tetraglycols with linear or branched aliphatic or cycloaliphatic carboxylic acids can serve Diethylene glycol bis (2-ethylhexanoate), triethylene glycol bis (2-ethylhexanoate), tri-ethylene glycol bis (2-ethylbu-ta-no-ate),
- Phosphates with aliphatic or aromatic ester alcohols e.g. Tris (2-ethylhexyl) phosphate (TOF), triethyl phosphate, diphenyl-2-ethylhexyl phosphate, and / or tricresyl phosphate
- Slides are one or more compounds selected from the group consisting of di-2-ethylhexyl sebacate (DOS), di-2-ethylhexyl adipate (DOA), dihexyl adipate (DHA), dibutyl sebacate (DBS), triethylene glycol bis-n-heptanoate (3G7), Tetraethylene glycol bis-n-heptanoate (4G7), triethylene glycol bis-2-ethylhexanoate (3GO or 3G8) tetraethylene glycol bis-n-2-ethylhexanoate (4GO or 4G8) di-2-butoxy-ethyl adipate (DBEA ), Di-2-butoxyethoxyethyl adipate (DBEEA) di-2-butoxyethyl sebacate (DBES), di-2-ethylhexyl phthalate (DOP), di-isononyl phthalate (DINP) triethylene glycol bis
- Plasticizers whose polarity expressed by the formula 100 ⁇ O / (C + H) is less than or equal to 9.4 are particularly suitable as plasticizers for the films used according to the invention, where O, C and H are the number of oxygen atoms. , Carbon and hydrogen atoms in each molecule.
- the following table shows plasticizers which can be used according to the invention and their polarity values according to the formula 100 ⁇ O / (C + H).
- the ion mobility which is possibly dependent on the water content of the film and thus the specific resistance can be influenced by the addition of silica, in particular pyrogenic SiO 2 .
- the plasticizer-containing films based on polyvinyl acetal preferably contain 0.001 to 15% by weight, preferably 0.01 to 10% by weight and in particular 2 to 5% by weight of SiO 2 .
- the films of the invention may additionally contain conventional additives, such as oxidation stabilizers, UV stabilizers, dyes, pigments and anti-adhesive.
- the photovoltaic modules are produced by laminating the transparent front cover a), the photosensitive semiconductor layers b) and the rear cover d) by means of at least one plasticizer-containing film based on polyvinyl acetal c) with fusion of the films, so that a bubble-free and schlierenoker Inclusion of the photosensitive semiconductor layer is obtained.
- the photosensitive semiconductor layers are embedded between two films c) and thus bonded to the covers a) and d).
- Foils are usually 0.38, 0.51, 0.76, 1.14, 1.52 or 2.28 mm.
- the photosensitive semiconductor layer is applied directly to a support (for example by vapor deposition, vapor deposition, sputtering or wet deposition). An encapsulation of the photosensitive semiconductor layer is not possible here.
- the photosensitive semiconductor layers are applied to the cover d) (for example by vapor deposition, vapor deposition, sputtering or wet deposition) and bonded to the transparent front cover a) by at least one film c).
- the photosensitive semiconductor layers are applied to the transparent front cover a) and glued by at least one film c) with the rear cover d).
- the photosensitive material In general, in thin-film modules, the photosensitive material
- this edge region can be very narrow, preferably below 3 cm, especially below 2 cm and in particular below 1 cm.
- the transparent front cover is usually made of glass or PMMA.
- the rear cover of the photovoltaic module according to the invention may consist of glass, plastic or metal or their composites, wherein at least one of the carrier may be transparent. It is also possible to use one or both covers as composite glazing (ie as a laminate of at least two glass panes and at least one PVB foil) or as insulating glazing with a gas gap. Of course, that too Combination of these measures possible.
- the photosensitive semiconductor layers used in the modules need not possess any special properties. Mono-, polycrystalline or amorphous systems can be used.
- Photovoltaic modules used vacuum laminators. These consist of a heatable and evacuable chamber, in which composite glazing can be laminated within 30 - 60 minutes. Reduced pressures of 0.01 to 300 mbar and temperatures of 100 to 200 0 C, in particular 130 - 160 0 C have proven in practice.
- a laminated as described above laminated body between at least one pair of rollers at a temperature of 60 to 150 ° C are pressed into a module according to the invention.
- Systems of this type are known for the production of laminated glazing and usually have at least one heating tunnel before or after the first press shop in systems with two pressing plants.
- the invention further provides for the use of plasticized polyvinyl acetal-based films c) containing more than 10 ppm metal ions selected from the group of alkaline earth metals, zinc and aluminum and less than 150 ppm alkali metal ions or with the preferred embodiments mentioned Production of photovoltaic modules.
- Photovoltaic modules according to the invention can be used as a facade component
- the measurement of the volume resistivity of the film is carried out according to DIN IEC 60093 at a defined temperature and ambient humidity (23 ° C and 85% rl_F) after the film has been conditioned for at least 24 hours under these conditions.
- a plate electrode Type 302 132 from Fetronic GmbH and an ohmmeter ISO-Digi 5 kV from Amprobe were used.
- the test voltage was 2.5kV, the waiting time after application of the test voltage to the value acquisition 60 sec.
- Polyvinyl acetals were determined according to ASTM D 1396-92. The analysis of the metal ion content was carried out by atomic absorption spectroscopy (AAS). The water or moisture content of the films is determined by the Karl Fischer method.
- the pendulum impact test is carried out in accordance with EN 12600; the result is given in the classification of this standard.
- the adhesion of the film to the glass is given in "punch values" in each case based on the fire or tin side of the glass.
- the haze is determined by the Haze value in% according to ASTM 1003 D on a smooth film.
- the PVB film to be tested is placed between two flat silicate glass panes of the format 300 mm ⁇ 300 mm with a thickness of 2 mm, vented in a Vorverbundofen calender rolls to a glass pre-composite and then in an autoclave at a pressure of 12 bar and at a temperature of 140 ° C within a total of 90 min. pressed into a flat laminated safety glass. From the laminated safety glass thus produced, 10 samples measuring 25.4 mm ⁇ 25.4 mm are cut.
- test parameters are as follows:
- Sheets of thickness 0.76 mm were prepared with the mixtures of the composition listed in the following table and examined for their electrical resistance and their adhesion to glass and the pendulum impact resistance of laminated glass with the structure 5 mm float glass / foil / 5 mm float glass ,
- Table 3 and 4 The amounts given in Table 3 and 4 are given in wt.%, Based on the sum PVB and plasticizer.
- 3G8 stands for triethylene glycol bis-2-ethylhexanoate
- AEROSIL 130 and TINUVIN 328 are commercial products of Evonik Degussa GmbH or CIBA.
- the volume resistivity according to DIN IEC 60093 is indicated on a film conditioned in ohms at 23 ° C./85% RH (as described above).
- the PVB was a high-viscosity polyvinyl butyral having a viscosity 60-90 mPas (measured according to DIN53015 as a 5% solution in ethanol (with 5% water) at 20 0 C) and a PVA content of 20.0 wt.%, The content thereof of Na ions by thorough washing below 3 ppm.
- films having the salt concentration according to the invention have a high specific resistance with good penetration resistance of the glass / foil / glass laminates produced therewith. Films of this type are suitable for photovoltaic applications. A further improvement of the resistivity could be achieved by adding SiO 2 .
Abstract
The invention relates to the use of plasticized, polyvinyl acetal-based films which comprise more than 10 ppm metal ions selected from the group including alkaline earth metals, zinc and aluminum and less than 150 ppm alkali metal ions, for producing photovoltaic modules. The films preferably have an electrical volume resistance of more than 1E11 ohm*cm in an ambient environment of 85% RH/23°C. The photovoltaic modules can be used as façade components, roof surfaces, conservatory covers, noise protection walls, balcony or breastwork elements or as components of window surfaces.
Description
Beschreibung Photovoltaikmodule enthaltend plastifizierte Zwischenschicht-Folien mit hohem Description Photovoltaic modules containing plasticized interlayer films with high
Durchgangswiderstand und guter Penetrationsfestigkeit Technisches GebietVolume resistance and good penetration resistance Technical field
[0001] Die Erfindung betrifft die Herstellung von Photovoltaikmodulen unter Verwendung von weichmacherhaltigen Folien auf Basis von Polyvinylacetal mit erhöhtem Durchgangswiderstand und guter PenetrationsfestigkeitThe invention relates to the production of photovoltaic modules using plasticized films based on polyvinyl acetal with increased volume resistance and good penetration resistance
Stand der TechnikState of the art
[0002] Photovoltaikmodule bestehen aus einer photosensitiven Halbleiterschicht, die zum Schutz gegen äußere Einflüsse mit einer transparenten Abdeckung versehen wird. Als photosensitive Halbleiterschicht können monokristalline Solarzellen oder polykristalline, dünne Halbleiterschichten auf einem Träger eingesetzt werden. Dünnschicht-Solarmodule bestehen aus einer photosensitiven Halbleiterschicht, die auf ein Substrat wie z.B. eine transparente Platte oder eine flexible Trägerfolie z.B. durch Aufdampfen, Gasphasenabscheidung, Sputtern oder Nassabscheidung aufgebracht ist.Photovoltaic modules consist of a photosensitive semiconductor layer, which is provided to protect against external influences with a transparent cover. As a photosensitive semiconductor layer, monocrystalline solar cells or polycrystalline, thin semiconductor layers can be used on a support. Thin-film solar modules consist of a photosensitive semiconductor layer deposited on a substrate such as a substrate. a transparent plate or a flexible carrier sheet e.g. by vapor deposition, vapor deposition, sputtering or wet deposition is applied.
[0003] Beide Systeme werden häufig zwischen eine Glasscheibe und eine rigide, hintere Abdeckplatte z.B. aus Glas oder Kunststoffen mit Hilfe eines transparenten Klebers laminiert.Both systems are often placed between a sheet of glass and a rigid, rear cover plate, e.g. laminated from glass or plastics using a transparent adhesive.
[0004] Der transparente Kleber muss die photosensitive Halbleiterschicht und deren elektrische Verbindungsleitungen vollständig umschließen, UV-stabil und Feuchtigkeitsunempfindlich sein und nach dem Laminierprozess vollständig blasenfrei sein.The transparent adhesive must completely enclose the photosensitive semiconductor layer and its electrical connection lines, be UV-stable and insensitive to moisture and be completely bubble-free after the lamination process.
[0005] Als transparente Kleber werden häufig aushärtende Gießharze oder vernetzbare, auf Ethylenvinylacetat (EVA) basierende Systeme eingesetzt, so wie beispielsweise in DE 41 22 721 C1 oder DE 41 28 766 A1 offenbart. Diese Klebesysteme können im ungehärteten Zustand so niedrigviskos eingestellt werden, dass sie die Solarzelleneinheiten blasenfrei umschließen. Nach Zugabe eines Härters oder Vernetzungsmittels wird eine mechanisch widerstandfähige Klebeschicht erhalten. Nachteilig diesen Klebesystemen ist, dass beim Aushärteprozess
häufig aggressive Substanzen wie Säuren freigesetzt werden, die die photosensitiven Halbleiterschichten, insbesondere Dünnschichtmodule, zerstören können. Zudem neigen einige Gießharze nach einigen Jahren zur Blasenbildung bzw. Delamination durch UV-Strahlung.Curing resins or crosslinkable systems based on ethylene-vinyl acetate (EVA) are frequently used as transparent adhesives, as disclosed, for example, in DE 41 22 721 C1 or DE 41 28 766 A1. These adhesive systems can be set in the uncured state so low viscosity that they surround the solar cell units bubble-free. After adding a hardener or crosslinking agent, a mechanically resistant adhesive layer is obtained. A disadvantage of these adhesive systems is that during the curing process often aggressive substances such as acids are released, which can destroy the photosensitive semiconductor layers, in particular thin-film modules. In addition, some casting resins tend after some years to blistering or delamination by UV radiation.
[0006] Eine Alternative zu aushärtenden Klebesystemen ist der Einsatz von weichmacherhaltigen Folien auf Basis von Polyvinylacetalen wie das aus der Verbundglasherstellung bekannte Polyvinylbutyral (PVB). Die Solarzelleneinheiten werden mit einer oder mehreren PVB-Folien bedeckt und diese unter erhöhtem Druck und erhöhter Temperatur mit den gewünschten Abdeckmaterialien zu einem Laminat verbunden.An alternative to thermosetting adhesive systems is the use of plasticized films based on polyvinyl acetals, such as polyvinyl butyral (PVB) known from the manufacture of laminated glass. The solar cell units are covered with one or more PVB films and bonded under elevated pressure and temperature with the desired covering materials into a laminate.
[0007] Verfahren zur Herstellung von Solarmodulen mit Hilfe von PVB-Folien sind z. B. durch DE 40 26 165 C2, DE 42 278 60 A1 , DE 29 237 70 C2, DE 35 38 986 C2 oder US 4,321 ,418 bekannt. Die Verwendung von PVB-Folien in Solarmodulen als Verbund-sicherheits-verglasungen ist z.B. in DE 20 302 045 U 1 , EP 1617487 A1 , und DE 35 389 86 C2 offenbart. Diese Schriften enthalten aber keine Information über die mechanischen, chemischen und elektrischen Eigenschaften der verwendeten PVB-Folien.Process for the production of solar modules by means of PVB films are z. Example by DE 40 26 165 C2, DE 42 278 60 A1, DE 29 237 70 C2, DE 35 38 986 C2 or US 4,321,418 known. The use of PVB films in solar modules as composite safety glazings is e.g. in DE 20 302 045 U 1, EP 1617487 A1, and DE 35 389 86 C2. However, these documents contain no information about the mechanical, chemical and electrical properties of the PVB films used.
[0008] Insbesondere die elektrischen Eigenschaften der Folien werden mit zunehmender Leistungsfähigkeit der photosensitiven Halbleiterschichten und der weltweiten Verbreitung von Solarmodulen immer wichtiger. Ladungsverluste oder gar Kurzschlüsse der Halbleiterschicht müssen auch unter extremen Witterungsbedingungen wie tropische Temperaturen, hohe Luftfeuchtigkeit oder starke UV-Strahlung über die gesamte Lebensdauer des Moduls vermieden werden. Photovoltaikmodule werden nach IEC 61215 einer Vielzahl von Tests unterzogen (Damp heat test, wet leakage current test) um Verlustströme der Module zu reduzieren.In particular, the electrical properties of the films are becoming increasingly important with increasing performance of the photosensitive semiconductor layers and the global distribution of solar modules. Charge losses or even short circuits of the semiconductor layer must be avoided even under extreme weather conditions such as tropical temperatures, high humidity or strong UV radiation over the entire life of the module. Photovoltaic modules are subjected to a multitude of tests according to IEC 61215 (damp heat test, wet leakage current test) in order to reduce the leakage currents of the modules.
[0009] Es ist bekannt, dass der elektrische Widerstand von PVB-Folien mit steigendem Feuchtegehalt steil abfällt, was das Auftreten von Leckströmen in Photovoltaikmodulen stark begünstigt. Im Randbereich des Photovoltaikmoduls sind die Folien als Einkapselungsmaterial zur Umgebung offen und den Umweltbedingungen wie z.B. hohen Umgebungsfeuchten ausgesetzt. Hierdurch kann der Wassergehalt der Folien im Randbereich stark zunehmen und Werte bis zur
Gleichgewichtsfeuchte (ca. 3 Gew.%) annehmen. Der erhöhte Wassergehalt im Randbereich der Folie reduziert deren elektrischen Widerstand in diesem Bereich stark. Der Wassergehalt nimmt zwar zur Folienmitte wieder ab, aber zur Vermeidung von Leckströmen können die photosensitiven Halbleiterschichten daher nicht bis in den Randbereich der Folie bzw. des Moduls verlegt werden. Dies reduziert die Flächenbelegung und damit die Stromausbeute des Moduls.It is known that the electrical resistance of PVB films drops steeply with increasing moisture content, which strongly favors the occurrence of leakage currents in photovoltaic modules. In the edge region of the photovoltaic module, the films are open as encapsulating material to the environment and exposed to environmental conditions such as high ambient humidity. As a result, the water content of the films in the edge region can increase sharply and values up to Equilibrium moisture content (about 3% by weight). The increased water content in the edge region of the film greatly reduces their electrical resistance in this area. Although the water content decreases again towards the center of the film, the photosensitive semiconductor layers can not be laid as far as the edge area of the film or module in order to avoid leakage currents. This reduces the area occupancy and thus the current efficiency of the module.
[0010] Solarzellen, insbesondere photosensitive Halbleiterschichten von Dünnschicht-Solarmodulen, z.B. auf Basis von CIS (Copper/lndium/(di)Selenit) oderSolar cells, in particular photosensitive semiconductor layers of thin-film solar modules, e.g. based on CIS (Copper / indium / (di) selenite) or
Copper/-Indium-/Gallium-/Sulphide-/Selenit (CIGS) oder die als elektrischer Leiter eingesetzten dünnen Schichten (TCO, „transparent conductive oxide") sind chemisch korrosionsanfällig. Das Einkapselungsmaterial muss daher weitestgehend chemisch innert sein und darf keine aggressiven chemischen Additive wie Vernetzer, Crosslinker oder Primer enthalten. Weiterhin ist die Anwesenheit von Wasser, Alkalimetallionen oder Säurespuren zu vermeiden.Copper / indium / gallium / sulphide / selenite (CIGS) or the thin conductive layers (TCO) are chemically susceptible to corrosion, so the encapsulant must be chemically inert and free from aggressive chemicals Additives such as crosslinkers, crosslinkers or primers, and the presence of water, alkali metal ions or traces of acid should be avoided.
[0011] Die üblicherweise in Photovoltaikmodulen verwendeten Kunststoffe sind zwar allgemein als elektrisch gut isolierende Materialien bekannt, weisen allerdings Restleitfähigkeiten auf, die in der Regel auf Verunreinigungen wie Wasser, ionische Katalysatorrückstände oder Salze zurückzuführen sind. Insbesondere das Zusammenwirken von ionischen Verunreinigungen mit eindiffundierendem Wasser, mit welchem bei gebrauchstypischen Umgebungsfeuchten in der Praxis immer zu rechnen ist, hat wesentlichen Anteil an der Restleitfähigkeit.Although the plastics commonly used in photovoltaic modules are generally known as electrically good insulating materials, however, have Restleitfähigkeiten, which are as a rule due to impurities such as water, ionic catalyst residues or salts. In particular, the interaction of ionic impurities with diffusing water, which is always to be expected in the case of ambient humidities typical for use, has a considerable share in the residual conductivity.
[0012] Aus diesem Grund erscheint es also zunächst naheliegend, bei Klebefolie für Photovoltaikmodulen, einen möglichst geringen Salzgehalt einzustellen. Bei den üblichen Polyvinylbutyral (PVB)-Folien, welche häufig zur Herstellung von Verbundsicherheitsglas eingesetzt werden, hängt der Salzgehalt der Folie zum einen vom Salzgehalt des PVB-Polymers ab, welches aus dem Herstellverfahren je nach Güte des dort zur Anwendung kommenden Wasch prozesses Salze von Mineralsäuren wie z.B. NaCI, KCl, NaNO3, KNO3, Na2SO4 oder K2SO4
typischerweise in Mengen zwischen 20 - 300 ppm enthält. Zum anderen werden den üblichen PVB-Folien häufig Alkali- und Erdalkalimetallsalze als sogenannte Antihaftmittel zur Erhöhung der Penetrationsfestigkeit der Glas/Folie/Glas-Verbunde in Mengen von etwa 20 - 500 ppm zugesetzt. Diese Salze sind zur Einstellung eines ausreichend niedrigen Haftungsniveaus der Folie am Glas erforderlich. Soll ein mit PVB-Folie hergestelltes Photovoltaikmodul also zusätzlich zu einer hohen Stromerzeugung auch noch die Sicherheitseigenschaften eines Verbundsicherheitsglases aufweisen, z.B. weil das Modul Teil einer Glasfassade ist, ergibt sich das Problem, dass die normalerweise zur Haftungsreduktion herangezogenen Antihaftmittelkombinationen und Mengen den elektrischen Widerstand beeinträchtigen als auch die Korrosion der Halbleiterschichten verstärken können.For this reason, it seems obvious that in the case of adhesive film for photovoltaic modules, the salt content should be as low as possible. In the usual polyvinyl butyral (PVB) films, which are often used for the production of laminated safety glass, the salt content of the film depends firstly on the salt content of the PVB polymer, which from the manufacturing process depending on the quality of the washing process used there, salts of Mineral acids such as NaCl, KCl, NaNO 3 , KNO 3 , Na 2 SO 4 or K 2 SO 4 typically in amounts between 20-300 ppm. On the other hand, alkali and alkaline earth metal salts are often added to the usual PVB films as so-called anti-adhesion agents to increase the penetration resistance of the glass / film / glass composites in amounts of about 20-500 ppm. These salts are required to set a sufficiently low level of adhesion of the film to the glass. If a photovoltaic module produced with PVB film is therefore also to have the safety properties of a laminated safety glass in addition to high power generation, for example because the module is part of a glass façade, the problem arises that the anti-adhesive agent combinations and quantities normally used to reduce adhesion impair the electrical resistance can also increase the corrosion of the semiconductor layers.
[0013] Die Sicherheitseigenschaften eines Glasbauteiles auf Verbundglases werden im Allgemeinen dann als ausreichend angesehen, wenn das Bauteil bei der Pendelschlagprüfung gemäß EN 12600 mindestens die Klasse 3B besteht, für die ein 50 kg schweres Doppelreifenpendel aus einer Höhe von 190 mm gegen das Glas gependelt wird. Durchschlägt das Pendel dabei nicht das Glasbauteil bzw. entsteht keine allzu große Öffnung und lösen sich keine Scharfkantigen Splitter ab, wird die Prüfung als bestanden gewertet. Bei den üblicherweise verwendeten haftungsreduzierten PVB-Folie in Dicke von 0.76 mm bestehen Verbundgläser den Pendelschlagtest auch bei wesentlich größeren Auslenkhöhen, insbesondere 1200 mm, womit dann die höchste Widerstandsklasse 1 B erreicht wird. Soll also ein Photovoltaikmodul zum Beispiel als Glasbauteil in eine Gebäudefassade integriert werden und dabei den üblichen hohen Anforderungen an Bruchsicherheit eines Verbundsicherheitsglases gerecht werden, sollte die PVB-Folie eine nicht zu hohe Haftung am Glas bzw. den benachbarten Funktionsschichten aufweisen.The safety properties of a glass component on laminated glass are generally considered to be sufficient if the component in the pendulum impact test according to EN 12600 at least Class 3B for which a 50 kg double tire pendulum from a height of 190 mm is levitated against the glass , If the pendulum does not break through the glass component or if there is no large opening and no Sharp-edged splinters detach, the test is passed. In the commonly used adhesion-reduced PVB film in thickness of 0.76 mm, laminated glass also has the pendulum impact test at significantly greater deflection heights, in particular 1200 mm, which then achieves the highest resistance class 1 B. If, for example, a photovoltaic module is to be integrated into a building façade as a glass component and thereby meet the usual high demands on the fracture safety of a laminated safety glass, the PVB film should have a not too high adhesion to the glass or the adjacent functional layers.
Technische AufgabeTechnical task
[0014] Aufgabe der vorliegenden Erfindung war es daher, weichmacherhaltige Folien auf Basis von Polyvinylacetal mit hohem Durchgangswiderstand
und guter Penetrationsfestigkeit in Verbindung mit Glasschichten zur Herstellung von Photovoltaikmodulen bereit zu stellen.Object of the present invention was therefore, plasticizer-containing films based on polyvinyl acetal with high volume resistance and provide good penetration resistance in conjunction with glass layers for the manufacture of photovoltaic modules.
Technische LösungTechnical solution
[0015] Es wurde gefunden, dass sich durch eine PVB-Folie mit einem Zusatz von z.B. Erdalkalisalzen und gleichzeitigem niedrigem Gehalt an Alkalimetallsalzen Photovoltaikmodule mit ausreichenden Penetrationseigenschaften erhalten lassen. Darüber hinaus wird der Durchgangswiderstand der auf weichmacherhaltigen Polyvinylacetalen basierenden Folien weiter erhöht sowie deren Korrosivität gegenüber Halbleiterschichten vermindert.It has been found that by a PVB film with an addition of e.g. Alkaline earth salts and at the same time a low content of alkali metal salts can be obtained photovoltaic modules with sufficient penetration properties. In addition, the volume resistivity of the films based on plasticized polyvinyl acetals is further increased and their corrosiveness to semiconductor layers is reduced.
Darstellung der ErfindungPresentation of the invention
[0016] Gegenstand der vorliegenden Erfindung sind daher Photovoltaikmodule, umfassend ein Laminat aus a) einer transparenten Frontabdeckung b) einer oder mehreren photosensitiven Halbleiterschichten c) mindestens eine weichmacherhaltige, auf Polyvinylacetal basierenden Folie und d) einer rückwärtigen Abdeckung wobei die weichmacherhaltige, auf Polyvinylacetal basierende Folie c) mehr als 10 ppm Metallionen ausgewählt aus der Gruppe Erdalkalimetalle, Zink und Aluminium und weniger als 150 ppm Alkalimetallionen aufweist.The present invention therefore relates to photovoltaic modules comprising a laminate of a) a transparent front cover b) one or more photosensitive semiconductor layers c) at least one plasticizer-containing polyvinyl acetal-based film and d) a back cover wherein the plasticizer-containing polyvinyl acetal-based Film c) has more than 10 ppm of metal ions selected from the group of alkaline earth metals, zinc and aluminum and less than 150 ppm of alkali metal ions.
[0017] Bei der Verwendung von mehreren verschiedenen Metallionen beziehen sich die genannten Konzentrationen auf die jeweiligen Summen der Einzelkonzentrationen, d.h. auf die Gesamtkonzentrationen an Alkalimetallionen oder mehrwertigen Metallionen.When using several different metal ions, said concentrations refer to the respective sums of the individual concentrations, i. E. to the total concentrations of alkali metal ions or polyvalent metal ions.
[0018] Bevorzugt enthält die erfindungsgemäß eingesetzte Folie c) mehr als 15 ppm, bevorzugt mehr als 20 ppm, bevorzugt mehr als 30 ppm, bevorzugt mehr als 50 ppm, bevorzugt mehr als 75 ppm, bevorzugt mehr als 100 ppm, bevorzugt mehr als 125 ppm und besonders bevorzugt mehr als 150 ppm Ionen der Erdalkalimetalle (Be, Mg, Ca, Sr, Ba, Ra), Zink bzw. Aluminium. Um unerwünschte Trübungen der Folie zu vermeiden, sollten andererseits aber nicht mehr als 1000 ppm der genannten mehrwertigen Metalle enthalten sein.
[0019] Gleichzeitig ist der Gehalt an Alkalimetallionen (Li, Na, K, Rb, Cs, Fr) in der weichmacherhaltigen, auf Polyvinylacetal basierenden Folie möglichst niedrig einzustellen. Insbesondere enthält die Folie weniger als 100 ppm, bevorzugt weniger als 75 ppm, bevorzugt weniger als 50 ppm, bevorzugt weniger als 25 ppm, bevorzugt weniger als 15 ppm, bevorzugt weniger als 10 ppm und besonders bevorzugt weniger als 5 ppm Alkalimetallionen.Preferably, the film used according to the invention c) contains more than 15 ppm, preferably more than 20 ppm, preferably more than 30 ppm, preferably more than 50 ppm, preferably more than 75 ppm, preferably more than 100 ppm, preferably more than 125 ppm and more preferably more than 150 ppm ions of the alkaline earth metals (Be, Mg, Ca, Sr, Ba, Ra), zinc or aluminum. On the other hand, in order to avoid undesired clouding of the film, not more than 1000 ppm of said polyvalent metals should be present. At the same time, the content of alkali metal ions (Li, Na, K, Rb, Cs, Fr) in the plasticizer-containing polyvinyl acetal-based film should be as low as possible. In particular, the film contains less than 100 ppm, preferably less than 75 ppm, preferably less than 50 ppm, preferably less than 25 ppm, preferably less than 15 ppm, preferably less than 10 ppm and more preferably less than 5 ppm alkali metal ions.
[0020] Die jeweiligen Erdalkalimetall-, Zink-, Aluminium- bzw. dieThe respective alkaline earth metal, zinc, aluminum or the
Alkalimetallionen werden der Folienmischung in Form der Salze von ein- oder mehrwertigen anorganischen oder ein- oder mehrwertigen organischen Säuren zugegeben. Beispiele für Gegenionen sind z.B. Salze organischer Carbonsäuren wie etwa Formiate, Acetate, Trifluoracetate, Propionate, Butyrate, Benzoate, 2-Ethylhexanoate usw., wobei bevorzugt Carbonsäuren mit weniger als 10 C-Atomen, bevorzugt weniger als 8, bevorzugt weniger als 6, bevorzugt weniger als 4 und besonders bevorzugt mit weniger als 3 C-Atomen verwendet werden. Beispiele für anorganische Gegenionen sind Chloride, Nitrate, Sulfate, Phosphate.Alkali metal ions are added to the film mixture in the form of the salts of mono- or polyvalent inorganic or mono- or polyvalent organic acids. Examples of counterions are e.g. Salts of organic carboxylic acids such as formates, acetates, trifluoroacetates, propionates, butyrates, benzoates, 2-ethylhexanoates, etc., preferably carboxylic acids having less than 10 C atoms, preferably less than 8, preferably less than 6, preferably less than 4 and especially preferably be used with less than 3 C-atoms. Examples of inorganic counterions are chlorides, nitrates, sulfates, phosphates.
[0021] Bevorzugt weisen die erfindungsgemäß eingesetzten Folien bei einerPreferably, the films used in the invention in a
Umgebungsfeuchte von 85% rF bei 23°C einen spezifischen Widerstand von mindestens 1 E+11 ohm*cm, bevorzugt mindestens 5E+11 ohm*cm, 1 E+12 ohm*cm, 5E+12 ohm*cm, 1 E+13, 5E+13 ohm*cm oder 1 E+14 ohm*cm auf.Ambient humidity of 85% RH at 23 ° C a resistivity of at least 1E + 11 ohms * cm, preferably at least 5E + 11 ohms * cm, 1E + 12 ohms * cm, 5E + 12 ohms * cm, 1E + 13 , 5E + 13 ohms * cm or 1E + 14 ohms * cm.
[0022] Zur Herstellung von Polyvinylacetal wird Polyvinylalkohol in Wasser gelöst und mit einem Aldehyd wie Butyraldehyd unter Zusatz eines Säurekatalysators acetalisiert. Das ausgefallene Polyvinylacetals wird abgetrennt, neutral gewaschen, ggf. in einem alkalisch eingestellten wässrigen Medium suspendiert, danach erneut neutral gewaschen und getrocknet.For the preparation of polyvinyl acetal polyvinyl alcohol is dissolved in water and acetalized with an aldehyde such as butyraldehyde with the addition of an acid catalyst. The precipitated polyvinyl acetal is separated, washed neutral, optionally suspended in an alkaline aqueous medium, then washed neutral again and dried.
[0023] Die zur Acetalisierung eingesetzte Säure muss nach erfolgter Reaktion wieder neutralisiert werden. Ein geringer Gehalt an Alkalimetallionen kann unter anderem bei der Synthese des Polyvinylacetals durch Verzicht auf die üblicherweise zur Neutralisation des Katalysators angewandten Natrium- oder Kaliumhydroxide bzw. Carbonate oder durch gründliches Waschen des bei der Acetalisierung erhaltenen Polyvinylacetals erzielt
werden. Alternativ zu den Basen NaOH oder KOH, kann die Katalysatorsäure aus dem Acetalisierungsschritt z.B. durch Einblasen von Kohlendioxid oder Ethylenoxid neutralisiert werden.The acid used for the acetalization must be neutralized again after the reaction. A low level of alkali metal ions can be achieved inter alia in the synthesis of the polyvinyl acetal by dispensing with the sodium or potassium hydroxides or carbonates usually used to neutralize the catalyst or by thoroughly washing the polyvinyl acetal obtained in the acetalization become. As an alternative to the bases NaOH or KOH, the catalyst acid can be neutralized from the acetalization step, for example by blowing in carbon dioxide or ethylene oxide.
[0024] Der Polyvinylalkoholgehalt des Polyvinylacetals kann durch die Menge des bei der Acetalisierung eingesetzten Aldehyds eingestellt werden.The polyvinyl alcohol content of the polyvinyl acetal can be adjusted by the amount of aldehyde used in the acetalization.
[0025] Es ist auch möglich, die Acetalisierung mit anderen oder mehrerenIt is also possible to acetalize with others or more
Aldehyden mit 2-10 Kohlenstoffatomen (z.B. Valeraldehyd) durchzuführen.Aldehydes having 2-10 carbon atoms (e.g., valeraldehyde).
[0026] Die auf weichmacherhaltigem Polyvinylacetal basierenden Folien enthalten bevorzugt unvernetztes Polyvinylbutyral (PVB), das durch Acetalisierung von Polyvinylalkohol mit Butyraldehyd gewonnen wird.The films based on plasticized polyvinyl acetal preferably contain uncrosslinked polyvinyl butyral (PVB), which is obtained by acetalization of polyvinyl alcohol with butyraldehyde.
[0027] Der Einsatz von vernetzten Polyvinylacetalen, insbesondere vernetztem Polyvinylbutyral (PVB) ist ebenso möglich. Geeignete vernetzte Polyvinylacetale sind z.B. in EP 1527107 B1 und WO 2004/063231 A1 (thermische Selbstvernetzung von Carboxylgruppenhaltigen Polyvinylacetalen), EP 1606325 A1 (mit Polyaldehyden vernetzte Polyvinylacetale) und WO 03/020776 A1 (mit Glyoxylsäure vernetzte Polyvinylacetale) beschrieben. Auf die Offenbarung dieser Patentanmeldungen wird vollumfänglich Bezug genommen.The use of crosslinked polyvinyl acetals, in particular crosslinked polyvinyl butyral (PVB) is also possible. Suitable crosslinked polyvinyl acetals are e.g. in EP 1527107 B1 and WO 2004/063231 A1 (thermal self-crosslinking of polyvinyl acetals containing carboxyl groups), EP 1606325 A1 (polyvinyl acetals crosslinked with polyaldehydes) and WO 03/020776 A1 (polyvinyl acetals crosslinked with glyoxylic acid). The disclosure of these patent applications is fully incorporated by reference.
[0028] Als Polyvinylalkohol können im Rahmen der vorliegenden Erfindung auch Terpolymere aus hydrolysierten Vinylacetat/Ethylen-Copolymeren eingesetzt werden. Diese Verbindungen sind in der Regel zu mehr als 98 Mol% hydrolysiert und enthalten 1 bis 10 Gew. auf Ethylen basierende Einheiten (z.B. Typ „Exceval" der Kuraray Europe GmbH).In the context of the present invention, terpolymers of hydrolyzed vinyl acetate / ethylene copolymers can also be used as the polyvinyl alcohol. These compounds are typically hydrolyzed to greater than 98 mole percent and contain from 1 to 10 weight percent ethylene based units (e.g., "Exceval" type from Kuraray Europe GmbH).
[0029] Als Polyvinylalkohol können im Rahmen der vorliegenden Erfindung weiterhin auch hydrolysierte Copolymere aus Vinylacetat und mindestens einem weiteren ethylenisch ungesättigten Monomer eingesetzt werden.As polyvinyl alcohol, hydrolyzed copolymers of vinyl acetate and at least one further ethylenically unsaturated monomer can also be used within the scope of the present invention.
[0030] Die Polyvinylalkohole können im Rahmen der vorliegenden Erfindung rein oder als Mischung von Polyvinylalkoholen mit unterschiedlichem Polymerisationsgrad oder Hydrolysegrad eingesetzt werden.The polyvinyl alcohols can be used in the context of the present invention purely or as a mixture of polyvinyl alcohols with different degree of polymerization or degree of hydrolysis.
[0031] Polyvinylacetale enthalten neben den Acetaleinheiten noch ausPolyvinyl acetals still contain in addition to the acetal units
Vinylacetat und Vinylalkohol resultierende Einheiten. Die erfindungsgemäß verwendeten Polyvinylacetale weisen bevorzugt einen Polyvinylalkoholanteil von weniger als 22 Gew.%, 20 Gew.% oder 18
Gew.%, weniger als 16 Gew.% oder 15 Gew.% und insbesondere weniger als 14 Gew.% auf. Ein Polyvinylalkoholanteil von 12 Gew.% sollte nicht unterschritten werden.Vinyl acetate and vinyl alcohol resulting units. The polyvinyl acetals used according to the invention preferably have a polyvinyl alcohol content of less than 22% by weight, 20% by weight or 18 % By weight, less than 16% by weight or 15% by weight and in particular less than 14% by weight. A polyvinyl alcohol content of 12% by weight should not be exceeded.
[0032] Der Polyvinylacetatgehalt des erfindungsgemäß eingesetztenThe polyvinyl acetate content of the invention used
Polyvinylacetals liegt bevorzugt unter 5 Gew.%, unter 3 Gew.% oder unter 1 Gew.%, besonders bevorzugt unter 0,75 Gew.%, ganz besonders bevorzugt unter 0,5 Gew.% und insbesondere unter 0,25 Gew.%.Polyvinyl acetal is preferably less than 5% by weight, less than 3% by weight or less than 1% by weight, particularly preferably less than 0.75% by weight, very preferably less than 0.5% by weight and in particular less than 0.25% by weight. ,
[0033] Aus dem Polyvinylalkoholanteil und dem Restacetatgehalt kann der Acetalisierungsgrad rechnerisch ermittelt werden.From the polyvinyl alcohol content and the residual acetate content, the degree of acetalization can be determined by calculation.
[0034] Bevorzugt weisen die Folien einen Weichmachergehalt von maximal 40 Gew.%, 35 Gew.%, 32 Gew.%, 30 Gew.%, 28 Gew.%, 26 Gew.%, 24 Gew.%, 22 Gew.%, 20 Gew.%, 18 Gew.%, 16 Gew.% auf, wobei ein Weichmachergehalt von 15 Gew.% aus Gründen der Verarbeitbarkeit der Folie nicht unterschritten werden sollte (jeweils bezogen auf die gesamte Folienformulierung). Erfindungsgemäße Folien bzw. Photovoltaikmodule können einen oder mehrere Weichmacher enthalten.Preferably, the films have a plasticizer content of at most 40% by weight, 35% by weight, 32% by weight, 30% by weight, 28% by weight, 26% by weight, 24% by weight, 22% by weight. , 20 wt.%, 18 wt.%, 16 wt.%, Wherein a plasticizer content of 15 wt.% For reasons of processability of the film should not be exceeded (in each case based on the total film formulation). Inventive films or photovoltaic modules may contain one or more plasticizers.
[0035] Grundsätzlich geeignete Weichmacher für die erfindungsgemäß eingesetzten Folien sind eine oder mehrere Verbindungen ausgewählt aus den folgenden Gruppen:Basically suitable plasticizers for the films used according to the invention are one or more compounds selected from the following groups:
- Ester von mehrwertigen aliphatischen oder aromatischen Säuren, z.B. Dialkyladipate wie Dihexyladipat, Dioctyladipat, Hexylcyclohexyladipat, Mischungen aus Heptyl- und Nonyl-adipaten, Diisononyladipat, Heptylnonyl-adipat sowie Ester der Adipinsäure mit cycloaliphatischen oder Etherbindungen enthaltenden Esteralkoholen, Dialkylsebazate wie Dibutylsebazat sowie Ester der Sebazinsäure mit cycloaliphatischen oder Etherbindungen enthaltenden Esteralkoholen, Estern der Phthalsäure wie Butylbenzylphthalat oder Bis-2-butoxyethylphthalatEsters of polyhydric aliphatic or aromatic acids, e.g. Dialkyladipates such as Dihexyladipat, Dioctyladipat, Hexylcyclohexyladipat, mixtures of heptyl and nonyl adipates, Diisononyladipat, heptylnonyl adipate and esters of adipic acid with cycloaliphatic or ether-containing ester alcohols, dialkyl sebacates such as dibutyl sebacate and esters of sebacic acid with cycloaliphatic or ether-containing ester alcohols, esters of phthalic acid such as butyl benzyl phthalate or bis-2-butoxyethyl phthalate
- Ester oder Ether von mehrwertigen aliphatischen oder aromatischen Alkoholen oder Oligoetherglykolen mit einem oder mehreren unverzweigen oder verzweigten aliphatischen oder aromatischen Substituenten, wie z.B. Estern von Di-, Tri- oder Tetraglykolen mit linearen oder verzweigten ali-phatischen oder cycloaliphatischen Carbonsäuren; Als Beispiele für letztere Gruppe können dienen
Diethylenglykol-bis-(2-ethyl-hexanoat), Triethylenglykol-bis-(2-ethyl-hexanoat), Tri-ethylen-glykol-bis-(2-ethylbu-ta-no-at),- esters or ethers of polyhydric aliphatic or aromatic alcohols or Oligoetherglykolen with one or more unbranched or branched aliphatic or aromatic substituents, such as esters of di-, tri- or tetraglycols with linear or branched aliphatic or cycloaliphatic carboxylic acids; As examples of the latter group can serve Diethylene glycol bis (2-ethylhexanoate), triethylene glycol bis (2-ethylhexanoate), tri-ethylene glycol bis (2-ethylbu-ta-no-ate),
Tetra-ethylen-glykol-bis-n-heptanoat, Triethylengly-kol-bis-n-heptanoat, Triethylenglykol-bis-n-hexanoat, Tetraethylen-glykol-dimethyl-ether und/oder DipropylenglykolbenzoatTetraethylene glycol bis-n-heptanoate, triethylene glycol bis-n-heptanoate, triethylene glycol bis-n-hexanoate, tetraethylene glycol dimethyl ether and / or Dipropylenglykolbenzoat
- Phosphate mit aliphatischen oder aromatischen Esteralkoholen wie z.B. Tris(2-ethylhexyl)phosphat (TOF), Triethylphosphat, Diphenyl-2-ethylhexylphosphat, und/oder TrikresylphosphatPhosphates with aliphatic or aromatic ester alcohols, e.g. Tris (2-ethylhexyl) phosphate (TOF), triethyl phosphate, diphenyl-2-ethylhexyl phosphate, and / or tricresyl phosphate
- Ester der Zitronensäure, Bernsteinsäure und/oder Fumarsäure [0036] Gut geeignet als Weichmacher für die erfindungsgemäß eingesetzten- Esters of citric acid, succinic acid and / or fumaric acid. Suitable as a plasticizer for the inventively used
Folien sind eine oder mehrere Verbindungen ausgewählt aus der folgenden Gruppe Di-2-ethylhexylsebacat (DOS), Di-2-ethylhexyladipat (DOA), Dihexyladipat (DHA), Dibutylsebacat (DBS), Triethylenglykol-bis-n-heptanoat (3G7), Tetraethylenglykol-bis-n-heptanoat (4G7), Triethylenglykol-bis-2-ethylhexanoat (3GO bzw. 3G8) Tetraethylenglykol-bis-n-2-ethylhexanoat (4GO bzw. 4G8) Di-2-butoxy-ethyl-adipat (DBEA), Di-2-butoxyethoxyethyladipat (DBEEA) Di-2-butoxyethylsebacat (DBES), Di-2-ethylhexylphthalat (DOP), Di-isononylphthalat (DINP) Triethylenglykol-bis-isononanoat, Triethylenglykol-bis-2-propylhexanoat, Tris(2-ethylhexyl)phosphat (TOF), 1 ,2-Cyclohexandicarbonsäurediisononylester (DINCH) und Dipropylenglykolbenzoat.Slides are one or more compounds selected from the group consisting of di-2-ethylhexyl sebacate (DOS), di-2-ethylhexyl adipate (DOA), dihexyl adipate (DHA), dibutyl sebacate (DBS), triethylene glycol bis-n-heptanoate (3G7), Tetraethylene glycol bis-n-heptanoate (4G7), triethylene glycol bis-2-ethylhexanoate (3GO or 3G8) tetraethylene glycol bis-n-2-ethylhexanoate (4GO or 4G8) di-2-butoxy-ethyl adipate (DBEA ), Di-2-butoxyethoxyethyl adipate (DBEEA) di-2-butoxyethyl sebacate (DBES), di-2-ethylhexyl phthalate (DOP), di-isononyl phthalate (DINP) triethylene glycol bis-isononanoate, triethylene glycol bis-2-propylhexanoate, tris ( 2-ethylhexyl) phosphate (TOF), 1, 2-cyclohexanedicarboxylic acid diisononyl ester (DINCH) and Dipropylenglykolbenzoat.
[0037] Ganz besonders geeignet als Weichmacher für die erfindungsgemäß eingesetzten Folien sind Weichmacher, deren Polarität, ausgedrückt durch die Formel 100 x O/(C+H) kleiner/gleich 9.4 ist, wobei O, C und H für die Anzahl der Sauerstoff-, Kohlenstoff- und Wasserstoffatome im jeweiligen Molekül steht. Die nachfolgende Tabelle zeigt erfindungsgemäß einsetzbare Weichmacher und deren Polaritätswerte nach der Formel 100 x O/(C+H).Plasticizers whose polarity expressed by the formula 100 × O / (C + H) is less than or equal to 9.4 are particularly suitable as plasticizers for the films used according to the invention, where O, C and H are the number of oxygen atoms. , Carbon and hydrogen atoms in each molecule. The following table shows plasticizers which can be used according to the invention and their polarity values according to the formula 100 × O / (C + H).
[0038][0038]
Tabelle 1Table 1
Name Polaritätswert
Name polarity value
[0039] Weiterhin kann die möglicherweise vom Wassergehalt der Folie abhängende lonenbeweglichkeit und damit der spezifische Widerstand durch den Zusatz von Kieselsäure, insbesondere pyrogenes SiO2 beeinflusst werden. Bevorzugt enthalten die weichmacherhaltigen, auf Polyvinylacetal basierenden Folien 0.001 bis 15 Gew.%, bevorzugt 0.01 bis 10 Gew.% und insbesondere 2 bis 5 Gew.% SiO2.Furthermore, the ion mobility which is possibly dependent on the water content of the film and thus the specific resistance can be influenced by the addition of silica, in particular pyrogenic SiO 2 . The plasticizer-containing films based on polyvinyl acetal preferably contain 0.001 to 15% by weight, preferably 0.01 to 10% by weight and in particular 2 to 5% by weight of SiO 2 .
[0040] Weiterhin können die erfindungsgemäßen Folien zusätzlich auch übliche Additive, wie zum Beispiel Oxidationsstabilisatoren, UV-Stabilisatoren, Farbstoffe, Pigmente sowie Antihaftmittel enthalten.Furthermore, the films of the invention may additionally contain conventional additives, such as oxidation stabilizers, UV stabilizers, dyes, pigments and anti-adhesive.
[0041] Die prinzipielle Herstellung und Zusammensetzung von Folien auf Basis von Polyvinylacetalen ist z. B. in EP 185 863 B1 , EP 1 118 258 B1 WO 02/102591 A1. EP 1 118 258 B1 oder EP 387 148 B1 beschrieben.The basic preparation and composition of films based on polyvinyl acetals is z. In EP 185 863 B1, EP 1 118 258 B1, WO 02/102591 A1. EP 1 118 258 B1 or EP 387 148 B1.
[0042] Die Herstellung der Photovoltaikmodule erfolgt durch Laminierung der transparenten Frontabdeckung a), den photosensitiven Halbleiterschichten b) und der rückwärtigen Abdeckung d) mittels mindestens einer weichmacherhaltigen, auf Polyvinylacetal basierenden Folie c) unter Verschmelzung der Folien, so dass ein blasen- und schlierenfreier Einschluss der photosensitiven Halbleiterschicht erhalten wird.The photovoltaic modules are produced by laminating the transparent front cover a), the photosensitive semiconductor layers b) and the rear cover d) by means of at least one plasticizer-containing film based on polyvinyl acetal c) with fusion of the films, so that a bubble-free and schlierenfreier Inclusion of the photosensitive semiconductor layer is obtained.
[0043] In dieser Variante der erfindungsgemäßen Photovoltaikmodule werden die photosensitiven Halbleiterschichten zwischen zwei Folien c) eingebettet und so mit den Abdeckungen a) und d) verklebt.In this variant of the photovoltaic modules according to the invention, the photosensitive semiconductor layers are embedded between two films c) and thus bonded to the covers a) and d).
[0044] Die Dicke der auf weichmacherhaltigem Polyvinylacetal basierendenThe thickness of the plasticized polyvinyl acetal based
Folien liegt üblicherweise bei 0.38, 0.51 , 0.76, 1.14, 1.52 oder 2.28 mm.
[0045] Insbesondere bei Dünnschicht-Solarmodulen ist die photosensitive Halbleiterschicht direkt auf einen Träger aufgebracht (z.B. durch Aufdampfen, Gasphasenabscheidung, Sputtern oder Nassabscheidung). Eine Einkapselung der photosensitive Halbleiterschicht ist hier nicht möglich.Foils are usually 0.38, 0.51, 0.76, 1.14, 1.52 or 2.28 mm. Particularly in the case of thin-film solar modules, the photosensitive semiconductor layer is applied directly to a support (for example by vapor deposition, vapor deposition, sputtering or wet deposition). An encapsulation of the photosensitive semiconductor layer is not possible here.
[0046] In einer Variante der erfindungsgemäßen Photovoltaikmodule werden die photosensitiven Halbleiterschichten auf die Abdeckung d) aufgebracht (z.B. durch Aufdampfen, Gasphasenabscheidung, Sputtern oder Nassabscheidung) und durch mindestens eine Folie c) mit der transparenten Frontabdeckung a) verklebt.In a variant of the photovoltaic modules according to the invention, the photosensitive semiconductor layers are applied to the cover d) (for example by vapor deposition, vapor deposition, sputtering or wet deposition) and bonded to the transparent front cover a) by at least one film c).
[0047] In einer anderen Variante werden die photosensitiven Halbleiterschichten auf die transparente Frontabdeckung a) aufgebracht und durch mindestens eine Folie c) mit der rückwärtigen Abdeckung d) verklebt..In another variant, the photosensitive semiconductor layers are applied to the transparent front cover a) and glued by at least one film c) with the rear cover d).
[0048] In der Regel wird bei Dünnschicht-Modulen die photosensitiveIn general, in thin-film modules, the photosensitive
Halbleiterschicht ganzflächig auf den Träger aufgebracht d.h. bis zum Rand des Trägers. Anschließend wird am Rand ein Teil der photosensitiven Halbleiterschicht wieder entfernt, sodass zu Isolationszwecken ein Halbleiter-freier Randbereich übrig bleibt (sog. Randentschichtung). Durch die hohen Widerstandswerte der erfindungsgemäß eingesetzten Folie kann dieser Randbereich mit bevorzugt unter 3 cm, ganz besonders unter 2 cm und insbesondere unter 1 cm sehr schmal ausfallen.Semiconductor layer applied over the entire surface of the carrier i. to the edge of the carrier. Subsequently, part of the photosensitive semiconductor layer is removed again at the edge, so that for isolation purposes, a semiconductor-free edge region remains (so-called edge deletion). Due to the high resistance values of the film used according to the invention, this edge region can be very narrow, preferably below 3 cm, especially below 2 cm and in particular below 1 cm.
[0049] Erfindungsgemäß eingesetzte Folien füllen während des[0049] Films used according to the invention fill during the
Laminierprozesses die an den photosensitiven Halbleiterschichten bzw. deren elektrischen Verbindungen vorhandenen Hohlräume aus.Laminierprozesses the existing on the photosensitive semiconductor layers or their electrical connections cavities.
[0050] Die transparente Frontabdeckung besteht in der Regel aus Glas oder PMMA. Die rückwärtige Abdeckung des erfindungsgemäßen Photovoltaikmoduls kann aus Glas, Kunststoff oder Metall oder deren Verbünden bestehen, wobei mindestens einer der Träger transparent sein kann. Es ist ebenfalls möglich, einen oder beide Abdeckungen als Verbundverglasung (d. h. als Laminat aus mindestens zwei Glasscheiben und mindestens einer PVB-Folie) oder als Isolier-verglasung mit einem Gaszwischenraum auszuführen. Selbstverständlich ist auch die
Kombination dieser Maßnahmen möglich.The transparent front cover is usually made of glass or PMMA. The rear cover of the photovoltaic module according to the invention may consist of glass, plastic or metal or their composites, wherein at least one of the carrier may be transparent. It is also possible to use one or both covers as composite glazing (ie as a laminate of at least two glass panes and at least one PVB foil) or as insulating glazing with a gas gap. Of course, that too Combination of these measures possible.
[0051] Die in den Modulen eingesetzten photosensitiven Halbleiterschichten müssen keine besonderen Eigenschaften besitzen. Es können mono-, polykristalline oder amorphe Systeme eingesetzt werden.The photosensitive semiconductor layers used in the modules need not possess any special properties. Mono-, polycrystalline or amorphous systems can be used.
[0052] Zur Laminierung der so erhaltenen Schichtkörpers können die demFor lamination of the laminate thus obtained, the
Fachmann geläufigen Verfahren mit und ohne vorhergehende Herstellung eines Vorverbundes eingesetzt werden.Those skilled in the art process with and without previous production of a pre-bond can be used.
[0053] So genannte Autoklaven prozesse werden bei einem erhöhten Druck von ca. 10 bis 15 bar und Temperaturen von 130 bis 145 °C über ca. 2 Stunden durchgeführt. Vakuumsack- oder Vakuumring-verfahren z.B. gemäß EP 1 235 683 B1 arbeiten bei ca. 200 mbar und 130 bis 145 0CSo-called autoclave processes are carried out at an elevated pressure of about 10 to 15 bar and temperatures of 130 to 145 ° C for about 2 hours. Vacuum bag or vacuum ring method, for example, according to EP 1 235 683 B1 operate at about 200 mbar and 130 to 145 0 C.
[0054] Vorzugsweise werden zur Herstellung der erfindungsgemäßenPreferably, for the preparation of the inventive
Photovoltaikmodule Vakuumlaminatoren eingesetzt. Diese bestehen aus einer beheizbaren und evakuierbaren Kammer, in denen Verbund-verglasungen innerhalb von 30 - 60 Minuten laminiert werden können. Verminderte Drücke von 0,01 bis 300 mbar und Temperaturen von 100 bis 200 0C, insbesondere 130 - 160 0C haben sich in der Praxis bewährt.Photovoltaic modules used vacuum laminators. These consist of a heatable and evacuable chamber, in which composite glazing can be laminated within 30 - 60 minutes. Reduced pressures of 0.01 to 300 mbar and temperatures of 100 to 200 0 C, in particular 130 - 160 0 C have proven in practice.
[0055] Alternativ kann ein so oben beschrieben zusammengelegter Schichtkörper zwischen mindestens einem Walzenpaar bei einer Temperatur von 60 bis 150 °C zu einem erfindungsgemäßen Modul verpresst werden. Anlagen dieser Art sind zur Herstellung von Verbundverglasungen bekannt und verfügen normalerweise über mindestens einen Heiztunnel vor bzw. nach dem ersten Presswerk bei Anlagen mit zwei Presswerken.Alternatively, a laminated as described above laminated body between at least one pair of rollers at a temperature of 60 to 150 ° C are pressed into a module according to the invention. Systems of this type are known for the production of laminated glazing and usually have at least one heating tunnel before or after the first press shop in systems with two pressing plants.
Gewerbliche AnwendbarkeitIndustrial Applicability
[0056] Weiterhin ist Gegenstand der Erfindung die Verwendung von weichmacherhaltigen, auf Polyvinylacetal basierenden Folien c), enthaltend mehr als 10 ppm Metallionen ausgewählt aus der Gruppe Erdalkalimetalle, Zink und Aluminium und weniger als 150 ppm Alkalimetallionen, bzw. mit den genannten bevorzugten Ausführungsformen zur Herstellung von Photovoltaikmodulen.The invention further provides for the use of plasticized polyvinyl acetal-based films c) containing more than 10 ppm metal ions selected from the group of alkaline earth metals, zinc and aluminum and less than 150 ppm alkali metal ions or with the preferred embodiments mentioned Production of photovoltaic modules.
[0057] Erfindungsgemäße Photovoltaikmodule können als Fassadenbauteil,Photovoltaic modules according to the invention can be used as a facade component,
Dachflächen, Wintergartenabdeckung, Schallschutzwand, Balkon- oder
Brüstungselement oder als Bestandteil von Fensterflächen verwendet werden.Roof areas, conservatory cover, soundproof wall, balcony or Parapet element or used as part of window surfaces.
Messmethoden:Measurement Methods:
[0058] Die Messung des spezifischen Durchgangswiderstandes der Folie erfolgt gemäß DIN IEC 60093 bei definierter Temperatur und Umgebungsfeuchte (23 °C und 85% rl_F) nachdem die Folie wenigstens 24h bei diesen Bedingungen konditioniert wurde. Zur Durchführung der Messung wurde eine Plattenelektrode Typ 302 132 von der Firma Fetronic GmbH sowie ein Widerstandsmeßgerät ISO-Digi 5kV von der Firma Amprobe verwendet. Die Prüfspannung betrug 2,5kV, die Wartezeit nach Anlegen der Prüfspannung bis zur Meßwerterfassung 60 sek. Damit ein ausreichender Kontakt zwischen den flachen Platten der Meßelektrode und der Folie gewährleistet ist, sollte deren Oberflächenrauhikgkeit Rz bei Messung nach DIN EN ISO 4287 nicht größer als 10 mm sein, d.h. gegebenenfalls muss die Originaloberfläche der PVB-Folie vor der Widerstandsmessung durch thermisches Umprägen geglättet werden.The measurement of the volume resistivity of the film is carried out according to DIN IEC 60093 at a defined temperature and ambient humidity (23 ° C and 85% rl_F) after the film has been conditioned for at least 24 hours under these conditions. To carry out the measurement, a plate electrode Type 302 132 from Fetronic GmbH and an ohmmeter ISO-Digi 5 kV from Amprobe were used. The test voltage was 2.5kV, the waiting time after application of the test voltage to the value acquisition 60 sec. To ensure adequate contact between the flat plates of the measuring electrode and the film, their surface roughness R z should not be greater than 10 mm when measured according to DIN EN ISO 4287, ie, if necessary, the original surface of the PVB film before the resistance measurement by thermal embossing be smoothed.
[0059] Der Polyvinylalkohol- und Polyvinylalkoholacetatgehalt derThe polyvinyl alcohol and polyvinyl alcohol acetate content of
Polyvinylacetale wurde gemäß ASTM D 1396-92 bestimmt. Die Analyse des Metallionengehaltes erfolgte durch Atomabsorptionsspektroskopie (AAS). Der Wasser- bzw. Feuchtegehalt der Folien wird mit der Karl-Fischer-Methode bestimmt.Polyvinyl acetals were determined according to ASTM D 1396-92. The analysis of the metal ion content was carried out by atomic absorption spectroscopy (AAS). The water or moisture content of the films is determined by the Karl Fischer method.
[0060] Die Pendelschlagprüfung wird gemäß EN 12600 durchgeführt; das Ergebnis wird in der Klasseneinteilung dieser Norm angegeben.The pendulum impact test is carried out in accordance with EN 12600; the result is given in the classification of this standard.
[0061] Das Haftungsvermögen der Folie am Glas wird in „Pummelwerten" jeweils bezogen auf die Feuer oder Zinn-Seite des Glases angegeben. Die Durchführung des Pummeltestes ist dem Fachmann bekannt.The adhesion of the film to the glass is given in "punch values" in each case based on the fire or tin side of the glass.
[0062] Die Trübung wird durch den Haze-Wert in % gemäß ASTM 1003 D an einer glatten Folie bestimmt.The haze is determined by the Haze value in% according to ASTM 1003 D on a smooth film.
[0063] Zur Beurteilung der Haftung einer PVB-Folie wird derTo assess the adhesion of a PVB film is the
Kompressionsschertest in Anlehnung an DE 197 56 274 A1 an einem Glas/Glas-Laminat ohne Solarzelle durchgeführt. Zur Herstellung der Prüfkörper wird die zu prüfende PVB-Folie zwischen zwei ebene Silikatglasscheiben des Formats 300 mm x 300 mm mit einer Dicke von 2
mm gebracht, in einem Vorverbundofen mit Kalanderwalzen zu einem Glas-Vorverbund entlüftet und anschließend in einem Autoklav bei einem Druck von 12 bar und bei einer Temperatur von 140 °C innerhalb von insgesamt 90 min. zu einem ebenen Verbundsicherheitsglas verpresst. Aus dem so hergestellten Verbundsicherheitsglas werden 10 Proben mit den Maßen 25,4 mm x 25,4 mm geschnitten. Diese werden unter einem Winkel von 45° in eine Prüfapparatur gemäß DE 197 56 274 A1 eingespannt, wobei die Tiefe der Aussparungen ca. 2/3 der jeweiligen Glasdicke beträgt. Die obere Hälfte wird mit einer stetig steigenden, genau vertikal nach unten gerichteten Kraft beaufschlagt, bis es zu einer Abscherung innerhalb des Prüfkörpers, d. h. der zu prüfenden Verbundsicherheits-glasscheiben, kommt.Compression shear test based on DE 197 56 274 A1 performed on a glass / glass laminate without solar cell. For the preparation of the test specimens, the PVB film to be tested is placed between two flat silicate glass panes of the format 300 mm × 300 mm with a thickness of 2 mm, vented in a Vorverbundofen calender rolls to a glass pre-composite and then in an autoclave at a pressure of 12 bar and at a temperature of 140 ° C within a total of 90 min. pressed into a flat laminated safety glass. From the laminated safety glass thus produced, 10 samples measuring 25.4 mm × 25.4 mm are cut. These are clamped at an angle of 45 ° in a test apparatus according to DE 197 56 274 A1, wherein the depth of the recesses is about 2/3 of the respective glass thickness. The upper half is subjected to a steadily increasing, exactly vertically downward force until it shears within the test body, ie the laminated safety glass panes to be tested.
[0064] Die Prüfparameter sind wie folgt:The test parameters are as follows:
[0065][0065]
Tabelle 2Table 2
[0066] Für jeden Prüfkörper wird die bei der Abscherung ausgeübte Kraft von zehn gleichen Prüfkörpern linear gemittelt. Soweit in den nachfolgenden Beispielen und den Ansprüchen auf den mittleren Kompressionsschertest-Wert Bezug genommen wird, ist damit dieser Mittelwert aus 10 Messungen gemeint. Im übrigen wird auf die DE 197 56 274 A1 verwiesen.For each test specimen, the force exerted during shearing is linearly averaged by ten equal specimens. As far as reference is made in the following examples and the claims to the mean compression shear test value, this means this mean of 10 measurements. For the rest, reference is made to DE 197 56 274 A1.
Beispiele
[0067] Es wurden Folien der Dicke 0,76 mm mit den Mischungen der in nachfolgenden Tabelle aufgeführten Zusammensetzung hergestellt und auf ihren elektrischen Widerstand sowie ihre Haftung an Glas und die Pendelschlagfestigkeit von Verbundgläsern mit dem Aufbau 5 mm Floatglas / Folie / 5 mm Floatglas untersucht.Examples Sheets of thickness 0.76 mm were prepared with the mixtures of the composition listed in the following table and examined for their electrical resistance and their adhesion to glass and the pendulum impact resistance of laminated glass with the structure 5 mm float glass / foil / 5 mm float glass ,
[0068] Die Mengenangaben in Tabelle 3 und 4 sind in Gew.% angegeben, bezogen auf die Summe PVB und Weichmacher. 3G8 steht für Triethylenglykol-bis-2-ethylhexanoat, AEROSIL 130 und TINUVIN 328 sind Handelsprodukte der Evonik Degussa GmbH bzw. CIBA. Der Durchgangswiderstand nach DIN IEC 60093 an einer bei 23°C/85%rF klimatisierten Folie in Ohm angegeben (wie oben beschrieben).The amounts given in Table 3 and 4 are given in wt.%, Based on the sum PVB and plasticizer. 3G8 stands for triethylene glycol bis-2-ethylhexanoate, AEROSIL 130 and TINUVIN 328 are commercial products of Evonik Degussa GmbH or CIBA. The volume resistivity according to DIN IEC 60093 is indicated on a film conditioned in ohms at 23 ° C./85% RH (as described above).
[0069] Als PVB wurde ein hochviskoses Polyvinylbutyral mit einer Viskosität 60 - 90 mPas (gemessen nach DIN53015 als 5 % Lösung in Ethanol (mit 5 % Wasser) bei 200C) und einem PVA-Gehalt von 20.0 Gew.%, dessen Gehalt an Na-Ionen durch gründliches Auswaschen unterhalb 3 ppm liegt.The PVB was a high-viscosity polyvinyl butyral having a viscosity 60-90 mPas (measured according to DIN53015 as a 5% solution in ethanol (with 5% water) at 20 0 C) and a PVA content of 20.0 wt.%, The content thereof of Na ions by thorough washing below 3 ppm.
[0070] Es zeigt sich, dass Folien mit der erfindungsgemäßen Salzkonzentration einen hohen spezifischen Widerstand bei guter Penetrationsfestigkeit der hiermit hergestellten Glas/Folie/Glas-Laminate besitzen. Folien dieser Art sind für Photovoltaikanwendungen geeignet. Eine weitere Verbesserung des spezifischen Widerstands konnte durch Zugabe von SiO2 erreicht werden.It has been found that films having the salt concentration according to the invention have a high specific resistance with good penetration resistance of the glass / foil / glass laminates produced therewith. Films of this type are suitable for photovoltaic applications. A further improvement of the resistivity could be achieved by adding SiO 2 .
[0071][0071]
Tabelle 3Table 3
72] 72]
Tabelle 4Table 4
Claims
1. Photovoltaikmodul, umfassend ein Laminat aus a) einer transparenten Frontabdeckung b) einer oder mehreren photosensitiven Halbleiterschichten c) mindestens einer weichmacherhaltigen, auf Polyvinylacetal basierenden Folie und d) einer rückwärtigen Abdeckung dadurch gekennzeichnet, dass die weichmacherhaltige, auf Polyvinylacetal basierende Folie c) mehr als 10 ppm Metallionen ausgewählt aus der Gruppe Erdalkalimetalle, Zink und Aluminium und weniger als 150 ppm Alkalimetallionen aufweist.A photovoltaic module comprising a laminate of a) a transparent front cover b) one or more photosensitive semiconductor layers c) at least one plasticizer-containing polyvinyl acetal-based film and d) a rear cover, characterized in that the plasticized polyvinyl acetal-based film c) more having 10 ppm metal ions selected from the group of alkaline earth metals, zinc and aluminum and less than 150 ppm of alkali metal ions.
2. Photovoltaikmodul nach Anspruch 1 dadurch gekennzeichnet, dass die weichmacherhaltigen, auf Polyvinylacetal basierenden Folien c) einen Weichmachergehalt von maximal 40 Gew.% aufweisen.2. Photovoltaic module according to claim 1, characterized in that the plasticizer-containing polyvinyl acetal-based films c) have a plasticizer content of at most 40% by weight.
3. Photovoltaikmodul nach Anspruch 1 oder 2 dadurch gekennzeichnet, dass das die weichmacherhaltigen, auf Polyvinylacetal basierenden Folien c) in einem Umgebungsklima von 85% rF/23°C einen elektrischen Durchgangswiderstand von mehr als 1 E11 Ohm*cm aufweisen.3. Photovoltaic module according to claim 1 or 2, characterized in that the plasticizer-containing, based on polyvinyl acetal films c) have an electrical contact resistance of more than 1 E11 ohm * cm in an ambient climate of 85% RH / 23 ° C.
4. Photovoltaikmodul nach einem der Ansprüche 1 bis 3 dadurch gekennzeichnet, dass das Polyvinylacetal einen Polyvinylacetatanteil von weniger als 5 Gew.% aufweist.4. Photovoltaic module according to one of claims 1 to 3, characterized in that the polyvinyl acetal has a polyvinyl acetate content of less than 5 wt.%.
5. Photovoltaikmodul nach einem der Ansprüche 1 bis 4 dadurch gekennzeichnet, dass als Weichmacher eine oder mehrere Verbindungen eingesetzt werden, deren Polarität, ausgedrückt durch die Formel 100 x O/(C+H) kleiner/gleich 9.4 ist, wobei O, C und H für die Anzahl der Sauerstoff-, Kohlenstoff- und Wasserstoffatome im jeweiligen Molekül steht.5. Photovoltaic module according to one of claims 1 to 4, characterized in that as plasticizer one or more compounds are used whose polarity, expressed by the formula 100 x O / (C + H) is less than or equal to 9.4, wherein O, C and H stands for the number of oxygen, carbon and hydrogen atoms in the respective molecule.
6. Photovoltaikmodul nach einem der Ansprüche 1 bis 5 dadurch gekennzeichnet, dass das Polyvinylacetal einen Polyvinylalkoholanteil von weniger als 22 Gew.% aufweist.6. Photovoltaic module according to one of claims 1 to 5, characterized in that the polyvinyl acetal has a polyvinyl alcohol content of less than 22 wt.%.
7. Photovoltaikmodul nach einem der Ansprüche 1 bis 6 dadurch gekennzeichnet, dass die weichmacherhaltige, auf Polyvinylacetal basierende Folie c) 0.001 bis 15 Gew.% SiO2 enthält.7. Photovoltaic module according to one of claims 1 to 6, characterized in that the plasticizer-containing, based on polyvinyl acetal film c) 0.001 to 15 wt.% SiO 2 .
8. Photovoltaikmodul nach einem der Ansprüche 1 bis 7 dadurch gekennzeichnet, dass eine oder mehrere photosensitive Halbleiterschichten b) auf eine transparente Frontabdeckung a) oder eine rückwärtige Abdeckung d) aufgebracht werden und durch mindestens eine weichmacherhaltige, auf Polyvinylacetal basierende Folie c) miteinander verklebt sind.8. Photovoltaic module according to one of claims 1 to 7, characterized in that one or more photosensitive semiconductor layers b) on a transparent front cover a) or a rear cover d) are applied and glued together by at least one plasticizer-containing, based on polyvinyl acetal film c).
9. Verwendung von weichmacherhaltigen, auf Polyvinylacetal basierenden Folien, die mehr als 10 ppm Metallionen ausgewählt aus der Gruppe Erdalkalimetalle, Zink und Aluminium und weniger als 150 ppm Alkalimetallionen enthalten zur Herstellung von Photovoltaikmodulen.9. Use of plasticized polyvinyl acetal based films containing more than 10 ppm metal ions selected from the group of alkaline earth metals, zinc and aluminum and less than 150 ppm alkali metal ions for the manufacture of photovoltaic modules.
10. Verwendung von Photovoltaikmodulen gemäß einem der Ansprüche 1 bis 8 als Fassadenbauteil, Dachflächen, Wintergartenabdeckung, Schallschutzwand, Balkon- oder Brüstungselement oder als Bestandteil von Fensterflächen. 10. Use of photovoltaic modules according to one of claims 1 to 8 as a facade component, roof surfaces, conservatory cover, sound insulation wall, balcony or parapet or as part of windows.
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
DE102008001654A DE102008001654A1 (en) | 2008-05-08 | 2008-05-08 | Photovoltaic modules containing plasticized interlayer films with high volume resistance and good penetration resistance |
PCT/EP2009/055586 WO2009135930A2 (en) | 2008-05-08 | 2009-05-08 | Photovoltaic modules containing plasticized interlayer films having a high volume resistance and good penetration resistance |
Publications (1)
Publication Number | Publication Date |
---|---|
EP2286463A2 true EP2286463A2 (en) | 2011-02-23 |
Family
ID=41152420
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP09742148A Withdrawn EP2286463A2 (en) | 2008-05-08 | 2009-05-08 | Photovoltaic modules containing plasticized interlayer films having a high volume resistance and good penetration resistance |
Country Status (6)
Country | Link |
---|---|
US (1) | US20110056555A1 (en) |
EP (1) | EP2286463A2 (en) |
JP (1) | JP2011520278A (en) |
CN (1) | CN102017185A (en) |
DE (1) | DE102008001654A1 (en) |
WO (1) | WO2009135930A2 (en) |
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EP2259334A1 (en) * | 2009-06-05 | 2010-12-08 | Kuraray Europe GmbH | Photovoltaic module with low flow angle plasticised films |
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EA201390523A1 (en) * | 2010-10-12 | 2013-08-30 | Сэн-Гобэн Гласс Франс | THIN-LAYER SOLAR MODULE WITH MULTILAYERED SHEET STRUCTURE |
CN103391906B (en) * | 2011-02-23 | 2017-05-31 | 积水化学工业株式会社 | Intermediate film for laminated glasses and laminated glass |
EP2711990A1 (en) | 2012-09-21 | 2014-03-26 | Ecole Polytechnique Fédérale de Lausanne (EPFL) | Solar module and its production process |
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WO2017136714A1 (en) * | 2016-02-04 | 2017-08-10 | University Of Maryland, College Park | Transparent wood composite, systems and method of fabrication |
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- 2008-05-08 DE DE102008001654A patent/DE102008001654A1/en not_active Ceased
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- 2009-05-08 JP JP2011507935A patent/JP2011520278A/en active Pending
- 2009-05-08 CN CN2009801164650A patent/CN102017185A/en active Pending
- 2009-05-08 EP EP09742148A patent/EP2286463A2/en not_active Withdrawn
- 2009-05-08 WO PCT/EP2009/055586 patent/WO2009135930A2/en active Application Filing
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Also Published As
Publication number | Publication date |
---|---|
JP2011520278A (en) | 2011-07-14 |
WO2009135930A2 (en) | 2009-11-12 |
WO2009135930A3 (en) | 2010-09-23 |
US20110056555A1 (en) | 2011-03-10 |
DE102008001654A1 (en) | 2009-11-12 |
CN102017185A (en) | 2011-04-13 |
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