JP2000124486A - Surface protective sheet for solar battery module and solar battery module using it - Google Patents

Abstract

PROBLEM TO BE SOLVED: To improve the moisture resistance of a surface protective film so as to minimize the long-term performance deterioration of various fastness properties, such as the light resistance, etc., of the sheet and to reduce the cost of the sheet, by successively laminating a filler layer, a solar battery element, another filler layer, a rear-surface protective sheet layer, etc., upon the surface a surface protective sheet layer carrying a vapor-deposited thin film. SOLUTION: A surface protective sheet A for solar battery module is provided with a vapor-deposited thin film 2 of an organic oxide on one surface of a fluororesin sheet, and a coating film 3 having a resin composition containing an ethylene-vinyl alcohol copolymer as the main component of its vehicle on the thin film 2. A solar battery module T is manufactured by laminating a filler layer 11, a solar battery element 12 which works as a photovoltaic element, another filler layer 13, a rear-surface protective sheet layer 14, etc., upon the coating film 3 and uniting the laminated layers into one molded body by utilizing an ordinary molding method, such as the lamination method, etc., in which the layers are sucked by vacuum and thermocompression bonded to each other.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

The present invention relates to a solar cell module.
More specifically, the present invention relates to a surface protection sheet for solar cells and a solar cell module using the same, and more specifically, a solar cell module excellent in light resistance, heat resistance, water resistance, moisture resistance, stain resistance, etc. and having extremely high protection ability. And a solar cell module using the same.

[0002]

2. Description of the Related Art In recent years, attention has been paid to solar cells as a clean energy source due to increasing awareness of environmental issues. Currently, solar cell modules of various forms have been developed and proposed. . Thus, the above-mentioned solar cell module usually includes a surface protection sheet layer, a filler layer,
It is manufactured by laminating a solar cell element as a photovoltaic element, a filler layer, a backside protective sheet layer, and the like in that order, vacuum-sucking and heat-compressing, for example, using a lamination method. By the way, a glass plate or the like is currently most commonly used as a surface protection sheet layer constituting the above-mentioned solar cell module, and recently, a resin sheet such as a fluorine-based resin sheet has been recently used. Is also attracting attention, and its development is proceeding rapidly.

[0003]

By the way, a solar cell generally absorbs sunlight and generates photovoltaic power.
As the surface protection sheet layer constituting the solar cell module, sunlight is incident, transmits and absorbs the sunlight, and is rich in transmission and absorptivity, and also has various robustness such as light resistance, heat resistance, water resistance and the like. It has excellent moisture resistance to prevent moisture and oxygen from entering, and has high surface hardness and prevents accumulation of dirt and dust on the surface, and has high protection ability. The conditions are as follows. However, a glass plate or the like which is currently most commonly used as a surface protection sheet layer constituting a solar cell module is excellent in sunlight transmission and absorption, light resistance and heat resistance. It has the advantages of excellent water-resistance and other robustness, and also has excellent moisture-proof properties, and has the advantage of having a high surface hardness and a high protective ability, but lacks plasticity, impact resistance, weight reduction, etc. Further, there is a problem that the workability and the workability are inferior, and the cost is not reduced. When a resin sheet such as a fluororesin is used as the surface protection sheet layer constituting the solar cell module, compared with a glass plate or the like,
Although it is rich in plasticity, impact resistance, weight reduction, cost reduction, etc., it is inferior in various fastnesses such as light resistance, heat resistance, water resistance and the like, and in particular, lacks moisture resistance. Thus, the present invention uses a fluorine-based resin sheet as a surface protection sheet layer constituting a solar cell module, but also significantly improves moisture-proof properties for preventing intrusion of moisture, oxygen, and the like,
Furthermore, with respect to various fastnesses such as light resistance, heat resistance, and water resistance, a long-term performance deterioration is minimized, and a protective solar cell module having excellent protection ability is provided at a lower cost. The purpose is to stably provide a surface protection sheet.

[0004]

The inventor of the present invention has conducted various studies to solve the problems with respect to the surface protective sheet layer constituting the solar cell module as described above. Focusing on the characteristics of the glass plate used as the surface protection sheet layer constituting
Sheet is used as a base sheet, and silicon oxide,
Alternatively, a transparent, glassy inorganic oxide vapor-deposited thin film such as aluminum oxide is provided, and further, on the vapor-deposited inorganic oxide thin film, an ethylene-vinyl alcohol copolymer is used as a main component of the vehicle. A coating film made of a resin composition is provided to produce a surface protection sheet for a solar cell module, and this is used as a surface protection sheet layer, with the inorganic oxide vapor-deposited thin film surface inside, and a filler. A layer, a solar cell element as a photovoltaic element, a filler layer, a backside protective sheet layer, and the like are sequentially laminated, and then, a vacuum suction method, a vacuum suction method, and a thermocompression bonding method are performed. When the solar cell module was manufactured using, especially, the moisture resistance to prevent the invasion of moisture, oxygen, etc. was remarkably improved, and further, the light fastness, heat resistance, and various robustness such as water resistance, Minimize long-term performance degradation The present invention has been completed by finding that a surface protection sheet for a solar cell module which is excellent in protection ability, is lower in cost, and is safer, and a solar cell module using the same can be manufactured. Things.

That is, according to the present invention, a vapor-deposited thin film of an inorganic oxide is provided on one surface of a fluororesin sheet, and an ethylene-vinyl alcohol copolymer is further coated on the vapor-deposited thin film of an inorganic oxide. The present invention relates to a surface protection sheet for a solar cell module, which is provided with a coating film made of a resin composition containing a main component of a vehicle, and a solar cell module using the same.

[0006]

BEST MODE FOR CARRYING OUT THE INVENTION The present invention will be described in more detail below with reference to the drawings. The layer structure of the surface protection sheet for a solar cell module according to the present invention and the solar cell module using the same will be described more specifically with reference to the drawings and the like. FIG. 4 is a schematic cross-sectional view illustrating a few examples of the layer configuration of the surface protection sheet for a solar cell module according to the present invention, and FIG. FIG. 4 is a schematic cross-sectional view illustrating an example of a layer configuration of a solar cell module manufactured using a surface protection sheet for a solar cell.

First, as shown in FIG. 1, a surface protection sheet A for a solar cell module according to the present invention is provided with an inorganic oxide vapor-deposited thin film 2 on one surface of a fluororesin sheet 1. ,
Further, the basic structure is such that a coating film 3 of a resin composition containing an ethylene-vinyl alcohol copolymer as a main component of a vehicle is provided on the inorganic oxide deposited thin film 2. Things. As another example of the surface protection sheet for a solar cell module according to the present invention, as shown in FIG. 2, as shown in FIG.
At least one of the inorganic oxide deposited thin films 2
A multilayer film 4 having at least two layers is formed, and a resin composition containing an ethylene-vinyl alcohol copolymer as a main component of a vehicle is further formed on the inorganic oxide vapor-deposited thin film 2 constituting the multilayer film 4. co - coating film solar cell module comprising 3 structure in which a - can be exemplified bets a ₁ - le for surface protection sheet. Further, as another example of the surface protection sheet for a solar cell module according to the present invention, as shown in FIG. 3, first, a chemical vapor deposition is performed on one surface of a fluorine-based resin sheet 1. A vapor-deposited thin film 2a of an inorganic oxide is provided by a method, and then a vapor-deposited thin film 2a of an inorganic oxide is provided on the vapor-deposited thin film 2a of the inorganic oxide by depositing a vapor-deposited thin film 2b of an inorganic oxide on the vapor-deposited inorganic oxide thin film 2a. 2b comprising a multilayer film 4a comprising two or more layers, and a resin containing an ethylene-vinyl alcohol copolymer as a main component of a vehicle on the inorganic oxide deposited thin film 2b constituting the multilayer film 4a. with compositions co - coating film solar cell module comprising 3 structure in which a - le surface protective sheet - can be exemplified bets a _2. Next, in the present invention, an example of a solar cell module manufactured by using the surface protection sheet for a solar cell module according to the present invention will be described. In the example using the surface protection sheet A for a solar cell module according to the present invention, as shown in FIG.
In the surface protection sheet A for a solar cell module according to the present invention, the surface of the coating film 3 is inward, a filler layer 11 and a solar cell element 12 as a photovoltaic element in this order. , A filler layer 13, a back protective sheet layer 14 and the like are laminated, and then they are integrally formed using a normal molding method such as a lamination method in which vacuum suction is performed and thermocompression bonding is performed. The solar cell module T can be manufactured by using each layer as an integrated body. The above examples are only examples of the surface protection sheet for a solar cell module according to the present invention and a solar cell module manufactured using the same, and the present invention is not limited thereto. Not something. For example, although not shown, in the above-described solar cell module, another layer can be arbitrarily added and laminated for the purpose of absorbing sunlight, reinforcing, and the like. is there.

Next, in the present invention, the surface protection sheet for a solar cell module according to the present invention, the material constituting the solar cell module using the same, the manufacturing method, and the like will be described in more detail. Examples of the fluorine resin sheet constituting the surface protection sheet for a solar cell module, the solar cell module and the like according to the present invention include polytetrafluoroethylene (PTFE), tetrafluoroethylene and perfluoroethylene. Perfluoroalkoxy resin (PF) consisting of a copolymer with alkyl vinyl ether
A), tetrafluoroethylene and hexafluoropropylene copolymer (FEP), tetrafluoroethylene and perfluoroalkylvinyl ether and hexafluoropropylene copolymer (EPE), copolymer of tetrafluoroethylene and ethylene or propylene (ET
FE), polychlorotrifluoroethylene resin (PCT)
FE), a copolymer of ethylene and chlorotrifluoroethylene (ECTFE), a vinylidene fluoride resin (P
VDF) or a transparent fluororesin film or sheet made of vinyl fluoride resin (PVF)
Can be used. In the present invention, among the above-mentioned fluororesin films or sheets, a vinyl fluoride resin (PVF) or a copolymer of tetrafluoroethylene and ethylene or propylene is used.
A fluororesin sheet made of (ETFE) has transparency, and is particularly preferable from the viewpoints of sunlight transmission and absorption. Thus, in the present invention, by using the above-mentioned fluorine-based resin sheet, the excellent properties of the fluorine-based resin sheet, particularly, mechanical properties, heat resistance, optical properties, etc. Furthermore, the surface protection sheet for a solar cell is formed by utilizing various properties such as light resistance, heat resistance, water resistance, etc., such as super weather resistance, contamination resistance, and chemical resistance. With the same optical characteristics as a conventional glass plate,
It has durability, is lighter than a glass plate due to its flexibility, mechanical properties, and the like, has excellent workability, and has advantages such as easy handling.

In the present invention, as the above-mentioned fluororesin film or sheet, for example, one or more of the above-mentioned fluororesins is used, and the extrusion method, cast molding method, T-die method is used. , Cutting method, inflation
A method of forming a film of the above-mentioned fluororesin alone, or a method of forming a multi-layer co-extrusion film using two or more kinds of fluororesins, Furthermore, by using two or more kinds of fluorine-based resins, a method of mixing and forming a film before forming a film to produce a film or sheet of a fluorine-based resin, and further, if necessary,
For example, a fluororesin film or sheet stretched in a uniaxial or biaxial direction using a tenter method or a tuber method can be used.
In the present invention, the thickness of the fluororesin sheet is
About 12 to 200 μm, more preferably 25 to 150 μm
The m position is desirable. In the present invention, the fluororesin sheet has a visible light transmittance of 90% or more, preferably 95% or more, and has a property of transmitting all incident sunlight and absorbing it. It is desirable to have. In the above, at the time of film formation of the fluororesin, for example, processability of the film, heat resistance, weather resistance, mechanical properties, dimensional stability, antioxidant properties, sliding properties, mold release properties, flame retardancy, Various plastic compounding agents and additives can be added for the purpose of improving or modifying the antifungal property, electric properties, etc., and the amount of addition can be from a very small amount to several tens%. They can be arbitrarily added according to the purpose. In the above, as a general additive,
For example, lubricants, crosslinking agents, antioxidants, ultraviolet absorbers, light stabilizers, fillers, reinforcing agents, reinforcing agents, antistatic agents, flame retardants, flame retardants, foaming agents, antifungal agents, pigments, etc. It can be used, and furthermore, a modifying resin or the like can be used. In the present invention, among the above additives,
In particular, it is desirable to use a fluororesin sheet obtained by kneading an antioxidant or an ultraviolet absorber.

[0010] In the present invention, the fluorine-based resin
If necessary, the surface of the substrate, for example, corona discharge treatment,
Pretreatment such as ozone treatment, low-temperature plasma treatment using oxygen gas or nitrogen gas, glow discharge treatment, oxidation treatment using chemicals, or the like, and the like can be arbitrarily performed. The surface pretreatment may be performed in a separate step before forming a vapor-deposited thin film of an inorganic oxide.
In the case of a surface treatment such as a low-temperature plasma treatment or a glow discharge treatment, the surface treatment can be performed by in-line treatment as a pre-treatment for forming a vapor-deposited thin film of the above inorganic oxide,
In such a case, there is an advantage that the manufacturing cost can be reduced. The above-mentioned surface pretreatment is performed as a method for improving the adhesion between the fluorine-based resin sheet and the deposited thin film of the inorganic oxide. For example, a primer coat agent layer, an undercoat agent layer, a vapor-deposited anchor coat agent layer, or the like can be arbitrarily formed in advance on the surface of the fluororesin sheet. As the coating agent layer for the above pretreatment, for example, a resin composition containing a polyester-based resin, a polyurethane-based resin, or the like as a main component of the vehicle can be used. In the above, as a method of forming the coating agent layer, for example, a solvent type, an aqueous type,
Alternatively, using a coating agent such as an emulsion type,
Rucote method, gravure roll method, kiss coat method,
The coating can be performed by using a coating method such as other methods, and the coating is performed after the film formation of the fluororesin sheet.
Alternatively, as a post-process after biaxial stretching, or
It can be carried out by film formation or in-line processing such as biaxial stretching.

Next, in the present invention, a surface protection sheet for a solar cell module and a solar cell module according to the present invention.
When the vapor-deposited thin film of the inorganic oxide constituting the metal or the like is described, as the vapor-deposited thin film of the inorganic oxide, for example, a physical vapor deposition method, or a chemical vapor deposition method, or a combination thereof, It can be manufactured by forming one or two or more multilayer films of a deposited thin film of an inorganic oxide. The inorganic oxide vapor-deposited thin film formed by the above-mentioned physical vapor deposition method will be described in further detail. Examples of the inorganic oxide vapor-deposited thin film formed by the physical vapor deposition method include a vacuum vapor deposition method, a sputtering method, and an ion plating method. Physical Vap (Physical Vap)
or Deposition method, PVD method) to form a deposited thin film of inorganic oxide. In the present invention, specifically, a metal oxide is used as a raw material, and the metal oxide is used as a raw material, or a vacuum evaporation method in which the metal oxide is heated and vapor-deposited on a fluororesin sheet. A vapor deposition film is formed using an oxidation reaction vapor deposition method in which oxygen is introduced and oxidized to vapor-deposit on a fluorine-based resin sheet, and a plasma-assisted oxidation reaction vapor deposition method in which the oxidation reaction is promoted by plasma. be able to. In the present invention, a specific example of a method of forming a thin film of an inorganic oxide by a physical vapor deposition method is shown in FIG. 5. FIG. 5 is a schematic configuration diagram showing an example of a roll-up type vacuum evaporation apparatus. As shown in FIG. 5, in a vacuum chamber 22 of a take-up type vacuum evaporation apparatus 21, a fluororesin sheet 1 fed from an unwinding roll 23 is guided through guide rolls 24 and 25.
It is guided to the cooled coating drum 26. Then, on the fluorine-based resin sheet 1 guided on the cooled coating drum 26, a vapor deposition source 28 heated by a crucible 27, for example, metal aluminum or aluminum oxide, is placed. It is evaporated, and if necessary, oxygen gas or the like is spouted from the oxygen gas outlet 29 and supplied, for example, through the masks 30, 30.
Forming a vapor-deposited thin film of an inorganic oxide such as aluminum oxide, and then forming a vapor-deposited thin film of an inorganic oxide such as aluminum oxide on the fluorine-based resin screen above;
The roll 1 is sent out through guide rolls 25 'and 24' and wound up on a take-up roll 31 to form a vapor-deposited inorganic oxide thin film by physical vapor deposition according to the present invention. it can.

In the above description, as the inorganic oxide vapor-deposited thin film, basically any thin film on which a metal oxide is vapor-deposited can be used. For example, silicon (Si), aluminum (Al), magnesium (Mg) , Calcium (C
a), potassium (K), tin (Sn), sodium (N
a) A vapor-deposited thin film of an oxide of a metal such as boron (B), titanium (Ti), lead (Pb), zirconium (Zr), and yttrium (Y) can be used. Thus, preferred are silicon (Si), aluminum (A
1) and the like. Thus, the vapor-deposited thin film of the above-described metal oxide can be referred to as a metal oxide such as silicon oxide, aluminum oxide, and magnesium oxide.
For example, SiO _X, AlO _X, as such as MgO _X MO
_X (wherein, M represents a metal element, and the value of X is
The range differs depending on the metal element. ). The range of the value of X is silicon (S
i) is 0-2, and aluminum (Al) is 0-1.
5. Magnesium (Mg) is 0-1, calcium (C
a) is 0-1, potassium (K) is 0-0.5, tin (Sn) is 0-2, and sodium (Na) is 0-0.
5, boron (B) is 0-1,5, titanium (Ti) is
0-2, lead (Pb): 0-1, zirconium (Zr)
Can have a value in the range of 0 to 2 and yttrium (Y) can have a value in the range of 0 to 1.5. In the above, when X = 0,
It is a perfect metal, is not transparent and cannot be used at all, and the upper end of the range of X is a fully oxidized value. In the present invention, generally, except for silicon (Si) and aluminum (Al), examples used are scarce. Silicon (Si) is 1.0 to 2.0, aluminum (A)
For l), a value in the range of 0.5 to 1.5 can be used. In the present invention, the thickness of the thin film of the inorganic oxide as described above varies depending on the type of the metal or the metal oxide to be used.
It is desirable to arbitrarily select and form it within the range of 0 °, preferably 100 to 1000 °. In the present invention, the inorganic oxide vapor-deposited thin film is not limited to one layer of the inorganic oxide vapor-deposited thin film, but may be a laminate of two or more layers. Alternatively, as the metal oxide, one kind or a mixture of two or more kinds may be used to form a thin film of an inorganic oxide mixed with different materials.

Next, in the present invention, the vapor-deposited thin film of an inorganic oxide formed by the chemical vapor deposition method will be further described. Chemical vapor deposition methods such as a vapor phase growth method, a thermochemical vapor deposition method, and a photochemical vapor deposition method.
A vapor-deposited thin film of an inorganic oxide can be formed using an n method, a CVD method, or the like. In the present invention, specifically,
On one side of the fluororesin sheet, a monomer gas for vapor deposition such as an organic silicon compound is used as a raw material, and an inert gas such as an argon gas or a helium gas is used as a carrier gas. Use oxygen gas, etc.
A deposited thin film of an inorganic oxide such as silicon oxide can be formed by using a low-temperature plasma chemical vapor deposition (CVD) method using a low-temperature plasma generator or the like. In the above, as the low-temperature plasma generator, for example, high-frequency plasma, pulse wave plasma, it is possible to use a generator such as microwave plasma, in the present invention,
In order to obtain highly active and stable plasma, it is desirable to use a generator using a high-frequency plasma method.

More specifically, an example of a method of forming a vapor-deposited thin film of an inorganic oxide by the low-temperature plasma enhanced chemical vapor deposition method will be described. FIG. FIG. 1 is a schematic configuration diagram of a low-temperature plasma chemical vapor deposition apparatus showing an outline of a method for forming a vapor-deposited thin film of an oxide. As shown in FIG. 6, in the present invention, the fluororesin sheet 1 is fed out from an unwinding roll 43 disposed in a vacuum chamber 42 of a plasma enhanced chemical vapor deposition apparatus 41. The fluororesin sheath
The roller 1 is conveyed over the peripheral surface of the cooling / electrode drum 45 at a predetermined speed via the auxiliary roll 44. In the present invention, oxygen gas, an inert gas, a monomer gas for vapor deposition such as an organic silicon compound, and the like are supplied from the gas supply devices 46 and 47 and the raw material volatile supply device 48 and the like. While adjusting the vapor-deposition mixed gas composition, the vapor-deposition mixed gas composition was introduced into the vacuum chamber 42 through the raw material supply nozzle 49, and the cooling / electrode drum 4
Plasma is generated by the glow discharge plasma 50 on the fluororesin sheet 1 conveyed on the 5 peripheral surfaces, and the plasma is irradiated to form a vapor-deposited thin film of an inorganic oxide such as silicon oxide. Film forming. In the present invention, at this time, a predetermined power is applied to the cooling / electrode drum 45 from a power source 51 disposed outside the chamber.
The generation of plasma is promoted by disposing a magnet 52 near the electrode drum 45. Next, the fluorine-based resin sheet 1 on which the deposited thin film of inorganic oxide such as silicon oxide is formed, Take-up roll 5 via roll 53
4 to produce a vapor-deposited inorganic oxide thin film by the plasma enhanced chemical vapor deposition method according to the present invention. In the figure, 55 represents a vacuum pump.
The above exemplification is merely an example, and it goes without saying that the present invention is not limited thereby. Although not shown, in the present invention,
The inorganic oxide vapor-deposited thin film is not limited to one layer of the inorganic oxide vapor-deposited thin film, but may be in the form of a laminate in which two or more layers are laminated, and one or two or more materials are used. It is also possible to use a mixture and form a vapor deposited thin film of an inorganic oxide mixed with different materials.

In the above, a monomer for vapor deposition of an organic silicon compound or the like for forming a vapor deposited thin film of an inorganic oxide such as silicon oxide.
As the gas, for example, 1.1.3.3-tetramethyldisiloxane, hexamethyldisiloxane, vinyltrimethylsilane, methyltrimethylsilane, hexamethyldisilane, methylsilane, dimethylsilane, trimethylsilane, diethylsilane, propylsilane, Phenylsilane, vinyltriethoxysilane, vinyltrimethoxysilane, tetramethoxysilane, tetraethoxysilane, phenyltrimethoxysilane, methyltriethoxysilane, octamethylcyclotetrasiloxane, and the like can be used. In the present invention, among the above-mentioned organosilicon compounds, the use of 1.1.3.3-tetramethyldisiloxane or hexamethyldisiloxane as a raw material is advantageous in terms of handleability and formed deposited film. It is a particularly preferable raw material in view of its characteristics and the like. In the above description, as the inert gas, for example, argon gas, helium gas, or the like can be used.

In the present invention, the silicon oxide vapor-deposited thin film formed as described above undergoes a chemical reaction between a monomer gas such as an organic silicon compound and oxygen gas and the reaction product is formed on a fluorine-based resin sheet. And can form a dense, thin film having high flexibility and the like. Usually, silicon oxide represented by the general formula SiO _X (where X represents a number of 0 to 2) is mainly used. This is a continuous vapor-deposited thin film. Thus, the above-mentioned vapor-deposited thin film of silicon oxide is represented by the general formula SiO _X (where X represents a number of 1.3 to 1.9) from the viewpoint of transparency, barrier properties and the like. It is preferably a thin film mainly composed of a deposited silicon oxide film. In the above,
The value of X changes depending on the molar ratio of the monomer gas to the oxygen gas, the energy of the plasma, and the like. Generally, as the value of X decreases, the gas permeability decreases, but the film itself exhibits yellowness. Takes on, the transparency becomes worse. Further, the above-mentioned deposited thin film of silicon oxide has silicon (Si) and oxygen (O) as essential constituent elements, and furthermore, one of carbon (C) and hydrogen (H), or both elements Consisting of a silicon oxide deposited film containing as a trace constituent element, and the film thickness thereof,
It is in the range of 50 ° to 500 °, and the composition ratio of the essential constituent elements and the trace constituent elements continuously changes in the film thickness direction. Further, when the silicon oxide vapor-deposited thin film contains a compound made of carbon, the carbon content is reduced in the depth direction of the film thickness.

Thus, in the present invention, the above-mentioned deposited silicon oxide thin film is, for example, an X-ray photoelectron spectrometer (X
ray Photoelectron Spectro
, XPS), secondary ion mass spectrometer (Se
condary Ion Mass Spectros
(Copies, SIMS), etc. to confirm the above physical properties by performing elemental analysis of the deposited silicon oxide thin film using a method of analyzing by ion etching in the depth direction, etc. using a surface analyzer such as SIMS. Is what you can do. In the present invention, the thickness of the above-described silicon oxide vapor-deposited thin film is desirably about 50 to 2000 °, and specifically, the thickness is about 100 to 100.
The 0 ° position is desirable, and in the above, 1000
If the thickness is more than 2000 °, cracks and the like are likely to occur in the film, which is not preferable.
If it is 0 ° or less than 50 °, it is difficult to achieve the barrier effect, which is not preferable. In the above description, the film thickness can be measured, for example, by a fundamental parameter method using a fluorescent X-ray analyzer (model name: RIX2000 type) manufactured by Rigaku Corporation. Further, in the above, as means for changing the thickness of the deposited silicon oxide thin film, increasing the volume velocity of the deposited film, that is, a method of increasing the amount of the monomer gas and the oxygen gas or the rate of the deposition. It can be performed by a method of slowing down.

Incidentally, in the present invention, as a vapor-deposited thin film of an inorganic oxide constituting a surface protection sheet for a solar cell module, a solar cell module or the like according to the present invention, for example, a physical vapor deposition method can be used. When forming a multilayer film composed of two or more layers of a vapor-deposited inorganic oxide thin film by using both of the chemical vapor deposition methods together, first, a chemical vapor deposition method is performed on a fluororesin sheet. A dense, highly flexible, thin film of inorganic oxide capable of relatively preventing cracks is provided, and then the inorganic oxide is formed on the thin film of inorganic oxide by physical vapor deposition. It is desirable to provide an evaporated thin film of inorganic oxide composed of two or more multilayer films by providing an evaporated thin film.

Next, in the present invention, a plasma treatment surface formed on the surface of the deposited inorganic oxide thin film will be described. The plasma treatment surface is provided with a plasma gas generated by ionizing a gas by arc discharge. A plasma-treated surface can be formed using a plasma surface treatment method or the like in which surface modification is performed by using the method. That is, in the present invention, the plasma processing surface can be formed by performing the plasma processing using a gas such as an oxygen gas, a nitrogen gas, an argon gas, or a helium gas as a plasma gas. Therefore, in the present invention, it is preferable that the plasma treatment is performed by using an oxygen gas or a mixed gas of an oxygen gas and an argon gas or a helium gas during the plasma discharge treatment. By such a plasma treatment, it is possible to perform the plasma treatment at a lower voltage, thereby preventing the deterioration of the deposited thin film of the inorganic oxide and the like, and providing a good plasma treatment surface on its surface. Is what you can do.

In the present invention, it is most preferable that the plasma treatment is performed by using a mixed gas of oxygen gas and argon gas or helium gas. It is desirable to perform the process in-line immediately after forming the deposited thin film of the object. That is, in the present invention, on the surface of the inorganic oxide deposited thin film, for example, immediately after its formation, and before the deposited thin film comes into contact with a guide roll or the like,
By performing in-line plasma treatment, impurities, dust and the like adhering to the surface of the deposited thin film of inorganic oxide are removed, and furthermore, a hydrocarbon group (for example, C -C, CH, C =
Etc.) and the degree of oxidation of the surface increases, and a large number of carboxyl groups, keto groups, aceto groups, OH groups, etc. are formed on the surface, and the surface wettability is greatly improved, and Post-processing suitability such as close adhesion, printability and coating property is improved. Thus, in the present invention, a coating film made of a resin composition containing an ethylene-vinyl alcohol copolymer as a main component of a vehicle is provided on the above-mentioned plasma-treated surface, as described later. Thereby, it is possible to form a laminated material having high tight adhesion, excellent laminating strength, etc., and furthermore, a barrier film composed of two layers of a deposited thin film of inorganic oxide and a coating film, It has a sufficiently high barrier property against oxygen gas, water vapor and the like, and can be used to produce laminated materials having various forms. In addition, in the present invention, since the adhesiveness is excellent and the laminating strength can be increased, for example, in the post-processing such as film winding, printing, laminating, or bag making. In addition, cracks and the like can be prevented from being formed in the above-mentioned inorganic oxide vapor-deposited thin film, and so-called post-processing suitability can be improved. Further, in the present invention, since the plasma processing is performed in-line, the manufacturing cost is extremely excellent.

In the present invention, in the above-mentioned plasma processing, plasma processing conditions are extremely important.
The effect obtained by the condition is completely different. Thus, in the present invention, factors affecting the plasma processing and the chemical reaction include plasma output, gas type, gas supply amount, processing time, and the like. In the present invention, as the plasma treatment, specifically, it is desirable to use a mixed gas of oxygen gas and argon gas or helium gas, and a gas mixture of oxygen gas and argon gas or helium gas. The pressure is preferably about 1 to 1 × 10 ⁻⁴ mbar, more preferably about 1 × 10 ⁻⁴ mbar.
It is desirably about × 10 ⁻¹ to 1 × 10 ⁻³ mbar, and the ratio of oxygen gas to argon gas or helium gas is argon gas or helium gas: oxygen gas = 1: 1 to 1:10 in partial pressure ratio. Position, more preferably 1: 2
1: 6 is desirable, and the plasma output is about 0.3 to 20 kW, more preferably 0.5 to 1 kW.
5 kW is desirable, and the processing speed is about 50 to 500 m / min, more preferably 10 to 500 m / min.
A range of 0 to 400 m / min is desirable. In the above partial pressure ratio of oxygen gas and argon gas or helium gas,
When the partial pressure of argon gas or helium gas increases, oxygen molecules activated by plasma decrease, and argon gas or helium gas acts as a reducing gas, forming an oxide film on the deposited thin film surface of the inorganic oxide, or This is not preferred because the introduction of a hydroxyl group or the like is inhibited. Further, the plasma output is less than 0.5 kW,
Further, when the power is less than 0.3 kW, the activation of the oxygen gas is reduced, and it is difficult to generate highly active oxygen atoms, which is not preferable.
If it exceeds kW, the plasma output is too high, so that cracks and the like tend to occur due to the deterioration of the deposited thin film of the inorganic oxide, which is not preferable because it causes a problem that the physical properties of the transparent barrier film itself deteriorate. is there. Further, when the above processing speed is 400 m / min or more, furthermore, 500 m / min or more, the amount of oxygen plasma is small, and less than 50 m / min.
If it is less than 30 m / min, the deterioration of the deposited thin film of the inorganic oxide or the like proceeds rapidly, and the barrier property is deteriorated, which is not preferable.

In the present invention, a method of generating plasma in the plasma processing includes, for example, a DC glow discharge and a high frequency (Audio Frequency).
ency: AF, Radio Frequency: R
F) It can be performed using three types of devices such as discharge and microwave discharge. Thus, in the present invention, it can be usually carried out using a 13.56 MHz high frequency (AF) discharge device.

In the present invention, a plasma-treated surface formed on the surface of the inorganic oxide vapor-deposited thin film by the above-described plasma treatment may be, for example, an X-ray photoelectron spectrometer (Xray Photoelectron Spec.).
Troscopy, XPS), secondary ion mass spectrometer (Secondary Ion Mass Spect)
roscopy, SIMS), etc.
By analyzing the plasma processing section using a method of performing analysis by ion etching in the depth direction or the like, impurities and dust are removed as described above, and furthermore, the processing surface is thinned. Plasma-treated surface on which an oxide film having high smoothness is formed, and further, for example, a hydroxyl group (-OH
It can be confirmed that the surface is a plasma-treated surface on which a functional group such as a group is formed. In particular,
MgKα1.2 as X-ray source, 15K as X-ray output
XPS analysis of the surface to 100 ° is performed under the measurement conditions of v and 20 mA, and the treatment state can be confirmed by measuring the element ratio of Si, C, O and the like. In the present invention, the surface free energy of the deposited thin film can be measured using a wetting reagent. In the present invention, the surface free energy
Is less than 45 dynes / cm, good close adhesion cannot be obtained, and the surface free energy becomes less than 45 dynes / cm.
Ne / cm, in particular, 50 dyne / cm or more is preferable from the viewpoint of obtaining good tight adhesion.

Next, in the present invention, the surface protection sheet for a solar cell module and the solar cell module according to the present invention.
A coating film made of a resin composition containing an ethylene-vinyl alcohol copolymer as a main component of a vehicle will be described. As the coating film, for example, an ethylene-vinyl alcohol copolymer is used. One or more of the following as the main component of the vehicle,
Further, if necessary, for example, fillers, stabilizers, plasticizers,
Add optional additives such as light stabilizers such as antioxidants and ultraviolet absorbers, dispersants, thickeners, drying agents, lubricants, antistatic agents, crosslinking agents, etc. A resin composition composed of a solvent type, an aqueous type, or an emulsion type is prepared by kneading the resin composition, and the resin composition is used, for example, by a roll coating method, gravure roll coating, or the like. Method, kiss roll coat method, squeeze roll coat method,
The coating amount, for example, 0.1 g / m ^{2 to} 10 g / m ² (dry state) is determined by a coating method such as a reverse roll coating method, a curtain flow coating method, or the like. preferably, co to be ^{0.5g / m 2 ~5g / m 2} ( dry state) position - and coating, and then drying by heating, and further, e - is subjected to treatment for aging, etc., according to the present invention A coating film can be formed. In the above, as the resin composition, an ethylene-vinyl alcohol copolymer or the like is dissolved or kneaded, and further, these are cured, so that the resin composition adjusted using an alcohol-water-based solution or the like is used. It is preferable to use an alcohol component such as n-propyl alcohol, isopropyl alcohol, n-butanol, or t-type alcohol.
-Butanol, ethyl alcohol, methyl alcohol and the like can be used. In the above-mentioned alcohol-water solution, the mixing ratio of alcohol and water is as follows:
For example, alcohol, 50 to 70 parts by weight of water, 50 parts by weight
It is desirable to prepare an alcohol-water solution by blending in an amount of up to 30 parts by weight.

In the above, ethylene-vinyl alcohol
Examples of the ethylene-vinyl acetate copolymer include ethylene-vinyl acetate copolymer having an ethylene content of 25 to 50 mol%, which is obtained by completely saponifying an ethylene-vinyl acetate copolymer having a vinyl acetate content of about 79 to 92 wt%. Coalescing can be used. The ethylene-vinyl alcohol copolymer has a high gas barrier property, and is further excellent in fragrance retention, transparency, and the like. % Or less is not preferred because the oxygen gas barrier property is rapidly lowered and the transparency is deteriorated, and if less than 25 mol%, the thin film becomes brittle and It is not preferable because the gas barrier property is lowered.

Further, in the above, specifically, as an additive, it reacts with hydroxyl and the like of the ethylene-vinyl alcohol copolymer to form molecules of the ethylene-vinyl alcohol copolymer by chemical bonding with each other. A polyfunctional compound capable of forming a three-dimensional network structure (cured) polymer compound or the like can be used in combination, for example, an alkoxysilane compound such as tetramethoxysilane, tetraethoxysilane, tetrabutoxysilane, or the like. Zirconium alkoxide compounds such as methoxyzirconium and tetraethoxyzirconium, and metal alkoxide compounds such as tetramethoxytitanium and tetraethoxytitanium titanium alkoxide compounds can be used. Further, in the present invention, as the additive, for example, a compound having a functional group that reacts with active hydrogen such as a —CH ＝ CH ₂ group, ＝ C ＝ O group, —C≡N group, epoxy group, ethyleneimine group, etc. , -OH group, -SH group, -COOH
Group, compound having active hydrogen, such as -NH ₂ group, and other,
A crosslinking agent comprising a compound having a halogen group, a salt, a chelate-forming group, or the like can be used. Specifically, for example, a dialdehyde compound, a dicarboxylic acid compound, a diimide compound, a di- or polyhydric alcohol compound, a diamine compound, a diisocyanate compound, a bisepoxy compound, a bisethyleneimine compound, a divinyl compound, a zirconium compound, Titanium chelate compounds and the like can be used.

Furthermore, in the present invention, a polymer having a high adhesion to a deposited thin film of an inorganic oxide, for example, an N-unsubstituted polyalkyleneimine such as polyethyleneimine,
Polyethyleneimine-based polymers such as N-alkyl-substituted polyalkyleneimines and N-acyl-substituted polyalkyleneimines; polycarbodiimide-based polymers such as polycarbodiimide; polyvinylpyrrolidone; polyalkylated vinylpyrrolidone; A polymer, a polyvinylpyrrolidone-based polymer such as a copolymer of vinylpyrrolidone and styrene, and the like can be used.

Next, in the present invention, a silane coupling agent having binary reactivity can be added. Examples of the silane coupling agent include, for example, γ
-Chloropropyltrimethoxysilane, vinyltrichlorosilane, vinyltriethoxysilane, vinyl-tris (β-methoxyethoxy) silane, γ-methacryloxypropyltrimethoxysilane, β- (3,4-epoxycyclohexyl) ethyltrimethoxysilane Γ-glycidoxypropyltrimethoxysilane, vinyltriacetoxysilane, γ-mercaptopropyltrimethoxysilane, N-β (aminoethyl) -γ-aminopropyltrimethoxysilane, N-β (aminoethyl) -γ- One or more of aminopropylmethyldimethoxysilane, γ-ureidopropyltriethoxysilane, bis (β-hydroxyethyl) -γ-aminopropyltriethoxysilane, γ-aminopropylsilicone can be used. As the amount of use, only a small amount may be added. Furthermore, in the present invention, when a hydroxyl group or the like of the ethylene-vinyl alcohol copolymer and the above-mentioned metal alkoxide compound, a cross-linking agent or the like reacts to form a cross-linked structure, for example, a curing catalyst or the like is added. can do. Examples of the above-mentioned curing catalyst include, for example, tertiary amines which are substantially insoluble in water and soluble in an organic solvent. N-dimethylbenzylamine, tripropylamine, tributylamine, tripentylamine and the like, and as the acids, for example, mineral acids such as sulfuric acid, hydrochloric acid and nitric acid, and organic acids such as acetic acid and tartaric acid can be used. It is sufficient to add a small amount as the amount used.

In the present invention, the above-mentioned ethylene-vinyl alcohol copolymer is used as a main component of the vehicle, and if necessary, an additive is optionally added thereto to form an alcohol-water-based solvent and a diluent. A resin composition which is sufficiently kneaded is prepared by a method such as the above, coated by a usual coating method, and then heated and dried, and further subjected to an aging treatment or the like to thereby obtain a coating. A film can be formed. Thus, the above-mentioned coating film is excellent in close adhesion to a vapor-deposited thin film of an inorganic oxide, the bonding strength between the two is extremely strong, and no phenomenon such as peeling between the layers is observed. In the present invention, a barrier film composed of two layers of a vapor-deposited thin film of an inorganic oxide and the above-described coating film is formed, thereby further improving the barrier properties against oxygen gas, water vapor gas, and the like, and It is excellent in transparency, heat resistance, hot water resistance, laminating suitability, etc., and can produce an extremely good laminated material.

Next, in the present invention, the solar cell module
The filler layer laminated below the surface protection sheet for a solar cell module constituting the solar cell module will be described. The filler layer is transparent because sunlight enters, transmits and absorbs sunlight. It is necessary to have a property to adhere to the surface protection sheet, and also to function to maintain the smoothness of the surface of the solar cell element as a photovoltaic element. Having thermoplasticity for
Further, since the solar cell element as a photovoltaic element is protected, it is necessary to have excellent scratch resistance, shock absorption, and the like. Specifically, as the filler layer, for example, a fluororesin, ethylene-vinyl acetate copolymer, ionomer resin, ethylene-acrylic acid, or methacrylic acid copolymer, polyethylene resin, polypropylene resin, Acrylic acid, itaconic acid, polyolefin resin such as polyethylene or polypropylene,
Acid-modified polyolene fin-based resin modified with unsaturated carboxylic acids such as maleic acid and fumaric acid, polyvinyl butyral
Resin, silicone resin, epoxy resin, (meth)
A mixture of one or more resins such as acrylic resins and other resins can be used. In the present invention, in order to improve the heat resistance, light resistance, weather resistance such as water resistance, etc. of the resin constituting the filler layer, as long as the transparency is not impaired, for example, crosslinking may be performed. Additives such as an agent, a thermal antioxidant, a light stabilizer, an ultraviolet absorber, a photooxidant, and others can be arbitrarily added and mixed. Thus, in the present invention, as the filler on the incident side of sunlight, in consideration of light resistance, heat resistance, and weather resistance such as water resistance, a fluororesin or an ethylene-vinyl acetate resin is a desirable material. is there. In addition, the thickness of the above-mentioned filler layer is about 200 to 1000 μm, more preferably about 3 μm.
About 50 to 600 μm is desirable.

Next, in the present invention, the solar cell module
A solar cell element as a photovoltaic element constituting a cell will be described. As such a solar cell element, a conventionally known solar cell element, for example, a crystalline silicon solar cell element, a polycrystalline silicon solar cell element, an amorphous silicon solar cell element , A copper indium selenide solar cell element, a compound semiconductor solar cell element, and the like can be used.
Further, for example, a thin-film polycrystalline silicon solar cell element, a thin-film microcrystalline silicon solar cell element, or a hybrid element of a thin-film crystalline silicon solar electronic element and an amorphous solar cell element can be used.

Next, in the present invention, the solar cell module
The filler layer laminated below the photovoltaic element constituting the solar cell module will be described. The filler layer is the same as the filler layer laminated below the surface protection sheet for a solar cell module. In addition, it is necessary to have an adhesive property with a back surface protection sheet, and further, to have a function of maintaining the smoothness of the back surface of the solar cell element as a photovoltaic element, and to have thermoplasticity. In order to protect a solar cell element as a photovoltaic element, it is necessary to have excellent scratch resistance, shock absorption and the like. However, the filler layer laminated below the photovoltaic element constituting the solar cell module is different from the filler layer laminated below the surface protection sheet for the solar cell module. ,
It is not necessary to have transparency. Specifically, as the above-mentioned filler layer, for example, as in the case of the above-mentioned filler layer laminated below the surface protection sheet for a solar cell module, for example, a fluorine-based resin, ethylene-vinyl acetate copolymer may be used. Coalesced, ionomer resin, ethylene-acrylic acid, or polyolefin-based resin such as methacrylic acid copolymer, polyethylene resin, polypropylene resin, polyethylene or polypropylene, etc., with acrylic acid, itaconic acid, maleic acid, fumaric acid, etc. One or more resins such as an acid-modified polyolefin resin modified with a saturated carboxylic acid, a polyvinyl butyral resin, a silicone resin, an epoxy resin, a (meth) acrylic resin, and the like. Mixtures can be used. In the present invention, in order to improve the heat resistance, light resistance, weather resistance such as water resistance, etc. of the resin constituting the filler layer, as long as the transparency is not impaired, for example, crosslinking may be performed. Additives such as an agent, a thermal antioxidant, a light stabilizer, an ultraviolet absorber, a photooxidant, and others can be arbitrarily added and mixed. The thickness of the filler layer is 200 to
About 1000 μm, more preferably 350 to 600 μm
Position is desirable.

Next, in the present invention, the solar cell module
The backside protective sheet layer constituting the sheet will be described. As the backside protective sheet, an insulating resin film or sheet can be used, and further, heat resistance, light resistance, and water resistance With weather resistance such as, physical or chemical strength, excellent in toughness, etc., furthermore, from the protection of the solar cell element as a photovoltaic element, scratch resistance,
It is necessary to be excellent in shock absorption and the like. Specific examples of the back surface protection sheet include polyamide resins (various nylons), polyester resins, polyethylene resins, polypropylene resins, polystyrene resins, polycarbonate resins, and the like. Films or sheets of various resins such as an acetal-based resin, a cellulose-based resin, a (meth) acrylic resin, and others can be used. As the above resin film or sheet, for example, a biaxially stretched resin film or sheet can also be used. The film thickness of the resin film or sheet is 12 to 20.
About 0 μm, more preferably about 25 to 150 μm is desirable.

In the present invention, when the solar cell module according to the present invention is manufactured, in order to improve its various strengths such as strength, weather resistance, scratch resistance, etc. Material, for example, low density polyethylene,
Medium density polyethylene, high density polyethylene, linear low density polyethylene, polypropylene, ethylene-propylene copolymer, ethylene-vinyl acetate copolymer, ionomer resin, ethylene-ethyl acrylate copolymer, ethylene-acrylic acid or methacrylic Acid copolymer, methylpentene polymer, polybutene resin, polyvinyl chloride resin, polyvinyl acetate resin, polyvinylidene chloride resin, vinyl chloride-vinylidene chloride copolymer, poly (meth) acrylic resin, poly Acrylonitrile resin, polystyrene resin, acrylonitrile-styrene copolymer (AS resin), acrylonitrile-butadiene-styrene copolymer (ABS resin), polyester resin, polyamide resin, polycarbonate resin , Polyvinyl alcohol tree , Ethylene - saponified vinyl acetate copolymer, fluorine resin, diene resin, polyacetal - Le resins, polyurethane resins, nitrocellulose -
And any other known resin film or sheet. In the present invention, the above-mentioned film or sheet can be used in any of unstretched and uniaxially or biaxially stretched. The thickness is arbitrary,
It can be used by selecting from a range of several μm to about 300 μm. Further, in the present invention, the film or sheet may be any film such as an extruded film, an inflation film, or a coating film.

Next, a method of manufacturing a solar cell module using the above-mentioned materials in the present invention will be described. Such a manufacturing method includes a known method, for example, the above-described method of the present invention. A surface protection sheet for a solar cell module according to (1), the surface of the inorganic oxide vapor-deposited thin film being on the inside, a filler layer, a solar cell element as a photovoltaic element, A filler layer, a backside protective sheet layer, etc. are laminated, and if necessary, other materials are optionally laminated between the respective layers. The solar cell module can be manufactured by using a conventional molding method such as a lamination method and forming the above-mentioned layers into an integrally molded body by thermocompression bonding. In the above, if necessary, a heat-melt adhesive containing a resin such as a (meth) acrylic resin, an olefin-based resin, a vinyl-based resin, or the like as a main component of the vehicle, in order to enhance adhesion between the layers, Solvent-based adhesives, photo-curable adhesives, and others can be used.

[0036]

Next, the present invention will be described more specifically with reference to examples. Example 1 (1). As a base material, a polyvinyl fluoride resin sheet (PVF) having a thickness of 50 μm is used, which is mounted on a delivery roll of a take-up type vacuum evaporation apparatus, and then placed on a coating drum. And then, under the following conditions, using aluminum as a deposition source and supplying oxygen gas,
By a reactive vacuum evaporation method using an electron beam (EB) heating method, an evaporated thin film of aluminum oxide having a thickness of 300 ° was formed on the surface of the above-mentioned polyvinyl fluoride resin film which had been subjected to the easy adhesion treatment. (Evaporation conditions) Evaporation source: Aluminum Degree of vacuum in vacuum chamber: 7.5 × 10 ⁻⁶ mbar Degree of vacuum in evaporation chamber: 2.1 × 10 ⁻⁶ mbar EB output: 40 KW Film transport speed: 600 m / Minutes (2). Next, immediately after the deposition, a glow discharge plasma generator was used to apply a plasma output power to the polyvinyl fluoride resin film on which the aluminum oxide vapor-deposited thin film having a thickness of 300 mm was formed. A mixed gas consisting of 1500 W, oxygen gas (O ₂ ): argon gas (Ar) = 19: 1, a mixed gas pressure of 6 × 10 ⁻⁵ Toor, and a processing speed of 420 m / min.
To perform an oxygen / argon mixed gas plasma treatment. (3). Next, using a gravure printing machine, a gravure coat roll was placed in the first color on the plasma-treated surface of the above-mentioned evaporated aluminum oxide thin film, and an ethylene-vinyl alcohol copolymer (ethylene A resin composition consisting of 100 parts by weight of a 15% solution of ion-exchanged water and n-propyl alcohol (1/1) solvent having a content of 32 mol%) was used for the gravure roll coating method. To form a coating film having a thickness of 1.1 g / m ² (dry state), followed by heat treatment at 120 ° C. for 5 minutes to form a cured coating film. The surface protection sheet for a solar cell module was manufactured. (4). Next, a 38 μm-thick biaxially stretched polyethylene terephthalate film (light-receiving) in which solar cell elements made of amorphous silicon are arranged in parallel on the plasma-treated surface of the deposited aluminum oxide thin film of the surface protection sheet manufactured above. The photovoltaic module according to the present invention was manufactured by laminating the photovoltaic module of the present invention with the photovoltaic cell face facing the photovoltaic cell element face and an acrylic resin adhesive layer. (5). In the above, instead of the above-mentioned 50 μm-thick polyvinyl fluoride resin sheet (PVF) as the base material, a 50 μm-thick fluororesin sheet made of tetrafluoroethylene-ethylene copolymer (ETF) was used.
Using E), in the same manner as described above, a similar surface protection sheet for a solar cell module according to the present invention, and
The solar cell module could be manufactured.

Embodiment 2 (1). As a base material, a polyvinyl fluoride resin film (PVF) having a thickness of 50 μm was used, which was mounted on a delivery roll of a plasma enhanced chemical vapor deposition apparatus, and a silicon oxide vapor-deposited thin film having a thickness of 300 ° was formed under the following conditions. Was formed on the easily treated surface of the polyvinyl fluoride resin film. (Evaporation conditions) Reaction gas mixture ratio: hexamethyldisiloxane: oxygen gas: helium = 1: 10: 10 (unit: slm) Degree of vacuum in vacuum chamber: 5.0 × 10 ⁻⁶ mbar In evaporation chamber Degree of vacuum: 6.0 × 10 ^-2 mbar Cooling / electrode drum supply power: 20 kW Film transport speed: 80 m / min Evaporation surface: Corona treated surface (2). Next, regarding the polyvinyl fluoride resin film on which the above-described 300-mm-thick silicon oxide vapor-deposited thin film was formed,
Immediately after the deposition, the output,
A corona discharge treatment was performed at 10 kW and a treatment speed of 100 m / min, and the surface tension of the vapor-deposited thin film surface was increased from 35 dyne to 6
0 dyne to improve the surface protection seal according to the present invention.
Manufactured. (3). Next, using a gravure printing machine, a gravure coat roll was placed on the first color of the silicon oxide vapor-deposited thin film on the corona-treated surface, and ethylene-vinyl alcohol was applied.
Copolymer (ethylene content: 32 mol%) 10 parts by weight,
34 parts by weight of tetraethoxysilane, 15 parts by weight of water, 10 parts by weight of isopropyl alcohol, tertiary amine catalyst 0.1
An aqueous resin composition consisting of 7 parts by weight and 3.4 parts by weight of epoxy silane was used.
A coating film having a thickness of 0.9 g / m ² (dry state) was formed by a coating method.
A coating cured film was formed by heat treatment for a minute to prepare a surface protection sheet for a solar cell module according to the present invention. (4). Next, a 38 μm-thick biaxially stretched polyethylene terephthalate film (light-receiving) in which solar cell elements made of amorphous silicon were arranged in parallel on the corona-treated surface of the deposited silicon oxide thin film of the surface protection sheet produced above. The photovoltaic module according to the present invention was manufactured by laminating the photovoltaic module of the present invention with the photovoltaic cell face facing the photovoltaic cell element face and an acrylic resin adhesive layer. (5). In the above, instead of the above-mentioned 50 μm-thick polyvinyl fluoride resin sheet (PVF) as the base material, a 50 μm-thick fluororesin sheet made of tetrafluoroethylene-ethylene copolymer (ETF) was used.
Using E), in the same manner as described above, a similar surface protection sheet for a solar cell module according to the present invention, and
The solar cell module could be manufactured.

Embodiment 3 (1). As a base material, a 50 μm-thick polyvinyl fluoride resin film (PV
F), a thin film of silicon oxide having a thickness of 300 mm was formed on the surface of the silicon oxide film in the same manner as in Example 2, and the surface of the thin film of the silicon oxide was subjected to corona discharge treatment. Was performed to increase the surface tension of the vapor-deposited thin film surface from 35 dyne to 60 dyne. (2). Next, using a polyvinyl fluoride resin film on which a vapor-deposited silicon oxide thin film subjected to the corona treatment was formed, the silicon oxide vapor deposition of the polyvinyl fluoride resin film was performed in exactly the same manner as in Example 1 above. An aluminum oxide deposited thin film having a thickness of 300 ° was formed on the corona-treated surface of the thin film, and plasma treatment was further performed on the aluminum oxide deposited thin film surface. (3). Next, using a gravure printing machine, a gravure coat roll was placed in the first color on the plasma-treated surface of the above-mentioned evaporated aluminum oxide thin film, and an ethylene-vinyl alcohol copolymer (ethylene Content 32 mol%) 1
An aqueous resin composition comprising 0 parts by weight, 34 parts by weight of tetraethoxysilane, 15 parts by weight of water, 10 parts by weight of isopropyl alcohol, 0.17 parts by weight of a tertiary amine catalyst, and 3.4 parts by weight of epoxysilane. This was coated by a gravure roll coating method and had a thickness of 0.9 g / m2.
² (dry state) coating film is formed.
A heat treatment is carried out at 20 ° C. for 1 minute to form a coating cured film, and the surface protection sheet for a solar cell module according to the present invention is provided.
Manufactured. (4). Next, a 38 μm-thick biaxially stretched polyethylene terephthalate film (light-receiving) in which solar cell elements made of amorphous silicon are arranged in parallel on the plasma-treated surface of the deposited aluminum oxide thin film of the surface protection sheet manufactured above. The photovoltaic module according to the present invention was manufactured by laminating the photovoltaic module of the present invention with the photovoltaic cell face facing the photovoltaic cell element face and an acrylic resin adhesive layer. (5). In the above, instead of the above-mentioned 50 μm-thick polyvinyl fluoride sheet (PVF) kneaded with an ultraviolet absorbent as the base material, a 50 μm-thick tetrafluoroethylene-kneaded tetrafluoroethylene resin sheet is used. Using a fluororesin sheet (ETFE) made of fluoroethylene-ethylene copolymer, in exactly the same manner as described above, a similar surface protection sheet for a solar cell module according to the present invention,
And a solar cell module was able to be manufactured.

Example 4 A gravure printing machine was used on the plasma-treated surface of the deposited aluminum oxide thin film produced in Example 1 above.
A roll for gravure coating is arranged in the first color, and an ethylene-vinyl alcohol copolymer (ethylene content 32
Mole%) of ion-exchanged water and n-propyl alcohol (1
/ 1) A resin composition containing 20 parts by weight of a 5% solution of polyethyleneimine (manufactured by Nippon Shokubai Kagaku Co., Ltd.) was used for 100 parts by weight of a 15% solution in a solvent, and this was obtained by a gravure roll coating method. Coating, thickness 1.1g /
forming a coating film of m ² (dry state);
A heat-treated film was formed at 120 ° C. for 5 minutes to form a cured coating film, thereby producing a surface protection sheet for a solar cell module according to the present invention. Further, the surface protection sheet manufactured as described above is used.
The solar cell module according to the present invention was manufactured in the same manner as in Example 1 using the above-described method.

Example 5 An ion-exchanged water of ethylene-vinyl alcohol copolymer (ethylene content: 32 mol%) and n-propyl alcohol were applied to the corona-treated surface of the silicon oxide vapor-deposited thin film produced in Example 2 above. 1% 15% solution in
A resin composition was prepared by adding 1 part by weight of a 30% solution of zirconium acetate in the same solvent to 00 parts by weight, and this was coated by a gravure roll coating method to have a thickness of 1.1 g. / M ² (dry state) to form a coating film, and then heat-treat at 120 ° C. for 5 minutes.
A surface cured sheet for a solar cell module according to the present invention was produced by forming a cured film. Further, a solar cell module according to the present invention was manufactured in the same manner as in Example 2 using the surface protection sheet manufactured as described above.

Example 6 An ethylene-vinyl alcohol was applied to the plasma-treated surface of the deposited aluminum oxide thin film produced in Example 1 above.
Of ethylene copolymer (ethylene content 32 mol%) with ion-exchanged water and n-propyl alcohol (1/1) solvent
% Solution is added to 100 parts by weight of the resin composition and 1 part by weight of a 30% solution of the carbodiimide in the same solvent is used. The resin composition is coated by a gravure roll coating method to give a thickness of 1%. A coating film of 0.1 g / m ² (dry state) was formed, followed by a heat treatment at 120 ° C. for 5 minutes to form a cured coating film. A protective sheet was produced. Further, a solar cell module according to the present invention was manufactured in the same manner as in Example 2 using the surface protection sheet manufactured as described above.

Comparative Example 1 (1). As a base material, a 50 μm thick polyvinyl fluoride resin film (PVF) was used, and this was used as a surface protection sheet.
And a 38 μm-thick biaxially stretched polyethylene terephthalate film (light-receiving surface) in which solar cell elements made of amorphous silicon are arranged in parallel on one side, with the solar cell element surfaces facing each other. The solar cell module was manufactured by laminating via an adhesive layer.

Comparative Example 2 Using a polyvinyl fluoride resin film (PVF) having a thickness of 50 μm as a substrate, a vapor-deposited thin film of aluminum oxide having a thickness of 300 ° was formed in exactly the same manner as in Example 1 above. Further, the surface of the deposited thin film of aluminum oxide was subjected to plasma treatment to produce a surface protection sheet. Then
A 38 μm-thick biaxially stretched polyethylene terephthalate film (light-receiving surface) in which solar cell elements made of amorphous silicon are arranged in parallel on the plasma-treated surface,
The photovoltaic module was manufactured by laminating the photovoltaic cell elements so as to face each other with an adhesive layer of an acrylic resin interposed therebetween.

COMPARATIVE EXAMPLE 3 A 50 μm thick polyvinyl fluoride resin film (PVF) was used as a base material. Adhesion processing surface formed, further, on the silicon oxide deposited thin film surface,
A corona discharge treatment was performed to produce a surface protection sheet.
Next, a 38 μm-thick biaxially stretched polyethylene terephthalate film (light-receiving surface) in which solar cell elements made of amorphous silicon are arranged in parallel on the corona-treated surface, with the solar cell element surfaces facing each other, The solar cell module was manufactured by laminating through a resin adhesive layer.

Experimental Example The total light transmittance of the surface protective sheets according to the present invention produced in Examples 1 to 6 and the surface protective sheets according to Comparative Examples 1 to 3 was measured. Examples 1 to 6
A solar cell module evaluation test was conducted for the solar cell modules manufactured in Comparative Examples 1 to 3 and the solar cell modules manufactured in Comparative Examples 1 to 3. (1). Measurement of Total Light Transmittance This is based on the base film and the color protection of the surface protection sheets according to the present invention manufactured in Examples 1 to 6 and the surface protection sheets according to Comparative Examples 1 to 3. The total light transmittance (%) was measured by using a negative electrode. (2). Solar cell module evaluation test This is based on JIS standard C8917-1989.
An environmental test of the solar cell module was performed, and the output of the photovoltaic power before and after the test was measured and compared. (3). Measurement of Water Vapor Permeability and Oxygen Permeability The water vapor permeability was determined by the surface protection sheet according to the present invention manufactured in Examples 1 to 6 and the surface protection sheet according to Comparative Examples 1 to 3.
Under the conditions of a temperature of 40 ° C. and a humidity of 90% RH, a measuring instrument manufactured by MOCON, USA [model name, part
MATTRAN (PERMATRAN)]
Oxygen permeability was measured at a temperature of 23 for the same object as described above.
C., humidity 90% RH, USA, MOCON (MOCO
N) [Model name, OXTRA
N)]. The above measurement results are shown in Table 1 below.

[0046]

[Table 1] In Table 1 above, the water vapor permeability is [g / m ² / d
ay.40 ° C. · 100% RH], and the oxygen permeability is [cc / m ² / day · 23 ° C. · 90% RH].
H].

As is clear from the measurement results shown in Table 1 above, the surface protection sheets for solar cell modules according to Examples 1 to 6 have high total light transmittance, high water vapor barrier property, It had excellent oxygen barrier properties. Examples 1 to 6
The solar cell module using the surface protection sheet according to (1) also has a low output reduction rate. In contrast,
Although the surface protection sheet according to Comparative Example 1 has a high total light transmittance, it has low water vapor barrier properties and oxygen barrier properties. Therefore, a solar cell module using the same has a high output reduction rate. There was a problem. Furthermore, the surface protection sheets according to Comparative Examples 2 and 3 had high total light transmittance, excellent water vapor barrier properties and oxygen barrier properties, and low output reduction rates. As compared with those of Examples 1 to 6, the water vapor barrier property and the oxygen barrier property were slightly inferior, and the output reduction rate was slightly higher.

[0048]

As is apparent from the above description, the present invention
Focusing on the properties of a glass plate used as a surface protection sheet layer constituting a solar cell module, first, a fluororesin sheet is used as a base sheet, and on one side thereof,
A vapor-deposited transparent thin film of an inorganic oxide such as silicon oxide or aluminum oxide is provided. Further, on the vapor-deposited thin film of the inorganic oxide, an ethylene-vinyl alcohol copolymer is mainly used as a vehicle. A coating film of a resin composition as a component is provided to produce a surface protection sheet for a solar cell module, and this is used as a surface protection sheet layer, with the surface of the coating film facing inside. Lamination in which a filler layer, a solar cell element as a photovoltaic element, a filler layer, a backside protection sheet layer, and the like are sequentially laminated, and then these are integrally vacuum-evacuated and heated and pressed. The solar cell module is manufactured by using the method and the like, and the moisture-proof property for preventing the invasion of moisture, oxygen, etc. is remarkably improved, and the light-fastness, heat-resistance, water-fastness, etc. Minimize long-term performance degradation For example, excellent protection capability, more cost and safe solar cell module - is that it can be produced Le - solar cell module using the door and it - Le for surface protection sheet.

[Brief description of the drawings]

FIG. 1 is a schematic cross-sectional view schematically showing a layer configuration of an example of a surface protection sheet for a solar cell module according to the present invention.

FIG. 2 is a schematic cross-sectional view schematically showing a layer configuration of an example of a surface protection sheet for a solar cell module according to the present invention.

FIG. 3 is a schematic cross-sectional view schematically showing a layer configuration of an example of a surface protection sheet for a solar cell module according to the present invention.

FIG. 4 is a photovoltaic module manufactured using the surface protection sheet for a photovoltaic module according to the present invention shown in FIG.
FIG. 3 is a schematic cross-sectional view schematically showing a layer configuration of an example of the structure.

FIG. 5 is a schematic configuration diagram of a take-up type vacuum evaporation apparatus showing an outline of a method of forming an evaporated thin film of an inorganic oxide by a physical vapor deposition method.

FIG. 6 is a schematic configuration diagram of a low-temperature plasma-enhanced chemical vapor deposition apparatus showing an outline of a method of forming a deposited thin film of an inorganic oxide by a chemical vapor deposition method.

[Explanation of symbols]

A Surface protection sheet for solar cell module A ₁ Surface protection sheet for solar cell module A ₂ Surface protection sheet for solar cell module 1 Fluoro resin sheet 2 Inorganic oxide Evaporated thin film 2a Evaporated thin film of inorganic oxide 2b Evaporated thin film of inorganic oxide 3 Coating film 4 Multilayer film 4a Multilayer film T Solar cell module 11 Filler layer 12 Solar cell element 13 Filler layer 14 Backside protection sheet G

 ──────────────────────────────────────────────────続 き Continued on the front page (72) Inventor Hiroshi Yamamoto 1-1-1, Ichigaya-Kagacho, Shinjuku-ku, Tokyo Inside Dai Nippon Printing Co., Ltd. (72) Katsutoshi Konno 1-chome, Ichigaya-cho, Shinjuku-ku, Tokyo No. 1 Dai Nippon Printing Co., Ltd. F term (reference) 5F051 AA05 BA18 EA01 EA18 JA02 JA04 JA05

Claims (16)

[Claims] An inorganic oxide vapor-deposited thin film is provided on one side of a fluororesin sheet, and an ethylene-vinyl alcohol copolymer is further provided on the inorganic oxide vapor-deposited thin film as a main component of a vehicle. Characterized in that a coating film made of a resin composition is provided.
G. 2. The solar cell module according to claim 1, wherein the fluororesin sheet is a transparent fluororesin sheet having a visible light transmittance of 90% or more. Surface protection sheet. 3. The transparent resin sheet according to claim 1, wherein the fluororesin sheet is a vinyl fluoride resin or a transparent fluororesin sheet made of ethylene-tetrafluoroethylene copolymer. 2. The surface protection sheet for a solar cell module according to item 2. 4. The surface protection for a solar cell module according to claim 1, wherein the fluororesin sheet is kneaded with an ultraviolet absorber and / or an antioxidant. Sheet. 5. The method according to claim 1, wherein the vapor-deposited thin film of the inorganic oxide comprises one or more multilayer films of the vapor-deposited inorganic oxide thin film formed by physical vapor deposition. The surface protection sheet for a solar cell module to be described. 6. The method according to claim 1, wherein the inorganic oxide vapor-deposited thin film comprises one or more multilayer films of the inorganic oxide vapor-deposited thin film formed by a chemical vapor deposition method. The surface protection sheet for a solar cell module to be described. 7. The solar cell according to claim 1, wherein the inorganic oxide vapor-deposited thin film comprises a multilayer film of two or more layers formed by a physical vapor deposition method and a chemical vapor deposition method. Surface protection sheet for modules. 8. A vapor-deposited thin film of an inorganic oxide, wherein a vapor-deposited thin film of an inorganic oxide is formed by a chemical vapor deposition method, and then the inorganic oxide is deposited on the vapor-deposited thin film of the inorganic oxide by a physical vapor deposition method. 8. The solar cell module according to claim 7, comprising a multilayer film of two or more layers provided with a deposited thin film of an object.
Surface protection sheet for 9. The method according to claim 1, wherein the deposited thin film of the inorganic oxide forms a plasma-treated surface.
2. A surface protection sheet for a solar cell module according to item 1. 10. The surface free energy of a plasma processing surface
Is not less than 45 dyne / cm, the surface protection sheet for a solar cell module according to claim 9, wherein 11. The surface protection seal for a solar cell module according to claim 1, wherein the ethylene-vinyl alcohol copolymer has an ethylene content of 25 to 50 mol%. G. 12. The surface protection sheet for a solar cell module according to claim 1, wherein the resin composition contains a metal alkoxide compound. 13. The surface protection sheet for a solar cell module according to claim 1, wherein the resin composition contains a crosslinking agent. 14. The surface protection for a solar cell module according to claim 1, wherein the resin composition contains a polymer having a high adhesiveness to a deposited thin film of an inorganic oxide. Sheet. 15. The surface protection sheet for a solar cell module according to claim 1, wherein the resin composition contains a silane coupling agent. 16. A vapor-deposited thin film of an inorganic oxide is provided on one surface of a fluororesin sheet, and an ethylene-vinyl alcohol copolymer is further provided on the vapor-deposited thin film of an inorganic oxide as a main component of a vehicle. A filler layer, a solar cell element as a photovoltaic element, and a filler, on the surface of a thin film of inorganic oxide deposited on a surface protection sheet for a solar cell module provided with a coating film made of a resin composition to be used A solar cell module comprising a layer and a backside protective sheet layer sequentially laminated, and vacuum-suctioning these layers to form an integrally formed body by a heat-compression lamination method or the like.