JP2007311443A - Method for manufacturing adhesive sheet for solar cell - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method for manufacturing an adhesive sheet for solar cell. <P>SOLUTION: In the method for manufacturing an adhesive sheet for solar cell; a laminated sheet is formed by integrally laminating a second resin composition sheet to both front and rear surfaces of a first resin composition sheet, and combining both opposing ends in the widthwise direction of the second resin composition by extruding the first resin composition mainly formed of ethylene system copolymer including an organic peroxide from an extruder, while extruding the second resin composition mainly formed of ethylene system copolymer including an organic peroxide or not including the same from the other extruder, wherein the second resin composition includes crosslinking properties lower than that of the first resin composition or not includes the crosslinking properties. Moreover, the adhesive sheet for solar cell formed of an intermediate sheet layer formed of the first resin composition and an external sheet layer formed of the second resin composition covering such intermediate sheet is molded through co-extrusion by developing the laminated sheet within a T die. <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

  The present invention relates to a method for producing a solar cell adhesive sheet that is preferably used to join a solar cell element and a protective material when a solar cell module is produced.

  A solar cell module consisting of a silicon or selenium semiconductor wafer is under reduced pressure on a laminate obtained by overlaying an upper transparent protective material on the upper surface of a solar cell element with adhesive sheets laminated on both sides and a lower substrate protective material on the lower surface. It is manufactured by heating while deaeration and laminating and integrating a protective material on the upper and lower surfaces of the solar cell element via an adhesive sheet.

  As an adhesive sheet for solar cells used in such a solar cell module, for example, Patent Document 1 discloses a main body layer (A) mainly composed of an ethylene-vinyl acetate copolymer and a (meth) acrylic ester content. Proposed is a cross-linkable laminated sheet having a thickness of 0.2 to 1.2 mm, comprising a sealing layer (B) mainly composed of 15 to 35% by weight of an ethylene- (meth) acrylate copolymer. Patent Document 2 discloses that a main body layer (A) mainly composed of an ethylene-vinyl acetate copolymer having a vinyl acetate content of 21 to 40% by weight and a vinyl acetate content of 10% by weight or more and less than 21% by weight. A crosslinkable laminated sheet having a thickness of 0.2 to 1.2 mm composed of a sealing layer (B) mainly composed of an ethylene-vinyl acetate copolymer has been proposed.

  And as a film forming method of the crosslinkable laminated sheet described in Patent Documents 1 and 2, an ethylene-vinyl acetate copolymer or an ethylene- (meth) acrylate copolymer is a main component in two extruders. A resin composition comprising a resin, a crosslinking agent such as an organic peroxide, and additives such as a crosslinking aid and a silane coupling agent added as necessary, and melt-kneaded at 120 ° C. Thereafter, a method of extruding a two-layer crosslinkable laminated sheet from a multilayer T die is disclosed.

  However, when the crosslinkable laminated sheet is formed as described above, the temperature of the inner surface of the T die is high, so that the resin composition developed in a sheet shape in the T die is heated to the inner surface of the T die. The crosslinking agent is decomposed, and the crosslinking of the resin proceeds. Therefore, the melt viscosity of the resin composition is increased, and the resin composition stays in the T die, resulting in a problem that a sheet having a uniform thickness cannot be obtained. In addition, if the resin composition stays in the T die, the contact time between the resin composition developed in the form of a sheet and the inner surface of the T die becomes longer, and the crosslinking of the resin further proceeds. There was also a situation in which the sheet could not be extruded due to solidification.

JP 2005-129925 A JP 2005-129926 A

  In view of the above-mentioned problems, the present invention provides a method for producing an adhesive sheet for a solar cell, in which an ethylene copolymer can be stably formed into a uniform thickness without staying or solidifying in a T-die. To do.

  The method for producing an adhesive sheet for a solar cell of the present invention is to supply a first resin composition containing an organic peroxide and containing an ethylene copolymer as a main component to an extruder, melt knead and extrude, In an extruder different from the extruder, it contains an organic peroxide or does not contain an ethylene copolymer as a main component and has a lower crosslinkability than the first resin composition or does not have a crosslinkability. The second resin composition is supplied, melt-kneaded, extruded, and the first and second resin compositions are merged to form a sheet-like second resin on the front and back surfaces of the first resin composition. The composition is laminated and integrated, and the opposite ends in the width direction of the second resin composition are merged to form a laminated sheet, and then the laminated sheet is supplied to a T die to which the extruder is connected. The laminated sheet is expanded in the width direction in the T die, and the first An intermediate sheet layer formed of a resin composition, characterized by co-extruding the adhesive sheet for become more solar cells and an outer sheet layer this becomes an intermediate sheet layer from the coated and second resin composition.

  The ethylene-based copolymer contained in the first and second resin compositions is a copolymer of ethylene and a copolymerizable monomer that can be copolymerized with ethylene, and such copolymerizable monomer. There are no particular limitations, and examples include vinyl acetate, acrylic acid, acrylic ester, methacrylic acid, methacrylic ester, maleic acid, maleic anhydride, maleic ester, and vinyl acetate is preferred. In addition, the said copolymerizable monomer may be copolymerized with ethylene independently, or 2 or more types may be copolymerized with ethylene.

  On the other hand, if the amount of the copolymerizable monomer contained in the ethylene-based copolymer is small, the resulting solar cell adhesive sheet may have insufficient transparency, and the power generation efficiency of the solar cell element may be reduced. If the amount is too large, the film-forming stability and mechanical strength of the adhesive sheet for solar cells may be insufficient, so 5 to 50% by weight is preferable.

  When the melt flow rate of the ethylene copolymer is small, the film-forming stability of the solar cell adhesive sheet may be reduced, whereas when the melt flow rate is large, the mechanical strength of the solar cell adhesive sheet is insufficient. 1 to 100 g / 10 min is preferable. The melt flow rate of the ethylene copolymer in the present invention refers to a value measured under conditions of a temperature of 190 ° C. and a load of 2.16 kgf (21.18 N) in accordance with JIS K7210.

  While the 1st resin composition has crosslinkability by containing an organic peroxide, the 2nd resin composition contains or does not contain an organic peroxide, and is more than the 1st resin composition. It has low crosslinkability or no crosslinkability. In addition, when not giving crosslinkability to the 2nd resin composition, what is necessary is just not to contain the organic peroxide mentioned later. Next, the case where both the first and second resin compositions have crosslinkability will be described.

  Both the first and second resin compositions contain an organic peroxide. Examples of such an organic peroxide include dicumyl peroxide (136 ° C.) and t-butylperoxy-2. -Ethylhexyl monocarbonate (119 ° C), t-butylperoxybenzoate (125 ° C), 1,1-di (t-butylperoxy) -2-methylcyclohexane (102 ° C), 1,1-di (t- Hexylperoxy) -3,3,5-trimethylcyclohexane (106 ° C.), 1,1-di (t-hexylperoxy) cyclohexane (107 ° C.), 1,1-di (t-butylperoxy) cyclohexane ( 111 ° C.), 2,2-bis (4,4′-di (t-butylperoxy) cyclohexyl) propane (114 ° C.), t-hexylperoxyisopropyl mono -Bonate (115 ° C), t-butylperoxyisopropyl monocarbonate (118 ° C), t-butylperoxylaurate (118 ° C), 2,5-dimethyl-2,5-bis (benzoylperoxy) hexane (119 ° C), t-hexylperoxybenzoate (119 ° C), t-butylperoxymaleic acid (119 ° C), t-butylperoxy-3,5,5-trimethylhexanoate (119 ° C), t-butyl Peroxyacetate (121 ° C), 2,2-di (t-butylperoxy) butane (122 ° C), n-butyl-4,4-di (t-butylperoxy) valerate (127 ° C), di- t-hexyl peroxide (136 ° C), t-butylcumyl peroxide (137 ° C), bis (2-t-butylperoxyisopropyl) ) Benzene (138 ° C.), 2,5-dimethyl-2,5-di (t-butylperoxy) hexane (138 ° C.), di-t-butyl peroxide (144 ° C.), 2,5-dimethyl- 2,5-di (t-butylperoxy) hexyne-3 (150 ° C.), p-menthane hydroperoxide (151 ° C.) and the like may be used, or two or more may be used in combination. . The temperature in the parenthesis represents a 1 hour half-life temperature.

  And as a method of making the crosslinkability of the 1st resin composition higher than the crosslinkability of the 2nd resin composition, for example, (1) Content of the organic peroxide contained in the 1st resin composition (2) the decomposition rate of the organic peroxide contained in the first resin composition is higher than the content of the organic peroxide contained in the second resin composition. 2 The method of adjusting so that it may become faster than the decomposition | disassembly rate of the organic peroxide contained in the resin composition, or the method of using together the method of said (1) (2). The decomposition rate of the organic peroxide may be a 1-hour half-life temperature.

  If the content of the organic peroxide contained in the first resin composition is small, crosslinking of the ethylene-based copolymer becomes insufficient during the production of the solar cell module, and the solar cell adhesive sheet While the heat resistance may be insufficient and the durability of the resulting solar cell module may be reduced, in many cases, during the thermocompression bonding process during the production of the solar cell module, acetone or A large amount of low molecular weight compounds such as carbon dioxide are generated, causing bubble expansion between the facing surfaces of the solar cell element and the protective material, resulting in a decrease in the adhesion between the solar cell element and the protective material, and the protective function of the solar cell element Or the adhesive sheet for solar cell may be discolored and the power generation efficiency of the solar cell element may be reduced. Therefore, 0.1 to 3 parts by weight with respect to 100 parts by weight of the ethylene-based copolymer Preferably, 0.3 ~ .5 parts by weight is more preferable.

  And the content of the organic peroxide contained in the second resin composition also depends on the ratio of the entire sheet, but if it is small, the crosslinking of the ethylene-based copolymer is caused during the production of the solar cell module. Is insufficient, the heat resistance of the solar cell adhesive sheet may be insufficient, and the durability of the resulting solar cell module may be reduced. The system copolymer crosslinks and stays in the T die, and it becomes impossible to obtain a solar cell adhesive sheet having a uniform thickness, or the ethylene copolymer is solidified in the T die and the solar cell 0.01 to 0.3 parts by weight is preferable with respect to 100 parts by weight of the ethylene copolymer.

  Further, instead of adjusting the amount of the organic peroxide contained in the first and second resin compositions or selecting the type, or in combination with this, the first, The crosslinkability of the second resin composition may be adjusted.

  Specifically, the crosslinking assistant is added to the first and second resin compositions, and the amount of the crosslinking assistant contained in the first resin composition is contained in the second resin composition. In addition to the method of adjusting the amount to be larger than the amount of the crosslinking aid, a method of adding the crosslinking aid only in the first resin composition can be mentioned.

  Examples of the crosslinking aid include polyfunctional monomers having two or more allyl groups, vinyl groups, acryloyl groups, or methacryloyl groups, which stabilize polymer radicals to increase crosslinking efficiency and concentrate crosslinking points. To promote gel formation. Examples of the polyfunctional monomer include diallyl phthalate, diallyl itaconate, diallyl maleate, triallyl isocyanurate, triallyl cyanurate, triallyl phosphate, divinylbenzene; 1,6-hexanediol di (meth) acrylate. (Meth) such as ethylene oxide modified bisphenol A di (meth) acrylate, trimethylolpropane tri (meth) acrylate, pentaerythritol tetra (meth) acrylate, dipentaerythritol hexa (meth) acrylate, ε-caprolactone modified dipentaerythritol Examples include acrylates and alkyl-modified dipentaerythritol (meth) acrylates, which may be used alone or in combination of two or more.

  If the amount of the crosslinking aid contained in the first resin composition is small, the durability of the solar cell module obtained using the solar cell adhesive sheet may be lowered, whereas if the amount is large, the T-die is used. The ethylene copolymer is cross-linked in the resin to increase the melt viscosity, and the ethylene copolymer stays in the T-die, and it becomes impossible to obtain a solar cell adhesive sheet having a uniform thickness. Since the ethylene copolymer is cross-linked and solidified in the die and the solar cell adhesive sheet cannot be extruded from the T die, it is 0.1 to 3 parts per 100 parts by weight of the ethylene copolymer. Part by weight is preferable, and 0.2 to 2.5 parts by weight is more preferable.

  Further, if the amount of the crosslinking aid contained in the second resin composition is large, the ethylene copolymer is crosslinked in the T die and the melt viscosity becomes high, and the ethylene copolymer is contained in the T die. It becomes impossible to obtain a solar cell adhesive sheet having a uniform thickness, or the ethylene copolymer is cross-linked and solidified in the T die and the solar cell adhesive sheet is extruded from the T die. Therefore, the amount is preferably less than 0.1 part by weight based on 100 parts by weight of the ethylene copolymer, and the second resin composition may not contain a crosslinking aid.

  Also, instead of adjusting the amount of organic peroxide contained in the first and second resin compositions or selecting the type, or in combination with this, scorch prevention in the second resin composition An agent may be included.

  The scorch inhibitor is not particularly limited and is 2,4-diphenyl-4-methyl-1-pentene, 2,5-di-t-butyl-p-cresol, hydroquinone, 2-mercaptobenzothiazole, octyl methacrylate. N-nitrosodiphenylamine and the like may be used alone or in combination of two or more.

  If the amount of the scorch inhibitor contained in the second resin composition is small, the ethylene copolymer is crosslinked and stays in the T-die when the adhesive sheet for solar cells is formed. It is impossible to obtain a solar cell adhesive sheet with a sufficient thickness, or the ethylene copolymer is solidified in the T-die and the solar cell adhesive sheet cannot be extruded. At the time of manufacturing the battery module, the ethylene copolymer is not sufficiently cross-linked, the heat resistance of the solar cell adhesive sheet is insufficient, and the durability of the resulting solar cell module is reduced. The amount is preferably 0.01 to 2 parts by weight with respect to 100 parts by weight of the combined body.

  Moreover, the scorch inhibitor may be added to the first resin composition as long as it does not inhibit the crosslinking of the ethylene copolymer, but it is preferable that the scorch inhibitor is not contained.

  In the case of adopting any of the above methods, the gel fraction of the entire adhesive sheet after manufacturing the solar cell module is preferably 70% by weight or more.

  In addition, if it is in the range which does not impair the physical property of the adhesive sheet A for solar cells in a 1st, 2nd resin composition, a coupling agent and a 2, 6- di-t- butyl -4 are needed as needed. Additives such as antioxidants such as methylphenol and ultraviolet absorbers such as 2-hydroxy-4-methoxybenzophenone may be added.

  The coupling agent is added for the purpose of improving the adhesion of the solar cell adhesive sheet, and the coupling agent is one or more selected from the group consisting of an amino group, a glycidyl group, a methacryloxy group, and a mercapto group. A silane coupling agent having a functional group of, for example, 3-aminopropyltriethoxysilane, 3-glycidoxypropyltrimethoxysilane, 3-methacryloxypropyltrimethoxysilane, 3-mercaptopropyltrimethoxy Silane etc. are mentioned, and it may be used independently or 2 or more types may be used together.

  Next, the first resin composition configured as described above is supplied to an extruder and melt-kneaded at a temperature at which the organic peroxide is not substantially decomposed, while the second resin composition is mixed with the extruder. Is supplied to another extruder and melt-kneaded at a temperature at which the organic peroxide is not substantially decomposed.

  As will be described later, since the second resin composition is laminated and integrated as a sheet on the front and back surfaces of the first resin composition formed into a sheet, two extruders for supplying the second resin composition are prepared. The second resin composition may be supplied to these extruders, or the second resin composition may be supplied to one extruder and extruded from the extruder and then branched into two. Also good.

  Moreover, when the intermediate sheet layer of the solar cell adhesive sheet to be manufactured is composed of a plurality of layers, a plurality of extruders for supplying the first resin composition are prepared, and the first resin composition is provided in each extruder. Can be supplied.

  And when the temperature at the time of melt-kneading the 1st and 2nd resin composition in an extruder is high, the organic peroxide in a resin composition will decompose | disassemble and the bridge | crosslinking of an ethylene-type copolymer will advance. Therefore, the temperature is preferably 10 ° C. or more lower than the one-hour half-life temperature of the organic peroxide used. In the case of using two or more organic peroxides, the organic peroxide used is Of these, the temperature is preferably 10 ° C. or lower than the one-hour half-life temperature of the lowest organic peroxide.

  Next, all the extruders supplied with the first and second resin compositions are connected to one multilayer T-die, and the first and second resin compositions melt-kneaded by the extruder are used as the extruder. After being pushed out and branched into a plurality as required, it is supplied to the multilayer T die through an adapter.

  Specifically, after both the first and second resin compositions are extruded from the extruder, they are merged in the multilayer T-die and formed into a sheet shape in the adapter before being fed into the T-die. The sheet-like second resin composition is laminated and integrated on the front and back surfaces of the first resin composition, and the sheet-like second resin composition is integrated in the width direction of the sheet-like first resin composition. It is set as the state made to protrude from both ends, and the both ends of the 2nd resin composition which protruded from the edge part of this 1st resin composition mutually merged, and is set as a laminated sheet. The laminated sheet is in a state in which the first resin composition is entirely covered with the second resin composition over the entire circumference in a cross section in a direction perpendicular to the extrusion direction. The end surfaces in the width direction of the second resin composition as well as the front and back surfaces of the two resin composition are completely covered with the second resin composition. When the first resin composition is extruded from a plurality of extruders, the sheet-like first resin composition is formed in a plurality of layers.

  The laminated sheet formed as described above is continuously supplied into the T-die and expanded in the width direction, and then extruded from the T-die. The molten sheet is cooled with a cooling roll, solidified, and wound up. Thereby, the adhesive sheet A for solar cells can be obtained.

  The obtained solar cell adhesive sheet A has an intermediate sheet layer B made of the first resin composition as shown in FIG. 1 and the intermediate sheet layer B in the circumferential direction (direction orthogonal to the extrusion direction). It consists of an outer sheet layer C that covers the entire surface and is made of the second resin composition. When the sheet-like first resin composition is formed in a plurality of layers, as shown in FIG. 2, the intermediate sheet layer B is formed from a plurality of sheet layers B1, B2,. ing.

  Here, the solar cell adhesive sheet is used by interposing between the upper transparent protective material and the lower substrate protective material and the solar cell element during the production of the solar cell module, and the solar cell is subjected to thermocompression bonding under reduced pressure. The element and the upper / lower protective material are bonded. The ethylene-based copolymer is excellent in transparency and adhesiveness among transparency, adhesiveness and heat resistance particularly required for an adhesive sheet for solar cells, but has low heat resistance, and is a solar cell module. As described above, an organic peroxide is added to the first resin composition and an organic is added to the second resin composition as necessary. A peroxide is contained, and the ethylene copolymer is crosslinked by heat applied during the production of the solar cell module, thereby improving the heat resistance of the adhesive sheet for solar cells.

  However, in the manufacturing process of the solar cell adhesive sheet as described above, if the ethylene copolymer is cross-linked, the ethylene copolymer stays in the T-die and has a uniform thickness. Cannot be obtained, or the ethylene copolymer is solidified in the T-die and a solar cell adhesive sheet cannot be produced.

  Then, in the manufacturing method of the adhesive sheet for solar cells of this invention, the outer peripheral surface of a lamination sheet which is easy to bridge | crosslink in direct contact with the T-die inner surface which is high temperature, crosslinkability of the whole adhesive sheet for solar cells obtained Is formed from the second resin composition having low crosslinkability or no crosslinkability within the range that does not impair the property, and prevents or suppresses the crosslinking of the ethylene-based copolymer during the production of the solar cell adhesive sheet. The production stability of the adhesive sheet for use is not impaired.

  Then, in the obtained solar cell adhesive sheet A, the intermediate sheet layer B and the outer sheet layer C are laminated and integrated in the thickness direction of the solar cell adhesive sheet A, in the thickness direction of the solar cell adhesive sheet. When the total thickness of the outer sheet layer C is too large, crosslinking of the ethylene copolymer is insufficient during the production of the solar cell module, and the heat resistance of the adhesive sheet for solar cells is insufficient. Since the durability of the module is reduced, it is preferably 30% or less of the total thickness of the solar cell adhesive sheet A. However, if the thickness is too thin, the solar cell adhesive sheet is formed in the intermediate sheet layer B at the time of film formation. The ethylene copolymer crosslinks and stays in the T die, and a uniform thickness solar cell adhesive sheet cannot be obtained, or the ethylene copolymer does not remain in the T die. And the solar cell adhesive sheet may not be extruded, so the lower limit of the sum of the thicknesses of the outermost sheet layers C of the solar cell adhesive sheet A is the thickness of the entire solar cell adhesive sheet A. It is preferably 5%.

  Further, the solar cell adhesive sheet A is preferably embossed on the surface in order to improve the deaeration in the thermocompression bonding step when the solar cell module is manufactured. In addition, as a method of embossing the surface of the adhesive sheet A for solar cells, a known method is used. For example, the adhesive sheet A for solar cells in a molten state immediately after being extruded from a T die is embossed on the surface. The embossing roll on which the pattern is applied and the rubber roll disposed opposite to the embossing roll are supplied, and the embossing roll is pressed against the molten sheet to emboss the surface of the solar cell adhesive sheet A. The method of giving is mentioned. The once produced solar cell adhesive sheet A may be heated again to a molten state and embossed as described above.

  And as a method of manufacturing a solar cell module using the adhesive sheet A for solar cells of this invention, first, the outer sheet | seat layer formed in the both ends of the width direction in the adhesive sheet A for solar cells first as needed. As shown in FIG. 3, the C portion is cut out so that both end portions in the width direction of the intermediate sheet layer B are exposed.

  Thus, the solar cell element is bonded to the upper transparent protective material and the lower substrate protective material by cutting off the outer sheet layer C portions formed at both ends in the width direction of the solar cell adhesive sheet A. The portion of the solar cell adhesive sheet A having a low or non-crosslinked portion is prevented from being located on the outer peripheral edge of the portion, and the solar cell element, the upper transparent protective material, and the lower substrate protective material are bonded to each other. Separation from the outer peripheral edge of the portion can be prevented, and the durability of the solar cell module can be improved by reliably bonding and integrating the two.

  Then, the upper transparent protective material is laminated on the upper surface of the solar cell element via the solar cell adhesive sheet A, and the lower substrate protective material is laminated on the lower surface of the solar cell element via the solar cell adhesive sheet A. The solar cell module in which the protective material is laminated and integrated on the upper and lower surfaces of the solar cell element via the solar cell adhesive sheet A can be obtained by producing the body and thermocompression bonding the laminated body under reduced pressure. .

  Since the manufacturing method of the adhesive sheet for solar cells of the present invention has the above-described configuration, the ethylene copolymer crosslinks and stays in the T-die when manufacturing the adhesive sheet for solar cells. Thus, the solar cell adhesive sheet having a uniform thickness can be stably produced. By using this solar cell adhesive sheet, the solar cell element and the protective material are entirely assembled. Therefore, it is possible to securely press and integrate.

  And since sufficient crosslinking | crosslinking property is provided to the intermediate sheet layer of the obtained adhesive sheet for solar cells, the heat | fever added at the time of manufacture of a solar cell module has sufficient crosslinked structure in the adhesive sheet for solar cells. It is given and heat resistance is improved. Therefore, the adhesive sheet for solar cells of the present invention reliably maintains excellent adhesion over a long period of time even when used outdoors where the temperature is high, and the resulting solar cell module has excellent durability.

  Hereinafter, embodiments of the present invention will be described in more detail with reference to examples. However, the present invention is not limited to these examples.

Example 1
Prepare three extruders, connect all these extruders to the three-layer feedblock T-die via adapters, and two of the three extruders to the outer sheet layer extruder, One machine was an intermediate sheet layer extruder.

  Next, an ethylene-vinyl acetate copolymer (vinyl acetate content: 27% by weight, melt flow rate: 13 g / 10 min), 100 parts by weight, n-butyl-4,4-diethylene was added to an intermediate sheet layer extruder. (T-Butylperoxy) valerate (1 hour half-life temperature: 127 ° C) 0.5 parts by weight, 2,6-di-t-butyl-4-methylphenol 0.1 parts by weight, 2-hydroxy-4- A first resin composition comprising 0.3 parts by weight of methoxybenzophenone and 0.3 parts by weight of 3-glycidoxypropyltrimethoxysilane is supplied and melt kneaded and extruded at 110 ° C. while extruding for the outer sheet layer In each of the machines, ethylene-vinyl acetate copolymer (vinyl acetate content: 27 wt%, melt flow rate: 13 g / 10 min), 100 parts by weight, dicumyl peroxide (1 hour half-life temperature: 1 6 ° C) 0.5 parts by weight, 0.1 parts by weight of 2,6-di-t-butyl-4-methylphenol, 0.3 parts by weight of 2-hydroxy-4-methoxybenzophenone and 3-glycidoxypropyltri A second resin composition comprising 0.3 parts by weight of methoxysilane was supplied, melted and kneaded at 110 ° C., and extruded.

  The first and second resin compositions extruded from the outer sheet layer extruder and the intermediate sheet layer extruder are both supplied to the three-layer feed block and merged, and formed into a sheet shape. The sheet-like second resin composition is laminated and integrated on the front and back surfaces of one resin composition, and both end portions in the width direction of the sheet-like second resin composition are bonded to the sheet-like first resin composition. It protruded from the both ends of the width direction, and the protrusion edge parts which oppose in this sheet-like 2nd resin composition were united and integrated, and it was set as the laminated sheet. This laminated sheet was in a state where the first resin composition was entirely covered with the second resin composition over the entire circumference in a cross section in a direction perpendicular to the extrusion direction.

  The laminated sheet is continuously supplied to a T-die maintained at 110 ° C., developed in the width direction, extruded from the T-die, and the molten sheet is cooled with a cooling roll, solidified and wound up. Thereby, the adhesive sheet A for solar cells was obtained.

  The obtained adhesive sheet for a solar cell has an intermediate sheet layer B made of the first resin composition as shown in FIG. 1 and the intermediate sheet layer B entirely in the circumferential direction (direction perpendicular to the extrusion direction). And an outer sheet layer C made of the second resin composition.

  As shown in FIG. 3, both end portions in the width direction of the adhesive sheet for solar cells are cut by slit processing so that both end surfaces in the width direction of the intermediate sheet layer B are exposed, and the overall thickness is 800 μm and the outer side. The adhesive sheet A for solar cells whose thickness of each sheet layer C is 75 micrometers was obtained. The total thickness of the outer sheet layer C in the thickness direction of the solar cell adhesive sheet A was 19% of the total thickness of the solar cell adhesive sheet A.

  Further, in order to measure the gel fraction of the first resin composition and the second resin composition, the resulting resin composition was kneaded at 100 ° C. for 3 minutes using a lab plast mill. The gel fractions of the first resin composition and the second resin composition measured after crosslinking by heating for 20 minutes were 78% by weight and 72% by weight, respectively.

(Example 2)
In the first resin composition, instead of n-butyl-4,4-di (t-butylperoxy) valerate, t-butylperoxy-2-ethylhexyl monocarbonate (1 hour half-life temperature: 119 ° C.) 0 6 parts by weight, and in the second resin composition, n-butyl-4,4-di (t-butylperoxy) valerate (1 hour half-life temperature: 127 ° C.) instead of dicumyl peroxide Adhesion for solar cells in which the total thickness is 500 μm and the thickness of each outer sheet layer C is 60 μm in the same manner as in Example 1 except that the amount is 5 parts by weight and the temperature of the T die is maintained at 105 ° C. Sheet A was obtained. The total thickness of the outer sheet layer C in the thickness direction of the solar cell adhesive sheet A was 24% of the total thickness of the solar cell adhesive sheet A. Further, the gel fractions of the first resin composition and the second resin composition obtained in the same manner as in Example 1 were 82% by weight and 78% by weight, respectively.

(Example 3)
In the first resin composition, instead of n-butyl-4,4-di (t-butylperoxy) valerate, t-butylperoxy-2-ethylhexyl monocarbonate (1 hour half-life temperature: 119 ° C.) 0 .8 parts by weight, except that the organic resin was not included in the second resin composition, the total thickness was 800 μm and the thickness of each of the outer sheet layers C was the same as in Example 1. The adhesive sheet A for solar cells which is 40 micrometers was obtained. The total thickness of the outer sheet layer C in the thickness direction of the solar cell adhesive sheet A was 10% of the total thickness of the solar cell adhesive sheet A. Further, the gel fractions of the first resin composition and the second resin composition obtained in the same manner as in Example 1 were 87% by weight and 0% by weight, respectively.

(Comparative Example 1)
In the first resin composition, instead of n-butyl-4,4-di (t-butylperoxy) valerate, 1,1-di (t-butylperoxy) cyclohexane (1 hour half-life temperature: 111 ° C. ) Adhesive sheet for solar cell in the same manner as in Example 1 except that 0.5 part by weight, single layer without lamination with the second resin composition, and maintaining the temperature of the T die at 105 ° C. As a result, the resin composition was solidified and clogged at both ends in the width direction of the T-die immediately after the start of production, and the solar cell adhesive sheet could not be produced. Moreover, the gel fraction of the single body of the 1st resin composition calculated | required similarly to Example 1 was 88 weight%.

(Comparative Example 2)
In the first resin composition, instead of n-butyl-4,4-di (t-butylperoxy) valerate, t-butylperoxy-2-ethylhexyl monocarbonate (1 hour half-life temperature: 119 ° C.) 0 6 parts by weight, and in the second resin composition, n-butyl-4,4-di (t-butylperoxy) valerate (1 hour half-life temperature: 127 ° C.) instead of dicumyl peroxide 5 parts by weight, and the second resin composition is joined at the same width dimension without protruding from both ends in the width direction of the first resin composition in the joining part of the first and second resin compositions, A solar cell adhesive sheet A having an overall thickness of 800 μm and an outer sheet layer C of 75 μm in the same manner as in Example 1 except that only the front and back surfaces of the composition were coated. Obtained. The total thickness of the outer sheet layer C in the thickness direction of the solar cell adhesive sheet A was 19% of the total thickness of the solar cell adhesive sheet A. However, the resin composition gelled at both ends in the width direction of the T-die, causing some clogging. Further, the gel fractions of the first resin composition and the second resin composition obtained in the same manner as in Example 1 were 82% by weight and 78% by weight, respectively.

(Comparative Example 3)
In the first resin composition, instead of n-butyl-4,4-di (t-butylperoxy) valerate, dicumyl peroxide (1 hour half-life temperature: 136 ° C.) is 0.5 parts by weight, 2 In the resin composition, instead of dicumyl peroxide, Example 1 except that t-butylperoxy-2-ethylhexyl monocarbonate (1 hour half-life temperature: 119 ° C.) was 0.6 parts by weight. In the same manner, a solar cell adhesive sheet A having an overall thickness of 800 μm and an outer sheet layer C thickness of 75 μm was obtained. The total thickness of the outer sheet layer C in the thickness direction of the solar cell adhesive sheet A was 19% of the total thickness of the solar cell adhesive sheet A. However, the resin composition gelled at both ends in the width direction of the T-die, causing some clogging. Moreover, the gel fraction of the single body of the 1st resin composition and the 2nd resin composition calculated | required similarly to Example 1 was 72 weight% and 82 weight%, respectively.

  Table 1 shows the resin composition, T-die temperature, and layer structure of the sheet layer in these Examples and Comparative Examples, and the following conditions were evaluated for the presence or absence of abnormalities in extrusion film formation, gel fraction, and appearance of the solar cell adhesive sheet. The results are shown in Table 2.

(Extrusion film forming property)
One hour after starting to produce the solar cell adhesive sheet, the solar cell adhesive sheet extruded from the T-die was visually observed, and the extrusion film forming property was evaluated according to the following criteria.
○: A sheet having a uniform thickness was obtained.
(Triangle | delta): The sheet | seat with nonuniform thickness was extruded.
X: The resin composition was clogged in the extrusion port of T-die, and the adhesive sheet for solar cells was not able to be manufactured.

(Gel fraction)
A solar cell adhesive sheet obtained 1 hour after the start of production of the solar cell adhesive sheet and a solar cell adhesive sheet obtained 1 hour after the production of the solar cell adhesive sheet were obtained at 150 ° C. A solar cell adhesive sheet that was crosslinked by heating for a minute was prepared. And the part (it described as "sheet edge part" in Table 1) 5 cm away from the edge of the width direction in these adhesive sheets for solar cells to the center side along the width direction, and the center part ( In Table 1, about 0.2 g of a test piece was cut out from each other. The exact balance value of this test piece was S (g).

Next, the test piece was immersed in 50 ml of xylene at 110 ° C. for 12 hours, the insoluble matter was filtered through a 200 mesh wire mesh, and the residue on the wire mesh was dried under reduced pressure at 80 ° C. for 4 hours to obtain a dry residue. The weight W (g) was weighed, and the gel fraction was calculated using the following formula (1). However, in Comparative Example 1, since the adhesive sheet for solar cells could not be obtained, the gel fraction could not be measured.
Gel fraction (% by weight) = 100 × W / S (1)

(Appearance of adhesive sheet for solar cells)
The solar cell adhesive sheet obtained 1 hour after the start of production of the solar cell adhesive sheet was visually observed for the presence or absence of abnormalities in the appearance. When x occurred, it was evaluated as x.

It is sectional drawing which showed typically the lamination | stacking state of the adhesive sheet for solar cells manufactured with the manufacturing method of the adhesive sheet for solar cells of this invention. It is sectional drawing which showed the other example which showed typically the lamination | stacking state of the adhesive sheet for solar cells manufactured with the manufacturing method of the adhesive sheet for solar cells of this invention. It is sectional drawing which shows the state which cut off the both ends of the width direction in the adhesive sheet for solar cells manufactured with the manufacturing method of the adhesive sheet for solar cells of this invention.

Explanation of symbols

A Adhesive sheet for solar cell B Intermediate sheet layer C Outer sheet layer

Claims (3)

A first resin composition containing an organic peroxide and containing an ethylene copolymer as a main component is supplied to an extruder and melt-kneaded and extruded. On the other hand, an organic peroxide is placed in an extruder different from the above extruder. A second resin composition containing an ethylene copolymer as a main component and having a lower crosslinkability than the first resin composition or having no crosslinkability is supplied and melt-kneaded and extruded. Then, the first and second resin compositions are merged, and the sheet-shaped second resin composition is laminated and integrated on the front and back surfaces of the sheet-shaped first resin composition, and the second resin composition The opposite end portions in the width direction of each other are joined together to form a laminated sheet, and then the laminated sheet is supplied to a T die connected to the extruder, and the laminated sheet is arranged in the width direction in the T die. An intermediate sheet layer made of the first resin composition, Production method of the adhesive sheet for a solar cell, which comprises coextruding become more solar cell adhesive sheet and the outer sheet layer comprising a sheet layer from the coated and second resin composition. The method for producing an adhesive sheet for a solar cell according to claim 1, wherein the intermediate sheet layer is entirely covered with an outer sheet layer in the circumferential direction. In the portion where the intermediate sheet layer and the outer sheet layer are laminated and integrated in the thickness direction of the solar cell adhesive sheet, the total thickness of the outer sheet layer in the thickness direction of the solar cell adhesive sheet is the entire solar cell adhesive sheet. It adjusts so that it may become 30% or less of thickness, The manufacturing method of the adhesive sheet for solar cells of Claim 1 or Claim 2 characterized by the above-mentioned.

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