JP2008193085A - ロールプレス法によりソーラーモジュールを製造する方法 - Google Patents

ロールプレス法によりソーラーモジュールを製造する方法 Download PDF

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Publication number
JP2008193085A
JP2008193085A JP2008020114A JP2008020114A JP2008193085A JP 2008193085 A JP2008193085 A JP 2008193085A JP 2008020114 A JP2008020114 A JP 2008020114A JP 2008020114 A JP2008020114 A JP 2008020114A JP 2008193085 A JP2008193085 A JP 2008193085A
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Prior art keywords
solar module
laminate
manufacturing
carrier
module according
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JP2008020114A
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JP5692956B2 (ja
Inventor
Andreas Karpinski
カルピンスキ アンドレアス
Bernhard Koll
コル ベルンハルト
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Kuraray Europe GmbH
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Kuraray Europe GmbH
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    • H01L31/18—Processes or apparatus specially adapted for the manufacture or treatment of these devices or of parts thereof
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    • B29C65/48—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
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Abstract

【課題】ソーラーモジュールの製造方法を提供する。
【解決手段】第一の担体と、該担体上に施与される少なくとも１のソーラーセルユニットと、第二の担体とからなる積層体を、中間に設置された、可塑剤を含有するポリビニルアセタールベースの少なくとも１のフィルムを用いて、少なくとも１対のローラーの間で５０〜１５０℃の温度で該積層体をプレスすることにより積層する。
【効果】連続的な製造および／または自動化可能な製造が可能となる。
【選択図】図１

Description

本発明は、ポリビニルブチラール（ＰＶＢ）ベースのフィルムを使用して、ロールプレス法により薄膜ソーラーモジュールを製造する方法に関する。
薄膜ソーラーモジュールは通常、多くの場合は透明な板の上に、たとえば蒸着法、気相堆積法、スパッタリング法または湿式堆積法により施与されている感光性の半導体層（以下ではソーラーセルユニットとよぶ）からなり、かつ外部からの影響に対する保護のために、場合により同様に透明なカバーを備えている。ソーラーセルユニットはしばしば、１のガラス板と、たとえばガラスからなる１のカバー板との間で、任意で透明な接着剤を用いて積層される。該接着剤は、該ソーラーセルユニットを完全に取り囲み、ＵＶ安定性であり、かつ積層後には、全く気泡を含まないものでなくてはならない。
透明な接着剤としてしばしば、たとえばＤＥ４１２２７２１Ｃ１またはＤＥ４１２８７６６Ａ１に開示されているように、硬化性注型樹脂、またはエチレンビニルアセテート（ＥＶＡ）をベースとする架橋性の系が使用される。これらの接着剤系は、未硬化状態で、気泡を含まずにソーラーセルユニットを覆うことができるような低い粘度に調整することができる。硬化剤または架橋剤を添加した後に、機械的な抵抗性を有する接着層が得られる。このようなソーラーモジュールの欠点は、その製造が高価であることである。特に面積の大きいファサード用部材の場合、ソーラーセルユニットを、液状の注型樹脂中へ埋め込むこと、およびその硬化を制御することは、制御が困難なプロセスである。さらに注型樹脂の中には、数年後に気泡を形成するか、もしくははく離する傾向を有するものもある。
硬化性接着剤系に対する代替法は、ポリビニルブチラール（ＰＶＢ）ベースのフィルムを使用することである。この場合、ソーラーセルユニットは、１もしくは複数のＰＶＢフィルムで覆われ、これらは高めた圧力と高めた温度の下で所望のカバー材料と共に積層されて積層品が得られる。ＰＶＢフィルムを用いたソーラーモジュールの製造方法は、たとえばＤＥ４０２６１６５Ｃ２、ＤＥ４２２７８６０Ａ１、ＤＥ２９２３７７０Ｃ２、ＤＥ３５３８９８６Ｃ２、ＤＥ１９７３２２１７、ＤＥ４０２６１６５、ＵＳ６，１６０，２１５、ＷＯ０２／１０３８０９、ＵＳ６，６６０，５５６、ＵＳ２００５／０１１５６６７またはＵＳ４，３２１，４１８から公知である。これらの刊行物中で、ＰＶＢフィルムは、結晶質のソーラーセルユニットを埋め込むために使用される。薄膜ソーラーモジュールのための単層の系もしくはこのために適切な製造法は記載されていない。
合わせガラスとしてのソーラーモジュール中でのＰＶＢフィルムの使用は、たとえばＤＥ２０３０２０４５Ｕ１、ＥＰ１６１７４８７Ａ１およびＤＥ３５３８９８６Ｃ２に開示されている。これらの文献は同様に、ソーラーセルを２つのＰＶＢフィルムの間に封入することに関する。
薄膜ソーラーモジュールの場合、ソーラーセルは直接、担体、たとえばガラス板、またはポリマーもしくは金属からなるフレキシブルな担体上に施与されている。担体中の構造に応じて、ソーラーセルの封入は不可能である。さらに薄膜ソーラーモジュールは、任意の大きさで、かつ大量に製造することができる。ＰＶＢフィルムの間に埋め込まれたソーラーセルを有するソーラーモジュールを製造するための公知の方法は、工業的な規模で薄膜ソーラーモジュールを有する複合材を製造するために十分に自動化することはできない。
さらに、ＤＥ３５３８９８６Ｃ２およびＤＥ４２２７８６０は、高めた温度および高めた圧力での積層法により、ソーラーモジュールを製造することを開示している。この目的のためにロール対を使用することは記載されていない。
ＤＥ４１２２７２１Ｃ１ ＤＥ４１２８７６６Ａ１ ＤＥ４０２６１６５Ｃ２ ＤＥ４２２７８６０Ａ１ ＤＥ２９２３７７０Ｃ２ ＤＥ３５３８９８６Ｃ２ ＤＥ１９７３２２１７ ＤＥ４０２６１６５ ＵＳ６，１６０，２１５ ＷＯ０２／１０３８０９ ＵＳ６，６６０，５５６ ＵＳ２００５／０１１５６６７ ＵＳ４，３２１，４１８ ＤＥ２０３０２０４５Ｕ１ ＥＰ１６１７４８７Ａ１ ＤＥ３５３８９８６Ｃ２ ＤＥ３５３８９８６Ｃ２ ＤＥ４２２７８６０
従って、本発明の課題は、中間層として熱可塑性フィルムを使用して、連続的な製造および／または自動化可能な製造を可能にする、薄膜ソーラーモジュールの製造方法を提供することである。
意外なことに、ロール対を用いた積層法が、機械的に不安定なソーラーセルを積層するためにも適切であることが判明した。
従って前記課題は本発明により、第一の担体と、該担体上に施与されている少なくとも１のソーラーセルユニットと、第二の担体とからなる積層体を、中間に配置された、可塑剤を含有するポリビニルアセタールベースの少なくとも１のフィルムを用いて、少なくとも１対のロールの間で５０〜１５０℃、特に６０〜１５０℃の温度で該積層体をプレスすることにより積層することによりソーラーモジュールを製造する方法により解決されることが判明した。
有利にはプレス装置中で、０．５Ｎ／ｍｍ〜１００Ｎ／ｍｍ、特に１０Ｎ／ｍｍ〜５０Ｎ／ｍｍの線圧力を加える。線圧力とは、フィルムの幅に対する、ロール対のプレス圧力であると理解する。
カバー板における破壊を防止するために、積層体の前方および／または後方の端部（積層品の始端部と終端部）において、線圧力を上側のプレスロールの自重まで低下させるか、または上側のプレスロールを引き上げることによってゼロまで低下させることができる。
さらに、積層体の妨害箇所、たとえば電気接点または導体路では、ロールプレスによる積層体の輸送速度を低減して、線圧力の作用時間を高めることが必要な場合がある。このことにより、妨害箇所の改善された脱気と、ポリビニルアセタールとの接着とが達成される。
図１は、２つのロール対を有する適切な装置の略図による構造を示す。
本発明による方法は、それぞれが１対のプレスロールからなる１つの、または複数の、有利には２つのプレス装置を使用して実施される。この場合、積層体を、少なくとも１対のロール対の間で、同一または異なった線圧力と、同一または異なった温度でプレスする。
この種の装置は、合わせガラスを製造するために知られており、かつ通常は、２つのプレス装置を有する装置の場合には、第一のプレス装置の前もしくは後ろで温度を上げるか、または均一にするための、少なくとも１の加熱トンネルを備えている。装置中での加工が、温度を上げるか、または均一にするために、最後のプレス装置の後方に存在する加熱トンネルを備えているか、または２つより多くのプレス装置を有する装置が、そのつど前方に存在する加熱トンネルを備えていることも考えられる。
前記の温度は、少なくとも最後に通過されるロール対の前の積層体に関する。
場合により最後のロール対の前に、前方に存在する加熱帯域を有するか、または有していない別のロール対が接続されていることも可能であり、この場合、積層体はここで前記の、または５０℃もしくは６０℃より低い温度を有していてよい。
本発明によれば、積層体をプレスの前に加熱トンネル中で、たとえば赤外線、マイクロ波または対流によってそのつど５０℃または６０℃〜１５０℃、有利にはそのつど７０℃または８０℃〜１００℃の温度に加熱する。複合材の温度はたとえば放射高温計により接触することなく測定することができる。
可塑剤を含有するポリビニルアセタールベースのフィルムは有利には、ポリビニルアルコールをブチルアルデヒドでアセタール化することにより得られる、架橋していないポリビニルブチラール（ＰＶＢ）を含む。
架橋したポリビニルアセタール、特に架橋したポリビニルブチラール（ＰＶＢ）の使用も同様に可能である。適切な架橋ポリビニルアセタールは、たとえばＥＰ１５２７１０７Ｂ１およびＷＯ２００４／０６３２３１Ａ１（カルボキシル基を有するポリビニルアセタールの熱による自己架橋）、ＥＰ１６０６３２５Ａ１（ポリアルデヒドにより架橋したポリビニルアセタール）およびＷＯ０３／０２０７７６Ａ１（グリオキシル酸により架橋したポリビニルアセタール）に記載されている。これらの特許出願の開示内容を全ての範囲で引用する。
その他の、または別のアルデヒド、たとえば５〜１０個の炭素原子を有するアルデヒド、たとえばバレロアルデヒドを用いてアセタール化を実施することも可能である。
ポリビニルアセタールを製造するために必要なポリビニルアルコールは、本発明の範囲で、加水分解されたビニルアセテート／エチレンコポリマーからなるターポリマーであってもよい。これらの化合物は通常、９８％以上が加水分解されており、かつエチレンベースの単位を１〜１０質量％含有している（たとえばＫｕｒａｒａｙ Ｅｕｒｏｐｅ社のＥｘｃｅｖａｌのタイプ）。アセタール化はポリビニルアルコールに関してと同様に行うことができる。
前記のポリビニルアセタール、特にＰＶＢをベースとする適切なフィルムは、５０〜８５質量％または５０〜８０質量％のポリビニルアセタール以外に、５０〜２０質量％もしくは５０〜１５質量％の可塑剤および少量の付着性調節剤、ブロッキング防止剤および紫外線安定剤を含有している。この種のフィルムを以下では略してＰＶＢフィルムとよぶ。複合安全ガラスのためのＰＶＢフィルムの原則的な製造および組成は、たとえばＥＰ１８５８６３Ｂ１、ＥＰ１１１８２５８Ｂ１またはＷＯ０２／１０２５９１Ａ１に記載されている。
本発明の特別な実施態様では、ソーラーモジュールは、フィルムの少なくとも１つが騒音防止特性を有することによって遮音性を有している。ＰＶＢをベースとする遮音性フィルムは、たとえばＥＰ１１１８２５８Ｂ１またはＥＰ３８７１４８Ｂ１に記載されており、これらの開示内容をここで全ての範囲において引用する。ＥＰ１１１８２５８Ｂ１に記載されている遮音性フィルムは、その一致周波数が１０００〜３５００Ｈｚの範囲の場合に、ＤＩＮ ＥＮ ＩＳＯ７１７により測定して少なくとも２ｄＢである場合に、複合安全ガラスの遮音性を高める。
可塑剤を含有するポリビニルアセタールベースのフィルムの厚さは有利には、これらのフィルムの工業的に通例の厚さ、たとえば０．３８、０．５１、０．７６、１．１４、１．５２または２．２８ｍｍである。
可塑剤を含有するポリビニルアセタールをベースとするフィルムは、有利に片面、または特に有利には両面に、Ｒz＞３５μｍ〜Ｒz＜１８０μｍ、有利にはＲz＞５０μｍ〜Ｒz<１５０μｍ、特に有利にはＲz＞７０μｍ〜Ｒz＜１３０μｍおよび特にＲz＞９０μｍ〜Ｒz＜１３０μｍの粗さを有する表面構造が施されている。この表面粗さＲzが、３５μｍ以下である場合、導体路の配線のため、またはその他の設置のために必要とされる温度で、空気を完全に押し出すことができる前に、複合材の周囲の閉鎖が早すぎることにつながる。その結果、複合材の中央に空気（気泡）が封入される。表面粗さが高すぎる（Ｒz＞１８０μｍ）場合には、粗さの先端が溶融するために必要なエネルギーが高くなり、かつプロセスは認容することができないほど長い時間が必要となる。
フィルムの表面構造は、押出成形法でＥＰ０１８５８６３Ｂ１に相応して、いわゆる流延もしくは溶融法(Fliess- oder Schmelzbruchverfahren)により、プラスチック溶融液が押出ノズルから出る前に直接作成することができる。異なった粗さのレベルは、出口のギャップ幅とノズルのリップ温度を変更することにより、ノズル出口で直接適切に作成することができる。この方法により、不規則な、ほぼ等方的な粗さが生じる。粗さの測定値はここで、全ての方向で測定してほぼ同一であるが、ただしその際、それぞれの凸部および凹部は、その高さおよび分布において不規則に配置されている。
あるいは、フィルムの表面構造は、たとえばＥＰ０６１１２１６３またはＥＰ０６１１２１５９に記載されているようなエンボス法により施すことができる。この場合、表面の規則的な粗さ／粗面構造が生じる。
表面粗さＲzまたは粗さ値Ｒzの測定は、ＤＩＮ ＥＮ ＩＳＯ４２８７により行う。記載の測定は、Ｍａｈｒ社のＳ２タイプ、機械的な等級付け試験機、ドライブユニットＰＧＫを有する粗さ測定装置ＭＦＷ−２５０を用いて行った。
プレスされた積層体を引き続き、高いか、または低い圧力と、そのつど高い温度とで処理することができる。これは、公知のオートクレーブ法、真空リング法または減圧バッグ法と同様に、たとえばＥＰ１２３５６８３Ｂ１に記載されているように行うことができる。
減圧バッグ法では、プレスされた積層体をプラスチックまたはゴムのバッグ中に導入する。引き続き該バッグを気密に封止し、かつ真空弁を有利には板の中央に設ける。大きな形状の積層体の場合、真空弁は２つ設けられていてもよい。真空ポンプを介してまず、２００ミリバールよりも小さい圧力を加え、かつ室温で少なくとも５分間、排気する。引き続き、真空を維持しながら換気炉中で、このサンドイッチ構造の積層体を１４０℃に加熱する。その際、加熱速度は加熱出力に応じて４〜６℃／分であるため、１４０℃の保持温度は２０〜３０分後に達成される。引き続き温度を３０分間、１４０℃に維持する。その後、少なくとも６０℃に冷却しなくてはならず、次いで真空を除去することができる。実地ではプレスされた積層体を、０．０１〜３００ミリバールの低い圧力と、１００〜２００℃の温度とで処理する。
あるいは、オートクレーブ法を使用することができる。これは合わせガラスを製造するために当業者に公知であり、かつ約７〜１５バールの高い圧力と、１３０〜１４５℃の温度で、１０〜１２０分間処理する。
本発明により使用することができるフィルムは、ソーラーセルユニットと、その電気接点とを、気泡を含むことなく、かつ強固に覆うか、または取り囲んでいなくてはならない。同時にできる限り少ないソーラーモジュールの全厚さが必要とされる。このために、フィルムは製造条件下でソーラーセルユニットと、その電気接点を「回避」する、つまり積層条件下で一定の流動性を有することが有利である。
ポリビニルアセタールベースのフィルムの、ガラスに対する付着力は、付着力調節剤、たとえばＷＯ０３／０３３５８３Ａ１に開示されている有機酸のアルカリ金属および／またはアルカリ土類金属の塩を添加することにより調節することができる。酢酸カリウムおよび／または酢酸マグネシウムが特に適切であることが判明した。高い付着力の値を得るために、付着力調節剤、たとえばアルカリ金属および／またはアルカリ土類金属の塩を添加しないで該フィルムを使用することが必要な場合がある。
本発明によるソーラーモジュールの第一および／または第二の担体は、ガラス、プラスチック、セラミックまたは金属またはこれらの複合材からなっていてもよく、その際、該担体の少なくとも１つは、透明でなくてはならない。１つ、または両方の担体が複合ガラスとして（つまり少なくとも２枚のガラス板と少なくとも１枚のフィルムとからなる積層品として）、または気体が中空部に充填された断熱ガラスとして構成されていることも可能である。当然のことながら、これらの措置の組み合わせも可能である。
ソーラーセルユニットを、第一の、特にフレキシブルな担体上に施与し、かつ該担体を、可塑剤を含有するポリビニルアセタールからなる２枚の層および２枚の、有利に透明な担体の間でプレスすることも可能である。図３〜５は、それぞれ本発明により製造された積層品の構成を略図で示しており、ここでＴ１、Ｔ２およびＴ３は、担体材料を表し、Ｆは、可塑剤を含有するポリビニルアセタールのフィルムまたは層を表し、Ｓは、ソーラーセルを表し、かつＥは、場合により必要とされる、個々のソーラーセルの電気接点を表す。図３および４において、ソーラーセルもしくは光活性層は担体材料上に施与されており、その際、図４に記載の変法では、有利にはフレキシブルな担体Ｔ３が使用される。
ソーラーモジュール中で使用されるソーラーセルは、特別な特性を有している必要はない。第一の担体上に施与されている、結晶質または非晶質の、無機または有機半導体系を使用することができる。十分な電圧を提供するために、複数のソーラーセルを相互に電気的に結合することができる。ソーラーセルは、薄膜モジュールの場合には機能層ともよばれるが、その厚さは少なくとも０．１μｍである。ソーラーセルの電気接点のために必要とされる導体路の厚さは通常、＞５０μｍである。
図２は、ソーラーモジュールの構造を略図で示しており、ここでＳは、ソーラーセルを表し、かつＰは導体路を表す。
本発明により製造されたソーラーモジュールはさらに、ファッサード部材、屋根表面、サンルーム用カバー、遮音壁、バルコニーもしくは欄干の部材として、または窓表面の部材として使用することができる。
長さ３０ｃｍ×幅２０ｃｍの大きさと、３．２ｍｍのガラス厚さとを有し、長さ方向で、幅２ｍｍおよび厚さ約２５０μｍを有し、それぞれ縁部から２０ｍｍ離れたガイドバンドを有する薄膜モジュールを、図１に記載されている装置中で、温度９０℃（最後のプレス装置の後）およびそのつどの線圧力３５Ｎ／ｍｍおよび前進速度３ｍ／分でプレスした。該複合材料の走行方向は、モジュールからの導体路の出口が後方に存在し、従って最後にプレスされるように選択した。可塑剤を含有するポリビニルアセタールフィルムとして、約１００μｍの粗さＲzを有するＴｒｏｓｉｆｏｌ ＨＲ１００タイプ（Ｋｕｒａｒａｙ Ｅｕｒｏｐｅ社）のフィルムを使用した。
プレス装置の線圧力は、積層体の最初の１０ｍｍおよび最後の３０ｍｍにおいて、上側のロールの自重まで低下させた。
わずかな濁りを有し、気泡を含まない積層品が得られた。
この濁りは、その後のオートクレーブプロセスにおいて、１４０℃および１２バールで３０分の保持時間によって完全に排除することができた。
オートクレーブ法の代わりに、この濁りは減圧法により１４５℃および１５０ミリバールで、２時間の保持時間によって排除することもできる。
従って本発明による方法は、ソーラーモジュールを製造するために適切であり、場合により、濁りはその後の方法工程で排除することができる。
２つのロール対を有する適切な装置の略図による構造を示す図 ソーラーモジュールの構造を示す略図 本発明により製造された積層品示す略図 本発明により製造された積層品示す略図 本発明により製造された積層品示す略図
符号の説明
Ｔ１、Ｔ２、Ｔ３ 担体材料、 Ｆ ポリビニルアセタールフィルム、 Ｓ ソーラーセル、 Ｅ 電気接点

Claims (10)

  1. 第一の担体と、該担体上に施与されている少なくとも１のソーラーセルユニットと、第二の担体とからなる積層体を、中間に配置された、可塑剤を含有するポリビニルアセタールベースの少なくとも１のフィルムを用いて、少なくとも１対のロールの間で５０〜１５０℃の温度で該積層体をプレスすることにより積層することによりソーラーモジュールを製造する方法。
  2. 複数のロール対の間で、０．５Ｎ／ｍｍ〜１００Ｎ／ｍｍの線圧力でプレスを実施することを特徴とする、請求項１記載のソーラーモジュールの製造方法。
  3. 前記積層体を、少なくとも２対のロール対の間で、同一または異なった線圧力と、同一または異なった温度とでプレスすることを特徴とする、請求項１または２記載のソーラーモジュールの製造方法。
  4. 可塑剤を含有するポリビニルアセタールベースのフィルムが、３５μｍ〜１８０μｍの粗さＲzを、片面または両面に有することを特徴とする、請求項１から３までのいずれか１項記載のソーラーモジュールの製造方法。
  5. 可塑剤を含有するポリビニルアセタールベースのフィルムが、規則的な粗さ構造を有することを特徴とする、請求項１から４までのいずれか１項記載のソーラーモジュールの製造方法。
  6. 可塑剤を含有するポリビニルアセタールベースのフィルムが、不規則な粗さ構造を有することを特徴とする、請求項１から４までのいずれか１項記載のソーラーモジュールの製造方法。
  7. 第一および／または第二の担体が、ガラス、プラスチック、金属またはこれらの複合材料、合わせガラスおよび／または断熱ガラスからなり、ただしその際、担体の少なくとも１つは透明であることを特徴とする、請求項１から６までのいずれか１項記載のソーラーモジュールの製造方法。
  8. プレスされた積層体を、高いか、または低い圧力と、高い温度とで処理することを特徴とする、請求項１から７までのいずれか１項記載のソーラーモジュールの製造方法。
  9. プレスされた積層体を、０．０１〜３００ミリバールの低い圧力と、１００〜２００℃の温度とで処理することを特徴とする、請求項８記載のソーラーモジュールの製造方法。
  10. プレスされた積層体を、７〜１５バールの高い圧力と、１３０〜１４５℃の温度とで処理することを特徴とする、請求項８記載のソーラーモジュールの製造方法。
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