JP2011511448A - 光起電力モジュールおよび製造プロセス - Google Patents
光起電力モジュールおよび製造プロセス Download PDFInfo
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- JP2011511448A JP2011511448A JP2010544646A JP2010544646A JP2011511448A JP 2011511448 A JP2011511448 A JP 2011511448A JP 2010544646 A JP2010544646 A JP 2010544646A JP 2010544646 A JP2010544646 A JP 2010544646A JP 2011511448 A JP2011511448 A JP 2011511448A
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- H01L31/0392—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof characterised by their semiconductor bodies characterised by their crystalline structure or particular orientation of the crystalline planes including thin films deposited on metallic or insulating substrates ; characterised by specific substrate materials or substrate features or by the presence of intermediate layers, e.g. barrier layers, on the substrate
- H01L31/03926—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof characterised by their semiconductor bodies characterised by their crystalline structure or particular orientation of the crystalline planes including thin films deposited on metallic or insulating substrates ; characterised by specific substrate materials or substrate features or by the presence of intermediate layers, e.g. barrier layers, on the substrate comprising a flexible substrate
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Abstract
Description
− 50μmのETFE
− 最大800μmの、ガラスフリースまたはガラスビーズ含有EVA(高含有量の酢酸ビニル、過酸化物架橋されており、接着促進剤を含む)。800μmは、優れた可燃性を得ることを可能にする最大厚である。
− 活性層(三接合)を支持する120μmのステンレス鋼箔
− 150μmのEVA(高含有量の酢酸ビニル、過酸化物架橋されており、接着促進剤を含む)
− 100μmのEVA低含有量の酢酸ビニル
− 数マイクロメートルのPUR接着剤
− 50μmのPET誘電性積層フィルム
− 数マイクロメートルのPUR接着剤
− 100μmのEVA低含有量の酢酸ビニル。
PETフィルムは、電気的安全性に必要である。“EVA低酢酸ビニル”層は、PUR接着剤でPETフィルムに接着される。EVAとPETとの間で良好な接着性を得ることは、容易な課題ではない。PETフィルムはモジュールの端部にまでさらに達する。そのようなモジュールを80℃で水中に4週間含浸した後には、PETの境界面で剥離が実際に観測され、その結果潜在的な安全性の問題が生じる。
− 高価なモジュールの製造
− 自己接着によるラミネーション
− 金属シート(アルミニウムシート)上へのラミネーション
− 典型的には20から250μmのKapton(登録商標)もしくはPEN(ポリエチレンナフタレート)またはPET(ポリエチレンテレフタレート)フィルムのようなベースのプラスチックフィルム、あるいはステンレス鋼フィルム(モノリシック集積化のための絶縁層を備える)
− このフィルム上に、安価なロールツーロール法で、次を堆積または転写させる:
i) 背後電極(アルミニウム等)
ii) 一つ又は複数の活性PV層
iii) 透明な導電性酸化物のような、透明前面電極。
− Konarka(有機光起電力およびGraetzelセルおよびモジュール)
− VHF−Flexcell(a−Si:Hセルおよびモジュール)
− Helianthos/AKZO NOBEL(a−Si:Hセルおよびモジュール)
− Powerfilm(Iowa Thin Film)(a−Si:Hセルおよびモジュール)
− Canon(a−Si:Hセルおよびモジュール)
− Fugi(a−Si:Hセルおよびモジュール)
− United Solar Ovonic(a−Si:Hおよび三接合セルならびにモジュール)
a) 好ましくはフッ素重合体フィルムである透明なフロントシート(必要に応じて、安定剤およびできる限り長持ちするUV吸収剤を含む、典型的には20〜200μmのETFE、FEP、PVDF/アクリル、…)。このフィルムは、層b)上に対する接着性を向上させるために表面処理される。
b) 1つまたは複数の透明接着剤層(例えばEVA、イオノマー、シリコーン、シリコーン−尿素ブロックポリマー、タイ−層、タイ−層/透明TPO/タイ−層、等をベースとする、総厚50〜2000μm)。
c) 好ましくはプラスチックPVセルであって、予め障壁層で被覆および/または層b)および層d)に対する接着性を向上させるために表面処理することができる。
d) タイ層または共有押出し成形層(タイ−層/TPO、タイ層1/TPO/タイ−層2)であって、最終製品、例えばPV TPO防水膜に、許容可能な外因性の耐火性能を与えるために、好ましくは不透明であり、必要に応じて難燃化される。
e) 基板、例えば金属シートまたは難燃化TPO防水膜。
− Al55/Zn45タイプの被覆鋼(Aluzinc、Galvalume、Galval、Zincalume)、例えばエポキシ被膜を有するAZ185から作製されるような、0.5〜2mmの単一シート金属プロファイル
− 0.5〜2mmの(侵食環境中での耐腐食性をさらに向上させるために可能な限り被覆された)アルミニウムシート
− 可撓性のPP(FPP):PP/EPR反応器混合樹脂(Basellが供給するHifax CA10、Hifax CA12、Hifax CA02、Hifax CA60、…)、またはエラストマーPP樹脂(例えばランダムPPコポリマーとの混合物で、商品名Versify2300.01または2400.01のもとでDowが供給しているような)、またはTPV(少量のエクステンションオイルを含む熱可塑性加硫物(Vulcanisates):Santoprene、等)。
− LLDPE、VLDPE(Dexplastomersが提供するExact 0201または8201のような)、OBC(DowからのInfuse)および同様物、あるいはコポリマー類(EVA(エチレン酢酸ビニル)、EEA(エチレン酢酸エチル)、EBA(エチレン酢酸ブチル)、イオノマー、等)。
− EAA(ポリエチレンアクリル酸)ポリマー
− 無水マレイン酸でグラフト化されたPO(PEまたはPPのようなポリオレフィン)
− TPO内層またはコア層(B層)
− 上述の組成物(EAA、EMA、無水マレイン酸グラフト化ポリマーを含む組成物)から成る2つの薄い外部タイ−層(A層およびC層)
− ポリプロピレンとエチレンとのランダムコポリマー(RCP)30〜60重量%、
− 上記のランダムコポリマーの剛性を低減し、耐衝撃性を向上するためのVLDPE(Exact 8201のような)40〜70重量%、
− Tinuvin 123、Tinuvin 770、Chimassorb 2020、およびベンゾフェノンのような、転移性および非転移性HALS、およびUV吸収剤、
− 浄化剤(clarifiers)(透明性を向上するため)。
− ULDPE(DowからのAttane SL4102のような)60〜80%、
− Versify 2400(Dow)20〜40%、
− Tinuvin 123、Tinuvin 770、Chimassorb 2020、およびベンゾフェノンのような、転移性および非転移性HALS、およびUV吸収剤、
− 浄化剤(透明性を向上するため)。
Primacor 1321 1410
Tm(DSC ℃) 101 96
Vicat(℃) 90 81
コモノマー(%) 6.5 9.7
a) 透明前面シート(1)
b) 透明接着剤層(2)
c) プラスチック(3)PVセル(4)
d) 好ましくは不透明で、明るい色(高い太陽光反射率)の接着剤層(5)
a) 透明前面シート(1)
b) 透明接着剤層(2)
c) プラスチック(3)PVセル(4)
d) 好ましくは不透明で、明るい色(高い太陽光反射率)の接着剤層(5)
− 例えば、防水膜(10)上へのタイ−層(5)の押出し被覆中に、かつそれによって、すでにタイ−層(5)と共に積層されたポリエステル/ガラスフリースTPO防水膜(10)であって:
i) (5)=通常の添加剤および必要に応じて難燃剤を有するOrevac C314−2の50μmフィルム
ii) (10)=TPO防水膜(Hifax CA10Aをベースとする、ポリエステルおよびガラスフリース強化された、通常の添加剤および難燃剤を含む)。
− 例えば金属シート(10)上へのタイ−層/TPO/タイ−層(5)の押出し被覆中に、かつそれによって、すでにタイ−層/TPO/タイ−層(5)と共に積層されたアルミニウムシートのような、金属シート(10)。
− (2)との良好な接着性を示すように表面処理された、典型的にはETFE(1)
− (1)上へのタイ−層/透明TPO/タイ−層(2)の押出し被覆中、かつそれによって(1)上に積層された、タイ−層/透明TPO/タイ−層(2)
最終的な積層体は、所定の寸法形状に切断される。電気的接続(穿孔−接触−はんだ付け)は、オフラインで行われる。
− 着火前に、試料の下端から50mmの距離および左端と右端との間の中央に、燃え木502(ZIPたきつけ)を位置決めする
− 試験角度=45°
− 燃え木(ZIPたきつけ)に着火する
− 試験の継続時間は20分
− 焼けた表面の観測および測定
実施形態1:金属基板を備えるモジュール−接着性、耐久性、電気的安全性および耐火安全性の品質の実証
モジュールM3を、周知のラミネーション方法、例えば、欧州特許出願公開第0769818A2号(特許文献3)に従って製造し、該モジュールM3は次の層のスタックを含む:
a) DuPontからのETFEフィルム50μm(EVAへの接着のために表面処理する)
b) 2つのEVA Vistasolar 486.10フィルムのスタック(厚さ±460μm)
c) 50μmPENフィルムであって、そのPENフィルムの背面で、Al2O3被膜(反応性スパッタリング)を有する活性層(例えば、TCO/pin/背面電極/接着剤層/PENに対する接着剤)を支持する
d) “50μEAA Primacor 1410/900μm VLDPE Exact 0203/50μm EAA Primacor 1410”の同時押出フィルムであって、このフィルムは、(平均値であり、アクリル酸官能基の中和を避けるためにすべての層に添加されるわけではない)抗酸化剤(Cibaからの0.3%Irganox B225)、HALS(0.3%Tinuvin 770および0.3%Chimassorb 944)、酸捕捉剤、顔料(5%TiO2 Kronos 2220)、24%Saytex 8010および8%のSb2O3を含む。
e) 必要に応じて耐腐食性/耐化学性をさらに向上させるために、それ自体周知のように、コーティングされた、1mmアルミニウム板。
例1
サンプルAは、ハロゲン化難燃剤を含む本発明によるポリエステル強化1.5mm多層TPO防水膜(10)である。多層膜の組成は次のとおりである:
− 通常の安定剤および顔料を含み、25%Saytex BT93ハロゲン化難燃剤および10%Sb2O3を有する、Hifax CA 10Aの、300μm最上層。
− 通常の安定剤および顔料を含み、17%Saytex 8010ハロゲン化難燃剤および6%Sb2O3を有する、Hifax CA10Aの、600μm中間層。
− 2*2 1100 dTExポリエステル強化材。
− 通常の安定剤および顔料を含み、17%Saytex 8010ハロゲン化難燃剤および6%Sb2O3を有する、Hifax CA10Aの600μm下層。
a) b)に接着させるために表面処理した50μmETFE
b) 460μmEtimex Vistasolar 486.10
c) 模擬プラスチックPVセル(当業者には周知のような、PVDによってえられたアルミニウムトップコート;大気プラズマによって処理された背面を有する、PETフィルム)
d) タイ−層/TPOをシミュレートする460μmEtimex Vistasolar 486.10であって:
a. タイ−層=100μmOrevac C314−2(MAHグラフト化PP)、
b. TPO=通常の安定剤および顔料を含む360μmのHifax CA60。
サンプルCは、通常の添加剤および顔料を含むHifax CA 10Aをベースとする従来のポリエステル強化TPO防水膜(10)であり、高い充填量(45%)のMg(OH)2難燃剤を含む。この防水膜は、機械特性の深刻な低下を補償するのにポリエステル強化材を必要とする。耐火試験後の焼けた表面積は2500mm2である。サンプルの焼けた部分には、鉱物性のクラスト(炭化物)が見られる。サンプルCは、サンプルAよりも良好な耐火性能を示す。
a) b)に接着させるために表面処理した50μmETFE
b) 460μmEtimex Vistasolar 486.10
c) 模擬プラスチックPVセル(当業者には周知のような、PVDによってえられたアルミニウムトップコート;大気プラズマによって処理された背面を有する、PETフィルム)
d) タイ−層/TPOをシミュレートする460μmEtimex Vistasolar 486.10であって:
a. タイ−層=100μmOrevac C314−2(MAHグラフト化PP)
b. TPO=通常の安定剤および顔料を含む360μmのHifax CA60
サンプルEは、Cと同じTPO防水膜であるが、その最上部上には次の層のスタックが積層される。
a) b)に接着させるために表面処理した50μmETFE
b) 460μmEtimex Vistasolar 486.10
c) 模擬プラスチックPVセル(Orevac C314−2への接着のために、当業者には周知のように、PVDによって得られるアルミニウムトップコート;N2/NH3雰囲気プラズマによって処理された背面を有する、PETフィルム)
d) タイ−層/TPOであって:
a. タイ−層=100μmOrevac C314−2(MAHグラフト化PP)、
b. TPO=通常の安定剤および顔料を含み、25%のSaytex 8010および8%のSb2O3を含む500μmのHifax CA60。ハロゲン化難燃剤の量は、約125g/m2である。
次の多層膜を実験室耐火試験に供する。
− 通常の安定剤および顔料を含み、難燃化剤を含まないHifax CA10Aの300μm最上層
− 通常の安定剤および顔料を含み、22%Saytex 8010ハロゲン化難燃剤および7%Sb2O3を含む、Hifax CA10Aの600μm中間層
− 2*2 1100dTExポリエステル強化材
− 通常の安定剤および顔料を含み、22%Saytex 8010ハロゲン化難燃剤および7%Sb2O3を含む、Hifax CA10Aの600μm下層
光起電力セルを、国際公開第98/13882号(特許文献6)に従って製造し、プラスチックフィルム(PENまたはPET)のセル基板上に接着する。活性光起電力層を備えるこのPENまたはPETフィルムを、当業者に周知の手法に従って真空ラミネーター中で封入し(放出フィルムは、TPO膜−層e)−および加熱板システム間で使用することができる)、これは次の層を備える。
a) DuPontからの50μmETFEフィルム(PV用途のために供給される;典型的に大気プラズマ処理によってEVAに接着する)
b) +/−460μmの2つのEVA Vistasolar 486.10フィルム
c) 活性層(相互接続されたTCO/pin/背面電極のストリップ)を支持し、相互接続された、並列に配列されたいくつかの50μmPENフィルム。PENフィルムの背面は、Primacor(EAA)フィルムとの接着性を向上させるために、例えば反応性スパッタリング(Al2O3のナノ層の堆積)によって処理する。
d) 次の各層の同時押出多層
− i) 50μmPrimacor 1410または1321
− ii) 50μmExact 0203
− iii) 混合状態の50μmExact 0203/Hifax CA 60/Versify 2400.00
各層は、抗酸化剤(例えば、Cibaからの0.3%Irganox B225)、HALS、およびUV吸収剤(例えば、0.3%Tinuvin 770、例えば0.3%Chimassorb 944および例えば、0.3%Chimassor 81)、顔料(例えば5%TiO2 Kronos 2220)、ハロゲン化難燃剤(例えば30%Saytex 8010)、および触媒として例えば8%のSb2O3を含む。EAA Primacor層は、PENフィルム(Al2O3のナノ層が堆積された)に対する優れた接着性を示す。HALSは、押出ステップ(混合段階)においてはPrimacor 1410または1321層に、好ましくは添加されないが、ラミネーション工程の間およびエイジングの間に、層ii)および層iii)に添加されて、これらの層から層i)へ移動する。Tinuvin 123は、Tinuvin 770よりも好ましい場合がある。他のNOR−HALS(酸性基との反応性がより少ない)を、当業者の定義の定義に従って使用することができる。抗酸剤は、層ii)および層iii)に添加されるだけである。
e) 通常の安定剤を含むHifax CA10Aをベースとする1.2mmTPOシートであって、酸捕捉剤および顔料および25%Saytex8010のような臭素化難燃剤および7%Sb2O3を含む。TPOシートは、層a)、層b)および層d)中へ移動する、例えばUV吸収剤のHALS安定剤を蓄積することができる。TPOシートの最上層は、層d)、部分iii)との接着性を最適化するためのExact0201、Hifax CA 60および/またはVersify 2400.00のような軟化樹脂(softenining resins)を含んでもよい。
ダブルベルト(1000−2000)プレス機(Teflon(登録商標)で放出処理(release treatment)のベルト)中で、次の層を積層する(プレス温度約175℃)。
I) 層b)の層a)上への押出被覆によって得られる層(1/2)
a) 次のb)に接着させるために、プラズマ処理した(雰囲気プラズマ処理した−N2/NH3雰囲気)、好ましくはUV吸収剤を含む(1)100μmETFEフィルム
b) 次のi)とii)を同時押出したフィルム(けば立て加工表面)
i) 通常の安定剤を含む25μmのOrevac C314−2(押出工程の間にMAH官能基と反応しないため、透明性を与える)
ii) 例えば次のような、300μmの透明TPO組成物
ポリプロピレン−エチレンランダムコポリマーおよびExact 8201(60/40比)のようなVLDPEの混合物であって、Tinuvin 123、Tinuvin 770、Chimassorb 2020およびベンゾフェノンのような、移動性および非移動性HalsおよびUV吸収剤を含み、透明性を向上するための および透明な抗酸剤を有する、該混合物。
iii) 通常の安定剤を含む25μmのOrevac C314−2(押出工程の間にMAH官能基と反応せず、透明性を与える)
II) プラスチックPVセル寸法形状(4/3)
c) 並列して相互接続されたプラスチックPVセルのフォーマット(必要に応じて、障壁層及び、例えばOrecac C314−2層のMAH官能基との反応のために両面上にスパッタリングしたAl2O3のナノメートルオーダーの層のような処理表面を有する)
III) 複合体(5/10)
d) 次のもののインライン同時押出−積層化によって製造された複合体
iii) 通常の添加剤および必要に応じて難燃剤を含む(5)Orevac C314−2の50μmフィルム
iv) (10)TPO防水膜(Hifax CA10Aをベースとする、ポリエステルおよびガラスフリースで強化した膜)
Claims (18)
- − 基板(10)、
− アクリル酸および/または無水マレイン酸の官能性を有する熱可塑性接着剤層(5)、
− 少なくとも2つの相互接続されたセル(4)、および
− スーパーストレート、
を含む、一段階過程で積層された集積化光起電力モジュール(110)。 - 前記基板(10)が、被覆され得る、好ましくは少なくとも0.5mm厚の金属シートであり、より好ましくは被覆され得る、少なくとも0.5mm厚のアルミニウムシートであり、そして前記熱可塑性接着剤層(5)が、タイ−層1/TPO/タイ−層2である、請求項1に記載の集積化光起電力モジュール(110)。
- 前記相互接続されたセル(4)がフィルム(3)上に構築され、そして透明接着剤層(2)および可撓性フッ素重合体前面シート(1)から成るスーパーストレートによって保護される、請求項2に記載の集積化光起電力モジュール(110)。
- 前記基板(10)が、支持足部および/または剛性化プロファイル(200)を備える、請求項2または3に記載の集積化光起電力モジュール(110)。
- 前記基板(10)がTPO防水膜であって、その際前記相互接続したセル(4)がフィルム(3)上に構築され、そして透明接着剤層(2)および可撓性フッ素重合体前面シート(1)から成るスーパーストレートによって保護され、そして前記熱可塑性接着剤層(5)がタイ−層/TPOである、請求項1に記載の集積化光起電力モジュール(110)。
- 前記セルの基板(4)の下に、少なくとも50g/m2、好ましくは少なくとも100g/m2のハロゲン化難燃剤、好ましくは臭素化難燃剤を含む、請求項5に記載の集積化光起電力モジュール(110)。
- 前記接着剤層(5)が、少なくとも50g/m2、好ましくは少なくとも100g/m2のハロゲン化難燃剤、好ましくは臭素化難燃剤を含むタイ−層/TPOである、請求項5または6に記載の集積化光起電力モジュール(110)。
- 前記プラスチック(3)PVセル(4)上の前記接着剤層(2)が、透明なタイ−層/TPO/タイ−層接着剤であることを特徴とする、請求項3から7のいずれか一つに記載の集積化光起電力モジュール(110)。
- ダブルベルトプレス機中で製造される、請求項8に記載の集積化光起電力モジュール(110)。
- 封止された端部(6)を有する、請求項1から9のいずれか一つに記載の集積化光起電力モジュール(110)。
- 前記接着剤層(5)または透明である場合の前記基板(10)が明るい色を有する、請求項10に記載の集積化光起電力モジュール(110)。
- 前記タイ−層が、積層化の間にかつその場で、隣接する層からの移動によって、HALSおよび/またはUV吸収剤および/または酸捕捉剤を含む、請求項3から11のいずれか一つに記載の集積化光起電力モジュール(110)。
- 前記防水膜(10)が、前記端部(6)の安定性を向上させるために、移動UV吸収剤および移動HALSを含む、請求項5から12のいずれか一つに記載の集積化光起電力モジュール(110)。
- 前記基板(10)がガラス強化プラスチックシートであって、その際前記相互接続されたセル(4)がフィルム(3)上に構築されて、そして透明接着剤層(2)および可撓性前面シート(1)から成るスーパーストレートによって保護される、請求項1に記載の集積化光起電力モジュール。
- 前記接着剤層(5)が、少なくとも50g/m2、好ましくは少なくとも100g/m2のハロゲン化難燃剤、好ましくは臭素化難燃剤を含むタイ−層/TPOである、請求項14に記載の集積化光起電力モジュール。
- 剛性基板(10)を備える集積化光起電力モジュール(110)を、取り付けられた防水膜(100)に取り付けるための方法であって、
− 剛性挿入部(105)および溶接可能なフラップ(134)を備える、柔軟なプロファイル(104)を前記防水膜に設けるステップ、
− 前記プロファイル(104)を前記防水膜(100)上に溶接するステップ、
− それぞれの剛性基板(10)を備える前記モジュールを、前記プロファイル(104)の前記剛性挿入部(105)に、ねじのような機械的締め具で取り付けるステップ、
を含む、上記方法。 - 前記モジュール内部の温度が、前記プロファイル間で、前記モジュールの下に通気空間を設けることによって、85℃以下に制御される、請求項16に記載のシステム。
- 前記熱可塑性接着剤層(5)が、少なくとも50g/m2のハロゲン化難燃剤、好ましくは少なくとも100g/m2の臭素化難燃剤を含む、請求項3に記載の集積化光起電力モジュール(110)。
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EP (1) | EP2250679A2 (ja) |
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WO2009095274A3 (en) | 2010-02-25 |
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AU2009210217A2 (en) | 2010-09-16 |
WO2009095274A2 (en) | 2009-08-06 |
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