JP2015525472A - 親環境光電池モジュール用バックシート及びその製造方法 - Google Patents
親環境光電池モジュール用バックシート及びその製造方法 Download PDFInfo
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- JP2015525472A JP2015525472A JP2015514929A JP2015514929A JP2015525472A JP 2015525472 A JP2015525472 A JP 2015525472A JP 2015514929 A JP2015514929 A JP 2015514929A JP 2015514929 A JP2015514929 A JP 2015514929A JP 2015525472 A JP2015525472 A JP 2015525472A
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- 230000006872 improvement Effects 0.000 description 1
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- 229910001862 magnesium hydroxide Inorganic materials 0.000 description 1
- 239000000395 magnesium oxide Substances 0.000 description 1
- CPLXHLVBOLITMK-UHFFFAOYSA-N magnesium oxide Inorganic materials [Mg]=O CPLXHLVBOLITMK-UHFFFAOYSA-N 0.000 description 1
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- 239000004137 magnesium phosphate Substances 0.000 description 1
- 229910000157 magnesium phosphate Inorganic materials 0.000 description 1
- 229960002261 magnesium phosphate Drugs 0.000 description 1
- 235000010994 magnesium phosphates Nutrition 0.000 description 1
- AXZKOIWUVFPNLO-UHFFFAOYSA-N magnesium;oxygen(2-) Chemical compound [O-2].[Mg+2] AXZKOIWUVFPNLO-UHFFFAOYSA-N 0.000 description 1
- 229910052751 metal Inorganic materials 0.000 description 1
- 239000002184 metal Chemical class 0.000 description 1
- 229920000609 methyl cellulose Polymers 0.000 description 1
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- 235000010981 methylcellulose Nutrition 0.000 description 1
- 229920003087 methylethyl cellulose Polymers 0.000 description 1
- 229910021424 microcrystalline silicon Inorganic materials 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 229910021421 monocrystalline silicon Inorganic materials 0.000 description 1
- 239000012860 organic pigment Substances 0.000 description 1
- 239000010815 organic waste Substances 0.000 description 1
- 235000021317 phosphate Nutrition 0.000 description 1
- 150000003013 phosphoric acid derivatives Chemical class 0.000 description 1
- 229920005668 polycarbonate resin Polymers 0.000 description 1
- 239000004431 polycarbonate resin Substances 0.000 description 1
- 238000012643 polycondensation polymerization Methods 0.000 description 1
- 230000000379 polymerizing effect Effects 0.000 description 1
- 229920002223 polystyrene Polymers 0.000 description 1
- 229920002451 polyvinyl alcohol Polymers 0.000 description 1
- 235000019422 polyvinyl alcohol Nutrition 0.000 description 1
- 229920000036 polyvinylpyrrolidone Polymers 0.000 description 1
- 239000001267 polyvinylpyrrolidone Substances 0.000 description 1
- 235000013855 polyvinylpyrrolidone Nutrition 0.000 description 1
- USHAGKDGDHPEEY-UHFFFAOYSA-L potassium persulfate Chemical compound [K+].[K+].[O-]S(=O)(=O)OOS([O-])(=O)=O USHAGKDGDHPEEY-UHFFFAOYSA-L 0.000 description 1
- 239000000843 powder Substances 0.000 description 1
- 238000010248 power generation Methods 0.000 description 1
- 239000000047 product Substances 0.000 description 1
- 125000001453 quaternary ammonium group Chemical group 0.000 description 1
- 150000003839 salts Chemical class 0.000 description 1
- 238000000646 scanning calorimetry Methods 0.000 description 1
- 229910052710 silicon Inorganic materials 0.000 description 1
- 239000010703 silicon Substances 0.000 description 1
- 229910052814 silicon oxide Inorganic materials 0.000 description 1
- 239000002356 single layer Substances 0.000 description 1
- 239000011734 sodium Substances 0.000 description 1
- 235000019333 sodium laurylsulphate Nutrition 0.000 description 1
- 238000003756 stirring Methods 0.000 description 1
- VEALVRVVWBQVSL-UHFFFAOYSA-N strontium titanate Chemical compound [Sr+2].[O-][Ti]([O-])=O VEALVRVVWBQVSL-UHFFFAOYSA-N 0.000 description 1
- XGFPOHQJFNFBKA-UHFFFAOYSA-B tetraaluminum;phosphonato phosphate Chemical compound [Al+3].[Al+3].[Al+3].[Al+3].[O-]P([O-])(=O)OP([O-])([O-])=O.[O-]P([O-])(=O)OP([O-])([O-])=O.[O-]P([O-])(=O)OP([O-])([O-])=O XGFPOHQJFNFBKA-UHFFFAOYSA-B 0.000 description 1
- UIERETOOQGIECD-ONEGZZNKSA-N tiglic acid Chemical compound C\C=C(/C)C(O)=O UIERETOOQGIECD-ONEGZZNKSA-N 0.000 description 1
- 238000002834 transmittance Methods 0.000 description 1
- QORWJWZARLRLPR-UHFFFAOYSA-H tricalcium bis(phosphate) Chemical compound [Ca+2].[Ca+2].[Ca+2].[O-]P([O-])([O-])=O.[O-]P([O-])([O-])=O QORWJWZARLRLPR-UHFFFAOYSA-H 0.000 description 1
- 238000002211 ultraviolet spectrum Methods 0.000 description 1
- 239000000326 ultraviolet stabilizing agent Substances 0.000 description 1
- 229920003169 water-soluble polymer Polymers 0.000 description 1
- 238000004383 yellowing Methods 0.000 description 1
- 239000011787 zinc oxide Substances 0.000 description 1
- LRXTYHSAJDENHV-UHFFFAOYSA-H zinc phosphate Chemical compound [Zn+2].[Zn+2].[Zn+2].[O-]P([O-])([O-])=O.[O-]P([O-])([O-])=O LRXTYHSAJDENHV-UHFFFAOYSA-H 0.000 description 1
- 229910000165 zinc phosphate Inorganic materials 0.000 description 1
- OMSYGYSPFZQFFP-UHFFFAOYSA-J zinc pyrophosphate Chemical compound [Zn+2].[Zn+2].[O-]P([O-])(=O)OP([O-])([O-])=O OMSYGYSPFZQFFP-UHFFFAOYSA-J 0.000 description 1
- 229910052984 zinc sulfide Inorganic materials 0.000 description 1
- DRDVZXDWVBGGMH-UHFFFAOYSA-N zinc;sulfide Chemical compound [S-2].[Zn+2] DRDVZXDWVBGGMH-UHFFFAOYSA-N 0.000 description 1
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- H01L31/04—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof adapted as photovoltaic [PV] conversion devices
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- C09D127/00—Coating compositions based on homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by a halogen; Coating compositions based on derivatives of such polymers
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Abstract
Description
以下、本発明による実施例及び本発明によらない比較例を通じて本発明をより詳しく説明するが、本発明の範囲が下記提示された実施例によって制限されるのではない。
水分散組成物の製造
水にエマルジョン形態で分散したポリビニリデンフルオライド樹脂(固形分20%)500gに、水分散バインダーとしてアクリル変性ポリエステル樹脂(ポリエチレンテレフタレート(PET)、グリシジルメタクリレート(GMA)、メチルメタクリレート(MMA)及びメチルメタクリル酸(MAA)共重合体の水分散液、モル比は、1:0.5:1:0.2、水分散時のMAAのカウンターイオンは、Na+使用、固形分30%)20g、架橋剤としてオキサゾリン基含有アクリル系共重合体(WS−500、固形分40%、日本触媒社製)5g及び顔料である二酸化チタン(Tipure TS6200、デュポン社製)50gを添加した後、撹拌器を利用して分散させて水分散組成物を製造した。
充分に乾燥させたポリエチレンテレフタレートチップを溶融押出器に注入した後、溶融押出されたポリエチレンテレフタレートをT−ダイを利用して厚さ2500μmの無延伸ポリエチレンテレフタレートフィルムを収得した後、100℃で機械方向に3.5倍延伸し、1軸延伸ポリエステルフィルムを製造した。上記製造された1軸延伸ポリエステルフィルムにコロナ放電処理を行った後、その上部に先立ってあらかじめ製造した水分散組成物をメイヤバーを利用して厚さ16μmで塗布した後、180℃で予熱乾燥過程を進行した後、横方向に3.5倍延伸し、二軸延伸ポリエステルフィルムを製造した。その後、240℃で10秒間熱処理を行い、200℃で機械方向及び横方向に10%弛緩させて、フッ素系高分子を含む厚さ2μmの樹脂層がコーティングされた厚さ300μmの光電池モジュール用バックシートを製造した。
上記実施例1で水分散組成物の製造時に架橋剤としてオキサゾリン基含有アクリル系共重合体の代わりに、ヘキサメトキシメラミン(Hexamethoxymelamine、Cyme1303、CYTEC社製)5gを使用したことを除いて実施例1と同一に実施し、光電池モジュール用バックシートを製造した。
上記実施例1で水分散組成物の製造時に架橋剤としてオキサゾリン基含有アクリル系共重合体の代わりにエポキシ樹脂(Denacol EX614B、ナガセケムテックス社製)5gを使用したことを除いて実施例1と同一に実施し、光電池モジュール用バックシートを製造した。
上記実施例1で水分散組成物の製造時に架橋剤としてオキサゾリン基含有アクリル系共重合体の代わりにカルボジイミド(Carbodilite V02−L2、Nisshinbochemical社製)5gを使用したことを除いて実施例1と同一に実施し、光電池モジュール用バックシートを製造した。
上記実施例1で水分散組成物の製造時に架橋剤であるオキサゾリン基含有アクリル系共重合体を使用しないことを除いて実施例1と同一に実施し、光電池モジュール用バックシートを製造した。
上記実施例1で水分散バインダーとして実施例1で使用したアクリル変性ポリエステル樹脂の代わりにアクリル樹脂(アクリロニトリル(AN)、メチルメタクリレート(MMA)、スチレン(ST)、ブチルアクリレート(BA)及びアルファ−メチルスチレン(AMST)の共重合体、15:5:28:50:2の重量比)を使用したことを除いて実施例1と同一に実施し、光電池モジュール用バックシートを製造した。
上記実施例1で水分散バインダーとして実施例1で使用したアクリル変性ポリエステル樹脂の代わりにウレタン樹脂(Takelac WS−5300、三井化学)を使用したことを除いて実施例1と同一に実施し、光電池モジュール用バックシートを製造した。
上記実施例1で水分散バインダーとして実施例1で使用したアクリル変性ポリエステル樹脂の代わりにシリコン系ウレタン樹脂(Takelac WS−5000、三井化学)を使用したことを除いて実施例1と同一に実施し、光電池モジュール用バックシートを製造した。
上記実施例1で水分散組成物の製造時に水にエマルジョン形態で分散したポリビニリデンフルオライド樹脂の代わりに結晶化度22%のビニリデンフルオライド(VDF;Vinylidene fluoride)及びヘキサフルオロプロピレン(HFP;Hexafluoropropylene)を85:15(VDF:HFP)の重量比率で重合された形態で含む共重合体を使用したことを除いて実施例1と同一に実施し、光電池モジュール用バックシートを製造した。
上記実施例1で水分散組成物の製造時に水にエマルジョン形態で分散したポリビニリデンフルオライド樹脂の代わりに結晶化度25%のビニリデンフルオライド(VDF;Vinylidene fluoride)及びクロロトリフルオルエチレン(CTFE;Chlorotrifluoroethylene)を85:15(VDF:CTFE)の重量比率で重合された形態で含む共重合体を使用したことを除いて実施例1と同一に実施し、光電池モジュール用バックシートを製造した。
上記実施例1の水分散組成物の代わりに、熱硬化性フッ素樹脂としてテトラフルオロエチレン(TFE)とヒドロキシ基が置換されたエチレンの共重合体であるZeffle GK−570(ダイキン社、固形分60%、60mgKOH/g)100重量部に、架橋剤としてイソホロンジイソシアネート25.1重量部(Zeffle GK−570内のOHと架橋剤のNCOの当量比=1:1)及び顔料として二酸化チタン(TiPure TS6200、デュポン社)60重量部を添加した後、さらにメチルエチルケトン10重量部を添加した後、充分に撹拌し、フッ素樹脂層形成用コーティング液を製造した。
商業的に販売されているTedlarフィルム/接着剤/PETフィルム/接着剤/Tedlarフィルムの積層構造体を多層フィルムとして使用した。上記積層構造体は、押出工程で製造されたデュポン社のTedlarフィルム(PVFフィルム、厚さ38μm)を接着剤を利用してPETフィルムの両面にラミネーションした製品である。
上記実施例1の水分散組成物の製造時に使用された水にエマルジョン形態で分散したポリビニリデンフルオライド樹脂の代わりに下記のようなエマルジョン形態のヒドロキシ基で官能化されたアクリル変性フッ素系高分子500g(固形分20%)を使用したことを除いて実施例1と同一の方法で光電池モジュール用バックシートを製造した。
1L高圧反応器で蒸留水400gに15%アンモニウムペルフルオロオクタノエート溶液5gを添加した後、VDF(ビニリデンフルオライド)70gと2−HEMA(2−ヒドロキシエチルメタクリル酸)30gを添加した後、反応器の温度を80℃に維持させた後、0.5%のカリウムペルサルフェート溶液1gを添加し、ヒドロキシ基で官能化されたアクリル変性フッ素系高分子を製造した。
クロスカット試験基準であるASTM D3002/D3359の規格に準拠して、クロスカットテストを行った。具体的に、試験片を1mmの間隔で横及び縦方向にそれぞれ11ラインずつ刀で引いて横及び縦がそれぞれ1mmである100個の正四角形格子を形成した。その後、Nichiban社のCT−24接着テープを上記カット面に付着した後、引き離すとき、一緒に脱離する面の状態を測定し、下記基準で評価した。
<クロス−ハッチ接着力評価基準>
5B:脱離した面がない場合
4B:脱離した面が全体面積に対して5%未満の場合
3B:脱離した面が全体面積に対して5%〜15%の場合
2B:脱離した面が全体面積に対して15%超過35%以下の場合
1B:脱離した面が全体面積に対して35%超過65%以下の場合
0B:脱離した面が全体面積に対して65%超過の場合
実施例及び比較例で製造された光電池モジュール用バックシートを2気圧、121℃及び100%R.H.の条件が維持されるオーブンに25時間、50時間及び75時間放置した後、上記クロス−ハッチ接着力の測定方法と同一に接着力の変化を観察した。
実施例1及び比較例2で製造された光電池モジュール用バックシートをShimadzu UV Visspectrometer(UV−3600)を利用して200〜800nm波長領域帯の反射率を測定し、図4に示す。
11 フッ素系樹脂層
12 基材
20 ウェハ系光電池モジュール
30 薄膜型光電池モジュール
21、31 受光シート
22、32 封止材層
22a 第1層
22b 第2層
23、33 光電池モジュール用バックシート
24、34 光電池素子
Claims (31)
- 結晶性フッ素系高分子がインラインコーティング工程によって基材の上にコーティングされる樹脂層を含み、
2気圧、121℃及び100%R.H.の条件が維持されるオーブンに75時間放置した後、ASTM D3002/D3359の規格に準拠して、クロスカットテストによって測定した接着力が4B以上である光電池モジュール用バックシート。 - 前記フッ素系高分子は、結晶化度が10〜55%の結晶性高分子であり、非官能性高分子(non−functionalized polymer)である、請求項1に記載の光電池モジュール用バックシート。
- 前記樹脂層は、結晶性フッ素系高分子、顔料、水分散バインダー及び水を含む水分散組成物をインラインコーティング工程によって基材の上にコーティングして形成される、請求項1に記載の光電池モジュール用バックシート。
- 前記フッ素系高分子は、ビニリデンフルオライド(VDF、Vinylidene Fluoride)、ビニルフルオライド(VF、Vinyl Fluoride)、テトラフルオロエチレン(TFE、Tetrafluoroethylene)、ヘキサフルオロプロピレン(HFP、Hexafluoropropylene)、クロロトリフルオロエチレン(CTFE、chlorotrifluoroethylene)、トリフルオロエチレン、ヘキサフルオロイソブチレン、ペルフルオロブチルエチレン、ペルフルオロメチルビニルエーテル(PMVE、perfluoro(methylvinylether))、ペルフルオロエチルビニルエーテル(PEVE、perfluoro(ethylvinylether))、ペルフルオロプロピルビニルエーテル(PPVE)、ペルフルオロヘキシルビニルエーテル(PHVE)、ペルフルオロ−2,2−ジメチル−1,3−ジオキソル(PDD)及びペルフルオロ−2−メチレン−4−メチル−1,3−ジオキソラン(PMD)よりなる群から選択された1つ以上の単量体を重合された形態で含む単独重合体、共重合体またはこれらの混合物である、請求項2に記載の光電池モジュール用バックシート。
- 前記フッ素系高分子は、ビニリデンフルオライド(VDF)またはビニルフルオライド(VF)とテトラフルオロエチレン(TFE、Tetrafluoroethylene)、ヘキサフルオロプロピレン(HFP、Hexafluoropropylene)、クロロトリフルオロエチレン(CTFE、chlorotrifluoroethylene)、トリフルオロエチレン、ヘキサフルオロイソブチレン、ペルフルオロブチルエチレン、ペルフルオロメチルビニルエーテル(PMVE、perfluoro(methylvinylether))、ペルフルオロエチルビニルエーテル(PEVE、perfluoro(ethylvinylether))、ペルフルオロプロピルビニルエーテル(PPVE)、ペルフルオロヘキシルビニルエーテル(PHVE)、ペルフルオロ−2,2−ジメチル−1,3−ジオキソル(PDD)及びペルフルオロ−2−メチレン−4−メチル−1,3−ジオキソラン(PMD)よりなる群から選択された1つ以上の共単量体を含む共重合体またはこれらの混合物である、請求項2に記載の光電池モジュール用バックシート。
- 前記共重合体に含まれた共単量体の含量は、全体共重合体の全体重量に対して0.5重量%〜50重量%である、請求項5に記載の光電池モジュール用バックシート。
- 前記フッ素系高分子の重量平均分子量は、5万〜100万である、請求項1に記載の光電池モジュール用バックシート。
- 前記フッ素系高分子の融点が80℃〜175℃である、請求項1に記載の光電池モジュール用バックシート。
- 前記フッ素系高分子の平均粒径が50μm以下である、請求項1に記載の光電池モジュール用バックシート。
- 前記顔料は、フッ素系高分子100重量部に対して1重量部〜200重量部で含まれる、請求項3に記載の光電池モジュール用バックシート。
- 前記水分散バインダーは、ポリウレタン樹脂、ポリアクリル樹脂、ポリウレア樹脂、ポリアミド樹脂、ポリオレフィン樹脂、ポリビニルアセテート樹脂、ポリエーテル樹脂、アルキド樹脂、ウレタン−アクリレート共重合体、ビニル−ウレタン共重合体、エチレン−ビニルアルコール共重合体、シリコン−アクリル−ウレタン共重合体、エチレン−ビニルアセテート共重合体及びアクリル変性ポリエステル樹脂よりなる群から選択される1つ以上である、請求項3に記載の光電池モジュール用バックシート。
- 前記水分散バインダーは、フッ素系高分子100重量部に対して0.1重量部〜50重量部で含まれる、請求項3に記載の光電池モジュール用バックシート。
- 前記水分散組成物が水分散バインダーの架橋剤をさらに含む、請求項3に記載の光電池モジュール用バックシート。
- 前記架橋剤は、イソシアネート系樹脂、オキサゾリン系樹脂、メラミン系樹脂、エポキシ系樹脂及びカルボジイミド系樹脂よりなる群から選択される1つ以上である、請求項13に記載の光電池モジュール用バックシート。
- 前記架橋剤は、フッ素系高分子100重量部に対して0.1重量部〜50重量部で含まれる、請求項13に記載の光電池モジュール用バックシート。
- 前記水は、フッ素系高分子100重量部に対して100重量部〜2,000重量部で含まれる、請求項3に記載の光電池モジュール用バックシート。
- 前記水分散組成物が界面活性剤をさらに含む、請求項3に記載の光電池モジュール用バックシート。
- 前記界面活性剤は、フッ素系高分子100重量部に対して0.1重量部〜100重量部で含まれる、請求項17に記載の光電池モジュール用バックシート。
- 前記樹脂層が前記基材の一面または両面に形成される、請求項1に記載の光電池モジュール用バックシート。
- 前記基材は、アクリルフィルム、ポリオレフィンフィルム、ポリアミドフィルム、ポリウレタンフィルム及びポリエステルフィルムよりなる群から選択された1つ以上の高分子フィルムである、請求項1に記載の光電池モジュール用バックシート。
- 前記ポリエステルフィルムは、ポリエチレンテレフタレート(PET)フィルム、ポリエチレンナフタレート(PEN)フィルム及びポリブチレンテレフタレート(PBT)フィルムよりなる群から選択される1つ以上である、請求項20に記載の光電池モジュール用バックシート。
- 前記基材の厚さは、50μm〜500μmである、請求項1に記載の光電池モジュール用バックシート。
- 前記樹脂層は、水分散組成物の溶融物を含む、請求項3に記載の光電池モジュール用バックシート。
- 前記樹脂層の厚さが0.5μm〜30μmである、請求項1に記載の光電池モジュール用バックシート。
- 前記基材の少なくとも一面にプラズマ、コロナ、プライマー、アンカー剤、カップリング剤処理及び熱処理のうち選択された1つ以上の表面処理が形成される、請求項1に記載の光電池モジュール用バックシート。
- 結晶性フッ素系高分子、顔料、水分散バインダー及び水を含む水分散組成物を基材の延伸工程で基材の一面または両面にコーティングし、加熱して樹脂層を形成する段階を含む、光電池モジュール用バックシートの製造方法。
- 前記基材の延伸工程は、二軸延伸工程で、基材を機械方向に延伸した後、前記水分散組成物をコーティングし、引き続いて横方向に延伸するものである、請求項26に記載の光電池モジュール用バックシートの製造方法。
- 前記基材の延伸工程は、二軸延伸工程で、前記水分散組成物を基材上にコーティングし、機械方向及び横方向に延伸するものである、請求項26に記載の光電池モジュール用バックシートの製造方法。
- 前記加熱温度は、150℃〜250℃である、請求項26に記載の光電池モジュール用バックシートの製造方法。
- 前記樹脂層を形成する前に基材の一面または両面にプラズマ処理、コロナ処理、プライマー処理、アンカー剤処理、カップリング剤処理、蒸着処理及び熱処理よりなる群から選択された1つ以上の表面処理を行う段階をさらに含む、請求項26に記載の光電池モジュール用バックシートの製造方法。
- 請求項1〜25のいずれかに記載の光電池モジュール用バックシートを含む光電池モジュール。
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WO2011139052A2 (ko) * | 2010-05-06 | 2011-11-10 | (주)Lg화학 | 다층 시트 및 이의 제조방법 |
JP2012104612A (ja) * | 2010-11-09 | 2012-05-31 | Fujifilm Corp | 太陽電池保護シート及びその製造方法、太陽電池用バックシート、並びに太陽電池モジュール |
WO2012064082A2 (ko) * | 2010-11-10 | 2012-05-18 | 주식회사 엘지화학 | 다층 필름 및 이를 포함하는 광전지 모듈 |
JP2012104763A (ja) * | 2010-11-12 | 2012-05-31 | Fujifilm Corp | 太陽電池用バックシート及びその製造方法、並びに太陽電池モジュール |
Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
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TWI603496B (zh) * | 2016-03-16 | 2017-10-21 | 台虹科技股份有限公司 | 光伏模組背板及光伏模組 |
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US20150083222A1 (en) | 2015-03-26 |
EP2858121B1 (en) | 2017-12-20 |
TWI482704B (zh) | 2015-05-01 |
KR20130135788A (ko) | 2013-12-11 |
WO2013180552A1 (ko) | 2013-12-05 |
TW201418011A (zh) | 2014-05-16 |
CN104335361B (zh) | 2016-08-17 |
EP2858121A1 (en) | 2015-04-08 |
EP2858121A4 (en) | 2016-01-13 |
JP6081581B2 (ja) | 2017-02-15 |
CN104335361A (zh) | 2015-02-04 |
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