JP2017504203A - 光モジュール用封止材、その製造方法及び光モジュール - Google Patents
光モジュール用封止材、その製造方法及び光モジュール Download PDFInfo
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- JP2017504203A JP2017504203A JP2016543005A JP2016543005A JP2017504203A JP 2017504203 A JP2017504203 A JP 2017504203A JP 2016543005 A JP2016543005 A JP 2016543005A JP 2016543005 A JP2016543005 A JP 2016543005A JP 2017504203 A JP2017504203 A JP 2017504203A
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- sealing material
- ethylene
- olefin copolymer
- silane
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- 229920000089 Cyclic olefin copolymer Polymers 0.000 claims description 79
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- 239000005977 Ethylene Substances 0.000 claims description 55
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- 229920003002 synthetic resin Polymers 0.000 claims description 34
- 125000000816 ethylene group Chemical group [H]C([H])([*:1])C([H])([H])[*:2] 0.000 claims description 31
- 239000011521 glass Substances 0.000 claims description 29
- 238000002844 melting Methods 0.000 claims description 26
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- 125000003710 aryl alkyl group Chemical group 0.000 claims description 14
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 claims description 14
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- 125000002252 acyl group Chemical group 0.000 claims description 12
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- 150000002367 halogens Chemical class 0.000 claims description 8
- 125000004435 hydrogen atom Chemical class [H]* 0.000 claims description 8
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- 125000004423 acyloxy group Chemical group 0.000 claims description 5
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Classifications
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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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- H01L31/048—Encapsulation of modules
- H01L31/0481—Encapsulation of modules characterised by the composition of the encapsulation material
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- C08F255/00—Macromolecular compounds obtained by polymerising monomers on to polymers of hydrocarbons as defined in group C08F10/00
- C08F255/02—Macromolecular compounds obtained by polymerising monomers on to polymers of hydrocarbons as defined in group C08F10/00 on to polymers of olefins having two or three carbon atoms
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- C08F255/08—Macromolecular compounds obtained by polymerising monomers on to polymers of hydrocarbons as defined in group C08F10/00 on to polymers of olefins having four or more carbon atoms
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- C08L23/04—Homopolymers or copolymers of ethene
- C08L23/06—Polyethene
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- C08L23/0807—Copolymers of ethene with unsaturated hydrocarbons only containing more than three carbon atoms
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- C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
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- C09D123/00—Coating compositions based on homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Coating compositions based on derivatives of such polymers
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- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
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- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
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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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Abstract
Description
前記前面及び後面封止材層2a、2bを構成する封止材(Encapsulant)としては、通常、エチレン−ビニルアセテート共重合体(ethylene vinylacetate,EVA)が使用される。エチレン−ビニルアセテート共重合体は、加工性、製造費用及び透明性などのような物性において有利な側面があり、従来、多く利用されてきた。
具体的に、本出願は、改善した接着性を示し、特に低い融点(Tm)による耐熱脆弱性に起因して長時間使用時に、太陽電池モジュール内の剥離現象を防止することができると同時に、透明性まで優れた光モジュール用封止材、その製造方法及び光モジュールを提供しようとする。
1つの例示で、前記封止材は、1)エチレン/α(アルファ)−オレフィン系共重合体、2)シラン変性エチレン/α−オレフィン系共重合体及び3)耐熱高分子樹脂を含むことができる。
1)エチレン/α−オレフィン系共重合体
本出願の前記エチレン/α−オレフィン系共重合体は、エチレンとα−オレフィンが重合された共重合体なら、特に制限されずに使用され得る。
また、前記エチレン/α−オレフィン共重合体は、溶融指数(melting index,MI)が190℃の温度及び2.16kgの荷重の下で、約1.0g/10分〜50.0g/10分、約1.0g/10分〜30.0g/10分、約1.0g/10分〜10.0g/10分、約1.0g/10分〜8.0g/10分または約3.0g/10分〜7.0g/10分であることができる。前記エチレン/α−オレフィン共重合体の溶融指数(MI)を前述した範囲に調節し、封止材に製造するとき、優れた成形性などを示すことができる。
本出願の前記シラン変性エチレン/α−オレフィン系共重合体は、エチレン/α−オレフィン系共重合体のシラン変性共重合体であることができる。
1つの例示で、前記シラン化合物は、下記化学式1で表示される化合物から選択され得る。
DSiR1 pR2 (3−p)
1つの例示で、前記シラン化合物は、下記化学式2で表示される化合物を含むことができる。
SiR5 qR6 (4−q)
前記アミノシラン化合物としては、例えばアミノプロピルトリメトキシシラン、アミノプロピルトリエトキシシラン、ビス[(3−トリエトキシシリル)プロピル]アミン、ビス[(3−トリメトキシシリル)プロピル]アミン、アミノプロピルメチルジエトキシシラン、アミノプロピルメチルジメトキシシラン、N−[3−(トリメトキシシリル)プロピル]エチレンジアミン、アミノエチルアミノプロピルトリエトキシシラン、アミノエチルアミノプロピルメチルジメトキシシラン、アミノエチルアミノプロピルメチルジエトキシシラン、アミノエチルアミノメチルトリエトキシシラン、アミノエチルアミノメチルメチルジエトキシシラン、ジエチレントリアミノプロピルトリメトキシシラン、ジエチレントリアミノプロピルトリエトキシシラン、ジエチレントリアミノプロピルメチルジメトキシシラン、ジエチレンアミノメチルメチルジエトキシシラン、(N−フェニルアミノ)メチルトリメトキシシラン、(N−フェニルアミノ)メチルトリエトキシシラン、(N−フェニルアミノ)メチルメチルジメトキシシラン、(N−フェニルアミノ)メチルメチルジエトキシシラン、3−(N−フェニルアミノ)プロピルトリメトキシシラン、3−(N−フェニルアミノ)プロピルトリエトキシシラン、3−(N−フェニルアミノ)プロピルメチルジメトキシシラン、3−(N−フェニルアミノ)プロピルメチルジエトキシシラン、N−(N−ブチル)−3−アミノプロピルトリメトキシシラン、グリシドキシプロピルトリメトキシシラン及びグリシドキシプロピルトリエトキシシランよりなる群から選択された1種以上を使用することができる。
−SiR12R13R14
−SiR25 rR26 (3−r)
R25及びR26は、それぞれ独立に、ハロゲン、アミン基、−R27R28または−R28であり、前記R27は、酸素(O)または硫黄(S)原子であり、前記R28は、水素、アルキル基、アリール基、アラルキル基またはアシル基であり、
rは、1〜3の整数である。
前記シラン変性エチレン/α−オレフィン系共重合体を構成する主鎖は、エチレン/α−オレフィン系共重合体であって、これは、前述した通りである。
本出願による封止材は、前述したエチレン/α−オレフィン系共重合体及びシラン変性エチレン/α−オレフィン系共重合体以外に耐熱高分子樹脂を含むことができる。
前記耐熱高分子樹脂の含量を前述した範囲内で調節して、封止材シートへの適用時に、クリープ特性の改善と同時に優れた透明性を確保することができる。
本出願の封止材は、前述した3つの成分を含み、選択的に他の樹脂成分や添加剤をさらに含むことができる。
1つの例示で、本出願の封止材は、下記一般式1を満足することができる。
△X≦3mm
図2を参照すれば、厚さが3.2mmであり、横20cm×縦30cmである第1ガラス板G1と;厚さが3.2mmであり、横20cm×縦30cmである第2ガラス板G2を準備する。この場合、前記ガラス板G1及びG2は、鉄含量が低い低鉄分強化ガラス板を使用することが好ましく、前記第1ガラス板G1及び第2ガラス板G2は、それぞれ約465g〜480gの重量を有することができる。
Y≦9%
例示的な前記封止材製造方法は、前述した成分を含む樹脂組成物からシート(sheet)形状で製造する段階を含む限り、特に制限されない。
例示的な光モジュールは、前述した封止材を含むものなら、特に制限されない。
図3に示されたように、本出願による例示的な光モジュールは、前面基板210、封止材層220、太陽電池セルC及びバックシート100を含む。
1.クリープ(Creep)特性測定及び評価
1)ガラス板及び封止材シート:厚さが3.2mmであり、サイズが20cm×30cm(横×縦)である2個の低鉄分強化ガラス板(重量475g)を準備した。また、前記各実施例及び比較例による封止材シート(厚さ:約500μm)を20cm×25cm(横×縦)のサイズに切断した。
○:ずれた距離を左側、中央及び右側でそれぞれ測定して平均した値(△X)が3mm以下の場合
×:ずれた距離を左側、中央及び右側でそれぞれ測定して平均した値(△X)が3mm以上の場合
各実施例及び比較例による封止材シートを横5cm×7cm(横×縦)のサイズに裁断した後、これを横5cm×7cm(横×縦)のサイズの低鉄分強化ガラスの間に挟持した後、150℃でラミネーションして製造した試験片に対して、ヘイズメーター(Hazemeter,Murakami社製),HM−150)を利用して通常的な方法で測定した電光線透過率(Total transmittance,Tt)及びヘイズ(Haze)値を測定した後、前記電光線透過率の値及び前記ヘイズ値の下記基準による評価を表2に示した。
○:測定されたヘイズの値が9%以上の場合
×:測定されたヘイズの値が9%以下の場合
〈シラン変性エチレン/α−オレフィン共重合体の製造〉
ビニルトリメトキシシラン(vinyltrimethoxysilane,VTMS)及びLuperox(登録商標)101(2,5−ビス(t−ブチルペルオキシ)−2,5−ジメチルヘキサン(2,5−Bis(tert−butylperoxy)−2,5−dimethylhexane)を50:1の重量比で混合した後、これを密度が0.870g/cm3であり、溶融指数(MI)が190℃、2.16kgの荷重の下で5g/10分のエチレン/1−オクテン共重合体(LC670、LG化学社製)100重量部に対して5重量部で二軸押出器(Twin screw extruder)に一緒に投入し、220℃の温度でグラフティング反応押出(加熱溶融撹拌)して、シラン変性エチレン/α−オレフィン共重合体のマスターバッチ(以下、「Si M/B」という)を製造した。
密度が0.870g/cm3であり、融点(Tm)が58℃であり、溶融指数(MI)が190℃、2.16kgの荷重の下で5g/10分のエチレン/1−オクテン共重合体(LC670,LG化学社製、以下、「ベース樹脂」という)に、UV吸収剤、UV安定剤及び酸化防止剤を一定量混合及び押出して、UVマスターバッチ(以下、「UV M/B」という)を製造した。
ベース樹脂及びSi M/Bを混合した混合物100重量部に対してLDPEを1重量部で含むことを除いて、前記実施例1と同一の方式で封止材シートを製造した。
耐熱高分子樹脂として融点(Tm)が約105℃であり、溶融指数(MI)が190℃、2.16kgの荷重の下で0.3g/10分のLDPE(BF0300、LG化学社製)を含むことを除いて、前記実施例1と同一の方式で封止材シートを製造した。
耐熱高分子樹脂として融点(Tm)が約105℃であり、溶融指数(MI)が190℃、2.16kgの荷重の下で8.5g/10分のLDPE(LB8500、LG化学社製)を含むことを除いて、前記実施例1と同一の方式で封止材シートを製造した。
耐熱高分子樹脂として融点(Tm)が約105℃であり、溶融指数(MI)が190℃、2.16kgの荷重の下で24g/10分のLDPE(MB9205,LG化学社製)を含むことを除いて、前記実施例1と同一の方式で封止材シートを製造した。
押出成形器のホッパーにLDPEを添加せずに、ベース樹脂、Si M/B及びUV M/Bを63.1:34:2.9の重量比率で混合した混合物を使用したことを除いて、前記実施例1と同一の方式で封止材シートを製造した。
ベース樹脂及びSiM/Bを混合した混合物100重量部に対してLDPEを3重量部で含むことを除いて、前記実施例1と同一の方式で封止材シートを製造した。
ベース樹脂及びSiM/Bを混合した混合物100重量部に対してLDPEを5重量部で含むことを除いて、前記実施例1と同一の方式で封止材シートを製造した。
耐熱高分子樹脂として融点(Tm)が約105℃であり、溶融指数(MI)が190℃、2.16kgの荷重の下で50g/10分のLDPE(MB9500,LG化学社製)を含むことを除いて、前記実施例1と同一の方式で封止材シートを製造した。
2a,221 前面封止材層
2b,222 後面封止材層
3 強化ガラス
10 基材
20,30 表面層
210 前面基板
220 封止材層
C 太陽電池セル
Claims (19)
- エチレン/α−オレフィン系共重合体と、
シラン変性エチレン/α−オレフィン系共重合体と、
前記エチレン/α−オレフィン系重合体より融点(Tm)が高い耐熱高分子樹脂とを含み、
前記耐熱高分子樹脂は、エチレン/α−オレフィン系共重合体とシラン変性エチレン/α−オレフィン系共重合体の混合100重量部に対して0.01重量部以上〜3重量部未満の範囲内で含まれる、光モジュール用封止材。 - 耐熱高分子樹脂は、エチレン/α−オレフィン系共重合体とシラン変性エチレン/α−オレフィン系共重合体の混合100重量部に対して1重量部〜2重量部の範囲内で含まれる、請求項1に記載の光モジュール用封止材。
- 耐熱高分子樹脂は、融点(Tm)が100℃以上である、請求項1に記載の光モジュール用封止材。
- 耐熱高分子樹脂は、融点(Tm)が100℃〜150℃の範囲内である、請求項1に記載の光モジュール用封止材。
- 耐熱高分子樹脂は、エチレン/α−オレフィン共重合体より低い溶融指数(MI)を有する、請求項1に記載の光モジュール用封止材。
- 耐熱高分子樹脂は、190℃の温度及び2.16kg荷重での溶融指数(MI)が0.1g/10分〜40g/10分以下の範囲内である、請求項1に記載の光モジュール用封止材。
- 耐熱高分子樹脂は、ポリエチレン系樹脂及び/またはポリプロピレン系樹脂である、請求項1に記載の光モジュール用封止材。
- 耐熱高分子樹脂は、低密度ポリエチレンを含む、請求項1に記載の光モジュール用封止材。
- 下記一般式1を満足する、請求項1に記載の光モジュール用封止材:
[一般式1]
△X≦3mm
前記一般式1で、△Xは、厚さ3.2mmの第1ガラス板(横20cm×縦30cm)と厚さ3.2mmの第2ガラス板(横20cm×縦30cm)との間に封止材(横20cm×縦25cm)を2枚重なって入れ、ラミネーションして20cm×35cm(横×縦)のサイズの試験片を製造した後、前記試験片を垂直(90゜)に立設し、第1ガラス板をつるして固定し、100℃で10時間維持した後、第2ガラス板の左側、中央及び右側が垂直方向にずれた距離の平均値である。 - 下記一般式2を満足する、請求項1に記載の光モジュール用封止材:
[一般式2]
Y≦9%
前記一般式2で、Yは、前記封止材を5cm×7cm(横×縦)のサイズに裁断した後、これを5cm×7cm(横×縦)のサイズの低鉄分強化ガラスに挟持した後、150℃でラミネーションして製造した試験片をヘイズメーターを使用して測定したヘイズを示す。 - シラン変性エチレン/α−オレフィン系共重合体は、エチレン/α−オレフィン系共重合体にシラン化合物がグラフト重合されたものである、請求項1に記載の光モジュール用封止材。
- シラン化合物は、不飽和シラン化合物及び/またはアミノシラン化合物を含む、請求項11に記載の光モジュール用封止材。
- シラン化合物は、下記化学式1で表示される化合物を含む、請求項11に記載の光モジュール用封止材:
[化学式1]
DSiR1 pR2 (3−p)
前記化学式1で、Dは、アルケニルであり、R1は、アルコキシ基、アルキルチオ基、アリールオキシ基、アシルオキシ基、ヒドロキシ基、ハロゲン基、アミン基または−R3R4であり、前記R3は、酸素(O)または硫黄(S)原子であり、R4は、アルキル基、アリール基またはアシル基であり、
R2は、水素、アルキル基、アリール基またはアラルキル基であり、
pは、1〜3の整数である。 - 前記シラン化合物は、下記化学式2で表示される化合物を含む、請求項11に記載の光モジュール用封止材:
[化学式2]
SiR5 qR6 (4−q)
前記化学式2で、
R5は、−CH2)vNR7R8であり、R7及びR8は、それぞれ独立に、窒素原子に結合された水素またはR9NH2であり、前記R9は、炭素数1〜6のアルキレンであり、
R6は、ハロゲン、アミン基、−R10R11または−R11であり、前記R10は、酸素(O)または硫黄(S)原子であり、R11は、水素、アルキル基、アリール基、アラルキル基またはアシル基であり、
qは、1〜4の整数である。 - 前記シラン変性エチレン/α−オレフィン系共重合体は、オレフィン系単量体の重合単位を含む主鎖及び前記主鎖に結合された分岐鎖を含み、
前記分岐鎖は、下記化学式3で表示される化合物を含む、請求項11に記載の光モジュール用封止材:
[化学式3]
−SiR12R13R14
前記化学式3で、
R12及びR13は、それぞれ独立に、ハロゲン、アミン基、−R15R16または−R16であり、前記R15は、酸素(O)または硫黄(S)原子であり、前記R16は、水素、アルキル基、アリール基、アラルキル基またはアシル基であり、
R14は、−OSiR17 mR18 (2−m)R19であり、前記R17及びR18は、それぞれ独立に、ハロゲン、アミン基、−R20R21または−R21であり、前記R20は、酸素(O)または硫黄(S)原子であり、前記R21は、水素、アルキル基、アリール基、アラルキル基またはアシル基であり、前記R19は、−(CH2)nNR22R23であり、前記R22及びR23は、それぞれ独立に、窒素原子に結合された水素またはR24NH2であり、前記R24は、アルキレンであり、前記mは、1または2の整数であり、前記nは、1以上の整数である。 - 前記シラン変性エチレン/α−オレフィン系共重合体は、オレフィン系単量体の重合単位を含む主鎖及び前記主鎖に結合された分岐鎖を含み、
前記分岐鎖は、下記化学式4で表示される化合物を含む、請求項11に記載の光モジュール用封止材:
[化学式4]
−SiR25 rR26 (3−r)
前記化学式4で、
R25及びR26は、それぞれ独立に、ハロゲン、アミン基、−R27R28または−R28であり、前記R27は、酸素(O)または硫黄(S)原子であり、前記R28は、水素、アルキル基、アリール基、アラルキル基またはアシル基であり、
rは、1〜3の整数である。 - エチレン/α−オレフィン系共重合体、シラン変性エチレン/α−オレフィン系共重合体及び前記エチレン/α−オレフィン系重合体より融点が高い耐熱高分子樹脂を含む樹脂組成物をシート形状に製造する段階を含む光モジュール用封止材の製造方法。
- 請求項1〜16のいずれかに記載の封止材を含む光モジュール。
- 前記光モジュールは、
前面基板と、
前記前面基板上に形成された封止材層と、
前記封止材層に封止された太陽電池セルと、
前記封止材層上に形成されたバックシートとを含む、請求項18に記載の光モジュール。
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JP6222507B2 (ja) | 2017-11-01 |
JP6296314B2 (ja) | 2018-03-20 |
KR101692610B1 (ko) | 2017-01-03 |
TWI550006B (zh) | 2016-09-21 |
TW201542655A (zh) | 2015-11-16 |
JP2017504200A (ja) | 2017-02-02 |
US20160336469A1 (en) | 2016-11-17 |
EP3112415A1 (en) | 2017-01-04 |
EP3112414A4 (en) | 2017-10-04 |
EP3112415B1 (en) | 2020-09-30 |
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