JP4887551B2 - Solar cell back cover material sealing film and solar cell - Google Patents

Solar cell back cover material sealing film and solar cell Download PDF

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JP4887551B2
JP4887551B2 JP2000201202A JP2000201202A JP4887551B2 JP 4887551 B2 JP4887551 B2 JP 4887551B2 JP 2000201202 A JP2000201202 A JP 2000201202A JP 2000201202 A JP2000201202 A JP 2000201202A JP 4887551 B2 JP4887551 B2 JP 4887551B2
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film
solar cell
cover material
back cover
sealing film
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JP2002026346A (en
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映生 三浦
一嘉 阿久沢
泰大 森村
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Bridgestone Corp
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Priority to ES01936908T priority patent/ES2391842T3/en
Priority to AU2001262717A priority patent/AU2001262717A1/en
Priority to PCT/JP2001/004832 priority patent/WO2002003475A1/en
Priority to EP01936908A priority patent/EP1228536B1/en
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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L31/00—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
    • 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
    • H01L31/042—PV modules or arrays of single PV cells
    • H01L31/048—Encapsulation of modules
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E10/00—Energy generation through renewable energy sources
    • Y02E10/50—Photovoltaic [PV] energy

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Description

【０００１】
【発明の属する技術分野】
本発明は、太陽電池用セルの裏面側保護部材として用いられるバックカバー材を兼ねた封止膜と、この封止膜を用いた太陽電池に係り、特に、防湿性、耐久性に優れ、しかも絶縁性が高く、リーク電流の問題のない太陽電池用バックカバー材兼用封止膜と、この封止膜を裏面側保護部材兼用封止膜として用いた高耐久性かつ高性能の太陽電池に関する。
【０００２】
【従来の技術】
近年、資源の有効利用や環境汚染の防止等の面から、太陽光を直接電気エネルギーに変換する太陽電池が注目され、開発が進められている。
【０００３】
太陽電池は、一般に、図３に示す如く、受光面側の表面側透明保護部材１１と裏面側保護部材（バックカバー材）１２との間にエチレン−酢酸ビニル共重合体（ＥＶＡ）フィルム１３Ａ，１３Ｂの封止膜により、太陽電池用セル、即ち、シリコン等の発電素子１４を封止した構成とされている。
【０００４】
このような太陽電池１０は、ガラス基板等の表面側透明保護部材１１、封止膜用ＥＶＡフィルム１３Ａ、シリコン発電素子１４、封止膜用ＥＶＡフィルム１３Ｂ及びバックカバー材１２をこの順で積層し、ＥＶＡを加熱溶融して架橋硬化させることにより接着一体化することで製造される。
【０００５】
このような太陽電池のバックカバー材は、太陽電池の軽量薄肉化の観点から、それ自体も軽量かつ薄肉であることが要求されるが、更に、発電素子や配線等の内部部品を外力、湿気等から保護するための耐久性、防湿性が要求される。即ち、太陽電池は、通常屋外に設置されることから、バックカバー材には、長期にわたる耐久性を有することに加えて、湿気ないし水の透過による内部の発電素子や、導線、電極等の部品の発錆を防止するべく、防湿性に優れることが極めて重要な要件となる。
【０００６】
従来、太陽電池のバックカバー材としては、防湿層としてのアルミニウム、亜鉛めっき鉄等の金属箔を２枚の樹脂フィルム間に挟んだ積層フィルムが設けられている。
【０００７】
【発明が解決しようとする課題】
しかしながら、金属箔を用いた従来のバックカバー材では、太陽電池に適用した場合、電流がリークする恐れがある。また、発電素子や内部配線等の突起が樹脂フィルムを貫通することにより、金属箔と短絡する恐れもある。これらの問題と環境面から、金属箔を用いる代わりに樹脂フィルムのみの積層体が開発されたが、この積層フィルムでは防湿性が不十分であった。
【０００８】
本発明は上記従来の問題点を解決し、太陽電池用セルの裏面側保護部材を兼ねた封止膜として用いられる太陽電池用バックカバー材兼用封止膜であって、軽量かつ薄肉で防湿性、耐久性に優れ、しかも絶縁性が高く、内部配線等の短絡やリーク電流の問題がない太陽電池用バックカバー材兼用封止膜と、この封止膜を裏面側保護部材を兼ねた封止膜として用いた、高耐久性かつ高性能の太陽電池を提供することを目的とする。
【０００９】
【課題を解決するための手段】
本発明の太陽電池用バックカバー材兼用封止膜は、太陽電池用セルの裏面側保護部材を兼ねた封止膜において、フッ素樹脂フィルム及びポリエステルフィルムから選ばれる２枚の耐熱、耐候性フィルムを防湿フィルムを介して積層一体化してなる本体部と、該本体部の一方の面に設けられた接着層とを有する太陽電池用バックカバー材兼用封止膜であって、該封止膜の透湿度が１．０ｇ／ｍ２／ｄａｙ以下であり、該耐熱、耐候性フィルムと防湿フィルムとが水添ポリブタジエン変性ウレタン系接着剤で接着されており、該防湿フィルムは、ポリエステルフィルムよりなる基材フィルムの表面に酸化ケイ素の蒸着膜を形成したフィルムであり、該酸化ケイ素は、一般式ＳｉＯ ｘ において、ｘ＝１．７〜１．９の酸化ケイ素であり、該酸化ケイ素の蒸着膜の膜厚が１００〜５００Åであることを特徴とする。
【００１０】
本発明の太陽電池用バックカバー材兼用封止膜は、積層フィルムよりなるため軽量かつ薄肉である。しかも、透湿度１．０ｇ／ｍ２／ｄａｙ以下と、極めて耐透湿性に優れるため、高い防湿性を得ることができる上に、絶縁性であるため短絡やリーク電流の問題もない。
【００１２】
また、防湿フィルムは、基材フィルムの表面に無機酸化物の蒸着膜を形成したフィルムであって、この無機酸化物が一般式ＳｉＯｘにおいて、ｘ＝１．７〜１．９の酸化ケイ素であり、蒸着膜の膜厚は１００〜５００Åである。
【００１３】
本発明の太陽電池は、表面側保護部材と裏面側保護部材との間に太陽電池用セルを封止してなる太陽電池において、該裏面側保護部材兼用封止膜として上記本発明の太陽電池用バックカバー材兼用封止膜を用いたものである。
【００１４】
【発明の実施の形態】
以下に図面を参照して本発明の実施の形態を詳細に説明する。
【００１５】
図１は本発明の太陽電池用バックカバー材兼用封止膜の実施の形態を示す断面図、図２はこの太陽電池用バックカバー材兼用封止膜を用いた本発明の太陽電池の実施の形態を示す断面図である。
【００１６】
図１に示す太陽電池用バックカバー材兼用封止膜１は、２枚の耐熱、耐候性フィルム２，２間に防湿フィルム３を介在させてこれらを積層一体化してなる本体部４と、この本体部４の一方の面に設けられた接着層５とを有する。
【００１７】
太陽電池の裏面からの水分の浸入を阻止するための防湿フィルム３としては、基材フィルムにＣＶＤ（化学蒸着）、ＰＶＤ（反応蒸着）法等による、酸化ケイ素等を主成分とする無機酸化物の蒸着膜を形成したものが用いられる。
【００１８】
防湿層としての無機酸化物の蒸着膜を構成する無機酸化物としては、酸化ケイ素が用いられる。湿熱条件下での耐久性に優れることから、特に酸化ケイ素が好適である。
【００１９】
なお、酸化ケイ素蒸着膜の組成はＳｉＯに近い状態が一般的であるが、ＳｉＯｘでｘ＝１．７未満であると耐久試験等で次第に透湿度が低下し、ｘ＝１．９を超えるものは生産性、コストの面から不利である。従って、防湿層としての酸化ケイ素蒸着膜のＳｉＯｘ組成はｘ＝１．７〜１．９である。
【００２０】
この蒸着膜の膜厚が薄過ぎると十分な防湿性を得ることができず、厚過ぎてもそれ以上の防湿性の改善効果は得られず、むしろクラックが入り易く、防湿性が低下する可能性があることから、この膜厚は１００〜５００Å、好ましくは２００〜４００Åとする。
【００２１】
一方、防湿フィルムの支持体となる基材フィルムとしては、太陽電池の作製時の熱や圧力条件に耐え得る耐熱性フィルムであれば良く、特に制限はないが、一般的には、ポリテトラフルオロエチレン（ＰＴＦＥ）、４−フッ化エチレン−パークロロアルコキシ共重合体（ＰＦＡ）、４−フッ化エチレン−６−フッ化プロピレン共重合体（ＦＥＰ）、２−エチレン−４−フッ化エチレン共重合体（ＥＴＦＥ）、ポリ３−フッ化塩化エチレン（ＰＣＴＦＥ）、ポリフッ化ビニリデン（ＰＶＤＦ）及びポリフッ化ビニル（ＰＶＦ）等のフッ素樹脂フィルムや、ポリエチレンテレフタレート（ＰＥＴ）等のポリエステル、ポリカーボネート、ポリメチルメタアクリレート（ＰＭＭＡ）、ポリアミド等の各種樹脂フィルムを用いることができる。この基材フィルムは、これらの樹脂の２種以上を含むものであっても良く、また、２枚以上のフィルムの積層フィルムであっても良い。基材フィルムには、必要に応じて顔料、紫外線吸収剤等の各種添加剤を含浸、塗布又は練り込みにより付与しても良い。
【００２２】
このような基材フィルムの厚さは、耐久性、取り扱い性、薄膜化等の観点から５〜２００μｍ程度であることが好ましい。
【００２３】
このような防湿フィルム３を介在させて積層一体化させることにより本体部４を構成する耐熱、耐候性フィルム２は、防湿フィルム３の保護と、太陽電池作製時の作業性の向上等の目的で設けられ、太陽電池作製時の熱や圧力条件に耐え、特に接着層５と反対側の耐熱、耐候性フィルム２としては、太陽電池組立時に最外層となるため、長期にわたる屋外曝露条件下でも劣化しないものであることが望まれるが、通常、前述の基材フィルムの材料として例示したものを用いることができる。この耐熱、耐候性フィルム２，２もまた、前述の基材フィルムと同様、前述の樹脂の２種以上を含むものであっても良く、また、２枚以上のフィルムの積層フィルムであっても良い。また、耐熱、耐候性フィルムには、必要に応じて顔料、紫外線吸収剤、カップリング剤等の各種添加剤を含浸、塗布又は練り込みにより付与しても良い。
【００２４】
耐熱、耐候性フィルム２の色については特に限定されないが、発電効率の向上のためには、白色系が好ましく、家屋等に設置した際の外観の向上のためには黒色又は各色の濃色が用いられる。
【００２５】
このような耐熱、耐候性フィルム２の厚さは、耐久性、取り扱い性、薄膜化等の観点から５〜２００μｍ程度であることが好ましい。
【００２６】
なお、２枚の耐熱、耐候性フィルム２，２は必ずしも同材質である必要はなく異材質のものであっても良い。
【００２７】
特に、太陽電池の外面側となる耐熱、耐候性フィルムには、耐候性に優れたフッ素樹脂フィルムを用いるのが好ましく、内面側となる耐熱、耐候性フィルムには、顔料等を練り込んで反射性能を付与したフィルムを用いるのが好ましい。
【００２８】
なお、本体部４は、実用的には、耐熱、耐候性フィルム２と防湿フィルム３との間に接着剤６，６を介してドライラミネーション法又はヒートプレス法等の方法で接着一体化することにより製造される。
【００２９】
このようなフィルムの積層時に使用される接着剤としては、一般に、ポリエステル系又はポリエーテル系等のウレタン接着剤が用いられるが、ポリエーテル系のものは初期接着力が低く、耐熱性に劣り、また、ポリエステル系では耐熱性は良好なものの耐湿熱性は低いという欠点があった。これは、これらの接着成分が、骨格中に−Ｏ−又は−Ｃ＝Ｏ−Ｏ−鎖を含むためである。
【００３０】
この欠点を解決するために、本発明では、耐熱、耐候性フィルム２，２と防湿フィルム３との接着に、主鎖をブタジエン骨格とし、更に二重結合の開裂による劣化を防止するため水添した、水添ポリブタジエン変性ウレタン系接着剤を用いる。このものは、主鎖が−ＣＨ２−となり従来品に比べ接着耐久性が大幅に改善される。
【００３１】
このような本体部４の一方の面に形成される接着層５は、太陽電池の発電素子、その他の内部部品の封止と、緩衝材として機能するものであり、ガラス等の表面側透明保護部材、ＩＴＯ等の金属酸化物導電膜やシリコン発電素子との熱接着性に優れ、これらを容易に接着して複合化できるものであれば良く、特に制限はないが、通常はＥＶＡ系樹脂、ＰＶＢ系樹脂などが用いられる。また、シリコン系、アクリル系、ブチル系、エポキシ系等の接着剤樹脂を使用しても良い。特に、作業性やコストの面から、ＥＶＡ系樹脂が多用される。このＥＶＡ系接着樹脂に用いられるＥＶＡ樹脂組成物の詳細は後述の通りである。
【００３２】
この接着層５の厚さは、０．１〜１ｍｍ程度であることが好ましい。
【００３３】
このような太陽電池用バックカバー材兼用封止膜を用いて本発明の太陽電池を製造するには、図３に示す従来の太陽電池のバックカバー材と封止用ＥＶＡフィルムの代りに本発明の太陽電池用バックカバー材兼用封止膜を用いて封止を行えば良い。
【００３４】
本発明の太陽電池１０Ａは、図２に示す如く、本発明の太陽電池用バックカバー材兼用封止膜１、シリコン発電素子１４等の太陽電池用セル、封止用ＥＶＡフィルム１３Ａ及び表面側透明保護部材１１としてのガラス板や高機能性積層フィルムの積層体を、常法に従って、真空ラミネーターで温度１２０〜１５０℃、脱気時間２〜１５分、プレス圧力０．５〜１ａｔｍ、プレス時間８〜４５分で加熱加圧圧着することにより容易に製造することができる。
【００３５】
なお、本発明の太陽電池用バックカバー材兼用封止膜及び太陽電池に用いられる封止用のＥＶＡ樹脂組成物には、好ましくは耐候性の向上のために架橋剤を配合して架橋構造を持たせるが、この架橋剤としては、一般に、１００℃以上でラジカルを発生する有機過酸化物が用いられ、特に、配合時の安定性を考慮に入れれば、半減期１０時間の分解温度が７０℃以上であるものが好ましい。このような有機過酸化物としては、例えば２，５−ジメチルヘキサン；２，５−ジハイドロパーオキサイド；２，５−ジメチル−２，５−ジ（ｔ−ブチルパーオキシ）ヘキサン；３−ジ−ｔ−ブチルパーオキサイド；ｔ−ジクミルパーオキサイド；２，５−ジメチル−２，５−ジ（ｔ−ブチルパーオキシ）ヘキシン；ジクミルパーオキサイド；α，α’−ビス（ｔ−ブチルパーオキシイソプロピル）ベンゼン；ｎ−ブチル−４，４−ビス（ｔ−ブチルパーオキシ）ブタン；２，２−ビス（ｔ−ブチルパーオキシ）ブタン；１，１−ビス（ｔ−ブチルパーオキシ）シクロヘキサン；１，１−ビス（ｔ−ブチルパーオキシ）３，３，５−トリメチルシクロヘキサン；ｔ−ブチルパーオキシベンゾエート；ベンゾイルパーオキサイド等を用いることができる。これらの有機過酸化物の配合量は、一般にＥＶＡ樹脂１００重量部に対して５重量部以下、好ましくは１〜３重量部である。
【００３６】
また、接着力向上の目的で、ＥＶＡ樹脂にシランカップリング剤を添加することができる。この目的に供されるシランカップリング剤としては公知のもの、例えばγ−クロロプロピルトリメトキシシラン；ビニルトリクロロシラン；ビニルトリエトキシシラン；ビニル−トリス−（β−メトキシエトキシ）シラン；γ−メタクリロキシプロピルトリメトキシシラン；β−（３，４−エトキシシクロヘキシル）エチルトリメトキシシラン；γ−グリシドキシプロピルトリメトキシシラン；ビニルトリアセトキシシラン；γ−メルカプトプロピルトリメトキシシラン；γ−アミノプロピルトリメトキシシラン；Ｎ−β−（アミノエチル）−γ−アミノプロピルトリメトキシシラン等を挙げることができる。これらのシランカップリング剤の配合量は、一般にＥＶＡ樹脂１００重量部に対して５重量部以下、好ましくは０．１〜２重量部である。
【００３７】
更に、ＥＶＡ樹脂のゲル分率を向上させ、耐久性を向上するためにＥＶＡ樹脂に架橋助剤を添加することができる。この目的に供される架橋助剤としては、公知のものとしてトリアリルイソシアヌレート；トリアリルイソシアネート等の３官能の架橋助剤の他、ＮＫエステル等の単官能の架橋助剤等も挙げることができる。これらの架橋助剤の配合量は、一般にＥＶＡ樹脂１００重量部に対して１０重量部以下、好ましくは１〜５重量部である。
【００３８】
更に、ＥＶＡ樹脂の安定性を向上する目的でハイドロキノン；ハイドロキノンモノメチルエーテル；ｐ−ベンゾキノン；メチルハイドロキノンなどを添加することができ、これらの配合量は、一般にＥＶＡ樹脂１００重量部に対して５重量部以下である。
【００３９】
更に、必要に応じ、上記以外に着色剤、紫外線吸収剤、老化防止剤、変色防止剤等を添加することができる。着色剤の例としては、金属酸化物、金属粉等の無機顔料、アゾ系、フタロシアニン系、アヂ系、酸性又は塩基染料系レーキ等の有機顔料がある。紫外線吸収剤には、２−ヒドロキシ−４−オクトキシベンゾフェノン；２−ヒドロキシ−４−メトキシ−５−スルフォベンゾフェノン等のベンゾフェノン系；２−（２’−ヒドロキシ−５−メチルフェニル）ベンゾトリアゾール等のベンゾトリアゾール系；フェニルサルシレート；ｐ−ｔ−ブチルフェニルサルシレート等のヒンダートアミン系がある。老化防止剤としては、アミン系；フェノール系；ビスフェニル系；ヒンダートアミン系があり、例えばジ−ｔ−ブチル−ｐ−クレゾール；ビス（２，２，６，６−テトラメチル−４−ピペラジル）セバケート等がある。
【００４０】
また、本発明のバックカバー材兼用封止膜は図３で示される単結晶Ｓｉや多結晶Ｓｉなどを用いたいわゆるバルク太陽電池素子だけでなく、図４に示すようなＳｉ系薄膜、II−VI化合物（ＣｄＴｅ）、カルコパライト薄膜（ＣＩＳ）、有機半導体、その他各種薄膜太陽電池２０にも同様の構造で適用することができ、更に、これらの薄膜太陽電池の表面側透明保護部材としてガラスの代わりに透明樹脂フィルムを用いた図５に示すようなフレキシブル太陽電池にも使用可能である。なお、図４において、２１はガラス、２２は透明電極、２３は薄膜半導体、２４は金属電極、２５は封止材、２６はバックカバー材を示す。また、図５において、３１は透明樹脂フィルム、３２は封止材、３３は薄膜太陽電池素子、３４はフィルム基材、３５は封止材、３６はバックカバー材を示す。
【００４１】
【実施例】
以下に実施例及び比較例を挙げて本発明をより具体的に説明する。
【００４２】
実施例１，２
一方の耐熱、耐候性フィルムとして白色顔料練り込みポリエステルフィルム（帝人デュポンフィルム（株）製「Ｕ２」厚さ３８μｍ）を用い、他方の耐熱、耐候性フィルムとしてＥＴＦＥフィルム（旭硝子（株）製「アフレックス」厚さ２１μｍ）を用い、これらの耐熱、耐候性フィルム間に、厚さ１２μｍのＰＥＴフィルムの表面に防湿層として厚さ２００ÅのＳｉＯｘ（ｘ＝１．８）の蒸着膜を形成してなる防湿フィルムを、表１に示す接着剤で接着して一体化し、更に、ポリエステルフィルム側に厚さ５０μｍのＥＶＡ接着層を形成して本発明の太陽電池用バックカバー材兼用封止膜を製造した。
【００４３】
得られた太陽電池用バックカバー材兼用封止膜について、一般的な条件（６５℃、９５％ＲＨ）よりも過酷な、８５℃、９０％ＲＨの条件下に１０００時間放置する耐久試験を行い、耐久試験後の透湿度をＭＯＣＯＮ法（４０℃、９０％ＲＨ）により測定すると共に、耐久試験前後の接着力をＴ型剥離試験により測定し、結果を表１に示した。
【００４４】
比較例１
白色ＰＶＦフィルム（デュポン社製「テドラー」厚さ３８μｍ）／透明ＰＥＴフィルム（帝人デュポンフィルム社製「Ｓ−ＰＥＴ」厚さ５０μｍ）／白色ＰＶＦフィルム（デュポン社製「テドラー」厚さ３８μｍ）の積層フィルムを実施例１と同様にして作成し、実施例１と同様に耐透湿性と接着性の耐久試験を行い、結果を表１に示した。
【００４５】
比較例２，３
実施例１において、耐熱、耐候性フィルムと防湿フィルムとの接着に表１に示す接着剤を用いたこと以外は同様にして太陽電池用バックカバー材兼用封止膜を作製し、同様に耐透湿性と接着性の耐久試験を行い、結果を表１に示した。
【００４６】
【表１】

Figure 0004887551
【００４７】
表１より本発明の太陽電池用バックカバー材兼用封止膜は、耐透湿性、接着性及びその耐久性に優れることがわかる。
【００４８】
【発明の効果】
以上詳述した通り、本発明の太陽電池用バックカバー材兼用封止膜は、軽量かつ薄肉で防湿性、耐久性に優れ、短絡やリーク電流の問題もないため、この太陽電池用バックカバー材兼用封止膜を太陽電池の裏面側保護部材を兼ねる封止膜として用いることにより、高防湿性で発錆の問題もなく、耐久性に優れ、短絡やリーク電流による性能低下の問題もない高性能の太陽電池を提供することができる。
【００４９】
本発明の太陽電池は、本発明の太陽電池用バックカバー材兼用封止膜を裏面側保護部材兼用封止膜として用いたものであり、高性能で耐久性にも優れる。
【図面の簡単な説明】
【図１】本発明の太陽電池用バックカバー材兼用封止膜の実施の形態を示す断面図である。
【図２】本発明の太陽電池の実施の形態を示す断面図である。
【図３】従来の太陽電池を示す断面図である。
【図４】本発明のバックカバー材兼用封止膜が適用される太陽電池の一例を示す断面図である。
【図５】本発明のバックカバー材兼用封止膜が適用される太陽電池の他の例を示す断面図である。
【符号の説明】
１ 太陽電池用バックカバー材兼用封止膜
２ 耐熱、耐候性フィルム
３ 防湿フィルム
４ 本体部
５ 接着層
６ 接着剤
１０，１０Ａ 太陽電池
１１ 表面側透明保護部材
１２ バックカバー材
１３Ａ，１３Ｂ 封止用ＥＶＡフィルム
１４ シリコン発電素子[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a sealing film that also serves as a back cover material used as a back surface side protection member of a solar battery cell, and a solar battery using this sealing film, and is particularly excellent in moisture resistance and durability. The present invention relates to a solar cell back cover material combined sealing film that has high insulation properties and no leakage current, and a highly durable and high performance solar cell that uses this sealing film as a back side protective member combined sealing film.
[0002]
[Prior art]
In recent years, solar cells that directly convert sunlight into electric energy have attracted attention and are being developed from the viewpoint of effective use of resources and prevention of environmental pollution.
[0003]
As shown in FIG. 3, a solar cell generally includes an ethylene-vinyl acetate copolymer (EVA) film 13 </ b> A between a surface-side transparent protective member 11 on the light-receiving surface side and a back-side protective member (back cover material) 12. It is set as the structure which sealed the cells for solar cells, ie, the electric power generating elements 14, such as a silicon | silicone, with the sealing film of 13B.
[0004]
Such a solar cell 10 includes a surface side transparent protective member 11 such as a glass substrate, a sealing film EVA film 13A, a silicon power generation element 14, a sealing film EVA film 13B, and a back cover material 12 stacked in this order. , EVA is produced by heating and melting and cross-linking and curing to integrate.
[0005]
Such a back cover material for a solar cell is required to be light and thin in itself from the viewpoint of reducing the weight and thickness of the solar cell. Durability and moisture proofing are required for protection from the above. In other words, since solar cells are usually installed outdoors, the back cover material has long-term durability, and components such as internal power generation elements, conductors, electrodes, etc. that permeate moisture or water. In order to prevent rusting, it is extremely important to have excellent moisture resistance.
[0006]
Conventionally, as a back cover material for a solar cell, a laminated film in which a metal foil such as aluminum or galvanized iron as a moisture-proof layer is sandwiched between two resin films is provided.
[0007]
[Problems to be solved by the invention]
However, in a conventional back cover material using a metal foil, current may leak when applied to a solar cell. In addition, projections such as power generation elements and internal wiring may penetrate the resin film, thereby causing a short circuit with the metal foil. In view of these problems and the environment, a laminate having only a resin film was developed instead of using a metal foil, but the moisture resistance of the laminate film was insufficient.
[0008]
The present invention solves the above-described conventional problems, and is a solar cell back cover material sealing film used as a sealing film that also serves as a back surface protection member for a solar battery cell, and is lightweight, thin and moisture-proof. A solar cell back cover material sealing film that has excellent durability and high insulation properties, and has no short circuit or leakage current problems such as internal wiring, etc., and a sealing film that also serves as a back side protection member An object is to provide a highly durable and high performance solar cell used as a film.
[0009]
[Means for Solving the Problems]
The solar cell back cover material combined sealing film of the present invention is a sealing film that also serves as a back surface side protection member of a solar cell cell, and includes two heat and weather resistant films selected from a fluororesin film and a polyester film. A solar cell back cover material sealing film having a main body portion laminated and integrated through a moisture-proof film and an adhesive layer provided on one surface of the main body portion, wherein the sealing film is transparent. The humidity is 1.0 g / m 2 / day or less, the heat and weather resistant film and the moisture proof film are bonded with a hydrogenated polybutadiene-modified urethane adhesive, and the moisture proof film is a substrate made of a polyester film. film der forming a deposited film of silicon oxide on the surface of the film is, the silicon oxide, in the general formula SiO x, a silicon oxide x = 1.7 to 1.9, the acid over a period The thickness of the deposited film of iodine is characterized 100~500Å der Rukoto.
[0010]
Since the back cover material combined sealing film for solar cells of this invention consists of laminated films, it is lightweight and thin. Moreover, since the moisture permeability is 1.0 g / m 2 / day or less and extremely excellent in moisture permeability, high moisture resistance can be obtained, and since it is insulative, there is no problem of short circuit or leakage current.
[0012]
The moisture-proof film is a film in which an inorganic oxide vapor-deposited film is formed on the surface of a base film, and the inorganic oxide is silicon oxide of x = 1.7 to 1.9 in the general formula SiO x . Yes, the film thickness of the deposited film is Ru 1 00~ 5 00Å der.
[0013]
The solar cell of the present invention is a solar cell in which a solar cell is sealed between a front surface side protective member and a back surface side protective member, and the solar cell of the present invention is used as the back surface side protective member sealing film. The back cover material combined sealing film is used.
[0014]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings.
[0015]
FIG. 1 is a cross-sectional view showing an embodiment of a solar cell back cover material combined sealing film of the present invention, and FIG. 2 shows an implementation of the solar cell of the present invention using this solar cell back cover material combined sealing film. It is sectional drawing which shows a form.
[0016]
The solar cell back cover material / sealing film 1 shown in FIG. 1 includes a main body 4 formed by laminating and integrating a moisture-proof film 3 between two heat- and weather-resistant films 2 and 2, And an adhesive layer 5 provided on one surface of the main body 4.
[0017]
As the moisture-proof film 3 for preventing moisture from entering from the back surface of the solar cell, an inorganic oxide mainly composed of silicon oxide or the like by a CVD (chemical vapor deposition), PVD (reactive vapor deposition) method or the like on a base film. Those having a deposited film are used.
[0018]
The inorganic oxide constituting the deposited film of an inorganic oxide as a moisture barrier, oxidation silicon is used. Silicon oxide is particularly preferred because of its excellent durability under wet heat conditions.
[0019]
The composition of the deposited silicon oxide film is generally close to that of SiO. However, if SiO x is less than 1.7, the moisture permeability gradually decreases in an endurance test or the like, and exceeds x = 1.9. Things are disadvantageous in terms of productivity and cost. Thus, SiO x composition of the silicon oxide vapor deposited film as moisture barrier Ru x = 1.7 to 1.9 der.
[0020]
If the thickness of this deposited film is too thin, sufficient moisture resistance cannot be obtained, and if it is too thick, no further improvement effect of moisture resistance can be obtained, rather cracking easily occurs and moisture resistance may be reduced. because of the sex, the film thickness is 100 Å to 500 Å, preferably it shall be the 200～400A.
[0021]
On the other hand, the base film that serves as a support for the moisture-proof film is not particularly limited as long as it is a heat-resistant film that can withstand the heat and pressure conditions during the production of the solar cell. Ethylene (PTFE), 4-fluorinated ethylene-perchloroalkoxy copolymer (PFA), 4-fluorinated ethylene-6-fluorinated propylene copolymer (FEP), 2-ethylene-4-fluorinated ethylene copolymer Fluoropolymer films such as coalescence (ETFE), poly-3-fluoroethylene chloride (PCTFE), polyvinylidene fluoride (PVDF) and polyvinyl fluoride (PVF), polyesters such as polyethylene terephthalate (PET), polycarbonate, polymethylmeta Various resin films such as acrylate (PMMA) and polyamide can be used. This base film may contain two or more of these resins, or may be a laminated film of two or more films. You may provide a base film with various additives, such as a pigment and a ultraviolet absorber, as needed by impregnation, application | coating, or kneading.
[0022]
The thickness of such a base film is preferably about 5 to 200 μm from the viewpoint of durability, handleability, thinning, and the like.
[0023]
The heat-resistant and weather-resistant film 2 constituting the main body portion 4 by laminating and integrating the moisture-proof film 3 is used for the purpose of protecting the moisture-proof film 3 and improving workability at the time of manufacturing a solar cell. It is provided and can withstand heat and pressure conditions at the time of solar cell fabrication. Especially, the heat-resistant and weather-resistant film 2 on the side opposite to the adhesive layer 5 is the outermost layer when the solar cell is assembled. Although it is desired that the material is not, normally those exemplified as the material for the base film can be used. The heat and weather resistant films 2 and 2 may also contain two or more of the aforementioned resins, as in the case of the aforementioned base film, or may be a laminated film of two or more films. good. Moreover, you may provide a heat-resistant and weather-resistant film by impregnating, apply | coating, or kneading | mixing various additives, such as a pigment, a ultraviolet absorber, and a coupling agent, as needed.
[0024]
The color of the heat-resistant and weather-resistant film 2 is not particularly limited, but a white system is preferable for improving power generation efficiency, and black or a dark color of each color is used for improving the appearance when installed in a house or the like. Used.
[0025]
The thickness of the heat and weather resistant film 2 is preferably about 5 to 200 μm from the viewpoints of durability, handleability, thinning, and the like.
[0026]
The two heat and weather resistant films 2 and 2 are not necessarily made of the same material, and may be made of different materials.
[0027]
In particular, it is preferable to use a fluororesin film having excellent weather resistance for the heat and weather resistant film on the outer surface side of the solar cell, and the heat and weather resistant film on the inner surface side is kneaded with a pigment or the like for reflection. It is preferable to use a film imparted with performance.
[0028]
The body 4 is practically bonded and integrated between the heat-resistant and weather-resistant film 2 and the moisture-proof film 3 by a method such as a dry lamination method or a heat press method with adhesives 6 and 6 interposed therebetween. Manufactured by.
[0029]
As an adhesive used when laminating such a film, a urethane adhesive such as a polyester or polyether is generally used, but a polyether-based one has a low initial adhesive force and is inferior in heat resistance, In addition, the polyester system has a drawback that it has good heat resistance but low heat and humidity resistance. This is because these adhesive components contain —O— or —C═O—O— chains in the skeleton.
[0030]
In order to solve this drawback, in the present invention, hydrogenation is applied to the heat-resistant and weather-resistant films 2 and 2 and the moisture-proof film 3 in order to prevent deterioration due to cleavage of double bonds in the main chain. The hydrogenated polybutadiene-modified urethane adhesive is used. In this product, the main chain becomes —CH 2 — and the adhesion durability is greatly improved as compared with the conventional product.
[0031]
The adhesive layer 5 formed on one surface of the main body 4 functions as a sealing material for solar cell power generation elements and other internal components, and functions as a cushioning material. Any member, any metal oxide conductive film such as ITO, or silicon power generation element can be used as long as it is excellent in thermal adhesiveness and can be easily bonded and combined, and is not particularly limited. PVB resin or the like is used. Moreover, you may use adhesive resin, such as a silicon type, an acrylic type, a butyl type, and an epoxy type. In particular, EVA resin is frequently used from the viewpoint of workability and cost. Details of the EVA resin composition used for this EVA adhesive resin are as described below.
[0032]
The thickness of the adhesive layer 5 is preferably about 0.1 to 1 mm.
[0033]
In order to manufacture the solar cell of the present invention using such a solar cell back cover material sealing film, the present invention is used instead of the conventional solar cell back cover material and sealing EVA film shown in FIG. Sealing may be performed using the solar battery back cover material sealing film.
[0034]
As shown in FIG. 2, the solar cell 10 </ b> A of the present invention includes a solar cell back cover material and sealing film 1, a solar cell such as a silicon power generation element 14, a sealing EVA film 13 </ b> A, and a transparent surface side. A laminated body of a glass plate or a highly functional laminated film as the protective member 11 is subjected to a vacuum laminator at a temperature of 120 to 150 ° C., a degassing time of 2 to 15 minutes, a press pressure of 0.5 to 1 atm, a press time of 8 according to a conventional method. It can be easily produced by heating and pressing in about 45 minutes.
[0035]
The solar cell back cover material sealing film and the sealing EVA resin composition used in the solar cell of the present invention preferably have a cross-linking structure by blending a cross-linking agent to improve weather resistance. As the cross-linking agent, generally, an organic peroxide that generates radicals at 100 ° C. or higher is used. In particular, taking into consideration the stability during compounding, the decomposition temperature with a half-life of 10 hours is 70. Those having a temperature not lower than ° C. are preferred. Examples of such an organic peroxide include 2,5-dimethylhexane; 2,5-dihydroperoxide; 2,5-dimethyl-2,5-di (t-butylperoxy) hexane; -T-butyl peroxide; t-dicumyl peroxide; 2,5-dimethyl-2,5-di (t-butylperoxy) hexyne; dicumyl peroxide; α, α'-bis (t-butylperoxide Oxyisopropyl) benzene; n-butyl-4,4-bis (t-butylperoxy) butane; 2,2-bis (t-butylperoxy) butane; 1,1-bis (t-butylperoxy) cyclohexane 1,1-bis (t-butylperoxy) 3,3,5-trimethylcyclohexane; t-butylperoxybenzoate; benzoyl peroxide, etc. Kill. The compounding amount of these organic peroxides is generally 5 parts by weight or less, preferably 1 to 3 parts by weight with respect to 100 parts by weight of the EVA resin.
[0036]
Moreover, a silane coupling agent can be added to EVA resin for the purpose of improving adhesive force. Known silane coupling agents for this purpose are, for example, γ-chloropropyltrimethoxysilane; vinyltrichlorosilane; vinyltriethoxysilane; vinyl-tris- (β-methoxyethoxy) silane; γ-methacryloxy. Propyltrimethoxysilane; β- (3,4-ethoxycyclohexyl) ethyltrimethoxysilane; γ-glycidoxypropyltrimethoxysilane; vinyltriacetoxysilane; γ-mercaptopropyltrimethoxysilane; γ-aminopropyltrimethoxysilane N-β- (aminoethyl) -γ-aminopropyltrimethoxysilane and the like can be mentioned. The amount of these silane coupling agents is generally 5 parts by weight or less, preferably 0.1 to 2 parts by weight, based on 100 parts by weight of the EVA resin.
[0037]
Furthermore, a crosslinking aid can be added to the EVA resin in order to improve the gel fraction of the EVA resin and improve the durability. Examples of crosslinking aids provided for this purpose include trifunctional crosslinking aids such as triallyl isocyanurate; triallyl isocyanate as well as monofunctional crosslinking aids such as NK esters. it can. The amount of these crosslinking aids is generally 10 parts by weight or less, preferably 1 to 5 parts by weight with respect to 100 parts by weight of the EVA resin.
[0038]
Furthermore, hydroquinone; hydroquinone monomethyl ether; p-benzoquinone; methyl hydroquinone, etc. can be added for the purpose of improving the stability of the EVA resin, and the blending amount thereof is generally 5 parts by weight with respect to 100 parts by weight of the EVA resin. It is as follows.
[0039]
Furthermore, if necessary, a colorant, an ultraviolet absorber, an anti-aging agent, a discoloration preventing agent and the like can be added in addition to the above. Examples of the colorant include inorganic pigments such as metal oxides and metal powders, and organic pigments such as azo-based, phthalocyanine-based, additive-based, acidic or basic dye-based lakes. Examples of ultraviolet absorbers include 2-hydroxy-4-octoxybenzophenone; benzophenones such as 2-hydroxy-4-methoxy-5-sulfobenzophenone; 2- (2′-hydroxy-5-methylphenyl) benzotriazole Benzotriazoles; phenyl salsylates; hindered amines such as pt-butylphenyl salsylates. Antiaging agents include amines; phenols; bisphenyls; hindered amines, such as di-t-butyl-p-cresol; bis (2,2,6,6-tetramethyl-4-piperazyl). ) Sebacate.
[0040]
Further, the back cover material combined sealing film of the present invention is not only a so-called bulk solar cell element using single crystal Si or polycrystalline Si shown in FIG. 3, but also a Si-based thin film as shown in FIG. It can be applied to VI compounds (CdTe), chalcopyrite thin films (CIS), organic semiconductors, and other various thin film solar cells 20 with the same structure. Further, instead of glass as the surface side transparent protective member of these thin film solar cells Moreover, it can be used also for a flexible solar cell as shown in FIG. 5 using a transparent resin film. In FIG. 4, 21 is glass, 22 is a transparent electrode, 23 is a thin film semiconductor, 24 is a metal electrode, 25 is a sealing material, and 26 is a back cover material. In FIG. 5, 31 is a transparent resin film, 32 is a sealing material, 33 is a thin-film solar cell element, 34 is a film substrate, 35 is a sealing material, and 36 is a back cover material.
[0041]
【Example】
Hereinafter, the present invention will be described more specifically with reference to Examples and Comparative Examples.
[0042]
Examples 1 and 2
One heat- and weather-resistant film is a polyester film kneaded with a white pigment (“U2” thickness 38 μm manufactured by Teijin DuPont Films Ltd.), and the other heat and weather-resistant film is an ETFE film (Asahi Glass Co., Ltd. “A” Using a “flex” thickness of 21 μm, a 200 μm thick SiO x (x = 1.8) vapor-deposited film is formed as a moisture-proof layer on the surface of a 12 μm thick PET film between these heat and weather resistant films. The moisture-proof film is bonded and integrated with the adhesive shown in Table 1, and further, an EVA adhesive layer having a thickness of 50 μm is formed on the polyester film side to form the solar cell back cover material sealing film of the present invention. Manufactured.
[0043]
The obtained solar cell back cover material sealing film is subjected to a durability test that is allowed to stand for 1000 hours under conditions of 85 ° C. and 90% RH, which are more severe than general conditions (65 ° C., 95% RH). The moisture permeability after the durability test was measured by the MOCON method (40 ° C., 90% RH), and the adhesive strength before and after the durability test was measured by the T-type peel test. The results are shown in Table 1.
[0044]
Comparative Example 1
Lamination of white PVF film (DuPont “Tedlar” thickness 38 μm) / transparent PET film (Teijin DuPont Films “S-PET” thickness 50 μm) / white PVF film (DuPont “Tedlar” thickness 38 μm) A film was prepared in the same manner as in Example 1. Durability tests for moisture permeation resistance and adhesiveness were conducted in the same manner as in Example 1, and the results are shown in Table 1.
[0045]
Comparative Examples 2 and 3
In Example 1, a solar cell back cover material sealing film was prepared in the same manner except that the adhesive shown in Table 1 was used for adhesion between the heat-resistant and weather-resistant film and the moisture-proof film. Wetness and adhesion durability tests were performed and the results are shown in Table 1.
[0046]
[Table 1]
Figure 0004887551
[0047]
It can be seen from Table 1 that the solar cell back cover material sealing film of the present invention is excellent in moisture permeability, adhesiveness and durability.
[0048]
【Effect of the invention】
As described above in detail, the solar cell back cover material combined sealing film of the present invention is light and thin, excellent in moisture resistance and durability, and has no short circuit or leakage current problem. By using the dual-purpose sealing film as a sealing film that also serves as the back side protection member of the solar cell, it is highly moisture-proof, has no rusting problem, has excellent durability, and has no problem of performance degradation due to short circuit or leakage current. A high performance solar cell can be provided.
[0049]
The solar cell of the present invention uses the solar cell back cover material combined sealing film of the present invention as a back surface side protective member combined sealing film, and has high performance and excellent durability.
[Brief description of the drawings]
FIG. 1 is a cross-sectional view showing an embodiment of a solar cell back cover material and sealing film of the present invention.
FIG. 2 is a cross-sectional view showing an embodiment of the solar cell of the present invention.
FIG. 3 is a cross-sectional view showing a conventional solar cell.
FIG. 4 is a cross-sectional view showing an example of a solar cell to which the back cover material sealing film of the present invention is applied.
FIG. 5 is a cross-sectional view showing another example of a solar cell to which the back cover material combined sealing film of the present invention is applied.
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 1 Solar cell back cover material combined sealing film 2 Heat-resistant, weather-resistant film 3 Moisture-proof film 4 Main body part 5 Adhesive layer 6 Adhesive 10, 10A Solar cell 11 Surface side transparent protective member 12 Back cover material 13A, 13B For sealing EVA film 14 Silicon power generation element

Claims (3)

太陽電池用セルの裏面側保護部材を兼ねた封止膜において、フッ素樹脂フィルム及びポリエステルフィルムから選ばれる２枚の耐熱、耐候性フィルムを防湿フィルムを介して積層一体化してなる本体部と、該本体部の一方の面に設けられた接着層とを有する太陽電池用バックカバー材兼用封止膜であって、
該封止膜の透湿度が１．０ｇ／ｍ２／ｄａｙ以下であり、
該耐熱、耐候性フィルムと防湿フィルムとが水添ポリブタジエン変性ウレタン系接着剤で接着されており、
該防湿フィルムは、ポリエステルフィルムよりなる基材フィルムの表面に酸化ケイ素の蒸着膜を形成したフィルムであり、
該酸化ケイ素は、一般式ＳｉＯ ｘ において、ｘ＝１．７〜１．９の酸化ケイ素であり、
該酸化ケイ素の蒸着膜の膜厚が１００〜５００Åであることを特徴とする太陽電池用バックカバー材兼用封止膜。In a sealing film that also serves as a back surface side protection member of a solar cell, a main body unit obtained by laminating and integrating two heat-resistant and weather-resistant films selected from a fluororesin film and a polyester film through a moisture-proof film; A back cover material combined sealing film for solar cells having an adhesive layer provided on one surface of the main body,
The moisture permeability of the sealing film is 1.0 g / m 2 / day or less,
The heat- and weather-resistant film and the moisture-proof film are bonded with a hydrogenated polybutadiene-modified urethane adhesive,
-Proof wet film Ri film der forming a deposited film of silicon oxide on the surface of the base film made of a polyester film,
The silicon oxide is a silicon oxide having a general formula SiO x and x = 1.7 to 1.9,
Deposited film of thickness 100~500Å der Rukoto wherein the solar cell back cover material combined sealing film of the silicon oxide. 請求項１において、該無機酸化物の蒸着膜の膜厚が２００〜４００Åであることを特徴とする太陽電池用バックカバー材兼用封止膜。Oite to claim 1, a solar cell back cover material combined sealing film, wherein the thickness of the deposited film of the inorganic oxide is 200～400A. 表面側保護部材と裏面側保護部材との間に太陽電池用セルを封止してなる太陽電池において、該裏面側保護部材兼用封止膜として請求項１又は２に記載される太陽電池用バックカバー材兼用封止膜を用いたことを特徴とする太陽電池。The solar cell back | bag for solar cells formed by sealing the cell for solar cells between the surface side protection member and the back surface side protection member, The solar cell bag described in Claim 1 or 2 as this back surface side protection member combined sealing film A solar cell using a sealing film also serving as a cover material.
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