JP4927317B2 - 高分子量ポリオール含有硬化性樹脂製のバリヤー層 - Google Patents
高分子量ポリオール含有硬化性樹脂製のバリヤー層 Download PDFInfo
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- JP4927317B2 JP4927317B2 JP2003564133A JP2003564133A JP4927317B2 JP 4927317 B2 JP4927317 B2 JP 4927317B2 JP 2003564133 A JP2003564133 A JP 2003564133A JP 2003564133 A JP2003564133 A JP 2003564133A JP 4927317 B2 JP4927317 B2 JP 4927317B2
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Classifications
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- B32B17/06—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material
- B32B17/10—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin
- B32B17/10005—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing
- B32B17/1055—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing characterized by the resin layer, i.e. interlayer
- B32B17/10761—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing characterized by the resin layer, i.e. interlayer containing vinyl acetal
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- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/38—Layered products comprising a layer of synthetic resin comprising epoxy resins
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- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
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- C08G18/06—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen
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- C08G18/4063—Mixtures of compounds of group C08G18/62 with other macromolecular compounds
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
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- C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
- C08G59/00—Polycondensates containing more than one epoxy group per molecule; Macromolecules obtained by polymerising compounds containing more than one epoxy group per molecule using curing agents or catalysts which react with the epoxy groups
- C08G59/18—Macromolecules obtained by polymerising compounds containing more than one epoxy group per molecule using curing agents or catalysts which react with the epoxy groups ; e.g. general methods of curing
- C08G59/40—Macromolecules obtained by polymerising compounds containing more than one epoxy group per molecule using curing agents or catalysts which react with the epoxy groups ; e.g. general methods of curing characterised by the curing agents used
- C08G59/62—Alcohols or phenols
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
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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
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- H—ELECTRICITY
- H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
- H10K—ORGANIC ELECTRIC SOLID-STATE DEVICES
- H10K50/00—Organic light-emitting devices
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- H—ELECTRICITY
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- H10K50/84—Passivation; Containers; Encapsulations
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- 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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- 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
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/31504—Composite [nonstructural laminate]
- Y10T428/31551—Of polyamidoester [polyurethane, polyisocyanate, polycarbamate, etc.]
- Y10T428/31627—Next to aldehyde or ketone condensation product
- Y10T428/3163—Next to acetal of polymerized unsaturated alcohol [e.g., formal butyral, etc.]
Description
シート抵抗ρs(オーム)は、エッジから薄層内部を見たときの薄層材料の抵抗の尺度である。式ρs=ρ/tにおいて、tは層の厚さ(cm)、ρは材料の固有抵抗(オーム・cm)である。固有抵抗はρ=RA/l〔但し、Rは層の抵抗(オーム)、Aは層の断面積(cm2)、lは層の長さ(cm)である〕として定義される。
積層構造、特に太陽モジュールへの湿気の拡散を防止する1つの可能性は、湿気拡散用の長い通路を作ることである。通路を作るには、15cmを超える十分に広いエッジ又はリムを必要とする。しかし、このように広いエッジ又はリムは、有効モジュール表面をかなり減少させるため、太陽モジュールでは許容できない。
ドイツ特許出願公開No.19514908は、基体、該基体上に設けた層構造、及び該層構造上に設けたバリヤー層を有し、該バリヤー層がポリイソシアネートと、トリメチロールプロパンをベースとする三官能性ポリオールとの反応生成物を含む部品を開示している。これは、従来のポリウレタン系である。
ここでヨーロッパ特許出願公開No.903790を参照する。この刊行物は、基体、該基体上に設けた層構造及び該層構造上に設けた封入性材料の上層を含む部品を開示している。上層の封入性材料は、エチレン−酢酸ビニル共重合体、エチレン−アクリル酸メチル共重合体、エチレン−アクリル酸エチル共重合体及びポリビニルブチラール樹脂のようなポリオレフィン系樹脂、ウレタン樹脂、シリコーン樹脂及び弗素樹脂を含有する。下層の封入性材料は、エチレン−酢酸ビニル又はポリビニルブチラールを含む。この刊行物は、本発明とは関係ない。
ここで、図1は、本発明部品の概略図であって、断面の縮尺図を示すものではない。
図2は、ポリビニルブチラールの構造式を示す。
図3は、ポリビニルブチラールとエポキシ樹脂との反応を示す。
図4は、テストで使用した部品の概略図であって、断面の縮尺図を示すものではない。
簡易化のため、通常操作中に発生する電流を運ぶ裏面電極3及び前面電極5に取付けた電気接点は図示しなかった。
本発明のバリヤー層は、耐湿性ばかりでなく、基体に良好に接着するので、基体1とバリヤー層4間のリム8での界面沿いの湿気の拡散が防止される。出願人は、バリヤー層自体を通る湿気の拡散は、バリヤー層と基体間の界面沿いの湿気の拡散に比べて、重要ではないことを見い出した。
液体樹脂組成物の塗布は、噴霧、刷毛塗り、浸漬、回転塗布、スクリーン印刷等により行える。
液体樹脂組成物の塗布後、高分子量ポリオールと硬化性樹脂間の反応を進行させる。
高分子量ポリオールは、特に分子量(molar mass)約1000以上の高分子量ポリオールである。高分子量ポリオールの例は、ポリビニルアルコール、ポリエステルポリオール及び/又はポリエーテルポリオールである。
高分子量ポリオールは、上記例の高分子量ポリオールの混合物であってもよい。
高分子量ポリオールと硬化性樹脂間の反応は、硬化又は架橋と呼ばれる。溶剤が存在すれば、反応は、溶剤のフラッシュ除去後、始める。反応は、例えば市販の水銀放電ランプによる紫外線(UV)照射処理により行われる。
硬化性樹脂は、エポキシ樹脂である。バリヤー層に装入されたエポキシ樹脂は、脂肪族、脂環式又は芳香族エポキシドであってよく、脂肪族エポキシド及び脂環式エポキシド、即ち、環エポキシ化エポキシドが好ましい。エポキシ樹脂は、脂肪族エポキシド及び/又は脂環式エポキシドが70重量%以上よりなるものが有利である。
高分子量ポリオールは、硬化性樹脂に対し好適には1重量%を超え、特に5重量%を超える。高分子量ポリオールの量割合は、硬化性樹脂に対し好ましくは1〜15重量%の範囲であるが、硬化性樹脂に対し30重量%以下であってもよい。
バリヤー層は、電気又は光学機能層或いは基体として使用される殆どの材料に対し良好な接着性を示す。別の接着性付与層を必要とするかも知れない。
本発明のバリヤー層は、次のようにして作製した。まず、液体樹脂組成物を製造した。液体樹脂組成物は、ポリビニルブチラール35g、脂環式エポキシ樹脂357g、OH−134 236g 、ビスフェノールAと脂環式エポキシ樹脂Araldit CY 179との1:3の割合からなる、エポキシ化大豆油157g、三官能性ポリエステルポリオール197g、トリアリールスルホニウムヘキサフルオロアンチモネート9.8g、(3−グリシドキシプロピル)トリメトキシシラン3.9g、ジメチルポリシロキサン誘導体3.4gよりなる。
次に、金属接点片(図示せず)に電気接続(図示せず)させた後、減衰−加熱テスト用の容器中にテスト部品を入れた。テスト中、シート抵抗を測定した。
得られた結果を比較するため、比較実験を行った。最初に部品は、バリヤー層で被覆しなかった。
次いで3つのテスト部品のシート抵抗を、本発明部品のシート抵抗を測定した条件と同じ条件下で測定した。シート抵抗は、初期のシート抵抗が全ての部品について1になるように標準化した。
これらの結果を下記表に示す。酸化亜鉛について測定した標準化シート抵抗は、本発明のバリヤー層及び3つの比較例で測定した。
0 1.0 1.0 1.0 1.0
200 1.0 1.7 1.1 1.0
400 1.1 3.0 1.7 1.2
600 1.4 4.1 2.5 1.4
800 1.5 4.8 3.2 2.0
1000 1.8 5.7 4.2 2.9
本発明によれば、いずれの層構造、特に大きな表面を有する感天候性で感腐蝕性の薄膜配列に対し、耐候性及び耐腐蝕性の安定な封入が巧妙に行える。本発明は、このように熱及び/又は湿度環境に曝される太陽電池のような薄膜配列用に特に好適である。勿論、これは通常、このような腐蝕促進性環境条件に曝されない層構造にも有効である。
2 層構造
3 裏面電極
4 吸収層
5 前面電極
7 バリヤー層
8 リム又はエッジ
10 透明ガラスのカバー
11 接着層
20 窓ガラス板ソーダ石灰ガラスの基体
21 朋素ドープ酸化亜鉛層
23 リム
24 リム
26 バリヤー層
28 ガラスカバー
29 接着層
Claims (11)
- 基体、該基体上に設けた層構造、及び該層構造上に設けた、該層構造を湿気に対し保護するためのバリヤー層を有し、該層構造が、光学的又は電気的に活性の膜を有し、該バリヤー層が、分子量1000以上の高分子量ポリオールとしてポリビニルブチラールと紫外線硬化性樹脂としてエポキシ樹脂との反応生成物(但し、該高分子量ポリオールの量は該硬化性樹脂に対し1重量%を超え、特に硬化性樹脂に対し1〜30重量%の範囲である)を含むことを特徴とする太陽電池。
- 前記バリヤー層を、前記太陽電池の1つの外表面に少なくとも配置したことを特徴とする請求項1に記載の太陽電池。
- 前記太陽電池が、カバーと、バリヤー層上に設けた中間接着層とを有する積層構造を更に有することを特徴とする請求項1又は2に記載の太陽電池。
- 前記カバーが、少なくとも1つのプラスチック層を有することを特徴とする請求項3に記載の太陽電池。
- 前記カバーが、ガラス板であることを特徴とする請求項3に記載の太陽電池。
- 前記中間接着層がポリビニルブチラールの層であることを特徴とする請求項3に記載の太陽電池。
- 前記層構造が、感湿性吸収層を有し、特に該感湿性吸収層は銅−インジウム−二セレン化物を含有することを特徴とする請求項1又は2に記載の太陽電池。
- 前記バリヤー層が、層構造の外表面を越えて延びていることを特徴とする請求項1又は2に記載の太陽電池。
- 基体を供給する工程、
該基体上に、感湿性吸収層を有する層構造を蒸着する工程、及び
該層構造の表面に、分子量1000以上の高分子量ポリオールとしてポリビニルブチラール及び紫外線硬化性樹脂としてエポキシ樹脂を含有する液体樹脂組成物(但し、該高分子量ポリオールの量は該硬化性樹脂に対し1重量%を超え、特に硬化性樹脂に対し1〜30重量%の範囲である)を塗布し、次いで該高分子量ポリオールを該硬化性樹脂と反応させて、該層構造を湿気から保護するためのバリヤー層を形成する工程、
を含む太陽電池の製造方法。 - 前記バリヤー層に、接着層、特にポリビニルブチラールの層により、カバーを積層する工程を更に含む請求項9に記載の方法。
- 前記反応が紫外線照射処理により行われる請求項9又は10に記載の方法。
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PCT/EP2003/001073 WO2003064529A1 (en) | 2002-02-01 | 2003-01-31 | Barrier layer made of a curable resin containing polymeric polyol |
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EP1470191A1 (en) | 2004-10-27 |
US20050072459A1 (en) | 2005-04-07 |
JP2005515920A (ja) | 2005-06-02 |
US7255926B2 (en) | 2007-08-14 |
ES2396118T3 (es) | 2013-02-19 |
WO2003064529A1 (en) | 2003-08-07 |
CN1625582A (zh) | 2005-06-08 |
CN100336210C (zh) | 2007-09-05 |
EP1470191B1 (en) | 2012-11-21 |
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