JP5366109B2 - Solar cell encapsulant - Google Patents
Solar cell encapsulant Download PDFInfo
- Publication number
- JP5366109B2 JP5366109B2 JP2005377888A JP2005377888A JP5366109B2 JP 5366109 B2 JP5366109 B2 JP 5366109B2 JP 2005377888 A JP2005377888 A JP 2005377888A JP 2005377888 A JP2005377888 A JP 2005377888A JP 5366109 B2 JP5366109 B2 JP 5366109B2
- Authority
- JP
- Japan
- Prior art keywords
- solar cell
- sealing material
- propylene
- copolymer
- amorphous
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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- 239000008393 encapsulating agent Substances 0.000 title claims description 20
- 229920001577 copolymer Polymers 0.000 claims description 29
- 239000003566 sealing material Substances 0.000 claims description 28
- 239000004711 α-olefin Substances 0.000 claims description 23
- 229920000089 Cyclic olefin copolymer Polymers 0.000 claims description 16
- QQONPFPTGQHPMA-UHFFFAOYSA-N propylene Natural products CC=C QQONPFPTGQHPMA-UHFFFAOYSA-N 0.000 claims description 14
- 125000004805 propylene group Chemical group [H]C([H])([H])C([H])([*:1])C([H])([H])[*:2] 0.000 claims description 13
- 239000006087 Silane Coupling Agent Substances 0.000 claims description 7
- 239000000654 additive Substances 0.000 claims description 7
- 238000003860 storage Methods 0.000 claims description 7
- 239000006096 absorbing agent Substances 0.000 claims description 5
- 239000003795 chemical substances by application Substances 0.000 claims description 5
- 238000002844 melting Methods 0.000 claims description 5
- 230000008018 melting Effects 0.000 claims description 5
- 230000000996 additive effect Effects 0.000 claims description 4
- 239000003963 antioxidant agent Substances 0.000 claims description 4
- 230000003078 antioxidant effect Effects 0.000 claims description 3
- 239000004611 light stabiliser Substances 0.000 claims description 3
- ISWSIDIOOBJBQZ-UHFFFAOYSA-N Phenol Chemical compound OC1=CC=CC=C1 ISWSIDIOOBJBQZ-UHFFFAOYSA-N 0.000 claims description 2
- 150000001412 amines Chemical class 0.000 claims description 2
- 239000003063 flame retardant Substances 0.000 claims description 2
- OJMIONKXNSYLSR-UHFFFAOYSA-N phosphorous acid Chemical compound OP(O)O OJMIONKXNSYLSR-UHFFFAOYSA-N 0.000 claims description 2
- 229920000098 polyolefin Polymers 0.000 claims description 2
- 229920001155 polypropylene Polymers 0.000 claims description 2
- 238000009792 diffusion process Methods 0.000 claims 1
- 210000004027 cell Anatomy 0.000 description 59
- 239000000463 material Substances 0.000 description 26
- 230000001681 protective effect Effects 0.000 description 18
- VGGSQFUCUMXWEO-UHFFFAOYSA-N Ethene Chemical compound C=C VGGSQFUCUMXWEO-UHFFFAOYSA-N 0.000 description 16
- 239000005977 Ethylene Substances 0.000 description 16
- 238000000034 method Methods 0.000 description 11
- 238000004519 manufacturing process Methods 0.000 description 10
- 150000001451 organic peroxides Chemical class 0.000 description 10
- 238000010248 power generation Methods 0.000 description 8
- 239000003431 cross linking reagent Substances 0.000 description 7
- -1 oxy compound Chemical class 0.000 description 6
- VXNZUUAINFGPBY-UHFFFAOYSA-N ethyl ethylene Natural products CCC=C VXNZUUAINFGPBY-UHFFFAOYSA-N 0.000 description 5
- 239000011521 glass Substances 0.000 description 5
- 230000008569 process Effects 0.000 description 5
- HQQADJVZYDDRJT-UHFFFAOYSA-N ethene;prop-1-ene Chemical group C=C.CC=C HQQADJVZYDDRJT-UHFFFAOYSA-N 0.000 description 4
- 239000006097 ultraviolet radiation absorber Substances 0.000 description 4
- 150000001875 compounds Chemical class 0.000 description 3
- 238000004132 cross linking Methods 0.000 description 3
- 238000010030 laminating Methods 0.000 description 3
- 239000010410 layer Substances 0.000 description 3
- 239000000155 melt Substances 0.000 description 3
- 239000000203 mixture Substances 0.000 description 3
- 230000000704 physical effect Effects 0.000 description 3
- 229920000728 polyester Polymers 0.000 description 3
- 238000006116 polymerization reaction Methods 0.000 description 3
- JYEUMXHLPRZUAT-UHFFFAOYSA-N 1,2,3-triazine Chemical compound C1=CN=NN=C1 JYEUMXHLPRZUAT-UHFFFAOYSA-N 0.000 description 2
- JBRZTFJDHDCESZ-UHFFFAOYSA-N AsGa Chemical compound [As]#[Ga] JBRZTFJDHDCESZ-UHFFFAOYSA-N 0.000 description 2
- CURLTUGMZLYLDI-UHFFFAOYSA-N Carbon dioxide Chemical compound O=C=O CURLTUGMZLYLDI-UHFFFAOYSA-N 0.000 description 2
- YCKRFDGAMUMZLT-UHFFFAOYSA-N Fluorine atom Chemical compound [F] YCKRFDGAMUMZLT-UHFFFAOYSA-N 0.000 description 2
- CTQNGGLPUBDAKN-UHFFFAOYSA-N O-Xylene Chemical compound CC1=CC=CC=C1C CTQNGGLPUBDAKN-UHFFFAOYSA-N 0.000 description 2
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 description 2
- 229910052782 aluminium Inorganic materials 0.000 description 2
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 2
- 230000008901 benefit Effects 0.000 description 2
- RWCCWEUUXYIKHB-UHFFFAOYSA-N benzophenone Chemical compound C=1C=CC=CC=1C(=O)C1=CC=CC=C1 RWCCWEUUXYIKHB-UHFFFAOYSA-N 0.000 description 2
- 239000012965 benzophenone Substances 0.000 description 2
- QRUDEWIWKLJBPS-UHFFFAOYSA-N benzotriazole Chemical compound C1=CC=C2N[N][N]C2=C1 QRUDEWIWKLJBPS-UHFFFAOYSA-N 0.000 description 2
- 239000012964 benzotriazole Substances 0.000 description 2
- 125000004432 carbon atom Chemical group C* 0.000 description 2
- 239000003054 catalyst Substances 0.000 description 2
- UIPVMGDJUWUZEI-UHFFFAOYSA-N copper;selanylideneindium Chemical compound [Cu].[In]=[Se] UIPVMGDJUWUZEI-UHFFFAOYSA-N 0.000 description 2
- 150000001993 dienes Chemical class 0.000 description 2
- 229920001038 ethylene copolymer Polymers 0.000 description 2
- 238000001125 extrusion Methods 0.000 description 2
- 229910052731 fluorine Inorganic materials 0.000 description 2
- 239000011737 fluorine Substances 0.000 description 2
- 230000001771 impaired effect Effects 0.000 description 2
- 230000006872 improvement Effects 0.000 description 2
- 229910052751 metal Inorganic materials 0.000 description 2
- 239000002184 metal Substances 0.000 description 2
- 239000012968 metallocene catalyst Substances 0.000 description 2
- 239000000178 monomer Substances 0.000 description 2
- 238000000465 moulding Methods 0.000 description 2
- 230000002093 peripheral effect Effects 0.000 description 2
- ZQBAKBUEJOMQEX-UHFFFAOYSA-N phenyl salicylate Chemical compound OC1=CC=CC=C1C(=O)OC1=CC=CC=C1 ZQBAKBUEJOMQEX-UHFFFAOYSA-N 0.000 description 2
- 229920005989 resin Polymers 0.000 description 2
- 239000011347 resin Substances 0.000 description 2
- 150000003902 salicylic acid esters Chemical class 0.000 description 2
- 229910052710 silicon Inorganic materials 0.000 description 2
- 239000010703 silicon Substances 0.000 description 2
- 239000000758 substrate Substances 0.000 description 2
- 238000002834 transmittance Methods 0.000 description 2
- 239000008096 xylene Substances 0.000 description 2
- POLSVAXEEHDBMJ-UHFFFAOYSA-N (2-hydroxy-4-octadecoxyphenyl)-phenylmethanone Chemical compound OC1=CC(OCCCCCCCCCCCCCCCCCC)=CC=C1C(=O)C1=CC=CC=C1 POLSVAXEEHDBMJ-UHFFFAOYSA-N 0.000 description 1
- SXJSETSRWNDWPP-UHFFFAOYSA-N (2-hydroxy-4-phenylmethoxyphenyl)-phenylmethanone Chemical compound C=1C=C(C(=O)C=2C=CC=CC=2)C(O)=CC=1OCC1=CC=CC=C1 SXJSETSRWNDWPP-UHFFFAOYSA-N 0.000 description 1
- VNFXPOAMRORRJJ-UHFFFAOYSA-N (4-octylphenyl) 2-hydroxybenzoate Chemical compound C1=CC(CCCCCCCC)=CC=C1OC(=O)C1=CC=CC=C1O VNFXPOAMRORRJJ-UHFFFAOYSA-N 0.000 description 1
- OMWSZDODENFLSV-UHFFFAOYSA-N (5-chloro-2-hydroxyphenyl)-phenylmethanone Chemical compound OC1=CC=C(Cl)C=C1C(=O)C1=CC=CC=C1 OMWSZDODENFLSV-UHFFFAOYSA-N 0.000 description 1
- MEZZCSHVIGVWFI-UHFFFAOYSA-N 2,2'-Dihydroxy-4-methoxybenzophenone Chemical compound OC1=CC(OC)=CC=C1C(=O)C1=CC=CC=C1O MEZZCSHVIGVWFI-UHFFFAOYSA-N 0.000 description 1
- RNFJDJUURJAICM-UHFFFAOYSA-N 2,2,4,4,6,6-hexaphenoxy-1,3,5-triaza-2$l^{5},4$l^{5},6$l^{5}-triphosphacyclohexa-1,3,5-triene Chemical compound N=1P(OC=2C=CC=CC=2)(OC=2C=CC=CC=2)=NP(OC=2C=CC=CC=2)(OC=2C=CC=CC=2)=NP=1(OC=1C=CC=CC=1)OC1=CC=CC=C1 RNFJDJUURJAICM-UHFFFAOYSA-N 0.000 description 1
- ZXDDPOHVAMWLBH-UHFFFAOYSA-N 2,4-Dihydroxybenzophenone Chemical compound OC1=CC(O)=CC=C1C(=O)C1=CC=CC=C1 ZXDDPOHVAMWLBH-UHFFFAOYSA-N 0.000 description 1
- JLZIIHMTTRXXIN-UHFFFAOYSA-N 2-(2-hydroxy-4-methoxybenzoyl)benzoic acid Chemical compound OC1=CC(OC)=CC=C1C(=O)C1=CC=CC=C1C(O)=O JLZIIHMTTRXXIN-UHFFFAOYSA-N 0.000 description 1
- ZMWRRFHBXARRRT-UHFFFAOYSA-N 2-(benzotriazol-2-yl)-4,6-bis(2-methylbutan-2-yl)phenol Chemical compound CCC(C)(C)C1=CC(C(C)(C)CC)=CC(N2N=C3C=CC=CC3=N2)=C1O ZMWRRFHBXARRRT-UHFFFAOYSA-N 0.000 description 1
- MJFOVRMNLQNDDS-UHFFFAOYSA-N 2-(benzotriazol-2-yl)-4,6-dimethylphenol Chemical compound CC1=CC(C)=C(O)C(N2N=C3C=CC=CC3=N2)=C1 MJFOVRMNLQNDDS-UHFFFAOYSA-N 0.000 description 1
- LHPPDQUVECZQSW-UHFFFAOYSA-N 2-(benzotriazol-2-yl)-4,6-ditert-butylphenol Chemical compound CC(C)(C)C1=CC(C(C)(C)C)=CC(N2N=C3C=CC=CC3=N2)=C1O LHPPDQUVECZQSW-UHFFFAOYSA-N 0.000 description 1
- NLWDAUDWBLSJGK-UHFFFAOYSA-N 2-(benzotriazol-2-yl)-4-tert-butyl-6-methylphenol Chemical compound CC1=CC(C(C)(C)C)=CC(N2N=C3C=CC=CC3=N2)=C1O NLWDAUDWBLSJGK-UHFFFAOYSA-N 0.000 description 1
- WXHVQMGINBSVAY-UHFFFAOYSA-N 2-(benzotriazol-2-yl)-4-tert-butylphenol Chemical compound CC(C)(C)C1=CC=C(O)C(N2N=C3C=CC=CC3=N2)=C1 WXHVQMGINBSVAY-UHFFFAOYSA-N 0.000 description 1
- ZSSVCEUEVMALRD-UHFFFAOYSA-N 2-[4,6-bis(2,4-dimethylphenyl)-1,3,5-triazin-2-yl]-5-(octyloxy)phenol Chemical compound OC1=CC(OCCCCCCCC)=CC=C1C1=NC(C=2C(=CC(C)=CC=2)C)=NC(C=2C(=CC(C)=CC=2)C)=N1 ZSSVCEUEVMALRD-UHFFFAOYSA-N 0.000 description 1
- XDLMVUHYZWKMMD-UHFFFAOYSA-N 3-trimethoxysilylpropyl 2-methylprop-2-enoate Chemical compound CO[Si](OC)(OC)CCCOC(=O)C(C)=C XDLMVUHYZWKMMD-UHFFFAOYSA-N 0.000 description 1
- OUWPEHOSUWXUFV-UHFFFAOYSA-N 4-(benzotriazol-2-yl)-3-methylphenol Chemical compound CC1=CC(O)=CC=C1N1N=C2C=CC=CC2=N1 OUWPEHOSUWXUFV-UHFFFAOYSA-N 0.000 description 1
- 239000004925 Acrylic resin Substances 0.000 description 1
- 229920000178 Acrylic resin Polymers 0.000 description 1
- 229910001218 Gallium arsenide Inorganic materials 0.000 description 1
- 239000004594 Masterbatch (MB) Substances 0.000 description 1
- 239000004820 Pressure-sensitive adhesive Substances 0.000 description 1
- BLRPTPMANUNPDV-UHFFFAOYSA-N Silane Chemical compound [SiH4] BLRPTPMANUNPDV-UHFFFAOYSA-N 0.000 description 1
- ATJFFYVFTNAWJD-UHFFFAOYSA-N Tin Chemical compound [Sn] ATJFFYVFTNAWJD-UHFFFAOYSA-N 0.000 description 1
- RTAQQCXQSZGOHL-UHFFFAOYSA-N Titanium Chemical compound [Ti] RTAQQCXQSZGOHL-UHFFFAOYSA-N 0.000 description 1
- XTXRWKRVRITETP-UHFFFAOYSA-N Vinyl acetate Chemical compound CC(=O)OC=C XTXRWKRVRITETP-UHFFFAOYSA-N 0.000 description 1
- 238000002441 X-ray diffraction Methods 0.000 description 1
- 125000002723 alicyclic group Chemical group 0.000 description 1
- 150000001336 alkenes Chemical class 0.000 description 1
- 125000003545 alkoxy group Chemical group 0.000 description 1
- 229910021417 amorphous silicon Inorganic materials 0.000 description 1
- WXNRYSGJLQFHBR-UHFFFAOYSA-N bis(2,4-dihydroxyphenyl)methanone Chemical compound OC1=CC(O)=CC=C1C(=O)C1=CC=C(O)C=C1O WXNRYSGJLQFHBR-UHFFFAOYSA-N 0.000 description 1
- SODJJEXAWOSSON-UHFFFAOYSA-N bis(2-hydroxy-4-methoxyphenyl)methanone Chemical compound OC1=CC(OC)=CC=C1C(=O)C1=CC=C(OC)C=C1O SODJJEXAWOSSON-UHFFFAOYSA-N 0.000 description 1
- IAQRGUVFOMOMEM-UHFFFAOYSA-N butene Natural products CC=CC IAQRGUVFOMOMEM-UHFFFAOYSA-N 0.000 description 1
- RPPBZEBXAAZZJH-UHFFFAOYSA-N cadmium telluride Chemical compound [Te]=[Cd] RPPBZEBXAAZZJH-UHFFFAOYSA-N 0.000 description 1
- 238000003490 calendering Methods 0.000 description 1
- 229910002092 carbon dioxide Inorganic materials 0.000 description 1
- 239000001569 carbon dioxide Substances 0.000 description 1
- 239000000470 constituent Substances 0.000 description 1
- 238000007796 conventional method Methods 0.000 description 1
- 125000000058 cyclopentadienyl group Chemical group C1(=CC=CC1)* 0.000 description 1
- WSSSPWUEQFSQQG-UHFFFAOYSA-N dimethylbutene Natural products CC(C)CC=C WSSSPWUEQFSQQG-UHFFFAOYSA-N 0.000 description 1
- 238000002845 discoloration Methods 0.000 description 1
- MCPKSFINULVDNX-UHFFFAOYSA-N drometrizole Chemical compound CC1=CC=C(O)C(N2N=C3C=CC=CC3=N2)=C1 MCPKSFINULVDNX-UHFFFAOYSA-N 0.000 description 1
- ZSWFCLXCOIISFI-UHFFFAOYSA-N endo-cyclopentadiene Natural products C1C=CC=C1 ZSWFCLXCOIISFI-UHFFFAOYSA-N 0.000 description 1
- 230000007613 environmental effect Effects 0.000 description 1
- 125000003700 epoxy group Chemical group 0.000 description 1
- 238000007765 extrusion coating Methods 0.000 description 1
- 230000002349 favourable effect Effects 0.000 description 1
- 238000001914 filtration Methods 0.000 description 1
- 238000009472 formulation Methods 0.000 description 1
- 210000003918 fraction a Anatomy 0.000 description 1
- 150000004820 halides Chemical class 0.000 description 1
- 229910010272 inorganic material Inorganic materials 0.000 description 1
- 239000011147 inorganic material Substances 0.000 description 1
- 238000005259 measurement Methods 0.000 description 1
- 150000002739 metals Chemical class 0.000 description 1
- KWKAKUADMBZCLK-UHFFFAOYSA-N methyl heptene Natural products CCCCCCC=C KWKAKUADMBZCLK-UHFFFAOYSA-N 0.000 description 1
- 238000002156 mixing Methods 0.000 description 1
- 229910021421 monocrystalline silicon Inorganic materials 0.000 description 1
- PHQOGHDTIVQXHL-UHFFFAOYSA-N n'-(3-trimethoxysilylpropyl)ethane-1,2-diamine Chemical compound CO[Si](OC)(OC)CCCNCCN PHQOGHDTIVQXHL-UHFFFAOYSA-N 0.000 description 1
- MQWFLKHKWJMCEN-UHFFFAOYSA-N n'-[3-[dimethoxy(methyl)silyl]propyl]ethane-1,2-diamine Chemical compound CO[Si](C)(OC)CCCNCCN MQWFLKHKWJMCEN-UHFFFAOYSA-N 0.000 description 1
- TVMXDCGIABBOFY-UHFFFAOYSA-N n-Octanol Natural products CCCCCCCC TVMXDCGIABBOFY-UHFFFAOYSA-N 0.000 description 1
- LIKMAJRDDDTEIG-UHFFFAOYSA-N n-hexene Natural products CCCCC=C LIKMAJRDDDTEIG-UHFFFAOYSA-N 0.000 description 1
- QUAMTGJKVDWJEQ-UHFFFAOYSA-N octabenzone Chemical compound OC1=CC(OCCCCCCCC)=CC=C1C(=O)C1=CC=CC=C1 QUAMTGJKVDWJEQ-UHFFFAOYSA-N 0.000 description 1
- JRZJOMJEPLMPRA-UHFFFAOYSA-N olefin Natural products CCCCCCCC=C JRZJOMJEPLMPRA-UHFFFAOYSA-N 0.000 description 1
- DXGLGDHPHMLXJC-UHFFFAOYSA-N oxybenzone Chemical compound OC1=CC(OC)=CC=C1C(=O)C1=CC=CC=C1 DXGLGDHPHMLXJC-UHFFFAOYSA-N 0.000 description 1
- 150000002978 peroxides Chemical class 0.000 description 1
- 229960000969 phenyl salicylate Drugs 0.000 description 1
- 229920000515 polycarbonate Polymers 0.000 description 1
- 239000004417 polycarbonate Substances 0.000 description 1
- 229910021420 polycrystalline silicon Inorganic materials 0.000 description 1
- 229920000642 polymer Polymers 0.000 description 1
- 239000002685 polymerization catalyst Substances 0.000 description 1
- 125000002924 primary amino group Chemical group [H]N([H])* 0.000 description 1
- 238000012545 processing Methods 0.000 description 1
- 230000009467 reduction Effects 0.000 description 1
- 238000011160 research Methods 0.000 description 1
- 239000011342 resin composition Substances 0.000 description 1
- 238000007789 sealing Methods 0.000 description 1
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- 229910000077 silane Inorganic materials 0.000 description 1
- 239000002356 single layer Substances 0.000 description 1
- 238000004544 sputter deposition Methods 0.000 description 1
- 239000003381 stabilizer Substances 0.000 description 1
- 229910001220 stainless steel Inorganic materials 0.000 description 1
- 239000010935 stainless steel Substances 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- CXVGEDCSTKKODG-UHFFFAOYSA-N sulisobenzone Chemical compound C1=C(S(O)(=O)=O)C(OC)=CC(O)=C1C(=O)C1=CC=CC=C1 CXVGEDCSTKKODG-UHFFFAOYSA-N 0.000 description 1
- 238000012360 testing method Methods 0.000 description 1
- 229920005992 thermoplastic resin Polymers 0.000 description 1
- 229910052718 tin Inorganic materials 0.000 description 1
- 229910052719 titanium Inorganic materials 0.000 description 1
- 239000010936 titanium Substances 0.000 description 1
- 150000003623 transition metal compounds Chemical class 0.000 description 1
- BPSIOYPQMFLKFR-UHFFFAOYSA-N trimethoxy-[3-(oxiran-2-ylmethoxy)propyl]silane Chemical compound CO[Si](OC)(OC)CCCOCC1CO1 BPSIOYPQMFLKFR-UHFFFAOYSA-N 0.000 description 1
- 229910052720 vanadium Inorganic materials 0.000 description 1
- LEONUFNNVUYDNQ-UHFFFAOYSA-N vanadium atom Chemical group [V] LEONUFNNVUYDNQ-UHFFFAOYSA-N 0.000 description 1
- 150000003682 vanadium compounds Chemical class 0.000 description 1
- 238000007740 vapor deposition Methods 0.000 description 1
- 125000000391 vinyl group Chemical group [H]C([*])=C([H])[H] 0.000 description 1
- 150000003755 zirconium compounds Chemical class 0.000 description 1
Classifications
-
- 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
Landscapes
- Photovoltaic Devices (AREA)
Description
本発明は、太陽電池モジュールにおける太陽電池素子の封止材及びそれを用いた太陽電池モジュールに関する。さらに詳しくは、太陽電池モジュールの形成が容易で、透明性、耐熱性、柔軟性等に優れた太陽電池封止材に関する。 The present invention relates to a sealing material for a solar cell element in a solar cell module and a solar cell module using the same. More specifically, the present invention relates to a solar cell encapsulant that is easy to form a solar cell module and is excellent in transparency, heat resistance, flexibility, and the like.
無尽蔵な自然エネルギーを利用し、二酸化炭素の削減やその他の環境問題の改善が図れる水力発電、風力発電並びに太陽光発電などが脚光を浴びている。このうち太陽光発電は、太陽電池モジュールの発電効率等の性能向上が著しい一方、価格の低下が進んだこと、国や自治体が住宅用太陽光発電システム導入促進事業を進めてきたことから、近年その普及が著しく進んでいる。しかしながら更なる普及には一層の低コスト化が必要であり、そのため発電効率の一層の向上に向けた研究も日夜続けられている。 Hydroelectric power generation, wind power generation, and solar power generation, which use inexhaustible natural energy to reduce carbon dioxide and improve other environmental problems, are in the spotlight. Among these, solar power generation has seen remarkable improvements in performance, such as power generation efficiency of solar cell modules, but the price has declined and the national and local governments have promoted the introduction of residential solar power generation systems. Its spread is remarkably advanced. However, further cost reduction is necessary for further dissemination, and research for further improvement of power generation efficiency is continued day and night.
太陽電池モジュールは、一般にシリコン、ガリウムー砒素、銅ーインジウムーセレンなどの太陽電池素子を上部透明保護材と下部基板保護材とで保護し、太陽電池素子と保護材とを封止材で固定し、パッケージ化したものである。このため太陽電池封止材としては、発電効率を高めるためにも、透明性が良好であることが求められている。また太陽電池モジュールの使用時に温度上昇しても、封止材が流動したり変形したりするトラブルを避けるために、耐熱性を有することが求められている。また近年では、太陽電池素子の薄肉化に伴い、一層柔軟性に優れた封止材も求められている。 Solar cell modules generally protect solar cell elements such as silicon, gallium-arsenide, copper-indium-selenium with an upper transparent protective material and a lower substrate protective material, and fix the solar cell element and protective material with a sealing material. And packaged. For this reason, as a solar cell sealing material, in order to improve electric power generation efficiency, it is calculated | required that transparency is favorable. Moreover, even if the temperature rises when using the solar cell module, it is required to have heat resistance in order to avoid troubles in which the sealing material flows or deforms. In recent years, as the solar cell element is made thinner, a sealing material with further flexibility is also required.
現在、太陽電池モジュールにおける太陽電池素子の封止材としては、柔軟性、透明性等の観点から、酢酸ビニル含量の高いエチレン・酢酸ビニル共重合体が使用されている。しかしながら、耐熱性が不足しているところから、有機過酸化物を併用する必要があった。そのため有機過酸化物を配合したエチレン・酢酸ビニル共重合体のシートを予め作成し、得られたシートを用いて太陽電池素子を封止するという２段階の工程を採用する必要があった。このシートの製造段階では、有機過酸化物が分解しないような低温度での成形が必要であるため、押出成形速度を高くすることができず、また太陽電池素子の封止段階では、ラミネーターにおいて数分乃至十数分かけて仮接着する工程と、オーブン内において有機過酸化物が分解する高温度で数十分ないし１時間かけて本接着する工程とからなる２段階の時間をかけての接着工程を経る必要があった。そのため太陽電池モジュールの製造には手間と時間がかかり、その製造コストを上昇させる要因の一つとなっていた。 Currently, an ethylene / vinyl acetate copolymer having a high vinyl acetate content is used as a sealing material for a solar cell element in a solar cell module from the viewpoint of flexibility, transparency, and the like. However, since the heat resistance is insufficient, it is necessary to use an organic peroxide in combination. Therefore, it was necessary to employ a two-step process in which a sheet of an ethylene / vinyl acetate copolymer blended with an organic peroxide was prepared in advance and the solar cell element was sealed using the obtained sheet. In the production stage of this sheet, it is necessary to form at a low temperature so that the organic peroxide is not decomposed. Therefore, the extrusion molding speed cannot be increased, and in the sealing stage of the solar cell element, in the laminator It takes two steps, consisting of a process of temporary bonding for several minutes to ten and several minutes and a process of main bonding for several tens of minutes to one hour at a high temperature at which the organic peroxide decomposes in the oven. It was necessary to go through an adhesion process. Therefore, it takes time and labor to manufacture the solar cell module, which is one of the factors that increase the manufacturing cost.
そこで本発明者らは、このような有機過酸化物の使用を必要とせず、したがって太陽電池モジュールの生産効率を顕著に改善することができ、しかも太陽電池用封止材として優れた特性を有する代替材料につき検討を行った。また有機過酸化物を使用する場合においても、エチレン・酢酸ビニル共重合体に代わる柔軟性に優れた代替材料につき検討を行った。その結果、後記する材料が、これら代替材料として適していることを見出し、本発明に到達した。 Therefore, the present inventors do not require the use of such an organic peroxide, and therefore can significantly improve the production efficiency of the solar cell module, and have excellent characteristics as a sealing material for solar cells. We examined alternative materials. In addition, when using organic peroxides, we examined alternative materials with excellent flexibility instead of ethylene / vinyl acetate copolymers. As a result, the inventors have found that the materials described later are suitable as these alternative materials, and have reached the present invention.
すなわち本発明は、Ｘ線による結晶化度が４０％以下の非晶性又は低結晶性のα−オレフィン系共重合体からななり、融点もしくは軟化点が８５℃以上、１５０℃の貯蔵弾性率が１０ ３ Ｐａ以上であるシート状太陽電池封止材（太陽電池素子封止材）に関する。上記非晶性又は低結晶性α−オレフィン系共重合体としては、ショアＤ硬度が６０以下のものが好ましく、０．５ｍｍ厚みにおけるＨＡＺＥが１０％以下のものであることが好ましい。 That is, the present invention Ri Do such a crystallinity amorphous or less 40% or low crystalline α- olefin copolymer by X-ray, melting point or softening point of 85 ° C. or higher, the storage elasticity of 0.99 ° C. rate is Ru der 10 3 Pa or more relates to a sheet-like solar cell sealing material (solar cell element sealing material). As the amorphous or low crystalline α- olefin copolymer, tio A D hardness preferably it has 60 or less and a HAZE is of 10% or less in 0.5mm thickness.
上記非晶性又は低結晶性のα−オレフィン系共重合体には、好ましくは、シランカップリング剤、酸化防止剤、紫外線吸収剤及び耐候安定剤から選ばれる少なくとも一種の添加剤が配合される。 The amorphous or low crystalline α-olefin copolymer is preferably blended with at least one additive selected from a silane coupling agent, an antioxidant, an ultraviolet absorber and a weathering stabilizer. .
本発明においてはまた、上記太陽電池封止材を用いて作成された太陽電池モジュールが提供される。 In this invention, the solar cell module produced using the said solar cell sealing material is also provided.
本発明の封止材は、透明性、耐熱性、柔軟性などに優れている。とくに適当な非晶性又は低結晶性のα−オレフィン系共重合体を選択することにより、融点が８５℃以上、１５０℃の貯蔵弾性率が１０３Ｐａ以上、ショア Ｄ硬度が６０以下、０．５ｍｍ厚みにおけるＨＡＺＥが１０％以下の封止材を容易に得ることができる。したがって本発明によれば、太陽電池モジュールの使用時に温度上昇しても、封止材が流動したり変形したりするトラブルを回避することが可能であり、太陽電池の外観を損なうことも無い。また上記のような有機過酸化物の使用が省略できるので、太陽電池モジュール製造工程における生産性を著しく高めることが可能であり、太陽電池モジュールの製造コストを大幅に低減させることが可能である。 The sealing material of the present invention is excellent in transparency, heat resistance, flexibility and the like. In particular, by selecting a suitable amorphous or low crystalline α-olefin copolymer, the melting point is 85 ° C. or higher, the storage elastic modulus at 150 ° C. is 10 3 Pa or higher, the Shore D hardness is 60 or lower, 0 A sealing material having a HAZE of 10% or less at a thickness of 0.5 mm can be easily obtained. Therefore, according to the present invention, even when the temperature rises when the solar cell module is used, it is possible to avoid the trouble that the sealing material flows or deforms, and the appearance of the solar cell is not impaired. Further, since the use of the organic peroxide as described above can be omitted, the productivity in the solar cell module manufacturing process can be remarkably increased, and the manufacturing cost of the solar cell module can be greatly reduced .
本発明の封止材として使用される非晶性又は低結晶性のα−オレフィン系共重合体は、炭素数が２〜１０のα−オレフィンの二種以上を構成成分とし、Ｘ線回折法によって測定される結晶化度が４０％以下（０〜４０％）の共重合体であって、ゴム的な性質を有するものである。耐熱性の点からは、完全非晶質のものより、いわゆる低結晶性共重合体に該当するような、結晶化度が１〜４０％程度のものを使用するのが好ましい。しかしながらエチレンを主成分とするもので、有機過酸化物を配合する場合には、完全非晶質（結晶化度０）のものでもよい。 The amorphous or low-crystalline α-olefin copolymer used as the sealing material of the present invention comprises two or more α-olefins having 2 to 10 carbon atoms as constituent components, and an X-ray diffraction method. Is a copolymer having a degree of crystallinity of 40% or less (0 to 40%) as measured by the formula (1), and has rubbery properties. From the viewpoint of heat resistance, it is preferable to use a material having a crystallinity of about 1 to 40%, which corresponds to a so-called low crystalline copolymer, rather than a completely amorphous material. However, it is mainly composed of ethylene, and when an organic peroxide is blended, it may be completely amorphous (crystallinity 0).
その共重合体の代表例は、エチレン又はプロピレンを主成分とし、それらに炭素数２〜１０の他のα−オレフィン１種または２種以上を副成分とし、必要に応じてジエンモノマーを少量共重合させた構成の共重合体である。 A typical example of the copolymer is mainly composed of ethylene or propylene, and one or more other α-olefins having 2 to 10 carbon atoms as subcomponents, and if necessary, a small amount of a diene monomer. A copolymer having a polymerized structure.
エチレンを主成分とする共重合体としては、エチレン重合単位を５０〜９０モル％、好ましくは７０〜８５モル％、エチレン以外のα−オレフィン重合単位を５０〜１０モル％、好ましくは３０〜１５モル％、必要に応じてジエンモノマー重合単位を２モル％以下、好ましくは１モル％以下含有するものを挙げることができる。そのようなエチレン系共重合体として、エチレン・プロピレン共重合体、エチレン・１−ブテン共重合体、エチレン・４−メチル−１−ペンテン共重合体、エチレン・１−ヘキセン共重合体、エチレン・１−オクテン共重合体、エチレン・プロピレン・ジシクペンタジエン共重合体、エチレン・プロピレン・５−エチリデン−２−ノルボルネン共重合体、エチレン・プロピレン・１，６−ヘキサジエン共重合体等を例示することができる。これらの中ではとくに、エチレン・プロピレン共重合体、エチレン・プロピレン・ジエン共重合体又はエチレン・１−ブテン共重合体が好ましい。 As a copolymer having ethylene as a main component, ethylene polymerized units are 50 to 90 mol%, preferably 70 to 85 mol%, and α-olefin polymerized units other than ethylene are 50 to 10 mol%, preferably 30 to 15 mol%. Examples include those containing 2 mol% or less, preferably 1 mol% or less of a diene monomer polymerization unit as required. Examples of such ethylene copolymers include ethylene / propylene copolymers, ethylene / 1-butene copolymers, ethylene / 4-methyl-1-pentene copolymers, ethylene / 1-hexene copolymers, ethylene Exemplifying 1-octene copolymer, ethylene / propylene / dicyclopentadiene copolymer, ethylene / propylene / 5-ethylidene-2-norbornene copolymer, ethylene / propylene / 1,6-hexadiene copolymer, etc. Can do. Among these, an ethylene / propylene copolymer, an ethylene / propylene / diene copolymer or an ethylene / 1-butene copolymer is particularly preferable.
またプロピレンを主成分とする共重合体は、プロピレン重合単位を７０〜９５モル％、好ましくは７２〜９０モル％、プロピレン以外のα−オレフィンの重合単位を５〜３０モル％、好ましくは１０〜２８モル％含有するものを例示することができる。そのようなプロピレン系共重合体としては、プロピレン・エチレン共重合体およびプロピレン・１−ブテン共重合体を例示することができる。 The copolymer mainly composed of propylene has a propylene polymerization unit of 70 to 95 mol%, preferably 72 to 90 mol%, and an α-olefin polymerization unit other than propylene of 5 to 30 mol%, preferably 10 to 10 mol%. What contains 28 mol% can be illustrated. Examples of such propylene copolymers include propylene / ethylene copolymers and propylene / 1-butene copolymers.
上記非晶性又は低結晶性のα−オレフィン系共重合体としては、成形性、機械的強度などを考慮すると、ＡＳＴＭ Ｄ−１２３８に準拠し、２３０℃、２１６０ｇ荷重下で測定したメルトフローレート（ＭＦＲ）が、０．１〜５０ｇ／１０分、とくに０．５〜２０ｇ／１０分のものを使用するのが好ましい。 As the amorphous or low crystalline α-olefin copolymer, the melt flow rate measured at 230 ° C. under a load of 2160 g in accordance with ASTM D-1238 in consideration of moldability, mechanical strength and the like. It is preferable to use (MFR) of 0.1 to 50 g / 10 min, particularly 0.5 to 20 g / 10 min.
上記非晶性又は低結晶性のα−オレフィン系共重合体は、エチレンを主成分とする共重合体の場合は、可溶性バナジウム化合物と有機アルミニウムハライドとからなるバナジウム系触媒、あるいはシクロペンタジエニル基等が配位したジルコニウム化合物等のメタロセン化合物と有機アルミニウムオキシ化合物とからなるメタロセン系触媒の存在下に、エチレン及びその他α−オレフィン類を共重合させることによって製造することができる。またプロピレンを主成分とする共重合体の場合は、高活性チタン触媒成分あるいはメタロセン系触媒成分などの遷移金属化合物成分、有機アルミニウム成分、必要に応じて電子供与体、担体等を含む立体規則性オレフィン重合触媒の存在下に、プロピレンと他のα−オレフィンを共重合させることによって製造することができる。 The amorphous or low crystalline α-olefin copolymer is a vanadium catalyst comprising a soluble vanadium compound and an organoaluminum halide, or cyclopentadienyl in the case of a copolymer containing ethylene as a main component. It can be produced by copolymerizing ethylene and other α-olefins in the presence of a metallocene catalyst composed of a metallocene compound such as a zirconium compound coordinated with a group and the like and an organoaluminum oxy compound. In the case of a copolymer containing propylene as a main component, a stereoregularity containing a transition metal compound component such as a highly active titanium catalyst component or a metallocene catalyst component, an organoaluminum component, and an electron donor or a carrier as required. It can be produced by copolymerizing propylene and another α-olefin in the presence of an olefin polymerization catalyst.
太陽電池封止材として使用するに際して、必要に応じ、他の重合体や種々の添加剤を配合することができる。このような添加剤として具体的には、架橋剤、架橋助剤、シランカップリング剤、紫外線吸収剤、ヒンダードフェノール系やホスファイト系の酸化防止剤、ヒンダードアミン系の光安定剤、光拡散剤、難燃剤、変色防止剤などを例示することができる。本発明においては、非晶性又は低結晶性のα−オレフィン系共重合体は、通常、架橋剤や架橋助剤を配合する必要はない。 When used as a solar cell encapsulant, other polymers and various additives can be blended as necessary. Specific examples of such additives include crosslinking agents, crosslinking aids, silane coupling agents, ultraviolet absorbers, hindered phenolic and phosphite antioxidants, hindered amine light stabilizers, and light diffusing agents. A flame retardant, a discoloration preventing agent and the like can be exemplified. In the present invention, the amorphous or low crystalline α-olefin copolymer does not usually need to contain a crosslinking agent or a crosslinking aid .
シランカップリング剤は、封止材の保護材や太陽電池素子等に対する接着性を向上させるのに有用であり、その例としては、ビニル基、アクリロキシ基、メタクリロキシ基などの不飽和基、アミノ基、エポキシ基などとともに、アルコキシ基のような加水分解可能な基を有する化合物を挙げることができる。シランカップリング剤として具体的には、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、Ｎ−（β−アミノエチル）−γ−アミノプロピルメチルジメトキシシラン、γ−アミノプロピルトリエトキシシラン、γ−グリシドキシプロピルトリメトキシシラン、γ−メタクリロキシプロピルトリメトキシシランなどを例示することができる。シランカップリング剤は、非晶性又は低結晶性α−オレフィン系共重合体１００重量部に対し、０．１〜５重量部程度配合することが望ましい。 Silane-coupling agents are useful for improving the adhesion to the protective material and the solar cell element or the like of the sealing material, and examples thereof include a vinyl group, acryloxy group, an unsaturated group such as methacryloxy group, amino A compound having a hydrolyzable group such as an alkoxy group together with a group and an epoxy group can be given. Specific examples of the silane coupling agent include N- (β-aminoethyl) -γ-aminopropyltrimethoxysilane, N- (β-aminoethyl) -γ-aminopropylmethyldimethoxysilane, and γ-aminopropyltriethoxy. Examples include silane, γ-glycidoxypropyltrimethoxysilane, γ-methacryloxypropyltrimethoxysilane, and the like. The silane coupling agent is desirably blended in an amount of about 0.1 to 5 parts by weight with respect to 100 parts by weight of the amorphous or low crystalline α-olefin copolymer.
本発明の太陽電池封止材に添加することができる紫外線吸収剤としては、ベンゾフェノン系、ベンゾトリアゾール系、トリアジン系、サリチル酸エステル系など各種タイプのものを挙げることができる。ベンゾフェノン系紫外線吸収剤としては、例えば、２−ヒドロキシ−４−メトキシベンゾフェノン、２−ヒドロキシ−４−メトキシ−２’−カルボキシベンゾフェノン、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−ｎ−ドデシルオキシベンゾフェノン、２−ヒドロキシ−４−ｎ−オクタデシルオキシベンゾフェノン、２−ヒドロキシ−４−ベンジルオキシベンゾフェノン、２−ヒドロキシ−４−メトキシ−５−スルホベンゾフェノン、２−ヒドロキシ−５−クロロベンゾフェノン、２，４−ジヒドロキシベンゾフェノン、２，２’−ジヒドロキシ−４−メトキシベンゾフェノン、２，２’−ジヒドロキシ−４，４’−ジメトキシベンゾフェノン、２，２’，４，４’−テトラヒドロキシベンゾフェノンなどを挙げることができる。 Examples of the ultraviolet absorber that can be added to the solar cell encapsulant of the present invention include various types such as benzophenone-based, benzotriazole-based, triazine-based, and salicylic acid ester-based materials. Examples of the benzophenone-based UV absorber include 2-hydroxy-4-methoxybenzophenone, 2-hydroxy-4-methoxy-2′-carboxybenzophenone, 2-hydroxy-4-octoxybenzophenone, 2-hydroxy-4-n. -Dodecyloxybenzophenone, 2-hydroxy-4-n-octadecyloxybenzophenone, 2-hydroxy-4-benzyloxybenzophenone, 2-hydroxy-4-methoxy-5-sulfobenzophenone, 2-hydroxy-5-chlorobenzophenone, 2 , 4-dihydroxybenzophenone, 2,2′-dihydroxy-4-methoxybenzophenone, 2,2′-dihydroxy-4,4′-dimethoxybenzophenone, 2,2 ′, 4,4′-tetrahydroxybenzophenone, etc. It is possible.
ベンゾトリアゾール系紫外線吸収剤としては、ヒドロキシフェニル置換ベンゾトリアゾール化合物であって、例えば、２−（２−ヒドロキシ−５−メチルフェニル）ベンゾトリアゾール、２−（２−ヒドロキシ−５−ｔ−ブチルフェニル）ベンゾトリアゾール、２−（２−ヒドロキシ−３，５−ジメチルフェニル）ベンゾトリアゾール、２−（２−メチル−４−ヒドロキシフェニル）ベンゾトリアゾール、２−（２−ヒドロキシ−３−メチル−５−ｔ−ブチルフェニル）ベンゾトリアゾール、２−（２−ヒドロキシ−３，５−ジ−ｔ−アミルフェニル）ベンゾトリアゾール、２−（２−ヒドロキシ−３，５−ジ−ｔ−ブチルフェニル）ベンゾトリアゾール、などを挙げることができる。またトリアジン系紫外線吸収剤としては、２−［４，６−ビス（２，４−ジメチルフェニル）−１，３，５−トリアジン−２−イル］−５−（オクチルオキシ）フェノール、２−（４，６−ジフェニル−１，３，５−トリアジン−２−イル）−５−（ヘキシルオキシ）フェノールなどを挙げることができる。サリチル酸エステル系としては、フェニルサリチレート、ｐ−オクチルフェニルサリチレートなどを挙げることができる。これら紫外線吸収剤は、非晶性又は低結晶性α−オレフィン系共重合体１００重量部に対し０〜２．０重量部配合することが好ましい。 The benzotriazole ultraviolet absorber is a hydroxyphenyl-substituted benzotriazole compound, for example, 2- (2-hydroxy-5-methylphenyl) benzotriazole, 2- (2-hydroxy-5-t-butylphenyl) Benzotriazole, 2- (2-hydroxy-3,5-dimethylphenyl) benzotriazole, 2- (2-methyl-4-hydroxyphenyl) benzotriazole, 2- (2-hydroxy-3-methyl-5-t- Butylphenyl) benzotriazole, 2- (2-hydroxy-3,5-di-t-amylphenyl) benzotriazole, 2- (2-hydroxy-3,5-di-t-butylphenyl) benzotriazole, and the like. Can be mentioned. Examples of triazine ultraviolet absorbers include 2- [4,6-bis (2,4-dimethylphenyl) -1,3,5-triazin-2-yl] -5- (octyloxy) phenol, 2- ( And 4,6-diphenyl-1,3,5-triazin-2-yl) -5- (hexyloxy) phenol. Examples of salicylic acid esters include phenyl salicylate and p-octylphenyl salicylate. These ultraviolet absorbers are preferably blended in an amount of 0 to 2.0 parts by weight with respect to 100 parts by weight of the amorphous or low crystalline α-olefin copolymer.
本発明の太陽電池封止材を用い、太陽電池素子を上下の保護材で固定することにより太陽電池モジュールを製作することができる。このような太陽電池モジュールとしては、種々のタイプのものを例示することができる。例えば上部透明保護材／封止材／太陽電池素子／封止材／下部保護材のように太陽電池素子の両側から封止材で挟む構成のもの、下部基板保護材の内周面上に形成させた太陽電池素子上に封止材と上部透明保護材を形成させるような構成のもの、上部透明保護材の内周面上に形成させた太陽電池素子、例えばフッ素樹脂系透明保護材材上にアモルファス太陽電池素子をスパッタリング等で作成したものの上に封止材と下部保護材を形成させるような構成のものなどを挙げることができる。 A solar cell module can be produced by fixing the solar cell element with upper and lower protective materials using the solar cell encapsulant of the present invention. Examples of such solar cell modules include various types. For example, the upper transparent protective material / encapsulant / solar cell element / encapsulant / lower protective material sandwiched between the solar cell elements from both sides, formed on the inner peripheral surface of the lower substrate protective material A solar cell element formed on the inner peripheral surface of the upper transparent protective material, such as a fluororesin-based transparent protective material In addition, a structure in which an encapsulant and a lower protective material are formed on an amorphous solar cell element formed by sputtering or the like can be used.
太陽電池素子としては、単結晶シリコン、多結晶シリコン、アモルファスシリコンなどのシリコン系、ガリウムー砒素、銅ーインジウムーセレン、カドミウムーテルルなどのIIIーＶ族やIIーVI族化合物半導体系等の各種太陽電池素子を用いることができる。 Solar cell elements include single-crystal silicon, polycrystalline silicon, amorphous silicon, and other silicon systems, and gallium-arsenic, copper-indium-selenium, cadmium-tellurium, and other III-V group and II-VI group compound semiconductor systems. Various solar cell elements can be used.
太陽電池モジュールを構成する上部保護材としては、ガラス、アクリル樹脂、ポリカーボネート、ポリエステル、フッ素含有樹脂などを例示することができる。下部保護材としては、金属や各種熱可塑性樹脂フィルムなどの単体もしくは多層のシートであり、例えば、錫、アルミ、ステンレススチールなどの金属、ガラス等の無機材料、ポリエステル、無機物蒸着ポリエステル、フッ素含有樹脂、ポリオレフィンなどの１層もしくは多層の保護材を例示することができる。このような上部及び／又は下部の保護材には、封止材との接着性を高めるためにプライマー処理を施すことができる。 Examples of the upper protective material constituting the solar cell module include glass, acrylic resin, polycarbonate, polyester, and fluorine-containing resin. The lower protective material is a single or multilayer sheet such as metal or various thermoplastic resin films, for example, metals such as tin, aluminum, and stainless steel, inorganic materials such as glass, polyester, inorganic vapor deposition polyester, fluorine-containing resin And a single-layer or multilayer protective material such as polyolefin. Such an upper and / or lower protective material can be subjected to a primer treatment in order to enhance the adhesion to the sealing material.
本発明の太陽電池封止材は、通常、０．１〜１ｍｍ程度の厚みのシート状で使用される。シート状太陽電池封止材は、Ｔ−ダイ押出機、カレンダー成形機などを使用する公知のシート成形法によって製造することができる。例えば非晶性又は低結晶性α−オレフィン系共重合体に、必要に応じて添加される架橋剤、架橋助剤、シランカップリング剤、紫外線吸収剤、酸化防止剤、光安定剤等の添加剤を予めドライブレンドしてＴ−ダイ押出機のホッパーから供給し、シート状に押出成形することによって得ることができる。勿論、これらドライブレンドに際して、一部又は全部の添加剤は、マスターバッチの形で使用することができる。またＴ−ダイ押出やカレンダー成形において、予め非晶性α−オレフィン系共重合体に一部又は全部の添加剤を、一軸押出機、二軸押出機、バンバリーミキサー、ニーダーなどを用いて溶融混合して得た樹脂組成物を使用することもできる。 The solar cell encapsulant of the present invention is usually used in the form of a sheet having a thickness of about 0.1 to 1 mm. The sheet-like solar cell encapsulant can be produced by a known sheet molding method using a T-die extruder, a calendar molding machine, or the like. For example, addition of a crosslinking agent, a crosslinking aid, a silane coupling agent, an ultraviolet absorber, an antioxidant, a light stabilizer, etc. added to an amorphous or low crystalline α-olefin copolymer as necessary. The agent can be obtained by dry blending in advance, supplying it from a hopper of a T-die extruder, and extruding it into a sheet. Of course, in these dry blends, some or all of the additives can be used in the form of a masterbatch. In addition, in T-die extrusion and calendering, some or all of the additive is previously melt-mixed into the amorphous α-olefin copolymer using a single screw extruder, twin screw extruder, Banbury mixer, kneader, etc. Thus obtained resin composition can also be used.
太陽電池モジュールの製造に当たっては、本発明の封止材のシートを予め作っておき、封止材料が溶融する温度で圧着するという従来同様の方法によって、すでに述べたような構成のモジュールを形成することができる。この場合、封止材に有機過酸化物のような架橋剤を含有させない場合は、封止材のシート成形を高温で生産性よく行うことができるとともに、モジュールの形成においても２段階の接着工程を経る必要はなく、高温度で短時間に完結することができる。また本発明の封止材を押出コーティングすることによって太陽電池素子や上部保護材あるいは下部保護材と積層する方法を採用すれば、わざわざシート成形することなく一段階で太陽電池モジュールを製造することが可能である。したがって本発明の封止材を使用すれば、モジュールの生産性を格段に改良することができる。 In manufacturing a solar cell module, a sheet having the above-described configuration is formed by a method similar to the conventional method in which a sheet of the sealing material of the present invention is prepared in advance and pressure-bonded at a temperature at which the sealing material melts. be able to. In this case, when the encapsulant does not contain a cross-linking agent such as an organic peroxide, the encapsulant sheet can be molded at high temperatures with high productivity, and the two-step adhesion process is also possible in forming the module. It is not necessary to go through and can be completed in a short time at a high temperature. Moreover, if the method of laminating with the solar cell element, the upper protective material or the lower protective material by extrusion coating the sealing material of the present invention is adopted, the solar cell module can be manufactured in one step without bothering to form a sheet. Is possible. Therefore, if the sealing material of this invention is used, the productivity of a module can be improved markedly.
一方、封止材に過酸化物を配合する場合は、架橋剤が実質的に分解せず、かつ本発明の封止材料が溶融するような温度で、太陽電池素子や保護材に該封止材を仮接着し、次いで昇温して充分な接着と非晶性又は低結晶性のα−オレフィン系共重合体の架橋を行えばよい。この場合は、封止材層の融点（ＤＳＣ法）が８５℃以上、１５０℃の貯蔵弾性率が１０３Ｐａ以上の耐熱性良好な太陽電池モジュールを得るために、封止材層におけるゲル分率（試料１ｇをキシレン１００ｍｌに浸漬し、１１０℃、２４時間加熱した後、２０メッシュ金網で濾過し未溶融分の質量分率を測定）が５０〜９８％、好ましくは７０〜９５％程度になるように架橋するのがよい。したがってこれら諸条件を満足できるような添加剤処方を選べばよく、例えば架橋剤等の種類及び配合量を適宜選択すればよい。 On the other hand, when a peroxide is blended in the encapsulant, the encapsulant is sealed in the solar cell element or the protective material at a temperature at which the crosslinking agent does not substantially decompose and the encapsulant of the present invention melts. The material may be temporarily bonded, and then heated to sufficiently bond and crosslink the amorphous or low crystalline α-olefin copolymer. In this case, in order to obtain a solar cell module with good heat resistance having a melting point of the sealing material layer (DSC method) of 85 ° C. or higher and a storage elastic modulus of 150 ° C. of 10 3 Pa or higher, the gel content in the sealing material layer The ratio (1 g of sample is immersed in 100 ml of xylene, heated at 110 ° C. for 24 hours, then filtered through a 20 mesh wire net and the mass fraction of unmelted portion is measured) is 50 to 98%, preferably about 70 to 95% It is good to crosslink so that it may become. Therefore, an additive formulation that can satisfy these conditions may be selected. For example, the type and amount of the crosslinking agent may be appropriately selected.
以下、実施例により本発明をさらに詳細に説明する。尚、本発明はこれら実施例によって何ら制限されるものではない。
本発明の諸物性は、下記の方法で測定した。
Hereinafter, the present invention will be described in more detail with reference to examples. In addition, this invention is not restrict | limited at all by these Examples.
Various physical properties of the present invention were measured by the following methods.
（１）貯蔵弾性率（Ｅ’）
１５０℃で１５分の条件で２ｍｍのプレスシートを作成し、下記の条件で１５０℃の貯蔵弾性率（Ｅ’）を測定した。
・装置：ユービーエム社製ＤＶＥ−Ｖ４
・測定モード：引張り
・サンプルサイズ：３０ｍｍ×５ｍｍ
・周波数：１０Ｈｚ
・昇温速度：３℃／ｍｉｎ
・振幅：２μｍ
(1) Storage elastic modulus (E ')
A 2 mm press sheet was prepared at 150 ° C. for 15 minutes, and the storage elastic modulus (E ′) at 150 ° C. was measured under the following conditions.
・ Apparatus: DVE-V4 manufactured by UBM
・ Measurement mode: Tensile ・ Sample size: 30mm × 5mm
・ Frequency: 10Hz
・ Rise rate: 3 ° C / min
・ Amplitude: 2μm
（２）ＨＡＺＥ、全光線透過率
２枚の３ｍｍの青色ガラスに０．５ｍｍシートを挟み、真空貼り合わせ機にて１５０℃で１５分間張り合わせ、ＪＩＳ Ｋ７１０５に準じてＨＡＺＥおよび全光線透過率を測定した。
（３）６０°傾斜試験
３ｍｍの青色ガラスとアルミ板に０．５ｍｍシートを挟み、真空貼り合わせ機にて１５０℃で１５分間張り合わせ、１００℃で６０°に傾斜して、シートが溶融してガラスからずれないかを５００時間まで観察した。
（４）ゲル分率
１５０℃で３０分の条件で１ｍｍのプレスシートを作成し、約１ｇを切り取り精秤した。キシレン１００ｃｃに浸漬し１１０℃で２４時間処理し、ろ過後残渣を乾燥し精秤した。処理前の重量で割りゲル分率を算出した。
(2) HAZE, total light transmittance A 0.5 mm sheet is sandwiched between two pieces of 3 mm blue glass and pasted at 150 ° C. for 15 minutes using a vacuum laminating machine, and HAZE and total light transmittance are measured according to JIS K7105. did.
(3) 60 ° tilt test A 0.5 mm sheet was sandwiched between 3 mm blue glass and an aluminum plate, and was laminated at 150 ° C. for 15 minutes with a vacuum laminating machine, tilted to 60 ° at 100 ° C., and the sheet melted. The glass was observed for up to 500 hours.
(4) Gel fraction A 1 mm press sheet was prepared at 150 ° C. for 30 minutes, and about 1 g was cut out and precisely weighed. It was immersed in 100 cc of xylene and treated at 110 ° C. for 24 hours. After filtration, the residue was dried and precisely weighed. The gel fraction was calculated by dividing the weight before treatment.
（実施例１）
非晶質又は低結晶性プロピレン・ブテン共重合体（ＰＢＲ）（三井化学（株）製、非晶質又は低結晶性α−オレフィン系共重合体、商品名：タフマーＸＲ１１０Ｔ、メルトフローレート（ＡＳＴＭ Ｄ１２３８）：３．２ｇ／１０分（１９０℃）、６．０ｇ／１０分（２３０℃）、融点：１１０℃、ショアＤ硬度：５６）を、異型押出機（スクリュー径４０ｍｍ、Ｌ／Ｄ＝２６、スクリューフルフライト ＣＲ＝２．６）を用いて加工温度１６０℃で厚み０．５ｍｍのシートを作成した。得られたシートについて、各種の物性を測定した。結果を表１に示す。
Example 1
Amorphous or low crystalline propylene / butene copolymer (PBR) (Mitsui Chemicals, Amorphous or low crystalline α-olefin copolymer, trade name: TAFMER XR110T, melt flow rate (ASTM D1238): 3.2 g / 10 min (190 ° C.), 6.0 g / 10 min (230 ° C.), melting point: 110 ° C., Shore D hardness: 56), a profile extruder (screw diameter 40 mm, L / D = 26, screw full flight CR = 2.6), and a sheet having a processing temperature of 160 ° C. and a thickness of 0.5 mm was prepared. Various physical properties of the obtained sheet were measured. The results are shown in Table 1.
（実施例２）
実施例１のプロピレン・ブテン−１共重合体に代えて、同プロピレン・ブテン−１共重合体と脂環族系粘着剤（商品名：アルコンＡＭ−１、荒川化学社製、軟化点：１２５℃）の、重量比９０：１０の混合物を用いるほかは同様にして厚み０．５ｍｍのシートを作成した。得られたシートについて、各種の物性を測定した。結果を表１に示す。
(Example 2)
Instead of the propylene / butene-1 copolymer of Example 1, the propylene / butene-1 copolymer and an alicyclic pressure-sensitive adhesive (trade name: Arcon AM-1, Arakawa Chemical Co., Ltd., softening point: 125 A sheet having a thickness of 0.5 mm was prepared in the same manner except that a 90:10 weight ratio mixture was used. Various physical properties of the obtained sheet were measured. The results are shown in Table 1.
本発明によって提供される太陽電池用封止材は、透明性、耐熱性、柔軟性などに優れている太陽電池用封止材である。
本発明によって提供される太陽電池用封止材は、有機過酸化物の使用を必須としないので、太陽電池モジュール製造工程における生産性を著しく高めることが可能であり、太陽電池モジュールの製造コストを大幅に低減させることが可能である。
本発明により提供される太陽電池封止材は、１５０℃の貯蔵弾性率が高く、ＨＡＺＥが低い上に、適度の硬度を有するので、それから得られる太陽電池モジュールの使用時に温度上昇しても、封止材が流動したり変形したりするトラブルを回避することが可能であり、太陽電池の外観を損なうことも無い。
また非晶性又は低結晶性のα−オレフィン系共重合体として、エチレンを主成分とする共重合体を選び、架橋剤を配合する場合は、上記製造上の利点はないが、柔軟性に優れた封止材層を形成することができるので、太陽電池素子の薄肉化にも充分対応することができる。
本発明によれば、本発明の太陽電池用封止材を用いたすぐれた性能を有する太陽電池モジュールが提供される。
The solar cell encapsulant provided by the present invention is a solar cell encapsulant that is excellent in transparency, heat resistance, flexibility, and the like.
Since the sealing material for solar cells provided by the present invention does not require the use of organic peroxides, it is possible to remarkably increase the productivity in the solar cell module manufacturing process, thereby reducing the manufacturing cost of the solar cell module. It can be greatly reduced.
The solar cell encapsulant provided by the present invention has a high storage elastic modulus at 150 ° C., a low HAZE, and an appropriate hardness, so even if the temperature rises when using the solar cell module obtained therefrom, It is possible to avoid trouble that the sealing material flows or deforms, and the appearance of the solar cell is not impaired.
In addition, when an amorphous or low-crystalline α-olefin copolymer is selected from a copolymer containing ethylene as a main component and a crosslinking agent is blended, there is no advantage in the above production, but flexibility Since an excellent sealing material layer can be formed, it can sufficiently cope with the thinning of the solar cell element.
ADVANTAGE OF THE INVENTION According to this invention, the solar cell module which has the outstanding performance using the sealing material for solar cells of this invention is provided.
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| WO2008087720A1 (en) * | 2007-01-17 | 2008-07-24 | Nichiban Company Limited | Surface protective sheet |
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