JP5500169B2 - 太陽電池モジュールおよびそのバックシート - Google Patents
太陽電池モジュールおよびそのバックシート Download PDFInfo
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- JP5500169B2 JP5500169B2 JP2011511390A JP2011511390A JP5500169B2 JP 5500169 B2 JP5500169 B2 JP 5500169B2 JP 2011511390 A JP2011511390 A JP 2011511390A JP 2011511390 A JP2011511390 A JP 2011511390A JP 5500169 B2 JP5500169 B2 JP 5500169B2
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- Prior art keywords
- sheet
- coating film
- layer
- water
- solar cell
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Description
EVAを含む封止剤層と水不透過性シートとが、硬化剤としてイソシアネート系プレポリマーおよび/またはメラミン樹脂を含む水酸基含有含フッ素ポリマー塗料の硬化塗膜層を介して積層されている積層体構造を含む太陽電池モジュール
にも関する。
具体例としては、テトラフルオロエチレン(TFE)の単独重合体、またはTFEとヘキサフルオロプロピレン(HFP)、パーフルオロ(アルキルビニルエーテル)(PAVE)などとの共重合体、さらにはこれらと共重合可能な他の単量体との共重合体などがあげられる。
具体例としては、たとえばCTFE/ヒドロキシブチルビニルエーテル/他の単量体の共重合体などがあげられる。
具体例としては、たとえばVdF/TFE/ヒドロキシブチルビニルエーテル/他の単量体の共重合体などがあげられる。
具体例としては、たとえばCF3CF2(CF2CF2)nCH2CH2OCOCH=CH2(n=3と4の混合物)/2−ヒドロキシエチルメタクリレート/ステアリルアクリレート共重合体などがあげられる。
水酸基含有TFE系共重合体(ダイキン工業(株)製のゼッフルGK570、固形分65質量%、水酸基価60mgKOH/g、溶剤:酢酸ブチル)223.2質量部、黒色顔料(大日精化(株)製のダイピロキサイド9510)250質量部、酢酸ブチル126.8質量部を攪拌下に予備混合した後、直径1.2mmのガラスビーズを780質量部入れ、顔料分散機にて1500rpmで1時間分散させた。その後、#80メッシュのフルイでガラスビーズをろ過し、その溶液に水酸基含有TFE系共重合体(ゼッフルGK570)を269.2質量部、酢酸ブチルを80.7質量部加えて黒色塗料を調製した。
水酸基含有TFE系共重合体(ゼッフルGK570)223.2質量部、黒色顔料(ダイピロキサイド9510)250質量部、酢酸ブチル126.8質量部を攪拌下に予備混合した後、直径1.2mmのガラスビーズを780質量部入れ、顔料分散機にて1500rpmで1時間分散させた。その後、#80メッシュのフルイでガラスビーズをろ過し、その溶液に水酸基含有TFE系共重合体(ゼッフルGK570)を269.2質量部、酢酸ブチルを80.7質量部加えて黒色塗料を調製した。
水酸基含有TFE系共重合体(ゼッフルGK570)223.2質量部、白色顔料として酸化チタン(堺化学(株)製のD918)250質量部、酢酸ブチル126.8質量部を攪拌下に予備混合した後、直径1.2mmのガラスビーズを780質量部入れ、顔料分散機にて1500rpmで1時間分散させた。その後、#80メッシュのフルイでガラスビーズをろ過し、その溶液に水酸基含有TFE系共重合体(ゼッフルGK570)を269.2質量部、酢酸ブチルを80.7質量部加えて白色塗料を調製した。
水酸基含有TFE系共重合体(ゼッフルGK570)223.2質量部、白色顔料として酸化チタン(デュポン社製のタイピュアR960)250質量部、酢酸ブチル126.8質量部を攪拌下に予備混合した後、直径1.2mmのガラスビーズを780質量部入れ、顔料分散機にて1500rpmで1時間分散させた。その後、#80メッシュのフルイでガラスビーズをろ過し、その溶液に水酸基含有TFE系共重合体(ゼッフルGK570)を269.2質量部、酢酸ブチルを80.7質量部加えて白色塗料を調製した。
水酸基含有TFE系共重合体(ゼッフルGK570)100質量部、酢酸ブチル100質量部、UV吸収剤(チバスペシャルティケミカルズ社製のチヌビン400と473)をそれぞれ1.3質量部を攪拌下に混合してクリア塗料を調製した。
硬化剤として低分子量のイソシアネート系硬化剤である日本ポリウレタン(株)製のコロネートHXを用いたほかは調製例1と同様にして比較用の硬化性塗料6を調製した。
調整例1で作られた黒色塗料100質量部にイソシアネート系プレポリマー硬化剤としてデスモジュールN3800を6.7質量部およびタケネートD−140N(三井化学(株)製)を7.0質量部配合して硬化性塗料7を調整した。
水不透過性シートとして、シリカ蒸着PETフィルム(三菱樹脂(株)製のバリアテックH、厚さ12μm。シートA)を使用し、このシートAの片面に調製例1で調製した硬化性塗料1を乾燥膜厚が20μmとなるようにエアスプレーにて塗装し、180℃で2分間乾燥して2層構造のバックシートA1を作製した。
1回試験:JIS K6900で規定する碁盤目試験(幅1mmにクロスカット)を1回行い、密着性を評価する。
JIS K 6854−2に基づき、EVA接着サンプルのバックシート部分にカッターナイフにより25mm幅で短冊状に切り目を入れ、EVAと塗膜面の密着性(剥離強度)を調べる。試験機器は(株)島津製作所製のオートグラフを用い、雰囲気温度は23℃、つかみ移動速度は200mm/分で行う。
バックシートを50mm×50mmにカットして試験片とする。試験片の塗膜面を外側にして直径2mmの丸棒に巻きつけるようにして180度折り曲げ(所要時間1秒間)、折り曲げ部分の割れの有無を目視で観察する。割れが観察できた場合は、試験片を2枚重ねて同様にして180度折り曲げる。これを繰返し、割れが観察できなかったときの試験片の枚数を記録する。枚数が少ない方が折り曲げ性がよい。
電磁式膜厚計で測定する。
バックシートを50mm×10mmにカットして試験片とする。試験片の塗膜面と下地が接触するように重ね、厚さ10mmの硬質ガラス板で挟む。そこに25kgの錘を載せて、加重圧力が5N/cm2になるように調整する。40℃雰囲気下で12時間、この状態を保持した後、試験片を放冷・除圧し、試験片同士を引き剥がし、その剥離の容易さを評価する。
評価基準
○:密着せず、力を加えなくても自然に剥離する。
△:密着しているが、引き剥がしても塗膜は破れない。
×:しっかり密着しており、引き剥がすと塗膜がやぶれる。
実施例1において、塗料として調製例6で調製した比較用の硬化性塗料6を用いたほかは実施例1と同様にして2層構造のバックシートA2およびEVA/比較硬化塗膜(黒)/シートAからなるEVA接着サンプルA2を作製し、実施例1と同様にして密着性、折り曲げ性を調べた。結果を表1に示す。
実施例1と同様にして作製した2層構造のバックシートA1のシートA側上にポリエステル系接着剤(東洋モートン(株)製のAD−76P1とCAT−10L(硬化剤))を用いてEVA樹脂シート、さらにガラス板を載せ、圧力100g/cm2にて150℃で圧着してEVA/接着剤/シートA/硬化塗膜(黒)からなるサンプルB1(図2に示す態様)を作製した。このEVA接着サンプルB1について、密着性2(EVAと塗膜間)および折り曲げ性を調べた。結果を表2に示す。
水不透過性シートとして、シリカ蒸着PETフィルム(シートA)を使用し、このシートAの片面に調製例4で調製した硬化性塗料4を乾燥膜厚が20μmとなるようにエアスプレーにて塗装し、180℃で10分間乾燥して2層構造のバックシートB2を作製した。
水不透過性シートとして、シリカ蒸着PETフィルム(シートA)を使用し、このシートAの両面に調製例1で調製した硬化性塗料1をいずれも乾燥膜厚が20μmとなるようにエアスプレーにて塗装し、180℃で2分間乾燥して3層構造のバックシートC1を作製した。
JIS B7753に準拠し、サンシャインウェザオメーター(スガ試験機(株)製のWEL−300)を用い、サンプルの両面に太陽光を当てて5000時間の促進耐候性試験を行う。
界面状態の評価基準
○:異常なし。
△:剥離、白化、膨れ等がある。
×:著しい剥離、白化、膨れ等がある。
外観の評価基準
○:異常なし。
△:剥離、白化、膨れ等がある。
×:著しい剥離、白化、膨れ等がある。
実施例4において、シートAに代えてアルミニウム板(シートB。0.5mm)を用い、また、硬化性塗料1に代えて硬化性塗料2を用いたほかは実施例4と同様にして3層構造のバックシートC2を作製し、実施例4と同様にして密着性1(塗膜とシートの間)および折り曲げ性を調べた。結果を表3に示す。
水不透過性シートとして、シリカ蒸着PETフィルム(シートA)を使用し、このシートAの両面に調製例3で調製した硬化性塗料3をいずれも乾燥膜厚が20μmとなるようにエアスプレーにて塗装し、180℃で10分間乾燥して3層構造のバックシートC3を作製した。
水不透過性シートとして、シリカ蒸着PETフィルム(シートA)を使用し、このシートAの両面に調製例4で調製した硬化性塗料4をいずれも乾燥膜厚が20μmとなるようにエアスプレーにて塗装し、180℃で10分間乾燥して3層構造のバックシートC4を作製した。
水不透過性シートとして、シリカ蒸着PETフィルム(シートA)を使用し、このシートAの片面に調製例1で調製した硬化性塗料1を乾燥膜厚が20μmとなるようにエアスプレーにて塗装し、他方の面に調製例5で調製した硬化性塗料5を乾燥膜厚が20μmとなるようにエアスプレーにて塗装し、180℃で2分間乾燥して3層構造のバックシートC5を作製した。
実施例1で作製した2層構造のバックシートA1のシートA側にポリエステル系接着剤を用いてポリエステル(PET)フィルム(東レ(株)製のルミラー。白色顔料入り。厚さ75μm)を貼り付け、3層構造のバックシートD1を作製した。
水不透過性シートとして、シリカ蒸着PETフィルム(シートA)を使用し、このシートAの両面に調製例7で調製した硬化性塗料7をいずれも乾燥膜厚が20μmとなるようにエアスプレーにて塗装し、180℃で2分間乾燥して3層構造のバックシートC6を作製した。このバックシートC6について、密着性1(シートAと硬化塗膜の間)および折り曲げ性を調べた。結果を表4に示す。
実施例1で作製した2層構造のバックシートA1の塗膜面上にEVA樹脂シート、ついで太陽電池セル、EVA樹脂シート、ガラス板を載せ、真空下に圧力0.7MPaにて150℃で圧着して太陽電池モジュール(図1の態様)を作製した。
実施例1で作製した2層構造のバックシートA1のシートA面上にポリエステル系接着剤を介してEVA樹脂シート、ついで太陽電池セル、EVA樹脂シート、ガラス板を載せ、真空下に圧力0.7MPaにて150℃で圧着して太陽電池モジュール(図2の態様)を作製した。
実施例4で作製した3層構造のバックシートC1の塗膜面上にEVA樹脂シート、ついで太陽電池セル、EVA樹脂シート、ガラス板を載せ、真空下に圧力0.7MPaにて150℃で圧着して太陽電池モジュール(図3の態様)を作製した。
実施例9で作製した3層構造のバックシートD1の塗膜面上にEVA樹脂シート、ついで太陽電池セル、EVA樹脂シート、ガラス板を載せ、真空下に圧力0.7MPaにて150℃で圧着して太陽電池モジュール(図4の態様)を作製した。
実施例9で作製した3層構造のバックシートD1のPETフィルム面上にEVA樹脂シート、ついで太陽電池セル、EVA樹脂シート、ガラス板を載せ、真空下に圧力0.7MPaにて150℃で圧着して太陽電池モジュール(図5の態様)を作製した。
2 封止剤層
3 表面層
4 バックシート
5 水不透過性シート
6 含フッ素硬化塗膜層
7 シートまたは塗膜
8、9 樹脂シート
Claims (10)
- 水不透過性シートの少なくとも一方の面に、硬化剤としてイソシアネート系プレポリマーを含む水酸基含有含フッ素ポリマー塗料の硬化塗膜層が直接形成されてなり、
前記イソシアネート系プレポリマーは、ポリイソシアネートとポリヒドロキシ化合物との反応生成物、又は、ポリイソシアネートとポリアミン化合物との反応生成物である
太陽電池モジュールのバックシート。 - 水不透過性シートの両面に水酸基含有含フッ素ポリマー塗料の硬化塗膜層が形成されてなる請求項1記載のバックシート。
- 水不透過性シートの一方の面に水酸基含有含フッ素ポリマー塗料の硬化塗膜層が直接形成され、他方の面に、硬化性官能基を有しない含フッ素ポリマー塗料の硬化塗膜層、含フッ素ポリマーシート、ポリエステルシートまたはポリエステル塗料の塗膜が形成されてなる請求項1記載のバックシート。
- 水不透過性シートが、Siまたはシリカ蒸着ポリエステルシートまたは金属シートである請求項1〜3のいずれかに記載のバックシート。
- 太陽電池モジュールの封止剤層側の水不透過性シート上に水酸基含有含フッ素ポリマー塗料の硬化塗膜層が直接形成されている請求項1〜4のいずれかに記載のバックシート。
- 請求項1〜5のいずれかに記載のバックシートを備えた太陽電池モジュール。
- エチレン/酢酸ビニル共重合体を含む封止剤層と、硬化剤としてイソシアネート系プレポリマーを含む水酸基含有含フッ素ポリマー塗料の硬化塗膜層とが直接積層されている積層体構造を含み、
前記イソシアネート系プレポリマーは、ポリイソシアネートとポリヒドロキシ化合物との反応生成物、又は、ポリイソシアネートとポリアミン化合物との反応生成物である
太陽電池モジュール。 - エチレン/酢酸ビニル共重合体を含む封止剤層と水不透過性シートとが、硬化剤としてイソシアネート系プレポリマーを含む水酸基含有含フッ素ポリマー塗料の硬化塗膜層を介して直接積層されている積層体構造を含み、
前記イソシアネート系プレポリマーは、ポリイソシアネートとポリヒドロキシ化合物との反応生成物、又は、ポリイソシアネートとポリアミン化合物との反応生成物である
太陽電池モジュール。 - 水不透過性シートの両面に前記水酸基含有含フッ素ポリマー塗料の硬化塗膜層が形成されてなる請求項8記載の太陽電池モジュール。
- 水不透過性シートの他方の面に、硬化性官能基を有しない含フッ素ポリマー塗料の硬化塗膜層、含フッ素ポリマーシート、ポリエステルシートまたはポリエステル塗料の塗膜が形成されてなる請求項8記載の太陽電池モジュール。
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CN102867868B (zh) * | 2011-07-07 | 2015-07-22 | 昆山雅森电子材料科技有限公司 | 太阳能电池背板结构 |
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