Classifications

• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
  • C08L3/00—Compositions of starch, amylose or amylopectin or of their derivatives or degradation products
• • 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
  • H01L31/0481—Encapsulation of modules characterised by the composition of the encapsulation material
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
  • C08K5/00—Use of organic ingredients
  • C08K5/04—Oxygen-containing compounds
  • C08K5/14—Peroxides
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
  • C08K5/00—Use of organic ingredients
  • C08K5/16—Nitrogen-containing compounds
  • C08K5/34—Heterocyclic compounds having nitrogen in the ring
  • C08K5/3467—Heterocyclic compounds having nitrogen in the ring having more than two nitrogen atoms in the ring
  • C08K5/3477—Six-membered rings
  • C08K5/3492—Triazines
  • C08K5/34924—Triazines containing cyanurate groups; Tautomers thereof
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
  • C08L23/00—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers
  • C08L23/02—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers not modified by chemical after-treatment
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
  • C08L23/00—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers
  • C08L23/02—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers not modified by chemical after-treatment
  • C08L23/04—Homopolymers or copolymers of ethene
  • C08L23/08—Copolymers of ethene
  • C08L23/0807—Copolymers of ethene with unsaturated hydrocarbons only containing more than three carbon atoms
  • C08L23/0815—Copolymers of ethene with aliphatic 1-olefins
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
  • C08L23/00—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers
  • C08L23/02—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers not modified by chemical after-treatment
  • C08L23/10—Homopolymers or copolymers of propene
• • 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
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
  • C08L2203/00—Applications
  • C08L2203/20—Applications use in electrical or conductive gadgets
  • C08L2203/206—Applications use in electrical or conductive gadgets use in coating or encapsulating of electronic parts
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
  • C08L2205/00—Polymer mixtures characterised by other features
  • C08L2205/02—Polymer mixtures characterised by other features containing two or more polymers of the same C08L -group
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
  • C08L23/00—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers
  • C08L23/02—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers not modified by chemical after-treatment
  • C08L23/10—Homopolymers or copolymers of propene
  • C08L23/14—Copolymers of propene
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
  • C08L2312/00—Crosslinking
• • 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

Definitions

• the present invention relates to an encapsulating material for solar cells in solar cell modules and solar cell modules using the encapsulating material. More specifically, the present invention is concerned with encapsulating material for solar cells having excellent transparency, heat resistance, flexibility and other properties that makes the formation of solar cell modules easy.
• a solar cell module is generally a package formed by protecting a solar cell comprising such solar cell element as silicon, gallium-arsenic and copper-iridium-selenium with a top transparent protective material and a bottom protective substrate material, with the solar cell and the protective materials fixed by use of an encapsulating material.
• any encapsulating material for solar cells is required to have satisfactory transparency so that power generation efficiency will be increased.
• Encapsulating material for solar cells is also required to have heat resistance so that any troubles such as the flow or deformation of the encapsulating material will not occur even when the temperature rises during the use of the solar cell module.
• encapsulating materials having excellent flexibility are also sought after.
• an ethylene-vinyl acetate copolymer having a high vinyl acetate content is used for the encapsulating materials for solar cells in solar cell modules from the viewpoint of flexibility, transparency and other properties.
• organic peroxide additionally for such ethylene-vinyl acetate copolymer.
• a sheet-like encapsulating material is first prepared from an ethylene-vinyl acetate copolymer containing an organic peroxide and then a solar cell element is sealed with the sheet thus obtained.
• step of making the sheet it is necessary to mold the sheet at such low temperature that will not cause the decomposition of the organic peroxide and as a result it is impossible to increase the extrusion rate.
• step of sealing the solar cell element it is commonly necessary to carry out a time-consuming two-step bonding process which comprises a step of preliminarily bonding the solar cell over several minutes to score of minutes by use of a laminator and then a step of firmly bonding it over scores of minutes to one hour in an oven at a high temperature at which the organic peroxide is decomposed. Consequently, it is troublesome and requires much time to produce a solar cell module, which in turn constitutes a factor in increasing the manufacturing cost.
• Reference 1 Japanese Patent Publication SHO 2-40709
• the present invention provides encapsulating material for solar cells showing excellent transparency, heat resistance, flexibility and other properties.
• the present invention provides encapsulating material for solar cells which without requiring the use of any organic peroxide makes possible a significant improvement in the efficiency in the production of solar cell modules and a substantial reduction in the manufacturing cost of solar cell modules.
• the use of the non-crystalline or low-crystalline ⁇ -olefin-based copolymer of the present invention or its composition (I) makes it possible to provide encapsulating material for solar cells that will prevent an occurrence of such troubles as the flow or deformation of the encapsulating material and an impairment of the appearance of the solar cell even when the temperature rises during the use of the solar cell module.
• the present invention makes it possible to provide encapsulating material for solar cells which shows a melting point of not lower than 85° C., a storage elastic modulus of not less than 10 3 Pa at 150° C., Shore D hardness of not more than 60, and haze at a thickness of 0.5 mm of not more than 10%.
• the present invention also provides an embodiment in which the non-crystalline or low-crystalline ⁇ -olefin-based copolymer or its composition (I) is a copolymer comprising ethylene as the main component and is cross-linked by the compounding of a cross-linking agent.
• the non-crystalline or low-crystalline ⁇ -olefin-based copolymer or its composition makes it possible to form encapsulating material for solar cells layer showing excellent flexibility and provide encapsulating material for solar cells that makes a reduction in the wall thickness of the solar cell possible.
• the present invention provides a solar cell module using the solar cell encapsulating material of the present invention.
• the present invention provides encapsulating material for solar cells comprising a non-crystalline or low-crystalline ⁇ -olefin-based copolymer or its composition (I).
• the present invention provides encapsulating material for solar cells as claimed in claim 1 , wherein the aforementioned copolymer or its composition (I) is resin composition (C) containing 50 to 100 parts by weight of non-crystalline ⁇ -olefin polymer (A) meeting the following requirements (a) to (c) and 50 to 0 parts by weight of crystalline ⁇ -olefin polymer (B) (the total of (A) and (B) being 100 parts by weight):
• the present invention also provides encapsulating material for solar cells as claimed in claim 1 .
• the aforementioned copolymer or its composition (I) is a non-crystalline or low-crystalline ⁇ -olefin copolymer (D) having a crystallinity of not higher than 40% as measured by use of X rays.
• Encapsulating material for solar cells wherein at least one kind of additives selected from among cross-linking agents, cross-linking aids, silane-coupling agents, antioxidants, ultraviolet absorbers and light stabilizers is compounded to the aforementioned copolymer or its composition (I) is a preferable embodiment of the present invention.
• Encapsulating material for solar cells wherein the storage elastic modulus at 150° C. of the aforementioned copolymer or its composition (I) is not lower than 10 3 Pa is a preferable embodiment of the present invention.
• the present invention also provides a solar cell module that can be obtained by using any of the aforementioned solar cell encapsulating materials.
• the present invention also provides a solar cell module, wherein the aforementioned solar cell encapsulating material layer is cross-linked.
• the present invention provides encapsulating material for solar cells having excellent transparency, heat resistance, flexibility and other properties.
• the present invention provides encapsulating material for solar cells which without requiring the use of any organic peroxide makes possible a significant improvement in the efficiency in the production of solar cell modules and a substantial reduction in the manufacturing cost of solar cell modules.
• the use of the non-crystalline or low-crystalline ⁇ -olefin-based copolymer of the present invention or its composition (I) makes it possible to provide encapsulating material for solar cells that will prevent an occurrence of such troubles as the flow or deformation of the encapsulating material and an impairment of the appearance of the solar cell even when the temperature rises during the use of the solar cell module.
• the present invention provides a solar cell module using the solar cell encapsulating material of the present invention which shows excellent performance.
• resin composition (C) containing 50 to 100 parts by weight of non-crystalline ⁇ -olefin polymer (A) meeting the following requirements (a) through (c) and 50 to 0 parts by weight of crystalline ⁇ -olefin polymer (B) (the total of (A) and (B) being 100 parts by weight) can be cited:
• the non-crystalline ⁇ -olefin polymer (A) that is used in the present invention is a polymer containing not less than 20%, preferably not less than 30%, of the monomer unit based on an ⁇ -olefin having 3 to 20 carbon atoms, with the content of all monomer units taken as 100 mol %. If the aforementioned content of the monomer unit is too low, polymer (A) may show inferior transparency and bleed resistance in some cases. Especially in the light of heat resistance and transparency, a polymer having the propylene unit content of not less than 30%, preferably not less than 50%, particularly preferably not less than 80%, is preferably used.
• Examples of the aforementioned ⁇ -olefin having 3 to 20 carbon atoms include straight-chain ⁇ -olefins such as propylene, 1-butene, 1-pentene, 1-hexene 1-heptene, 1-octene, 1-nonene, 1-decene, 1-undecene, 1-dodecene, 1-tridecene, 1-tetradecene, 1-pentadecene, 1-hexadecene, 1-heptadecene, 1-octadecene, 1-nanodecene and 1-eicocene and branched ⁇ -olefin such as 3-methyl-1-butene, 3-methyl-1-pentene, 4-methyl-1-pentene, 2-ethyl-1-hexene and 2,2,4-trimethyl-1-pentene. These may be used in combination of two more of them.
• straight-chain ⁇ -olefins such as propylene, 1-but
• the non-crystalline ⁇ -olefin polymer (A) may contain monomer units other than the ⁇ -olefins having 3 to 20 carbon atoms.
• monomers ethylene, polyen compounds, cyclic olefins and vinyl aromatic compounds, for example, may be cited.
• the content of such monomer is preferably not higher than 70 mol %, more preferably not higher than 50 mol %, particularly preferably not higher than 20 mol %, wherein the total content of all monomer in the non-crystalline ⁇ -olefin polymer refers as 100%.
• the non-crystalline ⁇ -olefin polymer (A) is preferably propylene homopolymer, propylene-ethylene copolymer, copolymer of ⁇ -olefin other than propylene and propylene, copolymer of ⁇ -olefin other than propylene, propylene and ethylene, more preferably propylene homopolymer, propylene-ethylene copolymer, propylene-1-butene copolymer, propylene-1-hexene copolymer, propylene-ethylene-1-butene copolymer, propylene-ethylene-1-hexene copolymer, further preferably propylene-1-butene copolymer, propylene-ethylene-1-butene copolymer, most preferably propylene-1-butene copolymer.
• the aforementioned polymers may be used singly or in combination of not less than two of them.
• the non-crystalline ⁇ -olefin polymer (A) is a polymer whose melt peak is not practically observed when tested by a differential scanning calorimeter (DSC). A polymer whose melt peak is observed shows unsatisfactory transparency in some cases.
• the non-crystalline ⁇ -olefin polymer (A) having such properties as mentioned above can be manufactured by the slurry polymerization process, solution polymerization process, mass polymerization process, gas-phase polymerization process, etc. using a metallocene catalyst.
• metallocene catalyst examples include those metallocene catalysts disclosed in Japanese Laid-open Patent Applications SHO 58-19309, SHO 60-35005, SHO 60-35006, SHO 60-35007, SHO 60-35008,SHO 61-130314, HEI 3-163088, HEI 4-268307, HEI 9,12790, HEI 9-87313, HEI 10-508055, HEI 11-80233 and Japanese publication of International Application HEI 10-508055.
• a process disclosed in European Patent Publication No.1211287 can be cited.
• the crystalline ⁇ -olefin polymer (B) which can be used together with non-crystalline ⁇ -olefin polymer (A) is a polymer or copolymer of an ⁇ -olefin having 2 to 10 carbon atoms whose crystallinity as measured by use of X rays is not lower than 30%.
• the use of propylene homopolymer or random copolymer of propylene and another ⁇ -olefin at a low ratio is preferable.
• ⁇ -olefins in such random copolymer examples include ⁇ -olefins having 2 to 10 carbon atoms such as ethylene, 1-butene, 4-methyl-1-pentene, 1-hexene and 1-octene. Out of these, ethylene and/or 1-butene is preferable.
• the random copolymer preferably has the above ⁇ -olefin content of not higher than 10 wt %.
• the aforementioned propylene homopolymer or random copolymer of propylene is a homopolymer or random copolymer preferably showing a melt peak of 120° C. to 170° C., particularly preferably 150° C. to 170° C., as measured by a differential scanning calorimeter (DSC) from the viewpoint of heat resistance.
• DSC differential scanning calorimeter
• Such propylene homopolymer or random copolymer of propylene and another ⁇ -olefin at a low ratio can be produced by polymerizing propylene or copolymerizing propylene and ⁇ -olefin in the presence of a stereoregular olefin polymerization catalyst containing a titanium- or metallocene-based transition metal compound component, an organic aluminum component, and as required, an electron donor, a support, etc.
• the solar cell encapsulating material of the present invention uses resin composition (C) which comprises 50 to 100, preferably 60 to 99, more preferably 70 to 95, parts by weight of the aforementioned non-crystalline ⁇ -olefin polymer (A) and 50 to 0, preferably 40 to 1, more preferably 30 to 5, parts by weight of the aforementioned crystalline ⁇ -olefin polymer (B) (the total of (A) and (B) being 100 parts by weight).
• resin component (C) the kinds and compounding ratios of (A) and (B) should be preferably so selected that it will show a melt peak (as measured by a differential scanning calorimeter) of 120° C. to 170° C., preferably 150° C.
• the non-crystalline or low-crystalline ⁇ -olefin-based copolymer of the present invention or its composition (I) the non-crystalline or low-crystalline ⁇ -olefin-based copolymer (D) whose crystallinity as measured by use of X rays is not higher than 40% can be cited.
• the non-crystalline or low-crystalline ⁇ -olefin-based copolymer (D) which is used as the encapsulating material of the present invention is a copolymer having rubber properties which uses not less than two kinds of ⁇ -olefin having 2 to 10 carbon atoms as the components and shows crystallinity of not higher than 40% (0 to 40%) as measured by the X-ray diffraction method. From the viewpoint of heat resistance, a copolymer showing crystallinity of approximately 1 to 40%, such as a copolymer falling under the category of what is called low-crystalline copolymers, is preferably used rather than a completely non-crystalline copolymer. However, any copolymer comprising ethylene as the main component that is compounded with an organic peroxide may be of the completely crystalline type (crystallinity: 0).
• a representative example of such copolymer (D) is a copolymer which comprises ethylene or propylene as the main component, one or two or more other ⁇ -olefins having 2 to 10 carbon atoms as the accessory components and as required a small amount of diene monomer.
• copolymers comprising ethylene as the main component include those copolymers which contain a 50 to 90 mol %, preferably 70 to 85 mol %, ethylene polymerization unit, a 50 to 10 mol %, preferably 30 to 15 mol % polymerization unit of ⁇ -olefins other than ethylene, and as required not higher than 2 mol %, preferably not higher than 1 mol %, diene monomer polymerization unit.
• ethylene-based copolymers examples include ethylene-propylene copolymer, ethylene-1-butene copolymer, ethylene-4-methyl-1-pentene copolymer, ethylene-1-hexene copolymer, ethylene-1-octene copolymer, ethylene-propylene-dicychlopentadiene copolymer, ethylene-propylene-5-ethylydene-2-norbornene copolymer, and ethylene-propylene-1,6-hexadiene copolymer.
• ethylene-propylene copolymer, ethylene-propylene-diene copolymer or ethylene-1-butene copolymer are particularly preferable.
• examples of the copolymers comprising propylene as the main component include those copolymers which contain a 70 to 95 mol %, preferably 72 to 90 mol %, propylene polymerization unit, and a 5 to 30 mol %, preferably 10 to 28 mol % polymerization unit of ⁇ -olefins other than propylene.
• examples of such propylene-based copolymers include propylene-ethylene copolymer and propylene-1-butene copolymer.
• those ⁇ -olefin-based copolymers which have a melt flow rate (MFR) of 0.1 to 50, preferably 0.5 to 20, g/10 minutes, as measured at 230° C. under a load of 2,160 g by the method based on ASTM D-1238 is preferably used from the viewpoint of moldability, mechanical strength and other properties.
• MFR melt flow rate
• non-crystalline or low-crystalline ⁇ -olefin-based copolymer (D) is a copolymer comprising ethylene as the main component, it can be manufactured by copolymerizing ethylene and other ⁇ -olefins in the presence of a vanadium catalyst comprising a soluble vanadium compound and an organic aluminum halide, or metallocene catalyst comprising a metallocene compound such as a cyclopentadienyl-coordinated zirconium compound and an organic aluminumoxy compound.
• a copolymer comprising propylene as the main component
• it can be manufactured by copolymerizing propylene and other ⁇ -olefins in the presence of a stereoregular olefin polymerization catalyst containing a transition metal compound component such as a high-activity titanium catalyst component or a metallocene catalyst component, an organic aluminum component, and as required an electron donor, a support, etc.
• a stereoregular olefin polymerization catalyst containing a transition metal compound component such as a high-activity titanium catalyst component or a metallocene catalyst component, an organic aluminum component, and as required an electron donor, a support, etc.
• additives include cross-linking agents, cross-linking aids, tackifiers, silane coupling agents, ultraviolet absorbers, hindered phenol-based and phosphite-based antioxidants, hindered amine-based light stabilizers, light diffusion agents, fire retardants, pigments (white pigment, for example), and anti-discoloration agents.
• a cross-linking agent or a cross-linking aid to the non-crystalline or low-crystalline ⁇ -olefin-based copolymer or its composition (I).
• a cross-linking agent or a cross-linking agent and an aid may be compounded.
• the compounding of these makes it possible to cross-link the non-crystalline or low-crystalline a-olefin-based copolymer or its composition (I) with the encapsulating material incorporated into a solar cell in such manner that the encapsulating material is in contact with the solar cell and to endow the solar cell with such heat resistance that will prevent the encapsulating material from melting and flowing when the solar cell is used at high temperature, while maintaining the transparency of the encapsulating material layer.
• organic peroxides the decomposition temperature (a temperature at which the half-life period is one hours) of which is 70° C. to 180° C., particularly 90° C. to 160° C. are preferably used.
• organic peroxides include tertiary butyl peroxy isopropyl carbonate, tertiary butyl peroxy acetate, tertiary butyl peroxy benzoate, dicumyl peroxide, 2,5-dimethyl-2,5-bis(tertiary butyl peroxy)hexane, ditertiary butyl peroxide, 2,5-dimethyl-2,5-bis(tertiary butyl peroxy)hexine-3,1,1-bis(tertiary butyl peroxy)-3,3,5,-trimethyl cyclohexane, 1,1-bis(tertiary butyl peroxy)cyclohexane, methylethylketone peroxide, 2,
• An optimum compounding ratio of a cross-linking agent varies with the types of cross-linking agent, but a ratio of 0.1 to 5 parts by weight, particularly 0.5 to 3 parts by weight, per 100 parts by weight of the non-crystalline or low-crystalline ⁇ -olefin-based copolymer or its composition (I) is effective.
• Cross-linking aids are effective in accelerating cross-linking reaction and raising the degree of the cross-linking of a non-crystalline ⁇ -olefin-based copolymer comprising ethylene as the main component.
• poly unsaturated compounds such as polyallyl compounds and poly(meth)acryloxy compounds can be cited. More specific examples include polyallyl compounds such as triallyl isocyanurate, triallyl cyanurate, diallyl phthalate, diallyl fumarate and diallyl maleate, poly(meth)acryloxy compounds such as ethylene glycol diacrylate, ethylene glycol dimethacrylate and trimethlol propane trimethacrylate, and divinyl benzene. It is effective for cross-linking aids to be compounded at a ratio of approximately 0.5 to 5 parts by weight to 100 part by weight of the non-crystalline or low-crystalline ⁇ -olefin-based copolymer or its composition (I).
• Silane coupling agents are useful for improving the adhesion of the encapsulating material to the protective materials, solar cells, etc.
• silane coupling agents compounds having hydrolysable groups such as the alkoxy group as well as unsaturated groups of the vinyl group, acryloxy group and methacryroxy group, the amino group and the epoxy group can be cited.
• silane coupling agents include N-( ⁇ -aminoethyl)- ⁇ -aminopropyltrimethoxy silane, N-( ⁇ -aminoethyl)- ⁇ -aminopropylmethyidimethoxy silane, ⁇ -aminopropyltriethoxy methoxy silane, ⁇ -glycidoxypropyltrimethoxy silane, and ⁇ -methacryloxypropyl triethoxy silane.
• a silane coupling agent is preferably compounded at a ratio of 0.1 to 5 parts by weight against 100 parts by weight of the non-crystalline or low-crystalline ⁇ -olefin-based copolymer or its composition (I).
• ultraviolet absorbers that can be added to the solar cell encapsulating material of the present invention, benzophenon-based, benzotriazol-based, triazine-based, salicyclic ester-based and many other types can be cited.
• benzophenon-based ultraviolet absorbers examples include 2-hydroxy4-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-hydroxy4-methoxy-5-sulfobenzophenon, 2-hydroxy-5-chlorobenzophenone, 2,4-dihydroxybenzophenone, 2,2′-dihydroxy-4-methoxybenzophenone, 2,2′-dihyroxy-4-4′-dimethoxybenzophenone, and 2,2′-4,4′-tetrahydroxy benzophenone.
• benzotriazol-based ultraviolet absorbers include hydroxyphenyl-substituted benzotriazol compound, such as 2-(2-hydroxy-5-methylphenyl) benzotriazol, 2-(2-hydroxy-5-t-butylphenyl) benzotriazol, 2-(2-hydroxy-3,5-t-dimethyl phenyl) benzotriazol, 2-(2-methyl-4-hydroxyphenyl) benzotriazol, 2-(2-hydroxy-3-methyl-5-t-butylphenyl) benzotriazol, 2-(2-hydroxy-3, 5-di-t-amylphenyl) benzotriazol and 2-(2-hydroxy-3,5-di-t-butylphenyl) benzotriazol.
• hydroxyphenyl-substituted benzotriazol compound such as 2-(2-hydroxy-5-methylphenyl) benzotriazol, 2-(2-hydroxy-5-t-butylphenyl) benzotriazol, 2-(2-hydroxy-3,5-t-
• examples of triazine-based ultraviolet absorbers include 2-[4,6-bis(2,4-dimethylphenyl)]-1,3,5-t-triazine-2-il]-5-(octyloxy)phenol, and 2-(4,6-diphenyl-1,3,5-tiazine-2-il)-5-(hexyloxy)phenol.
• examples of salicyclic ester-based absorbers include phenylsalicylate and p-octylphenylsalicylate.
• the compounding amount of an ultraviolet absorber is preferably 0 to 2 parts by weight per 100 parts by weight of the non-crystalline or low-crystalline ⁇ -olefin-based copolymer or its composition (I).
• Solar cell modules can be fabricated by using of the solar cell encapsulating material of the present invention and by fixing the solar cell element with top and bottom protective materials.
• various types can be cited.
• the following can be cited: a solar cell module in which a solar cell element is sandwiched on both sides by means of an encapsulating material in such manner as a top transparent protective material/encapsulating material/solar cell element /encapsulating material/bottom protective material, a solar cell module having such structure that an encapsulating material and a top transparent protective material are formed on a solar cell element formed on the inner circumference of the bottom substrate protective material, and a solar cell module in which an encapsulating material and a bottom transparent protective material are formed on a solar cell element formed on the inner circumference of the top transparent protective material, such as an amorphous solar cell element formed by sputtering or the like on the transparent fluororesin-based protective material.
• solar cell s elements As examples of solar cell s elements , a wide variety of solar cells elements can be cited, including solar cells based on silicon such as single-crystal silicon, polycrystal silicon and amorphous silicon and solar cells based on III-V-Group and II-VI-Group compounds such as gallium-arsenic, copper-indium-selenium and cadmium-tellurium.
• silicon such as single-crystal silicon, polycrystal silicon and amorphous silicon
• III-V-Group and II-VI-Group compounds such as gallium-arsenic, copper-indium-selenium and cadmium-tellurium.
• the top protective material making up solar cell modules glass, acrylic resin, polycarbonate, polyester, fluorine-containing resin, etc. can be cited.
• the bottom protective material is a single-layer or multi-layer sheet made of metal or various thermoplastic resin film, including metals such as tin, aluminum and stainless steel, inorganic materials such as glass, and single-layer or multi-layer protective materials made of polyester, inorganic compound vapor deposition polyester, fluorine-containing resin and polyolefin, for example. Primer treatment may be done to top and/or bottom protective materials in order to improve their adhesion with the encapsulating material.
• the solar cell encapsulating material of the present invention is used normally in the form of a sheet approximately 0.1 to 1 mm in thickness.
• the solar cell encapsulating material in the form of a sheet can be manufactured by the sheet forming method known to the public using a T-die extruder, calendering equipment, and other equipment.
• a cross-linking agent, cross-linking aid, silane coupling agent, ultraviolet absorber, antioxidant, light stabilizer, etc., which are added as required are dr ⁇ -blended in advance with a non-crystalline or low-crystalline ⁇ -olefin-based copolymer or its composition (I), fed from the hopper of a T-die extruder, and extruded to form a sheet.
• some or all of the additives may be used in the form of masterbatch.
• encapsulating material for solar cells in the form of a sheet which comprises resin composition (C) can be manufactured by the sheet forming method known to the public using a T-die extruder, calendering equipment.
• encapsulating material can be formed by dry-blending crystalline ⁇ -olefin polymer (B), a silane coupling agent, an ultraviolet absorber, an antioxidant, a light stabilizer and other additives with non-crystalline ⁇ -olefin polymer (A) as required and feeding them from the hopper of a T-die extruder to extrude a sheet.
• a cross-linking agent, cross-linking aid, silane coupling agent, ultraviolet absorber, antioxidant, light stabilizer, etc. which are added as required are dry-blended in advance with a non-crystalline or low-crystalline ⁇ -olefin-based copolymer (D), fed from the hopper of a T-die extruder, and extruded to form a sheet.
• a cross-linking agent, cross-linking aid, silane coupling agent, ultraviolet absorber, antioxidant, light stabilizer, etc. which are added as required are dry-blended in advance with a non-crystalline or low-crystalline ⁇ -olefin-based copolymer (D), fed from the hopper of a T-die extruder, and extruded to form a sheet.
• D non-crystalline or low-crystalline ⁇ -olefin-based copolymer
• some or all of the additives may be used in the form of masterbatch.
• the T-die extrusion or calendaring it is also possible to use a resin composition obtained by melting and mixing some or all of the additives together with the non-crystalline or low-crystalline ⁇ -olefin-based copolymer or its composition (I) beforehand by use of a single-screw extruder, twin-screw extruder, Banbury mixer, kneader, etc.
• a module of a structure as described above it is possible to form a module of a structure as described above by the method same as the conventional method in which a sheet of the encapsulating material for solar cell of the present invention is prepared in advance and is press-bonded at a temperature at which the solar cell encapsulating material melts.
• the molding of a sheet of the solar cell encapsulating material can be carried out with high productivity at high temperature, and it is possible to complete the formation of a module in a short time and high temperature without having to go through a two-step bonding process in the formation of a module.
• the use of the solar cell encapsulating material of the present invention makes it possible to improve productivity in the manufacture of modules substantially
• the cross-linking of the non-crystalline or low-crystalline ⁇ -olefin-based copolymer should preferably be carried so that the gelation percent will be 50% to 98%, preferably 70% to 95% (by immersing 1 g of the sample in 100 ml of xylene, heating it for 24 hours at 110° C. and measuring the mass percent of the undissolved filtrate filtrated through a 20-mesh wire netting). Therefore, what has to be done is only to select those formations of the additives which meet these conditions and to select the types and compounding amounts of the additives, for example, properly.
• the physical properties of the present invention were determined by the following methods:
• a 2-mm press-molded sheet was prepared under the conditions of 15 minutes at 150° C., and the storage elastic modulus of the sheet was determined at 150° C. under the following conditions:
• a 0.5-mm sheet was sandwiched with two sheets of 3-mm blue glass and laminated for 15 minutes at 150° C. by use of a vacuum laminating machine.
• the haze and total light transmission were measured by a method based on JIS K7105.
• a 0.5-mm sheet was sandwiched with a 3-mm blue glass plate and an aluminum plate and laminated for 15 minutes at 150° C. by use of a vacuum laminating machine.
• the sample slanted at 600 at 100° C. and then was observed for 500 hours as to whether the sheet would melt and be brought into slippage from the glass.
• a 1-mm press-molded sheet was prepared under the conditions of 30 minutes at 150° C., and approx. 1 g of the sheet was cut off and weighed accurately.
• the samples was immersed in 100 cc of xylene and treated for 24 hours at 110° C. After filtration, the residues were dried and weighed accurately. The gel percent was calculated by dividing the weight of the residues by the weight measured before the treatment.
• the physical properties of the resultant sheet were measured. Results are shown in Table 1.
• PBR propylene-butene copolymer
• a sheet 0.5 mm in thickness was prepared by the same method as described in Example 1 except that a mixture of the propylene-butene-1 copolymer and an alicyclic tackifier (trade name: Alcon AM-1; available from Arakawa Chemical Co.; softening point: 125° C.) in a weight ratio of 90:10 was used in place of the propylene-butene-1 copolymer of examplel.
• the physical properties of the resultant sheet were measured. Results are shown in Table 2.
• EBR non
• a sheet 0.5 mm in thickness was prepared by the same method as described in Example 4 except that the amount of the cross-linking agent was 1.2 parts by weight and the use of the cross-linking accelerator was omitted. The physical properties of the resultant sheet were measured. Results are shown in Table 2.
• a sheet 0.5 mm in thickness was prepared by the same method as described in Example 5 except that a non-crystalline or low-crystalline etylene-propylene copolymer (EPR) (available from Mitsui Chemicals, Inc.; a non-crystalline or low-crystalline ⁇ -olefin-based copolymer; trade name: TAFMER P0275; melt flow rate (ASTM D1238): 2.5 g/10 min (190° C.); melting point: 30° C.; JIS A hardness: 56) was used in place of the ethylene-butene-1 copolymer. The physical properties of the resultant sheet were measured. Results are shown in Table 2.
• EPR non-crystalline or low-crystalline etylene-propylene copolymer
• Example 2 Example 3
• Example 4 Example 5
• Example 6 Composition EBR 100 100 (parts by weight) EPR 100 PBR 100 90 Tackifier 10 Cross-linking agent 1.5 1.2 1.2 Cross-linking aid 2 Physical properties Haze (%) 5.8 3.8 1.8 1.9 2.8 Total light 87.1 87.2 90.4 90.4 90.1 transmission (%) Gelation percent (%) — — 92 82 80
• the encapsulating material for solar cell that is provided by the present invention is encapsulating material for solar cells showing excellent transparency, heat resistance, flexibility, etc.
• the use of an organic peroxide is not essential. For this reason, the encapsulating material for solar cell makes it possible to improve productivity in the solar cell module manufacturing process remarkably and reduce the solar cell module manufacturing cost substantially.
• the encapsulating material for solar cell that is provided by the present invention has high storage elastic modulus at 150° C., low haze and proper hardness. This makes it possible to avoid troubles such as the flow or deformation of the solar cell encapsulating material and an impairment of the appearance even when the temperature rises during the use of the solar cell module obtained from the solar cell encapsulating material.
• the use of the solar cell encapsulating material of the present invention provides a solar cell module showing excellent performance.

Landscapes

• Chemical & Material Sciences (AREA)
• Polymers & Plastics (AREA)
• Chemical Kinetics & Catalysis (AREA)
• Organic Chemistry (AREA)
• Medicinal Chemistry (AREA)
• Health & Medical Sciences (AREA)
• Condensed Matter Physics & Semiconductors (AREA)
• Electromagnetism (AREA)
• Power Engineering (AREA)
• Computer Hardware Design (AREA)
• Microelectronics & Electronic Packaging (AREA)
• Engineering & Computer Science (AREA)
• Physics & Mathematics (AREA)
• General Physics & Mathematics (AREA)
• Photovoltaic Devices (AREA)
• Compositions Of Macromolecular Compounds (AREA)
• Sealing Material Composition (AREA)

Applications Claiming Priority (5)

Related Parent Applications (1)

Related Child Applications (1)

Publications (1)

Family

ID=36614905

Family Applications (3)

Family Applications After (2)

Country Status (7)

Cited By (25)

Families Citing this family (15)

Citations (4)

Family Cites Families (20)

• 2005
  • 2005-12-27 WO PCT/JP2005/023882 patent/WO2006070793A1/ja active Application Filing
  • 2005-12-27 CN CN2005800446312A patent/CN101087842B/zh active Active
  • 2005-12-27 DE DE602005024050T patent/DE602005024050D1/de active Active
  • 2005-12-27 CN CN201010110176.4A patent/CN102061024B/zh active Active
  • 2005-12-27 US US11/794,353 patent/US20070267059A1/en not_active Abandoned
  • 2005-12-27 KR KR1020077014418A patent/KR100896302B1/ko active IP Right Grant
  • 2005-12-27 EP EP05822289A patent/EP1837372B1/de active Active
  • 2005-12-27 KR KR1020087017205A patent/KR100896305B1/ko active IP Right Grant
  • 2005-12-28 TW TW094147041A patent/TWI397187B/zh active
• 2010
  • 2010-08-23 US US12/861,187 patent/US8426544B2/en active Active
• 2013
  • 2013-01-02 US US13/732,683 patent/US8569437B2/en active Active

Patent Citations (4)

Also Published As

Similar Documents

Legal Events