WO2010106907A1 - 太陽電池裏面封止材用フィルム、それを用いた太陽電池裏面封止材および太陽電池モジュール - Google Patents

太陽電池裏面封止材用フィルム、それを用いた太陽電池裏面封止材および太陽電池モジュール Download PDF

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Publication number
WO2010106907A1
WO2010106907A1 PCT/JP2010/053314 JP2010053314W WO2010106907A1 WO 2010106907 A1 WO2010106907 A1 WO 2010106907A1 JP 2010053314 W JP2010053314 W JP 2010053314W WO 2010106907 A1 WO2010106907 A1 WO 2010106907A1
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Prior art keywords
film
solar cell
sealing material
resin
layer
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PCT/JP2010/053314
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English (en)
French (fr)
Japanese (ja)
Inventor
亀田俊輔
荒井崇
中島亜由子
廣田草人
俵林太郎
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東レ株式会社
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Priority to JP2010511001A priority Critical patent/JPWO2010106907A1/ja
Publication of WO2010106907A1 publication Critical patent/WO2010106907A1/ja

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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L31/00—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
    • H01L31/04—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof adapted as photovoltaic [PV] conversion devices
    • H01L31/042—PV modules or arrays of single PV cells
    • H01L31/048—Encapsulation of modules
    • H01L31/049—Protective back sheets
    • 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 has light resistance and moisture and heat resistance that can withstand use in harsh outdoor environments over a long period of time, and also has good design and adhesion to the terminal box adhesive silicone resin required for use in the outermost layer. It is related with the film for solar cell backside sealing materials which has the outstanding colored layer, the solar cell backside sealing material using the same, and a solar cell module.
  • Solar cells used for photovoltaic power generation constitute the heart of a photovoltaic power generation system that directly converts sunlight energy into electrical energy, and are made of semiconductors such as silicon.
  • solar cell elements are wired in series and in parallel, and various packaging is performed to protect the elements over a long period of about 20 years, and they are unitized.
  • the unit incorporated in this package is called a solar cell module, and generally has a structure in which the surface exposed to sunlight is covered with glass, the gap is filled with a filler made of thermoplastic resin, and the back surface is protected with a sealing sheet. Yes.
  • EVA resin ethylene-vinyl acetate copolymer resin
  • the backside sealing material has mechanical strength, weather resistance, heat resistance, water resistance, chemical resistance, light reflectivity, water vapor barrier properties, thermal adhesiveness with fillers typified by EVA resin, and design properties.
  • properties such as adhesion to the outermost terminal box mounting silicone resin, it is required to have excellent light resistance because it is exposed to ultraviolet rays.
  • a white or black polyvinyl fluoride film (DuPont Co., Ltd., trade name: Tedlar (registered trademark)) can be exemplified, and a polyester film is sandwiched between the films.
  • a back surface sealing material having a laminated structure is widely used in the application.
  • a weather-resistant film (patent document 1) in which a blackening agent, an ultraviolet absorber, and a light stabilizer are blended in a polypropylene resin film, and a weather-resistant film in which an inorganic oxide material is deposited on a polyphenylene sulfide film. (Patent Document 2).
  • the polyvinyl fluoride film described above is a film having excellent weather resistance, but on the other hand, its mechanical strength is weak and it is softened by the heat of a hot press at 140 to 150 ° C. applied at the time of manufacturing a solar cell module.
  • the protrusion of the element electrode portion may penetrate the filler layer. Furthermore, since it is expensive, it also becomes an obstacle in terms of reducing the cost of the solar cell module.
  • Patent Document 1 in the case of a black film in which a black pigment is kneaded and formed, in terms of small change in film appearance due to ultraviolet exposure due to the light absorption ability of the pigment component, Although it has a certain degree of UV resistance, since the resin of the main material is not light-resistant, there is a problem that film properties represented by, for example, breaking strength and elongation, gradually deteriorate with ultraviolet irradiation. In addition, in recent years, development related to prolonging the life of solar cell modules itself has been actively carried out, and in addition, the number of solar cell modules installed in a slanting manner on the ground surface is increasing mainly in Europe.
  • the sealing material since it is exposed to the ultraviolet rays reflected from the ground surface for a long period of time, if a layer having long-term stable light resistance is not formed on the outer layer surface of the back surface sealing material, the sealing material is In the extreme case, the sealing material is cracked, and there is a concern that various properties required for the sheet such as electrical insulation and water vapor barrier properties may be impaired.
  • the polyphenylene sulfide film used in Patent Document 2 is extremely excellent in hydrolysis resistance and is suitable as a film for a solar cell back surface sealing material, but is deteriorated by ultraviolet rays and visible light.
  • the base film is a polyethylene naphthalate film or a polyphenylene sulfide film, and at least one surface of the base film is provided with a resin, a color pigment and a plasticizer obtained by copolymerizing an ultraviolet absorber and / or a light stabilizer.
  • the plasticizer is at least one selected from the group consisting of a polyester plasticizer, an epoxy plasticizer, and a phthalate ester plasticizer.
  • the resin layer includes at least one polyisocyanate resin selected from the group consisting of an aliphatic polyisocyanate resin, an alicyclic polyisocyanate resin, and an araliphatic polyisocyanate resin.
  • a solar cell back surface sealing material comprising the solar cell back surface sealing material film according to any one of (1) to (5).
  • a solar cell module obtained by bonding the solar cell back surface sealing material according to (6) or (7) and the silicon cell filler layer surface.
  • the present invention has light resistance and heat-and-moisture resistance that can withstand use in a harsh outdoor environment for a long period of time, and has good design and adhesion to a silicone resin for terminal box adhesion when used in the outermost layer. Moreover, the film for solar cell backside sealing materials which has the coloring layer excellent also in is obtained.
  • the film for solar cell backside sealing material of the present invention is used, the adhesion to the silicon cell filler layer and the light reflectance are excellent, the performance of the solar cell module is improved, and the performance can be maintained for a long time.
  • a solar cell back surface sealing material to be obtained is obtained.
  • the film for solar cell backside sealing material according to the present invention includes a resin obtained by copolymerizing an ultraviolet absorber and / or a light stabilizer, a color pigment, and a plasticizer on at least one surface of a polyethylene naphthalate film or a polyphenylene sulfide film.
  • a resin obtained by copolymerizing an ultraviolet absorber and / or a light stabilizer, a color pigment, and a plasticizer on at least one surface of a polyethylene naphthalate film or a polyphenylene sulfide film By having a laminated resin layer structure, it has superior light resistance and moisture and heat resistance compared to conventional products, and also has excellent design and adhesion to the terminal box adhesive silicone resin required for use in the outermost layer. A colored film can be obtained.
  • the film for solar cell backside sealing material of the present invention is excellent in light resistance and moisture and heat resistance, in the solar cell backside sealing material configuration, it is most likely to be directly exposed to the outside air (humidity, temperature) or reflected ultraviolet rays from the ground surface. It can be suitably used for the outer layer.
  • Base film As a base film in the present invention, polyethylene naphthalate having excellent resistance to moisture and heat from the viewpoint that it has resistance to a severe external environment and can be used as the outermost layer of a solar cell back surface sealing material that is directly exposed to the outside air. PEN) film, or polyphenylene sulfide (PPS) film that is extremely excellent in heat and humidity resistance and flame resistance.
  • TORELINA registered trademark manufactured by Toray Industries, Inc. can be used for the PPS film, and since TORELINA has excellent heat resistance and electric insulation, it is used as a film capacitor dielectric and an electric insulator for motors and transformers. Has been.
  • Teonex (registered trademark) manufactured by Teijin DuPont Films Co., Ltd. can be used for the PEN film, and it has higher gas / ultraviolet barrier properties and mechanical strength than polyethylene terephthalate (PET) film. It is also used as a material for APS photographic film and electronic parts.
  • additives such as an antistatic agent, an ultraviolet absorber, a stabilizer, an antioxidant, a plasticizer, a lubricant, a filler, and a coloring pigment are added to the base film as necessary.
  • the resin film etc. which were added within the range which does not impair can also be used.
  • the thickness of the base film is preferably in the range of 3 to 250 ⁇ m, more preferably in the range of 5 to 100 ⁇ m. By setting the thickness to 3 ⁇ m or more, it is possible to prevent tearing during film formation and generation of pinhole scratches, and by setting the thickness to 250 ⁇ m or less, it is possible to suppress production costs.
  • the resin layer laminated on the base film in the present invention is composed of (1) a resin obtained by copolymerizing an ultraviolet absorber and / or a light stabilizer, (2) a color pigment, and (3) a plasticizer. Yes.
  • organic UV absorbers and inorganic UV absorbers are used alone or in combination with a plurality of types and mixed with a binder resin.
  • a light stabilizer (HALS) is used in combination for the purpose of increasing the light stability by a mechanism for deactivating radicals excited by.
  • the UV absorber or light stabilizer is removed from the coating film in a high-temperature humidified environment or with UV light reception. Bleeding out to the surface not only changes wettability, adhesion of the coating surface, etc., but also tends to cause problems such as loss of the originally expressed UV-cut performance.
  • the ultraviolet light absorber and / or light stabilizer is copolymerized with the binder resin to prevent the ultraviolet light absorber and light stabilizer from bleeding out on the surface of the coating film. The performance can be maintained for a long time.
  • the binder resin an acrylic resin that is relatively excellent in light resistance as compared with a polyester resin, an olefin resin, or the like is preferable.
  • the solar cell back surface sealing material using the film for solar cell back surface sealing material of the present invention for the purpose of improving the adhesion with the base film is exposed to high temperature treatment in the solar cell module manufacturing process.
  • an acrylic polyol resin is particularly preferable among the acrylic resins so that an appropriate crosslinked structure can be introduced.
  • vinyl monomers such as acrylic and styrene are highly versatile and economically preferable.
  • styrene vinyl monomers have an aromatic ring, and thus are easily yellowed, and in terms of light resistance, copolymerization with acrylic vinyl monomers is most preferably used. Therefore, one polymerization monomer component constituting the acrylic resin is one or more unsaturated compounds in the group consisting of unsaturated carboxylic acid ester, unsaturated carboxylic acid, unsaturated hydrocarbon and vinyl ester.
  • unsaturated carboxylic acid esters examples include methyl methacrylate, methyl acrylate, ethyl acrylate, ethyl methacrylate, n-propyl acrylate, n-propyl methacrylate, isopropyl acrylate, isopropyl methacrylate, n-butyl acrylate, n-butyl methacrylate, isobutyl acrylate, Examples thereof include isobutyl methacrylate, t-butyl acrylate, t-butyl methacrylate, 2-ethylhexyl acrylate and 2-ethylhexyl methacrylate.
  • unsaturated carboxylic acids examples include acrylic acid, methacrylic acid, maleic acid, itaconic acid, crotonic acid, and fumaric acid.
  • Suitable monomers that can be used include butadiene, ethylene, vinyl acetate and the like. Preference is given to unsaturated carboxylic acid esters. Among unsaturated carboxylic acid esters, methyl methacrylate and methyl acrylate are particularly preferable from the viewpoints of versatility, cost, and light stability.
  • Polymerization monomer components used for the purpose of giving hydroxyl groups to acrylic resins include, for example, 2-hydroxyethyl acrylate, 2-hydroxyethyl methacrylate, 2-hydroxypropyl acrylate, 2-hydroxypropyl methacrylate, 2-hydroxybutyl acrylate, 2-hydroxybutyl Examples thereof include monomers of unsaturated compounds such as methacrylate, 2-hydroxyvinyl ether, polyethylene glycol methacrylate, polypropylene glycol monoacrylate, and polypropylene glycol monomethacrylate. These unsaturated compounds having a hydroxyl group can be selected singly or in combination of two or more.
  • the thickness of the resin layer is preferably 0.2 to 5 ⁇ m, more preferably 1 to 4 ⁇ m, and particularly preferably 2 to 4 ⁇ m.
  • the resin layer is formed by a coating method, if the thickness of the resin layer is 0.2 ⁇ m or more, a phenomenon such as repellency or film breakage hardly occurs during coating, and a uniform coating film is easily formed. As a result, the adhesive strength to the substrate film, and above all, the ultraviolet ray cutting performance is sufficiently exhibited, which is preferable.
  • the thickness of the resin layer is 5 ⁇ m or less, it can be applied with a normal coating apparatus without using a specific process that allows thick film coating, so there is no restriction on the coating method and production cost can be reduced. preferable. Furthermore, it is preferable because it is difficult to cause adhesion of the coating film to the transport roll and peeling of the coating film associated therewith.
  • Examples of the solvent of the coating liquid for forming the resin layer in the present invention by the coating method include toluene, xylene, ethyl acetate, butyl acetate, acetone, methyl ethyl ketone, methyl isobutyl ketone, tetrahydrofuran, dimethylformamide, dimethylacetamide, methanol, Examples include ethanol and water, and the properties of the coating liquid may be either an emulsion type or a dissolution type.
  • the method for forming the resin layer on the base film is not particularly limited, and a known coating method can be used.
  • a coating method various methods can be applied.
  • a roll coating method, a dip coating method, a bar coating method, a die coating method, a gravure roll coating method, or a combination of these methods can be used. It can.
  • the gravure roll coating method is a preferable method for increasing the stability of the coating layer forming composition.
  • UV absorber examples of the ultraviolet absorber copolymerized with the binder resin include salicylic acid-based, benzophenone-based, benzotriazole-based, and cyanoacrylate-based ultraviolet absorbers.
  • examples of the light stabilizer copolymerized with the binder resin include hindered amine-based light stabilizers. Specifically, bis (1,2,2,6,6-pentamethyl-4-piperidyl) [[3,5-bis (1,1-dimethylethyl) -4-hydroxyphenyl] methyl] butyl malonate, Bis (1,2,2,6,6-pentamethyl-4-piperidyl) sebacate, methyl (1,2,2,6,6-pentamethyl-4-piperidyl) sebacate, bis (2,2,6) decanedioate , 6-tetramethyl-1-octyloxy] -4-piperidinyl] ester and the like, modified products, polymers and derivatives thereof.
  • hindered amine-based light stabilizers include hindered amine-based light stabilizers. Specifically, bis (1,2,2,6,6-pentamethyl-4-piperidyl) [[3,5-bis (1,1-dimethylethyl)
  • a production method for copolymerizing these ultraviolet absorbers and / or light stabilizers with a binder resin, particularly an acrylic polyol resin, is disclosed in detail in JP-A-2002-90515 [0019] to [0039]. Yes. Among them, HALS HYBRID (registered trademark) (manufactured by Nippon Shokubai Co., Ltd.) containing an acrylic monomer and UV absorber copolymer as an active ingredient can be used.
  • the color pigment used in the present invention is selected and used for the purposes of (1) coloring the resin layer, (2) maintaining the color tone (not fading), and (3) cutting ultraviolet rays and / or visible light.
  • a white sheet is mainly used from the viewpoint of light reflectivity and design properties, but when the sheet is black, the design property is compared with a white sheet in which gaps between power generating elements appear white. Excellent.
  • these pigments themselves also absorb and / or reflect light of a specific wavelength, the effect of protecting the base sheet from the light by coloring can be obtained.
  • a design pattern such as an electric wiring pattern in the solar cell module can be hidden.
  • the resin layer needs to have an ultraviolet cutting performance, and the polyphenylene sulfide film is deteriorated not only by ultraviolet rays but also by visible light. ⁇ It is necessary to cut light in the visible light region. Therefore, when using a polyphenylene sulfide film, the resin layer is made black so that ultraviolet rays and visible light are shielded by the resin layer, thereby preventing deterioration of the film.
  • the white pigment titanium oxide having ultraviolet resistance is preferable.
  • the number average particle diameter is preferably from 0.1 to 1.0 ⁇ m, more preferably from 0.2 to 0.5 ⁇ m from the viewpoint of dispersibility with respect to the acrylic polyol resin and cost.
  • the black pigment various colored pigments such as inorganic pigments and organic pigments can be used, but carbon black is preferable from the viewpoints of versatility, price, coloring performance, and ultraviolet resistance.
  • the average particle size of carbon black is preferably 0.01 to 0.5 ⁇ m from the viewpoint of color development, and more preferably 0.02 to 0.1 ⁇ m in view of dispersibility with respect to the binder resin and cost.
  • the blending amount of the color pigment may be appropriately adjusted according to the design of the color tone to be developed. However, if the amount of pigment is too small, a color appearance with excellent design cannot be obtained. Conversely, if the amount is too large, the cost will be high, and the hardness of the resin layer will be greatly improved. 10 to 10 parts by mass with respect to 100 parts by mass of a resin obtained by copolymerizing a binder resin with an ultraviolet absorber and / or a light stabilizer, for example, because it tends to cause poor adhesion between the substrate and the terminal box adhesive silicone resin. A range of 500 parts by weight is preferred.
  • the plasticizer contained in the resin layer of the present invention will be described.
  • the effect of containing a plasticizer in the resin layer appears remarkably.
  • the plasticizer in the present invention contributes to improving the adhesion between the base film, the resin layer containing the acrylic polyol resin and the color pigment, and the resin layer and the terminal box bonding silicone resin.
  • acrylic polyol resin is not a resin material that has a particularly poor adhesion to various resin films, but when a colored pigment is compounded at a relatively high concentration for the purpose of coloring the resin layer, the hardness of the resin layer increases.
  • the concentration of the acrylic polyol resin in the resin layer is relatively lowered, the adhesion between the base film and the resin layer and between the resin layer and the terminal box bonding silicone resin is lowered. There is a tendency. Therefore, by adding a plasticizer component that tends to have a lower resin softening point than acrylic polyol resins, the hardness of the resin layer is adjusted, and the adhesion between the base film and the silicone resin for terminal box adhesion is improved. Can be made.
  • a polyester plasticizer, an epoxy plasticizer, a phthalate ester plasticizer, or a combination thereof is preferable from the viewpoint of heat resistance, weather resistance, cost, versatility, and the like.
  • polyester plasticizer for example, an adipic acid plasticizer is preferably used.
  • epoxy plasticizer for example, an epoxidized fatty acid ester is preferably used.
  • epoxy plasticizer epoxidized vegetable oil can also be used, and examples thereof include epoxidized soybean oil and epoxidized linseed oil.
  • phthalate ester plasticizer for example, dioctyl phthalate, diisononyl phthalate, disisodecyl phthalate, or dibutyl phthalate is preferably used.
  • plasticizer used in the present invention examples include Polysizer W-220EL manufactured by DIC, which is a polyester plasticizer, Eposizer W-121 manufactured by DIC, which is an epoxy plasticizer, and DIC, which is an epoxidized soybean oil-based plasticizer.
  • Eposizer W-100-EL manufactured by DIC dioctyl phthalate manufactured by DIC, which is a phthalate ester plasticizer.
  • the amount of the plasticizer is preferably 4 to 40 parts by mass, more preferably 10 to 10 parts by mass with respect to 100 parts by mass of the resin obtained by copolymerizing the acrylic polyol resin with the ultraviolet absorber and / or the light stabilizer. 30 parts by mass.
  • the blending amount of the plasticizer is 4 parts by mass or more, an improvement effect such as adhesion strength appears.
  • the blending amount of the plasticizer is 40 parts by mass or less, since the relative amount of the acrylic polyol-based resin containing the ultraviolet absorber and / or the light stabilizer in the resin layer is sufficient, the resistance of the resin layer itself is increased. The UV property and the function of protecting the substrate film from UV rays (UV blocking performance) are not impaired.
  • a heat stabilizer an antioxidant, a reinforcing agent, a deterioration inhibitor, a weathering agent, a flame retardant, a plasticizer, a release agent, a lubricant, etc. are added to the resin layer in the present invention as long as the characteristics are not impaired. May be.
  • heat stabilizers, antioxidants and deterioration inhibitors examples include hindered phenols, phosphorus compounds, hindered amines, sulfur compounds, copper compounds, alkali metal halides, and mixtures thereof.
  • reinforcing agents examples include clay, talc, calcium carbonate, zinc carbonate, wollastonite, silica, alumina, magnesium oxide, calcium silicate, sodium aluminate, sodium aluminosilicate, magnesium silicate, glass balloon, carbon black, and oxidation.
  • examples include zinc, zeolite, hydrotalcite, metal fiber, metal whisker, ceramic whisker, potassium titanate whisker, boron nitride, graphite, glass fiber, and carbon fiber.
  • Crosslinking agent As described above, a crosslinking agent having a functional group capable of reacting with the hydroxyl group of the acrylic polyol may be blended for the purpose of improving the properties of the resin layer.
  • a crosslinking agent is used in combination, the effect of improving the adhesion between the base film and the resin layer or improving the heat resistance of the resin layer accompanying the introduction of a crosslinked structure can be obtained.
  • the solar cell back surface sealing material is designed so that the resin layer in the present invention is located in the outermost layer, in the solar cell module manufacturing process, specifically in the glass laminating process (cell filling process), Since the resin layer is exposed to a heat treatment of 30 minutes or longer at a high temperature of about 150 ° C.
  • a resin obtained by copolymerizing an acrylic polyol resin and an ultraviolet absorber and / or a light stabilizer is used, it is possible to use a crosslinking agent capable of reacting with the hydroxyl group of the resin.
  • a prescription that uses a polyisocyanate resin as a curing agent and promotes the formation of urethane bonds (crosslinked structure) is preferred.
  • the polyisocyanate resin used as a crosslinking agent include aromatic polyisocyanates, araliphatic polyisocyanates, alicyclic polyisocyanates, and aliphatic polyisocyanates. Each of the following diisocyanate compounds is used as a raw material. Resin.
  • diisocyanate used as a raw material for the aromatic polyisocyanate examples include m- or p-phenylene diisocyanate, 4,4'-diphenyl diisocyanate, 1,5-naphthalene diisocyanate (NDI), 4,4'-, 2,4.
  • NDI 1,5-naphthalene diisocyanate
  • Examples include '-or 2,2'-diphenylmethane diisocyanate (MDI), 2,4- or 2,6-tolylene diisocyanate (TDI), and 4,4'-diphenyl ether diisocyanate.
  • diisocyanate used as a raw material for the araliphatic polyisocyanate examples include 1,3- or 1,4-xylylene diisocyanate (XDI) and 1,3- or 1,4-tetramethylxylylene diisocyanate (TMXDI). Etc. are exemplified.
  • diisocyanate used as a raw material for the alicyclic polyisocyanate examples include 1,4-cyclohexane diisocyanate, 1,3-cyclohexane diisocyanate, 3-isocyanate methyl-3,5,5-trimethylcyclohexyl isocyanate (isophorone diisocyanate; IPDI).
  • diisocyanate used as a raw material for the aliphatic polyisocyanate examples include trimethylene diisocyanate, tetramethylene diisocyanate, hexamethylene diisocyanate (HDI), pentamethylene diisocyanate, 1,2-propylene diisocyanate, 1,2-, 2,3- Examples include 1,3-butylene diisocyanate and 2,4,4- or 2,2,4-trimethylhexamethylene diisocyanate.
  • a polyisocyanate raw material As a polyisocyanate raw material, a combination of a plurality of these diisocyanates may be used, and a modified product such as a burette modified product or a nurate modified product may be used.
  • a resin containing an aromatic ring having a light absorption band in the ultraviolet region in the resin skeleton easily yellows upon irradiation with ultraviolet rays. Therefore, an alicyclic polyisocyanate and an aliphatic polyisocyanate. It is preferable to use a curing agent containing as a main component.
  • ethanol is often used to wipe off the resin and dirt adhering to the outermost layer of the solar cell backside sealing material in the finishing process of the solar cell module, and the outermost layer of the solar cell backside sealing material has ethanol resistance.
  • Use of alicyclic polyisocyanate is required because curing of the resin layer proceeds from aliphatic polyisocyanate and ethanol resistance is improved by using a curing agent mainly composed of alicyclic polyisocyanate. Is preferred.
  • the nurate modified body of hexamethylene diisocyanate is preferable from the viewpoint of easy progress of the crosslinking reaction with the acrylic polyol-based resin, the degree of crosslinking, heat resistance, and ultraviolet resistance.
  • a solar cell back surface sealing material can be obtained by laminating a film for solar cell back surface sealing material obtained by the present invention and another resin film, but as a technique for laminating the film and processing it into a sheet shape, A dry laminating method can be used. Bonding of resin films using the dry laminating method is a known adhesive for dry laminating using a polyether polyurethane, polyester polyurethane, polyester, or polyepoxy resin as the main agent and a polyisocyanate resin as a curing agent. An agent can be used. However, the adhesive layer formed using these adhesives does not cause delamination due to deterioration of the adhesive strength after long-term outdoor use, and yellowing that leads to a decrease in light reflectance.
  • the thickness of the adhesive layer is preferably in the range of 1 to 5 ⁇ m. If it is less than 1 ⁇ m, it may be difficult to obtain sufficient adhesive strength. On the other hand, if it exceeds 5 ⁇ m, the coating speed of the adhesive does not increase, the aging performed for the purpose of developing the adhesive force (promoting the crosslinking reaction between the main agent and the curing agent), and further using the adhesive This is not preferable because the production cost increases due to an increase in the amount.
  • a known dry laminating adhesive can be used as a material used for forming the adhesive layer according to the present invention.
  • adhesives for dry laminating are prepared by diluting two resins, a main agent and a crosslinking agent, with a diluent solvent.
  • the crosslinking agent is highly reactive with active hydroxyl groups, its reaction rate and initial adhesion.
  • the prescription using an isocyanate group-containing polymer with a fast onset is preferred.
  • the main resin used in combination with this isocyanate group-containing polymer examples include polyether resins, polyester resins, polyol resins, and other urethane resins and epoxy resins, depending on the detailed required characteristics and suitability for processing conditions. Can be appropriately selected and used. Further, depending on the configuration of the solar cell back surface sealing material, it is also conceivable that ultraviolet rays reach the above adhesive layer and induce photodegradation of the resin. From such a viewpoint, the resin used for forming the adhesive layer is preferably an aliphatic resin or an alicyclic resin that does not contain an aromatic ring or has a low content.
  • the solar cell back surface sealing material is required to have various characteristics such as water vapor barrier property, light reflectivity, long-term moisture and light resistance, adhesion to cell filler, electrical insulation and the like.
  • various company-specific sheet designs laminate designs are made in combination with various functional films, processing techniques such as vapor deposition and wet coating in accordance with the concept of functional division.
  • the film for solar cell backside sealing material of the present invention is laminated with one or more of a white film, a film having an inorganic oxide vapor deposition layer, and a film having thermal adhesiveness with an ethylene-vinyl acetate copolymer.
  • the solar cell back surface sealing material which satisfy
  • a different type of film from the base film of the solar cell back surface sealing material film is laminated.
  • the solar cell back surface sealing material film of the present invention having hydrolysis resistance is applied to the portion of the solar cell back surface sealing material that becomes the outside when incorporated in the solar cell module, and the resin layer faces outward. Such a design is preferable.
  • a film having hydrolysis resistance By disposing a film having hydrolysis resistance, layers (adhesive layer, film layer, etc.) located on the inner layer side from the film are protected from hydrolysis. Moreover, since the resin layer which has an ultraviolet-ray and / or visible-light cutting performance is located in the outermost layer side, the layer inside this resin layer is protected from an ultraviolet-ray and / or visible light.
  • the solar cell back surface sealing material even on the resin layer in the present invention, even if a vapor deposition layer, a sputter layer, a wet coating layer or the like for the purpose of imparting functionality is formed on any layer good.
  • the white film is used for the purpose of assisting energy conversion in the semiconductor element by reflecting the light incident on the back sheet and improving the power generation efficiency, and is preferably arranged in a layer close to the cell.
  • a polyester resin film is preferable because it is excellent in strength, dimensional stability, and thermal stability, and a polyethylene terephthalate film such as PET or PEN is particularly preferable because it is inexpensive.
  • titanium oxide or zinc oxide can be used, and a white resin film having a whiteness of 80% or more and an opacity of 80% or more is obtained by kneading.
  • the white resin film may be added with additives such as an antistatic agent, an ultraviolet absorber, a stabilizer, an antioxidant, a plasticizer, a lubricant, and a filler, as necessary, without impairing the effects of the present invention.
  • a resin film or the like added within the range can also be used.
  • the thickness of the resin film is not particularly limited, but is preferably in the range of 25 to 250 ⁇ m in view of the voltage resistance characteristics, cost, etc. of the sealing sheet.
  • Water vapor barrier film As the solar cell back surface sealing material, a water vapor barrier film in which at least one inorganic oxide layer is formed by a vapor deposition method or the like may be used for the purpose of imparting a water vapor barrier property.
  • the “water vapor barrier film” in the present invention is a resin film having a water vapor transmission rate of 5 g / (m 2 ⁇ day) or less as measured by the method B described in JIS K7129 (2000 version).
  • the water vapor barrier resin film As the water vapor barrier resin film, at least one metal thin film layer or the like is formed on at least one surface of a polyester resin film such as polyethylene terephthalate (PET) or polyethylene naphthalate (PEN) or an olefin film such as polypropylene by vapor deposition or the like.
  • PET polyethylene terephthalate
  • PEN polyethylene naphthalate
  • an olefin film such as polypropylene by vapor deposition or the like.
  • the film which provided the inorganic oxide layer is mentioned, since it is requested
  • the gas barrier property of a film provided with an inorganic oxide layer by vapor deposition or the like is caused by at least the thermal dimensional stability of a polyester resin film as a base material. Therefore, a polyester resin film is a film
  • the thickness of the resin film is preferably in the range of 1 to 100 ⁇ m, more preferably in the range of 5 to 50 ⁇ m, and particularly preferably 10 for reasons such as stability and cost when forming the inorganic oxide layer. About 30 ⁇ m is practical.
  • Examples of the inorganic oxide constituting the inorganic oxide layer formed in the present invention include metal oxides and metal nitride oxides.
  • Examples of the metal oxide constituting the inorganic oxide layer include aluminum oxide, magnesium oxide, titanium oxide, tin oxide, indium oxide alloy, and silicon oxide.
  • the metal nitride oxide includes silicon oxynitride. Etc. can be illustrated.
  • inorganic oxides such as aluminum oxide, silicon oxide, silicon oxynitride, and mixtures thereof are preferably used from the viewpoint of water vapor barrier properties and production efficiency.
  • the film thickness of the inorganic oxide layer is appropriately selected depending on the kind and configuration of the inorganic substance used, but generally it is preferably in the range of 2 to 300 nm, more preferably in the range of 3 to 100 nm, The range is preferably 5 to 50 nm.
  • the film thickness exceeds 300 nm, especially in the case of a metal oxide layer, the flexibility (flexibility) decreases, and the thin film is cracked by an external force such as bending or pulling after film formation (in a post-processing step or the like). May cause pinholes and the like, and water vapor barrier properties may be significantly impaired.
  • productivity since the formation speed of an inorganic layer falls, productivity may be reduced remarkably.
  • by setting the film thickness to 2 nm or more a uniform film can be obtained, and furthermore, since the film thickness is sufficient, the water vapor blocking function can be sufficiently exhibited.
  • the resin film may be subjected to a discharge treatment such as corona discharge or plasma discharge, or a surface treatment such as acid treatment.
  • the film for solar cell backside sealing material of the present invention uses, as a base film, for example, a polyphenylene sulfide (PPS) film Torelina (registered trademark) manufactured by Toray Industries, Inc., and as a coating material, an ultraviolet absorber and / or After a paint containing acrylic polyol resin, black pigment, and plasticizer copolymerized with a light stabilizer is dispersed using a bead mill, a paint is prepared by adding a nurate hexamethylene diisocyanate resin as a crosslinking agent. And the film for solar cell backside sealing materials can be obtained by coating this base film using the gravure roll coating method.
  • PPS polyphenylene sulfide
  • the solar cell back surface sealing material of this invention has a white film and an inorganic oxide vapor deposition layer in the surface on the opposite side to the side by which the resin layer of the film for solar cell back surface sealing materials of this invention was laminated
  • the characteristic evaluation method used in the present invention is as follows.
  • the coating amount of the light-resistant coating layer was cut into an area of 500 cm 2 after forming the coating layer, and the mass of the test piece was defined as mass (1).
  • the resin layer was dissolved in methyl ethyl ketone from the test piece, peeled off, and the mass of the test piece was measured again to obtain mass (2).
  • the coating amount per unit area was calculated based on the following formula. This coating amount measurement was performed on three test pieces, and the average value was taken as the coating amount.
  • Application amount [g / m 2 ] ⁇ (mass (1)) ⁇ (mass (2)) ⁇ ⁇ 20.
  • the light-blocking performance of the film for solar cell backside sealing material is based on JIS K 7105 (Fiscal 2006 version), and the spectrum is measured using an ultraviolet-visible near-infrared spectrophotometer UV-3150 manufactured by Shimadzu Corporation. did.
  • the light-cut performance was evaluated by measuring the transmittance of a wavelength of particularly 360 nm in the ultraviolet region and particularly a wavelength of 600 nm in the visible light region.
  • Adhesive strength evaluation between base film / light-resistant coat layer (resin layer) Adhesive strength between base film and light-resistant coat layer (resin layer) of the produced solar cell backside sealing material film ( With respect to the coating strength), a cross-cut test was performed based on the method described in JIS K 5400 (1990 edition), and the following characteristic classification was performed. ++: 100 square coating film remaining / 100 square medium +: 81-99 mass coating film remaining / 100 square film ⁇ : 80 mass or less remaining coating film / 100 square film.
  • Solvent resistance evaluation The solvent resistance of the light-resistant coating layer was evaluated by evaluating the light-cutting performance after the sample was immersed in ethanol for 5 minutes and then rubbed 50 times using a Kimwipe. Moreover, the state of the coating film was observed and it classified into the following classification. +: There is no peeling between the substrate and the coating film, and no reduction in the light-cutting performance is observed.-: Peeling between the substrate and the coating film is observed.
  • the tested pseudo solar cell module sample is obtained by stacking an EVA sheet on the inner layer side surface (the surface on which the water vapor barrier film is laminated) of the produced solar cell back surface sealing material, and a 0.3 mm thick semi-tempered glass on the EVA sheet. After repeated evacuation using a commercially available glass laminator, a product subjected to press treatment at 135 ° C. under a heating condition of 29.4 N / cm 2 for 15 minutes was used.
  • As the EVA sheet a 500 ⁇ m thick sheet manufactured by Sanvik Co., Ltd. was used.
  • the width of the test piece of the adhesive strength test was 10 mm, and each of the two test pieces was measured once, and the average value of the two measured values was taken as the value of the adhesive strength. It is judged that the adhesive strength is 100 N / 50 mm or more as a practically acceptable level.
  • test pieces for measurement were cut out from this test piece in a strip shape having a width of 10 mm, and the adhesive strength was measured in a state where the peel angle was 90 ° by the same method as the measurement of the adhesive strength with the filler. The measurement was performed once for each of the three strip-shaped test pieces, and the average value of the obtained strengths was taken as the value of the silicone resin adhesive strength. If the adhesive strength is 8 N / 10 mm or more, it is a practically required characteristic level.
  • Halshybrid Polymer (registered trademark) BK1 (solid content concentration: 40) which is a coating agent manufactured by Nippon Shokubai Co., Ltd., characterized in that an ultraviolet absorber and a light stabilizer (HALS) are crosslinked with an acrylic polyol resin.
  • the color pigment and the solvent having the composition shown in Table 1 were mixed together and dispersed using a bead mill. Then, the plasticizer of the mixing
  • Desmodur (registered trademark) N3300 solid content concentration: 100% by mass
  • Sumika Bayer which is a nurate type (alicyclic) hexamethylene diisocyanate resin
  • the pre-calculated diluent: n-acetate was added so that the weight ratio of the solid content was 55/13, and the coating composition had a solid content concentration of 20% by mass (resin solid content concentration).
  • -Propyl was weighed and stirred for 15 minutes to obtain light-resistant coating layer forming coatings 1 to 5 having a solid content concentration of 20% by mass (resin solid content concentration).
  • White pigment Titanium oxide particles JR-709 manufactured by Teika
  • Black pigment Carbon black particles Special black 4A manufactured by Degussa
  • Plasticizer 1 DIC Polyester Plasticizer Polysizer W-220EL Plasticizer 2: Epoxy plasticizer manufactured by DIC Eposizer W-121 Plasticizer 3: Epoxidized soybean oil plasticizer manufactured by DIC Corporation Eposizer W-100-EL Plasticizer 4: Phthalic acid ester plasticizer dioctyl phthalate manufactured by DIC.
  • a light-resistant coating layer-forming coating material 8 was obtained in the same manner as the adjustment of the light-resistant coating layer-forming coating material 1 except that no color pigment was blended.
  • a light-resistant coating layer-forming coating material 9 was obtained in the same manner as the preparation of the light-resistant coating layer-forming coating material 1 except that no plasticizer was added.
  • Example 1 A polyphenylene sulfide film Torelina (registered trademark) 100 ⁇ m manufactured by Toray Industries, Inc. was prepared as a base film. On one surface of this base film, the light-resistant coating layer forming coating 1 is applied using a wire bar, dried at 120 ° C. for 30 seconds, and the coating amount after drying is 2.0 g / m 2. A light-resistant coating layer (resin layer) was provided. Thus, the film for solar cell back surface sealing material (henceforth, film for sealing materials) 1 was manufactured.
  • Example 2 A sealing material film 2 was produced in the same manner as described in Example 1 except that a polyethylene naphthalate film 100 ⁇ m was used as the base film.
  • Example 3 A sealing material film 3 was produced in the same manner as described in Example 1 except that the light-resistant coating layer-forming coating material 2 was applied instead of the light-resistant coating layer-forming coating material 1.
  • Example 4 A sealing material film 4 was produced in the same manner as in Example 1 except that the light-resistant coating layer forming coating 3 was applied instead of the light-resistant coating layer forming coating 1.
  • Example 5 A sealing material film 5 was produced in the same manner as in Example 1 except that the light-resistant coating layer-forming coating material 4 was applied instead of the light-resistant coating layer-forming coating material 1.
  • Example 6 A sealing material film 6 was produced in the same manner as in Example 1 except that the light-resistant coating layer-forming coating material 5 was applied instead of the light-resistant coating layer-forming coating material 1.
  • Example 7 A sealing material film 7 was produced in the same manner as in Example 1 except that the light-resistant coating layer-forming coating material 6 was applied instead of the light-resistant coating layer-forming coating material 1.
  • a sealing material film 8 was produced in the same manner as in Example 1 except that the light-resistant coating layer-forming coating material 7 was applied instead of the light-resistant coating layer-forming coating material 1.
  • Example 2 A sealing material film 9 was produced in the same manner as in Example 1 except that the light-resistant coating layer-forming coating material 8 was applied instead of the light-resistant coating layer-forming coating material 1.
  • Example 3 A sealing material film 10 was produced in the same manner as described in Example 1 except that the light-resistant coating layer-forming coating material 9 was applied instead of the light-resistant coating layer-forming coating material 1.
  • the light-resistant coating layer of the film 8 for encapsulating material obtained in Comparative Example 1 uses an acrylic resin to which an ultraviolet absorber and a light stabilizer (HALS) are added without crosslinking. Therefore, UV absorbers and light stabilizers bleed out from the paint film surface to the paint film surface in a high-temperature humidified environment or with UV light reception, and the UV cut performance deteriorates, so the ⁇ b value of the base film increases. To do.
  • HALS light stabilizer
  • the light-resistant coating layer of the encapsulant film 9 obtained in Comparative Example 2 does not contain a black pigment. Therefore, the appearance and color tone of the film cannot be changed, and the UV-cutting performance is higher than that of acrylic resin copolymerized with UV absorber and light stabilizer, but it has visible-light cutting performance. Not. Therefore, when assuming long-term outdoor use, the ⁇ b value of the base film increases and yellowing occurs. Moreover, the breaking strength / elongation after the ultraviolet irradiation is lower than that of the film for sealing material obtained in Example 1, which is considered to cause the resin deterioration. Therefore, by adding black pigment, not only can the color tone of the film appearance be controlled, but the UV resistance and visible light resistance of the film are further improved due to the effect of absorption of visible light by the black pigment. You can see that
  • the light-resistant coating layer of the sealing material film 10 obtained in Comparative Example 3 does not contain a plasticizer. Therefore, the adhesive force between the base film and the coat layer is slightly insufficient from the initial state, and the coating film (coat layer) after performing the moisture and heat resistance test and the ultraviolet irradiation test further has an adhesive force to the base film. It is getting worse. This is considered to be because the coating film hardness after drying (formation) was increased as a result of blending the black pigment. In the wet heat test or the ultraviolet irradiation test, the state of the coating film further changes due to heat and light energy, and the adhesion with the base film tends to be remarkably deteriorated.
  • the coating layer of the present invention is located on the outermost surface of the module in practical use, when exposed to a UV light receiving environment for a long time under high temperature and high humidity, the junction box is separated from the coating layer. A situation where the backside sealing sheet falls off in an integrated state is also assumed.
  • the film 11 for sealing material obtained in Comparative Example 4 has no ultraviolet and visible light cutting performance, and also forms a color pigment layer capable of adjusting the color tone of the film. It has not been. Therefore, resin degradation and yellowing occur with irradiation of ultraviolet rays and / or visible light. Therefore, when used as the outermost layer of the solar cell backside sealing material, in extreme cases, the film has cracks, pinholes, etc., and there are functions required for the sealing material such as electrical insulation and water vapor barrier properties. In addition to being lost, there is a concern that affects the operation of the solar cell module.
  • Example 8 On the film surface opposite to the light-resistant coating layer of the sealing material film 1 obtained by the method described in Example 1, a dry laminating adhesive was applied with a wire bar and dried at 80 ° C. for 45 seconds. A 3.5 ⁇ m adhesive layer 1 was formed. Next, a white polyethylene terephthalate film Lumirror (registered trademark) E20F (50 ⁇ m) manufactured by Toray Industries, Inc. was bonded to the adhesive layer 1 as a light reflective film using a hand roller. Further, a dry laminating adhesive was applied to the film surface of the laminated film opposite to the light-resistant coating layer with a wire bar and dried at 80 ° C. for 45 seconds to form a 3.5 ⁇ m adhesive layer 2. .
  • Lumirror registered trademark
  • E20F 50 ⁇ m
  • a water vapor barrier film an aluminum oxide vapor-deposited polyethylene terephthalate film manufactured by Toray Film Processing Co., Ltd. Barrier Rocks (registered trademark) 1031HGTS (12 ⁇ m) for forming an adhesive layer on the opposite side of the aluminum oxide vapor-deposited layer
  • a water vapor barrier film was prepared by sequentially coating the paint and the heat-adhesive resin layer forming paint under the following conditions using a two-head tandem direct gravure coater.
  • the aluminum oxide vapor deposition layer surface of the water vapor barrier film and the surface of the adhesive layer 2 of the laminate film were disposed so as to face each other, and were bonded together using a hand roller.
  • seat which consists of 3 films produced was aged in the oven heated at 40 degreeC for 3 days, and the solar cell back surface sealing material 1 was obtained.
  • Adhesive layer coating conditions Aiming at dry film thickness of 0.2 ⁇ m, drying oven set temperature 120 ° C -Thermal adhesive resin layer coating conditions: Aiming for dry film thickness of 1.0 ⁇ m, drying oven set temperature 100 ° C.
  • Coating speed 100m / min Aging: After application and winding, aging at 40 ° C. for 2 days.
  • the solar cell back surface sealing material obtained by the method described in Example 8 is an adhesion between the base film and the coating layer that accompanies UV irradiation to the light-resistant coating layer side located on the outer layer side in the solar cell module configuration. There is no reduction in force, and the yellowing of the coating layer and substrate film is very small. Moreover, it is excellent also in adhesiveness with the filler (EVA) which is the characteristic requested
  • EVA filler
  • the solar cell back surface sealing material obtained in Comparative Example 5 does not contain a plasticizer in the light-resistant coating layer, the adhesion between the light-resistant coating layer and the base film is at an initial point. Slightly insufficient, and after the wet heat test or ultraviolet irradiation test, the adhesion strength is poor. Due to such coating layer characteristics, the silicone resin adhesiveness is significantly weaker. The adhesion between the base film and the light-resistant coating layer decreases with the progress of the wet heat test or ultraviolet irradiation test, and when exposed to the outdoor environment, the adhesive strength with the silicone resin, that is, the terminal box also decreases. In extreme cases, the terminal box may be peeled off along with the coat layer.
  • the method of the present invention has light resistance and heat and humidity resistance that can withstand use in a harsh outdoor environment for a long period of time, and yet has a design property.
  • the film for solar cell back surface sealing materials which has a colored layer excellent also in the adhesive force with the silicone resin for terminal box adhesion required when using by outermost layer is obtained.
  • the solar cell back surface sealing that has excellent adhesion to the silicon cell filler layer and light reflectivity, improves the performance of the solar cell module, and can maintain the performance over a long period of time. A material is obtained.

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PCT/JP2010/053314 2009-03-18 2010-03-02 太陽電池裏面封止材用フィルム、それを用いた太陽電池裏面封止材および太陽電池モジュール WO2010106907A1 (ja)

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Cited By (2)

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JP2012142349A (ja) * 2010-12-28 2012-07-26 Henkel Japan Ltd 太陽電池バックシート用接着剤
JP2012248771A (ja) * 2011-05-31 2012-12-13 Mitsubishi Plastics Inc 太陽電池裏面保護用二軸配向ポリエステルフィルム

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Publication number Priority date Publication date Assignee Title
CN103107208B (zh) * 2013-01-24 2015-12-23 3M材料技术(合肥)有限公司 用于太阳能电池组件的电极隔离结构体

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JP2002100788A (ja) * 2000-09-20 2002-04-05 Mitsubishi Alum Co Ltd 太陽電池カバー材用バックシート及びそれを用いた太陽電池モジュール
JP2003152206A (ja) * 2001-11-13 2003-05-23 Dainippon Printing Co Ltd 太陽電池モジュ−ル用裏面保護シ−トおよびそれを使用した太陽電池モジュ−ル
JP2006179557A (ja) * 2004-12-21 2006-07-06 Toyo Aluminium Kk 太陽電池用シート部材
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JPH0749453B2 (ja) * 1988-04-12 1995-05-31 株式会社日本触媒 アクリルポリオールの製造方法
JP2002100788A (ja) * 2000-09-20 2002-04-05 Mitsubishi Alum Co Ltd 太陽電池カバー材用バックシート及びそれを用いた太陽電池モジュール
JP2003152206A (ja) * 2001-11-13 2003-05-23 Dainippon Printing Co Ltd 太陽電池モジュ−ル用裏面保護シ−トおよびそれを使用した太陽電池モジュ−ル
JP2006179557A (ja) * 2004-12-21 2006-07-06 Toyo Aluminium Kk 太陽電池用シート部材
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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2012142349A (ja) * 2010-12-28 2012-07-26 Henkel Japan Ltd 太陽電池バックシート用接着剤
JP2012248771A (ja) * 2011-05-31 2012-12-13 Mitsubishi Plastics Inc 太陽電池裏面保護用二軸配向ポリエステルフィルム

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