WO2010114028A1 - 太陽電池封止材用樹脂組成物、太陽電池封止材及びそれを用いた太陽電池モジュール - Google Patents
太陽電池封止材用樹脂組成物、太陽電池封止材及びそれを用いた太陽電池モジュール Download PDFInfo
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- WO2010114028A1 WO2010114028A1 PCT/JP2010/055883 JP2010055883W WO2010114028A1 WO 2010114028 A1 WO2010114028 A1 WO 2010114028A1 JP 2010055883 W JP2010055883 W JP 2010055883W WO 2010114028 A1 WO2010114028 A1 WO 2010114028A1
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- Prior art keywords
- solar cell
- component
- ethylene
- resin composition
- measured
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- ZSSVCEUEVMALRD-UHFFFAOYSA-N 2-[4,6-bis(2,4-dimethylphenyl)-1,3,5-triazin-2-yl]-5-(octyloxy)phenol Chemical compound OC1=CC(OCCCCCCCC)=CC=C1C1=NC(C=2C(=CC(C)=CC=2)C)=NC(C=2C(=CC(C)=CC=2)C)=N1 ZSSVCEUEVMALRD-UHFFFAOYSA-N 0.000 description 1
- WFUGQJXVXHBTEM-UHFFFAOYSA-N 2-hydroperoxy-2-(2-hydroperoxybutan-2-ylperoxy)butane Chemical compound CCC(C)(OO)OOC(C)(CC)OO WFUGQJXVXHBTEM-UHFFFAOYSA-N 0.000 description 1
- OXYZDRAJMHGSMW-UHFFFAOYSA-N 3-chloropropyl(trimethoxy)silane Chemical compound CO[Si](OC)(OC)CCCCl OXYZDRAJMHGSMW-UHFFFAOYSA-N 0.000 description 1
- SJECZPVISLOESU-UHFFFAOYSA-N 3-trimethoxysilylpropan-1-amine Chemical compound CO[Si](OC)(OC)CCCN SJECZPVISLOESU-UHFFFAOYSA-N 0.000 description 1
- UUEWCQRISZBELL-UHFFFAOYSA-N 3-trimethoxysilylpropane-1-thiol Chemical compound CO[Si](OC)(OC)CCCS UUEWCQRISZBELL-UHFFFAOYSA-N 0.000 description 1
- OUWPEHOSUWXUFV-UHFFFAOYSA-N 4-(benzotriazol-2-yl)-3-methylphenol Chemical compound CC1=CC(O)=CC=C1N1N=C2C=CC=CC2=N1 OUWPEHOSUWXUFV-UHFFFAOYSA-N 0.000 description 1
- DBCAQXHNJOFNGC-UHFFFAOYSA-N 4-bromo-1,1,1-trifluorobutane Chemical compound FC(F)(F)CCCBr DBCAQXHNJOFNGC-UHFFFAOYSA-N 0.000 description 1
- WSSSPWUEQFSQQG-UHFFFAOYSA-N 4-methyl-1-pentene Chemical compound CC(C)CC=C WSSSPWUEQFSQQG-UHFFFAOYSA-N 0.000 description 1
- QLZINFDMOXMCCJ-UHFFFAOYSA-N 7-(7-hydroxyheptylperoxy)heptan-1-ol Chemical compound OCCCCCCCOOCCCCCCCO QLZINFDMOXMCCJ-UHFFFAOYSA-N 0.000 description 1
- 239000004925 Acrylic resin Substances 0.000 description 1
- 229920000178 Acrylic resin Polymers 0.000 description 1
- 239000004342 Benzoyl peroxide Substances 0.000 description 1
- OMPJBNCRMGITSC-UHFFFAOYSA-N Benzoylperoxide Chemical compound C=1C=CC=CC=1C(=O)OOC(=O)C1=CC=CC=C1 OMPJBNCRMGITSC-UHFFFAOYSA-N 0.000 description 1
- ZOXJGFHDIHLPTG-UHFFFAOYSA-N Boron Chemical compound [B] ZOXJGFHDIHLPTG-UHFFFAOYSA-N 0.000 description 1
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 1
- 239000004641 Diallyl-phthalate Substances 0.000 description 1
- 239000004594 Masterbatch (MB) Substances 0.000 description 1
- OBROQZNWNGNLQG-UHFFFAOYSA-N OC1(C(C(=O)C2=CC=CC=C2)C=CC=C1)O.OC1=C(C(=O)C2=CC=CC=C2)C=C(C=C1)Cl Chemical compound OC1(C(C(=O)C2=CC=CC=C2)C=CC=C1)O.OC1=C(C(=O)C2=CC=CC=C2)C=C(C=C1)Cl OBROQZNWNGNLQG-UHFFFAOYSA-N 0.000 description 1
- 239000004743 Polypropylene Substances 0.000 description 1
- BLRPTPMANUNPDV-UHFFFAOYSA-N Silane Chemical compound [SiH4] BLRPTPMANUNPDV-UHFFFAOYSA-N 0.000 description 1
- ATJFFYVFTNAWJD-UHFFFAOYSA-N Tin Chemical compound [Sn] ATJFFYVFTNAWJD-UHFFFAOYSA-N 0.000 description 1
- OKKRPWIIYQTPQF-UHFFFAOYSA-N Trimethylolpropane trimethacrylate Chemical compound CC(=C)C(=O)OCC(CC)(COC(=O)C(C)=C)COC(=O)C(C)=C OKKRPWIIYQTPQF-UHFFFAOYSA-N 0.000 description 1
- XTXRWKRVRITETP-UHFFFAOYSA-N Vinyl acetate Chemical compound CC(=O)OC=C XTXRWKRVRITETP-UHFFFAOYSA-N 0.000 description 1
- NOZAQBYNLKNDRT-UHFFFAOYSA-N [diacetyloxy(ethenyl)silyl] acetate Chemical compound CC(=O)O[Si](OC(C)=O)(OC(C)=O)C=C NOZAQBYNLKNDRT-UHFFFAOYSA-N 0.000 description 1
- 239000002253 acid Substances 0.000 description 1
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 1
- 229910021417 amorphous silicon Inorganic materials 0.000 description 1
- 230000003078 antioxidant effect Effects 0.000 description 1
- 239000012298 atmosphere Substances 0.000 description 1
- 235000019400 benzoyl peroxide Nutrition 0.000 description 1
- FLPKSBDJMLUTEX-UHFFFAOYSA-N bis(1,2,2,6,6-pentamethylpiperidin-4-yl) 2-butyl-2-[(3,5-ditert-butyl-4-hydroxyphenyl)methyl]propanedioate Chemical compound C1C(C)(C)N(C)C(C)(C)CC1OC(=O)C(C(=O)OC1CC(C)(C)N(C)C(C)(C)C1)(CCCC)CC1=CC(C(C)(C)C)=C(O)C(C(C)(C)C)=C1 FLPKSBDJMLUTEX-UHFFFAOYSA-N 0.000 description 1
- RSOILICUEWXSLA-UHFFFAOYSA-N bis(1,2,2,6,6-pentamethylpiperidin-4-yl) decanedioate Chemical compound C1C(C)(C)N(C)C(C)(C)CC1OC(=O)CCCCCCCCC(=O)OC1CC(C)(C)N(C)C(C)(C)C1 RSOILICUEWXSLA-UHFFFAOYSA-N 0.000 description 1
- OSIVCXJNIBEGCL-UHFFFAOYSA-N bis(2,2,6,6-tetramethyl-1-octoxypiperidin-4-yl) decanedioate Chemical compound C1C(C)(C)N(OCCCCCCCC)C(C)(C)CC1OC(=O)CCCCCCCCC(=O)OC1CC(C)(C)N(OCCCCCCCC)C(C)(C)C1 OSIVCXJNIBEGCL-UHFFFAOYSA-N 0.000 description 1
- XITRBUPOXXBIJN-UHFFFAOYSA-N bis(2,2,6,6-tetramethylpiperidin-4-yl) decanedioate Chemical compound C1C(C)(C)NC(C)(C)CC1OC(=O)CCCCCCCCC(=O)OC1CC(C)(C)NC(C)(C)C1 XITRBUPOXXBIJN-UHFFFAOYSA-N 0.000 description 1
- WXNRYSGJLQFHBR-UHFFFAOYSA-N bis(2,4-dihydroxyphenyl)methanone Chemical compound OC1=CC(O)=CC=C1C(=O)C1=CC=C(O)C=C1O WXNRYSGJLQFHBR-UHFFFAOYSA-N 0.000 description 1
- SODJJEXAWOSSON-UHFFFAOYSA-N bis(2-hydroxy-4-methoxyphenyl)methanone Chemical compound OC1=CC(OC)=CC=C1C(=O)C1=CC=C(OC)C=C1O SODJJEXAWOSSON-UHFFFAOYSA-N 0.000 description 1
- ZPOLOEWJWXZUSP-AATRIKPKSA-N bis(prop-2-enyl) (e)-but-2-enedioate Chemical compound C=CCOC(=O)\C=C\C(=O)OCC=C ZPOLOEWJWXZUSP-AATRIKPKSA-N 0.000 description 1
- ZPOLOEWJWXZUSP-WAYWQWQTSA-N bis(prop-2-enyl) (z)-but-2-enedioate Chemical compound C=CCOC(=O)\C=C/C(=O)OCC=C ZPOLOEWJWXZUSP-WAYWQWQTSA-N 0.000 description 1
- QUDWYFHPNIMBFC-UHFFFAOYSA-N bis(prop-2-enyl) benzene-1,2-dicarboxylate Chemical compound C=CCOC(=O)C1=CC=CC=C1C(=O)OCC=C QUDWYFHPNIMBFC-UHFFFAOYSA-N 0.000 description 1
- 230000000740 bleeding effect Effects 0.000 description 1
- 229910052796 boron Inorganic materials 0.000 description 1
- RPPBZEBXAAZZJH-UHFFFAOYSA-N cadmium telluride Chemical compound [Te]=[Cd] RPPBZEBXAAZZJH-UHFFFAOYSA-N 0.000 description 1
- 238000003490 calendering Methods 0.000 description 1
- 229910052799 carbon Inorganic materials 0.000 description 1
- 239000001569 carbon dioxide Substances 0.000 description 1
- 229910002092 carbon dioxide Inorganic materials 0.000 description 1
- 239000007795 chemical reaction product Substances 0.000 description 1
- 239000003086 colorant Substances 0.000 description 1
- 239000000306 component Substances 0.000 description 1
- 238000007334 copolymerization reaction Methods 0.000 description 1
- 230000008878 coupling Effects 0.000 description 1
- 238000010168 coupling process Methods 0.000 description 1
- 238000005859 coupling reaction Methods 0.000 description 1
- 239000003484 crystal nucleating agent Substances 0.000 description 1
- 125000000058 cyclopentadienyl group Chemical group C1(=CC=CC1)* 0.000 description 1
- 238000011161 development Methods 0.000 description 1
- LSXWFXONGKSEMY-UHFFFAOYSA-N di-tert-butyl peroxide Chemical compound CC(C)(C)OOC(C)(C)C LSXWFXONGKSEMY-UHFFFAOYSA-N 0.000 description 1
- 239000002270 dispersing agent Substances 0.000 description 1
- 239000006185 dispersion Substances 0.000 description 1
- MCPKSFINULVDNX-UHFFFAOYSA-N drometrizole Chemical compound CC1=CC=C(O)C(N2N=C3C=CC=CC3=N2)=C1 MCPKSFINULVDNX-UHFFFAOYSA-N 0.000 description 1
- 238000010828 elution Methods 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 230000007613 environmental effect Effects 0.000 description 1
- FWDBOZPQNFPOLF-UHFFFAOYSA-N ethenyl(triethoxy)silane Chemical compound CCO[Si](OCC)(OCC)C=C FWDBOZPQNFPOLF-UHFFFAOYSA-N 0.000 description 1
- WOXXJEVNDJOOLV-UHFFFAOYSA-N ethenyl-tris(2-methoxyethoxy)silane Chemical compound COCCO[Si](OCCOC)(OCCOC)C=C WOXXJEVNDJOOLV-UHFFFAOYSA-N 0.000 description 1
- STVZJERGLQHEKB-UHFFFAOYSA-N ethylene glycol dimethacrylate Substances CC(=C)C(=O)OCCOC(=O)C(C)=C STVZJERGLQHEKB-UHFFFAOYSA-N 0.000 description 1
- 235000012438 extruded product Nutrition 0.000 description 1
- 238000007765 extrusion coating Methods 0.000 description 1
- 239000000945 filler Substances 0.000 description 1
- 238000001914 filtration Methods 0.000 description 1
- 239000006081 fluorescent whitening agent Substances 0.000 description 1
- 238000002347 injection Methods 0.000 description 1
- 239000007924 injection Substances 0.000 description 1
- 229910010272 inorganic material Inorganic materials 0.000 description 1
- 239000011147 inorganic material Substances 0.000 description 1
- 238000009434 installation Methods 0.000 description 1
- 230000010354 integration Effects 0.000 description 1
- 238000011835 investigation Methods 0.000 description 1
- 150000002500 ions Chemical class 0.000 description 1
- 238000010030 laminating Methods 0.000 description 1
- 150000002605 large molecules Chemical class 0.000 description 1
- 239000000314 lubricant Substances 0.000 description 1
- 239000011259 mixed solution Substances 0.000 description 1
- 229910021421 monocrystalline silicon Inorganic materials 0.000 description 1
- DXGLGDHPHMLXJC-UHFFFAOYSA-N oxybenzone Chemical compound OC1=CC(OC)=CC=C1C(=O)C1=CC=CC=C1 DXGLGDHPHMLXJC-UHFFFAOYSA-N 0.000 description 1
- 229930004008 p-menthane Natural products 0.000 description 1
- NFHFRUOZVGFOOS-UHFFFAOYSA-N palladium;triphenylphosphane Chemical compound [Pd].C1=CC=CC=C1P(C=1C=CC=CC=1)C1=CC=CC=C1.C1=CC=CC=C1P(C=1C=CC=CC=1)C1=CC=CC=C1.C1=CC=CC=C1P(C=1C=CC=CC=1)C1=CC=CC=C1.C1=CC=CC=C1P(C=1C=CC=CC=1)C1=CC=CC=C1 NFHFRUOZVGFOOS-UHFFFAOYSA-N 0.000 description 1
- 239000012071 phase Substances 0.000 description 1
- 229960000969 phenyl salicylate Drugs 0.000 description 1
- 239000004417 polycarbonate Substances 0.000 description 1
- 229920000515 polycarbonate Polymers 0.000 description 1
- 238000006068 polycondensation reaction Methods 0.000 description 1
- 229910021420 polycrystalline silicon Inorganic materials 0.000 description 1
- 239000002685 polymerization catalyst Substances 0.000 description 1
- 229920005672 polyolefin resin Polymers 0.000 description 1
- 229920001155 polypropylene Polymers 0.000 description 1
- 238000002360 preparation method Methods 0.000 description 1
- 230000002250 progressing effect Effects 0.000 description 1
- 229920005604 random copolymer Polymers 0.000 description 1
- 238000012827 research and development Methods 0.000 description 1
- 229920006395 saturated elastomer Polymers 0.000 description 1
- 229940116351 sebacate Drugs 0.000 description 1
- 239000004065 semiconductor Substances 0.000 description 1
- 238000004904 shortening Methods 0.000 description 1
- 229910000077 silane Inorganic materials 0.000 description 1
- 239000002210 silicon-based material Substances 0.000 description 1
- 239000002356 single layer Substances 0.000 description 1
- 238000007613 slurry method Methods 0.000 description 1
- 150000003384 small molecules Chemical class 0.000 description 1
- 238000001228 spectrum Methods 0.000 description 1
- 238000004544 sputter deposition Methods 0.000 description 1
- 230000000087 stabilizing effect Effects 0.000 description 1
- 229910001220 stainless steel Inorganic materials 0.000 description 1
- 239000010935 stainless steel Substances 0.000 description 1
- 238000003860 storage Methods 0.000 description 1
- 229920006132 styrene block copolymer Polymers 0.000 description 1
- 229920001935 styrene-ethylene-butadiene-styrene Polymers 0.000 description 1
- 150000003440 styrenes Chemical class 0.000 description 1
- 239000001384 succinic acid Substances 0.000 description 1
- CXVGEDCSTKKODG-UHFFFAOYSA-N sulisobenzone Chemical compound C1=C(S(O)(=O)=O)C(OC)=CC(O)=C1C(=O)C1=CC=CC=C1 CXVGEDCSTKKODG-UHFFFAOYSA-N 0.000 description 1
- SWAXTRYEYUTSAP-UHFFFAOYSA-N tert-butyl ethaneperoxoate Chemical compound CC(=O)OOC(C)(C)C SWAXTRYEYUTSAP-UHFFFAOYSA-N 0.000 description 1
- DLSMLZRPNPCXGY-UHFFFAOYSA-N tert-butylperoxy 2-ethylhexyl carbonate Chemical compound CCCCC(CC)COC(=O)OOOC(C)(C)C DLSMLZRPNPCXGY-UHFFFAOYSA-N 0.000 description 1
- 238000012360 testing method Methods 0.000 description 1
- NZNAAUDJKMURFU-UHFFFAOYSA-N tetrakis(2,2,6,6-tetramethylpiperidin-4-yl) butane-1,2,3,4-tetracarboxylate Chemical compound C1C(C)(C)NC(C)(C)CC1OC(=O)CC(C(=O)OC1CC(C)(C)NC(C)(C)C1)C(C(=O)OC1CC(C)(C)NC(C)(C)C1)CC(=O)OC1CC(C)(C)NC(C)(C)C1 NZNAAUDJKMURFU-UHFFFAOYSA-N 0.000 description 1
- 229920005992 thermoplastic resin Polymers 0.000 description 1
- 239000010409 thin film Substances 0.000 description 1
- 229910052718 tin Inorganic materials 0.000 description 1
- CFJYNSNXFXLKNS-UHFFFAOYSA-N trans-p-menthane Natural products CC(C)C1CCC(C)CC1 CFJYNSNXFXLKNS-UHFFFAOYSA-N 0.000 description 1
- GQIUQDDJKHLHTB-UHFFFAOYSA-N trichloro(ethenyl)silane Chemical compound Cl[Si](Cl)(Cl)C=C GQIUQDDJKHLHTB-UHFFFAOYSA-N 0.000 description 1
- BPSIOYPQMFLKFR-UHFFFAOYSA-N trimethoxy-[3-(oxiran-2-ylmethoxy)propyl]silane Chemical compound CO[Si](OC)(OC)CCCOCC1CO1 BPSIOYPQMFLKFR-UHFFFAOYSA-N 0.000 description 1
- 150000003682 vanadium compounds Chemical class 0.000 description 1
- 239000012808 vapor phase Substances 0.000 description 1
- 239000005050 vinyl trichlorosilane Substances 0.000 description 1
- 239000003643 water by type Substances 0.000 description 1
- 238000004383 yellowing Methods 0.000 description 1
- 150000003755 zirconium compounds Chemical class 0.000 description 1
Classifications
-
- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
- C09D123/00—Coating compositions based on homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Coating compositions based on derivatives of such polymers
- C09D123/02—Coating compositions based on homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Coating compositions based on derivatives of such polymers not modified by chemical after-treatment
- C09D123/04—Homopolymers or copolymers of ethene
- C09D123/08—Copolymers of ethene
- C09D123/0807—Copolymers of ethene with unsaturated hydrocarbons only containing more than three carbon atoms
- C09D123/0815—Copolymers of ethene with aliphatic 1-olefins
-
- 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
- C08K5/54—Silicon-containing compounds
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L2312/00—Crosslinking
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L2312/00—Crosslinking
- C08L2312/08—Crosslinking by silane
-
- 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 a resin composition for a solar cell encapsulant, a solar cell encapsulant, and a solar cell module using the same, and more particularly, an ethylene / ⁇ -olefin copolymer and an organic peroxide or silane coupling.
- a resin composition for a solar cell encapsulant that contains an agent, etc. has excellent heat resistance, transparency, flexibility, and adhesion to a glass substrate, and has a good balance between rigidity and crosslinking efficiency, solar cell encapsulant, and
- the present invention relates to a solar cell module using the same.
- solar power generation has come into focus again along with the effective use of hydropower, wind power, and geothermal heat.
- solar cell elements such as silicon, gallium-arsenic, copper-indium-selenium are generally protected with an upper transparent protective material and a lower substrate protective material, and the solar cell elements and protective material are sealed with resin.
- It uses solar cell modules that are fixed with materials and packaged, and although it is smaller in scale than hydropower and wind power, it can be distributed and placed in places where power is required.
- Research and development aimed at lowering the level is being promoted.
- the government and local governments are gradually promoting the spread of measures by substituting installation costs as a residential solar power generation system introduction promotion project. However, further cost reduction is necessary for further spread. Therefore, not only the development of solar cell elements using new materials to replace conventional silicon and gallium-arsenic, but also the manufacturing cost of solar cell modules Efforts to further reduce this are continuing.
- the solar cell encapsulant constituting the solar cell module As a condition of the solar cell encapsulant constituting the solar cell module, it is required to have good transparency in order to secure the incident amount of sunlight so as not to decrease the power generation efficiency of the solar cell. Moreover, since a solar cell module is usually installed outdoors, it is exposed to sunlight for a long period of time and the temperature rises. Therefore, in order to avoid troubles in which the resin sealing material flows and the module is deformed, it must have heat resistance. Moreover, thinning is progressing year by year in order to reduce the material cost of a solar cell element.
- a sealing material for a solar cell element in a solar cell module uses an ethylene / vinyl acetate copolymer having a high vinyl acetate content as a resin component from the viewpoint of flexibility, transparency, etc. Are used together as a crosslinking agent (see, for example, Patent Document 1). And in the sealing operation of the solar cell element, after the solar cell element is covered with a resin sealing material, the solar cell element is heated for several minutes to tens of minutes and temporarily bonded, and the organic peroxide is decomposed in the oven. Then, the heat treatment is performed for several minutes to 1 hour (see, for example, Patent Document 2).
- Patent Document 3 A solar cell encapsulant made of an amorphous or low crystalline ⁇ -olefin copolymer of 40% or less has been proposed (see Patent Document 3).
- Patent Document 3 it is exemplified that an amorphous or low crystalline ethylene / butene copolymer is mixed with an organic peroxide and a sheet is produced at a processing temperature of 100 ° C. using a profile extruder.
- sufficient productivity cannot be obtained due to the low processing temperature.
- the solar cell module Since the solar cell module is installed outdoors as described above, it is exposed to sunlight for a long period of time and the temperature rises, thereby reducing the adhesive force between the glass substrate and the resin sealing material, and the resin from the glass substrate. In some cases, the sealing material is separated, and air or moisture enters the space to deform the module.
- Patent Document 1 it is described that a silane coupling agent is blended in a sealing material resin, but it relates to a solar cell module using a flexible substrate such as a fluororesin film. Details are not disclosed.
- the patent document 2 also describes the blending of the silane coupling agent into the sealing material resin, it relates to a solar cell module using an EVA film and an FRP substrate, and the adhesion to the substrate is not sufficient. Absent.
- a sealing material for solar cell modules As a sealing material for solar cell modules, (a) a density of less than about 0.90 g / cc, (b) a 2% secant coefficient of less than about 150 megapascals (mPa) as measured by ASTM D-882-02 (C) a melting point of less than about 95 ° C., (d) an ⁇ -olefin content of at least about 15 and less than about 50% by weight based on the weight of the polymer, (e) a Tg of less than about ⁇ 35 ° C., and (f) A polymer material containing a polyolefin copolymer that satisfies one or more conditions of at least about 50 SCBDI has been proposed (see Patent Document 3).
- the solar cell encapsulant tends to become thinner as the solar cell element becomes thinner. At that time, when an impact is applied from the upper protective material side or the lower protective material side of the solar cell sealing material, the wiring is likely to be disconnected. If the polymer material of Patent Document 4 is used, the rigidity of the sealing material can be increased, but the crosslinking efficiency is deteriorated, which is not practical. As described above, the conventional technology provides a resin composition for a solar cell encapsulant that is excellent in productivity, heat resistance, transparency, flexibility and adhesion to a glass substrate, and has a good balance between rigidity and crosslinking efficiency. It wasn't.
- the object of the present invention is to contain an ethylene / ⁇ -olefin copolymer and an organic peroxide or a silane coupling agent, and is excellent in heat resistance, transparency, flexibility, and adhesion to a glass substrate.
- the object is to provide a resin composition for a solar cell encapsulant that is well balanced with the crosslinking efficiency, a solar cell encapsulant, and a solar cell module using the same.
- the present inventors have obtained an ethylene / ⁇ -olefin copolymer having a specific density, molecular weight distribution, and melt viscosity characteristics polymerized using a metallocene catalyst as a resin component.
- a metallocene catalyst as a resin component.
- a resin composition for a solar cell encapsulant comprising the following component (A) and component (B) and / or component (C): Provided.
- the ratio (Mz / Mn) of Z average molecular weight (Mz) and number average molecular weight (Mn) determined by gel permeation chromatography (GPC) was 8.0 or less (a3) Shear measured at 100 ° C.
- the number of branches (N) due to the comonomer in the polymer satisfies the following formula (a ′):
- a resin composition for a stopper is provided.
- the resin composition for solar cell sealing materials characterized by containing the following component (A), a component (B), and / or a component (C).
- component (A) ethylene / ⁇ -olefin copolymer (a1) having the following characteristics (a1) to (a4) and (a6): density is 0.860 to 0.920 g / cm 3 (A2)
- the ratio (Mz / Mn) of Z average molecular weight (Mz) and number average molecular weight (Mn) determined by gel permeation chromatography (GPC) was 8.0 or less (a3) Shear measured at 100 ° C.
- the solar cell encapsulating material is characterized in that the flow ratio (FR) of the characteristic (a6) is 5.0 to 6.2.
- a resin composition is provided.
- the following component (B) is contained in an amount of 0.2 to 5 parts by weight with respect to 100 parts by weight of the component (A).
- a resin composition for a solar cell encapsulant is provided.
- the content of the component (C) is 0.01 to 5 parts by weight with respect to 100 parts by weight of the component (A).
- the resin composition for solar cell sealing materials characterized by being a part is provided.
- a resin composition for a solar cell encapsulating material characterized in that in any one of the first to sixth inventions, the composition further comprises the following component (D): Provided.
- the content of the component (D) is 100 parts by weight of the component (A).
- a resin composition for a solar cell encapsulant is provided that is 0.01 to 2.5 parts by weight.
- the component (A) is an ethylene / 1-butene copolymer or an ethylene / 1-hexene copolymer.
- the resin composition for solar cell sealing materials characterized by these is provided.
- the ethylene / ⁇ -olefin copolymer of the component (A) has a melt viscosity ( ⁇ * 1 ) and a melt viscosity ( eta * 2) and the ratio ( ⁇ * 1 / ⁇ * 2 ) solar cell encapsulant resin composition characterized in that 4.5 or less is provided.
- the solar cell encapsulant resin composition according to any one of the first to tenth inventions is pelletized or sheeted.
- a solar cell encapsulating material is provided.
- a solar cell module using the solar cell sealing material of the eleventh aspect is provided.
- the resin composition for a solar cell encapsulant of the present invention contains an ethylene / ⁇ -olefin copolymer having a specific density, molecular weight distribution, and melt viscosity characteristics as a main component. Therefore, a silane coupling agent is added to the ethylene / ⁇ -olefin copolymer.
- the resin composition is formed into a sheet, the ethylene / ⁇ -olefin copolymer is relatively easy to adhere to the glass substrate.
- Crosslinking in a short time has sufficient adhesive strength, and the balance between rigidity and crosslinking efficiency is good, and it is easy to form a module as a solar cell sealing material, and the manufacturing cost can be reduced.
- the obtained solar cell module becomes excellent in transparency, flexibility, weather resistance, etc., and it can be expected to maintain stable conversion efficiency for a long period of time.
- Resin composition for solar cell encapsulant comprises the following ethylene / ⁇ -olefin copolymer component (A) and organic It contains a peroxide component (B) and / or a silane coupling agent (C).
- Component (A) used in the present invention is an ethylene / ⁇ -olefin copolymer having the following properties (a1) to (a4), and further has the properties (a5) and / or (a6). Preferred are ethylene / ⁇ -olefin copolymers.
- melt viscosity at 2.43 ⁇ 10s -1 ( ⁇ * 1 ) was measured at 9.0 ⁇ 10 4 poise or less (a4) 100 °C, shear rate at 2.43 ⁇ 10 2 s -1 Melt viscosity ( ⁇ * 2 ) is 1.8 ⁇ 10 4 poise or less
- (A5) The number of branches (N) due to the comonomer in the polymer satisfies the following formula (a).
- the ethylene / ⁇ -olefin copolymer used in the present invention is a random copolymer of ethylene and ⁇ -olefin, the main component of which is a constitutional unit derived from ethylene. .
- the ⁇ -olefin used as a comonomer is preferably an ⁇ -olefin having 3 to 12 carbon atoms. Specifically, propylene, 1-butene, 1-pentene, 1-hexene, 1-octene, 1-heptene, 4-methyl-pentene-1, 4-methyl-hexene-1, 4,4-dimethylpentene- 1 etc. can be mentioned.
- ethylene / ⁇ -olefin copolymers include ethylene / propylene copolymers, ethylene / 1-butene copolymers, ethylene / 1-hexene copolymers, ethylene / 1-octene copolymers, ethylene -4-methyl-pentene-1 copolymer and the like. Of these, ethylene / 1-butene copolymer and ethylene / 1-hexene copolymer are preferable.
- the ⁇ -olefin may be used alone or in combination of two or more.
- ethylene / propylene / 1-hexene terpolymer When combining two ⁇ -olefins into a terpolymer, ethylene / propylene / 1-hexene terpolymer, ethylene / 1-butene / 1-hexene terpolymer, ethylene / propylene Examples thereof include 1-octene terpolymer and ethylene / 1-butene / 1-octene terpolymer.
- the ethylene / ⁇ -olefin copolymer used in the present invention has an ⁇ -olefin content of 5 to 40% by weight, preferably 10 to 35% by weight, more preferably 15 to 30% by weight. Within this range, flexibility and heat resistance are good.
- the content of ⁇ -olefin is a value measured by 13C-NMR method under the following conditions.
- Solvent Orthodichlorobenzene
- the ethylene / ⁇ -olefin copolymer used in the present invention is a Ziegler catalyst, vanadium catalyst or metallocene catalyst, preferably a vanadium catalyst or metallocene catalyst, more preferably a metallocene catalyst.
- a high-pressure ion polymerization method a gas phase method, a solution method, and a slurry method.
- the catalyst which uses a metallocene compound, such as a zirconium compound coordinated with the group which has a cyclopentadienyl skeleton, etc., and a promoter as a catalyst component is mentioned.
- a metallocene compound such as a zirconium compound coordinated with the group which has a cyclopentadienyl skeleton, etc.
- a promoter as a catalyst component
- Commercially available products include Harmolex (registered trademark) series, Kernel (registered trademark) series manufactured by Japan Polyethylene, Evolue (registered trademark) series manufactured by Prime Polymer, Exelen (registered trademark) GMH series manufactured by Sumitomo Chemical, Exelen (registered trademark) FX series may be mentioned.
- the vanadium catalyst include a catalyst having a soluble vanadium compound and an organic aluminum halide as catalyst components.
- the ethylene / ⁇ -olefin copolymer used in the present invention has a density of 0.860 to 0.920 g / cm 3 , preferably 0.870 to 0.8. It is 915 g / cm 3 , more preferably 0.875 to 0.910 g / cm 3 .
- the density of the ethylene / ⁇ -olefin copolymer is less than 0.860 g / cm 3 , the processed sheet is blocked, and when the density exceeds 0.920 g / cm 3 , the rigidity of the processed sheet is too high. Thus, the handling property is lacking.
- the density of the polymer for example, a method of appropriately adjusting the ⁇ -olefin content, the polymerization temperature, the catalyst amount and the like can be employed.
- the density of the ethylene / ⁇ -olefin copolymer is measured according to JIS-K6922-2: 1997 appendix (in the case of low density polyethylene) (23 ° C.).
- the ethylene / ⁇ -olefin copolymer used in the present invention has a ratio (Mz / Mn) of Z average molecular weight (Mz) to number average molecular weight (Mn) determined by gel permeation chromatography (GPC) of 8.0. Or less, preferably 5.0 or less, more preferably 4.0 or less. Moreover, Mz / Mn is 2.0 or more, preferably 2.5 or more, more preferably 3.0 or more. However, when Mz / Mn exceeds 8.0, transparency deteriorates. In order to adjust Mz / Mn to a predetermined range, a method of selecting an appropriate catalyst system can be used.
- Mz / Mn is performed by gel permeation chromatography (GPC), and the measurement conditions are as follows.
- Apparatus Waters GPC 150C type detector: MIRAN 1A infrared spectrophotometer (measurement wavelength: 3.42 ⁇ m)
- Mz Z average molecular weight
- Mz / Mn is easier to confirm the presence of the high molecular weight component than Mw / Mn.
- the high molecular weight component is a factor that affects the transparency, and when the high molecular weight component is large, the transparency is deteriorated. Moreover, the tendency for crosslinking efficiency to deteriorate is seen. Therefore, the smaller Mz / Mn is preferable.
- the ethylene / ⁇ -olefin copolymer used in the present invention has a shear rate measured at 100 ° C. within a specific range.
- the reason for paying attention to the shear rate measured at 100 ° C. is to estimate the influence on the product when the composition at that temperature is commercialized. That is, the melt viscosity ( ⁇ * 1 ) at a shear rate of 2.43 ⁇ 10 sec ⁇ 1 is 9.0 ⁇ 10 4 poise or less, preferably 8.0 ⁇ 10 4 poise or less, and more preferably 7.0 ⁇ 10 4 poise.
- the melt viscosity ( ⁇ * 1 ) is preferably 1.0 ⁇ 10 4 poise or more, more preferably 1.5 ⁇ 10 4 poise or more. If the melt viscosity ( ⁇ * 1 ) is within this range, the productivity at low temperature and low speed molding is good, and there is no problem in processing into products.
- the melt viscosity ( ⁇ * 1 ) can be adjusted by the melt flow rate (MFR) or molecular weight distribution of the ethylene / ⁇ -olefin copolymer.
- melt viscosity ( ⁇ * 1 ) tends to decrease. If other properties such as molecular weight distribution are different, the magnitude relationship may be reversed.
- MFR JIS-K6922-2: 1997 annex (190 ° C., 21.18 N load)
- the melt viscosity ( ⁇ * 1 ) can be easily kept within a predetermined range.
- the ethylene / ⁇ -olefin copolymer used in the present invention has a melt viscosity ( ⁇ * 2 ) of 1.8 ⁇ 10 4 measured at 100 ° C. at a shear rate of 2.43 ⁇ 10 2 sec ⁇ 1. poise or less, preferably 1.7 ⁇ 10 4 poise or less, more preferably 1.5 ⁇ 10 4 poise or less, more preferably 1.4 ⁇ 10 4 poise or less, and most preferably 1.3 ⁇ 10 4 poise or less. is there.
- the melt viscosity ( ⁇ * 2 ) is preferably 5.0 ⁇ 10 3 poise or more, more preferably 8.0 ⁇ 10 3 poise or more.
- melt viscosity ( ⁇ * 2 ) is within this range, the productivity at low speed and low speed molding is good, and there is no problem in processing into products.
- the ratio of ⁇ * 1 to ⁇ * 2 is preferably 4.5 or less, more preferably 4.2. Hereinafter, it is more preferably 4.0 or less, and still more preferably 3.0 or less.
- the ratio of ⁇ * 1 and ⁇ * 2 ( ⁇ * 1 / ⁇ * 2 ) is preferably 1.1 or more, and more preferably 1.5 or more. If ( ⁇ * 1 / ⁇ * 2 ) is in the above range, the influence on the sheet surface during low speed molding and high speed molding is small, which is preferable.
- the number of branches (N) by the comonomer in the polymer and the tensile modulus (E) preferably satisfy the following formula (a).
- the number of branches (N) by the comonomer in the polymer is, for example, E.I. W. Hansen, R.A. Blom, and O.M. M.M. It can be calculated from the C-NMR spectrum with reference to Bade, Polymer, 36, 4295 (1997).
- the solar cell encapsulant tends to become thinner as the solar cell element becomes thinner.
- the solar cell encapsulating material having a reduced thickness when an impact is applied from the upper protective material side or the lower protective material side, the wiring is likely to be disconnected, so that the rigidity of the encapsulating material is required to be increased.
- the rigidity is increased, the crosslinking efficiency is deteriorated. Therefore, a copolymer having a high degree of branching of the polymer chain is used to improve the fluidity of the copolymer before crosslinking and to be used as a material having excellent moldability. There is a need.
- the balance between rigidity and crosslinking efficiency is good.
- the ethylene / ⁇ -olefin copolymer according to the present invention can be produced by a copolymerization reaction using a catalyst as described above, but the composition ratio of raw material monomers to be copolymerized and the type of catalyst used are selected. Thus, the degree of branching in the polymer chain can be easily adjusted.
- the comonomer in the ethylene / ⁇ -olefin copolymer is selected from propylene, 1-butene, or 1-hexene. Is preferred. Moreover, it is preferable to produce using a vapor phase method or a high pressure method, and it is more preferable to select a high pressure method. More specifically, in order to fix E and increase / decrease N, it is possible to mainly use a method of changing the carbon number of the comonomer copolymerized with ethylene.
- the ethylene / ⁇ -olefin copolymer is mixed by mixing so that the amount of 1-butene or 1-hexene is 60 to 80 wt% with respect to ethylene and using a metallocene catalyst to react at a polymerization temperature of 130 to 200 ° C. It is preferable to manufacture.
- the number of branches N of the ethylene / ⁇ -olefin copolymer can be appropriately adjusted, and the resulting sheet has a tensile modulus E of 40 MPa or less, and the ethylene / ⁇ -olefin within the range represented by the formula (a).
- a copolymer can be obtained.
- the relational expression of the characteristic (a5) is preferably represented by the following expression (a ′).
- the relational expression of the characteristic (a5) is more preferably the following expression (a ′′).
- FR Flow ratio (A6) Ethylene ⁇ alpha-olefin copolymer used in the present invention
- the I 10 a MFR value measured at 10kg load in the flow ratio (FR), i.e. 190 ° C., in MFR measured at 2.16kg load at 190 ° C. it is preferable ratio between certain I 2.16 (I 10 / I 2.16 ) is less than 7.0.
- the melt flow rate (MFR) is a value measured according to JIS-K7210-1999. It is known that FR has a strong correlation with the molecular weight distribution of ethylene / ⁇ -olefin copolymer and the amount of long chain branching.
- the MFR measurement value (I 10 ) at 190 ° C. under a 10 kg load and the MFR measurement value at 190 ° C. under a 2.16 kg load (I 2.16 ) and a ratio (I 10 / I 2.16 ) of less than 7.0 are used.
- a copolymer having a polymer structure characterized by such long-chain branching the balance between rigidity and crosslinking efficiency is good.
- FR is 7.0 or more, the crosslinking efficiency at the time of crosslinking as a solar cell sealing material tends to deteriorate.
- the FR of the ethylene / ⁇ -olefin copolymer used in the present invention is less than 7.0, preferably less than 6.5, more preferably less than 6.3. However, if the FR is less than 5.0, it may be difficult to obtain sufficient rigidity as a solar cell encapsulant.
- the flow ratio (FR) of the characteristic (a6) is most preferably 5.0 to 6.2.
- component (B) The organic peroxide of component (B) in the present invention is mainly used for crosslinking component (A).
- an organic peroxide having a decomposition temperature is 70 to 180 ° C., particularly 90 to 160 ° C.
- examples of such organic peroxides include t-butyl peroxyisopropyl carbonate, t-butyl peroxy-2-ethylhexyl carbonate, t-butyl peroxyacetate, t-butyl peroxybenzoate, dicumyl peroxide, , 5-dimethyl-2,5-di (t-butylperoxy) hexane, di-t-butylperoxide, 2,5-dimethyl-2,5-di (t-butylperoxy) hexyne-3, 1 , 1-di (t-butylperoxy) -3,3,5-trimethylcyclohexane, 1,1-di (t-butylperoxy) cyclohexane, methyl ethy
- Blending ratio of component (B) The blending ratio of component (B) is preferably 0.2 to 5 parts by weight, more preferably 0 when component (A) is 100 parts by weight. 5 to 3 parts by weight, more preferably 1 to 2 parts by weight.
- the blending ratio of the component (B) is less than the above range, crosslinking is not performed or it takes time for crosslinking.
- distribution will become inadequate and it will be easy to become non-uniform
- the component (C) used in the resin composition of the present invention is a silane coupling agent, and is mainly used for the purpose of improving the adhesive strength between the solar cell upper protective material and the solar cell element.
- the silane coupling agent in the present invention include ⁇ -chloropropyltrimethoxysilane; vinyltrichlorosilane; vinyltriethoxysilane; vinyltrimethoxysilane; vinyl-tris- ( ⁇ -methoxyethoxy) silane; ⁇ -methacryloxypropyl ⁇ - (3,4-epoxycyclohexyl) ethyltrimethoxysilane; ⁇ -glycidoxypropyltrimethoxysilane; vinyltriacetoxysilane; ⁇ -mercaptopropyltrimethoxysilane; ⁇ -aminopropyltrimethoxysilane; N- ⁇ - (aminoethyl) - ⁇ -aminopropyl
- Vinyltrimethoxysilane, ⁇ -methacryloxypropyltrimethoxysilane, and 3-acryloxypropyltrimethoxysilane are preferable.
- These silane coupling agents are used in an amount of 0 to 5 parts by weight, preferably 0.01 to 5 parts by weight, more preferably 0.01 to 2 parts by weight, based on 100 parts by weight of the ethylene / ⁇ -olefin copolymer. More preferably, it is used in an amount of 0.1 to 2 parts by weight, particularly preferably 0.5 to 1 part by weight, most preferably 0.05 to 1 part by weight.
- Hindered amine light stabilizer (D) In the present invention, it is preferable to blend a hindered amine light stabilizer in the resin composition.
- the hindered amine light stabilizer captures radical species harmful to the polymer and prevents generation of new radicals.
- Low molecular weight hindered amine light stabilizers include decanedioic acid bis (2,2,6,6-tetramethyl-1 (octyloxy) -4-piperidinyl) ester, 1,1-dimethylethyl hydroperoxide and Composed of 70% by weight of a reaction product of octane (molecular weight 737) and 30% by weight of polypropylene; bis (1,2,2,6,6-pentamethyl-4-piperidyl) [[3,5-bis (1,1 -Dimethylethyl) -4-hydroxyphenyl] methyl] butyl malonate (molecular weight 685); bis (1,2,2,6,6-pentamethyl-4-piperidyl) sebacate and methyl-1,2,2,6 6-Pentamethyl-4-piperidyl sebacate mixture (molecular weight 509); bis (2,2,6,6-tetramethyl-4-piperidyl) sebacate Molecular weight 481); tetraki
- High molecular weight hindered amine light stabilizers include poly [ ⁇ 6- (1,1,3,3-tetramethylbutyl) amino-1,3,5-triazine-2,4-diyl ⁇ ⁇ (2, 2,6,6-tetramethyl-4-piperidyl) imino ⁇ hexamethylene ⁇ (2,2,6,6-tetramethyl-4-piperidyl) imino ⁇ ] (molecular weight 2,000-3,100); succinic acid Polymer of dimethyl and 4-hydroxy-2,2,6,6-tetramethyl-1-piperidineethanol (molecular weight 3,100 to 4,000); N, N ′, N ′′, N ′′ ′-tetrakis- ( 4,6-bis- (butyl- (N-methyl-2,2,6,6-tetramethylpiperidin-4-yl) amino) -triazin-2-yl) -4,7-diazadecane-1,10- Diamine (molecular weight 2,286) and A mixture of a poly
- hindered amine light stabilizer poly [ ⁇ 6- (1,1,3,3-tetramethylbutyl) amino-1,3,5-triazine-2,4-diyl ⁇ ⁇ (2 , 2,6,6-tetramethyl-4-piperidyl) imino ⁇ hexamethylene ⁇ (2,2,6,6-tetramethyl-4-piperidyl) imino ⁇ ] (molecular weight 2,000-3,100); Polymer of dimethyl acid and 4-hydroxy-2,2,6,6-tetramethyl-1-piperidineethanol (molecular weight 3,100 to 4,000); N, N ′, N ′′, N ′′ ′-tetrakis- (4,6-bis- (butyl- (N-methyl-2,2,6,6-tetramethylpiperidin-4-yl) amino) -triazin-2-yl) -4,7-diazadecane-1,10 -Diamine (molecular weight 2,28 ) And the above-mentione
- the content of the hindered amine light stabilizer is 0.01 to 2.5 parts by weight, preferably 0.01 to 1. part by weight based on 100 parts by weight of the ethylene / ⁇ -olefin copolymer.
- the amount is 0 part by weight, more preferably 0.01 to 0.5 part by weight, still more preferably 0.01 to 0.2 part by weight, and most preferably 0.03 to 0.1 part by weight.
- the content is 0.01 parts by weight or more, a sufficient stabilizing effect is obtained, and when the content is 2.5 parts by weight or less, the resin is discolored due to excessive addition of a hindered amine light stabilizer.
- the weight ratio (B: D) of the organic peroxide (B) to the hindered amine light stabilizer (D) is 1: 0.1 to 1:10.
- the ratio is 1: 0.2 to 1: 6.5.
- crosslinking aid can be blended in the resin composition of the present invention.
- the crosslinking aid is effective in promoting the crosslinking reaction and increasing the degree of crosslinking of the ethylene / ⁇ -olefin copolymer.
- Specific examples thereof include polyaryl compounds and poly (meth) acryloxy compounds. Saturated compounds can be exemplified.
- polyallyl compounds such as triallyl isocyanurate, triallyl cyanurate, diallyl phthalate, diallyl fumarate, diallyl maleate, ethylene glycol diacrylate, ethylene glycol dimethacrylate, trimethylolpropane trimethacrylate, etc.
- poly (meth) acryloxy compounds examples include poly (meth) acryloxy compounds and divinylbenzene.
- the crosslinking aid can be blended at a ratio of about 0 to 5 parts by weight with respect to 100 parts by weight of component (A).
- UV absorber can be mix
- the ultraviolet absorber include various types such as benzophenone, benzotriazole, triazine, and salicylic acid ester.
- the benzophenone ultraviolet absorber include 2-hydroxy-4-methoxybenzophenone, 2-hydroxy-4-methoxy-2′-carboxybenzophenone, 2-hydroxy-4-n-octoxybenzophenone, 2-hydroxy-4 -N-dodecyloxybenzophenone, 2-hydroxy-4-n-octadecyloxybenzophenone, 2-hydroxy-4-benzyloxybenzophenone, 2-hydroxy-4-methoxy-5-sulfobenzophenone, 2-hydroxy-5-chlorobenzophenone 2,2-dihydroxybenzophenone, 2,2'-dihydroxy-4-methoxybenzophenone, 2,2'-dihydroxy-4,4'-dimethoxybenzophenone, 2,2 ', 4,4'-t
- benzotriazole ultraviolet absorber examples include hydroxyphenyl-substituted benzotriazole compounds such as 2- (2-hydroxy-5-methylphenyl) benzotriazole and 2- (2-hydroxy-5-tert-butylphenyl).
- Benzotriazole 2- (2-hydroxy-3,5-dimethylphenyl) benzotriazole, 2- (2-methyl-4-hydroxyphenyl) benzotriazole, 2- (2-hydroxy-3-methyl-5-t- Butylphenyl) benzotriazole, 2- (2-hydroxy-3,5-di-t-amylphenyl) benzotriazole, 2- (2-hydroxy-3,5-di-t-butylphenyl) benzotriazole, etc. Can be mentioned.
- triazine ultraviolet absorbers examples include 2- [4,6-bis (2,4-dimethylphenyl) -1,3,5-triazin-2-yl] -5- (octyloxy) phenol, 2- ( Examples include 4,6-diphenyl-1,3,5-triazin-2-yl) -5- (hexyloxy) phenol.
- salicylic acid esters include phenyl salicylate and p-octylphenyl salicylate. These ultraviolet absorbers are blended in an amount of 0 to 2.0 parts by weight, preferably 0.05 to 2.0 parts by weight, more preferably 0.1 to 1. parts by weight based on 100 parts by weight of the ethylene / ⁇ -olefin copolymer. 0 part by weight, more preferably 0.1 to 0.5 part by weight, and most preferably 0.2 to 0.4 part by weight is blended.
- additive components in the resin composition of the present invention, other additional optional components can be blended within a range that does not significantly impair the object of the present invention.
- optional components antioxidants, crystal nucleating agents, clearing agents, lubricants, colorants, dispersants, fillers, fluorescent whitening agents, UV absorbers used in ordinary polyolefin resin materials, A light stabilizer etc. can be mentioned.
- a crystalline ethylene / ⁇ -olefin copolymer polymerized by a Ziegler-based or metallocene-based catalyst within a range not impairing the object of the present invention.
- 3 to 75 parts by weight of high-pressure low-density polyethylene can be blended to impart melt tension and the like.
- the solar cell encapsulant of the present invention (hereinafter also simply referred to as encapsulant) is a pelletized or sheeted product of the resin composition.
- a solar cell module can be manufactured by fixing the solar cell element together with the upper and lower protective materials.
- solar cell modules include various types.
- a solar cell element formed on the inner peripheral surface of the upper transparent protective material for example, a fluororesin-based transparent protective material.
- the solar cell element is not particularly limited, and silicon-based materials such as single crystal silicon, polycrystalline silicon, and amorphous silicon, III-V group and II-VI group such as gallium-arsenic, copper-indium-selenium, cadmium-tellurium, etc.
- silicon-based materials such as single crystal silicon, polycrystalline silicon, and amorphous silicon, III-V group and II-VI group such as gallium-arsenic, copper-indium-selenium, cadmium-tellurium, etc.
- Various solar cell elements such as compound semiconductors can be used.
- the upper protective material constituting the solar cell module examples include glass, acrylic resin, polycarbonate, polyester, and fluorine-containing resin.
- the lower protective material is a single or multilayer sheet such as a metal or various thermoplastic resin films, for example, a metal such as tin, aluminum or stainless steel, an inorganic material such as glass, polyester, an inorganic vapor-deposited polyester, or fluorine.
- the protective material include a single layer or a multilayer such as a containing resin and polyolefin.
- Such an upper and / or lower protective material can be subjected to a primer treatment in order to enhance the adhesion to the sealing material.
- glass and fluorine-containing resin are preferable as the upper protective material.
- the solar cell encapsulant of the present invention may be used as a pellet, but is usually used after being formed into a sheet having a thickness of about 0.1 to 1 mm. If the thickness is less than 0.1 mm, the strength is small and the adhesion is insufficient. If the thickness is more than 1 mm, the transparency may be lowered, which may be a problem. A preferred thickness is 0.1 to 0.8 mm.
- the sheet-like solar cell encapsulant can be produced by a known sheet molding method using a T-die extruder, a calendar molding machine or the like.
- a cross-linking agent is added to an ethylene / ⁇ -olefin copolymer and, if necessary, a hindered amine light stabilizer, a cross-linking aid, a silane coupling agent, an ultraviolet absorber, an antioxidant, a light stabilizer.
- An additive such as an agent can be obtained by dry blending in advance and feeding from a hopper of a T-die extruder and extruding into a sheet at an extrusion temperature of 80 to 150 ° C.
- some or all of the additives can be used in the form of a masterbatch.
- some or all of the additive is previously melt-mixed into the ethylene / ⁇ -olefin copolymer using a single screw extruder, twin screw extruder, Banbury mixer, kneader, or the like.
- the obtained resin composition can also be used.
- the sheet of the sealing material of the present invention is prepared in advance, and is subjected to pressure bonding at a temperature at which the resin composition of the sealing material melts, for example, 150 to 200 ° C. as described above.
- a module having a simple structure can be formed.
- the solar cell module can be manufactured in one step without bothering to form a sheet. Is possible. Therefore, if the sealing material of this invention is used, the productivity of a module can be improved markedly.
- the sealing material is temporarily applied to the solar cell element or the protective material at a temperature at which the organic peroxide is not substantially decomposed and the sealing material of the present invention is melted. Adhesion is then performed, and the temperature is raised to achieve sufficient adhesion and crosslinking of the ethylene / ⁇ -olefin copolymer.
- the gel in the encapsulant layer is used in order to obtain a solar cell module with good heat resistance having a melting point of the encapsulant layer (DSC method) of 40 ° C. or higher and a storage elastic modulus of 150 ° C. of 10 3 Pa or higher.
- Fraction (1 g of sample is immersed in 100 ml of xylene, heated at 110 ° C. for 24 hours, then filtered through a 20 mesh wire net and the mass fraction of unmelted is measured) is 50 to 98%, preferably about 70 to 95% It is better to crosslink so that
- Patent Document 3 2,5-dimethyl-2,5-di (t-butylperoxy) hexane as an organic peroxide is added to 100 parts by weight of an amorphous or low crystalline ethylene / butene copolymer.
- a processing temperature 100 ° C. and a thickness of 0.5 mm
- the solar cell element is temporarily bonded by heating to a temperature at which the organic peroxide is not decomposed for several minutes to 10 minutes, For example, there is a method in which the organic peroxide is decomposed in the oven at a high temperature of about 150 to 200.degree.
- the resin composition of the present invention is optimal as a sealing material for solar cell modules as described above, but is also preferable for the manufacture of sealing sheets for water shielding sheets, tarpaulins, or ICs (integrated circuits). Can be applied.
- MFR Melt flow rate
- JIS-K6922-2 1997 appendix (190 ° C., 21.18 N load).
- Density As described above, the density of the ethylene / ⁇ -olefin copolymer was measured according to JIS-K6922-2: 1997 appendix (in the case of low-density polyethylene at 23 ° C.).
- Mz / Mn Measured by GPC as described above.
- Number of branches The number of branches (N) in the polymer was measured by NMR under the following conditions, and the amount of comonomer was determined by the number of main chains and side chains per 1000 carbons in total.
- Apparatus Bruker BioSpin Corporation AVANCE III cryo-400MHz
- Solvent: o-dichlorobenzene / heavy bromobenzene 8/2 mixed solution ⁇ sample amount> 460mg / 2.3ml ⁇ C-NMR> ⁇ H decouple, NOE available ⁇
- Number of integration 256scan ⁇
- FR Based on JIS-K7210-1999, MFR (I 10 ) measured under conditions of 190 ° C. and 10 kg load, and MFR (I 2.) measured under conditions of 190 ° C. and 2.16 kg load . 16 )
- HAZE Measurement was performed in accordance with JIS-K7136-2000 using a press sheet having a thickness of 0.7 mm.
- the press sheet piece was set in a glass cell containing special liquid paraffin made by Kanto Chemical Co., Ltd. and measured.
- the press sheet was stored in a hot press machine at 160 ° C. for 30 minutes, and prepared by crosslinking. The smaller the HAZE value, the better.
- the gel fraction As for the gel fraction, about 1 g of the sheet is cut out and weighed accurately, immersed in 100 cc of xylene, treated at 110 ° C. for 24 hours, the residue after filtration is dried and weighed, and divided by the weight before treatment. Calculate the gel fraction.
- Adhesiveness with glass A slide glass having a length of 7.6 cm, a width of 2.6 cm, and a thickness of 1 mm was used. The resin composition and the slide glass were brought into contact with each other and heated using a press machine at 160 ° C. for 30 minutes. The evaluation was made with “x” when the resin could be peeled off from the glass by hand in a 23 ° C. atmosphere for 24 hours, and “ ⁇ ” when it could not be peeled off.
- Silane coupling agent ⁇ -methacryloxypropyltrimethoxysilane (manufactured by Shin-Etsu Chemical Co., Ltd., KBM503) (3) Organic peroxide: 2,5-dimethyl-2,5-di (t-butylperoxy) hexane (manufactured by Arkema Yoshitomi, Luperox 101) (4) Hindered amine light stabilizer (a): dibutylamine, 1,3,5-triazine, N, N′-bis (2,2,6,6-tetramethyl-4-piperidyl-1,6- Hexamethylenediamine and N- (2,2,6,6-tetramethyl-4-piperidyl) butylamine polycondensation (Ciba Japan, CHIMASSORB 2020FDL) (5) Hindered amine light stabilizer (b): Polymer of dimethyl succinate and 4-hydroxy-2,2,6,6-tetramethyl-1-piperidineethanol (TINUVIN 622
- an ethylene / 1-hexene copolymer (PE—) having a 1-hexene content of 24% by weight, an MFR of 35 g / 10 min, a density of 0.880 g / cm 3 , and Mz / Mn of 3.7. 1) was obtained. Further, under the condition of PE-1 to 160 °C -0kg / cm 2, after 3 minutes preheat, under the condition of 160 °C -100kg / cm 2 pressure, 5-minute pressure, then cooling press set to 30 ° C. The press sheet of 0.7 mm thickness was obtained by cooling for 10 minutes on the conditions of 100 kg / cm ⁇ 2 > pressurization. The tensile modulus was measured in accordance with ISO 1184-1983, and as a result, it was 17 MPa. The characteristics of this ethylene / 1-hexene copolymer (PE-1) are shown in Table 1.
- Example 1 2,5-dimethyl-2,5-di (t-butylperoxy) hexane (Arkema Yoshitomi Co., Ltd.) as an organic peroxide with respect to 100 parts by weight of ethylene / hexene-1 copolymer (PE-1) And 1.5 parts by weight of Lupelox 101) as a hindered amine light stabilizer (a), dibutylamine, 1,3,5-triazine, N, N′-bis (2,2,6,6- Polycondensate of tetramethyl-4-piperidyl-1,6-hexamethylenediamine and N- (2,2,6,6-tetramethyl-4-piperidyl) butylamine (Cibassorb 2020FDL) 0.
- Example 2 A sheet was prepared in the same manner as in Example 1 except that PE-2 was used instead of PE-1. The sheet was measured for HAZE, light transmittance, tensile modulus, and heat resistance. The evaluation results are shown in Table 2.
- Example 3 In Example 1, 0.05 part by weight of a polymer of dimethyl succinate and 4-hydroxy-2,2,6,6-tetramethyl-1-piperidineethanol was used as the hindered amine light stabilizer (b). A sheet was produced in the same manner as in Example 1 except for the above. The sheet was measured for HAZE, light transmittance, tensile modulus, and heat resistance. The evaluation results are shown in Table 2.
- Example 4 In Example 3, a sheet was produced in the same manner as in Example 3 except that PE-2 was used instead of PE-1. The sheet was measured for HAZE, light transmittance, tensile modulus, and heat resistance. The evaluation results are shown in Table 2.
- Example 5 a sheet was produced in the same manner as in Example 3 except that PE-4 was used instead of PE-1.
- the sheet was measured for HAZE, light transmittance, tensile modulus, and heat resistance. The evaluation results are shown in Table 2.
- Example 6 In Example 3, a sheet was produced in the same manner as in Example 3 except that PE-5 was used instead of PE-1. The sheet was measured for HAZE, light transmittance, tensile modulus, and heat resistance. The evaluation results are shown in Table 2.
- Example 7 a sheet was prepared in the same manner as in Example 1 except that 0.3 part of 2-hydroxy-4-n-octoxybenzophenone (CYTEC UV531 manufactured by Sun Chemical Co., Ltd.) was added as an ultraviolet absorber. did. The sheet was evaluated for HAZE, light transmittance, tensile modulus, and heat resistance. The evaluation results are shown in Table 2.
- Example 8 In Example 4, a sheet was prepared in the same manner as in Example 1 except that 0.3 part of 2-hydroxy-4-n-octoxybenzophenone (CYTEC UV531 manufactured by Sun Chemical Co., Ltd.) was added as an ultraviolet absorber. did. The sheet was evaluated for HAZE, light transmittance, tensile modulus, and heat resistance. The evaluation results are shown in Table 2.
- Example 3 was the same as Example 1 except that PE-3 (ethylene / 1-butene copolymer, Tuffmer A4085S manufactured by Mitsui Chemicals, Inc.) was used instead of the copolymer of ethylene and hexene-1 (PE-1). Attempt to pelletize. However, the resin temperature rose due to shear heat generation, the decomposition rate of the organic peroxide increased, and the crosslinking proceeded, so that no pellet was obtained.
- PE-3 ethylene / 1-butene copolymer, Tuffmer A4085S manufactured by Mitsui Chemicals, Inc.
- Comparative Example 2 In Comparative Example 1, pelletization was performed by changing the conditions of the extruder at a set temperature of 100 ° C. and an extrusion rate of 9.7 kg / hour, and the sheet obtained by further sheeting was evaluated. The results are shown in Table 2. The amount of extrusion could not be increased, resulting in poor productivity.
- Example 3 Pelletization was performed in the same manner as in Example 1 except that PE-6 (ethylene / 1-octene copolymer, ENGAGE 8200 manufactured by Dow Chemical Company) was used instead of PE-1. However, the resin temperature rose due to shear heat generation, the decomposition rate of the organic peroxide increased, and the crosslinking proceeded, so that no pellet was obtained.
- PE-6 ethylene / 1-octene copolymer, ENGAGE 8200 manufactured by Dow Chemical Company
- Example 4 A sheet was prepared in the same manner as in Example 1 except that PE-7 (ethylene / 1-octene copolymer, ENGAGE 8400 manufactured by Dow Chemical Company) was used instead of PE-1. The sheet was measured for HAZE, light transmittance, tensile modulus, and heat resistance. The evaluation results are shown in Table 2. As a result, the crosslinking efficiency was poor and the heat resistance was poor.
- PE-7 ethylene / 1-octene copolymer, ENGAGE 8400 manufactured by Dow Chemical Company
- Example 9 1 part by weight of ⁇ -methacryloxypropyltrimethoxysilane (Shin-Etsu Chemical Co., Ltd., KBM503) as a silane coupling agent with respect to 100 parts by weight of ethylene / hexene-1 copolymer (PE-1), organic As a peroxide, 1.5 parts by weight of 2,5-dimethyl-2,5-di (t-butylperoxy) hexane (manufactured by Arkema Yoshitomi Corp., Luperox 101), a hindered amine light stabilizer (a) Dibutylamine, 1,3,5-triazine, N, N′-bis (2,2,6,6-tetramethyl-4-piperidyl-1,6-hexamethylenediamine and N- (2,2, 6,6-Tetramethyl-4-piperidyl) butylamine polycondensate (Ciba Japan, CHIMASSORB 2020FDL) was added in an amount of 0.2
- pelletization was performed using a 40 mm ⁇ single screw extruder under conditions of a set temperature of 130 ° C. and an extrusion rate (17 kg / hour).
- the resulting pellet 160 °C -0kg / cm 3 3 minutes preheat, (press molding 160 ° C. for 30 minutes) 160 °C -100kg / cm 3 27 minutes pressure, then, 100 kg in a cooling press set to 30 ° C.
- a sheet having a thickness of 0.7 mm was produced by cooling for 10 minutes under the conditions of / cm 3 .
- the sheet was measured and evaluated for HAZE, light transmittance, tensile modulus, heat resistance, and adhesiveness. The evaluation results are shown in Table 3.
- Example 10 a sheet was produced in the same manner as in Example 9 except that PE-2 was used instead of PE-1.
- the sheet was measured and evaluated for HAZE, light transmittance, tensile modulus, heat resistance, and adhesiveness. The evaluation results are shown in Table 3.
- Example 11 In Example 9, 0.05 part by weight of a polymer of dimethyl succinate and 4-hydroxy-2,2,6,6-tetramethyl-1-piperidineethanol was used as the hindered amine light stabilizer (b). A sheet was produced in the same manner as in Example 9 except for the above. The sheet was measured and evaluated for HAZE, light transmittance, tensile modulus, heat resistance, and adhesiveness. The evaluation results are shown in Table 3.
- Example 12 In Example 11, a sheet was produced in the same manner as in Example 11 except that PE-2 was used instead of PE-1. The sheet was measured and evaluated for HAZE, light transmittance, tensile modulus, heat resistance, and adhesiveness. The evaluation results are shown in Table 3.
- Example 13 In Example 11, a sheet was produced in the same manner as in Example 11 except that PE-4 was used instead of PE-1. The sheet was measured and evaluated for HAZE, light transmittance, tensile modulus, heat resistance, and adhesiveness. The evaluation results are shown in Table 3.
- Example 14 In Example 11, a sheet was produced in the same manner as in Example 11 except that PE-5 was used instead of PE-1. The sheet was measured and evaluated for HAZE, light transmittance, tensile modulus, heat resistance, and adhesiveness. The evaluation results are shown in Table 3.
- Example 15 In Example 11, a sheet was prepared in the same manner as in Example 11 except that 0.3 part of 2-hydroxy-4-n-octoxybenzophenone (CYTEC UV531 manufactured by Sun Chemical Co., Ltd.) was added as an ultraviolet absorber. did. The sheet was measured for HAZE, light transmittance, tensile modulus, heat resistance, and adhesiveness. The evaluation results are shown in Table 3.
- Example 16 In Example 12, a sheet was prepared in the same manner as in Example 12 except that 0.3 part of 2-hydroxy-4-n-octoxybenzophenone (CYTEC UV531 manufactured by Sun Chemical Co., Ltd.) was added as an ultraviolet absorber. did. The sheet was measured for HAZE, light transmittance, tensile modulus, heat resistance, and adhesiveness. The evaluation results are shown in Table 3.
- Example 3 was the same as Example 9 except that PE-3 (ethylene / 1-butene copolymer, Tuffmer A4085S manufactured by Mitsui Chemicals, Inc.) was used instead of the copolymer of ethylene and hexene-1 (PE-1). Attempt to pelletize. However, the resin temperature rose due to shear heat generation, the decomposition rate of the organic peroxide increased, and the crosslinking proceeded, so that no pellet was obtained.
- PE-3 ethylene / 1-butene copolymer, Tuffmer A4085S manufactured by Mitsui Chemicals, Inc.
- Comparative Example 6 In Comparative Example 5, pelletization was performed by changing the conditions of the extruder at a set temperature of 100 ° C. and an extrusion rate of 9.7 kg / hour, and the sheet obtained by sheeting was evaluated. The results are shown in Table 3. The amount of extrusion could not be increased, resulting in poor productivity.
- Example 7 Pelletization was performed in the same manner as in Example 9, except that PE-6 (ethylene / 1-octene copolymer, ENGAGE 8200 manufactured by Dow Chemical Company) was used instead of PE-1. However, the resin temperature rose due to shear heat generation, the decomposition rate of the organic peroxide increased, and the crosslinking proceeded, so that no pellet was obtained.
- PE-6 ethylene / 1-octene copolymer, ENGAGE 8200 manufactured by Dow Chemical Company
- Example 8 A sheet was prepared in the same manner as in Example 9 except that PE-7 (ethylene / 1-octene copolymer, ENGAGE 8400 manufactured by Dow Chemical Co., Ltd.) was used instead of PE-1.
- the sheet was measured and evaluated for HAZE, light transmittance, tensile modulus, heat resistance, and adhesiveness. The evaluation results are shown in Table 3. As a result, the crosslinking efficiency was poor and the heat resistance was poor.
- the resin composition for a solar cell encapsulant of the present invention is used for a solar cell encapsulant that requires transparency, flexibility, rigidity and a balance of crosslinking efficiency, weather resistance, and the like.
- it is useful as a sealing material for a thin film solar cell or a solar cell using a glass plate as a substrate.
- This resin composition can be preferably applied to the manufacture of a water shielding sheet, tarpaulin, or IC (integrated circuit) sealing in addition to the solar cell sealing material.
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Abstract
Description
太陽光発電は、一般にシリコン、ガリウム-砒素、銅-インジウム-セレンなどの太陽電池素子を上部透明保護材と下部基板保護材とで保護し、太陽電池素子と保護材とを樹脂製の封止材で固定し、パッケージ化した太陽電池モジュールを用いるものであり、水力、風力などと比べて規模は小さいものの、電力が必要な場所に分散して配置できることから、発電効率等の性能向上と価格の低下を目指した研究開発が推進されている。また、国や自治体で住宅用太陽光発電システム導入促進事業として設置費用を補助する施策が採られることで、徐々にその普及が進みつつある。しかしながら、更なる普及には一層の低コスト化が必要であり、そのため従来型のシリコンやガリウム-砒素などに代わる新たな素材を用いた太陽電池素子の開発だけでなく、太陽電池モジュールの製造コストをより一層低減する努力も地道に続けられている。
そして、太陽電池素子の封止作業では、太陽電池素子を樹脂製の封止材でカバーした後、数分から十数分程度加熱して仮接着し、オーブン内において有機過酸化物が分解する高温で数分から1時間加熱処理して接着させている(たとえば、特許文献2参照)。
太陽電池モジュールでは、太陽電池素子の薄膜化に伴い、太陽電池封止材も薄膜化する傾向がある。その際、太陽電池封止材の上部保護材側または下部保護材側から衝撃が加わると、配線が断線しやすいことが問題となっていた。特許文献4のポリマー材料を用いれば封止材の剛性を高くすることができるが、架橋効率が悪くなり実用的とはいえなかった。
このように従来の技術では、生産性、耐熱性、透明性、柔軟性及びガラス基板への接着性に優れ、剛性と架橋効率とのバランスもよい太陽電池封止材用樹脂組成物は得られていなかった。
成分(A):下記(a1)~(a5)の特性を有するエチレン・α-オレフィン共重合体
(a1)密度が0.860~0.920g/cm3
(a2)ゲルパーミエーションクロマトグラフィー(GPC)により求めたZ平均分子量(Mz)と数平均分子量(Mn)との比(Mz/Mn)が8.0以下
(a3)100℃で測定した、せん断速度が2.43×10s-1での溶融粘度(η* 1)が9.0×104poise以下
(a4)100℃で測定した、せん断速度が2.43×102s-1での溶融粘度(η* 2)が1.8×104poise以下
(a5)ポリマー中のコモノマーによる分岐数(N)が下記式(a)を満たす。
式(a): N ≧ -0.67×E+53
( ただし、Nは、NMRで測定した主鎖、側鎖の合計1000個の炭素数あたりの分岐数であり、Eは、ISO1184-1983に準拠して測定した、シートの引張弾性率である。)
成分(B):有機過酸化物
成分(C):シランカップリング剤
式(a’): -0.67×E+80 ≧ N ≧ -0.67×E+53
( ただし、Nは、NMRで測定した主鎖、側鎖の合計1000個の炭素数あたりの分岐数であり、Eは、ISO1184-1983に準拠して測定した、シートの引張弾性率である。)
成分(A):下記(a1)~(a4)及び(a6)の特性を有するエチレン・α-オレフィン共重合体
(a1)密度が0.860~0.920g/cm3
(a2)ゲルパーミエーションクロマトグラフィー(GPC)により求めたZ平均分子量(Mz)と数平均分子量(Mn)との比(Mz/Mn)が8.0以下
(a3)100℃で測定した、せん断速度が2.43×10s-1での溶融粘度(η* 1)が9.0×104poise以下
(a4)100℃で測定した、せん断速度が2.43×102s-1での溶融粘度(η* 2)が1.8×104poise以下
(a6)フローレシオ(FR):190℃における10kg荷重でのMFR測定値であるI10と、190℃における2.16kg荷重でのMFR測定値であるI2.16との比(I10/I2.16)が7.0未満
成分(B):有機過酸化物
成分(C):シランカップリング剤
また、本発明の第5の発明によれば、第1~4のいずれかの発明において、下記の成分(B)を成分(A)100重量部に対して、0.2~5重量部含有することを特徴とする太陽電池封止材用樹脂組成物が提供される。
また、本発明の第6の発明によれば、第1~5のいずれかの発明において、成分(C)の含有量が、成分(A)100重量部に対して、0.01~5重量部であることを特徴とする太陽電池封止材用樹脂組成物が提供される。
また、本発明の第7の発明によれば、第1~6のいずれかの発明において、さらに、下記の成分(D)を含有することを特徴とする太陽電池封止材用樹脂組成物が提供される。
成分(D):ヒンダードアミン系光安定化剤
また、本発明の第8の発明によれば、第7の発明において、成分(D)の含有量が、成分(A)100重量部に対して、0.01~2.5重量部であることを特徴とする太陽電池封止材用樹脂組成物が提供される。
また、本発明の第9の発明によれば、第1~8のいずれかの発明において、成分(A)が、エチレン・1-ブテン共重合体又はエチレン・1-ヘキセン共重合体であることを特徴とする太陽電池封止材用樹脂組成物が提供される。
さらに、本発明の第10の発明によれば、第1~9のいずれかの発明において、成分(A)のエチレン・α-オレフィン共重合体は、溶融粘度(η* 1)と溶融粘度(η* 2)との比(η* 1/η* 2)が4.5以下であることを特徴とする太陽電池封止材用樹脂組成物が提供される。
さらに、本発明の第12の発明によれば、第11の発明の太陽電池封止材を用いた太陽電池モジュールが提供される。
本発明の太陽電池封止材用樹脂組成物(以下、単に樹脂組成物ともいう)は、下記のエチレン・α-オレフィン共重合体成分(A)、及び有機過酸化物成分(B)及び/又はシランカップリング剤(C)を含有することを特徴とする。
本発明に用いる成分(A)は、下記(a1)~(a4)の特性を有したエチレン・α-オレフィン共重合体であり、さらに(a5)の特性及び/又は(a6)の特性を有したエチレン・α-オレフィン共重合体が好ましい。
(a1)密度が0.860~0.920g/cm3
(a2)ゲルパーミエーションクロマトグラフィー(GPC)により求めたZ平均分子量(Mz)と数平均分子量(Mn)との比(Mz/Mn)が8.0以下
(a3)100℃で測定した、せん断速度が2.43×10s-1での溶融粘度(η* 1)が9.0×104poise以下
(a4)100℃で測定した、せん断速度が2.43×102s-1での溶融粘度(η* 2)が1.8×104poise以下
式(a): N ≧ -0.67×E+53
( ただし、Nは、NMRで測定した主鎖、側鎖の合計1000個の炭素数あたりの個数であり、Eは、ISO1184-1983に準拠して測定した、シートの引張弾性率である。)
(a6)フローレシオ(FR):190℃における10kg荷重でのMFR測定値であるI10と、190℃における2.16kg荷重でのMFR測定値であるI2.16との比(I10/I2.16)が7.0未満
本発明に使用されるエチレン・α-オレフィン共重合体は、エチレンから誘導される構成単位を主成分としたエチレンとα-オレフィンのランダム共重合体である。
コモノマーとして用いられるα-オレフィンは、好ましくは炭素数3~12のα-オレフィンである。具体的には、プロピレン、1-ブテン、1-ペンテン、1-ヘキセン、1-オクテン、1-ヘプテン、4-メチル-ペンテン-1、4-メチル-ヘキセン-1、4,4-ジメチルペンテン-1等を挙げることができる。かかるエチレン・α-オレフィン共重合体の具体例としては、エチレン・プロピレン共重合体、エチレン・1-ブテン共重合体、エチレン・1-ヘキセン共重合体、エチレン・1-オクテン共重合体、エチレン・4-メチル-ペンテン-1共重合体等が挙げられる。なかでも、エチレン・1-ブテン共重合体、エチレン・1-ヘキセン共重合体が好ましい。また、α-オレフィンは1種または2種以上の組み合わせでもよい。2種のα-オレフィンを組み合わせて三元共重合体とする場合は、エチレン・プロピレン・1-ヘキセン三元共重合体、エチレン・1-ブテン・1-ヘキセン三元共重合体、エチレン・プロピレン・1-オクテン三元共重合体、エチレン・1-ブテン・1-オクテン三元共重合体等が挙げられる。
ここでα-オレフィンの含有量は、下記の条件の13C-NMR法によって計測される値である。
装置:日本電子製 JEOL-GSX270
濃度:300mg/2mL
溶媒:オルソジクロロベンゼン
本発明で用いるエチレン・α-オレフィン共重合体は、チーグラー触媒、バナジウム触媒又はメタロセン触媒等、好ましくはバナジウム触媒又はメタロセン触媒、より好ましくはメタロセン触媒を使用して製造することができる。製造法としては、高圧イオン重合法、気相法、溶液法、スラリー法等が挙げられる。
メタロセン触媒としては、特に限定されるわけではないが、シクロペンタジエニル骨格を有する基等が配位したジルコニウム化合物などのメタロセン化合物と助触媒とを触媒成分とする触媒が挙げられる。市販品としては、日本ポリエチレン社製のハーモレックス(登録商標)シリーズ、カーネル(登録商標)シリーズ、プライムポリマー社製のエボリュー(登録商標)シリーズ、住友化学社製のエクセレン(登録商標)GMHシリーズ、エクセレン(登録商標)FXシリーズが挙げられる。バナジウム触媒としては、可溶性バナジウム化合物と有機アルミニウムハライドとを触媒成分とする触媒が挙げられる。
(a1)密度
本発明で用いるエチレン・α-オレフィン共重合体は、密度が0.860~0.920g/cm3であり、好ましくは0.870~0.915g/cm3、さらに好ましくは0.875~0.910g/cm3である。エチレン・α-オレフィン共重合体の密度が0.860g/cm3未満では、加工後のシートがブロッキングしてしまい、密度が0.920g/cm3を超えると加工後のシートの剛性が高すぎて、取り扱い性に欠けるものとなる。
本発明で用いるエチレン・α-オレフィン共重合体は、ゲルパーミエーションクロマグラフィー(GPC)により求めたZ平均分子量(Mz)と数平均分子量(Mn)との比(Mz/Mn)が8.0以下であり、好ましくは5.0以下、より好ましくは4.0以下である。また、Mz/Mnは、2.0以上、好ましくは2.5以上、より好ましくは3.0以上である。ただし、Mz/Mnが8.0を超えると透明性が悪化する。Mz/Mnを所定の範囲に調整するには、適当な触媒系を選択する方法等によることができる。
装置:ウオーターズ社製GPC 150C型
検出器:MIRAN社製 1A赤外分光光度計(測定波長、3.42μm)
カラム:昭和電工製AD806M/S 3本(カラムの較正は、東ソー製単分散ポリスチレン(A500,A2500,F1,F2,F4,F10,F20,F40,F288の各0.5mg/ml溶液)の測定を行い、溶出体積と分子量の対数値を2次式で近似した。また、試料の分子量は、ポリスチレンとポリエチレンの粘度式を用いてポリエチレンに換算した。ここでポリスチレンの粘度式の係数は、α=0.723、logK=-3.967であり、ポリエチレンはα=0.733、logK=-3.407である。)
測定温度:140℃
濃度:20mg/10mL
注入量:0.2ml
溶媒:オルソジクロロベンゼン
流速:1.0ml/分
本発明で用いるエチレン・α-オレフィン共重合体は、100℃で測定した、せん断速度が特定の範囲でなければならない。100℃で測定した、せん断速度に着目するのは、当該温度での組成物を製品化する際の製品への影響を推定するためである。
すなわち、せん断速度2.43×10sec-1での溶融粘度(η* 1)が9.0×104poise以下、好ましくは8.0×104poise以下、より好ましくは7.0×104poise以下、さらに好ましくは5.5×104poise以下、さらにまた好ましくは5.0×104poise以下、特に好ましくは3.0×104poise以下、最も好ましくは2.5×104poise以下である。溶融粘度(η* 1)は、1.0×104poise以上、さらには1.5×104poise以上であることが好ましい。溶融粘度(η* 1)がこの範囲にあれば低温で低速成形時の生産性がよく、製品への加工に問題が生じない。
溶融粘度(η* 1)は、エチレン・α-オレフィン共重合体のメルトフローレート(MFR)や分子量分布などにより調整可能である。メルトフローレートの値を高めると溶融粘度(η* 1)は小さくなる傾向がある。分子量分布など他の性状が異なれば、大小関係が逆転することもありうるが、たとえば、好ましくはMFR(JIS-K6922-2:1997附属書(190℃、21.18N荷重))が5~50g/10分であり、より好ましくは10~40g/10分、さらに好ましくは15~35g/10分とすることで、溶融粘度(η* 1)を所定の範囲に収めやすい。
さらに、本発明で用いるエチレン・α-オレフィン共重合体は、100℃で測定した、せん断速度2.43×102sec-1での溶融粘度(η* 2)が、1.8×104poise以下、好ましくは1.7×104poise以下、より好ましくは1.5×104poise以下、さらに好ましくは1.4×104poise以下、最も好ましくは1.3×104poise以下である。溶融粘度(η* 2)は、5.0×103poise以上、さらには8.0×103poise以上であることが好ましい。溶融粘度(η* 2)がこの範囲にあれば低温で低速成形時の生産性がよく、製品への加工に問題が生じない。
ここで、溶融粘度(η* 1)、(η* 2)は、径1.0mm、L/D=10のキャピラリーを有するキャピラリーレオメーターを用いて得られる測定値である。
2種類のせん断速度を設けるのは、低速成形時、高速成形時の製品の表面への影響が小さく、それぞれの成形速度領域で同様の製品が得られるようにするためである。
本発明で用いるエチレン・α-オレフィン共重合体は、ポリマー中のコモノマーによる分岐数(N)と、引張弾性率(E)が下記式(a)を満たしていることが好ましい。
式(a): N ≧ -0.67×E+53
( ただし、Nは、NMRで測定した主鎖、側鎖の合計1000個の炭素数あたりの分岐数であり、Eは、ISO1184-1983に準拠して測定した、シートの引張弾性率である。)
ここで、ポリマー中のコモノマーによる分岐数(N)は、例えばE. W. Hansen, R. Blom, and O. M. Bade, Polymer, 36巻 4295頁(1997年)を参考にC-NMRスペクトルから算出することができる。
本発明に係るエチレン・α-オレフィン共重合体は、上述した様に、触媒を用いた共重合反応により製造できるが、共重合させる原料単量体の組成比や使用する触媒の種類を選択することにより、その高分子鎖中の分岐度を容易に調整することが可能である。本発明で用いるエチレン・α-オレフィン共重合体が式(a)を満たすためには、エチレン・α-オレフィン共重合体中のコモノマーは、プロピレン、1-ブテン、又は1-ヘキセンから選択するのが好ましい。また、気相法、高圧法を用いて製造するのが好ましく、特に、高圧法を選択するのがより好ましい。
より具体的にはEを固定してNを増減させるためには、主にエチレンと共重合させるコモノマーの炭素数を変更する方法によることができる。エチレンに対して1-ブテン又は1-ヘキセンの量が60~80wt%となるように混合し、メタロセン触媒を使用して、重合温度130~200℃で反応させエチレン・α-オレフィン共重合体を製造することが好ましい。これにより、エチレン・α-オレフィン共重合体の分岐数Nが適度に調整でき、得られるシートの引張弾性率Eが、40MPa以下となって、式(a)が示す範囲のエチレン・α-オレフィン共重合体を得ることができる。
式(a’): -0.67×E+80 ≧ N ≧ -0.67×E+53
式(a’’): -0.67×E+75 ≧ N ≧ -0.67×E+54
本発明で用いるエチレン・α-オレフィン共重合体は、フローレシオ(FR)、すなわち190℃における10kg荷重でのMFR測定値であるI10と、190℃における2.16kg荷重でのMFR測定値であるI2.16との比(I10/I2.16)が7.0未満であることが好ましい。なお、メルトフローレート(MFR)は、JIS-K7210-1999に準拠して測定した値である。
FRは、エチレン・α-オレフィン共重合体の分子量分布、長鎖分岐の量と相関が深いことが知られている。本発明では、上記(a1)~(a4)の条件を満たすポリマーの中でも、190℃における10kg荷重でのMFR測定値(I10)と、190℃における2.16kg荷重でのMFR測定値(I2.16)との比(I10/I2.16)が7.0未満であるものを使用する。このような長鎖分岐に特徴があるポリマー構造となっている共重合体を用いることで、剛性と架橋効率のバランスが良好なものとなる。これに対して、FRが7.0以上であると、太陽電池封止材として架橋する際の架橋効率が悪くなる傾向にある。
本発明で用いるエチレン・α-オレフィン共重合体のFRは、7.0未満であり、好ましくは、6.5未満、より好ましくは、6.3未満である。ただし、FRが5.0未満であると、太陽電池封止材として十分な剛性が得られにくくなることがある。特性(a6)のフローレシオ(FR)は、5.0~6.2であることが最も好ましい。
本発明における成分(B)の有機過酸化物は、主に成分(A)を架橋するために用いられる。
成分(B)の配合割合は、成分(A)を100重量部としたときに、好ましくは、0.2~5重量部であり、より好ましくは、0.5~3重量部、さらに好ましくは、1~2重量部である。成分(B)の配合割合が上記範囲よりも少ないと、架橋しないかまたは架橋に時間がかかる。また、上記範囲よりも大きいと、分散が不十分となり架橋度が不均一になりやすい。
本発明の樹脂組成物に用いる成分(C)は、シランカップリング剤であり、主に太陽電池の上部保護材や太陽電池素子との接着力を向上させる目的で用いられる。
本発明におけるシランカップリング剤としては、例えばγ-クロロプロピルトリメトキシシラン;ビニルトリクロルシラン;ビニルトリエトキシシラン;ビニルトリメトキシシラン;ビニル-トリス-(β-メトキシエトキシ)シラン;γ-メタクリロキシプロピルトリメトキシシラン;β-(3,4-エポキシシクロヘキシル)エチルトリメトキシシラン;γ-グリシドキシプロピルトリメトキシシラン;ビニルトリアセトキシシラン;γ-メルカプトプロピルトリメトキシシラン;γ-アミノプロピルトリメトキシシラン;N-β-(アミノエチル)-γ-アミノプロピルトリメトキシシラン、3-アクリロキシプロピルトリメトキシシラン等を挙げることができる。好ましくは、ビニルトリメトキシシラン、γ-メタクリロキシプロピルトリメトキシシラン、3-アクリロキシプロピルトリメトキシシランである。
これらのシランカップリング剤は、エチレン・α-オレフィン共重合体100重量部に対して0~5重量部使用し、好ましくは0.01~5重量部、より好ましくは0.01~2重量部、さらに好ましくは0.1~2重量部、特に好ましくは0.5~1重量部、最も好ましくは0.05~1重量部で使用される。
本発明において、樹脂組成物にはヒンダードアミン系光安定化剤を配合することが好ましい。ヒンダードアミン系光安定化剤は、ポリマーに対して有害なラジカル種を補足し、新たなラジカルを発生しないようにするものである。ヒンダードアミン系光安定化剤には、低分子量のものから高分子量のものまで多くの種類の化合物があるが、従来公知のものであれば特に制限されずに用いることができる。
前記含有量を0.01重量部以上とすることにより安定化への効果が十分に得られ、2.5重量部以下とすることによりヒンダードアミン系光安定化剤の過剰な添加による樹脂の変色を抑えることができる
また、本発明において、前記有機過酸化物(B)と前記ヒンダードアミン系光安定化剤(D)との重量比(B:D)を、1:0.1~1:10とし、好ましくは1:0.2~1:6.5とする。これにより、樹脂の黄変を顕著に抑制することが可能となる。
また、本発明の樹脂組成物には架橋助剤を配合することができる。架橋助剤は、架橋反応を促進させ、エチレン・α-オレフィン共重合体の架橋度を高めるのに有効であり、その具体例としては、ポリアリル化合物やポリ(メタ)アクリロキシ化合物のような多不飽和化合物を例示することができる。
本発明の樹脂組成物には、紫外線吸収剤を配合することができる。紫外線吸収剤としては、ベンゾフェノン系、ベンゾトリアゾール系、トリアジン系、サリチル酸エステル系など各種タイプのものを挙げることができる。
ベンゾフェノン系紫外線吸収剤としては、例えば、2-ヒドロキシ-4-メトキシベンゾフェノン、2-ヒドロキシ-4-メトキシ-2’-カルボキシベンゾフェノン、2-ヒドロキシ-4-n-オクトキシベンゾフェノン、2-ヒドロキシ-4-n-ドデシルオキシベンゾフェノン、2-ヒドロキシ-4-n-オクタデシルオキシベンゾフェノン、2-ヒドロキシ-4-ベンジルオキシベンゾフェノン、2-ヒドロキシ-4-メトキシ-5-スルホベンゾフェノン、2-ヒドロキシ-5-クロロベンゾフェノン、2,4-ジヒドロキシベンゾフェノン、2,2’-ジヒドロキシ-4-メトキシベンゾフェノン、2,2’-ジヒドロキシ-4,4’-ジメトキシベンゾフェノン、2,2’,4,4’-テトラヒドロキシベンゾフェノンなどを挙げることができる。
これら紫外線吸収剤は、エチレン・α-オレフィン共重合体100重量部に対し0~2.0重量部配合し、好ましくは0.05~2.0重量部、より好ましくは0.1~1.0重量部、さらに好ましくは0.1~0.5重量部、最も好ましくは0.2~0.4重量部配合するのがよい。
本発明の樹脂組成物には、本発明の目的を著しく損なわない範囲で、他の付加的任意成分を配合することができる。このような任意成分としては、通常のポリオレフィン系樹脂材料に使用される酸化防止剤、結晶核剤、透明化剤、滑剤、着色剤、分散剤、充填剤、蛍光増白剤、紫外線吸収剤、光安定剤等を挙げることができる。
本発明の太陽電池封止材(以下、単に封止材ともいう)は、上記樹脂組成物をペレット化し、あるいはシート化したものである。
また、下部保護材としては、金属や各種熱可塑性樹脂フィルムなどの単体もしくは多層のシートであり、例えば、錫、アルミ、ステンレススチールなどの金属、ガラス等の無機材料、ポリエステル、無機物蒸着ポリエステル、フッ素含有樹脂、ポリオレフィンなどの1層もしくは多層の保護材を例示することができる。このような上部及び/又は下部の保護材には、封止材との接着性を高めるためにプライマー処理を施すことができる。本発明においては、上部保護材としてガラス、フッ素含有樹脂が好ましい。
なお、本発明の樹脂組成物は、上記のように太陽電池モジュールの封止材として最適であるが、その他に遮水シート、又はターポリン、又はIC(集積回路)の封止の製造にも好ましく適用することができる。
(1)メルトフローレート(MFR):エチレン・α-オレフィン共重合体のMFRは、JIS-K6922-2:1997附属書(190℃、21.18N荷重)に準拠して測定した。
(2)密度:前述の通り、エチレン・α-オレフィン共重合体の密度は、JIS-K6922-2:1997附属書(23℃、低密度ポリエチレンの場合)に準拠して測定した。
(3)Mz/Mn:前述の通り、GPCにより測定した。
(4)溶融粘度:JIS-K7199-1999に準拠して、東洋精機製作所製キャピログラフ1-Bを用い、設定温度:100℃、D=1mm、L/D=10のキャピラリーを用いて、せん断速度2.43×10sec-1での溶融粘度(η* 1)、せん断速度2.43×102sec-1での溶融粘度(η* 2)の測定を行う。
装置 : ブルカー・バイオスピン(株) AVANCE III cryo-400MHz
溶媒 : o-ジクロロベンゼン/重化ブロモベンゼン = 8/2混合溶液
<試料量>
460mg/2.3ml
<C-NMR>
・Hデカップル、NOEあり
・積算回数:256scan
・フリップ角:90°
・パルス間隔20秒
・AQ(取り込み時間)=5.45s D1(待ち時間)=14.55s
(6)FR:JIS-K7210-1999に準拠し、190℃、10kg荷重の条件下で測定したMFR(I10)と、190℃、2.16kg荷重の条件下で測定したMFR(I2.16)との比(I10/I2.16)を計算し、FRとした。
(1)HAZE
厚み0.7mmのプレスシートを用いて、JIS-K7136-2000に準拠して測定した。プレスシート片を関東化学製特級流動パラフィンを入れたガラス製セルにセットし測定した。プレスシートは、160℃の条件で熱プレス機に30分間保管し、架橋させ準備した。HAZE値は、小さいほど良い。
厚み0.7mmのプレスシートを用いて、JIS-K7361-1997に準拠して測定した。プレスシート片を関東化学製特級流動パラフィンを入れたガラス製セルにセットし測定した。プレスシートは、160℃の条件で熱プレス機に30分間保管し、架橋させ準備した。
光線透過率は、80%以上であり、好ましくは、85%以上、さらに好ましくは90%以上である。
厚み0.7mmのプレスシートを用いて、ISO1184-1983に準拠して測定した。尚、引張速度1mm/min、試験片幅10mm、つかみ具間を100mmとし、伸び率1%のときの引張弾性率を求めた。この値が小さい程、柔軟性に優れていることを示す。
(4)耐熱性
160℃で30分架橋したシート及び150℃で30分架橋したシートのゲル分率で評価した。ゲル分率が高いほど架橋が進行しており、耐熱性が高いと評価できる。ゲル分率が70wt%のものを、耐熱性評価「○」とした。尚、ゲル分率は、当該シートを、約1gを切り取り精秤して、キシレン100ccに浸漬し110℃で24時間処理し、ろ過後残渣を乾燥し精秤して、処理前の重量で割りゲル分率を算出する。
縦7.6cm×横2.6cm×厚み1mmのスライドガラスを用いた。
樹脂組成物とスライドガラスを接触させ、160℃で30分の条件でプレス機を用いて加熱を行った。23℃雰囲気下に、24時間放置後、ガラスから樹脂を手で剥がせる場合を「×」、剥がせない場合を「○」として評価を行った。
(1)成分(A): エチレン・α-オレフィン共重合体
下記の<製造例1>で重合したエチレンとヘキセン-1の共重合体(PE-1)、<製造例2>で重合したエチレンとブテン-1の共重合体(PE-2)、及び市販のエチレン・α-オレフィン共重合体(PE-3)(PE-6)(PE-7)、<製造例3、4>で重合したエチレンとヘキセン-1の共重合体(PE-4)(PE-5)を用いた。物性を表1に示す。
(2)シランカップリング剤:γ-メタクリロキシプロピルトリメトキシシラン(信越化学工業社製、KBM503)
(3)有機過酸化物:2,5-ジメチル-2,5-ジ(t-ブチルパーオキシ)ヘキサン(アルケマ吉富社製、ルペロックス101)
(4)ヒンダードアミン系光安定化剤(a):ジブチルアミン・1,3,5-トリアジン・N,N’-ビス(2,2,6,6-テトラメチル-4-ピペリジル-1,6-ヘキサメチレンジアミンとN-(2,2,6,6-テトラメチル-4-ピペリジル)ブチルアミンの重縮合物(チバ・ジャパン社製、CHIMASSORB 2020FDL)
(5)ヒンダードアミン系光安定化剤(b):コハク酸ジメチルと4-ヒドロキシ-2,2,6,6-テトラメチル-1-ピペリジンエタノールの重合物(チバ・ジャパン社製、TINUVIN 622LD)
(6)紫外線吸収剤:2-ヒドロキシ-4-n-オクトキシベンゾフェノン(サンケミカル社製、CYTEC UV531)
(i)触媒の調製
エチレンとヘキセン-1の共重合体を製造するための触媒は、特表平7-508545号公報に記載された方法で調製した。即ち、錯体ジメチルシリレンビス(4,5,6,7-テトラヒドロインデニル)ハフニウムジメチル2.0mモルに、トリペンタフルオロフェニルホウ素を上記錯体に対して等モル加え、トルエンで10リットルに希釈して触媒溶液を調製した。
(ii)重合
内容積1.5リットルの撹拌式オートクレーブ型連続反応器を用い、反応器内の圧力を130MPaに保ち、エチレンと1-ヘキセンとの混合物を1-ヘキセンの組成が75重量%となるように40kg/時の割合で原料ガスを連続的に供給した。また、上記触媒溶液を連続的に供給し、重合温度が150℃を維持するようにその供給量を調整した。1時間あたりのポリマー生産量は約4.3kgであった。反応終了後、1-ヘキセン含有量が24重量%、MFRが35g/10分、密度が0.880g/cm3、Mz/Mnが3.7であるエチレン・1-ヘキセン共重合体(PE-1)を得た。
また、PE-1を160℃-0kg/cm2の条件で、3分予熱後、160℃-100kg/cm2加圧の条件で、5分加圧、その後、30℃に設定された冷却プレスに100kg/cm2加圧の条件で、10分間冷却することで、厚み0.7mmのプレスシートを得た。その引張弾性率を、ISO1184-1983に準拠し、測定を行った結果、17MPaであった。
このエチレン・1-ヘキセン共重合体(PE-1)の特性を表1に示す。
表1に示す組成、密度、および溶融粘度となるように、製造例1における重合時のモノマー組成、重合温度を変更して重合を行った。反応終了後、1-ブテン含有量=35重量%、MFR=33g/10分、密度=0.870g/cm3、Mz/Mn=3.5であるエチレン・1-ブテン共重合体(PE-2)を得た。製造例1と同様に引張弾性率測定を行った結果、8MPaであった。このエチレン・1-ブテン共重合体(PE-2)の特性を表1に示す。
製造例1において、重合時の1-ヘキセンの組成を74重量%にし、重合温度を135℃に代えた以外は製造例1と同様の製法で重合を行った。1時間あたりのポリマー生産量は約3.3kgであった。反応終了後、1-ヘキセン含有量=24重量%、MFR=8g/10分、密度=0.880g/cm3、Mz/Mn=3.7であるエチレン・1-ヘキセン共重合体(PE-3)を得た。製造例1と同様に引張弾性率測定を行った結果、17MPaであった。このエチレン・1-ヘキセン共重合体(PE-3)の特性を表1に示す。
製造例1において、重合時の1-ヘキセンの組成を71重量%にし、重合温度を157℃に代えた以外は製造例1と同様の製法で重合を行った。1時間あたりのポリマー生産量は約4.0kgであった。反応終了後、1-ヘキセン含有量=19重量%、MFR=30g/10分、密度=0.890g/cm3、Mz/Mn=3.7であるエチレン・1-ヘキセン共重合体(PE-4)を得た。製造例1と同様に引張弾性率測定を行った結果、34MPaであった。このエチレン・1-ヘキセン共重合体(PE-4)の特性を表1に示す。
エチレンとヘキセン-1の共重合体(PE-1)100重量部に対して、有機過酸化物として、2,5-ジメチル-2,5-ジ(t-ブチルパーオキシ)ヘキサン(アルケマ吉富社製、ルペロックス101)を1.5重量部と、ヒンダードアミン系光安定化剤(a)として、ジブチルアミン・1,3,5-トリアジン・N,N’-ビス(2,2,6,6-テトラメチル-4-ピペリジル-1,6-ヘキサメチレンジアミンとN-(2,2,6,6-テトラメチル-4-ピペリジル)ブチルアミンの重縮合物(チバ・ジャパン社製、CHIMASSORB 2020FDL)0.2重量部配合した。これを十分に混合し、40mmφ単軸押出機を用いて設定温度130℃、押出量(17kg/時)の条件でペレット化した。
得られたペレットを、160℃-0kg/cm2の条件で、3分予熱後、160℃-100kg/cm2の条件で、27分加圧(160℃で30分間プレス成形)、その後、30℃に設定された冷却プレスに100kg/cm2の加圧の条件で、10分間冷却することで、厚み0.7mmのシートを作製した。シートのHAZE、光線透過率、引張弾性率、耐熱性を測定、評価した。評価結果を表2に示す。
実施例1において、PE-1に替えて、PE-2を用いた以外は、実施例1と同様にシートを作製した。シートのHAZE、光線透過率、引張弾性率、耐熱性を測定、評価した。評価結果を表2に示す。
実施例1において、ヒンダードアミン系光安定化剤(b)として、コハク酸ジメチルと4-ヒドロキシ-2,2,6,6-テトラメチル-1-ピペリジンエタノールの重合物を0.05重量部用いた以外は、実施例1と同様にシートを作製した。シートのHAZE、光線透過率、引張弾性率、耐熱性を測定、評価した。評価結果を表2に示す。
実施例3において、PE-1に替えて、PE-2を用いた以外は、実施例3と同様にシートを作製した。シートのHAZE、光線透過率、引張弾性率、耐熱性を測定、評価した。評価結果を表2に示す。
実施例3において、PE-1に替えて、PE-4を用いた以外は、実施例3と同様にシートを作製した。シートのHAZE、光線透過率、引張弾性率、耐熱性を測定、評価した。評価結果を表2に示す。
実施例3において、PE-1に替えて、PE-5を用いた以外は、実施例3と同様にシートを作製した。シートのHAZE、光線透過率、引張弾性率、耐熱性を測定、評価した。評価結果を表2に示す。
実施例3において、さらに、紫外線吸収剤として、2-ヒドロキシ-4-n-オクトキシベンゾフェノン(サンケミカル社製 CYTEC UV531)0.3部を添加した以外は、実施例1と同様にシートを作製した。シートのHAZE、光線透過率、引張弾性率、耐熱性を測定、評価を行った。評価結果を表2に示す。
実施例4において、さらに、紫外線吸収剤として、2-ヒドロキシ-4-n-オクトキシベンゾフェノン(サンケミカル社製 CYTEC UV531)0.3部を添加した以外は、実施例1と同様にシートを作製した。シートのHAZE、光線透過率、引張弾性率、耐熱性を測定、評価を行った。評価結果を表2に示す。
エチレンとヘキセン-1の共重合体(PE-1)の代わりに、PE-3(エチレン・1-ブテン共重合体、三井化学社製 タフマーA4085S)を用いた以外は、実施例1と同様のペレット化を試みた。ところが、樹脂温度がせん断発熱により上昇して有機過酸化物の分解速度が速くなり、架橋が進行してペレットが得られなかった。
比較例1において、押出機の条件を設定温度100℃、押出量9.7kg/時に変えてペレット化を行い、さらにシート化して得られたシートの評価を行った。結果を表2に示す。押出量を高くすることができず、生産性が劣る結果となった。
PE-1の代わりに、PE-6(エチレン・1-オクテン共重合体、ダウ・ケミカル社製 ENGAGE8200)を用いた以外は、実施例1と同様のペレット化を試みた。ところが、樹脂温度がせん断発熱により上昇して有機過酸化物の分解速度が速くなり、架橋が進行してペレットが得られなかった。
PE-1の代わりに、PE-7(エチレン・1-オクテン共重合体、ダウ・ケミカル社製 ENGAGE8400)を用いた以外は、実施例1と同様にシートを作製した。シートのHAZE、光線透過率、引張弾性率、耐熱性を測定、評価した。評価結果を表2に示す。架橋効率が悪く耐熱性が劣る結果となった。
エチレンとヘキセン-1の共重合体(PE-1)100重量部に対して、シランカップリング剤としてγ-メタクリロキシプロピルトリメトキシシラン(信越化学工業社製、KBM503)を1重量部と、有機過酸化物として、2,5-ジメチル-2,5-ジ(t-ブチルパーオキシ)ヘキサン(アルケマ吉富社製、ルペロックス101)を1.5重量部と、ヒンダードアミン系光安定化剤(a)として、ジブチルアミン・1,3,5-トリアジン・N,N’-ビス(2,2,6,6-テトラメチル-4-ピペリジル-1,6-ヘキサメチレンジアミンとN-(2,2,6,6-テトラメチル-4-ピペリジル)ブチルアミンの重縮合物(チバ・ジャパン社製、CHIMASSORB 2020FDL)0.2重量部配合した。これを十分に混合し、40mmφ単軸押出機を用いて設定温度130℃、押出量(17kg/時)の条件でペレット化した。
得られたペレットを、160℃-0kg/cm3 3分予熱、160℃-100kg/cm3 27分加圧(160℃で30分間プレス成形)、その後、30℃に設定された冷却プレスに100kg/cm3の条件で、10分間冷却することで、厚み0.7mmのシートを作製した。シートのHAZE、光線透過率、引張弾性率、耐熱性、接着性を測定、評価した。評価結果を表3に示す。
実施例9において、PE-1に替えて、PE-2を用いた以外は、実施例9と同様にシートを作製した。シートのHAZE、光線透過率、引張弾性率、耐熱性、接着性を測定、評価した。評価結果を表3に示す。
実施例9において、ヒンダードアミン系光安定化剤(b)として、コハク酸ジメチルと4-ヒドロキシ-2,2,6,6-テトラメチル-1-ピペリジンエタノールの重合物を0.05重量部用いた以外は、実施例9と同様にシートを作製した。シートのHAZE、光線透過率、引張弾性率、耐熱性、接着性を測定、評価した。評価結果を表3に示す。
実施例11において、PE-1に替えて、PE-2を用いた以外は、実施例11と同様にシートを作製した。シートのHAZE、光線透過率、引張弾性率、耐熱性、接着性を測定、評価した。評価結果を表3に示す。
実施例11において、PE-1に替えて、PE-4を用いた以外は、実施例11と同様にシートを作製した。シートのHAZE、光線透過率、引張弾性率、耐熱性、接着性を測定、評価した。評価結果を表3に示す。
実施例11において、PE-1に替えて、PE-5を用いた以外は、実施例11と同様にシートを作製した。シートのHAZE、光線透過率、引張弾性率、耐熱性、接着性を測定、評価した。評価結果を表3に示す。
実施例11において、さらに、紫外線吸収剤として、2-ヒドロキシ-4-n-オクトキシベンゾフェノン(サンケミカル社製 CYTEC UV531)0.3部を添加した以外は、実施例11と同様にシートを作製した。シートのHAZE、光線透過率、引張弾性率、耐熱性、接着性を測定、評価を行った。評価結果を表3に示す。
実施例12において、さらに、紫外線吸収剤として、2-ヒドロキシ-4-n-オクトキシベンゾフェノン(サンケミカル社製 CYTEC UV531)0.3部を添加した以外は、実施例12と同様にシートを作製した。シートのHAZE、光線透過率、引張弾性率、耐熱性、接着性を測定、評価を行った。評価結果を表3に示す。
エチレンとヘキセン-1の共重合体(PE-1)の代わりに、PE-3(エチレン・1-ブテン共重合体、三井化学社製 タフマーA4085S)を用いた以外は、実施例9と同様のペレット化を試みた。ところが、樹脂温度がせん断発熱により上昇して有機過酸化物の分解速度が速くなり、架橋が進行してペレットが得られなかった。
比較例5において、押出機の条件を設定温度100℃、押出量9.7kg/時に変えてペレット化を行い、さらにシート化して得られたシートの評価を行った。結果を表3に示す。押出量を高くすることができず、生産性が劣る結果となった。
PE-1の代わりに、PE-6(エチレン・1-オクテン共重合体、ダウ・ケミカル社製 ENGAGE8200)を用いた以外は、実施例9と同様のペレット化を試みた。ところが、樹脂温度がせん断発熱により上昇して有機過酸化物の分解速度が速くなり、架橋が進行してペレットが得られなかった。
PE-1の代わりに、PE-7(エチレン・1-オクテン共重合体、ダウ・ケミカル社製 ENGAGE8400)を用いた以外は、実施例9と同様にシートを作製した。シートのHAZE、光線透過率、引張弾性率、耐熱性、接着性を測定、評価した。評価結果を表3に示す。架橋効率が悪く耐熱性が劣る結果となった。
この結果、表2、3から明らかなように、実施例1~16では、本発明の樹脂組成物を用いているために、これを押出成形して得られたシートは、HAZEが小さく、光線透過率が大きく、耐熱性、剛性と架橋効率のバランスが良く、特に実施例9~16では、ガラスに対する接着性も優れている。
これに対して、比較例1、5では、本発明とは異なり、溶融粘度が外れるエチレン・1-ブテン共重合体を含む樹脂組成物を用いているために、ペレットが得られなかった。比較例2、6では、押出温度を下げたためにシートを成形できたが、実施例1、9よりも大幅に生産性が低下した。また、得られたシートは、耐熱性、接着性が優れているものの、HAZEが大きく、柔軟性が小さいものとなった。比較例3、7では、溶融粘度が本発明から外れるエチレン・1-オクテン共重合体を含む樹脂組成物を用いたために、ペレットが得られなかった。比較例4、8では、式(a)及びFRが本発明から外れるエチレン・1-オクテン共重合体を含む樹脂組成物を用いたために、得られたシートは、架橋効率が悪く耐熱性が劣る結果となった。
Claims (12)
- 下記の成分(A)及び、成分(B)及び/または成分(C)を含有することを特徴とする太陽電池封止材用樹脂組成物。
成分(A):下記(a1)~(a5)の特性を有するエチレン・α-オレフィン共重合体
(a1)密度が0.860~0.920g/cm3
(a2)ゲルパーミエーションクロマトグラフィー(GPC)により求めたZ平均分子量(Mz)と数平均分子量(Mn)との比(Mz/Mn)が8.0以下
(a3)100℃で測定した、せん断速度が2.43×10s-1での溶融粘度(η* 1)が9.0×104poise以下
(a4)100℃で測定した、せん断速度が2.43×102s-1での溶融粘度(η* 2)が1.8×104poise以下
(a5)ポリマー中のコモノマーによる分岐数(N)が下記式(a)を満たす。
式(a): N ≧ -0.67×E+53
( ただし、Nは、NMRで測定した主鎖、側鎖の合計1000個の炭素数あたりの分岐数であり、Eは、ISO1184-1983に準拠して測定した、シートの引張弾性率である。)
成分(B):有機過酸化物
成分(C):シランカップリング剤 - (a5)ポリマー中のコモノマーによる分岐数(N)が、下記式(a’)を満たすことを特徴とする請求項1に記載の太陽電池封止材用樹脂組成物。
式(a’): -0.67×E+80 ≧ N ≧ -0.67×E+53
( ただし、Nは、NMRで測定した主鎖、側鎖の合計1000個の炭素数あたりの分岐数であり、Eは、ISO1184-1983に準拠して測定した、シートの引張弾性率である。) - 下記の成分(A)及び、成分(B)及び/または成分(C)を含有することを特徴とする太陽電池封止材用樹脂組成物。
成分(A):下記(a1)~(a4)及び(a6)の特性を有するエチレン・α-オレフィン共重合体
(a1)密度が0.860~0.920g/cm3
(a2)ゲルパーミエーションクロマトグラフィー(GPC)により求めたZ平均分子量(Mz)と数平均分子量(Mn)との比(Mz/Mn)が8.0以下
(a3)100℃で測定した、せん断速度が2.43×10s-1での溶融粘度(η* 1)が9.0×104poise以下
(a4)100℃で測定した、せん断速度が2.43×102s-1での溶融粘度(η* 2)が1.8×104poise以下
(a6)フローレシオ(FR):190℃における10kg荷重でのMFR測定値であるI10と、190℃における2.16kg荷重でのMFR測定値であるI2.16との比(I10/I2.16)が7.0未満
成分(B):有機過酸化物
成分(C):シランカップリング剤 - 特性(a6)のフローレシオ(FR)が、5.0~6.2であることを特徴とする請求項3に記載の太陽電池封止材用樹脂組成物。
- 下記の成分(B)の含有量が、成分(A)100重量部に対して、0.2~5重量部であることを特徴とする請求項1~4のいずれかに記載の太陽電池封止材用樹脂組成物。
- 成分(C)の含有量が、成分(A)100重量部に対して、0.01~5重量部であることを特徴とする請求項1~5のいずれかに記載の太陽電池封止材用樹脂組成物。
- さらに、下記の成分(D)を含有することを特徴とする請求項1~6のいずれかに記載の太陽電池封止材用樹脂組成物。
成分(D):ヒンダードアミン系光安定化剤 - 成分(D)の含有量が、成分(A)100重量部に対して、0.01~2.5重量部であることを特徴とする請求項7に記載の太陽電池封止材用樹脂組成物。
- 成分(A)が、エチレン・1-ブテン共重合体又はエチレン・1-ヘキセン共重合体であることを特徴とする請求項1~8のいずれかに記載の太陽電池封止材用樹脂組成物。
- 成分(A)のエチレン・α-オレフィン共重合体は、溶融粘度(η* 1)と溶融粘度(η* 2)との比(η* 1/η* 2)が4.5以下であることを特徴とする請求項1~9に記載の太陽電池封止材用樹脂組成物。
- 請求項1~10のいずれかに記載の太陽電池封止材用樹脂組成物をペレット化し、あるいはシート化してなる太陽電池封止材。
- 請求項11の太陽電池封止材を用いた太陽電池モジュール。
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Country Status (4)
Country | Link |
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US (1) | US8697984B2 (ja) |
EP (1) | EP2416375B1 (ja) |
CN (1) | CN102365754B (ja) |
WO (1) | WO2010114028A1 (ja) |
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CN102365754A (zh) | 2012-02-29 |
US20120000514A1 (en) | 2012-01-05 |
CN102365754B (zh) | 2014-03-12 |
EP2416375A1 (en) | 2012-02-08 |
EP2416375B1 (en) | 2014-09-10 |
US8697984B2 (en) | 2014-04-15 |
EP2416375A4 (en) | 2013-01-02 |
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