WO2011016557A1 - 太陽電池封止材用樹脂組成物の製造方法、太陽電池封止材用樹脂組成物、太陽電池封止材、および太陽電池モジュール - Google Patents
太陽電池封止材用樹脂組成物の製造方法、太陽電池封止材用樹脂組成物、太陽電池封止材、および太陽電池モジュール Download PDFInfo
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- WO2011016557A1 WO2011016557A1 PCT/JP2010/063388 JP2010063388W WO2011016557A1 WO 2011016557 A1 WO2011016557 A1 WO 2011016557A1 JP 2010063388 W JP2010063388 W JP 2010063388W WO 2011016557 A1 WO2011016557 A1 WO 2011016557A1
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- WO
- WIPO (PCT)
- Prior art keywords
- solar cell
- vinyl acetate
- resin composition
- ethylene
- acetate copolymer
- Prior art date
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- 239000011342 resin composition Substances 0.000 title claims abstract description 111
- 239000003566 sealing material Substances 0.000 title claims abstract description 58
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 36
- 239000005038 ethylene vinyl acetate Substances 0.000 claims abstract description 97
- 229920001200 poly(ethylene-vinyl acetate) Polymers 0.000 claims abstract description 97
- 239000003431 cross linking reagent Substances 0.000 claims abstract description 80
- 238000005470 impregnation Methods 0.000 claims abstract description 75
- 238000000034 method Methods 0.000 claims abstract description 26
- XTXRWKRVRITETP-UHFFFAOYSA-N Vinyl acetate Chemical group CC(=O)OC=C XTXRWKRVRITETP-UHFFFAOYSA-N 0.000 claims abstract description 19
- 239000008393 encapsulating agent Substances 0.000 claims description 113
- 239000002994 raw material Substances 0.000 claims description 47
- 239000004594 Masterbatch (MB) Substances 0.000 claims description 41
- 238000004132 cross linking Methods 0.000 claims description 35
- 239000006087 Silane Coupling Agent Substances 0.000 claims description 27
- 239000000203 mixture Substances 0.000 claims description 14
- 238000002156 mixing Methods 0.000 claims description 11
- 238000000465 moulding Methods 0.000 claims description 9
- 238000010438 heat treatment Methods 0.000 claims description 4
- 238000012545 processing Methods 0.000 abstract description 18
- 238000003860 storage Methods 0.000 abstract description 17
- 230000009467 reduction Effects 0.000 abstract description 3
- 230000015572 biosynthetic process Effects 0.000 abstract 1
- 239000007858 starting material Substances 0.000 abstract 1
- 238000011156 evaluation Methods 0.000 description 99
- 239000008188 pellet Substances 0.000 description 80
- 238000005259 measurement Methods 0.000 description 28
- 238000012360 testing method Methods 0.000 description 21
- 230000000903 blocking effect Effects 0.000 description 20
- 230000000052 comparative effect Effects 0.000 description 15
- 239000007788 liquid Substances 0.000 description 12
- 229920005989 resin Polymers 0.000 description 10
- 239000011347 resin Substances 0.000 description 10
- 239000000463 material Substances 0.000 description 9
- 238000001125 extrusion Methods 0.000 description 8
- 230000001681 protective effect Effects 0.000 description 7
- 238000006243 chemical reaction Methods 0.000 description 6
- 238000004898 kneading Methods 0.000 description 6
- -1 1,1-di (tert-butylperoxy) cyclohexane 1,1-di (tert-hexylperoxy) cyclohexane 1,1-di (tert-amylperoxy) cyclohexane Chemical compound 0.000 description 5
- DMWVYCCGCQPJEA-UHFFFAOYSA-N 2,5-bis(tert-butylperoxy)-2,5-dimethylhexane Chemical compound CC(C)(C)OOC(C)(C)CCC(C)(C)OOC(C)(C)C DMWVYCCGCQPJEA-UHFFFAOYSA-N 0.000 description 5
- 238000007654 immersion Methods 0.000 description 5
- 239000000758 substrate Substances 0.000 description 5
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 description 4
- 239000000155 melt Substances 0.000 description 4
- 238000003756 stirring Methods 0.000 description 4
- NALFRYPTRXKZPN-UHFFFAOYSA-N 1,1-bis(tert-butylperoxy)-3,3,5-trimethylcyclohexane Chemical compound CC1CC(C)(C)CC(OOC(C)(C)C)(OOC(C)(C)C)C1 NALFRYPTRXKZPN-UHFFFAOYSA-N 0.000 description 3
- KOMNUTZXSVSERR-UHFFFAOYSA-N 1,3,5-tris(prop-2-enyl)-1,3,5-triazinane-2,4,6-trione Chemical compound C=CCN1C(=O)N(CC=C)C(=O)N(CC=C)C1=O KOMNUTZXSVSERR-UHFFFAOYSA-N 0.000 description 3
- FIYMNUNPPYABMU-UHFFFAOYSA-N 2-benzyl-5-chloro-1h-indole Chemical compound C=1C2=CC(Cl)=CC=C2NC=1CC1=CC=CC=C1 FIYMNUNPPYABMU-UHFFFAOYSA-N 0.000 description 3
- KUDUQBURMYMBIJ-UHFFFAOYSA-N 2-prop-2-enoyloxyethyl prop-2-enoate Chemical compound C=CC(=O)OCCOC(=O)C=C KUDUQBURMYMBIJ-UHFFFAOYSA-N 0.000 description 3
- LZMNXXQIQIHFGC-UHFFFAOYSA-N 3-[dimethoxy(methyl)silyl]propyl 2-methylprop-2-enoate Chemical compound CO[Si](C)(OC)CCCOC(=O)C(C)=C LZMNXXQIQIHFGC-UHFFFAOYSA-N 0.000 description 3
- XDLMVUHYZWKMMD-UHFFFAOYSA-N 3-trimethoxysilylpropyl 2-methylprop-2-enoate Chemical compound CO[Si](OC)(OC)CCCOC(=O)C(C)=C XDLMVUHYZWKMMD-UHFFFAOYSA-N 0.000 description 3
- 239000000654 additive Substances 0.000 description 3
- 239000002671 adjuvant Substances 0.000 description 3
- 230000007423 decrease Effects 0.000 description 3
- 238000000605 extraction Methods 0.000 description 3
- 239000011521 glass Substances 0.000 description 3
- 239000012778 molding material Substances 0.000 description 3
- 239000000523 sample Substances 0.000 description 3
- 238000004904 shortening Methods 0.000 description 3
- WYTZZXDRDKSJID-UHFFFAOYSA-N (3-aminopropyl)triethoxysilane Chemical compound CCO[Si](OCC)(OCC)CCCN WYTZZXDRDKSJID-UHFFFAOYSA-N 0.000 description 2
- RIPYNJLMMFGZSX-UHFFFAOYSA-N (5-benzoylperoxy-2,5-dimethylhexan-2-yl) benzenecarboperoxoate Chemical compound C=1C=CC=CC=1C(=O)OOC(C)(C)CCC(C)(C)OOC(=O)C1=CC=CC=C1 RIPYNJLMMFGZSX-UHFFFAOYSA-N 0.000 description 2
- HQOVXPHOJANJBR-UHFFFAOYSA-N 2,2-bis(tert-butylperoxy)butane Chemical compound CC(C)(C)OOC(C)(CC)OOC(C)(C)C HQOVXPHOJANJBR-UHFFFAOYSA-N 0.000 description 2
- CSCPPACGZOOCGX-UHFFFAOYSA-N Acetone Chemical compound CC(C)=O CSCPPACGZOOCGX-UHFFFAOYSA-N 0.000 description 2
- VGGSQFUCUMXWEO-UHFFFAOYSA-N Ethene Chemical compound C=C VGGSQFUCUMXWEO-UHFFFAOYSA-N 0.000 description 2
- 239000005977 Ethylene Substances 0.000 description 2
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 2
- 229910052782 aluminium Inorganic materials 0.000 description 2
- 239000000538 analytical sample Substances 0.000 description 2
- 150000001875 compounds Chemical class 0.000 description 2
- 229920001577 copolymer Polymers 0.000 description 2
- 238000007865 diluting Methods 0.000 description 2
- 230000007613 environmental effect Effects 0.000 description 2
- 239000000284 extract Substances 0.000 description 2
- 238000004817 gas chromatography Methods 0.000 description 2
- 230000020169 heat generation Effects 0.000 description 2
- 238000000691 measurement method Methods 0.000 description 2
- 229910052757 nitrogen Inorganic materials 0.000 description 2
- 150000002978 peroxides Chemical class 0.000 description 2
- 229920000642 polymer Polymers 0.000 description 2
- 230000008569 process Effects 0.000 description 2
- CIHOLLKRGTVIJN-UHFFFAOYSA-N tert‐butyl hydroperoxide Chemical compound CC(C)(C)OO CIHOLLKRGTVIJN-UHFFFAOYSA-N 0.000 description 2
- 238000012546 transfer Methods 0.000 description 2
- SYXTYIFRUXOUQP-UHFFFAOYSA-N (2-methylpropan-2-yl)oxy butaneperoxoate Chemical compound CCCC(=O)OOOC(C)(C)C SYXTYIFRUXOUQP-UHFFFAOYSA-N 0.000 description 1
- MYOQALXKVOJACM-UHFFFAOYSA-N (2-methylpropan-2-yl)oxy pentaneperoxoate Chemical compound CCCCC(=O)OOOC(C)(C)C MYOQALXKVOJACM-UHFFFAOYSA-N 0.000 description 1
- KDGNCLDCOVTOCS-UHFFFAOYSA-N (2-methylpropan-2-yl)oxy propan-2-yl carbonate Chemical compound CC(C)OC(=O)OOC(C)(C)C KDGNCLDCOVTOCS-UHFFFAOYSA-N 0.000 description 1
- OXYKVVLTXXXVRT-UHFFFAOYSA-N (4-chlorobenzoyl) 4-chlorobenzenecarboperoxoate Chemical compound C1=CC(Cl)=CC=C1C(=O)OOC(=O)C1=CC=C(Cl)C=C1 OXYKVVLTXXXVRT-UHFFFAOYSA-N 0.000 description 1
- FYRCDEARNUVZRG-UHFFFAOYSA-N 1,1,5-trimethyl-3,3-bis(2-methylpentan-2-ylperoxy)cyclohexane Chemical compound CCCC(C)(C)OOC1(OOC(C)(C)CCC)CC(C)CC(C)(C)C1 FYRCDEARNUVZRG-UHFFFAOYSA-N 0.000 description 1
- XSZYESUNPWGWFQ-UHFFFAOYSA-N 1-(2-hydroperoxypropan-2-yl)-4-methylcyclohexane Chemical compound CC1CCC(C(C)(C)OO)CC1 XSZYESUNPWGWFQ-UHFFFAOYSA-N 0.000 description 1
- BJELTSYBAHKXRW-UHFFFAOYSA-N 2,4,6-triallyloxy-1,3,5-triazine Chemical compound C=CCOC1=NC(OCC=C)=NC(OCC=C)=N1 BJELTSYBAHKXRW-UHFFFAOYSA-N 0.000 description 1
- ODBCKCWTWALFKM-UHFFFAOYSA-N 2,5-bis(tert-butylperoxy)-2,5-dimethylhex-3-yne Chemical compound CC(C)(C)OOC(C)(C)C#CC(C)(C)OOC(C)(C)C ODBCKCWTWALFKM-UHFFFAOYSA-N 0.000 description 1
- KRDXTHSSNCTAGY-UHFFFAOYSA-N 2-cyclohexylpyrrolidine Chemical compound C1CCNC1C1CCCCC1 KRDXTHSSNCTAGY-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
- XYFRHHAYSXIKGH-UHFFFAOYSA-N 3-(5-methoxy-2-methoxycarbonyl-1h-indol-3-yl)prop-2-enoic acid Chemical compound C1=C(OC)C=C2C(C=CC(O)=O)=C(C(=O)OC)NC2=C1 XYFRHHAYSXIKGH-UHFFFAOYSA-N 0.000 description 1
- DCQBZYNUSLHVJC-UHFFFAOYSA-N 3-triethoxysilylpropane-1-thiol Chemical compound CCO[Si](OCC)(OCC)CCCS DCQBZYNUSLHVJC-UHFFFAOYSA-N 0.000 description 1
- URDOJQUSEUXVRP-UHFFFAOYSA-N 3-triethoxysilylpropyl 2-methylprop-2-enoate Chemical compound CCO[Si](OCC)(OCC)CCCOC(=O)C(C)=C URDOJQUSEUXVRP-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
- 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
- 239000004471 Glycine Substances 0.000 description 1
- 239000004698 Polyethylene Substances 0.000 description 1
- 239000004743 Polypropylene Substances 0.000 description 1
- PPBRXRYQALVLMV-UHFFFAOYSA-N Styrene Chemical compound C=CC1=CC=CC=C1 PPBRXRYQALVLMV-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
- 239000006096 absorbing agent Substances 0.000 description 1
- 238000004458 analytical method Methods 0.000 description 1
- 239000003963 antioxidant agent Substances 0.000 description 1
- 235000019400 benzoyl peroxide Nutrition 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
- 238000004364 calculation method Methods 0.000 description 1
- 239000003795 chemical substances by application Substances 0.000 description 1
- 238000004581 coalescence Methods 0.000 description 1
- 239000003086 colorant Substances 0.000 description 1
- 238000013329 compounding Methods 0.000 description 1
- 239000000470 constituent Substances 0.000 description 1
- 238000011109 contamination Methods 0.000 description 1
- 238000001816 cooling Methods 0.000 description 1
- 230000002542 deteriorative effect Effects 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
- 238000009792 diffusion process Methods 0.000 description 1
- 238000010790 dilution Methods 0.000 description 1
- 239000012895 dilution Substances 0.000 description 1
- 238000002845 discoloration Methods 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
- 238000010812 external standard method Methods 0.000 description 1
- 239000003063 flame retardant Substances 0.000 description 1
- XUCNUKMRBVNAPB-UHFFFAOYSA-N fluoroethene Chemical compound FC=C XUCNUKMRBVNAPB-UHFFFAOYSA-N 0.000 description 1
- 239000008187 granular material Substances 0.000 description 1
- 230000007062 hydrolysis Effects 0.000 description 1
- 238000006460 hydrolysis reaction Methods 0.000 description 1
- 238000009413 insulation Methods 0.000 description 1
- 239000004611 light stabiliser Substances 0.000 description 1
- 238000002844 melting Methods 0.000 description 1
- 230000008018 melting Effects 0.000 description 1
- 238000013508 migration Methods 0.000 description 1
- 230000005012 migration Effects 0.000 description 1
- 239000000178 monomer Substances 0.000 description 1
- PHQOGHDTIVQXHL-UHFFFAOYSA-N n'-(3-trimethoxysilylpropyl)ethane-1,2-diamine Chemical compound CO[Si](OC)(OC)CCCNCCN PHQOGHDTIVQXHL-UHFFFAOYSA-N 0.000 description 1
- MQWFLKHKWJMCEN-UHFFFAOYSA-N n'-[3-[dimethoxy(methyl)silyl]propyl]ethane-1,2-diamine Chemical compound CO[Si](C)(OC)CCCNCCN MQWFLKHKWJMCEN-UHFFFAOYSA-N 0.000 description 1
- 229920000573 polyethylene Polymers 0.000 description 1
- 229920000139 polyethylene terephthalate Polymers 0.000 description 1
- 239000005020 polyethylene terephthalate Substances 0.000 description 1
- 230000000379 polymerizing effect Effects 0.000 description 1
- 229920001155 polypropylene Polymers 0.000 description 1
- 239000000843 powder Substances 0.000 description 1
- 238000011002 quantification Methods 0.000 description 1
- PFBLRDXPNUJYJM-UHFFFAOYSA-N tert-butyl 2-methylpropaneperoxoate Chemical compound CC(C)C(=O)OOC(C)(C)C PFBLRDXPNUJYJM-UHFFFAOYSA-N 0.000 description 1
- GJBRNHKUVLOCEB-UHFFFAOYSA-N tert-butyl benzenecarboperoxoate Chemical compound CC(C)(C)OOC(=O)C1=CC=CC=C1 GJBRNHKUVLOCEB-UHFFFAOYSA-N 0.000 description 1
- 230000007704 transition Effects 0.000 description 1
- 238000009834 vaporization Methods 0.000 description 1
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- 238000010792 warming Methods 0.000 description 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 1
- 230000002087 whitening effect Effects 0.000 description 1
Classifications
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- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
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- C08L23/02—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers not modified by chemical after-treatment
- C08L23/04—Homopolymers or copolymers of ethene
- C08L23/08—Copolymers of ethene
- C08L23/0846—Copolymers of ethene with unsaturated hydrocarbons containing other atoms than carbon or hydrogen atoms
- C08L23/0853—Vinylacetate
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
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- C08L23/02—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers not modified by chemical after-treatment
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- B32B17/06—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material
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- B32B17/10005—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing
- B32B17/1055—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing characterized by the resin layer, i.e. interlayer
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- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B17/00—Layered products essentially comprising sheet glass, or glass, slag, or like fibres
- B32B17/06—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material
- B32B17/10—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin
- B32B17/10005—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing
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- B32B17/10788—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing characterized by the resin layer, i.e. interlayer containing ethylene vinylacetate
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
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- C08J3/20—Compounding polymers with additives, e.g. colouring
- C08J3/203—Solid polymers with solid and/or liquid additives
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- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
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- C08J3/20—Compounding polymers with additives, e.g. colouring
- C08J3/22—Compounding polymers with additives, e.g. colouring using masterbatch techniques
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- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J3/00—Processes of treating or compounding macromolecular substances
- C08J3/20—Compounding polymers with additives, e.g. colouring
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- C08J3/226—Compounding polymers with additives, e.g. colouring using masterbatch techniques using a polymer as a carrier
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L31/00—Compositions of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by an acyloxy radical of a saturated carboxylic acid, of carbonic acid or of a haloformic acid; Compositions of derivatives of such polymers
- C08L31/02—Homopolymers or copolymers of esters of monocarboxylic acids
- C08L31/04—Homopolymers or copolymers of vinyl acetate
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- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09K—MATERIALS FOR MISCELLANEOUS APPLICATIONS, NOT PROVIDED FOR ELSEWHERE
- C09K3/00—Materials not provided for elsewhere
- C09K3/10—Materials in mouldable or extrudable form for sealing or packing joints or covers
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
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- 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
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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
- H01L31/0481—Encapsulation of modules characterised by the composition of the encapsulation material
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J2323/00—Characterised by the use of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Derivatives of such polymers
- C08J2323/02—Characterised by the use of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Derivatives of such polymers not modified by chemical after treatment
- C08J2323/04—Homopolymers or copolymers of ethene
- C08J2323/08—Copolymers of ethene
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J2423/00—Characterised by the use of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Derivatives of such polymers
- C08J2423/02—Characterised by the use of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Derivatives of such polymers not modified by chemical after treatment
- C08J2423/04—Homopolymers or copolymers of ethene
- C08J2423/08—Copolymers of ethene
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- 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
- C08K5/0008—Organic ingredients according to more than one of the "one dot" groups of C08K5/01 - C08K5/59
- C08K5/0025—Crosslinking or vulcanising agents; including accelerators
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- 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
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- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09K—MATERIALS FOR MISCELLANEOUS APPLICATIONS, NOT PROVIDED FOR ELSEWHERE
- C09K2200/00—Chemical nature of materials in mouldable or extrudable form for sealing or packing joints or covers
- C09K2200/06—Macromolecular organic compounds, e.g. prepolymers
- C09K2200/0615—Macromolecular organic compounds, e.g. prepolymers obtained by reactions only involving carbon-to-carbon unsaturated bonds
- C09K2200/0617—Polyalkenes
- C09K2200/062—Polyethylene
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- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09K—MATERIALS FOR MISCELLANEOUS APPLICATIONS, NOT PROVIDED FOR ELSEWHERE
- C09K2200/00—Chemical nature of materials in mouldable or extrudable form for sealing or packing joints or covers
- C09K2200/06—Macromolecular organic compounds, e.g. prepolymers
- C09K2200/0615—Macromolecular organic compounds, e.g. prepolymers obtained by reactions only involving carbon-to-carbon unsaturated bonds
- C09K2200/0622—Polyvinylalcohols, polyvinylacetates
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- 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 method for producing a solar cell encapsulant resin composition, a solar cell encapsulant resin composition, a solar cell encapsulant, and a solar cell module.
- a solar cell generally has a solar cell module as a constituent unit.
- This solar cell module has a configuration in which protective glass / solar cell sealing material / solar cell element / solar cell sealing material / back sheet are laminated in order from the side receiving sunlight.
- a sheet of a resin composition made of an ethylene-vinyl acetate copolymer is used for the solar cell encapsulant from the viewpoint of transparency, mechanical properties, and cost.
- This resin composition that is, a resin composition for a solar cell encapsulant, crosslinks an ethylene-vinyl acetate copolymer as a raw material component to impart durability to the solar cell encapsulant, Generally, a crosslinking agent and a crosslinking aid are included.
- a resin composition for a solar cell encapsulant generally contains a silane coupling agent in order to maintain adhesion to the surface of protective glass or a solar cell element.
- the resin composition for solar cell encapsulant is manufactured by various methods.
- a cross-linking agent, a cross-linking aid and a silane coupling agent are mixed with an ethylene-vinyl acetate copolymer using a melt kneader such as a twin screw extruder.
- a method of kneading into a coalescence see Patent Document 1
- a liquid cross-linking agent, a cross-linking aid, etc. are mixed with an ethylene-vinyl acetate copolymer using a mixer such as a mixer, to obtain a mixture.
- a mixer such as a mixer
- the objective of this invention is related with the manufacturing method of the resin composition for solar cell sealing materials used for manufacture of a solar cell sealing material, the resin composition for solar cell sealing materials, a solar cell sealing material, and a solar cell module.
- a solar cell encapsulant that has excellent storage stability, realizes cost reduction by shortening the processing time when manufacturing the solar cell encapsulant, and greatly reduces the occurrence of shading.
- the first invention relates to a temperature relative to 1 g of an ethylene-vinyl acetate copolymer (A) having 25 to 35% by weight of a vinyl acetate unit as a raw material component and an ethylene-vinyl acetate copolymer (A).
- a crosslinking agent (B) having an impregnation weight of 40 to 80 mg per 24 hours at 23 ° C .
- the second invention relates to a method for producing a resin composition for a solar cell encapsulant of the above invention, wherein the crosslinking agent (B) has a surface tension of 23 to 28 mN / m.
- an impregnation weight per 24 hours at a temperature of 23 ° C. with respect to 1 g of the ethylene-vinyl acetate copolymer (A) is 80 to 120 mg.
- a crosslinking aid (C) having a surface tension of 33 to 38 mN / m is prepared,
- the ethylene-vinyl acetate copolymer (A) is impregnated with the crosslinking aid (C) together with the crosslinking agent (B).
- the present invention relates to a method for producing a resin composition for a battery sealing material.
- an impregnation weight per 24 hours at a temperature of 23 ° C. with respect to 1 g of the ethylene-vinyl acetate copolymer (A) is 80 to 150 mg.
- a silane coupling agent (D) having a surface tension of 27 to 32 mN / m is prepared,
- the ethylene-vinyl acetate copolymer (A) is impregnated with the silane coupling agent (D) together with the crosslinking agent (B). It is related with the manufacturing method of the resin composition for solar cell sealing materials.
- the fifth invention relates to a resin composition for a solar cell encapsulant obtained by the method for producing a resin composition for a solar cell encapsulant of the above invention.
- the sixth invention relates to a solar cell encapsulant characterized by being molded using an ethylene-vinyl acetate copolymer and the resin composition for a solar cell encapsulant of the above invention.
- a raw material component having an ethylene-vinyl acetate copolymer (A) having a vinyl acetate unit in an amount of 25 to 35% by weight and an ethylene-vinyl acetate copolymer (A) of 1 g has a temperature of 23 ° C.
- a method for producing a solar cell encapsulant comprising: molding the obtained mixture using a molding machine to obtain a solar cell encapsulant.
- the resin composition for solar cell encapsulant obtained by the method for producing a resin composition for solar cell encapsulant of the present invention has good storage stability, and this is used for production of the solar cell encapsulant. Thus, cost reduction can be achieved by shortening the processing time. Furthermore, by using this resin composition for a solar cell encapsulant, it is possible to obtain a solar cell encapsulant with greatly reduced occurrence of irregularities and good transparency.
- the method for producing a resin composition for a solar cell encapsulant of the present invention is obtained by adding a liquid to an ethylene-vinyl acetate copolymer (A) having a vinyl acetate unit at 25 to 35% by weight at a temperature of 15 to 80 ° C.
- a step of impregnating the cross-linking agent (B) (hereinafter also referred to as “impregnation step”). For example, by impregnating the ethylene-vinyl acetate copolymer (A) with a crosslinking agent (B) or the like at a high concentration, a resin composition for a solar cell encapsulant is obtained as a master batch (master batch for a solar cell encapsulant).
- concentration other than the crosslinking agent (B) can also be obtained.
- the produced resin composition for solar cell encapsulant also has a pellet shape.
- the form (shape) of the ethylene-vinyl acetate copolymer (A) includes, for example, a powder form, a granule form, a block form, and a block form in addition to a pellet form.
- the pellet of the ethylene-vinyl acetate copolymer (A) is referred to as “raw material pellet”, and the pellet of the obtained resin composition for solar cell encapsulant is simply referred to as “pellet”.
- the ethylene-vinyl acetate copolymer (A) having a vinyl acetate unit of 25 to 35% by weight used in the present invention means that when the total weight of ethylene and vinyl acetate as monomers is 100 parts by weight, It means a polymer obtained by polymerizing ethylene and vinyl acetate by adjusting the weight to 25 to 35 parts by weight.
- the degree of crystallinity of the ethylene-vinyl acetate copolymer decreases as the ratio (% by weight) of vinyl acetate units increases. For this reason, when the vinyl acetate unit is less than 25% by weight, the degree of crystallinity increases, and the impregnation efficiency of the liquid raw material component such as the crosslinking agent (B) is deteriorated. On the other hand, when the vinyl acetate unit is larger than 35% by weight, the degree of crystallinity is too low, and the impregnated crosslinking agent (B) migrates to the surface of the pellet, causing a problem of blocking where the pellets are gently adhered to each other. There is a risk that.
- EVA ethylene-vinyl acetate copolymer
- the ethylene-vinyl acetate copolymer (A) preferably has a melt flow rate (JIS K7210) of 0.1 to 60 g / 10 min in consideration of moldability, mechanical strength, More preferably, it is 0.5 to 45 g / 10 min. Furthermore, when producing a resin composition for a solar cell encapsulant as a masterbatch, it is necessary to consider the efficiency of diffusion of the masterbatch into the diluted resin in addition to the moldability and mechanical strength.
- the melt flow rate (hereinafter sometimes referred to as “MFR”) of the vinyl acetate copolymer (A) is preferably 2 to 50 g / 10 min, and more preferably 5 to 45 g / 10 min.
- the obtained pellets are impregnated with the raw material components deep inside, and the ethylene-vinyl acetate copolymer (A ), The raw material component is less likely to migrate to the surface of the pellet.
- the master batch will be described in detail later.
- the crosslinking agent (B) has an impregnation weight of 40 to 80 mg per 24 hours at a temperature of 23 ° C. with respect to 1 g of the ethylene-vinyl acetate copolymer (A).
- the impregnation weight of the crosslinking agent (B) is preferably 50 to 70 mg / EVA ⁇ 1 g.
- the impregnation weight can be determined as follows. That is, a sufficient amount of the crosslinking agent (B) is prepared for the pellets of the ethylene-vinyl acetate copolymer (A) having 30% by weight of vinyl acetate units, and Xg of Xg After immersing the ethylene-vinyl acetate copolymer (A) pellets at 23 ° C. for 24 hours, the pellets are taken out from the crosslinking agent (B), and the crosslinking agent (B) adhering to the surface of the pellets is sufficiently wiped off. .
- the weight of the pellet after immersion is measured, and the impregnation weight Yg of the crosslinking agent (B), which is the difference between the measured weight and the weight Xg of the pellet before immersion, is the weight Xg of the pellet before immersion.
- the amount is converted to the amount per 1 g of ethylene-vinyl acetate copolymer (A).
- the formula used for the calculation is shown below.
- EVA represents an ethylene-vinyl acetate copolymer.
- Impregnation weight (mg / EVA ⁇ 1 g) (Y / X) ⁇ 1000
- crosslinking agent (B) examples include tert-butyl peroxyisopropyl carbonate, tert-butyl peroxy-2-ethylhexyl carbonate, tert-butyl peroxyacetate, tert-butylcumyl peroxide, 2,5-dimethyl.
- the blending amount of the crosslinking agent (B) is preferably 0.3 to 20 parts by weight, more preferably 0.3 to 10 parts by weight with respect to 100 parts by weight of the ethylene-vinyl acetate copolymer (A).
- this masterbatch 5 to 60 parts by weight, more preferably 15 to 60 parts by weight, and more preferably 15 to 45 parts by weight of the crosslinking agent (B) with respect to 100 parts by weight of the ethylene-vinyl acetate copolymer (A). It is further preferable to include it.
- the cross-linking agent (B) preferably has a surface tension of 23 to 28 mN / m.
- the surface tension is less than 23 mN / m, depending on the environmental temperature at the time of storage of the pellet (resin composition for solar cell encapsulating material), the crosslinking agent (B) tends to migrate to the surface of the pellet, and blocking occurs. And may cause contamination of the working environment.
- the surface tension is greater than 28 mN / m, it may take too long to sufficiently impregnate the raw material pellets with the crosslinking agent (B).
- the impregnation step in the present invention is preferably performed at a processing temperature of 15 to 80 ° C., more preferably 30 to 70 ° C., and further preferably 40 to 70 ° C. If the processing temperature is higher than the upper limit, for example, depending on conditions such as the stirring speed in the impregnation step, the reaction of the crosslinking agent (B) and the melting of the ethylene-vinyl acetate copolymer (A) may occur. On the other hand, if the processing temperature is less than the lower limit, it may take too much time until the raw material pellets are sufficiently impregnated with the crosslinking agent (B).
- the time for the impregnation step is not particularly limited, but is preferably about 5 minutes to 2 hours, more preferably about 5 minutes to 1 hour.
- the raw material pellets can be impregnated with a necessary and sufficient amount of the crosslinking agent (B) in such a range of time. At this time, even when the processing temperature in the impregnation step is slightly high, it is possible to suitably prevent or suppress the cross-linking reaction from occurring in the cross-linking agent (B).
- the impregnation step it is also preferable to impregnate the raw material pellets with the crosslinking aid (C) and the silane coupling agent (D) simultaneously with the crosslinking agent (B).
- the crosslinking assistant (C) is used at a temperature of 23 ° C. per 24 hours for 1 g of the ethylene-vinyl acetate copolymer (A).
- the impregnation weight is preferably 80 to 120 mg and the surface tension is preferably 33 to 38 mN / m.
- Examples of such a crosslinking aid (C) include triallyl isocyanurate, triallyl cyanurate, vinylbenzene and the like.
- the blending amount of the crosslinking aid (C) is preferably 0.3 to 15 parts by weight, more preferably 0.3 to 10 parts by weight with respect to 100 parts by weight of the ethylene-vinyl acetate copolymer (A).
- the master which contains a crosslinking agent (B) and a crosslinking adjuvant (C) in high concentration in the resin composition for solar cell sealing materials (pellet).
- the master batch preferably contains 5 to 60 parts by weight, preferably 15 to 60 parts by weight of the crosslinking aid (C) with respect to 100 parts by weight of the ethylene-vinyl acetate copolymer (A). More preferably, it is more preferably 15 to 45 parts by weight.
- the silane coupling agent (D) is used for 24 hours at a temperature of 23 ° C. with respect to 1 g of the ethylene-vinyl acetate copolymer (A) in view of the impregnation efficiency of the ethylene-vinyl acetate copolymer (A) (raw material pellet). It is preferable that the impregnated weight of is 80 to 150 mg and the surface tension is 27 to 32 mN / m.
- silane coupling agent (D) examples include ⁇ -methacryloxypropyltrimethoxysilane, ⁇ -methacryloxypropyltriethoxysilane, ⁇ -methacryloxypropylmethyldimethoxysilane, vinyltris ( ⁇ -methoxyethoxy) silane. Vinyltriacetoxysilane, N- ( ⁇ -aminoethyl) - ⁇ -aminopropyltrimethoxysilane, N- ( ⁇ -aminoethyl) - ⁇ -aminopropylmethyldimethoxysilane, ⁇ -mercaptopropyltriethoxysilane, etc. It is done.
- the compounding amount of the silane coupling agent (D) is preferably 0.1 to 10 parts by weight, more preferably 0.1 to 5 parts by weight with respect to 100 parts by weight of the ethylene-vinyl acetate copolymer (A).
- a crosslinking agent (B) and a silane coupling agent (D) are made into high concentration by the resin composition for solar cell sealing materials (pellet).
- the master batch contains 5 to 60 parts by weight of the silane coupling agent (D) with respect to 100 parts by weight of the ethylene-vinyl acetate copolymer (A). More preferably, it is contained in an amount of 15 to 45 parts by weight.
- the equipment used in the impregnation step is preferably equipment capable of mixing or stirring each raw material component in the container, and most preferably equipment capable of heating and cooling. Even if the equipment to be used is not warmable, the present invention can be sufficiently carried out even by warming caused by self-heating due to friction when stirring the raw material components. Moreover, even if the equipment to be used cannot be cooled, for example, it is possible to prevent or suppress heat generation by controlling the number of rotations of the stirring blades of the equipment to implement the present invention. Examples of such equipment include an autoclave with a stirrer, a Henschel mixer, a ladyge mixer, and a super mixer.
- the ethylene-vinyl acetate copolymer (A), the cross-linking agent (B) and other raw material components are simultaneously mixed and stirred in the container, so that the cross-linking agent is added to the ethylene-vinyl acetate copolymer (A) at a time.
- (B) etc. can also be impregnated, it can also impregnate by putting each raw material component in a container in arbitrary orders.
- additives for a solar cell encapsulant of the present invention other various additives can be blended as necessary.
- additives include ultraviolet absorbers, light stabilizers, antioxidants, wavelength conversion agents, colorants, light diffusing materials, flame retardants, and discoloration preventing materials.
- Various additives are blended together with an ethylene-vinyl acetate copolymer (A) and at least one of a crosslinking agent (B), a crosslinking assistant (C), and a silane coupling agent (D) to form a solar cell.
- a resin composition for a sealing material can be produced, or can be added separately when producing a final molded product (for example, a solar cell sealing material described later).
- the master batch is, for example, a resin composition for a solar cell encapsulating material obtained by impregnating an ethylene-vinyl acetate copolymer (A) with a crosslinking agent (B) at a high concentration. That is, in order to adjust a molding material for molding a solar cell sealing material sheet when molding a sheet-shaped solar cell sealing material (hereinafter also referred to as “solar cell sealing material sheet”). It refers to a pellet-shaped resin composition for solar cell encapsulant.
- the molding material is prepared by mixing and kneading (diluting) the solar cell encapsulating resin composition and the diluted resin so that the content of the crosslinking agent (B) in the resulting molding material is a predetermined value. Can be obtained.
- a diluted resin As such a diluted resin, the same resin as the ethylene-vinyl acetate copolymer (A) used for the production of the resin composition for a solar cell encapsulant described above, or compatibility with the ethylene-vinyl acetate copolymer (A) is used.
- a certain resin can be used.
- examples of the resin compatible with the ethylene-vinyl acetate copolymer (A) include polyethylene, polypropylene, and ethylene-propylene copolymer.
- the master batch when the resin composition for a solar cell encapsulant is produced as a master batch, the master batch can further contain at least one of a crosslinking aid (C) or a silane coupling agent (D).
- a masterbatch contains all of a crosslinking agent (B), a crosslinking adjuvant (C), and a silane coupling agent (D) in high concentration.
- the resin composition for solar cell sealing materials after manufacturing the resin composition for solar cell sealing materials as a masterbatch, when manufacturing a solar cell sealing material, it compares with the case where a solar cell sealing material is shape
- the volatilization rate of the peroxide such as the crosslinking agent (B) used is high (for example, it is reduced by about 1 to 5% per hour at 50 ° C.), a master batch having a relatively small specific surface area is preferable. . If the solar cell encapsulant is molded through a master batch having a relatively small specific surface area, peroxide volatilization from the master batch can be suppressed.
- the solar cell encapsulant when the solar cell encapsulant is molded through a master batch, whitening due to uneven cross-linking of the solar cell encapsulant and a decrease in the gel fraction can be prevented. Further, even when a sheet-shaped solar cell encapsulant is molded, it is possible to prevent the mechanical properties from deteriorating.
- a compound is a pellet-shaped solar cell encapsulating containing raw material components such as a crosslinking agent (B) at a concentration (content rate) already required in a solar cell encapsulating material sheet that is a molded product. It refers to a resin composition for materials. Such a compound is used for forming a solar cell sealing material as it is without being diluted.
- the solar cell encapsulant of the present invention is the same as the solar cell encapsulant resin composition of the present invention or, for example, when the solar cell encapsulant resin composition is produced as a master batch.
- the master batch can be obtained by further diluting and adjusting the master batch and then molding the master batch into a sheet.
- the solar cell encapsulant sheet is generally produced by a molding method using a T-die extruder, a calendar molding machine or the like.
- the thickness of the solar cell encapsulant sheet is preferably about 0.01 to 1 mm.
- the solar cell module of the present invention can be manufactured by fixing the solar cell element (photoelectric conversion element) with upper and lower protective members (including a transparent substrate) using the solar cell sealing material sheet.
- the solar cell module can be manufactured by sandwiching (fixing) the upper and lower sides of the solar cell element with a solar cell sealing material sheet, but is generally manufactured by thermocompression bonding using a vacuum laminator.
- a transparent substrate / solar cell encapsulant sheet / solar cell element / solar cell encapsulant sheet / protective member are laminated in this order, that is, both sides of the solar cell element From a super straight structure sandwiched between solar cell encapsulant sheets and a structure in which a transparent substrate / solar cell element / solar cell encapsulant sheet / protective member are laminated in this order, that is, provided on the surface of the substrate A structure in which a solar cell encapsulant sheet and a protective member are laminated in this order on the solar cell element.
- a heat-strengthened white glass or a transparent sheet is used, and for the solar cell encapsulant sheet, a sheet formed of the resin composition for solar cell encapsulant of the present invention having excellent moisture resistance is used. It is done.
- protective members that require moisture proofing and insulation include a sheet material having a structure in which an aluminum sheet is sandwiched between vinyl fluoride sheets and a sheet material having a structure in which an aluminum sheet is sandwiched between hydrolysis-resistant polyethylene terephthalate sheets. Used.
- Ethylene-vinyl acetate copolymer (A-1) Vinyl acetate weight%: 26%, MFR: 25 g / 10 min (A-2) Vinyl acetate weight%: 33%, MFR: 34 g / 10 min (A-3) Vinyl acetate weight%: 23%, MFR: 18 g / 10 min (A-4) Vinyl acetate weight%: 37%, MFR: 42 g / 10 min
- Cross-linking agent B-1) 2,5-dimethyl-2,5-di (tert-butylperoxy) hexane (B-2) 1,1-di (tert-butylperoxy) -3,3,5- Trimethylcyclohexane (B-3) tert-butylperoxy-2-ethylhexyl carbonate (B-4) 2,5-dimethyl-2,5-di (tert-butylperoxy) hexane (B-5) 2,5- Dimethyl-2,5-di (benzoylperoxy) hexane (B-6) 1,1- (tert-butylperoxy) -2-methylcyclohexane (B-7) tert-butylperoxybenzoate
- Crosslinking aid (C-1) triallyl isocyanurate (C-2) ethylene glycol diacrylate (C-3) diallyl fumarate
- Silane coupling agent (D-1) ⁇ -methacryloxypropyltrimethoxysilane (D-2) ⁇ -methacryloxypropylmethyldimethoxysilane (D-3) ⁇ -aminopropyltriethoxysilane (D-4) 3-glycine Sidoxypropyltrimethoxysilane
- Crosslinking agents (B-1) to (B-7), crosslinking assistants (C-1) to (C-3), and silane coupling agents (D-1) to (D-4) are used as liquids to be measured.
- the impregnation weight and surface tension were measured, respectively.
- the measurement method of the impregnation weight and surface tension is as follows, and the measurement results are shown in Table 1.
- a sufficient amount of the liquid to be measured is prepared in a sealed container with respect to the pellet of ethylene-vinyl acetate copolymer having 30% vinyl acetate units, and Xg of ethylene-vinyl acetate copolymer is contained in the liquid to be measured. After the polymer pellets were immersed and allowed to stand at 23 ° C. for 24 hours, the pellets were taken out of the liquid to be measured, and the liquid to be measured adhered to the surface of the pellet was sufficiently wiped off.
- the weight of the pellet after immersion was measured, and the impregnation actual measurement weight Yg of the liquid to be measured calculated from the difference from the weight Xg of the pellet before immersion was obtained.
- the impregnation weight (mg / EVA ⁇ 1 g) of the liquid to be measured with respect to 1 g of the ethylene-vinyl acetate copolymer was determined by the formula: ((Y ⁇ X) ⁇ 1000).
- the impregnation rate p% Asked.
- the impregnation raw material component was quantified by extracting the pellets to obtain an analytical sample, and this analytical sample was quantified by gas chromatography using an external standard method. The extraction process and measurement conditions are shown below.
- the evaluation criteria based on the impregnation yield measurement results are as follows when the impregnation component is one component. A: 95% or more B: 90% or more and less than 95% C: Less than 90%
- the criteria for evaluation based on the measurement result of the impregnation yield are as follows when the impregnation component is two or more components. A: All components are 90% or more B: All components are 75% or more and less than 90% C: All components are each less than 75%
- ⁇ residual rate s ⁇ r ⁇ 100 ⁇
- storage of the resin composition for solar cell encapsulant or the resin composition for solar cell encapsulant manufactured as a masterbatch Stability was evaluated.
- Quantification of the impregnation raw material components was performed according to the same extraction treatment and measurement conditions as described in the item of impregnation yield.
- the criteria for storage stability evaluation based on the residual ratio calculated from the above formula are as follows. A: 99% or more B: 95% or more and less than 99% C: Less than 95%
- the blocking mass is an aggregate formed by adhering a plurality of pellets, and in this test, refers to an aggregate of pellets that cannot pass through a sieve having an opening of 1 cm.
- the criteria for blocking evaluation based on the blocking rate calculated from the above formula are as follows. A: 1% or more and less than 5% B: 5% or more and less than 30% C: 30% or more
- the pellet of the resin composition for solar cell encapsulant or the resin composition for solar cell encapsulant produced as a masterbatch was evaluated by visually observing the appearance of the pellet after leaving at 30 ° C. for 1 hour. .
- the criteria for appearance evaluation are as follows. A: Almost no transfer of raw material components to the surface of the pellet is observed B: Transfer of the raw material components to the surface of the pellet is partial and observed as generation of droplets C: To the surface of the pellets of the raw material component The transition is complete and is observed on the entire outer surface to surround the pellet
- Extrusion tester (Toyo Seiki Co., Ltd.) at a processing temperature of 80 ° C. using a mixture of a resin composition for a solar cell encapsulant or a pellet of a resin composition for a solar cell encapsulant produced as a masterbatch and a diluted resin.
- a sheet of a solar cell encapsulant with a thickness of 100 ⁇ m was produced by a laboratory lab plast mill), and the number of bumps generated in 0.3 m 2 of the sheet was measured, and the number was m.
- a sheet was prepared from an ethylene-vinyl acetate copolymer, and the number of bumps generated in the sheet was measured. The number was n.
- the bumps of the solar cell encapsulant were evaluated.
- the irregularity refers to a local cross-linked site having a size of 100 ⁇ m or more in the major axis direction generated in the sheet.
- the criteria for the evaluation of irregularities based on the number of substantial irregularities calculated from the above formula are as follows. A: Less than 5 B: 5 or more and less than 20 C: 20 or more
- the overall evaluation “4” when the impregnation component is one component is when the evaluation item is “A”.
- the comprehensive evaluation “3” is a case where all evaluation items are A or B and the number of B evaluations is one.
- the comprehensive evaluation “2” is a case where all evaluation items are A or B and the number of B evaluations is two.
- the comprehensive evaluation “1” is either the case where the number of B evaluations is 3 or more or the case where even one C evaluation is included.
- the comprehensive evaluation “4” when the impregnating component is two components is a case where all the evaluation items are A.
- the comprehensive evaluation “3” is a case where all evaluation items are A or B and the number of B evaluations is 1 or 2.
- the comprehensive evaluation “2” is a case where all the evaluation items are A or B and the number of B evaluations is 3 or more.
- the comprehensive evaluation “1” is a case including at least one C evaluation.
- Example 1 3600 parts of a pellet-like ethylene-vinyl acetate copolymer (A-1) and 400 parts of a cross-linking agent (B-1) were placed in a mixer (made by Kawata Co., Ltd.) having a capacity of 20 L, and 40
- the pellet of the resin composition for solar cell sealing materials was manufactured by controlling at 50 degreeC and mixing for 30 minutes at 500 rpm.
- the impregnation yield of the crosslinking agent (B-1) was measured for this pellet.
- the storage stability evaluation, blocking evaluation, and external appearance evaluation of this pellet were performed.
- test sheet (solar cell sealing material sheet) having a processing temperature of 80 ° C. and a thickness of 100 ⁇ m was produced by an extrusion tester (manufactured by Toyo Seiki Co., Ltd.) using the pellets obtained by this impregnation method. Using this test sheet, the number of bumps was measured and the transparent quality was evaluated. From the results of the above impregnation yield measurement, storage stability evaluation, blocking evaluation, appearance evaluation, and bump evaluation, comprehensive evaluation as a resin composition for a solar cell encapsulant was performed.
- Examples 2 to 7, Comparative Examples 1 to 7 Resin for solar cell encapsulating material in the same procedure as in Example 1 except that the ethylene-vinyl acetate copolymer and the crosslinking agent shown in Table 2 were used and the impregnation processing conditions were set as shown in Table 2. A pellet of the composition was produced and used to make a test sheet. Then, it carried out similarly to Example 1, and performed comprehensive evaluation as a resin composition for a measurement, each evaluation, and a solar cell sealing material.
- Comparative Example 8 Using a twin screw extruder (Nihon Placon Co., Ltd.), 3600 parts of a pellet-like ethylene-vinyl acetate copolymer (A-1) and 400 parts of a crosslinking agent (B-2) were processed at a processing temperature of 70 ° C.
- the pellet of the resin composition for solar cell sealing materials was manufactured by extrusion kneading, and a test sheet was prepared using this. Then, it carried out similarly to Example 1, and performed comprehensive evaluation as a resin composition for a measurement, each evaluation, and a solar cell sealing material. That is, in Comparative Example 8, pellets of the resin composition for a solar cell encapsulant were produced without going through the step of impregnating the ethylene-vinyl acetate copolymer (A-1) with the crosslinking agent (B).
- Example 8 Solar cell encapsulant using 3200 parts of pellet-shaped ethylene-vinyl acetate copolymer (A-1) and 800 parts of cross-linking agent (B-1) under the same procedure and impregnation conditions as in Example 1.
- the resin sheet pellet was manufactured, and a test sheet was prepared using the pellet. Then, it carried out similarly to Example 1, and performed comprehensive evaluation as a resin composition for a measurement, each evaluation, and a solar cell sealing material.
- Table 2 shows the raw material components, impregnation processing conditions, and evaluation results of Examples 1 to 8 and Comparative Examples 1 to 8.
- Example 9 A procedure similar to that in Example 1 using 3200 parts of a pellet-like ethylene-vinyl acetate copolymer (A-1), 400 parts of a crosslinking agent (B-1), and 400 parts of a crosslinking aid (C-1).
- the pellet of the resin composition for solar cell sealing materials was manufactured on the impregnation process conditions, and the test sheet was produced using this. Then, it carried out similarly to Example 1, and performed comprehensive evaluation as a resin composition for a measurement, each evaluation, and a solar cell sealing material.
- Example 10 3000 parts of a pellet-like ethylene-vinyl acetate copolymer (A-1), 400 parts of a crosslinking agent (B-1), 200 parts of a crosslinking aid (C-1) and 200 parts of a silane coupling agent (D-1)
- A-1 pellet-like ethylene-vinyl acetate copolymer
- B-1 crosslinking agent
- C-1 crosslinking aid
- D-1 silane coupling agent
- Example 11 Except that the silane coupling agent (D-1) was changed to the silane coupling agent (D-2), pellets of the resin composition for solar cell encapsulant were prepared in the same procedure and impregnation conditions as in Example 10. The test sheet was manufactured using this. Thereafter, in the same manner as in Example 10, measurements, evaluations, and comprehensive evaluation as a resin composition for a solar cell encapsulant were performed.
- Example 12 2000 parts of the pelleted ethylene-vinyl acetate copolymer (A-1) and 1100 parts of the cross-linking agent (B-1) were put into a mixer (made by Kawata Co., Ltd.) having a capacity of 20 L, and 40
- the pellet of the resin composition for solar cell sealing materials was manufactured as a masterbatch by controlling at 50 degreeC and mixing for 60 minutes at 500 rpm.
- the pellet was subjected to impregnation yield measurement, storage stability evaluation, blocking evaluation, and appearance evaluation.
- Example 13 2000 parts of a pellet-like ethylene-vinyl acetate copolymer (A-1), 550 parts of a crosslinking agent (B-1), 275 parts of a crosslinking assistant (C-1) and 275 parts of a silane coupling agent (D-1) was used to produce pellets of a resin composition for a solar cell encapsulant as a master batch under the same procedure and impregnation conditions as in Example 12. About this pellet, it carried out similarly to Example 12, and performed impregnation yield measurement, storage stability evaluation, blocking evaluation, and external appearance evaluation.
- Example 14 2000 parts of a pelleted ethylene-vinyl acetate copolymer (A-1), 110 parts of a crosslinking agent (B-1), 55 parts of a crosslinking aid (C-1) and 55 parts of a silane coupling agent (D-1)
- A-1 pelleted ethylene-vinyl acetate copolymer
- B-1 crosslinking agent
- C-1 crosslinking aid
- D-1 silane coupling agent
- Example 15 Except that the crosslinking aid (C-1) was changed to the crosslinking aid (C-2), a resin composition pellet for a solar cell encapsulant was produced in the same procedure and impregnation conditions as in Example 9. Using this, a test sheet was prepared. Thereafter, in the same manner as in Example 9, measurements, evaluations, and overall evaluation as a resin composition for a solar cell encapsulant were performed.
- Example 16 Except that the crosslinking aid (C-1) was changed to the crosslinking aid (C-3), the pellets of the resin composition for solar cell encapsulant were produced in the same procedure and impregnation conditions as in Example 9. Using this, a test sheet was prepared. Thereafter, in the same manner as in Example 9, measurements, evaluations, and overall evaluation as a resin composition for a solar cell encapsulant were performed.
- Example 17 Except for changing the silane coupling agent (D-1) to the silane coupling agent (D-3), the pellets of the resin composition for solar cell encapsulant were prepared in the same procedure and impregnation conditions as in Example 10. The test sheet was manufactured using this. Thereafter, in the same manner as in Example 10, measurements, evaluations, and comprehensive evaluation as a resin composition for a solar cell encapsulant were performed.
- Example 9 Comparative Example 9 Except that the crosslinking agent (B-1) was changed to the crosslinking agent (B-5), a resin composition pellet for a solar cell encapsulant was produced in the same procedure and impregnation conditions as in Example 10. A test sheet was prepared using. Thereafter, in the same manner as in Example 10, measurements, evaluations, and comprehensive evaluation as a resin composition for a solar cell encapsulant were performed.
- the resin composition for solar cell encapsulant having blocking resistance and excellent appearance by the method for producing a resin composition for solar cell encapsulant of the present invention can be obtained in a short time.
- the solar cell sealing material which can reduce droop significantly and also becomes transparent was able to be obtained.
- the method for producing a resin composition for a solar cell encapsulant of the present invention comprises a raw material component comprising an ethylene-vinyl acetate copolymer (A) having a vinyl acetate unit at 25 to 35% by weight, and an ethylene-vinyl acetate copolymer.
- the produced resin composition for a solar cell encapsulant has good storage stability, and when producing a solar cell encapsulant, the cost can be reduced by shortening the processing time. . Moreover, in the obtained solar cell encapsulant, the occurrence of bumps is greatly reduced and the transparency thereof is good, and the solar cell module provided with such a solar cell encapsulant has improved performance and reliability. To do. Therefore, the present invention has industrial applicability.
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Abstract
Description
一方、特許文献2に記載の方法では、前述のように、混合物を一昼夜放置するため、太陽電池封止材用樹脂組成物の製造に時間がかかり、生産性が悪く、コスト面で不利であるという問題がある。
15~80℃の温度下で、前記架橋剤(B)を前記エチレン-酢酸ビニル共重合体(A)へ含浸させる工程とを含むことを特徴とする太陽電池封止材用樹脂組成物の製造方法に関する。
前記架橋剤(B)の含浸工程において、前記架橋剤(B)とともに、前記架橋助剤(C)を前記エチレン-酢酸ビニル共重合体(A)に含浸させることを特徴とする上記発明の太陽電池封止材用樹脂組成物の製造方法に関する。
前記架橋剤(B)の含浸工程において、前記架橋剤(B)とともに、前記シランカップリング剤(D)を前記エチレン-酢酸ビニル共重合体(A)に含浸させることを特徴とする上記発明の太陽電池封止材用樹脂組成物の製造方法に関する。
15~80℃の温度下で、前記架橋剤(B)を前記エチレン-酢酸ビニル共重合体(A)へ含浸させて、太陽電池封止材用マスターバッチを得る工程と、
得られた太陽電池封止材用マスターバッチとエチレン-酢酸ビニル共重合体とを、加熱混合して、混合物を得る工程と、
得られた混合物を、成形機を用いて成形して、太陽電池封止材を得る工程とを含むことを特徴とする太陽電池封止材の製造方法。
また、以下の説明では、エチレン-酢酸ビニル共重合体(A)のペレットを「原料ペレット」と記載し、得られた太陽電池封止材用樹脂組成物のペレットを、単に「ペレット」と記載することもある。
含浸重量(mg/EVA・1g)=(Y/X)×1000
(A-1)酢酸ビニル重量%:26%、MFR:25g/10min
(A-2)酢酸ビニル重量%:33%、MFR:34g/10min
(A-3)酢酸ビニル重量%:23%、MFR:18g/10min
(A-4)酢酸ビニル重量%:37%、MFR:42g/10min
(B-1)2,5-ジメチル-2,5-ジ(tert-ブチルパーオキシ)ヘキサン
(B-2)1,1-ジ(tert-ブチルパーオキシ)-3,3,5-トリメチルシクロヘキサン
(B-3)tert-ブチルパーオキシ-2-エチルヘキシルカーボネート
(B-4)2,5-ジメチル-2,5-ジ(tert-ブチルパーオキシ)ヘキサン
(B-5)2,5-ジメチル-2,5-ジ(ベンゾイルパーオキシ)ヘキサン
(B-6)1,1-(tert-ブチルパーオキシ)-2-メチルシクロヘキサン
(B-7)tert-ブチルパーオキシベンゾエート
(C-1)トリアリルイソシアヌレート
(C-2)エチレングリコールジアクリレート
(C-3)ジアリルフマレート
(D-1)γ-メタクリロキシプロピルトリメトキシシラン
(D-2)γ-メタクリロキシプロピルメチルジメトキシシラン
(D-3)γ-アミノプロピルトリエトキシシラン
(D-4)3-グリシドキシプロピルトリメトキシシラン
酢酸ビニル単位を30%で有するエチレン-酢酸ビニル共重合体のペレットに対して、十分な量の測定対象液体を密閉容器内に用意し、この測定対象液体中に、Xgのエチレン-酢酸ビニル共重合体のペレットを浸漬させ、23℃で24時間放置した後、このペレットを測定対象液体から取り出して、ペレットの表面に付着した測定対象液体を十分に拭き取った。その後、浸漬後のペレットの重量を測定して、浸漬前のペレットの重量Xgとの差から計算される測定対象液体の含浸実測重量Ygを得た。そして、式:((Y÷X)×1000)により、エチレン-酢酸ビニル共重合体1gに対する測定対象液体の含浸重量(mg/EVA・1g)を求めた。
測定対象液体の表面表力を、協和界面科学株式会社製の自動表面張力計「CBVP-Z」を使用して23℃で測定した。
架橋剤(B-1)~(B-7)、架橋助剤(C-1)~(C-3)、およびシランカップリング剤(D-1)~(D-4)を測定対象の原料成分として、それぞれ、その含浸収率を測定した。
なお、含浸原料成分の定量は、ペレットを抽出処理することにより分析サンプルを得、この分析サンプルをガスクロマトグラフィーにより外部標準法を用いて定量した。なお、抽出処理および測定条件を、以下に示す。
(1)ペレットを液体窒素で凍結乾燥し、32メッシュの篩にかけ、パスしたものを採取した。
(2)これを容量5mLのメスフラスコに約0.5g秤量し、アセトンでメスアップした後、常温で一昼夜抽出して抽出液を得た。この抽出液を分析サンプルとした。
機器:株式会社島津製作所製 GC-9AM
カラム:Rtx-1701 内径0.25mm 長さ60m
カラム温度:210℃
試料気化室温度:120℃
検出器部温度:250℃
サンプル量:1μL
移動相:窒素、45mL/分
検出器:FID
A:95%以上
B:90%以上95%未満
C:90%未満
A:全成分それぞれが90%以上
B:全成分それぞれが75%以上90%未満
C:全成分それぞれが75%未満
前記測定対象の原料成分の含浸率をr%に調整した太陽電池封止材用樹脂組成物またはマスターバッチとして製造された太陽電池封止材用樹脂組成物のペレットを、35℃で1000時間放置した後、含浸された原料成分(含浸原料成分)の定量を行うことにより、放置後のペレットにおける含浸原料成分の含浸率s%を測定した。
A:99%以上
B:95%以上99%未満
C:95%未満
重量agの太陽電池封止材用樹脂組成物またはマスターバッチとして製造された太陽電池封止材用樹脂組成物のペレットを、30℃で1時間放置した後、発生したブロッキング塊の重量bgを測定した。
A:1%以上5%未満
B:5%以上30%未満
C:30%以上
太陽電池封止材用樹脂組成物またはマスターバッチとして製造された太陽電池封止材用樹脂組成物のペレットを、30℃で1時間放置した後、ペレットの外観状態を目視観察することにより評価した。
外観評価の基準は、下記の通りである。
A:原料成分のペレットの表面への移行がほとんど見られない
B:原料成分のペレットの表面への移行は部分的であり、液滴の発生として観察される
C:原料成分のペレットの表面への移行は全面的であり、ペレットを取り囲むように外面全てで観察される
太陽電池封止材用樹脂組成物またはマスターバッチとして製造された太陽電池封止材用樹脂組成物のペレットと希釈樹脂との混合物を用いて、加工温度80℃で押出試験機(東洋精機株式会社製ラボプラストミル)により、厚み100μmの太陽電池封止材のシートを作製し、このシート0.3m2中に発生したブツ個数を計測し、その個数をm個とした。また、これと同様にして、エチレン-酢酸ビニル共重合体でシートを作製して、このシート中に発生したブツ個数を計測し、その個数をn個とした。
上記式より計算される実質ブツ個数に基づく、ブツ評価の基準は、下記の通りである。
A:5個未満
B:5個以上20個未満
C:20個以上
含浸収率測定による評価、貯蔵安定性評価、ブロッキング評価、外観評価、ブツ評価の結果から、下記の評価基準に従って、太陽電池用封止材として、最も好ましいものを「4」、好ましいものを「3」、使用できるものを「2」、不適当なものを「1」として、総合評価の結果を表2および表3に示した。
含浸成分が2成分である場合の総合評価「4」とは、全評価項目がAの場合である。総合評価「3」とは、全評価項目がAまたはBであり、B評価の数が1または2個の場合である。総合評価「2」とは、全評価項目がAまたはBの場合でありB評価の数が3個以上の場合である。総合評価「1」とは、C評価を1つでも含む場合である。
ペレット状のエチレン-酢酸ビニル共重合体(A-1)3600部と架橋剤(B-1)400部とを、容量20Lの加温装置付きのミキサー(株式会社カワタ社製)に入れ、40℃に制御し、30分間、500rpmで混合を行うことにより、太陽電池封止材用樹脂組成物のペレットを製造した。このペレットについて、架橋剤(B-1)の含浸収率の測定を行った。また、このペレットの貯蔵安定性評価、ブロッキング評価、および外観評価を行った。
以上の、含浸収率測定、貯蔵安定性評価、ブロッキング評価、外観評価、ブツ評価の結果から、太陽電池封止材用樹脂組成物としての総合評価を行った。
エチレン-酢酸ビニル共重合体および架橋剤として表2に示すものを用い、含浸加工条件を表2に示すように設定した以外は、実施例1と同様の手順で、太陽電池封止材用樹脂組成物のペレットを製造し、これを用いて試験シートを作製した。その後、実施例1と同様にして、測定、各評価および太陽電池封止材用樹脂組成物としての総合評価を行った。
ペレット状のエチレン-酢酸ビニル共重合体(A-1)3600部と架橋剤(B-2)400部とを、二軸押出機(日本プラコン株式会社製)を用いて、70℃の加工温度で押出し混練加工することにより、太陽電池封止材用樹脂組成物のペレットを製造し、これを用いて試験シートを作製した。その後、実施例1と同様にして、測定、各評価および太陽電池封止材用樹脂組成物としての総合評価を行った。すなわち、比較例8では、架橋剤(B)をエチレン-酢酸ビニル共重合体(A-1)に含浸させる工程を経ずに、太陽電池封止材用樹脂組成物のペレットを製造した。
ペレット状のエチレン-酢酸ビニル共重合体(A-1)3200部と架橋剤(B-1)800部とを用いて、実施例1と同様の手順、含浸加工条件で、太陽電池封止材用樹脂組成物のペレットを製造し、これを用いて試験シートを作製した。その後、実施例1と同様にして、測定、各評価および太陽電池封止材用樹脂組成物としての総合評価を行った。
ペレット状のエチレン-酢酸ビニル共重合体(A-1)3200部と架橋剤(B-1)400部と架橋助剤(C-1)400部とを用いて、実施例1と同様の手順、含浸加工条件で、太陽電池封止材用樹脂組成物のペレットを製造し、これを用いて試験シートを作製した。その後、実施例1と同様にして、測定、各評価および太陽電池封止材用樹脂組成物としての総合評価を行った。
ペレット状のエチレン-酢酸ビニル共重合体(A-1)3000部と架橋剤(B-1)400部と架橋助剤(C-1)200部とシランカップリング剤(D-1)200部とを用いて、実施例9と同様の手順、含浸加工条件で、太陽電池封止材用樹脂組成物のペレットを製造し、これを用いて試験シートを作製した。その後、実施例9と同様にして、測定、各評価および太陽電池封止材用樹脂組成物としての総合評価を行った。
シランカップリング剤(D-1)をシランカップリング剤(D-2)に変更した以外は、実施例10と同様の手順、含浸加工条件で、太陽電池封止材用樹脂組成物のペレットを製造し、これを用いて試験シートを作製した。その後、実施例10と同様にして、測定、各評価および太陽電池封止材用樹脂組成物としての総合評価を行った。
ペレット状のエチレン-酢酸ビニル共重合体(A-1)2000部と架橋剤(B-1)1100部とを、容量20Lの加温装置付きのミキサー(株式会社カワタ社製)に入れ、40℃に制御し、60分間、500rpmで混合を行うことにより、マスターバッチとして太陽電池封止材用樹脂組成物のペレットを製造した。このペレットについて、含浸収率測定、貯蔵安定性評価、ブロッキング評価、外観評価を行った。
ペレット状のエチレン-酢酸ビニル共重合体(A-1)2000部と架橋剤(B-1)550部と架橋助剤(C-1)275部とシランカップリング剤(D-1)275部とを用いて、実施例12と同様の手順、含浸加工条件で、マスターバッチとして太陽電池封止材用樹脂組成物のペレットを製造した。このペレットについて、実施例12と同様にして、含浸収率測定、貯蔵安定性評価、ブロッキング評価、外観評価を行った。
ペレット状のエチレン-酢酸ビニル共重合体(A-1)2000部と架橋剤(B-1)110部と架橋助剤(C-1)55部とシランカップリング剤(D-1)55部とを用いて、実施例13と同様の手順、含浸加工条件で、マスターバッチとして太陽電池封止材用樹脂組成物のペレットを製造した。このペレットについて、実施例13と同様にして、含浸収率測定、ブロッキング評価、貯蔵安定性評価、外観評価を行った。
架橋助剤(C-1)を架橋助剤(C-2)に変更した以外は、実施例9と同様の手順、含浸加工条件で、太陽電池封止材用樹脂組成物のペレットを製造し、これを用いて試験シートを作製した。その後、実施例9と同様にして、測定、各評価および太陽電池封止材用樹脂組成物としての総合評価を行った。
架橋助剤(C-1)を架橋助剤(C-3)に変更した以外は、実施例9と同様の手順、含浸加工条件で、太陽電池封止材用樹脂組成物のペレットを製造し、これを用いて試験シートを作製した。その後、実施例9と同様にして、測定、各評価および太陽電池封止材用樹脂組成物としての総合評価を行った。
シランカップリング剤(D-1)をシランカップリング剤(D-3)に変更した以外は、実施例10と同様の手順、含浸加工条件で、太陽電池封止材用樹脂組成物のペレットを製造し、これを用いて試験シートを作製した。その後、実施例10と同様にして、測定、各評価および太陽電池封止材用樹脂組成物としての総合評価を行った。
架橋剤(B-1)を架橋剤(B-5)に変更した以外は、実施例10と同様の手順、含浸加工条件で、太陽電池封止材用樹脂組成物のペレットを製造し、これを用いて試験シートを作製した。その後、実施例10と同様にして、測定、各評価および太陽電池封止材用樹脂組成物としての総合評価を行った。
ペレット状のエチレン-酢酸ビニル共重合体(A-1)3200部と架橋剤(B-1)400部と架橋助剤(C-1)400部とを、二軸押出機(日本プラコン株式会社製)を用いて、70℃の加工温度で押出し混練加工することにより、太陽電池封止材用樹脂組成物のペレットを製造し、これを用いて試験シートを作製した。その後、実施例9と同様にして、測定、各評価および太陽電池封止材用樹脂組成物としての総合評価を行った。すなわち、比較例13では、各原料成分をエチレン-酢酸ビニル共重合体(A-1)に含浸させる工程を経ずに、太陽電池封止材用樹脂組成物のペレットを製造した。
ペレット状のエチレン-酢酸ビニル共重合体(A-1)3000部と架橋剤(B-1)400部と架橋助剤(C-1)400部とシランカップリング剤(D-1)200部とを、二軸押出機(日本プラコン株式会社製)を用いて、70℃の加工温度で押出し混練加工することにより、太陽電池封止材用樹脂組成物のペレットを製造し、これを用いて試験シートを作製した。その後、実施例9と同様にして、測定、各評価および太陽電池封止材用樹脂組成物としての総合評価を行った。すなわち、比較例14では、各原料成分をエチレン-酢酸ビニル共重合体(A-1)に含浸させる工程を経ずに、太陽電池封止材用樹脂組成物のペレットを製造した。
Claims (8)
- 原料成分として、酢酸ビニル単位を25~35重量%で有するエチレン-酢酸ビニル共重合体(A)と、エチレン-酢酸ビニル共重合体(A)1gに対する温度23℃で24時間当たりの含浸重量が40~80mgである架橋剤(B)とを用意する工程と、
15~80℃の温度下で、前記架橋剤(B)を前記エチレン-酢酸ビニル共重合体(A)へ含浸させる工程とを含むことを特徴とする太陽電池封止材用樹脂組成物の製造方法。 - 前記架橋剤(B)の表面張力が、23~28mN/mであることを特徴とする請求項1記載の太陽電池封止材用樹脂組成物の製造方法。
- 前記原料成分を用意する工程において、前記原料成分として、さらに、前記エチレン-酢酸ビニル共重合体(A)1gに対する温度23℃で24時間当たりの含浸重量が80~120mgであり、かつ表面張力が33~38mN/mである架橋助剤(C)を用意し、
前記架橋剤(B)の含浸工程において、前記架橋剤(B)とともに、前記架橋助剤(C)を前記エチレン-酢酸ビニル共重合体(A)に含浸させることを特徴とする請求項1または2記載の太陽電池封止材用樹脂組成物の製造方法。 - 前記原料成分を用意する工程において、前記原料成分として、さらに、前記エチレン-酢酸ビニル共重合体(A)1gに対する温度23℃で24時間当たりの含浸重量が80~150mgであり、かつ表面張力が27~32mN/mであるシランカップリング剤(D)を用意し、
前記架橋剤(B)の含浸工程において、前記架橋剤(B)とともに、前記シランカップリング剤(D)を前記エチレン-酢酸ビニル共重合体(A)に含浸させることを特徴とする請求項1~3いずれか記載の太陽電池封止材用樹脂組成物の製造方法。 - 請求項1~4いずれか記載の太陽電池封止材用樹脂組成物の製造方法により得られたことを特徴とする太陽電池封止材用樹脂組成物。
- エチレン-酢酸ビニル共重合体と、請求項5記載の太陽電池封止材用樹脂組成物とを用いて成形されてなることを特徴とする太陽電池封止材。
- 原料成分として、酢酸ビニル単位を25~35重量%で有するエチレン-酢酸ビニル共重合体(A)と、エチレン-酢酸ビニル共重合体(A)1gに対する温度23℃で24時間当たりの含浸重量が40~80mgである架橋剤(B)とを用意する工程と、
15~80℃の温度下で、前記架橋剤(B)を前記エチレン-酢酸ビニル共重合体(A)へ含浸させて、太陽電池封止材用マスターバッチを得る工程と、
得られた太陽電池封止材用マスターバッチとエチレン-酢酸ビニル共重合体とを、加熱混合して、混合物を得る工程と、
得られた混合物を、成形機を用いて成形して、太陽電池封止材を得る工程とを含むことを特徴とする太陽電池封止材の製造方法。 - 請求項6記載の太陽電池封止材、または請求項7記載の太陽電池封止材の製造方法により得られた太陽電池封止材を用いて太陽電池素子を封止してなることを特徴とする太陽電池モジュール。
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KR1020117019041A KR101304834B1 (ko) | 2009-08-07 | 2010-08-06 | 태양전지 봉지재용 수지 조성물의 제조방법, 태양전지 봉지재용 수지 조성물, 태양전지 봉지재, 및 태양전지 모듈 |
AU2010279959A AU2010279959B8 (en) | 2009-08-07 | 2010-08-06 | Method for producing resin composition for solar cell sealing material, resin composition for solar cell sealing material, solar cell sealing material, and solar cell module |
EP10806556.6A EP2463919A4 (en) | 2009-08-07 | 2010-08-06 | METHOD FOR MANUFACTURING RESIN COMPOSITION FOR SOLAR CELL SEALING MATERIAL, RESIN COMPOSITION FOR SOLAR CELL SEALING MATERIAL, SOLAR CELL SEALING MATERIAL, AND SOLAR CELL MODULE |
JP2010549960A JP4793512B2 (ja) | 2009-08-07 | 2010-08-06 | 太陽電池封止材用樹脂組成物の製造方法、太陽電池封止材用樹脂組成物、太陽電池封止材、および太陽電池モジュール |
SG2011073277A SG175119A1 (en) | 2009-08-07 | 2010-08-06 | Method for producing resin composition for solar cell sealing material, resin composition for solar cell sealing material, solar cell sealing material, and solar cell module |
BRPI1015076A BRPI1015076A2 (pt) | 2009-08-07 | 2010-08-06 | método para produção de composição de resina para material de vedação de célula solar, composição de resina para material de vedação de célula solar, material de vedação solar e módulo de célula solar |
CA2760390A CA2760390A1 (en) | 2009-08-07 | 2010-08-06 | Method for producing resin composition for solar cell sealing material, resin composition for solar cell sealing material, solar cell sealing material, and solar cell module |
US13/259,548 US20120024376A1 (en) | 2009-08-07 | 2010-08-06 | Method for producing resin composition for solar cell sealing material, resin composition for solar cell sealing material, solar cell sealing material, and solar cell module |
CN201080008063.1A CN102318082B (zh) | 2009-08-07 | 2010-08-06 | 太阳能电池封装材料用树脂组合物的制造方法、太阳能电池封装材料用树脂组合物、太阳能电池封装材料以及太阳能电池模块 |
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CN102318082A (zh) | 2012-01-11 |
EP2463919A4 (en) | 2013-04-24 |
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SG175119A1 (en) | 2011-11-28 |
AU2010279959B8 (en) | 2013-09-26 |
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