WO2011040281A1 - 封止材シート - Google Patents
封止材シート Download PDFInfo
- Publication number
- WO2011040281A1 WO2011040281A1 PCT/JP2010/066300 JP2010066300W WO2011040281A1 WO 2011040281 A1 WO2011040281 A1 WO 2011040281A1 JP 2010066300 W JP2010066300 W JP 2010066300W WO 2011040281 A1 WO2011040281 A1 WO 2011040281A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- sealing material
- material sheet
- sheet
- solar cell
- embossing
- Prior art date
Links
- 239000003566 sealing material Substances 0.000 title claims abstract description 78
- 238000004049 embossing Methods 0.000 claims abstract description 19
- 230000001681 protective effect Effects 0.000 claims abstract description 8
- 238000006243 chemical reaction Methods 0.000 claims abstract description 4
- 239000008393 encapsulating agent Substances 0.000 claims description 31
- 238000005259 measurement Methods 0.000 claims description 20
- 238000003860 storage Methods 0.000 claims description 7
- 238000000034 method Methods 0.000 abstract description 23
- 238000004519 manufacturing process Methods 0.000 abstract description 15
- 238000010438 heat treatment Methods 0.000 abstract description 9
- 239000000470 constituent Substances 0.000 abstract description 4
- 230000006835 compression Effects 0.000 abstract 1
- 238000007906 compression Methods 0.000 abstract 1
- 229920005989 resin Polymers 0.000 description 33
- 239000011347 resin Substances 0.000 description 33
- 229920001200 poly(ethylene-vinyl acetate) Polymers 0.000 description 20
- 239000005038 ethylene vinyl acetate Substances 0.000 description 19
- 239000000463 material Substances 0.000 description 11
- 239000000654 additive Substances 0.000 description 6
- 238000007872 degassing Methods 0.000 description 6
- 230000000996 additive effect Effects 0.000 description 5
- 230000000052 comparative effect Effects 0.000 description 4
- 239000003431 cross linking reagent Substances 0.000 description 4
- -1 polyethylene Polymers 0.000 description 4
- 238000009849 vacuum degassing Methods 0.000 description 4
- 239000006087 Silane Coupling Agent Substances 0.000 description 3
- 238000012790 confirmation Methods 0.000 description 3
- 230000000694 effects Effects 0.000 description 3
- 238000007789 sealing Methods 0.000 description 3
- 230000000007 visual effect Effects 0.000 description 3
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 description 2
- 239000003963 antioxidant agent Substances 0.000 description 2
- 238000004364 calculation method Methods 0.000 description 2
- 239000003795 chemical substances by application Substances 0.000 description 2
- 238000004132 cross linking Methods 0.000 description 2
- QUAMTGJKVDWJEQ-UHFFFAOYSA-N octabenzone Chemical compound OC1=CC(OCCCCCCCC)=CC=C1C(=O)C1=CC=CC=C1 QUAMTGJKVDWJEQ-UHFFFAOYSA-N 0.000 description 2
- 238000003825 pressing Methods 0.000 description 2
- DOEHJNBEOVLHGL-UHFFFAOYSA-N trichloro(propyl)silane Chemical compound CCC[Si](Cl)(Cl)Cl DOEHJNBEOVLHGL-UHFFFAOYSA-N 0.000 description 2
- 239000006097 ultraviolet radiation absorber Substances 0.000 description 2
- HCXVPNKIBYLBIT-UHFFFAOYSA-N (2-methylpropan-2-yl)oxy 3,5,5-trimethylhexaneperoxoate Chemical compound CC(C)(C)CC(C)CC(=O)OOOC(C)(C)C HCXVPNKIBYLBIT-UHFFFAOYSA-N 0.000 description 1
- VBQCFYPTKHCPGI-UHFFFAOYSA-N 1,1-bis(2-methylpentan-2-ylperoxy)cyclohexane Chemical compound CCCC(C)(C)OOC1(OOC(C)(C)CCC)CCCCC1 VBQCFYPTKHCPGI-UHFFFAOYSA-N 0.000 description 1
- HSLFISVKRDQEBY-UHFFFAOYSA-N 1,1-bis(tert-butylperoxy)cyclohexane Chemical compound CC(C)(C)OOC1(OOC(C)(C)C)CCCCC1 HSLFISVKRDQEBY-UHFFFAOYSA-N 0.000 description 1
- 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 1
- 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 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
- ZXDDPOHVAMWLBH-UHFFFAOYSA-N 2,4-Dihydroxybenzophenone Chemical compound OC1=CC(O)=CC=C1C(=O)C1=CC=CC=C1 ZXDDPOHVAMWLBH-UHFFFAOYSA-N 0.000 description 1
- 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 1
- LEVFXWNQQSSNAC-UHFFFAOYSA-N 2-(4,6-diphenyl-1,3,5-triazin-2-yl)-5-hexoxyphenol Chemical compound OC1=CC(OCCCCCC)=CC=C1C1=NC(C=2C=CC=CC=2)=NC(C=2C=CC=CC=2)=N1 LEVFXWNQQSSNAC-UHFFFAOYSA-N 0.000 description 1
- BIISIZOQPWZPPS-UHFFFAOYSA-N 2-tert-butylperoxypropan-2-ylbenzene Chemical compound CC(C)(C)OOC(C)(C)C1=CC=CC=C1 BIISIZOQPWZPPS-UHFFFAOYSA-N 0.000 description 1
- WPMYUUITDBHVQZ-UHFFFAOYSA-M 3-(3,5-ditert-butyl-4-hydroxyphenyl)propanoate Chemical compound CC(C)(C)C1=CC(CCC([O-])=O)=CC(C(C)(C)C)=C1O WPMYUUITDBHVQZ-UHFFFAOYSA-M 0.000 description 1
- 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 1
- ZVVFVKJZNVSANF-UHFFFAOYSA-N 6-[3-(3,5-ditert-butyl-4-hydroxyphenyl)propanoyloxy]hexyl 3-(3,5-ditert-butyl-4-hydroxyphenyl)propanoate Chemical compound CC(C)(C)C1=C(O)C(C(C)(C)C)=CC(CCC(=O)OCCCCCCOC(=O)CCC=2C=C(C(O)=C(C=2)C(C)(C)C)C(C)(C)C)=C1 ZVVFVKJZNVSANF-UHFFFAOYSA-N 0.000 description 1
- 239000004641 Diallyl-phthalate Substances 0.000 description 1
- JKIJEFPNVSHHEI-UHFFFAOYSA-N Phenol, 2,4-bis(1,1-dimethylethyl)-, phosphite (3:1) Chemical compound CC(C)(C)C1=CC(C(C)(C)C)=CC=C1OP(OC=1C(=CC(=CC=1)C(C)(C)C)C(C)(C)C)OC1=CC=C(C(C)(C)C)C=C1C(C)(C)C JKIJEFPNVSHHEI-UHFFFAOYSA-N 0.000 description 1
- 239000004698 Polyethylene Substances 0.000 description 1
- 239000004743 Polypropylene Substances 0.000 description 1
- 239000006096 absorbing agent Substances 0.000 description 1
- 230000003712 anti-aging effect Effects 0.000 description 1
- 230000003078 antioxidant effect Effects 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
- BXIQXYOPGBXIEM-UHFFFAOYSA-N butyl 4,4-bis(tert-butylperoxy)pentanoate Chemical compound CCCCOC(=O)CCC(C)(OOC(C)(C)C)OOC(C)(C)C BXIQXYOPGBXIEM-UHFFFAOYSA-N 0.000 description 1
- 238000001816 cooling Methods 0.000 description 1
- 229920001577 copolymer Polymers 0.000 description 1
- 238000005336 cracking Methods 0.000 description 1
- 238000002788 crimping Methods 0.000 description 1
- 238000005520 cutting process Methods 0.000 description 1
- 238000004649 discoloration prevention Methods 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
- 238000005516 engineering process Methods 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
- NKSJNEHGWDZZQF-UHFFFAOYSA-N ethenyl(trimethoxy)silane Chemical compound CO[Si](OC)(OC)C=C NKSJNEHGWDZZQF-UHFFFAOYSA-N 0.000 description 1
- YSDRNYACIITAFJ-UHFFFAOYSA-N ethoxy(phenyl)silane Chemical compound CCO[SiH2]C1=CC=CC=C1 YSDRNYACIITAFJ-UHFFFAOYSA-N 0.000 description 1
- 230000005484 gravity Effects 0.000 description 1
- 229920000554 ionomer Polymers 0.000 description 1
- 238000010030 laminating Methods 0.000 description 1
- 239000007788 liquid Substances 0.000 description 1
- 238000002844 melting Methods 0.000 description 1
- 230000008018 melting Effects 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- 238000002156 mixing Methods 0.000 description 1
- 239000000203 mixture Substances 0.000 description 1
- 229910052757 nitrogen Inorganic materials 0.000 description 1
- 230000003287 optical effect Effects 0.000 description 1
- 229920000573 polyethylene Polymers 0.000 description 1
- 229920000098 polyolefin Polymers 0.000 description 1
- 229920001155 polypropylene Polymers 0.000 description 1
- 229920000915 polyvinyl chloride Polymers 0.000 description 1
- 229920002620 polyvinyl fluoride Polymers 0.000 description 1
- 238000010248 power generation Methods 0.000 description 1
- 230000001737 promoting effect Effects 0.000 description 1
- 239000011342 resin composition Substances 0.000 description 1
- 239000003381 stabilizer Substances 0.000 description 1
- 239000005341 toughened glass Substances 0.000 description 1
- HQYALQRYBUJWDH-UHFFFAOYSA-N trimethoxy(propyl)silane Chemical compound CCC[Si](OC)(OC)OC HQYALQRYBUJWDH-UHFFFAOYSA-N 0.000 description 1
- TUQLLQQWSNWKCF-UHFFFAOYSA-N trimethoxymethylsilane Chemical compound COC([SiH3])(OC)OC TUQLLQQWSNWKCF-UHFFFAOYSA-N 0.000 description 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 1
- 238000005303 weighing Methods 0.000 description 1
Images
Classifications
-
- 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
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- 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
- 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
- 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
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- 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
- B32B17/10009—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 number, the constitution or treatment of glass sheets
- B32B17/10018—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 number, the constitution or treatment of glass sheets comprising only one glass sheet
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- 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
- 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
- B32B17/10559—Shape of the cross-section
- B32B17/10577—Surface roughness
- B32B17/10587—Surface roughness created by embossing
-
- 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
-
- 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 sealing material sheet used in a solar cell module manufacturing process.
- solar battery cells have been attracting attention as a clean power generation technology that uses sunlight.
- solar battery cells 3 are arranged in a sealing material layer 2, and the outside thereof is protected by a surface protection member 1 and a back surface protection member 4.
- the surface protection member 1, the sealing material sheet 22, the solar battery cell 3, the sealing material sheet 24, and the back surface protection member 4 are laminated in this order.
- the resulting product is heated and degassed in a vacuum, and then heated in a vacuum while applying a load of 1 atm to crosslink and cure the sealing material resin to bond and integrate.
- EVA ethylene vinyl acetate copolymer
- the EVA resin is provided with a crosslinking agent, a crosslinking aid, a silane coupling agent, a stabilizer, an ultraviolet absorber, an anti-aging agent, and a discoloration prevention.
- an additive such as an agent is contained in a certain ratio.
- this encapsulant sheet As a method for producing this encapsulant sheet, a “T-die method in which a molten resin is extruded from a die having linear slits and rapidly cooled and solidified in a cooling roll or a water tank” or “calendar method” is employed. By these film forming steps, a sealing material sheet having a thickness of about 500 ⁇ m is formed. Moreover, the embossing which makes an unevenness
- the invention according to claim 1 is formed by thermocompression-bonding a laminated body in which the first protective member, the first sealing material sheet, the photoelectric conversion cell, the second sealing material sheet, and the second protective member are laminated in this order.
- the first encapsulant sheet used as a member of the solar cell module the first encapsulant sheet is provided with an uneven pattern by embossing on one side or both sides of the first encapsulant sheet and the second encapsulant sheet.
- the percentage V H / V A ⁇ 100% of the total volume V H of the recesses per unit area of the material sheet and the second sealing material sheet and the apparent volume VA of the sheet obtained by multiplying the unit area by the maximum thickness is 1
- the sealing material sheet having a thickness of 1 mm is sandwiched between two Al plates having a diameter of 25 mm, and the temperature is increased from 5% strain, frequency 1 Hz, measurement start temperature 40 ° C. to measurement end temperature 150 ° C. 2.
- a minimum value of a storage elastic modulus is 10 4 Pa or less when dynamic viscoelasticity measurement of the sealing material sheet is performed every 1 ° C. in temperature during the process. It is a material sheet.
- the amount of air trapped inside the laminated body at the stage where the constituent members of the solar cell module are laminated by using an embossed sealing material sheet having a porosity of 1 to 4%.
- the time required for heat degassing in a vacuum in the solar cell module manufacturing process can be reduced.
- the cushioning property in the heating and pressurizing process at the time of manufacturing the solar cell module is lower than that of the encapsulant sheet having a porosity of 5 to 80%.
- a resin having a low elastic modulus as the resin that is the main material of the encapsulant sheet, it is possible to compensate for the decrease in cushioning properties and to prevent solar cell cracking in the heating and pressing step.
- liquidity of the resin in the heating deaeration process in the said vacuum increases, there also exists an effect that deaeration efficiency improves.
- FIG. 3 is an exploded cross-sectional view of a solar cell module using the sealing material sheet of the present invention.
- the solar cell module is a laminate in which the first protective member 5, the first sealing material sheet 6, the solar battery cell 7, the second sealing material sheet 8, and the second protective member 9 are laminated in this order. It is thermocompression bonded. On one side or both sides of the first sealing material sheet 6 and the second sealing material sheet 7, an uneven pattern by embossing is applied. Then, the percentage V H of the total volume V H of the recesses per unit area of the first sealing material sheet 6 and the second sealing material sheet 7 and the apparent volume VA of the sheet obtained by multiplying the unit area by the maximum thickness. / V A ⁇ 100% is embossed so as to be 1 to 4%.
- the 1st protection member 5 forms the surface protection member
- the 2nd protection member 9 forms the back surface protection member.
- Main materials of the first sealing material sheet 6 and the second sealing material sheet 8 include polyolefins such as polyethylene and polypropylene; ionomers; ethylene-vinyl acetate copolymers; polyvinyl fluorides; polyvinyl chlorides, or these Copolymers can be used.
- a highly transparent resin can be used, and an ethylene-vinyl acetate copolymer or the like can be preferably used.
- a cross-linking agent may be added to the first sealing material sheet 6 and the second sealing material sheet 8 for the purpose of increasing the strength within a range that does not impair the transparency.
- the crosslinking agent include 1,1-di (t-butylperoxy) cyclohexane, 1,1-di (t-hexylperoxy) cyclohexane, n-butyl 4,4-di- (t-butylperoxy) valerate.
- an additive for promoting the crosslinking reaction may be added to the first sealing material sheet 6 and the second sealing material sheet 8 in addition to the crosslinking agent.
- the additive include triallyl isocyanurate, diallyl phthalate, triallyl cyanurate and the like.
- a silane coupling agent an ultraviolet absorber, and an antioxidant may be added.
- silane coupling agents used for improving adhesion include ⁇ -methacryloxypropyltrimethoxysilane, trimethoxypropylsilane, trimethoxymethylsilane, vinyltrimethoxysilane, vinyltriethoxysilane, trichloropropylsilane, trichloropropylsilane, And ethoxyphenylsilane.
- ultraviolet absorbers used for improving light resistance examples include 2- (5-methyl-2-hydroxyphenyl) benzotriazole and 2- (3-t-butyl-5-methyl-2-hydroxyphenyl) -5. -Chlorobenzotriazole, 2- (4,6-diphenyl-1,3,5-triazin-2-yl) -5-[(hexyl) oxy] -phenol, 2,4-dihydroxybenzophenone, 2-hydroxy-4 -N-octyloxybenzophenone and the like.
- Antioxidants used for improving thermal stability include 1,6-hexanediol-bis [3- (3,5-di-t-butyl-4-hydroxyphenyl) propionate], pentaerythrityl- Tetrakis [3- (3,5-di-tert-butyl-4-hydroxyphenyl) propionate], tris (2,4-di-tert-butylphenyl) phosphite, 2,4-bis- (n-octylthio) And -6- (4-hydroxy-3,5-di-t-butylanilino) -1,3,5-triazine.
- a resin obtained by mixing and heating and melting the above main materials and additives is formed into a film using a T-die method or a calendar method, and a sealing material sheet is manufactured.
- the first encapsulant sheet 6 and the second encapsulant are obtained by applying the heat-melted resin sheet to a roll (made of metal or rubber) having an uneven pattern on the surface.
- the concavo-convex pattern of the roll can be transferred to one side or both sides of the sheet 8, and embossing can be applied to one side or both sides of the first sealing material sheet 6 and the second sealing material sheet 8.
- the porosity P defined by percentage V H / V a ⁇ 100% of a is 1-4%, it selects the uneven pattern in the roll of the film-forming step, carrying out the embossing of the sealing material sheet To do.
- the actual volume V 0 (mm 3 ) of the sealing material sheet of this unit area is the sealing material per unit area (1 m 2 ) of the specific gravity ⁇ (g / mm 3 ) of the resin constituting the sealing material sheet.
- V 0 (mm 3 ) W / ⁇
- the total volume VH (mm 3 ) of the recesses per unit area of the encapsulant sheet is calculated as follows by subtracting the actual volume V 0 from the apparent volume VA of the encapsulant sheet.
- the porosity (%) is calculated by the above formula, and is obtained by taking a microscopic image of a cross-section or an embossed surface of an actual sealing material sheet and performing image processing. You can also.
- the maximum thickness t max of the encapsulant sheet indicates the distance from the top of the convex part to the back surface when embossed on one side of the encapsulant sheet, and embossed on both sides of the film. When processed, the distance between the tips of the convex portions on both surfaces (the distance in the film thickness direction) is shown.
- the maximum thickness t max is preferably 50 to 2000 ⁇ m.
- the resin having a low elastic modulus is defined as follows.
- the sealing material sheet having a thickness of 1 mm is sandwiched between two Al plates having a diameter of 25 mm, the strain is 5%, the frequency is 1 Hz, and the temperature rises from the measurement start temperature of 40 ° C. to the measurement end temperature of 150 ° C.
- the minimum value of the storage elastic modulus is 10 4 Pa or less.
- the dynamic viscoelasticity measurement can be carried out by using, for example, a rheometer AR2000cx manufactured by TA Instruments.
- the resin having a low elastic modulus can be obtained by appropriately selecting the resin or appropriately adjusting the kind and amount of the additive.
- the EVA resin having a minimum storage elastic modulus of 9200 Pa was prepared by adjusting the resin composition and the additive composition. That is, this EVA resin sandwiches a 1 mm-thick sealing material sheet between two ⁇ 25 mm Al plates and increases the temperature in the process of raising the temperature from a measurement start temperature of 40 ° C. to a measurement end temperature of 150 ° C. When the dynamic viscoelasticity measurement of the sealing material sheet is performed every 1 ° C., the minimum value of the storage elastic modulus is 9200 Pa. Using this EVA resin, an EVA resin roll having embossed on both sides so as to have a porosity of 3 to 4% was prepared.
- a solar cell pseudo module was prototyped and the deaeration performance of the encapsulant sheet was confirmed.
- the procedure for making the pseudo module and the method for confirming the deaeration performance are shown below.
- a 290 mm ⁇ 210 mm back sheet (back surface protection member 11), a 280 mm ⁇ 200 mm encapsulant sheet 12, a solar battery cell 13, a 280 mm ⁇ 200 mm encapsulant sheet 14, and a 290 mm ⁇
- a laminate of 210mm large and 3mm thick tempered glass (surface protection member 15) can be evacuated in the upper lid side and in the laminate chamber (space surrounded by the laminator top lid 10 and the laminator bottom 16).
- the temperature in the laminate chamber was set to 150 ° C., the vacuum state on the laminator upper lid side was released, and the laminate was subjected to thermocompression bonding at atmospheric pressure for 10 minutes. (Fig. 4 (b), final crimping process)
- the pseudo module was prepared and the air bubbles were visually confirmed 30 times repeatedly for each of the vacuum degassing / temporary pressure bonding time of 60 seconds and 90 seconds.
- Table 1 shows the result of visual confirmation of bubbles in this example.
- the value of the porosity P described in this example is 10 cm from the two ends of the EVA resin roll 18 having a width of 110 cm (10 cm inward in the width direction from the roll end) and 10 cm from the center of the roll.
- This is an actual measurement value obtained by cutting out a square EVA resin film 17 having a size of 10 cm and measuring the film 17 as a sample.
- the film weight per 1 m 2 required for the calculation of the porosity P is obtained by weighing the weight of the film 20 of 10 cm ⁇ 10 cm with an electronic balance, and converting it to the weight per 1 m 2 based on the obtained measurement weight. Calculated. Further, the maximum film thickness is about 1 cm ⁇ 2 cm of a sample piece 19 from 5 points in the film 20 shown in FIG. 6, and the sample piece 19 is immersed in liquid nitrogen and frozen, and immediately after that, using a microtome. Measurement was performed using a sample cut to a size of 0.5 cm ⁇ 2 cm.
- the maximum film thicknesses at five points in the film 20 are respectively obtained, and the average value of the maximum film thicknesses at the five points is determined as the film 20.
- the maximum film thickness was adopted.
- the three maximum film thickness values thus obtained and the film weight value per 1 m 2 were substituted into the previously defined definition formula for the porosity, and calculated in three points in the roll width direction (both sides, The porosity P in the center) is the porosity of the EVA resin roll.
- Example 1 As a member of the laminated body, two sealing material sheets with embossing on both sides having a porosity of 7 to 9% were used, and the other conditions were the same as in Example 1 except that 1 mm inside the solar cell pseudo module. The presence or absence of two or more bubbles was confirmed. The results are shown in Table 1.
- Example 2 As a member of the laminated body, two sealing material sheets with embossing on both surfaces having a porosity of 20 to 22% were used, and the other conditions were the same as in Example 1, and 1 mm inside the solar cell pseudo module. The presence or absence of two or more bubbles was confirmed. The results are shown in Table 1.
- Example 3 As a member of the laminated body, two sealing material sheets with embossing on both sides having a porosity of 50 to 55% were used, and the other conditions were the same as in Example 1 except that 1 mm inside the solar cell pseudo module. The presence or absence of two or more bubbles was confirmed. The results are shown in Table 1.
- Two sheets were used, and the other conditions were the same as in Example 2.
- the presence or absence of bubbles / cell cracks of 1 mm 2 or more inside the solar cell pseudo module was confirmed.
- the results are shown in Table 2.
- Table 2 also shows the results of Example 1.
- the constituent members of the solar cell module were laminated by embossing so that the porosity P of the first sealing material sheet and the second sealing material sheet was 1 to 4%. It was found that the amount of air trapped inside the laminate at the stage was reduced, and the time required for heat degassing in vacuum in the solar cell module manufacturing process could be reduced.
- the time required for the laminating process can be shortened while preventing degassing failure in the module, so that the manufacturing yield of the solar cell module can be improved.
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- Physics & Mathematics (AREA)
- Condensed Matter Physics & Semiconductors (AREA)
- Electromagnetism (AREA)
- General Physics & Mathematics (AREA)
- Engineering & Computer Science (AREA)
- Computer Hardware Design (AREA)
- Microelectronics & Electronic Packaging (AREA)
- Power Engineering (AREA)
- Photovoltaic Devices (AREA)
- Sealing Material Composition (AREA)
- Laminated Bodies (AREA)
Abstract
Description
なお、上記のような太陽電池モジュールの製造方法は、例えば下記特許文献1および2に開示されている。
本発明は、上記課題を解決することを目的とする。
請求項2に記載の発明は、φ25mmのAlプレート2枚に厚さ1mmの前記封止材シートを挟み、ひずみ5%、周波数1Hz、測定開始温度40℃より測定終了温度150℃までの昇温過程において昇温1℃毎に前記封止材シートの動的粘弾性測定を行ったときの、貯蔵弾性率の最小値が104Pa以下であることを特徴とする請求項1記載の封止材シートである。
図3において、太陽電池モジュールは、第1保護部材5、第1封止材シート6、太陽電池セル7、第2封止材シート8、第2保護部材9をこの順で積層した積層体を加熱圧着してなる。第1封止材シート6および第2封止材シート7の片面もしくは両面には、エンボス加工による凹凸パターンが施されている。そして、第1封止材シート6および第2封止材シート7の単位面積あたりの凹部の合計体積VHと前記単位面積に最大厚みを乗じた該シートの見かけ体積VAとの百分比VH/VA×100%は、1~4%となるようにエンボス加工が施されている。また、図3の形態では、第1保護部材5が表面保護部材を、第2保護部材9が裏面保護部材を形成している。
VA(mm3)=tmax×106
一方、この単位面積の封止材シートの実際の体積V0(mm3)は封止材シートを構成する樹脂の比重ρ(g/mm3)と単位面積(1m2)当りの封止材シートの実際の重さW(g)とから次のように算出される。
V0(mm3)=W/ρ
封止材シートの単位面積当りの凹部の合計体積VH(mm3)は、封止材シートの見掛けの体積VAから実際の体積V0を差し引いた値として次のように算出される。
VH(mm3)=VA-V0=VA-(W/ρ)
従って、空隙率(%)は次のようにして求めることができる。
空隙率P(%)=VH/VA×100=(VA-(W/ρ))/VA×100
=1-W/(ρ・VA)×100=1-W/(ρ・tmax・106)×100
なお、この空隙率(%)は、上記のような計算式により算出する他、実際の封止材シートについて断面やエンボス加工が施された面を顕微鏡撮影し、画像処理を行うことにより求めることもできる。
また、封止材シートの最大厚みtmaxとは、封止材シートの一方の面にエンボス加工してある場合、凸部の最頂部から裏面までの距離を示し、フィルムの双方の面にエンボス加工してある場合には、双方の面の凸部の先端同士の距離(フィルム厚さ方向の距離)を示す。最大厚みtmaxは50~2000μmであることが好ましい。
前記弾性率が低い樹脂とは、本発明では次のように定義される。
φ25mmのAlプレート2枚に厚さ1mmの前記封止材シートを挟み、ひずみ5%、周波数1Hz、測定開始温度40℃より測定終了温度150℃までの昇温過程において昇温1℃毎に前記封止材シートの動的粘弾性測定を行ったときの、貯蔵弾性率の最小値が104Pa以下である。前記動的粘弾性測定は、例えばTAInstruments製レオメーター・AR2000cxを使用することで実施可能である。
前記弾性率が低い樹脂は、樹脂を適切に選定したり、添加剤の種類および量を適宜調整することにより、得ることが可能である。
積層体の部材として空隙率が7~9%の両面にエンボス加工が施してある封止材シート2枚を使い、それ以外の条件は実施例1と同様にして、太陽電池擬似モジュール内部の1mm2以上の気泡の有無を確認した。この結果を表1に示した。
積層体の部材として空隙率が20~22%の両面にエンボス加工が施してある封止材シート2枚を使い、それ以外の条件は実施例1と同様にして、太陽電池擬似モジュール内部の1mm2以上の気泡の有無を確認した。この結果を表1に示した。
積層体の部材として空隙率が50~55%の両面にエンボス加工が施してある封止材シート2枚を使い、それ以外の条件は実施例1と同様にして、太陽電池擬似モジュール内部の1mm2以上の気泡の有無を確認した。この結果を表1に示した。
2・・・・封止材層
3・・・・太陽電池セル
4・・・・裏面保護部材
5・・・・表面保護部材
6・・・・封止材シート
7・・・・太陽電池セル
8・・・・封止材シート
9・・・・裏面保護部材
10・・・ラミネーター上蓋
11・・・裏面保護部材
12・・・封止材シート
13・・・太陽電池セル
14・・・封止材シート
15・・・表面保護部材
16・・・ラミネーター底部
17・・・10cm×10cm EVA樹脂フィルム
18・・・EVA樹脂ロール
19・・・1cm×2cm 最大厚み測定用試料小片
20・・・10cm×10cm EVA樹脂フィルム
Claims (2)
- 第1保護部材、第1封止材シート、光電変換セル、第2封止材シート、第2保護部材をこの順で積層した積層体を加熱圧着してなる太陽電池モジュールの部材として使用される封止材シートにおいて、前記第1封止材シートおよび第2封止材シートの片面もしくは両面にエンボス加工による凹凸パターンが施されており、前記第1封止材シートおよび第2封止材シートの単位面積あたりの凹部の合計体積VHと前記単位面積に最大厚みを乗じた該シートの見かけ体積VAとの百分比VH/VA×100%が1~4%となるようにエンボス加工を施したことを特徴とする封止材シート。
- φ25mmのAlプレート2枚に厚さ1mmの前記封止材シートを挟み、ひずみ5%、周波数1Hz、測定開始温度40℃より測定終了温度150℃までの昇温過程において昇温1℃毎に前記封止材シートの動的粘弾性測定を行ったときの、貯蔵弾性率の最小値が104Pa以下であることを特徴とする請求項1記載の封止材シート。
Priority Applications (5)
Application Number | Priority Date | Filing Date | Title |
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EP10820400A EP2485269A1 (en) | 2009-09-29 | 2010-09-21 | Sealing material sheet |
US13/498,531 US20120180866A1 (en) | 2009-09-29 | 2010-09-21 | Sealing material sheet |
JP2011534203A JP5182432B2 (ja) | 2009-09-29 | 2010-09-21 | 封止材シート |
CN201080043206.2A CN102549771B (zh) | 2009-09-29 | 2010-09-21 | 密封材料片 |
KR1020127010061A KR101362030B1 (ko) | 2009-09-29 | 2010-09-21 | 밀봉재 시트 |
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JP2009-223906 | 2009-09-29 | ||
JP2009223906 | 2009-09-29 |
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WO2011040281A1 true WO2011040281A1 (ja) | 2011-04-07 |
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PCT/JP2010/066300 WO2011040281A1 (ja) | 2009-09-29 | 2010-09-21 | 封止材シート |
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US (1) | US20120180866A1 (ja) |
EP (1) | EP2485269A1 (ja) |
JP (1) | JP5182432B2 (ja) |
KR (1) | KR101362030B1 (ja) |
CN (1) | CN102549771B (ja) |
TW (1) | TW201125142A (ja) |
WO (1) | WO2011040281A1 (ja) |
Cited By (3)
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US20150034928A1 (en) * | 2012-02-24 | 2015-02-05 | Mitsui Chemicals, Inc. | Optical-device surface-sealing composition, optical-device surface-sealing sheet, display, and display manufacturing method |
CN107343383A (zh) * | 2015-02-04 | 2017-11-10 | 三井化学东赛璐株式会社 | 太阳能电池密封用膜、太阳能电池密封用膜卷及太阳能电池模块的制造方法 |
CN110634970A (zh) * | 2018-05-31 | 2019-12-31 | 米亚索能光伏科技有限公司 | 一种高温布、光伏组件及其制备方法 |
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KR101328138B1 (ko) * | 2013-05-24 | 2013-11-08 | 아익시스코리아(주) | 태양전지 모듈 및 그 제조 방법 |
CN112192911B (zh) * | 2020-09-30 | 2022-01-04 | 苏州福斯特光伏材料有限公司 | 光伏背板 |
KR102658247B1 (ko) * | 2021-12-03 | 2024-04-18 | 한국생산기술연구원 | Bipv 적용 가능한 고출력 슁글드 태양광 모듈 및 그 제조 방법 |
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- 2010-09-21 US US13/498,531 patent/US20120180866A1/en not_active Abandoned
- 2010-09-21 CN CN201080043206.2A patent/CN102549771B/zh not_active Expired - Fee Related
- 2010-09-21 EP EP10820400A patent/EP2485269A1/en not_active Withdrawn
- 2010-09-21 JP JP2011534203A patent/JP5182432B2/ja active Active
- 2010-09-21 KR KR1020127010061A patent/KR101362030B1/ko not_active IP Right Cessation
- 2010-09-28 TW TW099132777A patent/TW201125142A/zh unknown
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Also Published As
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CN102549771A (zh) | 2012-07-04 |
KR101362030B1 (ko) | 2014-02-13 |
US20120180866A1 (en) | 2012-07-19 |
EP2485269A1 (en) | 2012-08-08 |
CN102549771B (zh) | 2015-07-08 |
TW201125142A (en) | 2011-07-16 |
JP5182432B2 (ja) | 2013-04-17 |
JPWO2011040281A1 (ja) | 2013-02-28 |
KR20120068933A (ko) | 2012-06-27 |
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