WO2011114853A1 - Sealing material sheet for solar cell module, and solar cell module - Google Patents

Sealing material sheet for solar cell module, and solar cell module Download PDF

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Publication number
WO2011114853A1
WO2011114853A1 PCT/JP2011/054112 JP2011054112W WO2011114853A1 WO 2011114853 A1 WO2011114853 A1 WO 2011114853A1 JP 2011054112 W JP2011054112 W JP 2011054112W WO 2011114853 A1 WO2011114853 A1 WO 2011114853A1
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WIPO (PCT)
Prior art keywords
sealing material
solar cell
material sheet
cell module
sheet
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PCT/JP2011/054112
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French (fr)
Japanese (ja)
Inventor
武史 古屋
良助 古賀
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凸版印刷株式会社
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Priority to JP2012505586A priority Critical patent/JPWO2011114853A1/en
Publication of WO2011114853A1 publication Critical patent/WO2011114853A1/en

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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
    • 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
    • C08J5/00—Manufacture of articles or shaped materials containing macromolecular substances
    • C08J5/18—Manufacture of films or sheets
    • 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
    • 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 solar cell module sealing material sheet and a solar cell module.
  • solar cells have been attracting attention as a clean power generation technology that uses sunlight.
  • a general solar cell module a module in which solar cells are embedded and sealed in a sealing material layer, and both sides of the sealing material layer are protected by a surface protection member and a back surface protection member is known.
  • a surface protection member, a sealing material sheet, a solar battery cell, a sealing material sheet and a back surface protection member were laminated in this order, and these were heated and deaerated in a vacuum. Later, a method is widely used in which heating is performed while applying a load of 1 atm in a vacuum so that the sealing resin is crosslinked and cured while embedding the solar battery cells and bonded and integrated.
  • an ethylene-vinyl acetate copolymer (hereinafter referred to as “EVA”) is used as a main resin.
  • the encapsulant sheet often contains additives such as a crosslinking agent, a crosslinking assistant, a silane coupling agent, a light stabilizer, and an ultraviolet absorber at a certain ratio for the purpose of improving the durability.
  • a crosslinking agent used for the crosslinking of EVA, it is already known that a great number of crosslinking agents can be used, and it is also known that the crosslinking characteristics vary depending on the amount of addition.
  • a manufacturing method of a sealing material sheet for example, a T-die method in which a resin forming a sealing material sheet is extruded in a molten state from a die having a linear slit, and rapidly cooled and solidified in a cooling roll or a water tank, or a calendar method is used.
  • a film forming process is employed.
  • a sealing material sheet having a thickness of about 500 ⁇ m is formed by the film forming step.
  • corrugation to the sealing material sheet surface may be given in the said film forming process.
  • the conventional encapsulant sheet has a slow crosslinking rate of EVA due to a change in cross-linking properties depending on its composition, making it difficult to sufficiently increase the cross-linking rate of the encapsulant layer, resulting in decreased productivity.
  • the conventional sealing material sheet has a high crosslinking speed, and the crosslinking proceeds at the time of forming the sheet, so that gel is generated in the sealing material sheet and the quality may be lowered.
  • the sealing material layer formed by the sealing material sheet may become too hard and the solar cell to be sealed may be damaged, or the sealing material layer may become too soft and the sealing material may protrude from the module.
  • conventionally it is possible to suppress the generation of gel at the time of sheet molding, the decrease in the crosslinking rate of the sealing material layer when the solar battery module is manufactured, the damage of the solar battery cells, and the protrusion of the sealing material. It was difficult to obtain a sealing material sheet having excellent performance.
  • the present invention is excellent in sheet moldability, suppresses damage of the solar battery cells and protrusion of the sealing material during the production of the solar battery module, and has high reliability capable of stably forming a sealing material layer having a high crosslinking rate. It aims at provision of the sealing material sheet for solar cell modules. Moreover, this invention aims at provision of the solar cell module using the said sealing material sheet for solar cell modules.
  • the resin composition is put into a mixer having a mixer type of R100 so that the volume of the resin composition is 80% by volume with respect to the volume of the mixer, and kneaded at a kneading temperature of 140 ° C. and a rotation speed of 50 rpm.
  • the average particle diameter of the resin composition is 3.5 mm.
  • a solar battery cell, a sealing material layer that seals the solar battery cell, a surface protection member that protects the front surface side of the sealing material layer, and a back surface that protects the back surface side of the sealing material layer A solar cell module, wherein the sealing material layer is formed by the solar cell module sealing material sheet according to [1].
  • the encapsulant sheet for solar cell module of the present invention is excellent in sheet moldability, suppresses damage of the solar cells and the overhang of the encapsulant during the production of the solar cell module, and has an encapsulant layer having a high crosslinking rate. It can be formed stably and has high reliability. Further, the solar cell module of the present invention uses the solar cell module encapsulant sheet of the present invention, so that damage to the solar cells and protrusion of the encapsulant are suppressed, and sealing with a high crosslinking rate is achieved. It has a material layer and is highly reliable.
  • the sealing material sheet of this invention is a sealing material sheet formed from the resin composition containing EVA and an organic peroxide.
  • the resin base material contained in the resin composition in the present invention is a resin base material containing EVA, and preferably contains EVA as a main component.
  • EVA is advantageous in that it has high transparency, is inexpensive, and has a particularly large past record of use.
  • “Eva as a main component” means that EVA is 95% by mass or more based on the total amount of the resin base material.
  • the EVA used in the sealing material sheet of the present invention preferably has a vinyl acetate unit content of 20 to 40% by mass relative to the total units. If content of a vinyl acetate unit is 20 mass% or more, it will become easy to obtain a high crosslinking rate and the outstanding adhesiveness. If the content of the vinyl acetate unit is 40% by mass or less, it is easy to suppress the unreacted vinyl acetate side chain from being detached due to heat, ultraviolet rays or the like to cause deterioration of the resin.
  • the resin base material of the resin composition in the present invention may contain other resins.
  • other resins include polyolefins such as polyethylene and polypropylene; ionomers; ethylene-methacrylic acid copolymers; ethylene-acrylic acid copolymers; polyvinyl fluoride; polyvinyl chloride or copolymers thereof.
  • the proportion of EVA in the resin substrate of the resin composition in the present invention that is, the proportion of EVA in the resin substrate of the sealing material sheet of the present invention is preferably 95% by mass or more, more preferably 97% by mass or more, 100% by mass is particularly preferred.
  • the encapsulant sheet of the present invention contains an organic peroxide as a cross-linking agent that initiates the cross-linking reaction of EVA.
  • organic peroxides include 1,1-di (t-butylperoxy) cyclohexane, 1,1-di (t-hexylperoxy) cyclohexane, n-butyl-4,4-di- (t-butylperoxide).
  • Oxy) valerate t-butylperoxy-3,5,5-trimethylhexanoate, 2,5-dimethyl-2,5-di (t-butylperoxy) hexane, t-butylcumyl peroxide, 2, Examples include 2-di- (t-butylperoxy) butane.
  • the sealing material sheet of the present invention may contain a crosslinking aid for promoting the crosslinking reaction in addition to the organic peroxide.
  • a crosslinking aid for promoting the crosslinking reaction in addition to the organic peroxide.
  • the crosslinking aid include triallyl isocyanurate, diallyl phthalate, triallyl cyanurate and the like.
  • the sealing material sheet of the present invention may contain a silane coupling agent in order to improve the adhesion between the sealing material layer, the surface protection member, and the back surface protection member.
  • a silane coupling agent examples include ⁇ -methacryloxypropyltrimethoxysilane, limethoxypropylsilane, trimethoxymethylsilane, vinyltrimethoxysilane, vinyltriethoxysilane, trichloropropylsilane, triethoxyphenylsilane, and the like. Of these, ⁇ -methacryloxypropyltrimethoxysilane is preferred because of its high adhesion promoting performance and low cost.
  • the encapsulant sheet of the present invention contains a stabilizer such as an ultraviolet absorber, an antioxidant, and a light stabilizer in order to improve the durability of the encapsulant layer to be formed. Also good.
  • a stabilizer such as an ultraviolet absorber, an antioxidant, and a light stabilizer in order to improve the durability of the encapsulant layer to be formed. Also good.
  • the ultraviolet absorber By containing the ultraviolet absorber, the light resistance of the sealing material layer formed by the sealing material sheet of the present invention is improved.
  • Examples of the ultraviolet absorber include 2- (5-methyl-2-hydroxyphenyl) benzotriazole, 2- (3-tert-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, etc. It is done.
  • antioxidant By containing an antioxidant, the thermal stability of the encapsulant layer formed by the encapsulant sheet of the present invention is improved.
  • antioxidant phosphorus antioxidant and phenolic antioxidant are preferable.
  • Specific examples of the antioxidant include 1,6-hexanediol-bis [3- (3,5-di-tert-butyl-4-hydroxyphenyl) propionate], pentaerythrityl-tetrakis [3- (3 5-di-t-butyl-4-hydroxyphenyl) propionate], tris (2,4-di-t-butylphenyl) phosphite, 2,4-bis- (n-octylthio) -6- (4-hydroxy -3,5-di-t-butylanilino) -1,3,5-triazine, octadecyl-3- (3,5-di-t-butyl-4-hydroxyphenyl) propionate and the like.
  • the light stabilizer include bis
  • the sealing material sheet of the present invention contains at least EVA and an organic peroxide, and if necessary, other resin base materials, crosslinking aids, silane coupling agents, ultraviolet absorbers, and antioxidants.
  • a resin composition containing an agent, a light stabilizer and the like.
  • the resin composition has a maximum torque C (unit: N ⁇ m) in the following mixer test of 55 ⁇ C ⁇ 85, and a maximum torque time D (unit: minute) of 6.5 ⁇ D ⁇ 11. It is characterized by being a composition of 7.
  • the resin composition is put into a mixer having a mixer type of R100 so that the volume of the resin composition is 80% by volume with respect to the volume of the mixer, and kneaded at a kneading temperature of 140 ° C. and a rotation speed of 50 rpm.
  • the average particle size of the resin composition is 3.5 mm.
  • the resin composition is pelletized so that the average particle diameter is 3.5 mm, and the resin composition pelletized so that the average particle diameter is 3.5 mm is put into a mixer and the maximum torque C and The maximum torque time D is measured.
  • the maximum torque C in the present invention means the maximum torque in the mixer test as shown in FIG. In the initial stage of the mixer test, the torque decreases as each component contained in the resin composition melts, and then the torque increases as the EVA crosslinking reaction with organic peroxide proceeds, and the maximum torque C is measured. Is done.
  • the maximum torque time D in the present invention means the time from the start of the mixer test (at the start of kneading) until the maximum torque C is measured. Specifically, after the temperature of the mixer is raised to 140 ° C., each component to be contained in the resin composition is added to the mixer, and kneading is immediately started at a rotation speed of 50 rpm. Is the maximum torque time D.
  • a mixer for the mixer test for example, a lab plast mill (main body model: 4C150, mixer model: R100, mixer capacity: 100 g, manufactured by Toyo Seiki Seisakusho) can be used.
  • each component of the resin composition is added so as to be 80 g corresponding to 80% by volume of the mixer capacity of 100 g, and kneading is performed at a kneading temperature of 140 ° C. and a rotation speed of 50 rpm. Torque C and maximum torque time D are measured.
  • the maximum torque C (N ⁇ m) in the mixer test is 55 ⁇ C ⁇ 5, more preferably 60 ⁇ C ⁇ 80.
  • the maximum torque C is 55 ⁇ C ⁇ 5, more preferably 60 ⁇ C ⁇ 80.
  • the maximum torque time D (minute) in the mixer test is 6.5 ⁇ D ⁇ 11.7, and more preferably 7.5 ⁇ D ⁇ 10.7.
  • the maximum torque time D is 6.5 minutes or more, it is possible to suppress the generation of gel during sheet forming, and the productivity is improved.
  • the maximum torque C and the maximum torque time D in the mixer test are particularly affected by the type and addition amount of the organic peroxide, and the maximum torque C increases as the addition amount of the organic peroxide increases. D tends to be shorter.
  • the degree of change in the maximum torque C and the maximum torque time D differs depending on the type of organic peroxide, and the addition amount and the change in the maximum torque C and the maximum torque time D are not always in a proportional relationship. Therefore, the composition of the resin composition forming the encapsulant sheet of the present invention is to measure the maximum torque C and the maximum torque time D while changing the type and amount of additives such as organic peroxide, It is necessary to decide to satisfy the conditions.
  • the manufacturing method of the sealing material sheet of this invention measures the maximum torque C and the maximum torque time D by the said mixer test, and adds additives, such as an organic peroxide, so that they may become the said range, and resin composition A step (X) for determining the composition of the product, and a step (Y) for forming a sealing material sheet from the resin composition having the composition determined in the step (X).
  • the determination of the composition of the resin composition by the mixer test in the step (X) is as described above.
  • a well-known method can be employ
  • a method of forming a sealing material sheet by a co-extrusion method in which a resin composition is heated and melted and extruded using a T die or the like can be mentioned.
  • the surface of the heat-melted resin sheet is brought into close contact with a roll (made of metal or rubber) having a concavo-convex pattern so that the resin sheet is provided on one or both surfaces.
  • the uneven pattern of the roll may be transferred to emboss the encapsulant sheet.
  • the sealing material sheet of the present invention described above is formed of a resin composition in which the maximum torque C and the maximum torque time D are adjusted to predetermined ranges, so that the sheet moldability is excellent, and the solar cell module is manufactured. Since the damage of the solar battery cell and the sticking out of the sealing material can be suppressed and a sealing material layer having a high crosslinking rate can be stably formed, the reliability is high.
  • the solar battery module of the present invention includes a solar battery cell, a sealing material layer that seals the solar battery cell, a surface protection member that protects the surface side of the sealing material layer, and a back surface of the sealing material layer.
  • the solar cell module 1 of the present embodiment includes solar cells 4 and 4, a sealing material layer 3 that seals the solar cells 4 and 4, and a surface side of the sealing material layer 3. And a back surface protection member 5 for protecting the back surface side of the sealing material layer 3.
  • the solar battery cell 4 is a cell having a function of converting light incident on the light receiving surface into electricity by a photoelectric effect.
  • a plurality (two in FIG. 2) of solar cells 4 are connected by electrodes (not shown) in the solar cell module 1.
  • the number of solar cells 4 is not particularly limited. Examples of the material of the solar battery cell 4 include crystalline silicon. Among these, polycrystalline silicon is particularly preferable from the viewpoint of manufacturing simplicity and cost.
  • the sealing material layer 3 is a layer that embeds and seals the solar cells 4 and 4 and is formed of the sealing material sheet of the present invention.
  • the thickness of the sealing material layer 3 is preferably 0.3 to 0.6 mm.
  • the surface protective material 2 As the surface protective material 2, those excellent in durability, weather resistance, and transparency are preferable, and examples thereof include a glass sheet, a resin sheet such as polyethylene terephthalate, and the like. Moreover, you may use resin sheets, such as a polycarbonate.
  • the thickness of the surface protection member 2 is preferably 3 to 6 mm.
  • back protection member 5 As the back surface protection member 5, those excellent in durability and weather resistance are preferable, and examples thereof include resin sheets such as polyethylene terephthalate, polyvinyl fluoride, EVA, and laminates thereof. Moreover, you may laminate
  • the thickness of the back surface protection member 5 is preferably 0.2 to 0.4 mm.
  • the manufacturing method of the said solar cell module 1 is demonstrated as an example of the manufacturing method of the solar cell module of this invention.
  • the manufacturing method of the solar cell module of the present invention is not limited to the following method.
  • the back surface protection member 2, the sealing material sheet 3A, the solar battery cells 4, 4, the sealing material sheet 3B, and the surface protection member 5 are laminated in this order to form a laminated body 1A.
  • the laminated body 1A is vacuum-laminated by heating and pressing in a vacuum state, solar cells 4 and 4 are embedded in the sealing material sheets 3A and 3B, and the resin base material (EVA) of the sealing material sheets 3A and 3B.
  • the sealing material sheet 3A and the sealing material sheet 3B are the sealing material sheets of the present invention, may be the same composition sealing material sheet, may be different composition sealing material sheet, but uniform It is preferable that the sealing material sheet has the same composition from the viewpoint that a good quality module is easily obtained by forming a crosslinked structure.
  • the solar cell module of the present invention described above uses the encapsulant sheet of the present invention, the solar cell module is prevented from being damaged and protruding from the encapsulant, and the encapsulant layer having a high crosslinking rate. It has high reliability.
  • EVA-1 EVA having a vinyl acetate unit content of 30% by mass
  • V-1 Bis (2,2,6,6-tetramethyl-4-piperidyl) sebacate
  • Example 1 0.4 parts by mass of organic peroxide I-1, 0.4 parts by mass of silane coupling agent II-1, and cross-linking aid III-1 with respect to 100 parts by mass of EVA-1 as a resin base material
  • Resin composition containing 0.6 part by weight, 0.1 part by weight of UV absorber IV-1, 0.1 part by weight of light stabilizer V-1 and 0.1 part by weight of antioxidant VI-1 was used to prepare a sealing material sheet having a thickness of 0.45 mm by the T-die method.
  • Example 2 The amount of organic peroxide I-1 added is 0.6 parts by mass, and the amount of silane coupling agent II-1 added is. A sealing material sheet was produced in the same manner as in Example 1 except that the amount was 5 parts by mass.
  • Example 3 A sealing material sheet was prepared in the same manner as in Example 1 except that the addition amount of the organic peroxide I-1 was 0.55 parts by mass and the addition amount of the silane coupling agent II-1 was 0.4 parts by mass. Produced.
  • Example 4 A sealing material sheet was prepared in the same manner as in Example 1 except that the addition amount of the organic peroxide I-1 was 0.75 parts by mass and the addition amount of the silane coupling agent II-1 was 0.4 parts by mass. Produced.
  • Example 1 A sealing material sheet was prepared in the same manner as in Example 1 except that the addition amount of the organic peroxide I-1 was 0.3 parts by mass and the addition amount of the silane coupling agent II-1 was 0.6 parts by mass. Produced.
  • Example 2 A sealing material sheet was prepared in the same manner as in Example 1 except that the addition amount of the organic peroxide I-1 was 0.3 parts by mass and the addition amount of the silane coupling agent II-1 was 0.4 parts by mass. Produced.
  • a sealing material sheet was prepared in the same manner as in Example 1 except that the addition amount of the organic peroxide I-1 was 0.6 parts by mass and the addition amount of the silane coupling agent II-1 was 0.2 parts by mass. Produced.
  • Example 4 A sealing material sheet was prepared in the same manner as in Example 1 except that the addition amount of the organic peroxide I-1 was 0.75 parts by mass and the addition amount of the silane coupling agent II-1 was 0.2 parts by mass. Produced. Table 1 shows the maximum torque C (unit: N ⁇ m) and the maximum torque time D (unit: minute) in the mixer test of the resin composition used for producing the sealing material sheet of each example.
  • each component contained in the resin composition is 80% by volume (80 g) with respect to the mixer capacity. And kneaded at a kneading temperature of 140 ° C. and a rotation speed of 50 rpm, and the maximum torque C and the maximum torque time D were measured.
  • Crosslinking rate [mass of non-molten component (g) / mass before melting (1 g)] ⁇ 100 The cross-linking rate was 80% or more.
  • the number of gels generated per 1 m 2 in the encapsulant sheet obtained in each example was visually measured and evaluated according to the following criteria.
  • the gel to be measured has a radius of 2 mm or more.
  • the confirmation area was 2 m 2 .
  • Comparative Examples 1 and 2 in which a sealing material sheet was obtained by molding a resin composition having a maximum torque C of less than 55 N ⁇ m and a maximum torque time D exceeding 11.7 minutes, The crosslinking rate was low, and the quality of the module was low. Further, in Comparative Example 1 in which the maximum torque C is smaller, the protrusion of EVA was confirmed as compared with Comparative Example 2, and the quality of the module was further lower. In Comparative Examples 3 and 4 in which a sealing material sheet was obtained by molding a resin composition having a maximum torque C exceeding 85 N ⁇ m and a maximum torque time D being less than 6.5 minutes, the sealing material layer becomes harder. Too much cell cracking occurred. Further, in Comparative Example 4 in which the maximum torque time D is shorter, the generation of gel at the time of forming the sheet was confirmed as compared with Comparative Example 3, and the quality of the sealing material sheet was also low.

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Abstract

Provided is a sealing material sheet for a solar cell module, in which the sealing material sheet is highly reliable, has excellent sheet formability, prevents damage to solar cells and sealing material from protruding during manufacturing of solar cell modules, and can stably form sealing material layers having a high crosslinking ratio. Also provided is a solar cell module which uses the sealing material sheet for a solar cell module. The sealing material sheet for a solar cell module is a sealing material sheet which is formed from a resin composition containing EVA and an organic peroxide, wherein the resin composition has, in a mixer test having predetermined conditions, a maximum torque (C) (unit: N·m) of 55 ≤ C ≤ 85 and a maximum torque time (D) (unit: minutes) of 6.5 ≤ D ≤ 11.7. In addition, a solar cell module uses the sealing material sheet.

Description

太陽電池モジュール用封止材シートおよび太陽電池モジュールSolar cell module sealing material sheet and solar cell module
　本発明は、太陽電池モジュール用封止材シートおよび太陽電池モジュールに関する。 The present invention relates to a solar cell module sealing material sheet and a solar cell module.
　太陽光を利用するクリーンな発電技術として、太陽電池が近年注目を集めている。一般的な太陽電池モジュールとしては、太陽電池セルを封止材層内に包埋させて封止し、該封止材層の両面側を表面保護部材と裏面保護部材で保護したモジュールが知られている。該太陽電池モジュールの製造方法としては、表面保護部材、封止材シート、太陽電池セル、封止材シート及び裏面保護部材をこの順序で積層し、これらを真空中で加熱して脱気させた後に、真空中で１気圧の荷重をかけながら加熱して、太陽電池セルを包埋させつつ封止材樹脂を架橋硬化させて接着一体化する方法が広く用いられている。 In recent years, solar cells have been attracting attention as a clean power generation technology that uses sunlight. As a general solar cell module, a module in which solar cells are embedded and sealed in a sealing material layer, and both sides of the sealing material layer are protected by a surface protection member and a back surface protection member is known. ing. As a manufacturing method of this solar cell module, a surface protection member, a sealing material sheet, a solar battery cell, a sealing material sheet and a back surface protection member were laminated in this order, and these were heated and deaerated in a vacuum. Later, a method is widely used in which heating is performed while applying a load of 1 atm in a vacuum so that the sealing resin is crosslinked and cured while embedding the solar battery cells and bonded and integrated.
　封止材シートの材料としては、一般的に、主成分となる樹脂としてエチレン－酢酸ビニル共重合体（以下、「ＥＶＡ」という。）が使用される。また、封止材シートには、その耐久性を向上させる目的で、架橋剤、架橋助剤、シランカップリング剤、光安定剤、紫外線吸収剤といった添加物が一定割合で含有されることが多い（例えば、特許文献１）。ＥＶＡの架橋に用いる架橋剤については、すでに非常に多くのものが使用可能であることが知られており、また添加量によって架橋特性が変わってくることも知られている。
　封止材シートの製造方法としては、例えば、直線状スリットを有するダイから封止材シートを形成する樹脂を溶融状態で押し出し、冷却ロールもしくは水槽で急冷固化するＴダイ法、又はカレンダー法等の製膜工程が採用される。前記製膜工程により５００μｍ程度の厚みの封止材シートが製膜される。また、前記製膜工程の中で、封止材シート表面に凹凸を付与するエンボス加工が施されることもある。 As a material for the encapsulant sheet, generally, an ethylene-vinyl acetate copolymer (hereinafter referred to as “EVA”) is used as a main resin. In addition, the encapsulant sheet often contains additives such as a crosslinking agent, a crosslinking assistant, a silane coupling agent, a light stabilizer, and an ultraviolet absorber at a certain ratio for the purpose of improving the durability. (For example, patent document 1). As for the crosslinking agent used for the crosslinking of EVA, it is already known that a great number of crosslinking agents can be used, and it is also known that the crosslinking characteristics vary depending on the amount of addition.
As a manufacturing method of a sealing material sheet, for example, a T-die method in which a resin forming a sealing material sheet is extruded in a molten state from a die having a linear slit, and rapidly cooled and solidified in a cooling roll or a water tank, or a calendar method is used. A film forming process is employed. A sealing material sheet having a thickness of about 500 μm is formed by the film forming step. Moreover, the embossing which provides an unevenness | corrugation to the sealing material sheet surface may be given in the said film forming process.
特許第３３２３５６０号公報Japanese Patent No. 3323560
　しかし、従来の封止材シートは、その組成による架橋特性の変化により、ＥＶＡの架橋速度が遅くなって封止材層の架橋率を充分に高くすることが困難になり、生産性が低下することがある。架橋速度が遅い封止材シートであっても高温条件で架橋反応を行えば、架橋速度を速めて生産性を高めることはできるが、該方法では封止材層の熱劣化を招くおそれがある。また、従来の封止材シートは、架橋速度が速くなってシート成形時に架橋が進行し、封止材シート内にゲルが発生して品質が低下することもある。さらに、封止材シートにより形成される封止材層が硬くなりすぎて封止する太陽電池セルが破損したり、封止材層が柔らかくなりすぎて封止材がモジュールからはみだすこともある。
　以上のように、従来は、シート成形時のゲルの発生、並びに太陽電池モジュールを製造したときの封止材層の架橋率の低下、太陽電池セルの破損、及び封止材のはみだしを抑制できる優れた性能を有する封止材シートを得ることは困難であった。 However, the conventional encapsulant sheet has a slow crosslinking rate of EVA due to a change in cross-linking properties depending on its composition, making it difficult to sufficiently increase the cross-linking rate of the encapsulant layer, resulting in decreased productivity. Sometimes. Even if it is a sealing material sheet with a slow crosslinking rate, if the crosslinking reaction is carried out under high temperature conditions, the crosslinking rate can be increased to increase the productivity, but this method may cause thermal deterioration of the sealing material layer. . In addition, the conventional sealing material sheet has a high crosslinking speed, and the crosslinking proceeds at the time of forming the sheet, so that gel is generated in the sealing material sheet and the quality may be lowered. Furthermore, the sealing material layer formed by the sealing material sheet may become too hard and the solar cell to be sealed may be damaged, or the sealing material layer may become too soft and the sealing material may protrude from the module.
As described above, conventionally, it is possible to suppress the generation of gel at the time of sheet molding, the decrease in the crosslinking rate of the sealing material layer when the solar battery module is manufactured, the damage of the solar battery cells, and the protrusion of the sealing material. It was difficult to obtain a sealing material sheet having excellent performance.
　本発明は、シート成形性に優れ、太陽電池モジュールの製造時に太陽電池セルの破損及び封止材のはみだしを抑制し、高い架橋率を有する封止材層を安定して形成できる信頼性の高い太陽電池モジュール用封止材シートの提供を目的とする。また、本発明は、前記太陽電池モジュール用封止材シートを用いた太陽電池モジュールの提供を目的とする。 The present invention is excellent in sheet moldability, suppresses damage of the solar battery cells and protrusion of the sealing material during the production of the solar battery module, and has high reliability capable of stably forming a sealing material layer having a high crosslinking rate. It aims at provision of the sealing material sheet for solar cell modules. Moreover, this invention aims at provision of the solar cell module using the said sealing material sheet for solar cell modules.
　本発明は、前記課題を解決するために以下の構成を採用した。
［１］ＥＶＡと有機過酸化物とを含有する樹脂組成物から形成された太陽電池モジュール用封止材シートであって、前記樹脂組成物が、下記ミキサー試験における最大トルクＣ（単位：Ｎ・ｍ）が５５≦Ｃ≦８５であり、かつ最大トルク時間Ｄ（単位：分）が６．５≦Ｄ≦１１．７の組成物であることを特徴とする太陽電池モジュール用封止材シート。
（ミキサー試験）
　ミキサー型式がＲ１００のミキサーに、前記樹脂組成物を前記ミキサーの容量に対して８０容量％となるように投入し、混錬温度１４０℃、回転数５０ｒｐｍで混練する。ただし、前記樹脂組成物の平均粒径は３．５ｍｍである。
［２］太陽電池セルと、前記太陽電池セルを封止する封止材層と、前記封止材層の表面側を保護する表面保護部材と、前記封止材層の裏面側を保護する裏面保護部材と、を有し、前記封止材層が、前記［１］に記載の太陽電池モジュール用封止材シートにより形成されている太陽電池モジュール。 The present invention employs the following configuration in order to solve the above problems.
[1] A solar cell module sealing material sheet formed from a resin composition containing EVA and an organic peroxide, wherein the resin composition has a maximum torque C (unit: N · m) is a composition of 55 ≦ C ≦ 85, and the maximum torque time D (unit: minute) is 6.5 ≦ D ≦ 11.7.
(Mixer test)
The resin composition is put into a mixer having a mixer type of R100 so that the volume of the resin composition is 80% by volume with respect to the volume of the mixer, and kneaded at a kneading temperature of 140 ° C. and a rotation speed of 50 rpm. However, the average particle diameter of the resin composition is 3.5 mm.
[2] A solar battery cell, a sealing material layer that seals the solar battery cell, a surface protection member that protects the front surface side of the sealing material layer, and a back surface that protects the back surface side of the sealing material layer A solar cell module, wherein the sealing material layer is formed by the solar cell module sealing material sheet according to [1].
　本発明の太陽電池モジュール用封止材シートは、シート成形性に優れ、太陽電池モジュールの製造時に太陽電池セルの破損及び封止材のはみだしを抑制し、高い架橋率を有する封止材層を安定して形成でき、信頼性が高い。
　また、本発明の太陽電池モジュールは、本発明の太陽電池モジュール用封止材シートを用いていることにより、太陽電池セルの破損及び封止材のはみだしが抑制され、かつ高い架橋率の封止材層を有しており、信頼性が高い。 The encapsulant sheet for solar cell module of the present invention is excellent in sheet moldability, suppresses damage of the solar cells and the overhang of the encapsulant during the production of the solar cell module, and has an encapsulant layer having a high crosslinking rate. It can be formed stably and has high reliability.
Further, the solar cell module of the present invention uses the solar cell module encapsulant sheet of the present invention, so that damage to the solar cells and protrusion of the encapsulant are suppressed, and sealing with a high crosslinking rate is achieved. It has a material layer and is highly reliable.
本発明における最大トルクＣ及び最大トルク時間Ｄの説明図である。It is explanatory drawing of the maximum torque C and the maximum torque time D in this invention. 本発明の太陽電池モジュールの実施形態の一例を示した断面図である。It is sectional drawing which showed an example of embodiment of the solar cell module of this invention. 図２の太陽電池モジュールの製造方法の一工程を示した断面図である。It is sectional drawing which showed 1 process of the manufacturing method of the solar cell module of FIG.
＜太陽電池モジュール用封止材シート＞
　以下、本発明の太陽電池モジュール用封止材シート（以下、「封止材シート」という。）の実施形態の一例について詳細に説明する。
　本発明の封止材シートは、ＥＶＡと有機過酸化物を含有する樹脂組成物から形成された封止材シートである。 <Sealant sheet for solar cell module>
Hereinafter, an example of an embodiment of a sealing material sheet for solar cell modules of the present invention (hereinafter referred to as “sealing material sheet”) will be described in detail.
The sealing material sheet of this invention is a sealing material sheet formed from the resin composition containing EVA and an organic peroxide.
　本発明における樹脂組成物に含有される樹脂基材、すなわち本発明の封止材シートの樹脂基材は、ＥＶＡを含む樹脂基材であり、ＥＶＡを主成分とすることが好ましい。ＥＶＡは、高い透明性を有し、安価であり、特に過去の使用実績が膨大である点で有利である。ＥＶＡを主成分とするとは、樹脂基材の総量に対して、ＥＶＡを９５質量％以上とすることを意味する。
　本発明の封止材シートに用いられるＥＶＡは、全単位に対する酢酸ビニル単位の含有量が２０～４０質量％であることが好ましい。酢酸ビニル単位の含有量が２０質量％以上であれば、高い架橋率及び優れた密着性が得られやすくなる。酢酸ビニル単位の含有量が４０質量％以下であれば、未反応の酢酸ビニル側鎖が熱や紫外線等の刺激により脱離して樹脂の劣化を招くことを抑制しやすい。 The resin base material contained in the resin composition in the present invention, that is, the resin base material of the sealing material sheet of the present invention is a resin base material containing EVA, and preferably contains EVA as a main component. EVA is advantageous in that it has high transparency, is inexpensive, and has a particularly large past record of use. “Eva as a main component” means that EVA is 95% by mass or more based on the total amount of the resin base material.
The EVA used in the sealing material sheet of the present invention preferably has a vinyl acetate unit content of 20 to 40% by mass relative to the total units. If content of a vinyl acetate unit is 20 mass% or more, it will become easy to obtain a high crosslinking rate and the outstanding adhesiveness. If the content of the vinyl acetate unit is 40% by mass or less, it is easy to suppress the unreacted vinyl acetate side chain from being detached due to heat, ultraviolet rays or the like to cause deterioration of the resin.
　本発明における樹脂組成物の樹脂基材には、ＥＶＡに加えて他の樹脂が含有されていてもよい。他の樹脂としては、ポリエチレン、ポリプロピレン等のポリオレフィン；アイオノマー；エチレン－メタクリル酸共重合体；エチレン－アクリル酸共重合体；ポリフッ化ビニル；ポリ塩化ビニル、またはこれらの共重合体等が挙げられる。
　本発明における樹脂組成物の樹脂基材中のＥＶＡの割合、すなわち本発明の封止材シートの樹脂基材中のＥＶＡの割合は、９５質量％以上が好ましく、９７質量％以上がより好ましく、１００質量％が特に好ましい。 In addition to EVA, the resin base material of the resin composition in the present invention may contain other resins. Examples of other resins include polyolefins such as polyethylene and polypropylene; ionomers; ethylene-methacrylic acid copolymers; ethylene-acrylic acid copolymers; polyvinyl fluoride; polyvinyl chloride or copolymers thereof.
The proportion of EVA in the resin substrate of the resin composition in the present invention, that is, the proportion of EVA in the resin substrate of the sealing material sheet of the present invention is preferably 95% by mass or more, more preferably 97% by mass or more, 100% by mass is particularly preferred.
　また、本発明の封止材シートには、前述のように、ＥＶＡの架橋反応を開始させる架橋剤として有機過酸化物が含有される。
　有機過酸化物としては、１，１－ジ（ｔ－ブチルパーオキシ）シクロヘキサン、１，１－ジ（ｔ－ヘキシルパーオキシ）シクロヘキサン、ｎ－ブチル－４，４－ジ－（ｔ－ブチルパーオキシ）バレレート、ｔ－ブチルパーオキシ－３，５，５－トリメチルヘキサノエート、２，５－ジメチル－２，５－ジ（ｔ－ブチルパーオキシ）ヘキサン、ｔ－ブチルクミルパーオキシド、２，２－ジ－（ｔ－ブチルパーオキシ）ブタン等が挙げられる。 In addition, as described above, the encapsulant sheet of the present invention contains an organic peroxide as a cross-linking agent that initiates the cross-linking reaction of EVA.
Examples of organic peroxides include 1,1-di (t-butylperoxy) cyclohexane, 1,1-di (t-hexylperoxy) cyclohexane, n-butyl-4,4-di- (t-butylperoxide). Oxy) valerate, t-butylperoxy-3,5,5-trimethylhexanoate, 2,5-dimethyl-2,5-di (t-butylperoxy) hexane, t-butylcumyl peroxide, 2, Examples include 2-di- (t-butylperoxy) butane.
　また、本発明の封止材シートには、前記有機過酸化物の他に、架橋反応を促進する架橋助剤が含有されていてもよい。架橋助剤としては、トリアリルイソシアヌレート、ジアリルフタレート、トリアリルシアヌレート等が挙げられる。 Moreover, the sealing material sheet of the present invention may contain a crosslinking aid for promoting the crosslinking reaction in addition to the organic peroxide. Examples of the crosslinking aid include triallyl isocyanurate, diallyl phthalate, triallyl cyanurate and the like.
　また、本発明の封止材シートには、太陽電池モジュールにおいて、封止材層と表面保護部材および裏面保護部材との接着性を向上させるために、シランカップリング剤が含有されていてもよい。シランカップリング剤としては、γ－メタクリロキシプロピルトリメトキシシラン、リメトキシプロピルシラン、トリメトキシメチルシラン、ビニルトリメトキシシラン、ビニルトリエトキシシラン、トリクロロプロピルシラン、トリエトキシフェニルシラン等が挙げられる。なかでも、接着促進性能が高いこと、及び、安価であることから、γ－メタクリロキシプロピルトリメトキシシランが好ましい。 Moreover, in the solar cell module, the sealing material sheet of the present invention may contain a silane coupling agent in order to improve the adhesion between the sealing material layer, the surface protection member, and the back surface protection member. . Examples of the silane coupling agent include γ-methacryloxypropyltrimethoxysilane, limethoxypropylsilane, trimethoxymethylsilane, vinyltrimethoxysilane, vinyltriethoxysilane, trichloropropylsilane, triethoxyphenylsilane, and the like. Of these, γ-methacryloxypropyltrimethoxysilane is preferred because of its high adhesion promoting performance and low cost.
　また、本発明の封止材シートには、形成される封止材層の耐久性を向上させるために、紫外線吸収剤、酸化防止剤、光安定化剤等の安定化剤が含有されていてもよい。
　紫外線吸収剤を含有させることにより、本発明の封止材シートにより形成される封止材層の耐光性が向上する。紫外線吸収剤としては、２－（５－メチル－２－ヒドロキシフェニル）ベンゾトリアゾール、２－（３－ｔ－ブチル－５－メチル－２－ヒドロキシフェニル）－５－クロロベンゾトリアゾール、２－（４，６－ジフェニル－１，３，５－トリアジン－２－イル）－５－［（ヘキシル）オキシ］－フェノール、２，４－ジヒドロキシベンゾフェノン、２－ヒドロキシ－４－ｎ－オクチルオキシベンゾフェノン等が挙げられる。 The encapsulant sheet of the present invention contains a stabilizer such as an ultraviolet absorber, an antioxidant, and a light stabilizer in order to improve the durability of the encapsulant layer to be formed. Also good.
By containing the ultraviolet absorber, the light resistance of the sealing material layer formed by the sealing material sheet of the present invention is improved. Examples of the ultraviolet absorber include 2- (5-methyl-2-hydroxyphenyl) benzotriazole, 2- (3-tert-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, etc. It is done.
　酸化防止剤を含有させることにより、本発明の封止材シートにより形成される封止材層の熱安定性が向上する。酸化防止剤としては、リン系酸化防止剤、フェノール系酸化防止剤が好ましい。酸化防止剤の具体例としては、１，６－ヘキサンジオール－ビス［３－（３，５－ジ－ｔ－ブチル－４－ヒドロキシフェニル）プロピオネート］、ペンタエリスリチル－テトラキス［３－（３，５－ジ－ｔ－ブチル－４－ヒドロキシフェニル）プロピオネート］、トリス（２，４－ジ－ｔ－ブチルフェニル）フォスファイト、２，４－ビス－（ｎ－オクチルチオ）－６－（４－ヒドロキシ－３，５－ジ－ｔ－ブチルアニリノ）－１，３，５－トリアジン、オクタデシル－３－（３，５－ジ－ｔ－ブチル－４－ヒドロキシフェニル）プロピオネート等が挙げられる。
　光安定化剤としては、ビス（２，２，６，６－テトラメチル－４－ピペリジル）セバケート等が挙げられる。 By containing an antioxidant, the thermal stability of the encapsulant layer formed by the encapsulant sheet of the present invention is improved. As antioxidant, phosphorus antioxidant and phenolic antioxidant are preferable. Specific examples of the antioxidant include 1,6-hexanediol-bis [3- (3,5-di-tert-butyl-4-hydroxyphenyl) propionate], pentaerythrityl-tetrakis [3- (3 5-di-t-butyl-4-hydroxyphenyl) propionate], tris (2,4-di-t-butylphenyl) phosphite, 2,4-bis- (n-octylthio) -6- (4-hydroxy -3,5-di-t-butylanilino) -1,3,5-triazine, octadecyl-3- (3,5-di-t-butyl-4-hydroxyphenyl) propionate and the like.
Examples of the light stabilizer include bis (2,2,6,6-tetramethyl-4-piperidyl) sebacate.
　本発明の封止材シートは、前述したように、ＥＶＡと有機過酸化物を少なくとも含有し、必要に応じて他の樹脂基材、架橋助剤、シランカップリング剤、紫外線吸収剤、酸化防止剤、光安定化剤等を含有する樹脂組成物により形成される。また、該樹脂組成物は、下記ミキサー試験における最大トルクＣ（単位：Ｎ・ｍ）が５５≦Ｃ≦８５であり、かつ最大トルク時間Ｄ（単位：分）が６．５≦Ｄ≦１１．７の組成物であることを特徴とする。
（ミキサー試験）
　ミキサー型式がＲ１００のミキサーに、前記樹脂組成物を前記ミキサーの容量に対して８０容量％となるように投入し、混錬温度１４０℃、回転数５０ｒｐｍで混練する。ただし、樹脂組成物の平均粒径は３．５ｍｍである。言い換えると、樹脂組成物は平均粒径が３．５ｍｍになるようにペレット化され、該平均粒径が３．５ｍｍとなるようにペレット化された樹脂組成物がミキサーに投入され最大トルクＣ及び最大トルク時間Ｄが測定される。 As described above, the sealing material sheet of the present invention contains at least EVA and an organic peroxide, and if necessary, other resin base materials, crosslinking aids, silane coupling agents, ultraviolet absorbers, and antioxidants. Formed of a resin composition containing an agent, a light stabilizer and the like. In addition, the resin composition has a maximum torque C (unit: N · m) in the following mixer test of 55 ≦ C ≦ 85, and a maximum torque time D (unit: minute) of 6.5 ≦ D ≦ 11. It is characterized by being a composition of 7.
(Mixer test)
The resin composition is put into a mixer having a mixer type of R100 so that the volume of the resin composition is 80% by volume with respect to the volume of the mixer, and kneaded at a kneading temperature of 140 ° C. and a rotation speed of 50 rpm. However, the average particle size of the resin composition is 3.5 mm. In other words, the resin composition is pelletized so that the average particle diameter is 3.5 mm, and the resin composition pelletized so that the average particle diameter is 3.5 mm is put into a mixer and the maximum torque C and The maximum torque time D is measured.
　本発明における最大トルクＣとは、図１に示すように、ミキサー試験における最大のトルクを意味する。ミキサー試験の初期では、樹脂組成物に含有させる各成分が溶融することによりトルクが低下し、その後に有機過酸化物によるＥＶＡの架橋反応が進行することでトルクが増大し、最大トルクＣが計測される。
　また、本発明における最大トルク時間Ｄとは、ミキサー試験の開始時（混錬開始時）から、最大トルクＣが計測されるまでの時間を意味する。具体的には、ミキサーを１４０℃まで昇温した後に、該ミキサーに樹脂組成物に含有させる各成分を投入し、直ちに回転数５０ｒｐｍで混練を開始し、その時点を開始時として、最大トルクＣが計測されるまでの時間を最大トルク時間Ｄとする。 The maximum torque C in the present invention means the maximum torque in the mixer test as shown in FIG. In the initial stage of the mixer test, the torque decreases as each component contained in the resin composition melts, and then the torque increases as the EVA crosslinking reaction with organic peroxide proceeds, and the maximum torque C is measured. Is done.
Further, the maximum torque time D in the present invention means the time from the start of the mixer test (at the start of kneading) until the maximum torque C is measured. Specifically, after the temperature of the mixer is raised to 140 ° C., each component to be contained in the resin composition is added to the mixer, and kneading is immediately started at a rotation speed of 50 rpm. Is the maximum torque time D.
　前記ミキサー試験のミキサーとしては、例えば、ラボプラストミル（本体型式：４Ｃ１５０、ミキサー型式：Ｒ１００、ミキサー容量：１００ｇ、東洋精機製作所製）が使用できる。
　前記ラボプラストミルを使用する場合、ミキサー容量１００ｇの８０容量％に相当する８０ｇとなるように樹脂組成物の各成分を投入し、混錬温度１４０℃、回転数５０ｒｐｍで混練することにより、最大トルクＣと最大トルク時間Ｄを測定する。該ラボプラストミルにより実施されるミキサー試験では、２本のスクリューを定速回転させ、スクリュー間およびスクリューとミキサー内壁との間で樹脂組成物を混練し、その混練抵抗が主ローラーの軸に受けるトルクとして測定される。
　ミキサー試験における測定環境温度は、２０～２５℃の範囲内でおこなわれる。 As a mixer for the mixer test, for example, a lab plast mill (main body model: 4C150, mixer model: R100, mixer capacity: 100 g, manufactured by Toyo Seiki Seisakusho) can be used.
When using the lab plast mill, each component of the resin composition is added so as to be 80 g corresponding to 80% by volume of the mixer capacity of 100 g, and kneading is performed at a kneading temperature of 140 ° C. and a rotation speed of 50 rpm. Torque C and maximum torque time D are measured. In the mixer test carried out by the Laboplast mill, two screws are rotated at a constant speed to knead the resin composition between the screws and between the screw and the mixer inner wall, and the kneading resistance is received by the shaft of the main roller. Measured as torque.
The measurement environment temperature in the mixer test is performed within a range of 20 to 25 ° C.
　前記ミキサー試験における最大トルクＣ（Ｎ・ｍ）は、５５≦Ｃ≦５であり、さらには６０≦Ｃ≦８０であることが好ましい。最大トルクＣが５５Ｎ・ｍ以上とすることにより、形成される封止材層が柔らかすぎて太陽電池モジュールの製造時に封止材がはみだすことを抑制できる。最大トルクＣが８５Ｎ・ｍ以下とすることにより、形成される封止材層が硬くなりすぎ、太陽電池セルに加わる物理的ストレスが大きくなってセル割れが生じることを抑制できる。 The maximum torque C (N · m) in the mixer test is 55 ≦ C ≦ 5, more preferably 60 ≦ C ≦ 80. By setting the maximum torque C to 55 N · m or more, it is possible to prevent the sealing material layer formed from being too soft and the sealing material from protruding when the solar cell module is manufactured. By setting the maximum torque C to 85 N · m or less, it is possible to suppress the formed sealing material layer from becoming too hard and causing physical stress applied to the solar battery cell to increase, resulting in cell cracking.
　また、前記ミキサー試験における最大トルク時間Ｄ（分）は、６．５≦Ｄ≦１１．７であり、さらには７．５≦Ｄ≦１０．７であることが好ましい。最大トルク時間Ｄが６．５分以上とすることにより、シート成形時にゲルが発生することを抑制でき、生産性が向上する。最大トルク時間Ｄが１１．７分以下とすることにより、形成される封止材層の架橋率が低くなることを抑制でき、また太陽電池モジュールの製造をより短時間で行え、太陽電池モジュール製造時の架橋反応の温度を著しく高温にする必要もなくなる。 The maximum torque time D (minute) in the mixer test is 6.5 ≦ D ≦ 11.7, and more preferably 7.5 ≦ D ≦ 10.7. By setting the maximum torque time D to 6.5 minutes or more, it is possible to suppress the generation of gel during sheet forming, and the productivity is improved. By setting the maximum torque time D to 11.7 minutes or less, it is possible to suppress a reduction in the crosslinking rate of the formed sealing material layer, and it is possible to manufacture the solar cell module in a shorter time. There is no need to make the temperature of the crosslinking reaction extremely high.
　前記ミキサー試験における最大トルクＣと最大トルク時間Ｄは、特に有機過酸化物の種類及び添加量の影響が大きく、有機過酸化物の添加量が増加するほど最大トルクＣが増大し、最大トルク時間Ｄが短くなる傾向がある。ただし、有機過酸化物の種類によって最大トルクＣと最大トルク時間Ｄの変化の程度は異なり、また添加量と最大トルクＣ及び最大トルク時間Ｄの変化も常に比例関係にあるわけではない。そのため、本発明の封止材シートを形成する樹脂組成物の組成は、有機過酸化物等の添加剤の種類及び添加量を変化させつつ、最大トルクＣ及び最大トルク時間Ｄを測定し、前記条件を満たすように決定する必要がある。 The maximum torque C and the maximum torque time D in the mixer test are particularly affected by the type and addition amount of the organic peroxide, and the maximum torque C increases as the addition amount of the organic peroxide increases. D tends to be shorter. However, the degree of change in the maximum torque C and the maximum torque time D differs depending on the type of organic peroxide, and the addition amount and the change in the maximum torque C and the maximum torque time D are not always in a proportional relationship. Therefore, the composition of the resin composition forming the encapsulant sheet of the present invention is to measure the maximum torque C and the maximum torque time D while changing the type and amount of additives such as organic peroxide, It is necessary to decide to satisfy the conditions.
（封止材シートの製造方法）
　以下、本発明の封止材シートの製造方法について説明する。
　本発明の封止材シートの製造方法は、前記ミキサー試験により最大トルクＣと最大トルク時間Ｄを測定し、それらが前記範囲となるように有機過酸化物等の添加剤を添加して樹脂組成物の組成を決定する工程（Ｘ）と、前記工程（Ｘ）で決定した組成の樹脂組成物により封止材シートを成形する工程（Ｙ）とを有する。
　工程（Ｘ）におけるミキサー試験による樹脂組成物の組成の決定については、前述したとおりである。 (Method for producing sealing material sheet)
Hereinafter, the manufacturing method of the sealing material sheet of this invention is demonstrated.
The manufacturing method of the sealing material sheet of this invention measures the maximum torque C and the maximum torque time D by the said mixer test, and adds additives, such as an organic peroxide, so that they may become the said range, and resin composition A step (X) for determining the composition of the product, and a step (Y) for forming a sealing material sheet from the resin composition having the composition determined in the step (X).
The determination of the composition of the resin composition by the mixer test in the step (X) is as described above.
　また、工程（Ｙ）における封止材シートの成形方法は、公知の方法を採用できる。例えば、樹脂組成物を加熱溶融させた状態でＴダイ等を用いて押し出す、共押し出し法により、封止材シートを製膜する方法が挙げられる。前記製膜においては、ブロッキング防止のため、熱溶融した状態の樹脂シートの表面を、凹凸パターンが施されているロール（金属またはゴム製）に密着させることで、該樹脂シート片面もしくは両面に該ロールの凹凸パターンを転写させ、封止材シートにエンボス加工を施してもよい。 Moreover, a well-known method can be employ | adopted as the shaping | molding method of the sealing material sheet in a process (Y). For example, a method of forming a sealing material sheet by a co-extrusion method in which a resin composition is heated and melted and extruded using a T die or the like can be mentioned. In the film formation, in order to prevent blocking, the surface of the heat-melted resin sheet is brought into close contact with a roll (made of metal or rubber) having a concavo-convex pattern so that the resin sheet is provided on one or both surfaces. The uneven pattern of the roll may be transferred to emboss the encapsulant sheet.
　以上説明した本発明の封止材シートは、最大トルクＣ及び最大トルク時間Ｄを所定の範囲に調整した樹脂組成物により形成されていることで、シート成形性に優れ、太陽電池モジュールの製造時に太陽電池セルの破損及び封止材のはみだしを抑制でき、高い架橋率を有する封止材層を安定して形成できるので、信頼性が高い。 The sealing material sheet of the present invention described above is formed of a resin composition in which the maximum torque C and the maximum torque time D are adjusted to predetermined ranges, so that the sheet moldability is excellent, and the solar cell module is manufactured. Since the damage of the solar battery cell and the sticking out of the sealing material can be suppressed and a sealing material layer having a high crosslinking rate can be stably formed, the reliability is high.
＜太陽電池モジュール＞
　本発明の太陽電池モジュールは、太陽電池セルと、前記太陽電池セルを封止する封止材層と、前記封止材層の表面側を保護する表面保護部材と、前記封止材層の裏面側を保護する裏面保護部材と、を有し、前記封止材層が、前述した本発明の封止材シートにより形成されているモジュールである。以下、本発明の太陽電池モジュールの実施形態の一例を示して詳細に説明する。 <Solar cell module>
The solar battery module of the present invention includes a solar battery cell, a sealing material layer that seals the solar battery cell, a surface protection member that protects the surface side of the sealing material layer, and a back surface of the sealing material layer. A back surface protection member that protects the side, wherein the sealing material layer is formed of the sealing material sheet of the present invention described above. Hereinafter, an exemplary embodiment of the solar cell module of the present invention will be described in detail.
　本実施形態の太陽電池モジュール１は、図２に示すように、太陽電池セル４、４と、太陽電池セル４、４を封止する封止材層３と、封止材層３の表面側を保護する表面保護部材２と、封止材層３の裏面側を保護する裏面保護部材５とを有する。 As shown in FIG. 2, the solar cell module 1 of the present embodiment includes solar cells 4 and 4, a sealing material layer 3 that seals the solar cells 4 and 4, and a surface side of the sealing material layer 3. And a back surface protection member 5 for protecting the back surface side of the sealing material layer 3.
（太陽電池セル）
　太陽電池セル４は、光電効果により受光面に入射した光を電気に変換する機能を有するセルである。太陽電池セル４は、太陽電池モジュール１内において複数個（図２では２つ）が電極（図示省略）によって接続されている。太陽電池セル４の数は特に限定されない。
　太陽電池セル４の材料としては、例えば、結晶系シリコンが挙げられる。なかでも、製造の簡便さとコスト面から、多結晶シリコンが特に好ましい。 (Solar cell)
The solar battery cell 4 is a cell having a function of converting light incident on the light receiving surface into electricity by a photoelectric effect. A plurality (two in FIG. 2) of solar cells 4 are connected by electrodes (not shown) in the solar cell module 1. The number of solar cells 4 is not particularly limited.
Examples of the material of the solar battery cell 4 include crystalline silicon. Among these, polycrystalline silicon is particularly preferable from the viewpoint of manufacturing simplicity and cost.
（封止材層）
　封止材層３は、太陽電池セル４、４を包埋させて封止する層であり、本発明の封止材シートにより形成される。
　封止材層３の厚さは、０．３～０．６ｍｍが好ましい。 (Encapsulant layer)
The sealing material layer 3 is a layer that embeds and seals the solar cells 4 and 4 and is formed of the sealing material sheet of the present invention.
The thickness of the sealing material layer 3 is preferably 0.3 to 0.6 mm.
（表面保護部材）
　表面保護材２としては、耐久性、耐候性、透明性に優れたものが好ましく、例えば、ガラス板、ポリエチレンテレフタレート等の樹脂シート等が挙げられる。また、ポリカーボネート等の樹脂シートを用いてもよい。
　表面保護部材２の厚さは、３～６ｍｍが好ましい。 (Surface protection member)
As the surface protective material 2, those excellent in durability, weather resistance, and transparency are preferable, and examples thereof include a glass sheet, a resin sheet such as polyethylene terephthalate, and the like. Moreover, you may use resin sheets, such as a polycarbonate.
The thickness of the surface protection member 2 is preferably 3 to 6 mm.
（裏面保護部材）
　裏面保護部材５としては、耐久性、耐候性に優れたものが好ましく、例えば、ポリエチレンテレフタレート、ポリビニルフロライド、ＥＶＡ等の樹脂シート、及びそれらの積層体等が挙げられる。また、前記樹脂シートや積層体には、水蒸気バリア性、酸素バリア性付与するバリア層を積層してもよい。
　裏面保護部材５の厚さは、０．２～０．４ｍｍが好ましい。 (Back protection member)
As the back surface protection member 5, those excellent in durability and weather resistance are preferable, and examples thereof include resin sheets such as polyethylene terephthalate, polyvinyl fluoride, EVA, and laminates thereof. Moreover, you may laminate | stack the barrier layer which provides water vapor | steam barrier property and oxygen barrier property to the said resin sheet and laminated body.
The thickness of the back surface protection member 5 is preferably 0.2 to 0.4 mm.
（製造方法）
　以下、本発明の太陽電池モジュールの製造方法の一例として、前記太陽電池モジュール１の製造方法を説明する。ただし、本発明の太陽電池モジュールの製造方法は以下の方法には限定されない。
　図３に示すように、裏面保護部材２、封止材シート３Ａ、太陽電池セル４、４、封止材シート３Ｂ、表面保護部材５をこの順に積層して積層体１Ａとする。次いで、積層体１Ａを真空状態で加熱加圧する真空ラミネートを行い、封止材シート３Ａ、３Ｂ内に太陽電池セル４、４を埋没させ、封止材シート３Ａ、３Ｂの樹脂基材（ＥＶＡ）を架橋硬化させて接着一体化することで封止材層３を形成させる。これにより、太陽電池モジュール１が得られる。
　封止材シート３Ａと封止材シート３Ｂは本発明の封止材シートであり、同じ組成の封止材シートであってもよく、異なる組成の封止材シートであってもよいが、均一に架橋構造が形成されることで良好な品質のモジュールが得られやすい点から、同じ組成の封止材シートであることが好ましい。 (Production method)
Hereinafter, the manufacturing method of the said solar cell module 1 is demonstrated as an example of the manufacturing method of the solar cell module of this invention. However, the manufacturing method of the solar cell module of the present invention is not limited to the following method.
As shown in FIG. 3, the back surface protection member 2, the sealing material sheet 3A, the solar battery cells 4, 4, the sealing material sheet 3B, and the surface protection member 5 are laminated in this order to form a laminated body 1A. Subsequently, the laminated body 1A is vacuum-laminated by heating and pressing in a vacuum state, solar cells 4 and 4 are embedded in the sealing material sheets 3A and 3B, and the resin base material (EVA) of the sealing material sheets 3A and 3B. Are cured by cross-linking, and the sealing material layer 3 is formed. Thereby, the solar cell module 1 is obtained.
The sealing material sheet 3A and the sealing material sheet 3B are the sealing material sheets of the present invention, may be the same composition sealing material sheet, may be different composition sealing material sheet, but uniform It is preferable that the sealing material sheet has the same composition from the viewpoint that a good quality module is easily obtained by forming a crosslinked structure.
　以上説明した本発明の太陽電池モジュールは、本発明の封止材シートを用いているため、太陽電池セルの破損及び封止材のはみだしが抑制されており、また高い架橋率の封止材層を有しているので、信頼性が高い。 Since the solar cell module of the present invention described above uses the encapsulant sheet of the present invention, the solar cell module is prevented from being damaged and protruding from the encapsulant, and the encapsulant layer having a high crosslinking rate. It has high reliability.
　以下、実施例及び比較例を示して本発明を詳細に説明する。ただし、本発明は以下の記載によっては限定されない。
［使用原料］
　本実施例で使用した原料を以下に示す。
（ＥＶＡ）
　ＥＶＡ－１：酢酸ビニル単位の含有量が３０質量％のＥＶＡ Hereinafter, the present invention will be described in detail with reference to Examples and Comparative Examples. However, the present invention is not limited by the following description.
[Raw materials]
The raw materials used in this example are shown below.
(EVA)
EVA-1: EVA having a vinyl acetate unit content of 30% by mass
（有機過酸化物）
　Ｉ－１：ｔ－ブチルパーオキシ－２－エチルヘキシルモノカーボネート (Organic peroxide)
I-1: t-Butylperoxy-2-ethylhexyl monocarbonate
（シランカップリング剤）
　ＩＩ－１：γ－メタクリロキシプロピルトリメトキシシラン (Silane coupling agent)
II-1: γ-methacryloxypropyltrimethoxysilane
（架橋助剤）
　ＩＩＩ－１：トリアリルイソシアヌレート (Crosslinking aid)
III-1: Triallyl isocyanurate
（紫外線吸収剤）
　ＩＶ－１：２－ヒドロキシ－４－ｎ－オクチルオキシベンゾフェノン (UV absorber)
IV-1: 2-hydroxy-4-n-octyloxybenzophenone
（光安定剤）
　Ｖ－１：ビス（２，２，６，６－テトラメチル－４－ピペリジル）セバケート (Light stabilizer)
V-1: Bis (2,2,6,6-tetramethyl-4-piperidyl) sebacate
（酸化防止剤）
　ＶＩ－１：トリス（２，４－ジ－ｔ－ブチルフェニル）フォスファイト (Antioxidant)
VI-1: Tris (2,4-di-t-butylphenyl) phosphite
［実施例１］
　樹脂基材であるＥＶＡ－１の１００質量部に対し、有機過酸化物Ｉ－１を０．４質量部、シランカップリング剤ＩＩ－１を０．４質量部、架橋助剤ＩＩＩ－１を０．６質量部、紫外線吸収剤ＩＶ－１を０．１質量部、光安定剤Ｖ－１を０．１質量部、及び酸化防止剤ＶＩ－１を０．１質量部配合した樹脂組成物を用いて、Ｔダイ法により厚み０．４５ｍｍの封止材シートを作製した。 [Example 1]
0.4 parts by mass of organic peroxide I-1, 0.4 parts by mass of silane coupling agent II-1, and cross-linking aid III-1 with respect to 100 parts by mass of EVA-1 as a resin base material Resin composition containing 0.6 part by weight, 0.1 part by weight of UV absorber IV-1, 0.1 part by weight of light stabilizer V-1 and 0.1 part by weight of antioxidant VI-1 Was used to prepare a sealing material sheet having a thickness of 0.45 mm by the T-die method.
［実施例２］
　有機過酸化物Ｉ－１の添加量が０．６質量部、シランカップリング剤ＩＩ－１の添加量が．５質量部である以外は、実施例１と同様にして封止材シートを作製した。 [Example 2]
The amount of organic peroxide I-1 added is 0.6 parts by mass, and the amount of silane coupling agent II-1 added is. A sealing material sheet was produced in the same manner as in Example 1 except that the amount was 5 parts by mass.
［実施例３］
　有機過酸化物Ｉ－１の添加量が０．５５質量部、シランカップリング剤ＩＩ－１の添加量が０．４質量部である以外は、実施例１と同様にして封止材シートを作製した。 [Example 3]
A sealing material sheet was prepared in the same manner as in Example 1 except that the addition amount of the organic peroxide I-1 was 0.55 parts by mass and the addition amount of the silane coupling agent II-1 was 0.4 parts by mass. Produced.
［実施例４］
　有機過酸化物Ｉ－１の添加量が０．７５質量部、シランカップリング剤ＩＩ－１の添加量が０．４質量部である以外は、実施例１と同様にして封止材シートを作製した。 [Example 4]
A sealing material sheet was prepared in the same manner as in Example 1 except that the addition amount of the organic peroxide I-1 was 0.75 parts by mass and the addition amount of the silane coupling agent II-1 was 0.4 parts by mass. Produced.
［比較例１］
　有機過酸化物Ｉ－１の添加量が０．３質量部、シランカップリング剤ＩＩ－１の添加量が０．６質量部である以外は、実施例１と同様にして封止材シートを作製した。 [Comparative Example 1]
A sealing material sheet was prepared in the same manner as in Example 1 except that the addition amount of the organic peroxide I-1 was 0.3 parts by mass and the addition amount of the silane coupling agent II-1 was 0.6 parts by mass. Produced.
［比較例２］
　有機過酸化物Ｉ－１の添加量が０．３質量部、シランカップリング剤ＩＩ－１の添加量が０．４質量部である以外は、実施例１と同様にして封止材シートを作製した。 [Comparative Example 2]
A sealing material sheet was prepared in the same manner as in Example 1 except that the addition amount of the organic peroxide I-1 was 0.3 parts by mass and the addition amount of the silane coupling agent II-1 was 0.4 parts by mass. Produced.
［比較例３］
　有機過酸化物Ｉ－１の添加量が０．６質量部、シランカップリング剤ＩＩ－１の添加量が０．２質量部である以外は、実施例１と同様にして封止材シートを作製した。 [Comparative Example 3]
A sealing material sheet was prepared in the same manner as in Example 1 except that the addition amount of the organic peroxide I-1 was 0.6 parts by mass and the addition amount of the silane coupling agent II-1 was 0.2 parts by mass. Produced.
［比較例４］
　有機過酸化物Ｉ－１の添加量が０．７５質量部、シランカップリング剤ＩＩ－１の添加量が０．２質量部である以外は、実施例１と同様にして封止材シートを作製した。
　各例の封止材シートの作製に用いた樹脂組成物のミキサー試験における最大トルクＣ（単位：Ｎ・ｍ）と最大トルク時間Ｄ（単位：分）を表１に示す。 [Comparative Example 4]
A sealing material sheet was prepared in the same manner as in Example 1 except that the addition amount of the organic peroxide I-1 was 0.75 parts by mass and the addition amount of the silane coupling agent II-1 was 0.2 parts by mass. Produced.
Table 1 shows the maximum torque C (unit: N · m) and the maximum torque time D (unit: minute) in the mixer test of the resin composition used for producing the sealing material sheet of each example.
［ミキサー試験］
　ラボプラストミル（本体型式：４Ｃ１５０、ミキサー型式：Ｒ１００、ミキサー容量：１００ｇ、東洋精機製作所）を使用し、樹脂組成物に含有させる各成分を該ミキサー容量に対して８０容量％（８０ｇ）となるように投入し、混錬温度１４０℃、回転数５０ｒｐｍで混練し、最大トルクＣと最大トルク時間Ｄを測定した。 [Mixer test]
Using a lab plast mill (main body model: 4C150, mixer model: R100, mixer capacity: 100 g, Toyo Seiki Seisakusho), each component contained in the resin composition is 80% by volume (80 g) with respect to the mixer capacity. And kneaded at a kneading temperature of 140 ° C. and a rotation speed of 50 rpm, and the maximum torque C and the maximum torque time D were measured.
［評価方法］
　実施例及び比較例で得られた封止材シートについて、「セル割れ」、「ＥＶＡのはみだし」、「架橋率」、「シート成形性」を以下に示す方法で評価した。
（セル割れ）
　各例で得られた封止材シート２枚と、太陽電池セル、表面保護部材及び裏面保護部材とを図３のように重ね合わせ、１気圧で加圧しながら１５０℃、１０分間キュアして擬似モジュールを作製し、表面保護部材側から目視にてセル割れを確認して下記基準で評価した。表面保護部材としては白板ガラス（３ｍｍ厚）を、裏面保護部材としてはフッ化ビニルポリマーフィルム（３８μｍ厚）を用いた。また、太陽電池セルとしては多結晶シリコンセルを用いた。
　　「○」：セル割れが確認されなかった。
　　「×」：セル割れが生じた。 [Evaluation methods]
About the sealing material sheet obtained by the Example and the comparative example, "the cell crack", "the protrusion of EVA", "crosslinking rate", and "sheet moldability" were evaluated by the method shown below.
(Cell crack)
The two sealing material sheets obtained in each example, the solar battery cell, the front surface protection member, and the back surface protection member are overlapped as shown in FIG. 3, and cured at 150 ° C. for 10 minutes while being pressurized at 1 atm. A module was prepared, and cell cracks were visually confirmed from the surface protective member side and evaluated according to the following criteria. White plate glass (3 mm thickness) was used as the surface protection member, and a vinyl fluoride polymer film (38 μm thickness) was used as the back surface protection member. Moreover, a polycrystalline silicon cell was used as the solar battery cell.
"(Circle)": The cell crack was not confirmed.
“×”: Cell cracking occurred.
（ＥＶＡのはみだし）
　前記セル割れと同様にして作製した擬似モジュールについて、表面保護部材側から見たときのＥＶＡのはみだしの有無を目視により確認し、下記基準で評価した。
　　「○」：ＥＶＡのはみだしが確認された。
　　「×」：ＥＶＡのはみだしが確認されなかった。 (The overhang of EVA)
About the pseudo module produced similarly to the said cell crack, the presence or absence of the protrusion of EVA when it sees from the surface protection member side was confirmed visually, and the following reference | standard evaluated.
“◯”: The overhang of EVA was confirmed.
"X": The protrusion of EVA was not confirmed.
（架橋率）
　各例で作製した封止材シートを１５０℃で１０分間真空加圧した後、そのうちの１ｇをサンプリングしてキシレン１００ｍＬに浸漬し、１１０℃で１２時間溶融させた後、非溶融成分の質量を測定し、下式の質量比を算出することにより架橋率（単位：％）を求め、下記基準で評価した。
　　架橋率＝［非溶融成分の質量（ｇ）／溶融前の質量（１ｇ）］×１００
　　架橋率は、８０％以上のものを合格とした。 (Crosslinking rate)
The encapsulant sheet produced in each example was vacuum-pressurized at 150 ° C. for 10 minutes, 1 g of which was sampled and immersed in 100 mL of xylene and melted at 110 ° C. for 12 hours. It measured and calculated | required the crosslinking ratio (unit:%) by calculating the mass ratio of the following Formula, and evaluated it on the following reference | standard.
Crosslinking rate = [mass of non-molten component (g) / mass before melting (1 g)] × 100
The cross-linking rate was 80% or more.
（シート成形性）
　各例で得られた封止材シートにおける１ｍ２あたりのゲルの発生数を目視で計測し、下記基準で評価した。計測するゲルは半径２ｍｍ以上のものとした。また、確認面積は２ｍ２とした。
　　「○」：１ｍ２あたりのゲルの発生数が０個であった。
　　「×」：１ｍ２あたりのゲルの発生数が１個以上であった。
　実施例及び比較例における各評価結果を表１に示す。 (Sheet formability)
The number of gels generated per 1 m 2 in the encapsulant sheet obtained in each example was visually measured and evaluated according to the following criteria. The gel to be measured has a radius of 2 mm or more. The confirmation area was 2 m 2 .
“◯”: The number of gels generated per 1 m 2 was zero.
“X”: The number of gels generated per 1 m 2 was 1 or more.
Table 1 shows the results of evaluation in Examples and Comparative Examples.
Figure JPOXMLDOC01-appb-T000001
Figure JPOXMLDOC01-appb-T000001
　表１に示すように、最大トルクＣ及び最大トルク時間Ｄが適切な樹脂組成物をシート成形して封止材シートを得た実施例１～４では、シート成形時にゲルが発生しておらず、品質が良好な封止材シートが得られた。また、該封止材シートは、セル割れ及びＥＶＡのはみだしを抑制しつつ、高い架橋率の封止材層を形成できた。 As shown in Table 1, in Examples 1 to 4 in which a sealing material sheet was obtained by sheet-molding a resin composition having appropriate maximum torque C and maximum torque time D, no gel was generated during sheet molding. A sealing material sheet with good quality was obtained. Moreover, this sealing material sheet was able to form the sealing material layer of a high crosslinking rate, suppressing the cell crack and the protrusion of EVA.
　一方、最大トルクＣが５５Ｎ・ｍ未満で、最大トルク時間Ｄが１１．７分を超えるの樹脂組成物をシート成形して封止材シートを得た比較例１及び２では、封止材層の架橋率が低く、モジュールの品質が低かった。また、最大トルクＣがより小さい比較例１では、比較例２に比べてＥＶＡのはみだしも確認され、モジュールの品質はさらに低かった。
　最大トルクＣが８５Ｎ・ｍを超え、最大トルク時間Ｄが６．５分未満の樹脂組成物をシート成形して封止材シートを得た比較例３及び４では、封止材層が硬くなりすぎてセル割れが生じた。また、最大トルク時間Ｄがより短い比較例４では、比較例３に比べてシート成形時のゲルの発生も確認され、封止材シートの品質も低かった。 On the other hand, in Comparative Examples 1 and 2 in which a sealing material sheet was obtained by molding a resin composition having a maximum torque C of less than 55 N · m and a maximum torque time D exceeding 11.7 minutes, The crosslinking rate was low, and the quality of the module was low. Further, in Comparative Example 1 in which the maximum torque C is smaller, the protrusion of EVA was confirmed as compared with Comparative Example 2, and the quality of the module was further lower.
In Comparative Examples 3 and 4 in which a sealing material sheet was obtained by molding a resin composition having a maximum torque C exceeding 85 N · m and a maximum torque time D being less than 6.5 minutes, the sealing material layer becomes harder. Too much cell cracking occurred. Further, in Comparative Example 4 in which the maximum torque time D is shorter, the generation of gel at the time of forming the sheet was confirmed as compared with Comparative Example 3, and the quality of the sealing material sheet was also low.
　１　　太陽電池モジュール
　２　　表面保護部材
　３　　封止材層
　３Ａ、３Ｂ　　封止材シート
　４　　太陽電池セル
　５　　裏面保護部材 DESCRIPTION OF SYMBOLS 1 Solar cell module 2 Surface protection member 3 Sealing material layer 3A, 3B Sealing material sheet 4 Solar cell 5 Back surface protection member

Claims (2)

  1. 　エチレン－酢酸ビニル共重合体と有機過酸化物とを含有する樹脂組成物から形成された太陽電池モジュール用封止材シートであって、
    　前記樹脂組成物が、下記ミキサー試験における最大トルクＣ（単位：Ｎ・ｍ）が５５≦Ｃ≦８５であり、かつ最大トルク時間Ｄ（単位：分）が６．５≦Ｄ≦１１．７の組成物であることを特徴とする太陽電池モジュール用封止材シート。
    （ミキサー試験）
    　ミキサー型式がＲ１００のミキサーに、前記樹脂組成物を前記ミキサーの容量に対して８０容量％となるように投入し、混錬温度１４０℃、回転数５０ｒｐｍで混練する。ただし、前記樹脂組成物の平均粒径は３．５ｍｍである。     A solar cell module sealing material sheet formed from a resin composition containing an ethylene-vinyl acetate copolymer and an organic peroxide,
    In the resin composition, the maximum torque C (unit: N · m) in the following mixer test is 55 ≦ C ≦ 85, and the maximum torque time D (unit: minute) is 6.5 ≦ D ≦ 11.7. It is a composition, The sealing material sheet for solar cell modules characterized by the above-mentioned.
    (Mixer test)
    The resin composition is put into a mixer having a mixer type of R100 so that the volume of the resin composition is 80% by volume with respect to the volume of the mixer, and kneaded at a kneading temperature of 140 ° C. and a rotation speed of 50 rpm. However, the average particle diameter of the resin composition is 3.5 mm.
  2. 　太陽電池セルと、前記太陽電池セルを封止する封止材層と、前記封止材層の表面側を保護する表面保護部材と、前記封止材層の裏面側を保護する裏面保護部材と、を有し、
    　前記封止材層が、請求項１に記載の太陽電池モジュール用封止材シートにより形成されている太陽電池モジュール。     A solar battery cell, a sealing material layer that seals the solar battery cell, a surface protection member that protects the front surface side of the sealing material layer, and a back surface protection member that protects the back surface side of the sealing material layer; Have
    The solar cell module in which the said sealing material layer is formed with the sealing material sheet for solar cell modules of Claim 1.
PCT/JP2011/054112 2010-03-16 2011-02-24 Sealing material sheet for solar cell module, and solar cell module WO2011114853A1 (en)

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2014187316A (en) * 2013-03-25 2014-10-02 Du Pont Mitsui Polychem Co Ltd Sheet for solar battery sealing material, and solar battery module

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Publication number Priority date Publication date Assignee Title
JP2007134352A (en) * 2005-10-13 2007-05-31 Sekisui Film Kk Adhesive sheet for solar cell
JP2008098457A (en) * 2006-10-13 2008-04-24 Sekisui Chem Co Ltd Method of manufacturing adhesive sheet for solar cell
JP2008205448A (en) * 2007-01-22 2008-09-04 Bridgestone Corp Sealing film for solar cells and solar cells using the same

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2007134352A (en) * 2005-10-13 2007-05-31 Sekisui Film Kk Adhesive sheet for solar cell
JP2008098457A (en) * 2006-10-13 2008-04-24 Sekisui Chem Co Ltd Method of manufacturing adhesive sheet for solar cell
JP2008205448A (en) * 2007-01-22 2008-09-04 Bridgestone Corp Sealing film for solar cells and solar cells using the same

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2014187316A (en) * 2013-03-25 2014-10-02 Du Pont Mitsui Polychem Co Ltd Sheet for solar battery sealing material, and solar battery module

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