WO2011132589A1 - 光半導体保護材及びその前駆体並びに光半導体保護材の製造方法 - Google Patents
光半導体保護材及びその前駆体並びに光半導体保護材の製造方法 Download PDFInfo
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- WO2011132589A1 WO2011132589A1 PCT/JP2011/059217 JP2011059217W WO2011132589A1 WO 2011132589 A1 WO2011132589 A1 WO 2011132589A1 JP 2011059217 W JP2011059217 W JP 2011059217W WO 2011132589 A1 WO2011132589 A1 WO 2011132589A1
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- WIPO (PCT)
- Prior art keywords
- optical semiconductor
- protective material
- semiconductor protective
- weight
- olefin
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- KKEYFWRCBNTPAC-UHFFFAOYSA-L terephthalate(2-) Chemical compound [O-]C(=O)C1=CC=C(C([O-])=O)C=C1 KKEYFWRCBNTPAC-UHFFFAOYSA-L 0.000 description 1
- SWAXTRYEYUTSAP-UHFFFAOYSA-N tert-butyl ethaneperoxoate Chemical compound CC(=O)OOC(C)(C)C SWAXTRYEYUTSAP-UHFFFAOYSA-N 0.000 description 1
- DLSMLZRPNPCXGY-UHFFFAOYSA-N tert-butylperoxy 2-ethylhexyl carbonate Chemical compound CCCCC(CC)COC(=O)OOOC(C)(C)C DLSMLZRPNPCXGY-UHFFFAOYSA-N 0.000 description 1
- 150000003512 tertiary amines Chemical class 0.000 description 1
- CIHOLLKRGTVIJN-UHFFFAOYSA-N tert‐butyl hydroperoxide Chemical compound CC(C)(C)OO CIHOLLKRGTVIJN-UHFFFAOYSA-N 0.000 description 1
- LFQCEHFDDXELDD-UHFFFAOYSA-N tetramethyl orthosilicate Chemical compound CO[Si](OC)(OC)OC LFQCEHFDDXELDD-UHFFFAOYSA-N 0.000 description 1
- 238000005979 thermal decomposition reaction Methods 0.000 description 1
- 229920002725 thermoplastic elastomer Polymers 0.000 description 1
- 229920005992 thermoplastic resin Polymers 0.000 description 1
- 229920001187 thermosetting polymer Polymers 0.000 description 1
- 239000010409 thin film Substances 0.000 description 1
- 125000003396 thiol group Chemical group [H]S* 0.000 description 1
- 150000004992 toluidines Chemical class 0.000 description 1
- 125000005270 trialkylamine group Chemical group 0.000 description 1
- VPYJNCGUESNPMV-UHFFFAOYSA-N triallylamine Chemical compound C=CCN(CC=C)CC=C VPYJNCGUESNPMV-UHFFFAOYSA-N 0.000 description 1
- UMFJXASDGBJDEB-UHFFFAOYSA-N triethoxy(prop-2-enyl)silane Chemical compound CCO[Si](CC=C)(OCC)OCC UMFJXASDGBJDEB-UHFFFAOYSA-N 0.000 description 1
- ROWWCTUMLAVVQB-UHFFFAOYSA-N triethoxysilylmethanamine Chemical compound CCO[Si](CN)(OCC)OCC ROWWCTUMLAVVQB-UHFFFAOYSA-N 0.000 description 1
- ZIBGPFATKBEMQZ-UHFFFAOYSA-N triethylene glycol Chemical compound OCCOCCOCCO ZIBGPFATKBEMQZ-UHFFFAOYSA-N 0.000 description 1
- LFBULLRGNLZJAF-UHFFFAOYSA-N trimethoxy(oxiran-2-ylmethoxymethyl)silane Chemical compound CO[Si](OC)(OC)COCC1CO1 LFBULLRGNLZJAF-UHFFFAOYSA-N 0.000 description 1
- ZNOCGWVLWPVKAO-UHFFFAOYSA-N trimethoxy(phenyl)silane Chemical compound CO[Si](OC)(OC)C1=CC=CC=C1 ZNOCGWVLWPVKAO-UHFFFAOYSA-N 0.000 description 1
- LFRDHGNFBLIJIY-UHFFFAOYSA-N trimethoxy(prop-2-enyl)silane Chemical compound CO[Si](OC)(OC)CC=C LFRDHGNFBLIJIY-UHFFFAOYSA-N 0.000 description 1
- DQZNLOXENNXVAD-UHFFFAOYSA-N trimethoxy-[2-(7-oxabicyclo[4.1.0]heptan-4-yl)ethyl]silane Chemical compound C1C(CC[Si](OC)(OC)OC)CCC2OC21 DQZNLOXENNXVAD-UHFFFAOYSA-N 0.000 description 1
- ZNXDCSVNCSSUNB-UHFFFAOYSA-N trimethoxy-[2-(oxiran-2-ylmethoxy)ethyl]silane Chemical compound CO[Si](OC)(OC)CCOCC1CO1 ZNXDCSVNCSSUNB-UHFFFAOYSA-N 0.000 description 1
- XHGIFBQQEGRTPB-UHFFFAOYSA-N tris(prop-2-enyl) phosphate Chemical compound C=CCOP(=O)(OCC=C)OCC=C XHGIFBQQEGRTPB-UHFFFAOYSA-N 0.000 description 1
- 229920001567 vinyl ester resin Polymers 0.000 description 1
- 150000007964 xanthones Chemical class 0.000 description 1
- 229910052726 zirconium Inorganic materials 0.000 description 1
- 239000004711 α-olefin Substances 0.000 description 1
Images
Classifications
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- C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
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- H01L31/04—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof adapted as photovoltaic [PV] conversion devices
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- H01L31/048—Encapsulation of modules
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- H01L31/04—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof adapted as photovoltaic [PV] conversion devices
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- H01L33/48—Semiconductor devices having potential barriers specially adapted for light emission; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof characterised by the semiconductor body packages
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- C08F230/085—Copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and containing phosphorus, selenium, tellurium or a metal containing a metal containing silicon the monomer being a polymerisable silane, e.g. (meth)acryloyloxy trialkoxy silanes or vinyl trialkoxysilanes
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- C08F232/08—Copolymers of cyclic compounds containing no unsaturated aliphatic radicals in a side chain, and having one or more carbon-to-carbon double bonds in a carbocyclic ring system having condensed rings
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- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
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- C08F4/44—Metals; Metal hydrides; Metallo-organic compounds; Use thereof as catalyst precursors selected from light metals, zinc, cadmium, mercury, copper, silver, gold, boron, gallium, indium, thallium, rare earths or actinides
- C08F4/60—Metals; Metal hydrides; Metallo-organic compounds; Use thereof as catalyst precursors selected from light metals, zinc, cadmium, mercury, copper, silver, gold, boron, gallium, indium, thallium, rare earths or actinides together with refractory metals, iron group metals, platinum group metals, manganese, rhenium technetium or compounds thereof
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- C08F4/65908—Component covered by group C08F4/64 containing a transition metal-carbon bond in combination with an ionising compound other than alumoxane, e.g. (C6F5)4B-X+
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- C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
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- C08F4/42—Metals; Metal hydrides; Metallo-organic compounds; Use thereof as catalyst precursors
- C08F4/44—Metals; Metal hydrides; Metallo-organic compounds; Use thereof as catalyst precursors selected from light metals, zinc, cadmium, mercury, copper, silver, gold, boron, gallium, indium, thallium, rare earths or actinides
- C08F4/60—Metals; Metal hydrides; Metallo-organic compounds; Use thereof as catalyst precursors selected from light metals, zinc, cadmium, mercury, copper, silver, gold, boron, gallium, indium, thallium, rare earths or actinides together with refractory metals, iron group metals, platinum group metals, manganese, rhenium technetium or compounds thereof
- C08F4/62—Refractory metals or compounds thereof
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- C08F4/65912—Component covered by group C08F4/64 containing a transition metal-carbon bond in combination with an organoaluminium compound
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- C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
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- C08F4/60—Metals; Metal hydrides; Metallo-organic compounds; Use thereof as catalyst precursors selected from light metals, zinc, cadmium, mercury, copper, silver, gold, boron, gallium, indium, thallium, rare earths or actinides together with refractory metals, iron group metals, platinum group metals, manganese, rhenium technetium or compounds thereof
- C08F4/62—Refractory metals or compounds thereof
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- C08F4/6592—Component covered by group C08F4/64 containing a transition metal-carbon bond containing at least one cyclopentadienyl ring, condensed or not, e.g. an indenyl or a fluorenyl ring
- C08F4/65922—Component covered by group C08F4/64 containing a transition metal-carbon bond containing at least one cyclopentadienyl ring, condensed or not, e.g. an indenyl or a fluorenyl ring containing at least two cyclopentadienyl rings, fused or not
- C08F4/65925—Component covered by group C08F4/64 containing a transition metal-carbon bond containing at least one cyclopentadienyl ring, condensed or not, e.g. an indenyl or a fluorenyl ring containing at least two cyclopentadienyl rings, fused or not two cyclopentadienyl rings being mutually non-bridged
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- H01L2933/0008—Processes
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- H01L2933/005—Processes relating to semiconductor body packages relating to encapsulations
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
- Y02E10/00—Energy generation through renewable energy sources
- Y02E10/50—Photovoltaic [PV] energy
Definitions
- the present invention relates to a protective material (or sealing material) for optical semiconductors used for solar cell elements, light emitting diodes (LEDs), inorganic or organic EL elements, precursors thereof, and a method for manufacturing an optical semiconductor protective material.
- a protective material or sealing material for optical semiconductors used for solar cell elements, light emitting diodes (LEDs), inorganic or organic EL elements, precursors thereof, and a method for manufacturing an optical semiconductor protective material.
- Optical semiconductors are used in various applications, for example, solar cells that convert light energy into electrical energy, and light emitting elements such as LEDs and inorganic or organic EL. These optical semiconductors need to be protected from external impacts and scratches while maintaining transparency, and depending on the application, it is necessary to protect them from corrosion by preventing moisture and moisture from entering.
- a solar cell element (module) 1 is a solar cell on a windshield 2 with a sealing material 3 interposed between the windshield 2 and the back sheet 5.
- the cell 4 is enclosed, and the solar battery cell 4 is closely fixed between the windshield 2 and the back sheet 5 by a sealing material (or filler) 3 made of an adhesive resin.
- the solar cell element 1 includes a sealing material sheet (or a sealing material precursor) 3 a, a solar battery cell 2, a sealing material sheet 3 b, and a back sheet 5 on a windshield 2. It is obtained by laminating in this order and then heat laminating.
- the windshield side sealing material sheet 3a and the back sheet side sealing material sheet 3b melt and flow into the gap between the solar cells 4, and the both are integrated and sealed.
- a material 3 is formed.
- This encapsulant (or encapsulant sheet) protects the windshield, solar cells, adhesion to the back sheet, transparency to transmit light, solar cells and wiring (not shown). Therefore, it is required to have elasticity or buffering properties, weather resistance (heat resistance and light resistance) for maintaining transparency and elasticity, and moisture resistance (gas barrier properties) for preventing moisture from permeating.
- weather resistance heat resistance and light resistance
- moisture resistance gas barrier properties
- a sheet composed of an ethylene-vinyl acetate copolymer is widely used, but its moisture resistance, adhesion and weather resistance are not sufficient.
- an acetyl group is present in this copolymer, free acid is generated due to thermal decomposition during lamination processing or long-term use, and corrosion or foaming is likely to occur in the cell.
- high weather resistance is required because it is exposed to sunlight and wind and rain for a long period of time outdoors, but this sealing material is weather resistant, especially durability under sunlight exposure (light resistance). Is not enough.
- polar groups such as an acetic acid group and a hydroxyl group, are present, the hydrophilicity is high and the moisture resistance is difficult. Therefore, the improvement of the solar cell sealing material which provided the said characteristic highly is performed.
- this sealing material has a high elastic modulus from room temperature to 100 ° C., it is difficult to absorb strain due to expansion and contraction caused by temperature change in an environment exposed to the outdoors, and has a cell protection function. Not enough. Furthermore, adhesion and transparency are also low.
- Patent Document 2 a film made of a fluororesin or polymethyl methacrylate and an amorphous cyclic olefin copolymer having a glass transition temperature of 80 ° C. or more laminated on the inner surface thereof are disclosed.
- the back surface protective layer for solar cell modules which consists of a laminated body with the film which consists of unification is disclosed.
- this back surface protective layer is made of a hard resin, its elasticity and adhesion are low and it is difficult to use it as a sealing material.
- multilayer materials can be used in various fields such as films, sheets, containers, packaging materials, automotive parts, electrical / electronic parts, building materials, civil engineering materials, etc.
- the protective material is not described.
- JP 2004-214641 A (Claim 1, Example) JP-A-8-306947 (Claim 1) Japanese Patent No. 3274702 (claims, paragraphs [0019] [0057], Examples)
- an object of the present invention is to provide an optical semiconductor protective material, a precursor thereof, and an optical semiconductor protective material that have high transparency and weather resistance (heat resistance and light resistance), have appropriate elasticity, and can effectively protect an optical semiconductor. It is in providing the manufacturing method of.
- Another object of the present invention is to provide an optical semiconductor protective material having high adhesion, a precursor thereof, and a method for producing the optical semiconductor protective material.
- Still another object of the present invention is to provide an optical semiconductor protective material having an excellent gas barrier property (for example, water vapor barrier property), a precursor thereof, and a method for producing the optical semiconductor protective material.
- an optical semiconductor protective material having an excellent gas barrier property (for example, water vapor barrier property), a precursor thereof, and a method for producing the optical semiconductor protective material.
- Another object of the present invention is to provide a photosemiconductor protective material excellent in light resistance, a precursor thereof, and a method for producing a photosemiconductor protective material, which can suppress decomposition of a stabilizer such as an ultraviolet absorber even after long-term use. There is to do.
- Still another object of the present invention is to provide an optical semiconductor protective material having high adhesion to inorganic materials such as glass substrates and silicon cells, and suitable as a sealing material (or filler) for solar cells, and a precursor thereof. It is providing the manufacturing method of a body and an optical semiconductor protective material.
- the inventors of the present invention have a high transparency and weather resistance (heat resistance and light resistance) when the optical semiconductor is protected with a chain olefin-cyclic olefin copolymer elastomer.
- the present invention has been completed by finding that it has excellent elasticity and can effectively protect an optical semiconductor.
- the chain olefin-cyclic olefin copolymer elastomer may have a crystallinity of 20% or less and a glass transition temperature of 30 ° C. or less.
- the chain olefin-cyclic olefin copolymer elastomer may have a storage elastic modulus E ′ at 25 ° C. of about 50 to 200 MPa.
- the photosemiconductor protective material of the present invention may further contain an organosilicon compound having a hydrolyzable condensation group.
- the temperature at which the radical generator is halved in 1 hour may be higher than the melting point of the chain olefin-cyclic olefin copolymer elastomer.
- the ratio of the radical generator is about 0.01 to 5 parts by weight with respect to 100 parts by weight of the chain olefin-cyclic olefin copolymer elastomer.
- the optical semiconductor protective material of the present invention may further contain a crosslinking agent.
- the crosslinking agent may have two or more vinyl groups in the molecule.
- the ratio of the crosslinking agent is about 0.01 to 5 parts by weight with respect to 100 parts by weight of the chain olefin-cyclic olefin copolymer elastomer.
- FIG. 1 is a schematic diagram showing a laminated structure of solar cell elements.
- FIG. 2 is a schematic diagram showing a laminated structure of solar cell elements before thermal lamination.
- FIG. 3 is a graph showing the light resistance of the ultraviolet absorber in the resin sheets obtained in Examples 11 and 12 and Comparative Example 3.
- chain olefin examples include chain C such as ethylene, propylene, 1-butene, isobutene, 1-pentene, 3-methyl-1-pentene, 4-methyl-1-pentene, 1-hexene and 1-octene. And 2-10 olefins. These chain olefins can be used alone or in combination of two or more. Of these chain olefins, ⁇ -chain C 2-8 olefins are preferable, and ⁇ -chain C 2-4 olefins (particularly ethylene) are more preferable.
- the chain olefin-cyclic olefin copolymer elastomer may be an elastomer obtained by addition polymerization or a resin obtained by ring-opening polymerization (such as ring-opening metathesis polymerization).
- the polymer elastomer obtained by ring-opening metathesis polymerization may be a hydrogenated hydrogenated product.
- the elongation at break may be about 500% or more, for example, 500 to 2500%, preferably 600 to 2000%, more preferably 800 to It may be about 1800% (particularly 1000 to 1500%).
- the chain olefin-cyclic olefin copolymer elastomer exhibits elastic deformability, it is preferable that it does not exhibit a yield point in the tensile test.
- the number average molecular weight of the chain olefin-cyclic olefin copolymer elastomer is, for example, about 15,000 to 200,000, preferably 20,000 to 100,000, more preferably 30,000 to 80,000 (particularly 40,000 to 70,000).
- the chain olefin-cyclic olefin copolymer elastomer is also excellent in transparency, and has a total light transmittance of 80% or more, preferably 85 to 99%, in a method (thickness 0.5 mm) based on JIS K7105.
- 88 to 98% (particularly about 90 to 95%, haze (cloudiness value) is 30% or less (eg 1 to 30%), preferably 2 to 20% (eg 3 to 15%), Preferably, it is about 5 to 12% (especially 6 to 9%), and the total light transmittance and haze can be measured by the methods described in the examples below.
- silane coupling agents such as propyltrimethoxysilane], ethylenically unsaturated bond group containing silane coupling agents [eg , Vinyl group-containing silane coupling (E.g., vinyltrimethoxysilane, vinyltriethoxysilane, vinyl tri C 1-4 alkoxysilane such as vinyl triisopropoxysilane, allyl trimethoxysilane, etc.
- Arirutori C 1-4 alkoxysilane such as allyl triethoxysilane
- (Meth) acryloyl group-containing silane coupling agents for example, 2- (meth) acryloxyethyltrimethoxysilane, 3- (meth) acryloxypropyltrimethoxysilane, 3- (meth) acryloxypropyltriethoxysilane ( meth) acryloxy C 2-4 alkyl tri C 1-4 alkoxy silane, 3- (meth) acryloxypropylmethyldimethoxysilane, 3- (meth) acryloxy propyl methyl diethoxy silane such as (meth) acryloxy C 2-4 Archi C, such as 1-4 alkyl di C 1-4 alkoxysilane), etc.], a mercapto group-containing silane coupling agent (e.g., mercapto C 2-4 alkyl tri C 1-4 alkoxysilane such as 3-mercaptopropyltrimethoxy
- a silane coupling agent having an acryloyl group is particularly preferred because of its mild reactivity and stable kneadability, which can improve the uniformity of cross-linking in the laminating process.
- the ratio of the organosilicon compound is, for example, 0.01 to 20 parts by weight (for example, 0.1 to 10 parts by weight), preferably 0.3 to 5 parts by weight with respect to 100 parts by weight of the copolymer elastomer. More preferably, it is about 0.5 to 3 parts by weight (particularly 0.8 to 2 parts by weight).
- the amount may be small, and is 3 parts by weight or less, preferably 0.01 to 2 parts per 100 parts by weight of the copolymer elastomer. Part by weight, more preferably about 0.01 to 1.5 parts by weight (particularly 0.01 to 1 part by weight).
- the photo radical generator may be combined with a photo sensitizer.
- the photosensitizer include conventional components such as tertiary amines [for example, trialkylamine, trialkanolamine (such as triethanolamine), ethyl N, N-dimethylaminobenzoate, N, N-dimethyl.
- Dialkylaminobenzoic acid alkyl esters such as amyl aminobenzoate, bis (dialkylamino) benzophenones such as 4,4-bis (dimethylamino) benzophenone (Michler's ketone), 4,4'-diethylaminobenzophenone], triphenylphosphine, etc.
- Phosphines such as N, N-dimethyltoluidine, anthracene such as 9,10-dimethoxyanthracene, 2-ethyl-9,10-dimethoxyanthracene, 2-ethyl-9,10-diethoxyanthracene, etc. It is done.
- the photosensitizers may be used alone or in combination of two or more.
- a generator for example, a dialkyl peroxide is preferred, and it has two oxygen / oxygen bonds (—OO—) in the molecule, and has a high radical generating ability, so that 2,5-dimethyl-2,5-di (t Di (C 1-6 alkylperoxy) C 4-10 alkanes such as -butylperoxy) hexane are particularly preferred.
- C 2-10 alkylene glycol di (meth) such as di (meth) acrylate, neopentyl glycol di (meth) acrylate, 1,6-hexanediol di (meth) acrylate, 1,9-nonanediol di (meth) acrylate Acrylate etc.]
- polyalkylene glycol di (meth) acrylate for example, diethylene glycol di (meth) acrylate, triethylene glycol di (meth) acrylate, polyethylene glycol di (meth) acrylate, dipropy Poly C 2-4 alkylene glycol di (meth) acrylate such as lenglycol di (meth) acrylate, tripropylene glycol di (meth) acrylate, polypropylene glycol di (meth) acrylate, polytetramethylene glycol di (meth) acrylate, etc.]
- Polyhydric alcohol di (meth) acrylate for example, glycerin di (
- cross-linking agents can be used alone or in combination of two or more.
- a compound having 3 or more functional groups such as pentaerythritol tri (meth) acrylate, pentaerythritol tetra (meth) acrylate, and dipentaerythritol can be used because the crosslinking density can be improved.
- the ratio of the crosslinking agent may be 5 parts by weight or less (0 to 5 parts by weight) with respect to 100 parts by weight of the copolymer elastomer, for example, 0.01 to 5 parts by weight, preferably 0.1 to 4 parts by weight. Part by weight, more preferably about 0.3 to 3 parts by weight (particularly 0.5 to 2 parts by weight).
- HALS light stabilizer
- hindered amines such as 1,2-bis (2,2,6,6-tetramethyl-4-piperidyloxy) ethane, phenylnaphthylamine, N, N′-diphenyl-1, 4-phenylenediamine, N-phenyl-N′-cyclohexyl-1,4-phenylenediamine, etc .
- 2,2,6,6-tetramethylpiperidine skeleton 1,2,2,6,6-pentamethyl-4-piperidine
- Compounds having a skeleton such as N, N ′, N ′′, N ′ ′′-tetrakis (4,6-bis (butyl- (N-methyl-2,2,6,6-tetramethylpiperidine-4- Yl) amino) triazin-2-yl) -4,7-diazadecane-1,10-diamine, bis (2,2,6,6-tetramethyl-1-octyloxy-4-pipe
- heat stabilizers examples include phosphite stabilizers (tris (branched alkylphenyl) phosphites such as tris (2,4-di-t-butylphenyl) phosphite), bis (alkylaryl) pentaerythritol diphosphites. And the like, phosphorus-based stabilizers (or phosphate esters), sulfur-based heat stabilizers, hydroxylamine-based heat stabilizers, and the like.
- phosphite stabilizers tris (branched alkylphenyl) phosphites such as tris (2,4-di-t-butylphenyl) phosphite), bis (alkylaryl) pentaerythritol diphosphites.
- phosphorus-based stabilizers or phosphate esters
- sulfur-based heat stabilizers hydroxylamine-based heat stabilizers, and the like.
- These stabilizers may be used alone or in a combination of two or more components (for example, a combination of a light stabilizer and an antioxidant, an ultraviolet absorber, a light stabilizer and an antioxidant). May be used in combination).
- a combination or the like is preferable, and a combination of an ultraviolet absorber, a light stabilizer, an antioxidant, and a heat stabilizer is particularly preferable.
- the ratio in these combinations is 10 to 1000 parts by weight (especially 100 to 300 parts by weight) of the light stabilizer and 10 to 500 parts by weight (particularly 50 to 200 parts by weight) of the antioxidant with respect to 100 parts by weight of the ultraviolet absorber.
- the heat stabilizer may be about 10 to 300 parts by weight (particularly 20 to 50 parts by weight).
- each stabilizer is, for example, 0.01 to 5 parts by weight, preferably 0.05 to 3 parts by weight, more preferably 0.1 to 1 part by weight, based on 100 parts by weight of the copolymer elastomer. Part (particularly 0.2 to 0.5 part by weight). If the proportion of the stabilizer is too large, various functions (light transmission, strength, adhesion, moisture resistance, etc.) of the optical semiconductor protective material tend to be reduced, but in the present invention, decomposition of the stabilizer is suppressed. In addition, a protective function can be expressed over a long period of time with a small amount of stabilizer, and various functions of the protective material can be sufficiently expressed.
- the optical semiconductor protective material can be obtained by melt-mixing and molding a resin composition containing at least a chain olefin-cycloolefin copolymer elastomer.
- the shape is not particularly limited and can be selected depending on the application, but is usually a sheet or a film.
- a conventional method for example, a method of melt kneading by supplying to a conventional melt mixer such as a single or twin screw extruder, a Banbury mixer, a kneader, or a mixing roll can be used.
- the temperature in the melt mixing is, for example, about 70 to 150 ° C., preferably about 80 to 130 ° C., more preferably about 100 to 120 ° C., and the mixing time is usually about 5 to 10 minutes. It can be appropriately selected depending on the smelting recipe.
- an extrusion method such as a press molding method, an extrusion method [die (flat, T-shaped, circular, etc.), inflation, etc.], etc.
- a stretching method using a tenter method, a tube method, an inflation method, or the like can be used, and a press molding method, an extrusion method, or the like is widely used.
- the melt mixing temperature and the molding temperature are lower than the temperature at which the radical generator halves in one hour.
- the treatment may be performed by adjusting the temperature to less than 140 ° C., preferably 90 ° C. or more and less than 140 ° C., more preferably about 100 to 130 ° C. (particularly 100 to 120 ° C.). Since the molded body (particularly the sheet-shaped molded body) treated at such a temperature is held in an unreacted state with the silane coupling agent and / or crosslinking agent having a polymerizable group, It can be used as a precursor.
- the solar cell encapsulant or filler is a sheet-like encapsulant or filler (adhesive or encapsulant) for sealing solar cells between the windshield and the backsheet. Is laminated with these members in a vacuum lamination process. The lamination process is performed at a temperature equal to or higher than the above half temperature (for example, 140 ° C. or higher, preferably 140 to 200 ° C., more preferably about 150 to 180 ° C.). ) Can improve the adhesion of the precursor (or encapsulant sheet) to the member.
- the photo-semiconductor protective material of this invention may bridge
- a radical generator may not be included.
- the optical semiconductor protective material of the present invention is excellent in elasticity and flexibility, and the storage elastic modulus E ′ at 25 ° C. is, for example, 30 to 300 MPa, preferably 50 to 200 MPa, more preferably 60 to 180 MPa (particularly 80 to 180 MPa). 150 MPa).
- the optical semiconductor protective material of the present invention is excellent in transparency, and has a total light transmittance of 80% or more, preferably 85 to 99%, more preferably 88 in a method (thickness 0.5 mm) based on JIS K7105. ⁇ 98% (especially about 90 to 95%, haze (haze value) of 30% or less (eg 1 to 30%), preferably 2 to 20% (eg 3 to 15%), more preferably 5% About 12% (especially 6-9%).
- the optical semiconductor protective material of the present invention is excellent in gas barrier property (particularly, water vapor barrier property), and the water vapor permeability (per 100 ⁇ m thickness) in an atmosphere of temperature 60 ° C. and humidity 90% RH is, for example, 100 g / m.
- 2 ⁇ day or less (eg, about 0.1 to 100 g / m 2 ⁇ day), preferably 80 g / m 2 ⁇ day or less (eg, 0.5 to 80 g / m 2 ⁇ day or less), more preferably 60 g / m
- It may be about m 2 ⁇ day or less (for example, 1 to 60 g / m 2 ⁇ day or less), particularly about 50 g / m 2 ⁇ day or less (for example, 5 to 50 g / m 2 ⁇ day).
- the optical semiconductor protective material of the present invention has high light resistance because decomposition of the ultraviolet absorber (particularly, benzophenone-based ultraviolet absorber) is suppressed.
- the residual ratio of the ultraviolet absorber after irradiation of the xenon lamp with an illumination intensity of 180 W / m 2 for 200 hours at a black panel temperature (BPT) of 44 ⁇ 2 ° C. is 50% or more, preferably 80% or more. (For example, 80 to 99%), more preferably about 85 to 98% (particularly 88 to 95%).
- BPT black panel temperature
- the residual rate of a ultraviolet absorber it can measure in detail using a weathering tester by the method as described in an Example.
- the form of protection of the optical semiconductor by the optical semiconductor protective material of the present invention is not particularly limited, and may be sealed or filled in a form of embedding an optical semiconductor such as a solar battery cell, or covered or sealed with a sheet-like protective material. Form may be sufficient.
- the solar battery cell when it is used as a sealing material (or adhesive) for a solar battery, the solar battery cell is covered with a sheet-like sealing material (sealing material sheet or precursor) from at least one side and thermally laminated.
- sealing material sheet or precursor from at least one side and thermally laminated.
- the present invention will be described in more detail based on examples, but the present invention is not limited to these examples.
- seat which comprises a soft layer, haze, a crystallinity degree, a tensile test, light resistance and hydrolysis resistance, and the embossing property of a lamination sheet were measured with the following method.
- Total light transmittance and haze The resin sheet after heat lamination obtained in the example or the comparative example was crushed, and sandwiched between glass plates having a Teflon (registered trademark) spacer having a height of 0.5 mm on the periphery, and pressed with a glass plate on both sides.
- a molten film was prepared by placing under vacuum at ⁇ 160 ° C. for 20-40 minutes. After cooling to room temperature, the glass plate was removed, the film was taken out, and the total light transmittance and haze of the film were measured using a haze meter (NDH-500, manufactured by Nippon Denshoku Industries Co., Ltd.).
- the resin sheet before thermal lamination obtained in the examples or comparative examples was sandwiched between clips, and after crimping at 100 ° C. for 2 minutes using a vacuum laminator, The temperature was raised to 180 ° C., held for 20 minutes and subjected to pressure heat treatment, and then allowed to stand at room temperature to produce a glass substrate / resin sheet / PET film laminate. Next, both the resin sheet and the PET film of this laminate were folded back 180 ° and subjected to a 180 ° tensile test in accordance with JIS K6854-2. The peeling force at a pulling speed of 300 mm / min was defined as the adhesive force between the resin sheet and the glass substrate.
- the resin sheets before thermal lamination obtained in Examples 11 and 12 and Comparative Example 3 were sandwiched with clips, and pressure-bonded at 100 ° C. for 2 minutes using a vacuum laminator. Further, the temperature was raised to 180 ° C., held for 20 minutes and subjected to pressure heat treatment, and then allowed to stand at room temperature to prepare a quartz glass substrate / resin sheet / quartz glass substrate laminate. Next, the resin sheet of this laminate was subjected to a light resistance test (irradiation illuminance 180 W / m 2 , BPT temperature 44 ⁇ 2) using an accelerated weather resistance tester (“Super Xenon Weather Meter SX2” manufactured by Suga Test Instruments Co., Ltd.).
- a light resistance test irradiation illuminance 180 W / m 2 , BPT temperature 44 ⁇ 2
- an accelerated weather resistance tester (“Super Xenon Weather Meter SX2” manufactured by Suga Test Instruments Co., Ltd.).
- the laminate before and after the test was measured for light transmittance in the ultraviolet / visible region with a spectrophotometer (“U-3900H” manufactured by Hitachi High-Technologies Corporation). Furthermore, the ultraviolet absorbent residual rate was calculated from the change in transmittance at the characteristic absorption wavelength of the ultraviolet absorbent.
- a benzophenone ultraviolet absorber (“2-hydroxy-4-octyloxybenzophenone” manufactured by Tokyo Chemical Industry Co., Ltd.)
- the characteristic absorption wavelength is 328 nm
- the transmittance at the characteristic absorption wavelength before and after the test is 328 nm
- Residual rate (%) (A ⁇ A 0 ) ⁇ 100 (Where A 0 is the absorptance before the test at 328 nm, and A is the absorptance after the test).
- a solar cell sealed cell was prepared by the method described in Example 1, and a heat cycle test ( ⁇ 40 ° C. to 85 ° C., 50 cycles) and a condensation freezing test (85 ° C., humidity 85% to ⁇ 40) according to IEC 61215 C., 10 cycles). While visually observing the appearance (sealed state) of the encapsulant sheet after this weather resistance test, the change in power generation efficiency before and after the test was evaluated. If the decrease in power generation efficiency after the test is less than 5%, it is judged that there is weather resistance that can be used continuously, and if there is a decrease of 5% or more, the weather resistance is poor and the test cannot be performed and a failure occurs. It is judged that
- the polymer solution was poured into 15 liters of methanol to precipitate the polymer.
- the polymer was separated by filtration and dried to obtain an ethylene-norbornene copolymer 1.
- the yield was 3.58 kg, and the polymerization activity was 52 kg / gZr (yield per gram of zirconium).
- Production Example 2 (ethylene-norbornene copolymer 2)
- ethylene and norbornene were copolymerized in the same manner as in Production Example 1 except that 0.75 mmol of bis (cyclopentadienyl) dichlorozirconium was used instead of zirconium tetrachloride.
- the resulting ethylene-norbornene copolymer 2 had a norbornene content of 10 mol%, a glass transition temperature of 2.0 ° C., and a melting point of 81 ° C.
- Example 1 To 100 parts by weight of the ethylene-norbornene copolymer obtained in Production Example 1, 0.3 part by weight of a hindered amine light stabilizer (“TINUVIN 622LD” manufactured by Ciba Japan Co., Ltd.), hindered phenol-based oxidation 0.3 parts by weight of an inhibitor (“IRGANOX 1010" manufactured by Ciba Japan Co., Ltd.) was charged into a lab plast mill (manufactured by Toyo Seiki Seisakusho Co., Ltd.) and kneaded at a temperature of 100 to 120 ° C for 5 minutes Thus, a resin composition was obtained.
- TINUVIN 622LD hindered amine light stabilizer
- an inhibitor IRGANOX 1010
- the melt viscosity of the obtained resin composition was measured by holding it at a temperature of 130 to 180 ° C. with a viscoelasticity measuring device (manufactured by Nippon Siebel Hegner), and it was 2 ⁇ 10 7 Pa at the time of melting (100 ° C.). The viscosity decreased to 2 ⁇ 10 4 Pa at 150 ° C., indicating good laminating characteristics in the production of solar cell modules.
- the resulting resin composition was pressurized at 100 ° C. and 10 MPa for 5 minutes, and the thickness was about 0.7 mm.
- the resin sheet was molded.
- the glass substrate / resin sheet (sealing material) / solar battery cell / resin sheet (sealing material) / glass substrate are stacked in this order, and 150 to 180 ° C., 20 to 40 minutes with a vacuum laminator.
- the solar cell sealing cell was obtained by holding.
- the obtained resin sheet, as a solar cell module sealing material sheet retains uniform and good optical properties and appropriate flexibility, and is laminated with other members to laminate the solar cell module. It was a suitable sheet to obtain.
- Example 2 A resin sheet was molded in the same manner as in Example 1 except that the ethylene-norbornene copolymer obtained in Production Example 2 was used as the ethylene-norbornene copolymer and the kneading time was 10 minutes. A battery-sealed cell was produced.
- the obtained resin sheet was a sheet suitable as a sealing material sheet for a solar cell module, as in Example 1.
- Example 4 To 100 parts by weight of the ethylene-norbornene copolymer obtained in Production Example 2, 1 part by weight of triallyl isocyanurate (manufactured by Tokyo Chemical Industry Co., Ltd.), 2,5-dimethyl-2,5-di (t-butyl) Peroxy) hexane (Lupelox 101) 1 part by weight, 3-acryloxypropyltrimethoxysilane 1 part by weight, hindered amine light stabilizer (Tinuvin 622LD) 0.3 part by weight, hindered phenol antioxidant (Irganox 1010) ) A resin sheet was formed in the same manner as in Example 1 except that 0.3 part by weight was charged, and then a solar cell encapsulated cell was produced. The obtained resin sheet was a sheet suitable as a sealing material sheet for a solar cell module, as in Example 1.
- triallyl isocyanurate manufactured by Tokyo Chemical Industry Co., Ltd.
- the obtained resin sheet was a sheet suitable as a sealing material sheet for a solar cell module, as in Example 1. Further, the sealing material sheet after the weather resistance test was only peeled at one place. In addition, the power generation efficiency of the battery after the weather resistance test was 11.6%, and the rate of decrease was 0.1%. That is, the weather resistance evaluation was good “ ⁇ ”.
- Example 6 To 100 parts by weight of the ethylene-norbornene copolymer obtained in Production Example 1, 2 parts by weight of triallyl isocyanurate, 2,5-dimethyl-2,5-di (t-butylperoxy) hexane (Lupelox 101) 1 Other than charging 5 parts by weight, 5 parts by weight of 3-acryloxypropyltrimethoxysilane, 0.3 parts by weight of a hindered amine light stabilizer (Tinuvin 622LD), and 0.3 parts by weight of a hindered phenol antioxidant (Irganox 1010). In the same manner as in Example 1, after molding a resin sheet, a solar cell encapsulated cell was produced.
- Tinuvin 622LD hindered amine light stabilizer
- Irganox 101010 a hindered phenol antioxidant
- the obtained resin sheet was a sheet suitable as a sealing material sheet for a solar cell module, as in Example 1. Furthermore, the appearance of the sealing material sheet after the weather resistance test was not peeled off. Further, the power generation efficiency of the battery after the weather resistance test was 11.9%, and the reduction rate was also less than 0.1%. That is, the evaluation of weather resistance was very good “ ⁇ ”.
- Example 7 A resin sheet was molded in the same manner as in Example 4 except that 1 part by weight of pentaerythritol tetraacrylate (manufactured by Daicel Cytec Co., Ltd.) was used instead of triallyl isocyanurate as a crosslinking agent. A stop cell was prepared. The obtained resin sheet was a sheet suitable as a sealing material sheet for a solar cell module, as in Example 1.
- Example 8 After a resin sheet was molded in the same manner as in Example 4 except that 1 part by weight of 1,6-heptadiene (manufactured by Tokyo Chemical Industry Co., Ltd.) was used instead of triallyl isocyanurate which is a crosslinking agent, a solar cell was formed. A sealed cell was produced. The obtained resin sheet was a sheet suitable as a sealing material sheet for a solar cell module, as in Example 1.
- 1,6-heptadiene manufactured by Tokyo Chemical Industry Co., Ltd.
- Example 9 A resin sheet was molded in the same manner as in Example 3 except that 0.1 parts by weight of n-hexyltrimethoxysilane (manufactured by Dow Corning Toray) was used instead of 3-acryloxypropyltrimethoxysilane. After that, a solar cell sealing cell was produced. The obtained resin sheet was a sheet suitable as a sealing material sheet for a solar cell module, as in Example 1.
- Example 10 The ratio of 2,5-dimethyl-2,5-di (t-butylperoxy) hexane (Lupelox 101) is 0.1 parts by weight, and n-hexyltrimethoxy is used instead of 3-acryloxypropyltrimethoxysilane.
- a resin sheet was formed in the same manner as in Example 4 except that 0.1 part by weight of silane was used, and then a solar cell encapsulated cell was produced. The obtained resin sheet was a sheet suitable as a sealing material sheet for a solar cell module, as in Example 1.
- Example 11 To 100 parts by weight of the ethylene-norbornene copolymer obtained in Production Example 2, 1.0 part by weight of 2,5-dimethyl-2,5-di (t-butylperoxy) hexane (Lupelox 101), 3-acrylic acid Roxypropyltrimethoxysilane 0.1 part by weight, hindered amine light stabilizer (Tinuvin 622LD) 0.5 part by weight, hindered phenol antioxidant (Irganox 1010) 0.3 part by weight, phosphite heat stabilizer ("Irgafos 168" manufactured by Ciba Japan Co., Ltd.) 0.1 parts by weight, benzophenone ultraviolet absorber ("2-hydroxy-4-octyloxybenzophenone” manufactured by Tokyo Chemical Industry Co., Ltd.) 0.3 A solar battery encapsulated cell was prepared after molding a resin sheet in the same manner as in Example 1 except that the parts by weight were charged.
- hindered amine light stabilizer Tivin 622LD
- the obtained resin sheet was a sheet suitable as a sealing material sheet for a solar cell module, as in Example 1. Furthermore, the result of having used the resin sheet before carrying out heat lamination as a sealing cell for a light resistance test, and measuring the ultraviolet absorber residual rate after 100 hours and 200 hours is shown in FIG.
- the obtained resin sheet was a sheet suitable as a sealing material sheet for a solar cell module, as in Example 1. Furthermore, the result of having used the resin sheet before carrying out heat lamination as a sealing cell for a light resistance test, and measuring the ultraviolet absorber residual rate after 100 hours and 200 hours is shown in FIG.
- Comparative Example 1 100 parts by weight of low density polyethylene (LDPE) (Sumitomo Chemical Co., Ltd. “Sumikasen-L GA804”), 0.3 parts by weight of hindered amine light stabilizer (Tinuvin 622LD), hindered phenol antioxidant (Irganox 1010) ) 0.3 part by weight was charged in a lab plast mill (manufactured by Toyo Seiki Seisakusho Co., Ltd.) and kneaded at a temperature of 180 to 210 ° C. for 10 minutes to obtain a resin composition.
- LDPE low density polyethylene
- Tivin 622LD hindered amine light stabilizer
- Irganox 1010 hindered phenol antioxidant
- the resulting resin composition was pressurized at 200 ° C. and 10 MPa for 5 minutes, and the thickness was about 0.7 mm.
- the resin sheet was molded. Although the obtained resin sheet was excellent in water vapor barrier property, the light transmission amount was not sufficient and the haze was large. Further, compared with a resin composition obtained from an ethylene-norbornene copolymer, the elastic modulus and flexibility were low, and the cushioning property for protecting the glass substrate and the solar battery cell was inferior. Furthermore, the melt viscosity is high, and the laminating process for sealing the solar battery cells is difficult.
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Abstract
Description
本発明の光半導体保護材は、鎖状オレフィンと環状オレフィンとを重合成分とする鎖状オレフィン-環状オレフィン共重合体エラストマーを含む。この共重合体エラストマーは、極性基を有していないため、化学安定性、水蒸気バリア性、光学特性に優れている。また、適度な弾性(クッション性)を有しており、保護性と密着性とを両立できる。さらに、主鎖構造に多数の3級炭素を有するため、ラジカルにより水素引抜が容易であり、ラジカル重合性基を有するカップリング剤や架橋剤と共存させた場合にもラジカル反応性に優れるという特徴を有する。
本発明の光半導体保護材は、密着性(特にガラス基板やシリコンセルなどの無機材料との密着性)を向上させるために、さらに加水分解性縮合基を有する有機ケイ素化合物を含んでもよい。本発明では、この有機ケイ素化合物を配合することにより、太陽電池の封止材に利用した場合、モジュールの受光ガラスや太陽電池セルと封止材を適度に密着させて、剥離を防止できるため、気密性を保持し、気泡の発生を防止できる。
本発明の光半導体保護材は、前記有機ケイ素化合物や後述する架橋剤がラジカル重合性基を有する場合、さらにラジカル発生剤を含んでいてもよい。ラジカル発生剤を含有させることにより、前記有機ケイ素化合物や架橋剤の反応を促進できるとともに、光半導体保護材の使用温度に応じて半減温度を調整することにより前記反応を制御できる。
本発明の光半導体保護材は、適度な弾性を付与するために、さらに架橋剤を含んでいてもよい。架橋剤としては、複数(2~8程度)の重合性基を有する二官能性又は多官能性化合物を利用できる。本発明では、架橋剤を配合することにより、太陽電池の封止材として利用した場合、モジュールが高温下で使用されても、適度な硬さと形状を保持でき、軟化によるクッション性の低下、シート形状の消失や膨張・収縮を抑制できる。さらに、架橋剤を配合することにより、前記共重合体エラストマーの環状オレフィン含有量に応じて適度な架橋構造を付与できるため、適度な弾性を調整できる。
本発明の光半導体保護材は、さらに紫外線吸収剤、光安定剤、酸化防止剤、熱安定剤などの安定剤を含んでいてもよい。特に、太陽電池の封止材として利用される場合、長期間に亘り太陽光に照射されるため、紫外線吸収剤や光安定剤などの安定剤を含む保護材が有用である。
光半導体保護材は、鎖状オレフィン-環状オレフィン共重合体エラストマーを少なくとも含有する樹脂組成物を溶融混合して成形することにより得られる。その形状は特に限定されず、用途に応じて選択できるが、通常、シート又はフィルム状である。
示差走査熱量計(セイコー電子工業(株)製「DSC6200」)を用い、窒素気流下、昇温速度10℃/分で測定を行った。
実施例又は比較例で得られた熱ラミネート後の樹脂シートを粉砕し、周辺部に高さ0.5mmのテフロン(登録商標)スペーサーを配置したガラス板にはさみ、両面のガラス板で押し付けながら150~160℃で20~40分間真空下に置いて溶融フィルムを作製した。室温まで冷却した後、ガラス板をはずしてフィルムを取り出し、ヘーズメーター(日本電色工業(株)製、NDH-500)を用いて、フィルムの全光線透過率およびヘーズを測定した。
固体粘弾性測定装置(ティー・エイ・インスツルメント・ジャパン製)により、実施例及び比較例で得られた熱ラミネート後の樹脂シートに-50℃から120℃までの温度変化を与えて、25℃での貯蔵弾性率E′の値から室温弾性率を求めた。
容器に塩化カルシウムを入れ、実施例又は比較例で得られた熱ラミネート後の樹脂シートで上部を密閉し、60℃、湿度90%RHの高温高湿槽に24時間放置した。放置後、高温高湿槽から取り出した容器内の塩化カルシウムが吸収した水分量を重量法により測定し、容器の開口面積から求められる樹脂シートの有効面積とシート厚みから水蒸気透過量を算出した。
ガラス基板上とPETフィルム(0.1mm厚)の間に、実施例又は比較例で得られた熱ラミネート前の樹脂シートをクリップで挟み、真空ラミネーターを用いて100℃で2分間圧着した後、180℃まで昇温させ20分間保持して加圧加熱処理した後、室温で放置してガラス基板/樹脂シート/PETフィルムの積層体を作製した。次に、この積層体の樹脂シートとPETフィルムとを共に180°折り返して、JIS K6854-2に準拠した180°引張試験に供した。引張速度300mm/分における引き剥がし力を、樹脂シートとガラス基板との接着力とした。
石英ガラス基板の間に、実施例11、12および比較例3で得られた熱ラミネート前の樹脂シートをクリップで挟み、真空ラミネーターを用いて100℃で2分間圧着した。さらに180℃まで昇温させ20分間保持して加圧加熱処理した後、室温で放置して石英ガラス基板/樹脂シート/石英ガラス基板の積層体を作製した。次に、この積層体の樹脂シートを、促進耐候性試験機(スガ試験機(株)製「スーパーキセノンウェザーメーターSX2」)にて耐光性試験(照射照度180W/m2、BPT温度44±2℃、200時間、水噴霧なし)に供した。このような耐光性試験において、試験前後の積層体を分光光度計(日立ハイテクノロジーズ(株)製「U-3900H」)にて、紫外・可視領域の光線透過率を測定した。さらに、紫外線吸収剤残存率は、紫外線吸収剤の特性吸収波長における透過率の変化から算出した。具体的には、ベンゾフェノン系紫外線吸収剤(東京化成工業(株)製「2-ヒドロキシ-4-オクチルオキシベンゾフェノン」)の場合、特性吸収波長は328nmであり、試験前後の特性吸収波長における透過率を測定し、吸収率A(%)=100(%)-透過率T(%)の式から吸収率を算出した。すなわち、紫外線吸収剤残存率は、試験前の吸収率で規格化しており、下記式に基づいて算出した。
(式中、A0は328nmでの試験前の吸収率であり、Aは試験後の吸収率である)。
実施例1に記載の方法で太陽電池封止セルを調製し、IEC 61215に準拠したヒートサイクル試験(-40℃~85℃、50サイクル)及び結露凍結試験(85℃、湿度85%~-40℃、10サイクル)に供した。この耐候性試験後における封止材シートの外観(封止状態)を目視で観察するとともに、試験前後の発電効率の変化を評価した。試験後の発電効率の低下が5%未満であれば、継続使用可能な耐候性があると判断され、5%以上の低下があった場合、耐候性が乏しく試験に耐えられずに故障が生じたと判断される。
窒素雰囲気下、室温において30リットルのオートクレーブに、トルエン15リットル、トリイソブチルアルミニウム(TIBA)15ミリモル、四塩化ジルコニウム0.75ミリモル、テトラキス(ペンタフルオロフェニル)硼酸アニリニウム0.75ミリモルをこの順番に投入し、続いてノルボルネンを70重量%含有するトルエン溶液1.5リットルを加えた。50℃に昇温した後、エチレン分圧が5kgf/cm2になるように、連続的にエチレンを導入しつつ、60分間の反応を行った。反応終了後、ポリマー溶液を15リットルのメタノール中に投入し、ポリマーを析出させた。このポリマーを濾別、乾燥し、エチレン-ノルボルネン共重合体1を得た。収量は3.58kg、重合活性は52kg/gZr(ジルコニウム1g当りの収量)であった。
製造例1において、四塩化ジルコニウムの代わりにビス(シクロペンタジエニル)ジクロロジルコニウム0.75ミリモルを用いた以外は、製造例1と同様にエチレンとノルボルネンとの共重合を行った。得られたエチレン-ノルボルネン共重合体2のノルボルネン含量は10モル%、ガラス転移温度は2.0℃、融点は81℃であった。
製造例1で得られたエチレン-ノルボルネン共重合体100重量部に、ヒンダードアミン系光安定剤(チバ・ジャパン(株)製「チヌビン(TINUVIN)622LD」)0.3重量部、ヒンダードフェノール系酸化防止剤(チバ・ジャパン(株)製「イルガノックス(IRGANOX)1010」)0.3重量部をラボプラストミル((株)東洋精機製作所製)に仕込み、100~120℃の温度で5分間混練して樹脂組成物を得た。
エチレン-ノルボルネン共重合体として、製造例2で得られたエチレン-ノルボルネン共重合体を用いて、混練時間を10分間とする以外は実施例1と同様にして、樹脂シートを成形した後、太陽電池封止セルを作製した。得られた樹脂シートは、実施例1と同様に、太陽電池モジュールの封止材シートとして好適なシートであった。
製造例2で得られたエチレン-ノルボルネン共重合体100重量部に、2,5-ジメチル-2,5-ジ(t-ブチルパーオキシ)ヘキサン(アルケマ吉富(株)製「ルペロックス(Luperox)101」)0.1重量部、3-アクリロキシプロピルトリメトキシシラン(東京化成工業(株)製)0.1重量部、ヒンダードアミン系光安定剤(チヌビン622LD)0.3重量部、ヒンダードフェノール系酸化防止剤(イルガノックス1010)0.3重量部を仕込む以外は実施例1と同様にして、樹脂シートを成形した後、太陽電池封止セルを作製した。得られた樹脂シートは、実施例1と同様に、太陽電池モジュールの封止材シートとして好適なシートであった。
製造例2で得られたエチレン-ノルボルネン共重合体100重量部に、トリアリルイソシアヌレート(東京化成工業(株)製)1重量部、2,5-ジメチル-2,5-ジ(t-ブチルパーオキシ)ヘキサン(ルペロックス101)1重量部、3-アクリロキシプロピルトリメトキシシラン1重量部、ヒンダードアミン系光安定剤(チヌビン622LD)0.3重量部、ヒンダードフェノール系酸化防止剤(イルガノックス1010)0.3重量部を仕込む以外は実施例1と同様にして、樹脂シートを成形した後、太陽電池封止セルを作製した。得られた樹脂シートは、実施例1と同様に、太陽電池モジュールの封止材シートとして好適なシートであった。
製造例2で得られたエチレン-ノルボルネン共重合体100重量部に、トリアリルイソシアヌレート0.1重量部、2,5-ジメチル-2,5-ジ(t-ブチルパーオキシ)ヘキサン(ルペロックス101)0.1重量部、3-アクリロキシプロピルトリメトキシシラン0.1重量部、ヒンダードアミン系光安定剤(チヌビン622LD)0.3重量部、ヒンダードフェノール系酸化防止剤(イルガノックス1010)0.3重量部を仕込む以外は実施例1と同様にして、樹脂シートを成形した後、太陽電池封止セルを作製した。得られた樹脂シートは、実施例1と同様に、太陽電池モジュールの封止材シートとして好適なシートであった。さらに、耐候性試験後の封止材シートには剥離が1箇所で見られただけであった。また、耐候性試験後の電池の発電効率は11.6%であり、低下率も0.1%であった、すなわち、耐候性の評価は良好「○」であった。
製造例1で得られたエチレン-ノルボルネン共重合体100重量部に、トリアリルイソシアヌレート2重量部、2,5-ジメチル-2,5-ジ(t-ブチルパーオキシ)ヘキサン(ルペロックス101)1重量部、3-アクリロキシプロピルトリメトキシシラン5重量部、ヒンダードアミン系光安定剤(チヌビン622LD)0.3重量部、ヒンダードフェノール系酸化防止剤(イルガノックス1010)0.3重量部を仕込む以外は実施例1と同様にして、樹脂シートを成形した後、太陽電池封止セルを作製した。得られた樹脂シートは、実施例1と同様に、太陽電池モジュールの封止材シートとして好適なシートであった。さらに、耐候性試験後の封止材シートの外観は剥離が見られなかった。また、耐候性試験後の電池の発電効率は11.9%であり、低下率も0.1%未満であった。すなわち、耐候性の評価は極めて良好「◎」であった。
架橋剤であるトリアリルイソシアヌレートの代わりに、ペンタエリスリトールテトラアクリレート(ダイセル・サイテック(株)製)1重量部を用いる以外は実施例4と同様にして、樹脂シートを成形した後、太陽電池封止セルを作製した。得られた樹脂シートは、実施例1と同様に、太陽電池モジュールの封止材シートとして好適なシートであった。
架橋剤であるトリアリルイソシアヌレートの代わりに、1,6-ヘプタジエン(東京化成工業(株)製)1重量部を用いる以外は実施例4と同様にして、樹脂シートを成形した後、太陽電池封止セルを作製した。得られた樹脂シートは、実施例1と同様に、太陽電池モジュールの封止材シートとして好適なシートであった。
3-アクリロキシプロピルトリメトキシシランの代わりに、n-ヘキシルトリメトキシシラン(東レ・ダウコーニング(株)製)0.1重量部を用いる以外は実施例3と同様にして、樹脂シートを成形した後、太陽電池封止セルを作製した。得られた樹脂シートは、実施例1と同様に、太陽電池モジュールの封止材シートとして好適なシートであった。
2,5-ジメチル-2,5-ジ(t-ブチルパーオキシ)ヘキサン(ルペロックス101)の割合を0.1重量部とし、3-アクリロキシプロピルトリメトキシシランの代わりに、n-ヘキシルトリメトキシシラン0.1重量部を用いる以外は実施例4同様にして、樹脂シートを成形した後、太陽電池封止セルを作製した。得られた樹脂シートは、実施例1と同様に、太陽電池モジュールの封止材シートとして好適なシートであった。
製造例2で得られたエチレン-ノルボルネン共重合体100重量部に、2,5-ジメチル-2,5-ジ(t-ブチルパーオキシ)ヘキサン(ルペロックス101)1.0重量部、3-アクリロキシプロピルトリメトキシシラン0.1重量部、ヒンダードアミン系光安定剤(チヌビン622LD)0.5重量部、ヒンダードフェノール系酸化防止剤(イルガノックス1010)0.3重量部、ホスファイト系熱安定剤(チバ・ジャパン(株)製「イルガフォス(Irgafos)168」)0.1重量部、ベンゾフェノン系紫外線吸収剤(東京化成工業(株)製「2-ヒドロキシ-4-オクチルオキシベンゾフェノン」)0.3重量部を仕込む以外は実施例1と同様にして、樹脂シートを成形した後、太陽電池封止セルを作製した。得られた樹脂シートは、実施例1と同様に、太陽電池モジュールの封止材シートとして好適なシートであった。さらに、封止セルとして熱ラミネートする前の樹脂シートを耐光性試験に供して100時間後及び200時間後の紫外線吸収剤残存率を測定した結果を図3に示す。
製造例2で得られたエチレン-ノルボルネン共重合体100重量部に、2,5-ジメチル-2,5-ジ(t-ブチルパーオキシ)ヘキサン(ルペロックス101)1.0重量部、3-アクリロキシプロピルトリメトキシシラン0.1重量部、ヒンダードアミン系光安定剤(チヌビン(TINUVIN)770)0.5重量部、ヒンダードフェノール系酸化防止剤(イルガノックス1010)0.3重量部、ホスファイト系熱安定剤(イルガフォス168)0.1重量部、ベンゾフェノン系紫外線吸収剤(2-ヒドロキシ-4-オクチルオキシベンゾフェノン)0.3重量部を仕込む以外は実施例1と同様にして、樹脂シートを成形した後、太陽電池封止セルを作製した。得られた樹脂シートは、実施例1と同様に、太陽電池モジュールの封止材シートとして好適なシートであった。さらに、封止セルとして熱ラミネートする前の樹脂シートを耐光性試験に供して100時間後及び200時間後の紫外線吸収剤残存率を測定した結果を図3に示す。
低密度ポリエチレン(LDPE)(住友化学(株)製「スミカセンーL GA804」)100重量部に、ヒンダードアミン系光安定剤(チヌビン622LD)0.3重量部、ヒンダードフェノール系酸化防止剤(イルガノックス1010)0.3重量部をラボプラストミル((株)東洋精機製作所製)に仕込み、180~210℃の温度で10分間混練して樹脂組成物を得た。
低密度ポリエチレン(住友化学(株)製「スミカセンーL GA804」)100重量部に、トリアリルイソシアヌレート(東京化成工業(株)製)2重量部、2,5-ジメチル-2,5-ジ(t-ブチルパーオキシ)ヘキサン(ルペロックス101)1重量部、3-アクリロキシプロピルトリメトキシシラン5重量部、ヒンダードアミン系光安定剤(チヌビン622LD)0.3重量部、ヒンダードフェノール系酸化防止剤(イルガノックス1010)0.3重量部をラボプラストミル((株)東洋精機製作所製)に仕込み、180~210℃の温度で10分間混練して樹脂組成物を得た。
エチレン-酢酸ビニル共重合体(EVA)((株)東ソー製「ウルトラセン751」、酢酸ビニル含量28%)100重量部に、トリアリルイソシアヌレート0.1重量部、2,5-ジメチル-2,5-ジ(t-ブチルパーオキシ)ヘキサン1.0重量部、3-アクリロキシプロピルトリメトキシシラン0.1重量部、ヒンダードアミン系光安定剤(チヌビン7700.5重量部、ヒンダードフェノール系酸化防止剤(イルガノックス1010)0.3重量部、ホスファイト系熱安定剤(イルガフォス168)0.1重量部、ベンゾフェノン系紫外線吸収剤(2-ヒドロキシ-4-オクチルオキシベンゾフェノン)0.3重量部をラボプラストミル((株)東洋精機製作所製)に仕込み、70~100℃の温度で10分間混練して樹脂組成物を得た。
2…フロントガラス
3…封止材
3a,3b…封止材前駆体(封止材シート)
4…太陽電池セル
5…バックシート
Claims (26)
- 光半導体を保護するための保護材であって、鎖状オレフィンと環状オレフィンとを重合成分とする鎖状オレフィン-環状オレフィン共重合体エラストマーを含む光半導体保護材。
- 鎖状オレフィン-環状オレフィン共重合体エラストマーが、α-鎖状C2-4オレフィンと多環式オレフィンとを重合成分とし、かつ両者のモル比が、α-鎖状C2-4オレフィン/多環式オレフィン=80/20~99/1である請求項1記載の光半導体保護材。
- 鎖状オレフィン-環状オレフィン共重合体エラストマーが、20%以下の結晶化度及び30℃以下のガラス転移温度を有するとともに、25℃における貯蔵弾性率E′が50~200MPaである請求項1又は2記載の光半導体保護材。
- さらに加水分解性縮合基を有する有機ケイ素化合物を含む請求項1~3のいずれかに記載の光半導体保護材。
- 有機ケイ素化合物が、アルキルトリC1-4アルコキシシラン、ビニル基を有するシランカップリング剤、及び(メタ)アクリロイル基を有するシランカップリング剤からなる群から選択された少なくとも一種である請求項4記載の光半導体保護材。
- 有機ケイ素化合物が、(メタ)アクリロイル基を有するシランカップリング剤である請求項4記載の光半導体保護材。
- 有機ケイ素化合物の割合が、鎖状オレフィン-環状オレフィン共重合体エラストマー100重量部に対して0.01~20重量部である請求項4~6のいずれかに記載の光半導体保護材。
- さらにラジカル発生剤を含む請求項1~7のいずれかに記載の光半導体保護材。
- ラジカル発生剤を1時間で半減する温度が、鎖状オレフィン-環状オレフィン共重合体エラストマーの融点よりも高い請求項8記載の光半導体保護材。
- ラジカル発生剤の割合が、鎖状オレフィン-環状オレフィン共重合体エラストマー100重量部に対して0.01~5重量部である請求項8又は9記載の光半導体保護材。
- さらに架橋剤を含む請求項1~10のいずれかに記載の光半導体保護材。
- 架橋剤が分子内に2以上のビニル基を有する請求項11記載の光半導体保護材。
- 架橋剤の割合が、鎖状オレフィン-環状オレフィン共重合体エラストマー100重量部に対して0.01~5重量部である請求項11又は12記載の光半導体保護材。
- さらに紫外線吸収剤を含む請求項1~13のいずれかに記載の光半導体保護材。
- ブラックパネル温度44±2℃においてキセノンランプを照射照度180W/m2で200時間照射した後の紫外線吸収剤の残存率が80%以上である請求項14記載の光半導体保護材。
- 25℃における貯蔵弾性率E′が50~200MPaである請求項1~15のいずれかに記載の光半導体保護材。
- ヘーズが、JIS K7105に準拠した方法(厚み0.5mm)において、20%以下である請求項1~16のいずれかに記載の光半導体保護材。
- 太陽電池の封止材又は充填材である請求項1~17のいずれかに記載の光半導体保護材。
- 鎖状オレフィンと環状オレフィンとを重合成分とする鎖状オレフィン-環状オレフィン共重合体エラストマーと、重合性基を有するシランカップリング剤及びラジカル発生剤からなる群から選択された少なくとも一種とを含む樹脂組成物を溶融混練した光半導体保護材の前駆体。
- ラジカル発生剤が1時間で半減する温度未満の溶融温度で溶融混練して得られた請求項19記載の光半導体保護材の前駆体。
- シート状である請求項19又は20記載の光半導体保護材の前駆体。
- 請求項19~21のいずれかに記載の前駆体を、熱又は活性エネルギー線で処理して光半導体保護材を製造する方法。
- ラジカル発生剤が1時間で半減する温度以上で加熱処理する請求項22記載の製造方法。
- 請求項18記載の太陽電池の封止材又は充填材を備える太陽電池モジュールであって、バックシートを有していない太陽電池モジュール。
- 鎖状オレフィンと環状オレフィンとを重合成分とする鎖状オレフィン-環状オレフィン共重合体エラストマーを含む保護材を光半導体を保護するために使用する方法。
- 請求項19~21のいずれかに記載の前駆体を光半導体保護材として使用する方法。
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KR1020127030516A KR20130069639A (ko) | 2010-04-22 | 2011-04-13 | 광반도체 보호재 및 그 전구체 및 광반도체 보호재의 제조 방법 |
US13/640,967 US20130102734A1 (en) | 2010-04-22 | 2011-04-13 | Photosemiconductor protective material and precursor thereof, and process for producing photosemiconductor protective material |
JP2012511627A JPWO2011132589A1 (ja) | 2010-04-22 | 2011-04-13 | 光半導体保護材及びその前駆体並びに光半導体保護材の製造方法 |
CN201180031140XA CN102947949A (zh) | 2010-04-22 | 2011-04-13 | 光半导体保护材料及其前体以及光半导体保护材料的制造方法 |
EP11771924A EP2562821A1 (en) | 2010-04-22 | 2011-04-13 | Optical semiconductor protective material, precursor for same, and method for manufacturing optical semiconductor protective material |
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JP2019071471A (ja) * | 2013-03-28 | 2019-05-09 | 東芝ホクト電子株式会社 | 発光装置の製造方法 |
JP2019145801A (ja) * | 2013-11-07 | 2019-08-29 | 東芝ホクト電子株式会社 | 発光装置 |
JP2015147899A (ja) * | 2014-02-07 | 2015-08-20 | 大日本印刷株式会社 | 太陽電池モジュール用の封止材シート及びその製造方法 |
JP2016119339A (ja) * | 2014-12-18 | 2016-06-30 | ソーラーフロンティア株式会社 | 太陽電池モジュール |
JP2017183546A (ja) * | 2016-03-30 | 2017-10-05 | 日本ゼオン株式会社 | 有機系太陽電池用シール剤組成物および有機系太陽電池 |
JP2020529481A (ja) * | 2017-05-31 | 2020-10-08 | ダウ グローバル テクノロジーズ エルエルシー | 封止材フィルム用のリン酸トリアリルを含む非極性エチレン系組成物 |
JP7518987B1 (ja) | 2024-02-21 | 2024-07-18 | 大日本印刷株式会社 | 自発光型表示体用又は直下型バックライト用の封止材シート、自発光型表示体、及び、直下型バックライト |
JP7521714B1 (ja) | 2024-02-21 | 2024-07-24 | 大日本印刷株式会社 | 自発光型表示体用又は直下型バックライト用の封止材シート、自発光型表示体、及び、直下型バックライト |
Also Published As
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US20130102734A1 (en) | 2013-04-25 |
TW201209065A (en) | 2012-03-01 |
KR20130069639A (ko) | 2013-06-26 |
CN102947949A (zh) | 2013-02-27 |
JPWO2011132589A1 (ja) | 2013-07-18 |
EP2562821A1 (en) | 2013-02-27 |
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