WO2013108816A1 - 多層シート、太陽電池用バックシート及び太陽電池モジュール - Google Patents
多層シート、太陽電池用バックシート及び太陽電池モジュール Download PDFInfo
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- WO2013108816A1 WO2013108816A1 PCT/JP2013/050756 JP2013050756W WO2013108816A1 WO 2013108816 A1 WO2013108816 A1 WO 2013108816A1 JP 2013050756 W JP2013050756 W JP 2013050756W WO 2013108816 A1 WO2013108816 A1 WO 2013108816A1
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- WIPO (PCT)
- Prior art keywords
- resin layer
- multilayer sheet
- polyvinylidene fluoride
- polyolefin
- adhesive
- Prior art date
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- 239000002270 dispersing agent Substances 0.000 description 1
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- 238000007720 emulsion polymerization reaction Methods 0.000 description 1
- 125000003700 epoxy group Chemical group 0.000 description 1
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- 229920006242 ethylene acrylic acid copolymer Polymers 0.000 description 1
- 229920005648 ethylene methacrylic acid copolymer Polymers 0.000 description 1
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- 238000002474 experimental method Methods 0.000 description 1
- 230000002349 favourable effect Effects 0.000 description 1
- 238000010304 firing Methods 0.000 description 1
- XUCNUKMRBVNAPB-UHFFFAOYSA-N fluoroethene Chemical compound FC=C XUCNUKMRBVNAPB-UHFFFAOYSA-N 0.000 description 1
- 239000011888 foil Substances 0.000 description 1
- 239000001530 fumaric acid Substances 0.000 description 1
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- 235000011852 gelatine desserts Nutrition 0.000 description 1
- 238000007429 general method Methods 0.000 description 1
- 230000009477 glass transition Effects 0.000 description 1
- 229910052736 halogen Inorganic materials 0.000 description 1
- 150000002367 halogens Chemical class 0.000 description 1
- HCDGVLDPFQMKDK-UHFFFAOYSA-N hexafluoropropylene Chemical compound FC(F)=C(F)C(F)(F)F HCDGVLDPFQMKDK-UHFFFAOYSA-N 0.000 description 1
- LNCPIMCVTKXXOY-UHFFFAOYSA-N hexyl 2-methylprop-2-enoate Chemical compound CCCCCCOC(=O)C(C)=C LNCPIMCVTKXXOY-UHFFFAOYSA-N 0.000 description 1
- 125000004051 hexyl group Chemical group [H]C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])* 0.000 description 1
- 230000007062 hydrolysis Effects 0.000 description 1
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- 235000019447 hydroxyethyl cellulose Nutrition 0.000 description 1
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- 229920000554 ionomer Polymers 0.000 description 1
- 229910052742 iron Inorganic materials 0.000 description 1
- JMMWKPVZQRWMSS-UHFFFAOYSA-N isopropanol acetate Natural products CC(C)OC(C)=O JMMWKPVZQRWMSS-UHFFFAOYSA-N 0.000 description 1
- 229940011051 isopropyl acetate Drugs 0.000 description 1
- GWYFCOCPABKNJV-UHFFFAOYSA-N isovaleric acid Chemical compound CC(C)CC(O)=O GWYFCOCPABKNJV-UHFFFAOYSA-N 0.000 description 1
- 238000005304 joining Methods 0.000 description 1
- 238000003475 lamination Methods 0.000 description 1
- RYZCLUQMCYZBJQ-UHFFFAOYSA-H lead(2+);dicarbonate;dihydroxide Chemical compound [OH-].[OH-].[Pb+2].[Pb+2].[Pb+2].[O-]C([O-])=O.[O-]C([O-])=O RYZCLUQMCYZBJQ-UHFFFAOYSA-H 0.000 description 1
- 229920000092 linear low density polyethylene Polymers 0.000 description 1
- VTHJTEIRLNZDEV-UHFFFAOYSA-L magnesium dihydroxide Chemical compound [OH-].[OH-].[Mg+2] VTHJTEIRLNZDEV-UHFFFAOYSA-L 0.000 description 1
- 239000000347 magnesium hydroxide Substances 0.000 description 1
- 229910001862 magnesium hydroxide Inorganic materials 0.000 description 1
- 239000000395 magnesium oxide Substances 0.000 description 1
- CPLXHLVBOLITMK-UHFFFAOYSA-N magnesium oxide Inorganic materials [Mg]=O CPLXHLVBOLITMK-UHFFFAOYSA-N 0.000 description 1
- AXZKOIWUVFPNLO-UHFFFAOYSA-N magnesium;oxygen(2-) Chemical compound [O-2].[Mg+2] AXZKOIWUVFPNLO-UHFFFAOYSA-N 0.000 description 1
- VZCYOOQTPOCHFL-UPHRSURJSA-N maleic acid Chemical compound OC(=O)\C=C/C(O)=O VZCYOOQTPOCHFL-UPHRSURJSA-N 0.000 description 1
- 239000011976 maleic acid Substances 0.000 description 1
- AMWRITDGCCNYAT-UHFFFAOYSA-L manganese oxide Inorganic materials [Mn].O[Mn]=O.O[Mn]=O AMWRITDGCCNYAT-UHFFFAOYSA-L 0.000 description 1
- 238000005259 measurement Methods 0.000 description 1
- 239000007769 metal material Substances 0.000 description 1
- 229920000609 methyl cellulose Polymers 0.000 description 1
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- LVHBHZANLOWSRM-UHFFFAOYSA-N methylenebutanedioic acid Natural products OC(=O)CC(=C)C(O)=O LVHBHZANLOWSRM-UHFFFAOYSA-N 0.000 description 1
- 229910052759 nickel Inorganic materials 0.000 description 1
- 229920006113 non-polar polymer Polymers 0.000 description 1
- QUAMTGJKVDWJEQ-UHFFFAOYSA-N octabenzone Chemical compound OC1=CC(OCCCCCCCC)=CC=C1C(=O)C1=CC=CC=C1 QUAMTGJKVDWJEQ-UHFFFAOYSA-N 0.000 description 1
- 238000001579 optical reflectometry Methods 0.000 description 1
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- 239000012188 paraffin wax Substances 0.000 description 1
- 238000007719 peel strength test Methods 0.000 description 1
- GYDSPAVLTMAXHT-UHFFFAOYSA-N pentyl 2-methylprop-2-enoate Chemical compound CCCCCOC(=O)C(C)=C GYDSPAVLTMAXHT-UHFFFAOYSA-N 0.000 description 1
- 125000001147 pentyl group Chemical group C(CCCC)* 0.000 description 1
- 150000002978 peroxides Chemical class 0.000 description 1
- JRKICGRDRMAZLK-UHFFFAOYSA-L peroxydisulfate Chemical compound [O-]S(=O)(=O)OOS([O-])(=O)=O JRKICGRDRMAZLK-UHFFFAOYSA-L 0.000 description 1
- ISWSIDIOOBJBQZ-UHFFFAOYSA-N phenol group Chemical group C1(=CC=CC=C1)O ISWSIDIOOBJBQZ-UHFFFAOYSA-N 0.000 description 1
- 239000002530 phenolic antioxidant Substances 0.000 description 1
- 239000010452 phosphate Substances 0.000 description 1
- 230000001699 photocatalysis Effects 0.000 description 1
- 150000003053 piperidines Chemical class 0.000 description 1
- 229920003023 plastic Polymers 0.000 description 1
- 229920006112 polar polymer Polymers 0.000 description 1
- 229920000636 poly(norbornene) polymer Polymers 0.000 description 1
- 229920002857 polybutadiene Polymers 0.000 description 1
- 229920000515 polycarbonate Polymers 0.000 description 1
- 239000004417 polycarbonate Substances 0.000 description 1
- 229920000728 polyester Polymers 0.000 description 1
- 229920001195 polyisoprene Polymers 0.000 description 1
- 229920000098 polyolefin Polymers 0.000 description 1
- 229920001955 polyphenylene ether Polymers 0.000 description 1
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- 235000019422 polyvinyl alcohol Nutrition 0.000 description 1
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- 238000012545 processing Methods 0.000 description 1
- 235000019260 propionic acid Nutrition 0.000 description 1
- NHARPDSAXCBDDR-UHFFFAOYSA-N propyl 2-methylprop-2-enoate Chemical compound CCCOC(=O)C(C)=C NHARPDSAXCBDDR-UHFFFAOYSA-N 0.000 description 1
- 125000001436 propyl group Chemical group [H]C([*])([H])C([H])([H])C([H])([H])[H] 0.000 description 1
- QQONPFPTGQHPMA-UHFFFAOYSA-N propylene Natural products CC=C QQONPFPTGQHPMA-UHFFFAOYSA-N 0.000 description 1
- 125000004805 propylene group Chemical group [H]C([H])([H])C([H])([*:1])C([H])([H])[*:2] 0.000 description 1
- IUVKMZGDUIUOCP-BTNSXGMBSA-N quinbolone Chemical compound O([C@H]1CC[C@H]2[C@H]3[C@@H]([C@]4(C=CC(=O)C=C4CC3)C)CC[C@@]21C)C1=CCCC1 IUVKMZGDUIUOCP-BTNSXGMBSA-N 0.000 description 1
- 238000010526 radical polymerization reaction Methods 0.000 description 1
- 150000003254 radicals Chemical class 0.000 description 1
- YGSDEFSMJLZEOE-UHFFFAOYSA-M salicylate Chemical compound OC1=CC=CC=C1C([O-])=O YGSDEFSMJLZEOE-UHFFFAOYSA-M 0.000 description 1
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- 239000012321 sodium triacetoxyborohydride Substances 0.000 description 1
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- BFKJFAAPBSQJPD-UHFFFAOYSA-N tetrafluoroethene Chemical group FC(F)=C(F)F BFKJFAAPBSQJPD-UHFFFAOYSA-N 0.000 description 1
- 238000005979 thermal decomposition reaction Methods 0.000 description 1
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- 239000010409 thin film Substances 0.000 description 1
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- STCOOQWBFONSKY-UHFFFAOYSA-N tributyl phosphate Chemical compound CCCCOP(=O)(OCCCC)OCCCC STCOOQWBFONSKY-UHFFFAOYSA-N 0.000 description 1
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- KOWVWXQNQNCRRS-UHFFFAOYSA-N tris(2,4-dimethylphenyl) phosphate Chemical compound CC1=CC(C)=CC=C1OP(=O)(OC=1C(=CC(C)=CC=1)C)OC1=CC=C(C)C=C1C KOWVWXQNQNCRRS-UHFFFAOYSA-N 0.000 description 1
- HQUQLFOMPYWACS-UHFFFAOYSA-N tris(2-chloroethyl) phosphate Chemical compound ClCCOP(=O)(OCCCl)OCCCl HQUQLFOMPYWACS-UHFFFAOYSA-N 0.000 description 1
- 238000007740 vapor deposition Methods 0.000 description 1
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- 229920003169 water-soluble polymer Polymers 0.000 description 1
- 239000011701 zinc Substances 0.000 description 1
- 229910052725 zinc Inorganic materials 0.000 description 1
Images
Classifications
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L31/00—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
- H01L31/04—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof adapted as photovoltaic [PV] conversion devices
- H01L31/042—PV modules or arrays of single PV cells
- H01L31/048—Encapsulation of modules
- H01L31/0481—Encapsulation of modules characterised by the composition of the encapsulation material
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
- B32B27/08—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/30—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers
- B32B27/304—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers comprising vinyl halide (co)polymers, e.g. PVC, PVDC, PVF, PVDF
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/32—Layered products comprising a layer of synthetic resin comprising polyolefins
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
- B32B7/04—Interconnection of layers
- B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L31/00—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
- H01L31/04—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof adapted as photovoltaic [PV] conversion devices
- H01L31/042—PV modules or arrays of single PV cells
- H01L31/048—Encapsulation of modules
- H01L31/049—Protective back sheets
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02S—GENERATION OF ELECTRIC POWER BY CONVERSION OF INFRARED RADIATION, VISIBLE LIGHT OR ULTRAVIOLET LIGHT, e.g. USING PHOTOVOLTAIC [PV] MODULES
- H02S20/00—Supporting structures for PV modules
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/30—Properties of the layers or laminate having particular thermal properties
- B32B2307/306—Resistant to heat
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/70—Other properties
- B32B2307/712—Weather resistant
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/70—Other properties
- B32B2307/726—Permeability to liquids, absorption
- B32B2307/7265—Non-permeable
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2457/00—Electrical equipment
- B32B2457/12—Photovoltaic modules
-
- 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 multilayer sheet, a solar cell backsheet using the multilayer sheet, and a solar cell module. More specifically, the present invention relates to a multilayer sheet provided with a polyvinylidene fluoride resin layer, a solar cell backsheet, and a solar cell module.
- solar cell module Since a solar cell module is used outdoors for a long period of time, in order to ensure mechanical strength and prevent deterioration under an environmental atmosphere, in general, solar cells are sealed with a synthetic resin so that sunlight is not emitted. The irradiated surface is covered with transparent tempered glass, and the back surface is protected with a back sheet.
- the solar cell backsheet used at that time include a laminate of an aluminum foil and a resin film, and a laminate of a plurality of resin films having different compositions (see, for example, Patent Documents 1 to 5).
- Patent Document 1 proposes a solar cell back surface protection sheet having a configuration in which a polyethylene resin having a specific density is laminated or a polyethylene resin having a specific density is laminated on a thermoplastic polyester resin film in order to improve environmental resistance.
- Patent Document 2 proposes a back sheet in which a skin film and a moisture-proof film are laminated and integrated with an ethylene-vinyl acetate copolymer adhesive.
- a film in which an inorganic oxide coating film is formed on the surface of a base film is used as a moisture-proof film, and a fluororesin film is used as an outer film.
- a flexible polypropylene resin film is laminated.
- the halogen mass ratio is 50% or more on one or both sides of the base sheet made of polyphenylene ether.
- a certain fluororesin layer is laminated.
- a solar cell backsheet composed of these multilayer sheets is generally formed by laminating a plurality of films via an adhesive.
- the acrylic adhesive which has a hydrolysis resistance, insulation resistance, and a moisture barrier property It has been proposed to use
- the above-mentioned conventional multilayer sheet can satisfy the weather resistance, heat resistance, moisture resistance and other various characteristics in the back sheet for solar cells and the solar cell module using the same. There is a need for improvement.
- fluorine resins and polyolefin resins have low adhesion to other resins, a multilayer sheet using these resins has a problem that interlayer adhesion cannot be sufficiently ensured.
- the main object of the present invention is to provide a multilayer sheet, a solar cell back sheet and a solar cell module which are excellent in weather resistance, heat resistance and moisture resistance and have good interlayer adhesion.
- the present inventor has conducted extensive experiments to solve the above-described problems, and as a result, has obtained the following knowledge.
- the present inventor laminated a layer made of a polyolefin resin composition and a layer made of a polyvinylidene fluoride resin composition to provide weather resistance, heat resistance, moisture resistance, electrical insulation and other solar cells. It has been found that various properties required for the backsheet of this product are improved.
- the present inventor examined a method for laminating these resin layers.
- a plurality of films are bonded together via an adhesive as in the case of a conventional multilayer sheet
- each process of film formation, winding, adhesive coating, drying and bonding is performed through each resin film.
- Processing costs increase.
- the resin of each layer is melted using an extruder, and the coextrusion film forming and the adhesive layer and the layer to be bonded are bonded and bonded together by joining them in a molten state. A method to match them can be considered.
- the present inventor has studied to improve the interlayer adhesion between the layer made of the polyvinylidene fluoride resin composition and the layer made of the polyolefin resin composition. Then, by laminating these layers through an adhesive resin layer composed of a conjugated diene polymer, a conjugated diene copolymer, or a hydride thereof, a multilayer sheet having excellent interlayer adhesion can be obtained.
- the headline, the present invention has been reached.
- the multilayer sheet according to the present invention comprises a polyolefin-based resin composition, and has a melt flow rate of 0.5 to 25 g / 10 min at 230 ° C. and a load of 2.16 kg as measured by A method defined in JIS K7210.
- a first resin layer comprising a polyolefin-based resin composition and a polyvinylidene fluoride system having a melt flow rate of 0.5 to 25 g / 10 min at 230 ° C. and a load of 2.16 kg measured by A method defined in JIS K7210
- the second resin layer made of the resin composition is a conjugated diene-based weight having a melt flow rate of 0.1 to 50 g / 10 min at 230 ° C.
- the adhesive resin layer is formed of a homopolymer of a conjugated diene having 4 to 8 carbon atoms, a copolymer of a conjugated diene having 4 to 8 carbon atoms and another monomer, or a hydride thereof. May be.
- the adhesive resin layer can be formed of, for example, a copolymer of a conjugated diene having 4 to 8 carbon atoms and an aromatic vinyl compound or a hydride thereof.
- the polyvinylidene fluoride-based resin composition forming the second resin layer is based on 100 parts by mass of a resin component composed of polyvinylidene fluoride: 50 to 99% by mass and polymethyl methacrylate: 1 to 50% by mass. It may contain 1 to 40 parts by weight of a white inorganic pigment.
- the thickness of the first resin layer can be, for example, 50 to 500 ⁇ m
- the thickness of the second resin layer and the thickness of the adhesive resin layer can be, for example, 5 to 50 ⁇ m.
- the polyolefin resin composition forming the first resin layer has, as a resin component, a homopolymer of an olefinic hydrocarbon having 2 to 20 carbon atoms or an olefinic hydrocarbon having 2 to 20 carbon atoms and another unit.
- a copolymer with a monomer may be contained.
- the resin component of the polyolefin resin composition may contain 70% by mass or more of units derived from olefin hydrocarbons having 2 to 20 carbon atoms.
- a flame retardant and / or a weathering agent may be blended in the polyolefin resin composition forming the first resin layer.
- this multilayer sheet is formed by, for example, melt coextrusion molding at a temperature range of 130 to 260 ° C., or individually formed into a first resin layer, an adhesive resin layer, and a second resin layer. Can be laminated in this order and pressure-bonded under a temperature condition of 130 to 260 ° C. Furthermore, a third resin layer containing an ethylene vinyl acetate copolymer as a resin component may be laminated on at least one surface.
- the solar cell backsheet according to the present invention uses the multilayer sheet described above. Moreover, the solar cell module according to the present invention uses the above-described back sheet.
- a polyolefin resin layer and a polyvinylidene fluoride resin layer are laminated via an adhesive resin layer made of a conjugated diene polymer, a conjugated diene copolymer, or a hydride thereof. Therefore, a multilayer sheet excellent in weather resistance, heat resistance and moisture resistance and having good interlayer adhesion can be realized.
- FIG. 1 is a diagram schematically showing the configuration of the multilayer sheet of the present embodiment.
- the polyolefin resin layer 1 and the polyvinylidene fluoride resin layer 2 are a conjugated diene polymer, a conjugated diene copolymer, or a hydride thereof. Is laminated via an adhesive resin layer 3 made of
- the polyolefin resin layer 1 is formed of a polyolefin resin composition whose main component is a polyolefin resin.
- This polyolefin-based resin composition contains, as a resin component, a homopolymer of an olefinic hydrocarbon having 2 to 20 carbon atoms or a copolymer of an olefinic hydrocarbon having 2 to 20 carbon atoms and another monomer. It is preferable to do.
- the mechanical strength and elastic modulus of the multilayer sheet are improved, and handling properties are improved.
- thermal durability is also improved, a multilayer sheet suitable for a solar cell backsheet or the like can be obtained.
- the content of the unit derived from the olefinic hydrocarbon having 2 to 20 carbon atoms is preferably 70% by mass or more, and more preferably 90% by mass or more in the polyolefin resin as the main component.
- the mechanical strength and elastic modulus of the multilayer sheet are improved, and not only thermal durability but also resistance to thermal stress when changing from a low temperature environment to a high temperature environment is improved.
- each resin component contained in a polyolefin-type resin composition is a thermoplastic resin.
- polyolefin resins examples include low density polyethylene, medium density polyethylene, high density polyethylene, linear (linear) low density polyethylene, polypropylene, propylene-ethylene copolymer, propylene-butene copolymer, Examples thereof include polymethylpentene and ethylene-polymethylpentene copolymer.
- cyclic olefin polymers such as polynorbornene, ethylene-norbornene copolymer and propylene-norbornene copolymer, or copolymers thereof can also be used.
- the stereoregularity may be any of isotactic, syndiotactic and atactic.
- the resin component is a copolymer of an olefinic hydrocarbon and another monomer
- the other monomer includes acrylic acid or a derivative thereof, methacrylic acid or a derivative thereof, maleic anhydride or a derivative thereof.
- Derivatives, vinyl esters of carboxylic acids and the like can be used.
- copolymers include ethylene-vinyl acetate copolymers, ionomer resins, ethylene-ethyl acrylate copolymers, ethylene-acrylic acid copolymers, ethylene-methacrylic acid copolymers, polyethylene or polypropylene.
- acid-modified polyolefin-based resins modified with an unsaturated carboxylic acid such as acrylic acid, methacrylic acid, maleic anhydride, fumaric acid or itaconic acid.
- a polyolefin resin having a melting point or glass transition temperature of 120 ° C. or higher is preferable, and a melting point of 120 ° C. or higher.
- High density polyethylene and polypropylene are more preferred.
- the polyolefin-based resin it is preferable to use polypropylene having isotactic stereoregularity, whereby excellent mechanical strength and elastic modulus can be obtained when a back sheet for a solar cell is obtained.
- polypropylene has a high gas barrier property when formed into a sheet
- the use of polypropylene for the polyolefin resin layer 1 of the multilayer sheet 10 makes the solar highly durable against cell deterioration due to intrusion of moisture.
- a battery module can be realized.
- a flame retardant can be blended in the polyolefin resin composition forming the polyolefin resin layer 1 as necessary.
- a flame retardant By making the polyolefin resin layer 1 contain a flame retardant, it is possible to make it difficult to ignite even when arc discharge occurs due to poor electrical connection or deterioration when a solar cell backsheet or solar cell module is obtained. it can.
- the flame retardant blended in the polyolefin resin composition is not particularly limited, and a chlorine flame retardant, a bromine flame retardant, a phosphorus flame retardant, an inorganic flame retardant and the like can be used.
- a chlorine flame retardant examples include chlorinated paraffin, perchlorocyclopentadecane, and chlorendic acid.
- the brominated flame retardant examples include tetrabrocemobisphenol A (TBA), decabromodiphenyl oxide, TBA epoxy oligomer, TBA polycarbonate, octabromodiphenyl ether, and tribromophenol.
- Examples of the phosphorus flame retardant include triphenyl phosphate, tricresyl phosphate, trixylenyl phosphate, tributyl phosphate, tris-chloroethyl phosphate, and tris-chloropropyl phosphate.
- Examples of the inorganic flame retardant include aluminum hydroxide, magnesium hydroxide, and antimony trioxide.
- the polyolefin resin composition forming the polyolefin resin layer 1 may be blended with weathering agents such as an ultraviolet absorber, a light stabilizer and an antioxidant. By blending these weathering agents, the light resistance and durability of the multilayer sheet 10 can be further improved.
- the weathering agent to be blended in the polyolefin resin composition is not particularly limited, and examples of the ultraviolet absorber include benzophenone, benzotriazole, salicylate, acrylonitrile, metal complex, ultrafine titanium oxide and Ultrafine zinc oxide or the like can be used.
- the light stabilizer for example, hindered amine compounds and hindered piperidine compounds can be used.
- the antioxidant for example, phenolic, amine-based, sulfur-based and phosphoric acid-based ones can be used, for example, the above-mentioned benzophenone-based in the main chain or side chain constituting the polymer, etc.
- polymer type UV absorbers, light stabilizers or antioxidants which are chemically bonded with UV stabilizers, hindered amine compound light stabilizers or phenolic antioxidants. .
- the polyolefin-based resin layer 1 contains a weathering agent such as an ultraviolet absorber, a light stabilizer and an antioxidant, in order to exert the effect of the weathering agent without deteriorating mechanical properties such as impact strength.
- a weathering agent such as an ultraviolet absorber, a light stabilizer and an antioxidant
- the total amount is preferably 0.1 to 10% by mass of the whole.
- a weathering agent can also be used together with the flame retardant mentioned above, it can also be used independently.
- the polyvinylidene fluoride resin layer 2 is formed of a polyvinylidene fluoride resin composition in which 50% by mass or more of the resin component is a polyvinylidene fluoride resin.
- the polyvinylidene fluoride resin blended in the polyvinylidene fluoride resin composition is preferably a homopolymer of vinylidene fluoride, but may be a copolymer of vinylidene fluoride and other monomers.
- monomers that form copolymers with vinylidene fluoride include fluorine such as vinyl fluoride, tetrafluoroethylene, ethylene trifluorochloride, propylene hexafluoride, isobutylene hexafluoride, and various fluoroalkyl vinyl ethers. And known vinyl monomers such as styrene, ethylene, butadiene, and propylene.
- the amount of monomers other than vinylidene fluoride in the polyvinylidene fluoride resin is preferably 50% by mass or less in order to ensure weather resistance and light stability in the entire polyvinylidene fluoride resin layer and multilayer sheet. .
- the method for producing the polyvinylidene fluoride resin described above is not particularly limited, and the polymerization can be performed by a general method such as suspension polymerization or emulsion polymerization.
- a solvent such as water, a polymerization initiator, a suspending agent (or emulsifier), a chain transfer agent, etc.
- the reactor is degassed and degassed to form a gaseous vinylidene fluoride monomer.
- the polymerization of the vinylidene fluoride monomer may be promoted while controlling the reaction temperature.
- an inorganic peroxide such as persulfate or an organic peroxide can be used, and specifically, dinormal propyl peroxydicarbonate (NPP) or diisopropyl peroxydioxide. Examples include carbonate.
- NPP dinormal propyl peroxydicarbonate
- diisopropyl peroxydioxide examples include carbonate.
- Chain transfer agents include acetone, isopropyl acetate, ethyl acetate, diethyl carbonate, dimethyl carbonate, ethyl carbonate, propionic acid, trifluoroacetic acid, trifluoroethyl alcohol, formaldehyde dimethyl acetal, 1,3-butadiene epoxide, 1,4 -Dioxane, ⁇ -butyllactone, ethylene carbonate, vinylene carbonate and the like.
- acetone and ethyl acetate are particularly preferable from the viewpoint of availability and ease of handling.
- water-soluble cellulose ethers such as partially saponified polyvinyl alcohol, methyl cellulose and hydroxyethyl cellulose, water-soluble polymers such as acrylic acid polymers and gelatin can be used as the suspending agent (or emulsifier).
- a resin other than the polyvinylidene fluoride resin can be blended in the polyvinylidene fluoride resin composition, and a methacrylic ester resin is particularly preferable from the viewpoint of flexibility and workability.
- the “methacrylic ester resin” here is polymethyl methacrylate obtained by polymerizing methyl methacrylate produced by ACH method, modified ACH method, direct method or ethylene method by radical polymerization or the like.
- the methacrylic ester resin has the effect of increasing the adhesion with other resins when it is formed into a film.
- the polyvinylidene fluoride resin is inferior in adhesiveness to other materials, but the adhesiveness can be improved by blending a methacrylic ester resin.
- the amount of the methacrylic ester resin in the resin component exceeds 50% by mass, the amount of polyvinylidene fluoride resin decreases, so that the weather resistance decreases.
- the amount of the methacrylic ester resin is less than 5% by mass, the above-described addition effect cannot be obtained. Therefore, when a methacrylic ester resin is blended, the content is desirably 5 to 50% by mass based on the total amount of the resin components.
- the structure and the like of the methacrylic ester resin blended in the polyvinylidene fluoride resin composition is not particularly limited as long as it is a vinyl polymer based on a methacrylic ester monomer.
- the methacrylic acid ester monomer include methyl methacrylate, ethyl methacrylate, propyl methacrylate, butyl methacrylate, pentyl methacrylate, hexyl methacrylate and the like, and methyl methacrylate is particularly preferable.
- alkyl groups such as propyl group, butyl group, pentyl group and hexyl group in the methacrylic acid ester monomer may be linear or branched.
- the methacrylate ester resin blended in the resin composition of the present embodiment may be a homopolymer of a methacrylate ester monomer or a copolymer of a plurality of methacrylate ester monomers. Alternatively, it may have a monomer unit derived from ethylene, propylene, butadiene, styrene, ⁇ -methylstyrene, acrylonitrile, acrylic acid and the like, which are known vinyl compounds other than methacrylic acid esters.
- the polyvinylidene fluoride-based resin composition for forming the polyvinylidene fluoride-based resin layer 2 is provided with magnesium oxide, barium sulfate, titanium oxide, basic lead carbonate, and zinc oxide for the purpose of imparting light reflectivity, if necessary.
- White inorganic pigments such as can also be blended.
- rutile crystal titanium dioxide having a large refractive index and coloring power and a small photocatalytic action is suitable.
- the blending amount of the white inorganic pigment is less than 1 part by mass per 100 parts by mass of the resin component, the intended light reflection characteristics may not be obtained, and it exceeds 40 parts by mass per 100 parts by mass of the resin component. If blended, the dispersion in the composition becomes non-uniform or the film formation becomes difficult. Therefore, when a white inorganic pigment is blended with the polyvinylidene fluoride resin composition, the amount is preferably 1 to 40 parts by mass per 100 parts by mass of the resin component.
- the blending amount of the white inorganic pigment is more preferably 10 to 35 parts by mass, and further preferably 15 to 30 parts by mass per 100 parts by mass of the resin component.
- a toning inorganic pigment may be added to the polyvinylidene fluoride resin composition together with the white inorganic pigment described above.
- Inorganic pigments for toning use complex oxide pigments in which two or more of oxides of metallic materials such as chromium, zinc, iron, nickel, aluminum, cobalt, manganese and copper are selected and solid-dissolved by firing Etc. can be used. These complex oxide pigments can be used alone or in combination of two or more.
- the amount is preferably 0.01 to 7 parts by mass, more preferably 0.1 to 5 parts by mass, per 100 parts by mass of the resin component. More preferably, it is 0.5 to 3 parts by mass.
- the above-mentioned polyvinylidene fluoride resin composition can be obtained by blending a polyvinylidene fluoride resin with a methacrylate ester resin, a white inorganic pigment, a toning inorganic pigment, and the like, if necessary, and melt-kneading them.
- various mixers and kneaders equipped with a heating device such as a twin screw extruder, continuous and batch type kneader can be used. This is a twin screw extruder.
- a dispersant may be added as necessary within a range not affecting the above-described effects.
- the adhesive resin layer 3 is formed of a conjugated diene polymer, a copolymer, or a hydride thereof. By using these for the adhesive resin layer 3, it is possible to bond the polyolefin resin that is a nonpolar polymer and the polyvinylidene fluoride resin that is a polar polymer. Since the polyolefin resin layer 1 and the polyvinylidene fluoride resin layer 2 can be firmly bonded by the adhesive resin layer 3, stable adhesiveness can be maintained even at a high temperature of about 120 ° C. . As a result, the multilayer sheet 10 has sufficient durability in the usage environment of the solar cell module.
- the adhesive resin layer 3 may be formed of a conjugated diene homopolymer having 4 to 8 carbon atoms, a copolymer of a conjugated diene having 4 to 8 carbon atoms and another monomer, or a hydride thereof.
- conjugated dienes butadiene and isoprene are particularly preferred.
- conjugated diene polymers and copolymers include polybutadiene, polyisoprene, butadiene-styrene copolymers, isoprene-styrene copolymers, and the like.
- the adhesive resin layer 3 is formed of a copolymer of a conjugated diene having 4 to 8 carbon atoms and an aromatic vinyl compound or a hydride thereof, durability and adhesive strength can be maintained over a long period of time.
- a copolymer of a conjugated diene having 4 to 8 carbon atoms such as a hydrogenated butadiene-styrene copolymer or a hydrogenated isoprene-styrene copolymer and an aromatic vinyl compound.
- the hydride of is preferred.
- the adhesive resin layer 3 is composed of block type conjugated diene type and aromatic vinyl type such as hydrogenated butadiene-styrene block copolymer (SEBS) and hydrogenated isoprene-styrene block copolymer (SEPS).
- SEBS hydrogenated butadiene-styrene block copolymer
- SEPS hydrogenated isoprene-styrene block copolymer
- a hydride of a copolymer with a compound is preferable.
- the form of block copolymerization is not particularly limited, and may be any of diblock, triblock, multiblock or star type. Further, these polymers may be subjected to modification such as terminal modification.
- the polyolefin-based resin layer 1 and the polyvinylidene fluoride-based resin layer 2 have a melt flow rate (MFR) of 0.5 to 25 g / 10 min at 230 ° C. and a load of 2.16 kg measured by the A method defined in JIS K7210. It is.
- the adhesive resin layer 3 has a melt flow rate (MFR) of 0.1 to 50 g / 10 min at 230 ° C. and a load of 2.16 kg as measured by A method defined in JIS K7210.
- each resin layer constituting the multilayer sheet 10 is formed of a resin composition or polymer having an MFR in the above-described range, for example, in the case of forming a film by the melt coextrusion molding method, the molten state flowing in the flow path The flow velocity distribution of the resin is made uniform, and the resin is merged at a substantially constant speed, and the resin is discharged from the die with no speed fluctuation. As a result, it is possible to produce a multilayer sheet with little variation in the thickness of each layer and a good adhesion state. Moreover, since the dispersion state of the pigment contained in the polyvinylidene fluoride resin composition becomes good, the occurrence of defects can be suppressed.
- the resin layer is formed with a resin composition or polymer in the MFR range described above.
- the softened and molten state of each resin layer becomes uniform, and the adhesive force between each resin layer can be made uniform throughout.
- the polyolefin resin layer 1 and / or the polyvinylidene fluoride resin layer 2 is formed of a resin composition having an MFR of less than 0.5 g / 10 minutes, the viscosity of the melt increases.
- melt coextrusion molding When the method is applied, it becomes difficult to adjust to a desired thickness. Further, even when each resin layer is formed individually and is pressure-bonded under heating, the resin layer is not sufficiently softened and it is difficult to develop a high adhesive force. As a method for solving these problems, it is conceivable to raise the temperature at the time of molding. However, there is a possibility that the polyvinylidene fluoride resin 2 may be colored or a decomposition gas may be generated.
- the polyolefin resin layer 1 and / or the polyvinylidene fluoride resin layer 2 is formed of a resin composition having an MFR exceeding 25 g / 10 minutes, it becomes difficult to obtain a desired thickness by the melt coextrusion molding method.
- each resin layer is individually formed and pressure-bonded with heating, variation in the thickness of the resin layer is likely to occur.
- the adhesive resin layer 3 is formed of a polymer, copolymer or hydride having an MFR of less than 0.1 g / 10 minutes, sufficient adhesive force cannot be obtained. Moreover, when it forms with the polymer etc. which MFR exceeds 50 g / 10min, the dispersion
- the resin composition for forming the polyvinylidene fluoride resin layer 2 and the adhesive resin layer 3 on the basis of the MFR of the polyolefin resin layer 1 is 0. It is preferable to use one having an MFR of 1 to 10 times, preferably 0.2 to 5 times. Thereby, film formability is stabilized and the fluctuation
- the MFR of each resin layer can be adjusted by changing the polymerization degree of the resin component contained therein. Specifically, it can be adjusted according to the polymerization temperature when polymerizing the resin component, the type and amount of the polymerization initiator, the type and amount of the chain transfer agent, and the like. Moreover, you may use commercially available resin that MFR of each resin layer becomes in the range mentioned above.
- the thickness of each layer described above is not particularly limited and can be appropriately set according to the application and required characteristics.
- the thickness of the polyolefin-based resin layer 1 is set to 50 to 500 ⁇ m
- the thicknesses of the polyvinylidene fluoride resin layer 2 and the adhesive resin layer 3 can be 5 to 50 ⁇ m, respectively.
- the thickness of the polyolefin-based resin layer 1 is less than 50 ⁇ m, when applied to a solar cell module, the mechanical strength of the multilayer sheet 10 is insufficient and the cell is easily damaged, and the water vapor barrier property is insufficient. Thus, cell deterioration and power generation output decrease are likely to occur.
- the polyolefin resin layer 1 has a thickness exceeding 500 ⁇ m, the rigidity of the multilayer sheet 10 is increased, handling properties such as winding property are lowered, and the manufacturing cost is further increased.
- the thickness of the polyvinylidene fluoride resin layer 2 is less than 5 ⁇ m, the weather resistance is lowered, and when applied to a solar cell module, sufficient durability may not be obtained.
- the thickness of the polyvinylidene fluoride resin layer 2 exceeds 50 ⁇ m, the manufacturing cost increases.
- the thickness of the adhesive resin layer 3 is less than 5 ⁇ m, the adhesive force between the polyolefin resin layer 1 and the polyvinylidene fluoride resin layer 2 is insufficient, and delamination tends to occur. As a result, when applied to a solar cell module, durability may not be sufficiently obtained. On the other hand, when the thickness of the adhesive resin layer 3 exceeds 50 ⁇ m, the manufacturing cost increases.
- each resin composition forming the polyolefin resin layer 1 and the polyvinylidene fluoride resin layer 2 and the polymer forming the adhesive resin layer 3 are melted by separate extruders. Then, it is preferable to form a film by a co-extrusion method in which they are merged and integrated.
- melt coextrusion molding at a material temperature of 130 to 260 ° C.
- a material temperature of 130 to 260 ° C.
- melting may be insufficient, and fish eyes may be generated in the sheet, or adhesion between layers may be insufficient.
- the resin component forming each layer may be thermally decomposed, and the sheet may be colored or decomposed gas may be generated.
- a more preferable material temperature during film formation is 180 to 250 ° C.
- the coextrusion method includes a T-die coextrusion method and an inflation coextrusion method.
- a single screw extruder, a biaxial (multi-screw) extruder, etc. can be used for an extruder, A general thing can be used for the cylinder and screw of an extruder.
- a twin-screw extruder it can be used with either two parallel shafts or a conical type with screw shafts obliquely crossed, screw flight meshing type, non-meshing type, screw rotation in the same direction Any of those and different directions may be used.
- various screw designs such as a dull image type, a rotor type, and a flute mixing type can be used as a mixing part, and even those shapes that do not have a mixing part are melted and formed into a sheet. It is possible. Further, in the twin-screw extruder, a kneading disk, a rotor segment, a reverse screw flight, or the like may be disposed as a mixing unit, but a full flight screw without these may be disposed.
- the cylinder can be used in either a vent type or a no vent type.
- each resin composition which forms the polyolefin-type resin layer 1 and the polyvinylidene fluoride-type resin layer 2, the merge of the polymer which forms the adhesive resin layer 3, and the film formation of a multilayer sheet, after making it merge with a feed block It is possible to apply a method in which a molten sheet discharged by flowing into a flat die (T die) or the like is taken out while being cooled. At that time, as the flat die, a T-type manifold die, a fishtail die, a coat hanger die, a screw die, or the like can be used. Further, a method of flowing into a multi-manifold die and discharging a molten sheet, a method of discharging from an inflation die, or the like may be applied.
- the thickness of each resin layer can be adjusted within the above-described range by adjusting the discharge rate of the material from the extruder.
- the discharge speed is adjusted by changing the screw rotation speed.
- a twin screw extruder it is performed by changing the feed speed of the raw material to be fed into the extruder by the feeder, changing the screw rotation speed of the extruder, or changing the rotation speed of the gear pump. be able to.
- the production of the multilayer sheet 10 is not limited to the above-described coextrusion molding method.
- a polyolefin-based resin film, an adhesive resin film, and a polyvinylidene fluoride-based resin film formed in advance are laminated in this order.
- an extrusion lamination molding method in which a molten adhesive resin film and a molten polyvinylidene fluoride resin film are laminated on a pre-formed polyolefin resin film and pressure-bonded with a roll or the like is also possible. It is.
- an adhesive resin film in a molten state and a polyolefin resin film in a molten state may be laminated on a pre-formed polyvinylidene fluoride-based resin film, and pressure bonded with a roll or the like.
- the multilayer sheet 10 of the present embodiment uses the polyvinylidene fluoride resin layer 2 and thus has excellent weather resistance and heat resistance.
- the adhesive resin layer 3 is formed of a conjugated diene polymer, a conjugated diene copolymer, or a hydride thereof, interlayer adhesion between the polyolefin resin layer 1 and the polyvinylidene fluoride resin layer 2 Can be improved.
- the EVA resin layer can be formed of an EVA resin composition that is generally used as a sealing material for solar cell modules.
- an EVA resin composition for example, an ethylene-vinyl acetate copolymer resin having a vinyl acetate content of 10 to 30% by mass as a main component is used as a cross-linking agent with respect to 100 parts by mass of the EVA resin.
- a compound containing 1 to 5 parts by mass of an organic peroxide that generates radicals as described above can be used.
- an EVA resin layer is provided on at least the polyolefin-based resin layer 1, and the back sheet and the sealing material are integrated, thereby simplifying the assembly process of the solar cell module. can do. Specifically, in the assembly process of the solar cell module, glass, a sealing material sheet, a cell, a sealing material sheet, and a back sheet are sequentially laminated and laminated. The laminating operation can be omitted. In addition, in the multilayer sheet of this modification, it is possible to prevent the sealing material and the back sheet from shifting in the solar cell module.
- a solar cell backsheet (hereinafter also simply referred to as a backsheet) according to a second embodiment of the present invention will be described.
- the back sheet of this embodiment uses the multilayer sheet of the first embodiment described above or its modification.
- the backsheet of this embodiment can be used for solar cells of various types such as crystalline silicon, polycrystalline silicon, amorphous silicon, compound, and organic.
- a thin film solar cell using amorphous silicon or the like may require a high degree of moisture resistance compared to a crystalline solar cell.
- a moisture-proof layer or a moisture-proof coating layer having a high moisture-proof property made of, for example, an inorganic oxide or the like may be further provided on the multilayer sheet of the first embodiment or its modification.
- a polyolefin resin layer and a polyvinylidene fluoride resin layer are laminated via an adhesive resin layer made of a conjugated diene polymer, a conjugated diene copolymer, or a hydride thereof. Since the multilayer sheet is used, it is excellent in weather resistance, heat resistance, mechanical strength, elastic modulus, electrical insulation and moisture resistance, and also has good interlayer adhesion.
- the solar cell backsheet of this embodiment suppresses deterioration with time of the solar cell module, and is reliable. Can be improved.
- FIG. 2 is a cross-sectional view schematically showing the structure of the solar cell module of the present embodiment.
- solar cells 15 that are photovoltaic elements are sealed with a sealing material 13 made of a synthetic resin such as EVA resin.
- the transparent substrate 12 which consists of glass etc. is laminated
- an adhesive resin layer in which a polyolefin resin layer and a polyvinylidene fluoride resin layer are formed of a conjugated diene polymer, a conjugated diene copolymer, or a hydride thereof on a back sheet. Since the multilayer sheet 10 laminated via is used, it is excellent in weather resistance, heat resistance, mechanical strength, elastic modulus, electrical insulation and moisture resistance, and high reliability is obtained.
- the multilayer sheets of Examples 1 to 12 and Comparative Examples 1 to 10 were produced by the method described below, and the characteristics when used as solar cell back sheets were evaluated.
- the MFR value is a value measured at 230 ° C. and a 2.16 kg load based on the JIS K7210 method A.
- SEBS hydride of styrene-butadiene-styrene block copolymer
- black pigments comprising chromium, manganese and copper oxide solid solutions 1 part by mass (1% by mass) as a toning pigment, and rutile crystal dioxide as a white inorganic pigment Titanium powder: 20 parts by mass (16% by mass), polyvinylidene fluoride resin (MFR: 5 g / 10 min): 80 parts by mass (65% by mass), and polymethyl methacrylate resin (MFR: 2 g / 10 min): What mixed 20 mass parts (16 mass%) with the Henschel mixer (MFR: 4.7g / 10min) was prepared.
- each resin layer was formed into a film under the conditions of 200 ° C. and 5 MPa using a heating press machine to obtain three types of films.
- the thickness of each resin layer was polyolefin resin layer 1: 320 ⁇ m, adhesive resin layer 3:50 ⁇ m, and polyvinylidene fluoride resin layer 2:50 ⁇ m.
- these three films were overlaid and integrated using a vacuum laminator by thermocompression bonding at 160 ° C. and 0.1 MPa to produce a multilayer sheet of Example 1.
- a solar cell module was manufactured using the multilayer sheet of Example 1 manufactured by the method described above. Specifically, a glass plate having a thickness of 3 mm, a sealing material sheet made of an ethylene-vinyl acetate copolymer having a thickness of 400 ⁇ m, four polycrystalline silicon cells assembled with series wiring, a sealing material sheet, Back sheets (multilayer sheets of Example 1) were laminated in this order, and laminated by applying pressure and heating at 135 ° C. for 10 minutes in a vacuum laminator to produce a solar cell module.
- Adhesive strength evaluation of each layer of the multilayer sheet Each of the multilayer sheets of Example 1 conforms to “Adhesive—Peeling peel strength test method—Part 3: T-type peel” defined in JIS K6854-3. The peel strength between layers was measured. At this time, the shape of the sample was a strip shape with a width of 15 mm and an adhesive part of 250 mm, and the tensile speed during the peel test was set to 100 mm / min. The multilayer sheet was also evaluated for peel strength after being held for 1000 hours in an environment of temperature 85 ° C. and humidity 85%. Further, this environmental test was conducted up to 3000 hours, and the peel strength thereafter was measured.
- a multilayer sheet was produced in the same manner as described above. The thickness of each resin layer was polyolefin resin layer 1: 320 ⁇ m, adhesive resin layer 3:50 ⁇ m, and polyvinylidene fluoride resin layer 2:50 ⁇ m.
- SEPS styrene-isoprene-styrene block copolymer
- the raw material for the polyvinylidene fluoride resin layer 2 is a black pigment made of an oxide solid solution of chromium, manganese and copper as a toning pigment: 1 part by mass (1% by mass), and a white inorganic pigment as titanium dioxide having a rutile crystal.
- Example 5 ⁇ Preparation of raw material for polyolefin resin layer 1> 300 kg of random polypropylene resin (trade name: Nobrene FH3315, manufactured by Sumitomo Chemical Co., Ltd.) is used as a raw material for the polyolefin resin layer 1, and a phosphate ester-based flame retardant (product name: ADK STAB FP-500) is used as a flame retardant. 45 kg, 2 kg of a benzophenone ultraviolet absorber (trade name: Sumisorb 130 manufactured by Sumitomo Chemical Co., Ltd.) as an ultraviolet absorber was prepared, and dry-mixed with a mixer. The MFR of the obtained polyolefin resin composition was 3.0 g / 10 minutes.
- a toning pigment 1 kg of a black pigment composed of an oxide solid solution of chromium, manganese and copper, and 20 kg of rutile crystal titanium dioxide powder as a white inorganic pigment were prepared and mixed in a mixer.
- a strand die having a hole diameter of 3 mm and a hole of 3 was attached to the outlet portion.
- Feeder A is charged with a mixture of toning pigment and titanium dioxide
- feeder B is a polyfluoride having an MFR of 20 g / 10 min at 230 ° C. under a load of 3.8 kg according to the MFR measurement method defined in JIS K7210 method A.
- a vinylidene fluoride resin was charged.
- the feeder C is made of polymethyl methacrylate resin (hereinafter referred to as PMMA) having an MFR of 9 g / 10 min at 230 ° C. and a load of 10 kg in the MFR measurement method defined in JIS K 7210 Method A. Prepared.
- PMMA polymethyl methacrylate resin
- the mixture of toning pigment and titanium dioxide charged in feeder A was 5.25 kg / hour
- the polyvinylidene fluoride resin charged in feeder B was 20.00 kg / hour
- PMMA charged in feeder C was 5.00 kg / hour. Feeded at the time input speed. Then, the twin-screw extruder was extruded from the strand die with a rotation speed of 300 rotations / minute and a barrel set temperature of 230 ° C.
- the extruded strand was cooled and cut with a pelletizer to obtain 60 kg of a pellet-shaped resin composition having a diameter of about 2 mm and a length of about 4 mm.
- the blend composition of the obtained resin composition was 80 parts by mass (66% by mass) of polyvinylidene fluoride resin, 20 parts by mass (16% by mass) of PMMA, 20 parts by mass (17% by mass) of white inorganic pigment, The color pigment was 1 part by mass (1% by mass), and the MFR was 4.7 g / 10 min.
- Extruder 1 for polyolefin-based resin layer 1: screw rotation speed 100 rotations / minute, discharge speed 150 kg / hour, extruder barrel set temperature 230 ° C.
- Extruder 2 for adhesive resin layer 3): screw rotation speed 25 rotations / minute, discharge speed 15 kg / hour, extruder barrel set temperature 230 ° C.
- Extruder 3 for the polyvinylidene fluoride resin layer 2): screw rotation speed 25 rotations / minute, discharge speed 10 kg / hour, extruder barrel set temperature 230 ° C.
- Resins discharged from extruders 1 to 3 are merged in a feed block, discharged from a coat hanger die set to a lip opening of 0.5 mm, introduced into a take-out machine, and sandwiched between two cooling rolls for cooling. Thus, a multilayer sheet was obtained. The obtained multilayer sheet was then introduced into a winder and wound into a roll.
- the thickness of each layer in the multilayer sheet of Example 5 was 300 ⁇ m for the polyolefin resin layer 1, 20 ⁇ m for the adhesive resin layer 3, and 20 ⁇ m for the polyvinylidene fluoride resin layer 2, and each layer was completely adhered.
- SEP hydride of isoprene-styrene block copolymer
- MFR 0.1 g / 10 min
- a multilayer sheet was produced in the same manner as in No. 5.
- the average thickness of each resin layer was polyolefin resin layer 1: 300 ⁇ m, adhesive resin layer 3:20 ⁇ m, and polyvinylidene fluoride resin layer 2:20 ⁇ m.
- the multilayer sheet of Example 6 there was some variation in the thickness of the adhesive resin layer 3, and the minimum thickness was 15 ⁇ m and the maximum thickness was 25 ⁇ m. In addition, each layer was completely adhered.
- SEBS styrene-butadiene-styrene block copolymer
- MFR 50 g / 10 min
- a multilayer sheet was produced in the same manner as in No. 5.
- the average thickness of each resin layer was polyolefin resin layer 1: 300 ⁇ m, adhesive resin layer 3:20 ⁇ m, and polyvinylidene fluoride resin layer 2:20 ⁇ m.
- the multilayer sheet of Example 7 had slight variations in the thickness of the adhesive resin layer 3, and the minimum thickness was 16 ⁇ m and the maximum thickness was 25 ⁇ m. In addition, each layer was completely adhered.
- the average thickness of each resin layer was polyolefin resin layer 1: 300 ⁇ m, adhesive resin layer 3:20 ⁇ m, and polyvinylidene fluoride resin layer 2:20 ⁇ m.
- the multilayer sheet of Example 8 had slight variations in the thickness of the polyolefin-based resin layer 1, and the minimum thickness was 290 ⁇ m and the maximum thickness was 310 ⁇ m. In addition, each layer was completely adhered.
- the average thickness of each resin layer was polyolefin resin layer 1: 300 ⁇ m, adhesive resin layer 3:20 ⁇ m, and polyvinylidene fluoride resin layer 2:20 ⁇ m.
- the multilayer sheet of Example 9 had slight variations in the thickness of the polyolefin-based resin layer 1 and had a minimum thickness of 290 ⁇ m and a maximum thickness of 310 ⁇ m. In addition, each layer was completely adhered.
- Example 10 In the preparation and preparation of the polyvinylidene fluoride-based resin layer 2, the MFR is measured at 230 ° C. under a load of 12.5 kg at 15 g / 10 min in the MFR measurement method defined in the method A of JIS K7210.
- the feeder C is charged with PMMA having an MFR of 9 g / 10 min at 230 ° C. and a load of 10 kg in the MFR measurement method defined in Method A of JIS K 7210, and the pellet is in the form of a pellet with an MFR of 0.5 g / 10 min.
- a multilayer sheet was prepared in the same manner as in Example 5 except that a polyvinylidene fluoride resin composition was obtained.
- each resin layer was, on average, polyolefin resin layer 1: 300 ⁇ m, adhesive resin layer 3:20 ⁇ m, and polyvinylidene fluoride resin layer 2:20 ⁇ m.
- the multilayer sheet of Example 10 had slight variations in the thickness of the polyvinylidene fluoride resin layer 2, and the minimum thickness was 17 ⁇ m and the maximum thickness was 23 ⁇ m. It was. In addition, each layer was completely adhered.
- Example 11 In the preparation and preparation of the polyvinylidene fluoride resin layer 2, the MFR is measured at 230 ° C. under a load of 3.8 kg and the MFR is 25 g / 10 minutes in the MFR measurement method defined in the method A of JIS K7210.
- the feeder C was charged with PMMA having an MFR of 35 g / 10 min at a load of 3.8 kg at a temperature of 3.8 kg in the MFR measurement method defined in Method A of JIS K 7210, and the pellet was in the form of a pellet having an MFR of 25 g / 10 min.
- a multilayer sheet was prepared in the same manner as in Example 5 except that a polyvinylidene fluoride resin composition was obtained.
- each resin layer was, on average, polyolefin resin layer 1: 300 ⁇ m, adhesive resin layer 3:20 ⁇ m, and polyvinylidene fluoride resin layer 2:20 ⁇ m.
- polyolefin resin layer 1 300 ⁇ m
- adhesive resin layer 3 20 ⁇ m
- polyvinylidene fluoride resin layer 2 20 ⁇ m.
- the minimum thickness 16 ⁇ m
- the maximum thickness 22 ⁇ m. It was.
- each layer was completely adhered.
- Example 12 In the same manner as in Example 5 described above, a raw material for the polyolefin resin layer 1, a raw material for the adhesive resin layer 3, and a polyvinylidene fluoride resin composition as a raw material for the polyvinylidene fluoride resin layer 2 were prepared. And using the raw material of the polyolefin-type resin layer 1, the single layer film was produced and wound up with the film forming line which attached the coat hanger die to the single screw extruder.
- the raw material for the adhesive resin layer 3 and the raw material for the polyvinylidene fluoride-based resin layer 2 are used by using a film forming line in which the resins discharged from the two extruders are joined together by a feed block and discharged from a coat hanger die.
- the film in a molten state to which is adhered was discharged onto the upper surface of the polyolefin-based resin layer 1 formed in advance.
- each layer in the multilayer sheet of Example 6 was 300 ⁇ m for the polyolefin resin layer 1, 50 ⁇ m for the adhesive resin layer 3, and 50 ⁇ m for the polyvinylidene fluoride resin layer 2.
- Comparative Example 1 A multilayer sheet of Comparative Example 1 is laminated in the order of a polyvinyl fluoride film, a polyethylene terephthalate (PET) film, and a polyvinyl fluoride film, and after applying a urethane adhesive between each layer, it is bonded and integrated by heating and pressing. It was.
- the thickness of each resin layer in the multilayer sheet of Comparative Example 1 was polyvinyl fluoride film: 50 ⁇ m, polyethylene terephthalate (PET) film: 320 ⁇ m, and polyvinyl fluoride film: 50 ⁇ m.
- Comparative Example 2 A polyolefin modified by introducing an epoxy group into the raw material of the adhesive resin layer 3 is used, and the raw materials of the polyolefin resin layer 1 and the polyvinylidene fluoride resin layer 2 are the same as in the example, using a vacuum laminator, A multilayer sheet of Comparative Example 2 was produced by thermocompression bonding at 160 ° C. and 0.1 MPa. Since the multilayer sheet of Comparative Example 2 had a very low initial peel strength, various evaluations could not be performed.
- Example 3 The polyolefin resin layer 1 and the polyvinylidene fluoride resin layer 2 produced by the same method as in Example 1 were thermocompression bonded under conditions of 160 ° C. and 0.1 MPa through a terpene hot melt adhesive.
- the multilayer sheet of Example 3 was produced.
- the multilayer sheet of Comparative Example 3 had a sufficient initial peel strength, but had a very low peel strength at a high temperature (100 ° C.).
- Example 4 The polyolefin-based resin layer 1 and the polyvinylidene fluoride-based resin layer 2 produced by the same method as in Example 1 were used as a low density polyethylene, medium density polyethylene, high density polyethylene, maleic acid modified polyethylene, polypropylene, olefin elastomer, cycloolefin.
- a multi-layer sheet was prepared by laminating via various olefin resins such as ethylene resin, ethylene-vinyl acetate copolymer, ethylene-vinyl acetate-maleic anhydride copolymer.
- the film was formed by thermocompression bonding using a vacuum laminator under the conditions of 160 ° C. and 0.1 MPa. Furthermore, using these resins having different melt viscosities, multilayer sheets were produced in the same manner. As a result, none of the multilayer sheets adhered at the interface with the polyvinylidene fluoride resin composition, or the peel strength was very small, and therefore various evaluations could not be performed.
- the minimum thickness of the polyolefin resin layer 1 is 200 ⁇ m
- the maximum thickness is 390 ⁇ m
- the minimum thickness of the adhesive resin layer 3 is less than 1 ⁇ m
- the maximum thickness is 43 ⁇ m
- the minimum thickness of the layer 2 was 5 ⁇ m and the maximum thickness was 35 ⁇ m, and the variation in the thickness of each resin layer was large.
- SEPS styrene-isoprene-styrene block copolymer
- a multilayer sheet was produced in the same manner as described above.
- the average thickness of each resin layer was polyolefin resin layer 1: 300 ⁇ m, adhesive resin layer 3:20 ⁇ m, and polyvinylidene fluoride resin layer 2:20 ⁇ m.
- the minimum thickness of the polyolefin resin layer 1 is 180 ⁇ m
- the maximum thickness is 400 ⁇ m
- the minimum thickness of the adhesive resin layer 3 is 2 ⁇ m
- the maximum thickness is 37 ⁇ m
- the polyvinylidene fluoride resin layer 2 had a minimum thickness of 5 ⁇ m and a maximum thickness of 35 ⁇ m, and the thickness of each resin layer varied greatly.
- a multilayer sheet was produced in the same manner as described above. The average thickness of each resin layer was polyolefin resin layer 1: 300 ⁇ m, adhesive resin layer 3:20 ⁇ m, and polyvinylidene fluoride resin layer 2:20 ⁇ m.
- the minimum thickness of the polyolefin resin layer 1 is 200 ⁇ m
- the maximum thickness is 390 ⁇ m
- the minimum thickness of the adhesive resin layer 3 is 2 ⁇ m
- the maximum thickness is 36 ⁇ m. 1 and the thickness of the adhesive resin layer 3 varied greatly. Further, there was a portion where the adhesive strength was extremely low locally between the polyolefin resin layer 1 and the adhesive resin layer 3.
- the multilayer sheet of Comparative Example 8 has a polyolefin resin layer 1 having a minimum thickness of 150 ⁇ m, a maximum thickness of 390 ⁇ m, an adhesive resin layer 3 having a minimum thickness of 3 ⁇ m, and a maximum thickness of 34 ⁇ m. 1 and the thickness of the adhesive resin layer 3 varied greatly. Further, there was a portion where the adhesive strength was extremely low locally between the polyolefin resin layer 1 and the adhesive resin layer 3.
- each resin layer was, on average, polyolefin resin layer 1: 300 ⁇ m, adhesive resin layer 3:20 ⁇ m, and polyvinylidene fluoride resin layer 2:20 ⁇ m.
- the minimum thickness of the adhesive resin layer 3 is 4 ⁇ m
- the maximum thickness is 30 ⁇ m
- the minimum thickness of the polyvinylidene fluoride resin layer 2 is 5 ⁇ m
- the maximum thickness is 37 ⁇ m. 3 and the thickness variation of the polyvinylidene fluoride resin layer 2 were large. Further, there was a portion where the adhesive strength was extremely low locally between the adhesive resin layer 3 and the polyvinylidene fluoride resin layer 2.
- each resin layer was, on average, polyolefin resin layer 1: 300 ⁇ m, adhesive resin layer 3:20 ⁇ m, and polyvinylidene fluoride resin layer 2:20 ⁇ m.
- the multilayer sheet of Comparative Example 10 has an adhesive resin layer 3 with a minimum thickness of 3 ⁇ m, a maximum thickness of 32 ⁇ m, a polyvinylidene fluoride resin layer 2 with a minimum thickness of 7 ⁇ m, and a maximum thickness of 38 ⁇ m.
- the thickness of the layer 3 and the polyvinylidene fluoride resin layer 2 varied greatly. Further, there was a portion where the adhesive strength was extremely low locally between the adhesive resin layer 3 and the polyvinylidene fluoride resin layer 2.
- the multilayer sheets of Examples 1 to 12 produced within the scope of the present invention had high adhesive strength between the respective layers, and maintained the peel strength even in a high temperature and high humidity environment. Moreover, even if the solar cell module produced using these multilayer sheets as a back sheet was kept in a high temperature and high humidity environment, the reduction rate of the maximum power was small. This is because the multilayer sheet is excellent in weather resistance, heat resistance, and moisture resistance, and these characteristics are maintained even in a high temperature and high humidity environment, and the adhesive strength between each sheet layer is maintained. This is probably because the moisture permeation into the solar cell was small and the characteristics of the solar battery cell were maintained well.
- a multilayer sheet suitable for a solar cell back sheet can be realized because of excellent weather resistance, heat resistance and moisture resistance, and good interlayer adhesion.
- 1 polyolefin resin layer
- 2 polyvinylidene fluoride resin layer
- 3 adhesive resin layer
- 10 multilayer sheet
- 11 solar cell module
- 12 transparent substrate
- 13 sealing material
- 14 frame
- 15 Solar cell
- 16 sunlight
Abstract
Description
この多層シートでは、前記接着樹脂層が、炭素数4~8の共役ジエンの単独重合体、炭素数4~8の共役ジエンと他の単量体との共重合体又はこれらの水素化物により形成されていてもよい。
その場合、前記接着樹脂層は、例えば炭素数4~8の共役ジエンと芳香族ビニル系化合物との共重合体又はその水素化物により形成することができる。
また、第2の樹脂層を形成するポリフッ化ビニリデン系樹脂組成物は、ポリフッ化ビニリデン:50~99質量%及びポリメタクリル酸メチル:1~50質量%からなる樹脂成分100質量部に対して、白色無機顔料を1~40質量部含有していてもよい。
前記第1の樹脂層の厚さは例えば50~500μmとすることができ、前記第2の樹脂層の厚さ及び前記接着樹脂層の厚さは例えば5~50μmとすることができる。
また、第1の樹脂層を形成するポリオレフィン系樹脂組成物は、樹脂成分として、炭素数2~20のオレフィン系炭化水素の単独重合体又は炭素数2~20のオレフィン系炭化水素と他の単量体との共重合体を含有していてもよい。
その場合、前記ポリオレフィン系樹脂組成物の樹脂成分は、炭素数2~20のオレフィン系炭化水素に由来する単位を70質量%以上含有していてもよい。
更に、第1の樹脂層を形成するポリオレフィン系樹脂組成物には、難燃剤及び/又は耐候剤が配合されていてもよい。
一方、この多層シートは、例えば130~260℃の温度範囲で、溶融共押出成形により製膜したり、個別に製膜された第1の樹脂層と、接着樹脂層と、第2の樹脂層とを、この順に積層し、130~260℃の温度条件下で加圧接着したりすることができる。
更に、少なくとも一方の面に、エチレン酢酸ビニル共重合体を樹脂成分として含有する第3の樹脂層が積層されていてもよい。
また、本発明に係る太陽電池モジュールは、前述したバックシートを用いたものである。
先ず、本発明の第1の実施形態に係る多層シートについて説明する。図1は本実施形態の多層シートの構成を模式的に示す図である。図1に示すように、本実施形態の多層シート10では、ポリオレフィン系樹脂層1と、ポリフッ化ビニリデン系樹脂層2とが、共役ジエン系重合体、共役ジエン系共重合体又はこれらの水素化物からなる接着樹脂層3を介して積層されている。
ポリオレフィン系樹脂層1は、主成分がポリオレフィン系樹脂であるポリオレフィン系樹脂組成物により形成されている。このポリオレフィン系樹脂組成物は、樹脂成分として、炭素数2~20のオレフィン系炭化水素の単独重合体又は炭素数2~20のオレフィン系炭化水素と他の単量体との共重合体を含有することが好ましい。これにより、多層シートにしたときの機械的強度や弾性率が良好となり、ハンドリング性が向上する。また、熱的な耐久性も向上するため、太陽電池のバックシートなどに好適な多層シートが得られる。
ポリフッ化ビニリデン系樹脂層2は、樹脂成分の50質量%以上がポリフッ化ビニリデン樹脂であるポリフッ化ビニリデン系樹脂組成物により形成されている。このポリフッ化ビニリデン系樹脂組成物に配合されるポリフッ化ビニリデン樹脂は、フッ化ビニリデンの単独重合体が好適であるが、フッ化ビニリデンと他の単量体の共重合体であってもよい。
接着樹脂層3は、共役ジエン系の重合体、共重合体又はこれらの水素化物により形成されている。接着樹脂層3にこれらを使用することにより、非極性ポリマーであるポリオレフィン系樹脂と、極性ポリマーであるポリフッ化ビニリデン系樹脂との接着が可能となる。この接着樹脂層3により、ポリオレフィン系樹脂層1と、ポリフッ化ビニリデン系樹脂層2とを強固に接着することができるため、120℃程度の高温下においても安定した接着性を維持することができる。その結果、多層シート10は、太陽電池モジュールの使用環境において十分耐久性を有するものとなる。
ポリオレフィン系樹脂層1及びポリフッ化ビニリデン系樹脂層2は、JIS K7210に規定されるA法により測定した230℃、2.16kg荷重におけるメルトフローレート(MFR)が、0.5~25g/10分である。また、接着樹脂層3は、JIS K7210に規定されるA法により測定した230℃、2.16kg荷重におけるメルトフローレート(MFR)が、0.1~50g/10分である。
前述した各層の厚さは、特に限定されるものではなく、用途や求められる特性に応じて、適宜設定することができるが、例えばポリオレフィン系樹脂層1の厚さを50~500μmとすると共に、ポリフッ化ビニリデン系樹脂層2及び接着樹脂層3の厚さをそれぞれ5~50μmとすることができる。
次に、前述の如く構成された多層シート10の製造方法について説明する。本実施形態の多層シート10は、ポリオレフィン系樹脂層1及びポリフッ化ビニリデン系樹脂層2を形成する各樹脂組成物、並びに接着樹脂層3を形成する重合体を、それぞれ別の押出機で溶融させた後、合流して一体化する共押出法により製膜することが好ましい。
次に、本発明の第1の実施形態の変形例に係る多層シートについて説明する。本変形例の多層シートにおいては、図1に示す多層シート10の少なくともポリオレフィン系樹脂層1上に、エチレン-酢酸ビニル共重合体(EVA)樹脂層が設けられている。
EVA樹脂層は、太陽電池モジュール用封止材として一般に使用されているEVA樹脂組成物により形成することができる。このようなEVA樹脂組成物としては、例えば、酢酸ビニル含有量が10~30質量%のエチレン-酢酸ビニル共重合体樹脂を主成分とし、EVA樹脂100質量部に対して、架橋剤として100℃以上でラジカルが発生する有機過酸化物を1~5質量部配合したものが挙げられる。
次に、本発明の第2の実施形態に係る太陽電池用バックシート(以下、単にバックシートともいう。)について説明する。本実施形態のバックシートは、前述した第1の実施形態又はその変形例の多層シートを用いたものである。
次に、本発明の第3の実施形態に係る太陽電池モジュールについて説明する。図2は本実施形態の太陽電池モジュールの構造を模式的に示す断面図である。図2に示すように、本実施形態の太陽電池モジュール11は、光起電力素子である太陽電池セル15が、EVA樹脂などの合成樹脂からなる封止材13により封止されている。
ポリオレフィン系樹脂層1の原料として、ランダムポリプロピレン樹脂(住友化学社製 商品名:ノーブレンFH3315、MFR=3.0g/10分、融点=143℃)を準備した。また、接着樹脂層3の原料には、スチレン-ブタジエン-スチレンブロック共重合体の水素化物(SEBS、旭化成ケミカルズ社製 商品名:タフテックH1053、MFR=1.8g/10分)を用いた。
次に、前述した方法で作製した実施例1多層シ-トを使用して、太陽電池モジュールを製造した。具体的には、厚さ3mmのガラス板、厚さ400μmのエチレン-酢酸ビニル共重合体からなる封止材シ-ト、直列配線を組んだ4枚の多結晶シリコンセル、封止材シート、バックシート(実施例1の多層シート)の順に積層し、真空ラミネータ中にて1気圧、135℃で10分間加圧、加熱して積層し、太陽電池モジュ-ルを製造した。
(1)多層シートの各層の接着力評価
JIS K6854-3に規定される「接着剤-はく離接着強さ試験方法-第3部:T型はく離」に準拠し、実施例1の多層シートにおける各層間の剥離強度を測定した。このとき、サンプルの形状は、幅15mm×接着部250mmの短冊状とし、剥離試験の際の引張速度を100mm/分とした。また、この多層シートを、温度85℃、湿度85%の環境下に1000時間保持した後の剥離強度についても評価した。更に、この環境試験は3000時間まで行い、その後の剥離強度を測定した。
JIS Z0208に規定される「防湿包装材料の透湿度試験方法(カップ法)」に準拠し、実施例1の多層シートの40℃、相対湿度90%における透湿度を測定した。
JIS C8990の10.13高温高湿試験に準拠して、温度85℃、湿度85%、1000時間の環境試験を実施し、ソーラーシミュレーターにて試験前後の最大電力を測定し、最大電力の低下率を評価した。同様の測定を、2000時間経過後及び3000時間経過後にも行った。
ポリオレフィン系樹脂層1の原料として、高密度ポリエチレン樹脂(日本ポリエチレン社製 商品名:ノバテックHF560、MFR=7.0g/10分、融点=134℃)を用いたこと以外は、前述した実施例1と同様の方法で多層シートを作製した。各樹脂層の厚さは、ポリオレフィン系樹脂層1:320μm、接着樹脂層3:50μm、ポリフッ化ビニリデン系樹脂層2:50μmであった。
接着樹脂層3の原料として、スチレン-イソプレン-スチレンブロック共重合体の水素化物(SEPS、クラレプラスチックス社製 商品名:セプトン2007、MFR=2.4g/10分)を用いたこと以外は、前述した実施例1と同様の方法で多層シートを作製した。各樹脂層の厚さは、ポリオレフィン系樹脂層1:320μm、接着樹脂層3:50μm、ポリフッ化ビニリデン系樹脂層2:50μmであった。
ポリフッ化ビニリデン系樹脂層2の原料として、調色用顔料としてクロム、マンガン、銅の酸化物固溶体からなる黒色顔料:1質量部(1質量%)と、白色無機顔料としてルチル型結晶の二酸化チタン粉末:20質量部(16質量%)と、ポリフッ化ビニリデン樹脂(MFR:5g/10分):50質量部(40質量%)と、ポリメタクリル酸メチル樹脂(MFRが2g/10分):50質量部(40質量%)とを、ヘンシェルミキサーにて混合したもの(MFR=4.0g/10分)を用いた以外は、前述した実施例1と同様の方法で多層シートを作製した。各樹脂層の厚さは、ポリオレフィン系樹脂層1:320μm、接着樹脂層3:50μm、ポリフッ化ビニリデン系樹脂層2:50μmであった。
<ポリオレフィン系樹脂層1の原料準備>
ポリオレフィン系樹脂層1の原料として、ランダムポリプロピレン樹脂(住友化学社製 商品名:ノーブレンFH3315)を300kg、難燃化剤としてリン酸エステル系難燃剤(ADEKA社製 商品名:アデカスタブFP-500)を45kg、紫外線吸収剤としてベンゾフェノン系紫外線吸収剤(住友化学社製 商品名:スミソーブ130)を2kg準備し、ミキサーにて乾式混合を行った。得られたポリオレフィン系樹脂組成物のMFRは、3.0g/10分であった。
接着樹脂層3の原料として、スチレン-ブタジエン-スチレンブロック共重合体の水素化物(SEBS、旭化成ケミカルズ社製 商品名:タフテックH1053、MFR=1.8g/10分)を、30kg準備した。
調色用顔料としてクロム、マンガン及び銅の酸化物固溶体からなる黒色顔料:1kgと、白色無機顔料としてルチル型結晶の二酸化チタン粉末:20kgとを準備し、ミキサーにて混合した。樹脂組成物調製のための混練装置として、スクリュー径30mm、L/D=40の二軸押出機を準備し、押出機の原料供給部にの3基のスクリューフィーダーA~Cを取り付け、押出機の出口部に穴径3mm、3穴のストランドダイを取り付けた。
3層共押出用設備として単軸押出機3台を3種3層のフィードブロックに接続し、更にこのフィードブロックで合流した3層の樹脂が、リップ幅600mmのコートハンガーダイに流入するように接続した。なお、単軸押出機3台の仕様は、以下の通りである。
・押出機1(ポリオレフィン系樹脂層1用):スクリュー径90mm、L/D=30、スクリューはフルフライトスクリュー。
・押出機2(接着樹脂層3用):スクリュー径40mm、L/D=30、スクリューはフルフライトスクリュー。
・押出機3(ポリフッ化ビニリデン系樹脂層2用):スクリュー径40mm、L/D=30、スクリューはフルフライトスクリュー。
・押出機1(ポリオレフィン系樹脂層1用):スクリュー回転数100回転/分、吐出速度150kg/時間、押出機バレル設定温度230℃。
・押出機2(接着樹脂層3用):スクリュー回転数25回転/分、吐出速度15kg/時間、押出機バレル設定温度230℃。
・押出機3(ポリフッ化ビニリデン系樹脂層2用):スクリュー回転数25回転/分、吐出速度10kg/時間、押出機バレル設定温度230℃。
接着樹脂層3の原料として、イソプレン-スチレンブロック共重合体の水素化物(SEP、クラレ社製 商品名:セプトン1001、MFR=0.1g/10分)を用いたこと以外は、前述した実施例5と同様の方法で多層シートを作製した。各樹脂層の厚さは、平均で、ポリオレフィン系樹脂層1:300μm、接着樹脂層3:20μm、ポリフッ化ビニリデン系樹脂層2:20μmであった。この実施例6の多層シートは、接着樹脂層3の厚さに若干のばらつきが発生し、最小厚さが15μm、最大厚さが25μmであったが、実用上問題無いレベルであった。また、各層間は完全に接着していた。
接着樹脂層3の原料として、スチレン-ブタジエン-スチレンブロック共重合体の水素化物(SEBS、クラレ社製 商品名:セプトン8076、MFR=50g/10分)を用いたこと以外は、前述した実施例5と同様の方法で多層シートを作製した。各樹脂層の厚さは、平均で、ポリオレフィン系樹脂層1:300μm、接着樹脂層3:20μm、ポリフッ化ビニリデン系樹脂層2:20μmであった。この実施例7の多層シートは、接着樹脂層3の厚さに若干のばらつきが発生し、最小厚さが16μm、最大厚さが25μmであったが、実用上問題無いレベルであった。また、各層間は完全に接着していた。
ポリオレフィン系樹脂層1の原料として、ポリプロピレン樹脂(住友化学社製 商品名:ノーブレンFH1016、MFR=0.5g/10分)を用いたこと以外は、前述した実施例5と同様の方法で多層シートを作製した。各樹脂層の厚さは、平均で、ポリオレフィン系樹脂層1:300μm、接着樹脂層3:20μm、ポリフッ化ビニリデン系樹脂層2:20μmであった。この実施例8の多層シートは、ポリオレフィン系樹脂層1の厚さに若干のばらつきが発生し、最小厚さが290μm、最大厚さが310μmであったが、実用上問題無いレベルであった。また、各層間は完全に接着していた。
ポリオレフィン系樹脂層1の原料として、ポリプロピレン樹脂(住友化学社製 商品名:ノーブレンZ101、MFR=25g/10分)を用いたこと以外は、前述した実施例5と同様の方法で多層シートを作製した。各樹脂層の厚さは、平均で、ポリオレフィン系樹脂層1:300μm、接着樹脂層3:20μm、ポリフッ化ビニリデン系樹脂層2:20μmであった。この実施例9の多層シートは、ポリオレフィン系樹脂層1の厚さに若干のばらつきが発生し、最小厚さが290μm、最大厚さが310μmであったが、実用上問題無いレベルであった。また、各層間は完全に接着していた。
ポリフッ化ビニリデン系樹脂層2の準備・調製において、フィーダーBにJIS K7210のA法に規定されたMFRの測定法において230℃、12.5kg荷重におけるMFRが15g/10分であるポリフッ化ビニリデン樹脂を、フィーダーCにJIS K 7210のA法に規定されたMFRの測定法において230℃、10kg荷重におけるMFRが9g/10分であるPMMAを仕込み、MFRが0.5g/10分のペレット状のポリフッ化ビニリデン系樹脂組成物を得たこと以外は、前述の実施例5と同様の方法で多層シートを作製した。
ポリフッ化ビニリデン系樹脂層2の準備・調製において、フィーダーBにJIS K7210のA法に規定されたMFRの測定法において230℃、3.8kg荷重におけるMFRが25g/10分であるポリフッ化ビニリデン樹脂を、フィーダーCにJIS K 7210のA法に規定されたMFRの測定法において230℃、3.8kg荷重におけるMFRが35g/10分であるPMMAを仕込み、MFRが25g/10分のペレット状のポリフッ化ビニリデン系樹脂組成物を得たこと以外は、前述の実施例5と同様の方法で多層シートを作製した。
前述した実施例5と同様に、ポリオレフィン系樹脂層1の原料、接着樹脂層3の原料、ポリフッ化ビニリデン系樹脂層2の原料のポリフッ化ビニリデン系樹脂組成物を準備した。そして、ポリオレフィン系樹脂層1の原料を用いて、単軸押出機にコートハンガーダイを取り付けた製膜ラインで、単層フィルムを作製し、巻き取った。次に2台の押出機から吐出した樹脂がフィードブロックで合流し、コートハンガーダイから吐出される構造の製膜ラインを用いて、接着樹脂層3の原料とポリフッ化ビニリデン系樹脂層2の原料が接着した溶融状態のフィルムを、予め製膜しておいたポリオレフィン系樹脂層1の上面に吐出させた。
ポリフッ化ビニルフィルム、ポリエチレンテレフタレート(PET)フィルム、ポリフッ化ビニルフィルムの順で積層し、各層間にウレタン系接着剤を塗布した後、加熱及び加圧することにより接着一体化し、比較例1の多層シートとした。比較例1の多層シートにおける各樹脂層の厚さは、ポリフッ化ビニルフィルム:50μm、ポリエチレンテレフタレート(PET)フィルム:320μm、ポリフッ化ビニルフィルム:50μmであった。
接着樹脂層3の原料にエポキシ基を導入して変性したポリオレフィンを使用し、ポリオレフィン系樹脂層1及びポリフッ化ビニリデン系樹脂層2の原料は、実施例と同じにして、真空ラミネータを用いて、160℃、0.1MPaで加熱圧着し、比較例2の多層シートを作製した。この比較例2の多層シートは、初期の剥離強度が非常に小さいものであったため、各種評価を行うことができなかった。
実施例1と同様の方法で作製したポリオレフィン系樹脂層1及びポリフッ化ビニリデン系樹脂層2を、テルペン系のホットメルト接着剤を介して、160℃、0.1MPaの条件で加熱圧着し、比較例3の多層シートを作製した。この比較例3の多層シートは、初期の剥離強度は十分であったが、高温下(100℃)での剥離強度が非常に小さいものであった。
実施例1と同様の方法で作製したポリオレフィン系樹脂層1及びポリフッ化ビニリデン系樹脂層2を、低密度ポリエチレン、中密度ポリエチレン、高密度ポリエチレン、マレイン酸変性ポリエチレン、ポリプロピレン、オレフィン系エラストマー、シクロオレフィン系樹脂、エチレン-酢酸ビニル共重合体、エチレン-酢酸ビニル-無水マレイン酸共重合体などの各種オレフィン系樹脂を介して、積層し、多層シートを作製した。
接着層3の原料として、スチレン-ブタジエン-スチレンブロック共重合体の水素化物(SEBS、クラレ社製 商品名:セプトン8004、MFR=0.05g/10分)を用いたこと以外は、前述した実施例5と同様の方法で多層シートを作製した。各樹脂層の厚さは、平均で、ポリオレフィン系樹脂層1:300μm、接着樹脂層3:20μm、ポリフッ化ビニリデン系樹脂層2:20μmであった。
接着層3の原料として、スチレン-イソプレン-スチレンブロック共重合体の水素化物(SEPS、クラレ社製 商品名:セプトン2002、MFR=70g/10分)を用いたこと以外は、前述した実施例5と同様の方法で多層シートを作製した。各樹脂層の厚さは、平均で、ポリオレフィン系樹脂層1:300μm、接着樹脂層3:20μm、ポリフッ化ビニリデン系樹脂層2:20μmであった。
ポリオレフィン系樹脂層1の原料として、ランダムポリプロピレン樹脂の代わりにポリプロピレン樹脂(日本ポリプロピレン社製 商品名:ノバテックPP EA9FT、MFR=0.4g/10分)を用いたこと以外は、前述した実施例5と同様の方法で多層シートを作製した。各樹脂層の厚さは、平均で、ポリオレフィン系樹脂層1:300μm、接着樹脂層3:20μm、ポリフッ化ビニリデン系樹脂層2:20μmであった。
ポリオレフィン系樹脂層1の原料として、ランダムポリプロピレン樹脂の代わりにポリプロピレン樹脂(住友化学社製 商品名:ノーブレンAZ564、MFR=30g/10分)を用いたこと以外は、前述した実施例5と同様の方法で多層シートを作製した。各樹脂層の厚さは、平均で、ポリオレフィン系樹脂層1:300μm、接着樹脂層3:20μm、ポリフッ化ビニリデン系樹脂層2:20μmであった。
ポリフッ化ビニリデン系樹脂層2の準備・調製において、フィーダーBにJIS K7210のA法に規定されたMFRの測定法において230℃、12.5kg荷重におけるMFRが5g/10分であるポリフッ化ビニリデン樹脂を、フィーダーCにJIS K 7210のA法に規定されたMFRの測定法において230℃、10kg荷重におけるMFRが9g/10分であるPMMAを仕込み、MFRが0.3g/10分のペレット状のポリフッ化ビニリデン系樹脂組成物を得たこと以外は、実施例5と同様の方法で多層シートを作製した。
ポリフッ化ビニリデン系樹脂層2の準備・調製において、フィーダーBにJIS K7210のA法に規定されたMFRの測定法において230℃、12.5kg荷重におけるMFRが25g/10分であるポリフッ化ビニリデン樹脂を、フィーダーCにJIS K 7210のA法に規定されたMFRの測定法において3.8kg荷重におけるMFRが40g/10分であるPMMAを仕込み、MFRが27g/10分のペレット状のポリフッ化ビニリデン系樹脂組成物を得たこと以外は、実施例5と同様の方法で多層シートを作製した。
Claims (13)
- JIS K7210に規定されるA法により測定した230℃、2.16kg荷重におけるメルトフローレートが0.5~25g/10分のポリオレフィン系樹脂組成物からなる第1の樹脂層と、
JIS K7210に規定されるA法により測定した230℃、2.16kg荷重におけるメルトフローレートが0.5~25g/10分のポリフッ化ビニリデン系樹脂組成物からなる第2の樹脂層とが、
JIS K7210に規定されるA法により測定した230℃、2.16kg荷重におけるメルトフローレートが0.1~50g/10分である共役ジエン系重合体、共役ジエン系共重合体又はこれらの水素化物からなる接着樹脂層を介して積層された多層シート。 - 前記接着樹脂層は、炭素数4~8の共役ジエンの単独重合体、炭素数4~8の共役ジエンと他の単量体との共重合体又はこれらの水素化物により形成されていることを特徴とする請求項1に記載の多層シート。
- 前記接着樹脂層は、炭素数4~8の共役ジエンと芳香族ビニル系化合物との共重合体又はその水素化物により形成されていることを特徴とする請求項2に記載の多層シート。
- 第2の樹脂層を形成するポリフッ化ビニリデン系樹脂組成物は、ポリフッ化ビニリデン:50~99質量%及びポリメタクリル酸メチル:1~50質量%からなる樹脂成分100質量部に対して、白色無機顔料を1~40質量部含有することを特徴とする請求項1~3のいずれか1項に記載の多層シート。
- 前記第1の樹脂層の厚さが50~500μmであり、前記第2の樹脂層の厚さ及び前記接着樹脂層の厚さが5~50μmであることを特徴とする請求項1~4のいずれか1項に記載の多層シート。
- 第1の樹脂層を形成するポリオレフィン系樹脂組成物は、樹脂成分として、炭素数2~20のオレフィン系炭化水素の単独重合体又は炭素数2~20のオレフィン系炭化水素と他の単量体との共重合体を含有することを特徴とする請求項1~5のいずれか1項に記載の多層シート。
- 前記ポリオレフィン系樹脂組成物の樹脂成分は、炭素数2~20のオレフィン系炭化水素に由来する単位を70質量%以上含有することを特徴とする請求項6に記載の多層シート。
- 第1の樹脂層を形成するポリオレフィン系樹脂組成物には、難燃剤及び/又は耐候剤が配合されていることを特徴とする請求項1~7のいずれか1項に記載の多層シート。
- 130~260℃の温度範囲で、溶融共押出成形により製膜されたものであることを特徴とする請求項1~8のいずれか1項に記載の多層シート。
- 個別に製膜された第1の樹脂層と、接着樹脂層と、第2の樹脂層とを、この順に積層し、130~260℃の温度条件下で加圧接着したものであることを特徴とする請求項1~8のいずれか1項に記載の多層シート。
- 更に、少なくとも一方の面に、エチレン酢酸ビニル共重合体を樹脂成分として含有する第3の樹脂層が積層されていることを特徴とする請求項1~10のいずれか1項に記載の多層シート。
- 請求項1~11のいずれか1項に記載の多層シートを用いた太陽電池用バックシート。
- 請求項12に記載のバックシートを用いた太陽電池モジュール。
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Also Published As
Publication number | Publication date |
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CN104066577B (zh) | 2016-02-10 |
US9450129B2 (en) | 2016-09-20 |
EP2805822A4 (en) | 2015-09-23 |
TW201334965A (zh) | 2013-09-01 |
KR20140114870A (ko) | 2014-09-29 |
KR101997526B1 (ko) | 2019-07-08 |
EP2805822A1 (en) | 2014-11-26 |
JPWO2013108816A1 (ja) | 2015-05-11 |
CN104066577A (zh) | 2014-09-24 |
US20140373915A1 (en) | 2014-12-25 |
EP2805822B1 (en) | 2017-08-02 |
JP5952838B2 (ja) | 2016-07-13 |
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