WO2014156518A1 - Procédé de fabrication de module de cellule solaire - Google Patents

Procédé de fabrication de module de cellule solaire Download PDF

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Publication number
WO2014156518A1
WO2014156518A1 PCT/JP2014/055572 JP2014055572W WO2014156518A1 WO 2014156518 A1 WO2014156518 A1 WO 2014156518A1 JP 2014055572 W JP2014055572 W JP 2014055572W WO 2014156518 A1 WO2014156518 A1 WO 2014156518A1
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WIPO (PCT)
Prior art keywords
resin film
film
solar cell
heat
cell module
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PCT/JP2014/055572
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English (en)
Japanese (ja)
Inventor
直史 三宅
ゆう佳 芦田
的場　健
崇太 能浦
Original Assignee
東レフィルム加工株式会社
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Priority to JP2014517920A priority Critical patent/JPWO2014156518A1/ja
Publication of WO2014156518A1 publication Critical patent/WO2014156518A1/fr

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    • 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
    • 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
    • B32B27/36—Layered products comprising a layer of synthetic resin comprising polyesters
    • 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
    • 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
    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
    • 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
    • B32B2457/14—Semiconductor wafers
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E10/00—Energy generation through renewable energy sources
    • Y02E10/50—Photovoltaic [PV] energy

Definitions

  • the present invention relates to a method for manufacturing a solar cell module.
  • a solar cell module uses a solar cell element such as a crystalline silicon solar cell, a polycrystalline silicon solar cell, or an amorphous silicon solar cell, and is sealed with a surface protective sheet or glass, ethylene / vinyl acetate copolymer resin, etc. It is manufactured by a method in which a material sheet, a solar cell element, a sealing material sheet, and a back surface protection sheet are laminated in that order, and vacuum suction is performed and thermocompression bonding is performed for integration.
  • a back surface protection sheet constituting the solar cell module a plastic base material that is light in weight and excellent in electrical characteristics and strength has been generally used.
  • the back protection sheet Since solar cell modules are required to maintain their performance over a long period of 20 years or longer, the back protection sheet has strength, weather resistance, heat resistance, water resistance, light resistance, chemical resistance, moisture resistance, design, etc. It is excellent that they are not significantly degraded over time.
  • the back surface protection sheet used in the solar cell module is a sheet obtained by laminating a plurality of functional films in advance with an adhesive, a pressure sensitive adhesive or the like in order to satisfy the above various required characteristics (Patent Document 1). Furthermore, it is common to laminate functional layers by coating or the like before or after lamination, and after aging for several days after processing, but there have been problems of cost reduction and shortening of the manufacturing process. That is, there is a problem that the loss increases according to the number of the above steps, and the yield of the final product decreases.
  • the present invention reduces a loss in a manufacturing process of a back surface protection sheet for a solar cell module, and can improve yield by fundamentally solving the problem of warping of the back surface protection sheet in a manufacturing method of a solar cell module. It aims at providing the manufacturing method of.
  • the present inventors manufacture a solar cell module in which a surface protective sheet, a sealing material sheet 1, a solar battery cell, a sealing material sheet 2, and two or more back surface protective sheet member films are integrally formed by heating and pressure-bonding treatment.
  • the adhesion strength between the sealing material sheet 2 laminated according to the heating temperature and pressure bonding conditions at the time of molding and the back surface protective sheet member film facing the sealing material sheet is 40 N / cm or more, and the two or more sheets
  • the method for manufacturing a solar cell module according to the present invention can integrally mold a plurality of back surface protection sheet member films, and can manufacture a solar cell module with higher yield by solving the problem of warpage of the back surface protection sheet. It is possible to reduce the loss of the back surface protective sheet member film.
  • FIG. 1 It is a schematic diagram which shows one manufacturing method of the solar cell module of this invention. It is an example of the back surface protection sheet member film for solar cell modules in this invention. It is an example of the back surface protection sheet member film for solar cell modules in this invention. It is an example of the back surface protection sheet member film for solar cell modules in this invention. It is an example of the back surface protection sheet member film for solar cell modules in this invention. It is an example of the back surface protection sheet member film for solar cell modules in this invention.
  • the manufacturing method of the solar cell module of the present invention includes a surface protection sheet, a sealing material sheet 1, a solar battery cell, a sealing material sheet 2, and two or more back surface protection sheet member films in this order by heating and pressure bonding treatment.
  • the surface protection sheet for this purpose is generally a surface protection glass, and it is a resin sheet that ensures transparency, strength, weather resistance, heat resistance, gas barrier performance, etc. that can replace glass. There may be.
  • the encapsulant sheet in the present invention (referred to collectively as encapsulant sheets 1 and 2) is used for the purpose of covering the unevenness of the solar battery cell and protecting the solar battery cell from temperature change, humidity, impact, and the like. .
  • a known heat-adhesive film can be used as a sealing material sheet of a solar cell module.
  • ethylene / vinyl acetate copolymer resin hereinafter sometimes abbreviated as EVA
  • ethylene / acrylic examples include methyl acid copolymer resin, ethylene / ethyl acrylate copolymer resin, polyurethane resin, polyvinyl butyral, ethylene / vinyl acetate partially saponified product, silicone resin, polyester resin, and the like.
  • EVA is particularly preferably used from the viewpoint of light resistance, transparency, moisture resistance, and economy, and a vinyl acetate content of 15 to 40% by weight is particularly preferable.
  • the vinyl acetate content is 15 to 40% by weight, the transparency is not lowered, the resin is not sticky, and the processability and handleability are good.
  • additives such as a crosslinking agent such as an organic peroxide, an ultraviolet absorber, and an antioxidant can be used as necessary.
  • a sheet that has been embossed in advance may be used.
  • the back surface protective sheet member film in the present invention is composed of two or more sheets, and these are laminated to exhibit comprehensively strength, weather resistance, heat resistance, water resistance, light resistance, chemical resistance, moisture resistance, design, etc. It can be arbitrarily combined depending on the function required for the back surface protection sheet. Especially, it is preferable to arrange
  • the heat-adhesive resin film in the present invention is a film having heat-adhesiveness with the above-mentioned sealing material sheet, and polyolefin is preferably used as the resin of the heat-adhesive resin film.
  • Polyolefins are olefin monomers such as ethylene, propylene, 1-butene, and 1-pentene, which are singly or copolymerized. From the viewpoint of heat resistance, polyethylene resins and polypropylene resins are preferable, and polypropylene is mainly used rather than polyethylene.
  • the resin (polypropylene-based resin) is more excellent in heat resistance, is less susceptible to deformation under high temperatures and pressures when molding a solar cell module, and is more preferably used when the processing temperature is high.
  • the melting point of the polypropylene resin is preferably in the range of 140 ° C. to 170 ° C. from the viewpoints of heat resistance, slipperiness, film handling properties, curl resistance, and thermal adhesiveness with the adhesive resin layer.
  • the melting point is 140 ° C. or higher, it has excellent heat resistance, and when it is heat-sealed with a sealing material sheet as a back surface protection sheet member film for a solar cell module, the thickness is reduced or the insulation resistance is lowered. Such a problem can be suppressed, which is preferable.
  • By setting the melting point to 170 ° C. or lower it is possible to ensure excellent adhesion with the sealing material sheet.
  • the thermal adhesive resin film in the present invention may be a nylon film.
  • nylon resin nylon-6, nylon-66, nylon-11, nylon-12 or the like having excellent mechanical strength, dimensional stability, and heat resistance is desirable.
  • the thermal adhesive resin film in the present invention may be a fluororesin film.
  • a fluororesin film for example, a resin mainly composed of polyvinyl fluoride (PVF), ethylene / chlorotrifluoroethylene copolymer (ECTFE), or ethylene / tetrafluoroethylene copolymer (ETFE) is used. desirable.
  • PVF polyvinyl fluoride
  • ECTFE ethylene / chlorotrifluoroethylene copolymer
  • ETFE ethylene / tetrafluoroethylene copolymer
  • the heat adhesive resin film in the present invention may be an ethylene / vinyl acetate copolymer resin film having a vinyl acetate content of 2 to 20% by weight.
  • the vinyl acetate content is 2% by weight or more, the adhesiveness with the sealing material sheet can be made good, and when it is 20% by weight or less, the handling property is good without blocking.
  • a resin to which white fine particles are added or a resin to which black fine particles are added is preferably used for the heat-adhesive resin film in the present invention according to customer requirements.
  • white fine particles include calcium carbonate, silica, alumina, magnesium hydroxide, zinc oxide, talc, titanium oxide, and barium sulfate.
  • the addition of white fine particles is expected to improve power generation efficiency due to the effect of improving reflectivity. it can.
  • carbon black, a carbon nanotube, aniline black, black iron oxide, etc. can be added as black fine particles. By adding these black fine particles, the design is improved.
  • the back surface protective sheet member film is composed of two or more sheets, and when one sheet is the above heat-adhesive resin film, one or more resin films are further configured as a set. Usually, it is preferable that there are two sheets of a heat adhesive resin film and a resin film.
  • the resin film is preferably a hydrolysis-resistant polyester film or a fluororesin film.
  • the hydrolysis resistant polyester film in the present invention is a polyester film in which the tensile elongation after storage for 10 hours at 140 ° C. high pressure steam maintains 60% or more in both the longitudinal and transverse directions of the film.
  • the polyester film having hydrolysis resistance has performances excellent in heat resistance, moisture resistance and hydrolysis resistance, and can reliably protect the solar cell module.
  • the hydrolysis-resistant polyester film is preferably biaxially stretched by a conventional method from the viewpoint of strength, heat resistance, and flatness.
  • the hydrolysis-resistant polyester film is a polyethylene terephthalate having an intrinsic viscosity [ ⁇ ] of 0.70 to 1.20, more preferably 0.75 to 1.00, using terephthalic acid as the dicarboxylic acid component and ethylene glycol as the diol component.
  • Biaxially stretched films of polyethylene-2,6-naphthalate using 2,6-naphthalenedicarboxylic acid as the dicarboxylic acid component and ethylene glycol as the diol component are heat resistance, hydrolysis resistance, and weather resistance. Particularly preferred in terms of mechanical strength.
  • the intrinsic viscosity [ ⁇ ] is a value measured by dissolving a polyester film using o-chlorophenol as a solvent and measuring at a temperature of 25 ° C., and the viscosity is proportional to the degree of polymerization of the polyester.
  • the intrinsic viscosity is 0.70 or more, it is easy to impart hydrolysis resistance and heat resistance, and this is preferable because the hydrolysis resistance of the back surface protection sheet and further the solar cell module is improved.
  • this numerical value is 1.20 or less, melt viscosity becomes low, melt extrusion molding becomes easy, and the film-forming property of the film is improved, which is preferable.
  • an appropriate additive in an amount that does not impair the effects of the present invention, for example, a heat resistance stabilizer, an oxidation resistance stabilizer, an ultraviolet absorber, a weather resistance stabilizer, an organic easy stabilizer.
  • a lubricant, organic fine particles, a filler, an antistatic agent, a nucleating agent, a dye, a dispersant, a coupling agent and the like may be blended.
  • the hydrolysis-resistant polyester film has a structure in which white fine particles are added to the surface layer opposite to the sealing material sheet side to improve the ultraviolet resistance of the hydrolysis-resistant polyester, that is, hydrolysis-resistant polyethylene terephthalate and white water-resistant
  • a structure in which a decomposable polyethylene terephthalate film is formed by coextrusion may be used.
  • the ratio of the thickness of the hydrolysis-resistant polyethylene terephthalate layer to the white hydrolysis-resistant polyethylene terephthalate layer is such that the hydrolysis-resistant polyethylene terephthalate is 2 to 8 times the white hydrolysis-resistant polyethylene terephthalate. It is desirable to be.
  • an ultraviolet absorbing layer is laminated on the surface of the resin film of the back surface protective sheet member film in the present invention which is disposed on the back surface of the solar cell module.
  • the UV absorbing layer is provided to prevent UV degradation of the back surface protection sheet.
  • the back surface protection sheet for solar cell modules in the present invention is laminated on the back surface side of the solar cell module as the name suggests, and the ultraviolet absorption layer is disposed on the back surface side of the solar cell module, so that it can be ground even for long-term outdoor exposure.
  • the ultraviolet absorbing layer in the present invention refers to a layer having a function of setting the light transmittance at a wavelength of 380 nm to 10% or less, and the light transmittance at the wavelength is more preferably 7% or less, and 5% or less. Most preferred. This characteristic is determined by the concentration of the ultraviolet absorber in the ultraviolet absorbing layer and the thickness of the ultraviolet absorbing layer, and is designed according to the required performance.
  • UV absorbing layers are preferably formed by coating the resin film of the back protective sheet member film.
  • organic UV absorbers, inorganic UV absorbers, and additions in combination thereof can be preferably used without any particular limitation, but they are excellent in moist heat resistance and can be uniformly dispersed. desired.
  • organic UV absorbers include salicylic acid, benzophenone, benzotriazole, and cyanoacrylate UV absorbers, which are low extractable and low volatile.
  • a hindered amine-based UV absorber that is excellent in compatibility is also preferable.
  • these UV absorbers include salicylic acid-based pt-butylphenyl salicylate, p-octylphenyl salicylate, benzophenone-based 2,4-dihydroxybenzophenone, 2-hydroxy-4-methoxybenzophenone, 2-hydroxy -4-methoxy-5-sulfobenzophenone, 2,2 ', 4,4'-tetrahydroxybenzophenone, bis (2-methoxy-4-hydroxy-5-benzoylphenyl) methane, benzotriazole 2- (2' -Hydroxy-5'-methylphenyl) benzotriazole, 2- (2'-hydroxy-5'-methylphenyl) benzotriazole, 2,2'-methylenebis [4- (1,1,3,3-tetramethylbutyl ) -6- (2Hbenzotriazol-2-yl) phenol Cyanoacrylate-based ethyl-2-cyano-3,3′-diphenyl acrylate), 2- (4,6
  • examples of inorganic ultraviolet absorbers include metal oxides such as titanium oxide, zinc oxide, and cerium oxide, and carbon-based components such as carbon, fullerene, carbon fiber, and carbon nanotube.
  • these UV absorbers may be added to the binder resin and applied together with the binder resin, or an organic UV absorber may be used.
  • an organic UV absorber may be used.
  • the binder resin for this purpose can be selected from known resin systems such as polyester, acrylic and urethane.
  • an inorganic UV absorber In consideration of long-term outdoor use, it is desirable to use an inorganic UV absorber.
  • an organic UV absorber is used as the binder resin. It is preferable to use a binder resin added in combination or copolymerized with a monomer having an ultraviolet absorber ability.
  • Fluorine-based resin film may be selected as the resin film of the back protective sheet member film in the present invention.
  • the fluorine-based resin include polyvinyl fluoride (PVF), hexafluoropropylene / tetrafluoroethylene copolymer (FEP), ethylene / chlorotrifluoroethylene copolymer (ECTFE), or ethylene / tetrafluoroethylene as described above. It is desirable to use a resin mainly composed of a copolymer (ETFE).
  • the resin film preferably has an easy-adhesion layer formed thereon, and the sealing material sheet 2, the heat-adhesive resin film, and the resin film on which the easy-adhesion layer is formed are in this order. It is preferable in order to stabilize the adhesive force between a heat-adhesive resin film and a resin film by laminating so that the easily bonding layer of an adhesive film and a resin film may oppose.
  • an easily adhesive layer may be formed on the thermal adhesive film, and the sealing material sheet 2, the thermal adhesive resin film on which the easy adhesive layer is formed, and the resin film are in this order. Even if the easy-adhesion layer of the heat-adhesive resin film and the resin film are laminated so as to face each other, it is also preferable in order to stabilize the adhesion between the heat-adhesive resin film and the resin film.
  • the easily bonding layer may be formed in the heat bondable film and the easily bonding layer may be formed in the resin film, and the sealing material sheet 2 and the heat bonding in which the easily bonding layer was formed
  • the resin film in which the adhesive resin film and the easy-adhesion layer are formed are in this order, and even if the easy-adhesion layer of the heat-adhesive resin film and the easy-adhesion layer of the resin film are laminated to face each other, This is preferable in order to further increase the adhesion between the resin films.
  • Examples of the material for the easy-adhesion layer formed on the heat-adhesive resin film or resin film of the back surface protection sheet member film for solar cell modules in the present invention include acrylic resin, polyurethane resin, epoxy resin, polyester resin, polyamide, phenol, and polyolefin. , Ionomers, ethylene / vinyl acetate copolymer resins, polyvinyl acetals, and the like, and copolymers or mixtures thereof may be used.
  • the material for the easy adhesion layer is most preferably a combination of an acrylic resin and an isocyanate curing agent.
  • These easy-adhesion layer materials may be any of a one-component curable type, a two-component curable type, a three-component curable type, and the like, but a two-component curable adhesive is preferable in terms of adhesion and prevention of bubble generation.
  • the thickness of the easy adhesion layer is preferably from 0.1 to 15 ⁇ m, more preferably from 0.5 to 10 ⁇ m.
  • the method for forming the heat-adhesive resin film or the easy-adhesion layer on the resin film is not particularly limited.
  • the material is diluted with an appropriate solvent and dried. In that case, you may apply
  • a biaxially stretched film of polyethylene terephthalate or polyethylene-2,6-naphthalate is used as the resin film, in addition to the cost merit that coating and drying can be carried out in the same process, it is coated after stretching in the longitudinal direction and then stretched laterally. By setting it as a process, a uniform easy-adhesion layer can be suitably obtained with high productivity.
  • a coating method for example, a reverse coating method, a spray coating method, a bar coating method, a gravure coating method, a rod coating method, a die coating method, or the like can be used. Since the film thickness of the easy-adhesion layer to be formed is proportional to the concentration of the coating liquid and the coating amount, it is preferable to adjust these in order to obtain a predetermined film thickness of the easy-adhesion layer. Moreover, the said material is heat-melted with the heat-adhesive resin film or the material of a resin film, and the heat-adhesive resin film or resin film in which the easy-adhesion resin layer was laminated
  • a heat adhesive resin film, an easily adhesive resin film, and a resin film in this order a heat adhesive resin film and a resin film
  • an easy-adhesion layer may be formed on at least one of the heat-adhesive resin film or the resin film.
  • the heat-adhesive resin film or resin film or the easy-adhesive resin film obtained by laminating the easy-adhesive resin layer thus obtained may be embossed to improve film transportability and handling properties.
  • ethylene, acrylic acid, methacrylic acid, acrylic ester, methacrylic ester, acrylic are used as the easy-adhesive resin for easy-adhesion layer lamination or single film molding by coextrusion.
  • a copolymer with at least one selected from the group consisting of glycidyl acrylate, glycidyl methacrylate, vinyl acetate and maleic anhydride is preferably used, and in particular, ethylene / glycidyl methacrylate copolymer (EGMA) is a heat-adhesive resin. It is preferable for increasing the adhesion between the film and the resin film.
  • the thickness of the heat-adhesive resin film by coextrusion or the easy-adhesion resin layer in the resin film, or the thickness of the single easy-adhesion resin film is preferably 5 to 100 ⁇ m, more preferably 10 to 50 ⁇ m.
  • the two back protection sheet member films may be plasma-treated at low pressure or normal pressure on at least one of the opposing surfaces regardless of the presence or absence of an easy-adhesion layer. This is preferable in order to develop the desired adhesion strength.
  • the two back protective sheet member films are an adhesive resin film in which an easy adhesion layer is not formed and a resin film in which an easy adhesion layer is not formed, these treatments are applied to at least one of the opposing surfaces. Is preferably applied to both surfaces.
  • the low-pressure plasma treatment mentioned here means that the surface is activated by glow discharge generated by applying a high-voltage voltage at a direct current, commercial frequency, high-frequency, or microwave frequency in a low-pressure specific gas atmosphere of about 1.3 to 133 Pa.
  • atmospheric pressure plasma treatment refers to performing discharge treatment in a specific gas atmosphere at atmospheric pressure. In order to maintain the purity of the gas atmosphere, the atmospheric pressure plasma treatment may be used when the pressure is reduced to about 0.05 to 0.15 MPa or the positive pressure due to the structure of the apparatus.
  • the gas used for these plasma treatments is selected according to the material to be plasma treated, such as oxygen, nitrogen, argon, helium, neon, carbon dioxide, laughing gas, hydrogen, hydrocarbon gases such as methane, ammonia, and mixed gases thereof. Is done.
  • the treatment intensity of these plasma treatments can be determined from the relationship between the input power and the treatment speed, and treatment at a treatment intensity of 50 to 5000 W ⁇ min / m 2 is preferable from the balance of treatment effect and economy.
  • the total thickness of the back protective sheet member film in the present invention is preferably in the range of 100 to 400 ⁇ m.
  • the thickness is 100 ⁇ m or more, the insulation resistance can be satisfied, and the problem that the wiring connecting the solar cells can be easily seen through can be easily solved.
  • the thickness is 400 ⁇ m or less, the cutting property can be kept good.
  • a surface protective sheet of a predetermined size, a sealing material sheet 1, a solar battery cell, a sealing material sheet 2, and two or more back surface protective sheet member films are superposed. It is characterized by integrally molding by heating and pressure-bonding treatment.
  • the plurality of films are simultaneously unwound from each unwinding section, and simultaneously cut in a single state with a plurality of sheets stacked. Is preferred.
  • a single easy-adhesive resin film is used, a thin, non-rigid easy-adhesive resin film is likely to be wrinkled and difficult to handle.
  • the surface protection sheet, the encapsulant sheet 1, the solar cell, the encapsulant sheet 2, and two or more back surface protection sheet member films are integrally formed by heating and pressure-bonding treatment.
  • the adhesion strength between the sealing material sheet 2 laminated according to the heating temperature and pressure bonding conditions at the time of molding and the back surface protection sheet member film facing the sealing material sheet is 40 N / cm or more. If the adhesion strength between the sealing material sheet 2 and the back surface protective sheet member film facing the sealing material sheet is less than 40 N / cm, peeling occurs at the time of installation or after installation of the solar cell module, so that it cannot be used.
  • the adhesion strength between two or more back surface protection sheet member films laminated depending on the heating temperature and pressure bonding conditions during molding is 1 N / cm or more, preferably 5 N / cm. It is above, More preferably, it is 10 N / cm or more.
  • adhesion strengths can be measured by cutting out a sample from the completed solar cell module, but the surface protection sheet, the sealing material sheets 1 and 2, the thermoadhesive resin film, and the resin film are heated at the time of molding. In addition, by checking and laminating according to the pressure bonding conditions, it is possible to determine the suitability of these materials prior to the actual molding of the solar cell module.
  • Adhesion strength with the sealing material sheet (N / cm) After producing the pseudo solar cell module by the method described in (1), after cutting to 1 cm width from the back surface protective sheet member side for the solar cell module, after peeling between the EVA sheet and the back surface protective sheet member film, ORIENTEC Using Tensilon PTM-50 manufactured by the company, the peel strength was measured at a peel angle of 180 ° and a peel speed of 100 mm / min, and this value was taken as the adhesion strength.
  • Example 1 Hydrolysis resistant polyester film 125 ⁇ m “Lumirror” (registered trademark) X10S manufactured by Toray Industries, Inc. was used, and heat treatment was performed for 44 seconds at a drying temperature of 180 ° C. using a film coater manufactured by Okazaki Machinery Co., Ltd. Thereafter, 5.8 parts by weight of urethane curing agent G-18N manufactured by DIC Corporation is added to 100 parts by weight of acrylic easy-adhesion coat DICSEAL HS EXP120228 manufactured by DIC Corporation. After adding 4.8 parts by weight of epoxy compound ADDITIVE EP-10 manufactured by Co., Ltd., it was diluted with a diluent solvent and dried at a drying temperature of 120 ° C.
  • the vacuum time is 5 minutes
  • the control time is 1 minute
  • the press time is 15 minutes
  • the temperature is 145 ° C.
  • Thermocompression bonding was performed under the conditions. After the pressure bonding, it was cooled to room temperature to produce a pseudo solar cell module.
  • Example 2 The same procedure as in Example 1 was performed except that the heat-adhesive resin film described in Example 1 was changed to a white polyethylene film 4807W having a thickness of 150 ⁇ m manufactured by Toray Film Processing Co., Ltd.
  • Example 3 Instead of the hydrolysis-resistant polyester film described in Example 1, a fluororesin film (50 ⁇ m “Toyoflon” (registered trademark) EL2 manufactured by Toray Film Processing Co., Ltd.) with double-sided easy adhesion treatment was used, and a heat-adhesive resin The same procedure as in Example 1 was performed except that the film was changed to 50 ⁇ m white polyethylene 4807W manufactured by Toray Film Processing Co., Ltd.
  • a fluororesin film 50 ⁇ m “Toyoflon” (registered trademark) EL2 manufactured by Toray Film Processing Co., Ltd.
  • Example 4 The same procedure as in Example 1 was performed except that the heat-adhesive resin film described in Example 1 was changed to an unstretched nylon film (100 ⁇ m “Rayfan” (registered trademark) NO manufactured by Toray Film Processing Co., Ltd.).
  • unstretched nylon film 100 ⁇ m “Rayfan” (registered trademark) NO manufactured by Toray Film Processing Co., Ltd.
  • Example 5 In place of the heat-adhesive resin film described in Example 1, a double-sided easy-adhesive fluororesin film (50 ⁇ m “Toyoflon” (registered trademark) EL2 manufactured by Toray Film Processing Co., Ltd.) was used. It carried out similarly.
  • a double-sided easy-adhesive fluororesin film 50 ⁇ m “Toyoflon” (registered trademark) EL2 manufactured by Toray Film Processing Co., Ltd.
  • Example 6 Hydrolysis-resistant polyester film Toray Co., Ltd. 125 ⁇ m “Lumirror” (registered trademark) X10S was used as the resin film, and a film coater manufactured by Okazaki Kikai Kogyo Co., Ltd. was used for 44 seconds at a drying temperature of 180 ° C. did.
  • a heat-adhesive resin film having an easy-adhesion resin layer it has a three-layer structure of the following A layer / B layer / C layer, and each layer resin described below is used at 220 ° C. using a uniaxial melt extruder.
  • a white polypropylene film having a thickness of 150 ⁇ m obtained by melt coextrusion and cooling and solidifying on a casting drum maintained at 30 ° C. was used.
  • Resin used for layer A melting point 127 ° C., density 0.940 g / cm 3 , melt flow rate (MFR) 5.0 g / 10 min linear low density polyethylene 40 parts by weight, melting point 112 ° C., density 0. 912 g / cm 3 , 10 parts by weight of low density polyethylene of MFR 4.0 g / 10 min, and ethylene / propylene random copolymer having a melting point of 150 ° C., a density of 0.900 g / cm 3 , and an MFR of 7 mol / 10 min.
  • Resin used for layer B resin obtained by mixing 12 parts by weight of titanium oxide with 88 parts by weight of homopolypropylene having a melting point of 162 ° C.
  • Easy-adhesion resin used for layer C “Bond First” (registered trademark) grade E manufactured by Sumitomo Chemical Co., Ltd. (ethylene / glycidyl methacrylate copolymer having a glycidyl methacrylate content of 12% by weight and an MFR of 3.0 g / 10 min) ).
  • the pseudo-solar cell module was produced by the method similar to Example 1 by making C layer which is an easily bonding resin layer correspond to a hydrolysis-resistant polyester film.
  • Example 7 In the same manner as in Example 6, except that the hydrolysis resistant polyester film 125 ⁇ m “Lumirror” (registered trademark) X10S manufactured by Toray Industries, Inc. was used as the resin film, and the easy adhesion coat described in Example 1 was applied thereto. A pseudo solar cell module was produced.
  • the hydrolysis resistant polyester film 125 ⁇ m “Lumirror” (registered trademark) X10S manufactured by Toray Industries, Inc. was used as the resin film, and the easy adhesion coat described in Example 1 was applied thereto.
  • a pseudo solar cell module was produced.
  • Example 8 The resin film described in Example 1 is a white hydrolysis-resistant polyester film 75 ⁇ m manufactured by Toray Industries, Inc., in which the ratio of the thickness of the hydrolysis-resistant polyethylene terephthalate layer to the white hydrolysis-resistant polyethylene terephthalate layer is 1: 5. Changed to "Lumirror” (registered trademark) MX11, and changed the heat-adhesive resin film to an unstretched polyethylene film (50m "LL film” 4801 manufactured by Toray Film Processing Co., Ltd.). The same operation as in Example 1 was performed except that a terephthalate layer was laminated so as to face 4801.
  • Example 9 Hydrolysis resistant polyester film 125 ⁇ m “Lumirror” (registered trademark) X10S manufactured by Toray Industries, Inc. was used, and heat treatment was performed for 44 seconds at a drying temperature of 180 ° C. using a film coater manufactured by Okazaki Machinery Co., Ltd.
  • “bond first” (registered trademark) grade 7M manufactured by Sumitomo Chemical Co., Ltd. ethylene glycidyl content 6 wt%, methyl acrylate content 27 wt%, MFR 7.0 g / 10 min ethylene) -Glycidyl methacrylate-methyl acrylate copolymer), which is melt-extruded at 200 ° C.
  • Example 10 A solar cell module was produced.
  • Example 10 a hydrolysis-resistant polyester film 125 ⁇ m “Lumirror” (registered trademark) X10S manufactured by Toray Industries, Inc.
  • Processing width 0.1m
  • Treatment speed 3 m / min
  • Introduction gas Nitrogen pressure: 40 Pa
  • Power supply frequency 50 kHz
  • Input power 60 W (the input power was determined as the product of the plate voltage and plate current of the vacuum tube of the high-frequency power source)
  • Processing intensity 200 W ⁇ min / m 2
  • a 150 ⁇ m white polypropylene film B011W manufactured by Toray Film Processing Co., Ltd. was also subjected to low-pressure plasma treatment under the same conditions.
  • Example 11 The surfaces subjected to low-pressure plasma treatment were made to face each other, and a pseudo solar cell module was produced under the same conditions as in Example 1.
  • Example 11 low-pressure plasma treatment was performed only on 150 ⁇ m white polypropylene film B011W manufactured by Toray Film Processing Co., Ltd. under the same conditions as in Example 8.
  • the surface on which the easy adhesion layer was formed and the surface subjected to the low-pressure plasma treatment of B011W were made to face each other under the same conditions as in Example 1.
  • a pseudo solar cell module was produced.
  • Example 12 the low-pressure plasma treatment was performed under the same conditions as in Example 10 after heat-treating 125 ⁇ m ⁇ 10S produced by hydrolysis resistant polyester film Toray Industries, Inc.
  • a pseudo solar cell module was manufactured by making the C layer, which is an easily adhesive resin layer of a white polypropylene film, face the low-pressure plasma treated surface of the hydrolysis-resistant polyester film.
  • Example 13 In Example 10, in the low-pressure plasma treatment of the hydrolysis-resistant polyester film 125 ⁇ m “Lumirror” (registered trademark) X10S manufactured by Toray Industries, Inc. and the 150 ⁇ m white polypropylene film B011W manufactured by Toray Film Processing Co., Ltd., the input power was 30 W.
  • a pseudo solar cell module was manufactured using a processing speed of 4 m / min and a processing intensity of 100 W ⁇ min / m 2 .
  • Example 14 In Example 10, the introduced gas was changed to argon, and atmospheric pressure plasma treatment was performed under atmospheric pressure.
  • 125 ⁇ m “Lumirror” (registered trademark) X10S made by hydrolysis-resistant polyester film Toray Co., Ltd. and Toray Film Processing Co., Ltd. with an input voltage of 100 W, a treatment speed of 10 m / min and a treatment strength of 100 W ⁇ min / m 2
  • a manufactured 150 ⁇ m white polypropylene film B011W was processed.
  • a pseudo solar cell module was produced by making these atmospheric pressure plasma treated surfaces face each other.
  • Example 1 The acrylic easy-adhesion coat to be applied to the hydrolysis-resistant polyester film described in Example 1 is 100 parts by weight of DIC Corporation acrylic easy-adhesion coat DICSEAL HS WHITE EXP120820, DIC Corporation hardener DF HARDNER A pseudo solar cell module was produced in the same manner as in Example 1, except that 12 parts by weight of HA-100 and EP-103 parts by weight of epoxy additive EP-103 manufactured by DIC Corporation were added and diluted with a diluent solvent.
  • Example 3 (Comparative Example 3) In Example 1, by the method of (1) above, thermocompression treatment was performed under the conditions of a vacuum time of 5 minutes, a control time of 1 minute, a press time of 15 minutes, and a temperature of 100 ° C. A battery module was produced.
  • the method for manufacturing a solar cell module according to the present invention can integrally mold a plurality of back surface protection sheet member films, and can manufacture a solar cell module with higher yield by solving the problem of warpage of the back surface protection sheet. It is possible to reduce the loss of the back surface protection sheet member film, which can contribute to resource saving.

Abstract

L'invention concerne un procédé de fabrication de modules de cellule solaire, par lequel une feuille protectrice de surface, une feuille de matériau de scellage (1), une cellule solaire, une feuille de matériau de scellage (2), et au moins deux films d'élément de feuille protectrice de surface arrière sont moulés d'un seul tenant par chauffage et sertissage de ceux-ci. Le procédé de fabrication de module de cellule solaire est caractérisé par le fait que la force d'adhésion entre la feuille de matériau de scellage (2) stratifiée par les conditions de température de chauffage et de sertissage durant le moulage et un film d'élément de feuille protectrice de surface arrière faisant face à celle-ci est d'au moins 40 N/cm et que la force d'adhésion entre les au moins deux films d'élément de feuille protectrice de surface arrière est d'au moins 1 N/cm. L'invention concerne un élément de feuille protectrice de surface arrière pour modules de cellule solaire, qui : augmente le rendement de module de cellule solaire par réduction des pertes dans le processus de fabrication pour les feuilles protectrices de surface arrière pour des modules de cellule solaire ; et est apte à résoudre de manière fondamentale le problème de gauchissement dans des éléments de feuille protectrice de surface arrière dans le procédé de fabrication de module solaire.
PCT/JP2014/055572 2013-03-26 2014-03-05 Procédé de fabrication de module de cellule solaire WO2014156518A1 (fr)

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Cited By (3)

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CN108329586A (zh) * 2018-01-30 2018-07-27 苏州赛伍应用技术股份有限公司 一种三层结构水汽阻隔膜及其制备方法
CN108456351A (zh) * 2018-01-30 2018-08-28 苏州赛伍应用技术股份有限公司 一种水汽阻隔膜及其制备方法
CN109964320A (zh) * 2016-11-11 2019-07-02 帝斯曼知识产权资产管理有限公司 包含面向背面封装剂的基于聚烯烃的功能层的背板

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Publication number Priority date Publication date Assignee Title
WO2012029733A1 (fr) * 2010-08-31 2012-03-08 東レフィルム加工株式会社 Feuille de protection de face arrière pour module de cellules solaires, et module de cellules solaires utilisant ladite feuille

Patent Citations (1)

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Publication number Priority date Publication date Assignee Title
WO2012029733A1 (fr) * 2010-08-31 2012-03-08 東レフィルム加工株式会社 Feuille de protection de face arrière pour module de cellules solaires, et module de cellules solaires utilisant ladite feuille

Cited By (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN109964320A (zh) * 2016-11-11 2019-07-02 帝斯曼知识产权资产管理有限公司 包含面向背面封装剂的基于聚烯烃的功能层的背板
JP2019536271A (ja) * 2016-11-11 2019-12-12 ディーエスエム アイピー アセッツ ビー．ブイ．Ｄｓｍ Ｉｐ Ａｓｓｅｔｓ Ｂ．Ｖ． 背面封止材に面しているポリオレフィンをベースとする機能層を含むバックシート
CN109964320B (zh) * 2016-11-11 2024-03-05 赢润太阳能解决方案有限公司 包含面向背面封装剂的基于聚烯烃的功能层的背板
CN108329586A (zh) * 2018-01-30 2018-07-27 苏州赛伍应用技术股份有限公司 一种三层结构水汽阻隔膜及其制备方法
CN108456351A (zh) * 2018-01-30 2018-08-28 苏州赛伍应用技术股份有限公司 一种水汽阻隔膜及其制备方法
CN108456351B (zh) * 2018-01-30 2021-09-28 苏州赛伍应用技术股份有限公司 一种水汽阻隔膜及其制备方法

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