WO2017057217A1 - 太陽電池封止材用多層シート、太陽電池封止材用多層シートの製造方法および太陽電池モジュール - Google Patents
太陽電池封止材用多層シート、太陽電池封止材用多層シートの製造方法および太陽電池モジュール Download PDFInfo
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- WO2017057217A1 WO2017057217A1 PCT/JP2016/078159 JP2016078159W WO2017057217A1 WO 2017057217 A1 WO2017057217 A1 WO 2017057217A1 JP 2016078159 W JP2016078159 W JP 2016078159W WO 2017057217 A1 WO2017057217 A1 WO 2017057217A1
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- WIPO (PCT)
- Prior art keywords
- solar cell
- ethylene
- copolymer
- multilayer sheet
- cell sealing
- Prior art date
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- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
- C09J2301/00—Additional features of adhesives in the form of films or foils
- C09J2301/40—Additional features of adhesives in the form of films or foils characterized by the presence of essential components
- C09J2301/414—Additional features of adhesives in the form of films or foils characterized by the presence of essential components presence of a copolymer
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- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
- C09J2423/00—Presence of polyolefin
- C09J2423/04—Presence of homo or copolymers of ethene
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- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
- C09J2423/00—Presence of polyolefin
- C09J2423/04—Presence of homo or copolymers of ethene
- C09J2423/046—Presence of homo or copolymers of ethene in the substrate
-
- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
- C09J2433/00—Presence of (meth)acrylic polymer
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- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
- C09J2433/00—Presence of (meth)acrylic polymer
- C09J2433/006—Presence of (meth)acrylic polymer in the substrate
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- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
- C09J2451/00—Presence of graft polymer
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
- Y02E10/00—Energy generation through renewable energy sources
- Y02E10/50—Photovoltaic [PV] energy
Definitions
- the present invention relates to a multilayer sheet for solar cell encapsulant, a method for producing a multilayer sheet for solar cell encapsulant, and a solar cell module.
- Photovoltaic power generation directly converts solar energy into electrical energy using a semiconductor (solar cell element) such as a silicon cell.
- a semiconductor solar cell element
- the solar cell elements used here are thin and easy to break, and there are those whose functions deteriorate when directly in contact with the outside air. For this reason, the solar cell element is sandwiched between sealing materials to protect the solar cell element and prevent entry of foreign matter or moisture.
- the sealing material is required to be transparent.
- a sealing material for solar cells for example, a material containing an ethylene / vinyl acetate copolymer as a main component is widely used because it is excellent in transparency, adhesiveness, cost, and the like (for example, Patent Documents). 1 to 3).
- the level of technology required for various properties of solar cell encapsulants is increasing.
- the present inventors have found the following problems regarding a sealing material for solar cells containing an ethylene / vinyl acetate copolymer as a main component.
- the sealing material for solar cells containing ethylene / vinyl acetate copolymer as a main component was inferior in moisture resistance. Therefore, depending on the type of transparent substrate or back sheet placed on the side where sunlight enters, the adhesion conditions, the usage environment of the solar cell, etc., moisture may enter the solar cell module, reducing the performance as a solar cell.
- Solar cell encapsulant containing ethylene / vinyl acetate copolymer has lower volume resistivity than general polyolefin materials, and it has an insulating surface as a material to protect high power and high performance solar cells. May be insufficient.
- the present invention has been made in view of the above circumstances, and provides a multilayer sheet for a solar cell encapsulant that is excellent in the performance balance of transparency, adhesiveness, moisture resistance and insulation.
- the inventors of the present invention have made extensive studies in order to achieve the above problems.
- the above trade-off can be achieved by laminating a resin layer containing an ethylene / unsaturated carboxylic acid copolymer or its ionomer as a main component and an adhesive layer containing a specific ethylene copolymer. It has been found that the above relationship can be improved, and transparency and adhesiveness, moisture proofing and insulating properties can be improved in a balanced manner, and the present invention has been achieved.
- the following multilayer sheet for solar cell encapsulant, method for producing the multilayer sheet for solar cell encapsulant, and solar cell module are provided.
- a solar cell comprising: a resin layer (A) containing an ethylene / unsaturated carboxylic acid copolymer or its ionomer as a main component; and an adhesive layer (B) provided on one or both sides of the resin layer (A).
- a multilayer sheet for sealing material The adhesive layer (B) is at least selected from an epoxy group-containing ethylene copolymer (B1), an ethylene / polar monomer copolymer, and an ethylene / ⁇ -olefin copolymer having a density of 920 kg / m 3 or less.
- a multilayer sheet for a solar cell encapsulating material comprising a type of ethylene copolymer (B2) (excluding the epoxy group-containing ethylene copolymer (B1)).
- B2 ethylene copolymer
- B1 epoxy group-containing ethylene copolymer
- the multilayer sheet for solar cell sealing materials whose whole thickness is 50 micrometers or more and 2000 micrometers or less.
- the multilayer sheet for solar cell encapsulant according to any one of [1] to [3] above The multilayer sheet for solar cell sealing materials whose Haze measured based on JISK7136 is 40% or less.
- the epoxy group-containing ethylene copolymer (B1) is composed of ethylene / (meth) acrylic acid glycidyl copolymer, ethylene / (meth) acrylic acid glycidyl / vinyl acetate copolymer, and ethylene / (meth) acrylic acid glycidyl /
- the ethylene / polar monomer copolymer contains at least one selected from an ethylene / vinyl ester copolymer, an ethylene / unsaturated carboxylic acid ester copolymer, and an ethylene / unsaturated carboxylic acid copolymer.
- Multi-layer sheet for materials is not limited to an ethylene / vinyl ester copolymer, an ethylene / unsaturated carboxylic acid ester copolymer, and an ethylene / unsaturated carboxylic acid copolymer.
- the resin layer (A) is a multilayer sheet for a solar cell encapsulant containing the ionomer of the ethylene / unsaturated carboxylic acid copolymer as a main component.
- the multilayer sheet for solar cell sealing materials used in order to adhere attach the electrically insulating resin film layer in which at least one surface is not corona-treated.
- the manufacturing method of the multilayer sheet for solar cell sealing materials including the process of carrying out multilayer extrusion molding of the thing (B).
- a substrate on which sunlight is incident A solar cell element; A backsheet, A sealing resin constituted by the multilayer sheet for solar cell sealing material according to any one of [1] to [10], for sealing the solar cell element between the substrate and the back sheet.
- Layers, A solar cell module comprising:
- the multilayer sheet for solar cell sealing materials excellent in the performance balance of transparency, adhesiveness, moisture resistance, and insulation can be provided.
- the multilayer sheet can also be used as an interlayer film for laminated glass, and can provide an interlayer film for laminated glass and a laminated glass excellent in the performance balance of transparency, adhesiveness, and moisture resistance.
- X to Y represents X or more and Y or less unless otherwise specified.
- (meth) acryl means one or both of acryl and methacryl.
- FIG. 1 is sectional drawing which showed typically an example of the structure of the multilayer sheet 10 for solar cell sealing materials of embodiment which concerns on this invention.
- the solar cell encapsulant multilayer sheet 10 (hereinafter also referred to as a multilayer sheet) according to the present embodiment is used for encapsulating a solar cell element, and is an ethylene / unsaturated carboxylic acid copolymer or its
- the resin layer (A) which contains an ionomer as a main component, and the contact bonding layer (B) provided in the single side
- the adhesive layer (B) is selected from an epoxy group-containing ethylene copolymer (B1), an ethylene / polar monomer copolymer, and an ethylene / ⁇ -olefin copolymer having a density of 920 kg / m 3 or less. And at least one ethylene copolymer (B2) (excluding the epoxy group-containing ethylene copolymer (B1)).
- an ethylene / vinyl acetate copolymer that has been conventionally used is provided by including a resin layer (A) and an adhesive layer (B).
- the transparency, adhesiveness, moisture resistance and insulation can be improved in a balanced manner.
- the adhesiveness outstanding also with respect to the surface which is not corona-treated of electrically insulating resin film layers, such as a polyester film, is shown.
- the ethylene / unsaturated carboxylic acid copolymer or a layer containing the ionomer as a main component is preferably composed of a single layer. Or a ratio of other copolymerizable monomers contained in the ethylene / unsaturated carboxylic acid copolymer may be composed of a plurality of layers.
- the “main component” means that the ethylene / unsaturated carboxylic acid copolymer or its ionomer is contained in the resin layer (A) in an amount of 60% by mass or more.
- the adhesive layer (B) is laminated on one side or both sides of the resin layer (A).
- the adhesive layer (B) is preferably provided on both surfaces of the resin layer (A) from the viewpoint of improving the adhesion between the multilayer sheet, the solar cell element, the transparent substrate, and the back sheet in a balanced manner.
- the adhesive layer (B) is also composed of a single layer like the resin layer (A), it may be composed of a plurality of layers having different compositions and blending amounts of the copolymer. Good.
- the solar cell encapsulant multilayer sheet 10 has a plurality of layers formed by the resin layer (A) and the adhesive layer (B), more preferably the resin layer (A) and the adhesive layer. It is a two-layer sheet including (B), particularly preferably a three-layer sheet including an intermediate layer composed of a resin layer (A) and an outer layer composed of an adhesive layer (B) provided on both surfaces thereof.
- the total thickness of the solar cell encapsulant multilayer sheet 10 is preferably in the range of 50 ⁇ m to 2000 ⁇ m, more preferably 50 ⁇ m to 1000 ⁇ m, and particularly preferably 50 ⁇ m to 800 ⁇ m.
- the total thickness of the solar cell encapsulant multilayer sheet 10 is equal to or greater than the lower limit, damage to the solar cell element due to impact or the like can be further suppressed.
- seat improves more as the whole thickness of the multilayer sheet 10 for solar cell sealing materials is below the said upper limit, solar light reception amount can be maintained, and output can be maintained much higher. Can do.
- the multilayer sheet according to this embodiment is excellent in the performance balance of transparency, adhesiveness, moisture resistance, and insulation, the entire thickness of the multilayer sheet can be reduced to 800 ⁇ m or less.
- the thickness (a) of the resin layer (A) constituting the multilayer sheet according to this embodiment and the thickness of the adhesive layer (B) is 1/1 to 10/1, preferably 2/1 to 6/1.
- a / b is within the above range, the performance balance of transparency, adhesion, moisture resistance, insulation, flexibility, heat resistance, and workability can be further improved.
- the resin layer (A) is 1/1 to 10/1, preferably 2/1 to 6/1. is there.
- a / b is within the above range, the performance balance of transparency, adhesion, moisture resistance, insulation, flexibility, heat resistance, and workability can be further improved.
- the outer layer has the above thickness ratio, the thicknesses of the two outer layers may be different.
- the flexural modulus measured according to JIS K7171 is preferably 50 MPa or more and 500 MPa or less, and more preferably 100 MPa or more and 450 MPa or less.
- the performance of the solar cell encapsulant multilayer sheet 10 such as fracture strength, impact resistance and puncture resistance and the productivity balance of the solar cell module may be further improved. it can.
- the composition of the resin layer (A), the composition of the adhesive layer (B), the thickness ratio between the resin layer (A) and the adhesive layer (B), etc. can be adjusted as appropriate. Good.
- the moisture permeability measured under conditions of a temperature of 40 ° C. and a humidity of 90% RH is 15 g / (m 2 ⁇ 24 h) or less in accordance with JIS Z0208. It is preferable, more preferably at most 10g / (m 2 ⁇ 24h) , and particularly preferably 5g / (m 2 ⁇ 24h) or less. Since the multilayer sheet 10 for solar cell sealing materials whose moisture permeability is below the said upper limit is hard to hold
- the Haze measured according to JIS K7136 is preferably 40% or less, more preferably 35% or less, and 30% or less. It is particularly preferred. Thereby, the photovoltaic power generation amount of the solar cell module obtained can be further improved.
- the resin layer (A) contains an ethylene / unsaturated carboxylic acid copolymer or its ionomer as a main component.
- the structural unit derived from ethylene is preferably 65% by mass to 95% by mass, more preferably 75% by mass to 92% by mass.
- the structural unit derived from the acid is preferably 5% by mass or more and 25% by mass or less, more preferably 8% by mass or more and 25% by mass or less.
- the structural unit derived from the unsaturated carboxylic acid is at least the above lower limit, the transparency, flexibility, adhesiveness and the like of the multilayer sheet can be made better. Moreover, the workability of a multilayer sheet can be made more favorable as the structural unit guide
- Examples of the unsaturated carboxylic acid in the ethylene / unsaturated carboxylic acid copolymer include acrylic acid, methacrylic acid, maleic acid, fumaric acid, itaconic acid, maleic anhydride, itaconic anhydride, monomethyl maleate, and monoethyl maleate. Etc. Among these, at least one selected from acrylic acid and methacrylic acid is preferable from the viewpoints of productivity and hygiene of the ethylene / unsaturated carboxylic acid copolymer. In addition, these unsaturated carboxylic acids may be used individually by 1 type, and may be used in combination of 2 or more type.
- the ethylene / unsaturated carboxylic acid copolymer is preferably 0% by mass or more and 30% by mass or less, more preferably 0% by mass or more and 25% by mass with respect to 100% by mass in total of ethylene and unsaturated carboxylic acid copolymer. % Or less of other structural units derived from other copolymerizable monomers may be contained.
- Other copolymerizable monomers include unsaturated esters such as vinyl esters such as vinyl acetate and vinyl propionate; methyl (meth) acrylate, ethyl (meth) acrylate, isobutyl (meth) acrylate, and (meth) acrylic.
- (meth) acrylic acid esters such as n-butyl acid and 2-ethylhexyl (meth) acrylate.
- structural unit derived from the other copolymerizable monomer is contained in the above range, it is preferable in that the flexibility of the multilayer sheet is improved.
- the ionomer can be used instead of the ethylene / unsaturated carboxylic acid copolymer.
- the resin layer (A) contains an ionomer of an ethylene / unsaturated carboxylic acid copolymer as a main component, the moisture permeability of the multilayer sheet 10 for a solar cell encapsulant is reduced and the moisture resistance is further improved. It can be.
- the ion source in the ionomer include alkali metals such as lithium and sodium; polyvalent metals such as calcium, magnesium, zinc and aluminum.
- the ionomer those having a neutralization degree of usually 80% or less are used.
- the degree of neutralization is in the above range, a multilayer sheet excellent in transparency and storage stability at high temperatures can be obtained.
- the minimum of a neutralization degree is not specifically limited, For example, it is 1% or more, and 5% or more is preferable.
- the above-mentioned ethylene / unsaturated carboxylic acid copolymer can be obtained by radical copolymerization of each polymerization component under high temperature and high pressure.
- the ionomer can be obtained by reacting such a copolymer with a metal compound.
- the ethylene / unsaturated carboxylic acid copolymer or its ionomer has a melt flow rate at 190 ° C. under a load of 2160 g (JIS K7210-1999) of 0.1 to 150 g / 10 min in consideration of processability and mechanical strength. In particular, it is preferable to use 0.1 to 50 g / 10 min.
- the ethylene / unsaturated carboxylic acid copolymer or its ionomer is usually 80% by mass or more, preferably 90% by mass or more.
- the transparency, insulation and moisture resistance of the multilayer sheet can be further improved.
- the resin layer (A) can contain various additives within a range that does not impair the object of the present invention.
- additives include a crosslinking agent, a crosslinking aid, a silane coupling agent, an ultraviolet absorber, a light stabilizer, and an antioxidant.
- an organic peroxide having a decomposition temperature of half-life of 1 hour is usually 90 to 180 ° C, preferably 100 to 150 ° C.
- organic peroxides include t-butyl peroxyisopropyl carbonate, t-butyl peroxyacetate, t-butyl peroxybenzoate, dicumyl peroxide, 2,5-dimethyl-2,5-bis.
- crosslinking agent can be contained in an amount of usually 0.1 to 5 parts by mass, preferably 0.5 to 3 parts by mass with respect to 100
- crosslinking aid examples include polyunsaturated compounds such as polyallyl compounds and poly (meth) acryloxy compounds.
- polyallyl compounds such as triallyl isocyanurate, triallyl cyanurate, diallyl phthalate, diallyl fumarate, diallyl maleate; poly (meth) acryloxy such as ethylene glycol diacrylate, ethylene glycol dimethacrylate, trimethylolpropane trimethacrylate Compound; and divinylbenzene.
- the crosslinking aid can be contained in an amount of usually 5 parts by mass or less, preferably 0.1 to 3 parts by mass with respect to 100 parts by mass of the ethylene / unsaturated carboxylic acid copolymer or its ionomer.
- silane coupling agent examples include a silane coupling agent having a vinyl group, an amino group or an epoxy group and a hydrolyzable group such as an alkoxy group.
- the silane coupling agent can be contained in an amount of usually 5 parts by mass or less, preferably 0.02 to 3 parts by mass with respect to 100 parts by mass of the ethylene / unsaturated carboxylic acid copolymer or its ionomer.
- the silane coupling agent is contained in the above range, the adhesion between the multilayer sheet and the protective material or solar cell element can be further improved.
- the resin layer (A) in order to prevent deterioration of the multilayer sheet based on ultraviolet rays, it is preferable to contain an ultraviolet absorber, a light stabilizer, an antioxidant and the like in the resin layer (A).
- the ultraviolet absorber examples include 2-hydroxy-4-methoxybenzophenone, 2,2′-dihydroxy-4-methoxybenzophenone, 2-hydroxy-4-methoxy-2-carboxybenzophenone, 2-hydroxy-4-n- Benzophenone ultraviolet absorbers such as octoxybenzophenone; 2- (2H-benzotriazol-2-yl) -4,6-di-tert-pentylphenol, 2- (2′-hydroxy-3 ′, 5′-di benzotriazole ultraviolet absorbers such as t-butylphenyl) benzotriazole, 2- (2′-hydroxy-5-methylphenyl) benzotriazole, 2- (2′-hydroxy-5-t-octylphenyl) benzotriazole; Salicylic acid esters such as phenyl salicylate and p-octylphenyl salicylate Ether-based ultraviolet absorbers and the like are used.
- the light stabilizer a hindered amine light stabilizer or the like is used.
- the antioxidant various hindered phenol antioxidants, phosphite antioxidants, and the like are used.
- the antioxidant, light stabilizer and ultraviolet absorber are each usually 5 parts by mass or less, preferably 0.1 to 3 parts by mass with respect to 100 parts by mass of the ethylene / unsaturated carboxylic acid copolymer or its ionomer. It can be included.
- additives such as a coloring agent, a light-diffusion agent, and a flame retardant
- the colorant include pigments, inorganic compounds, dyes, and the like
- examples of the white colorant include titanium oxide, zinc oxide, and calcium carbonate.
- Examples of the light diffusing agent include glass beads, silica beads, silicon alkoxide beads, and hollow glass beads as inorganic spherical substances.
- Examples of the organic spherical material include acrylic and vinylbenzene plastic beads.
- flame retardants examples include halogen flame retardants such as bromides, phosphorus flame retardants, silicone flame retardants, metal hydrates such as magnesium hydroxide and aluminum hydroxide, and the like.
- the adhesive layer (B) is at least one selected from an epoxy group-containing ethylene copolymer (B1), an ethylene / polar monomer copolymer, and an ethylene / ⁇ -olefin copolymer having a density of 920 kg / m 3 or less.
- Ethylene copolymer (B2) (excluding the epoxy group-containing ethylene copolymer (B1)).
- Examples of the epoxy group-containing ethylene copolymer (B1) include a glycidyl group-containing ethylene copolymer.
- Examples of the glycidyl group-containing ethylene copolymer include ethylene / (meth) acrylic acid glycidyl copolymer, ethylene / (meth) acrylic acid glycidyl / vinyl acetate copolymer, and ethylene / (meth) acrylic acid glycidyl / Examples thereof include at least one selected from (meth) acrylic acid ester copolymers.
- the epoxy group-containing ethylene copolymer (B1) is composed of a polymerizable group such as glycidyl (meth) acrylate, vinyl glycidyl ether, 1,2-epoxy-4-vinylcyclohexane, 3,4-epoxycyclohexylmethyl methacrylate, and epoxy. It is obtained by copolymerizing a monomer having a group with ethylene. Further, an epoxy group may be introduced by graft polymerization of a monomer having an epoxy group to an ethylene-based copolymer.
- the content ratio of the structural unit derived from the monomer such as glycidyl (meth) acrylate in the epoxy group-containing ethylene copolymer (B1) is preferably 2% by mass or more and 30% by mass or less, more preferably 3% by mass or more. 25% by mass or less.
- the multilayer sheet 10 for solar cell encapsulant and the solar cell module component (solar cell element, substrate, etc.)
- the adhesive property of the solar cell sealing material is lower than the above upper limit, the processability as the multilayer sheet for sealing material is improved, and in addition, the transparency and flexibility of the multilayer sheet 10 for solar cell sealing material are also improved.
- “Glycidyl (meth) acrylate” represents one or both of glycidyl methacrylate and glycidyl acrylate.
- the “ethylene copolymer” in the epoxy group-containing ethylene copolymer (B1) means that a structural unit derived from ethylene is a main component.
- the “main component” here means that the content of “structural unit derived from ethylene” is the largest among all the structural units.
- the ratio of the structural units derived from ethylene is the structural unit derived from glycidyl (meth) acrylate. Or larger than a structural unit derived from vinyl acetate.
- the proportion of the “ethylene-derived structural unit” in the epoxy group-containing ethylene copolymer (B1) is preferably 50% by mass or more, more preferably 65% by mass or more, further preferably 70% by mass or more, and particularly preferably. 80% by mass or more.
- the epoxy group-containing ethylene-based copolymer can further include other monomer units other than the monomer having ethylene and a polymerizable group and an epoxy group.
- Other monomers include vinyl esters such as vinyl acetate and vinyl propionate; acrylic esters, methacrylic esters, ethacrylic esters, crotonic esters, fumaric esters, maleic esters, maleic anhydride esters, itaconic esters, And unsaturated carboxylic acid esters such as itaconic anhydride.
- the ester group include alkyl ester groups having 1 to 12 carbon atoms, and more specifically, methyl ester, ethyl ester, n-propyl ester, isopropyl ester, n-butyl ester, isobutyl ester, secondary butyl ester.
- alkyl ester groups such as 2-ethylhexyl ester and isooctyl ester.
- at least one selected from vinyl acetate and (meth) acrylic acid esters is preferable.
- a composition derived from vinyl acetate in addition to these two structural units, a composition derived from vinyl acetate.
- examples thereof include a copolymer containing at least one of a unit and a structural unit derived from a (meth) acrylic acid ester.
- the content ratio of the structural unit derived from vinyl ester such as vinyl acetate and the structural unit derived from unsaturated carboxylic acid ester such as (meth) acrylic acid ester is preferably 30% by mass or less, and 20% by mass or less. It is more preferable. Thereby, the moisture permeability of the multilayer sheet 10 for solar cell sealing materials falls, and it can make moisture-proof further better.
- the lower limit of the content ratio of the structural unit derived from a vinyl ester such as vinyl acetate and the structural unit derived from an unsaturated carboxylic acid ester such as (meth) acrylic acid ester is not particularly limited, but is preferably 0.1 mass. % Or more, more preferably 0.5% by mass or more, and further preferably 1% by mass or more. Further, the content ratio of the structural unit derived from vinyl ester such as vinyl acetate or the structural unit derived from unsaturated carboxylic acid ester such as (meth) acrylic acid ester is preferably in the range of 0.1 to 30% by mass, Furthermore, the range of 0.5 to 20% by mass is preferable, and the range of 1 to 20% by mass is particularly preferable.
- the epoxy group-containing ethylene copolymer (B1) can be used alone or in combination of two or more different copolymerization ratios.
- the ethylene copolymer (B2) contains at least one selected from an ethylene / polar monomer copolymer and an ethylene / ⁇ -olefin copolymer having a density of 920 kg / m 3 or less.
- the “ethylene copolymer” in the ethylene copolymer (B2) means that a structural unit derived from ethylene is a main component. Further, the “main component” here means that the proportion of “ethylene-derived structural units” with respect to all the structural units is preferably 50% by mass or more, more preferably 60% by mass or more, and still more preferably 65% by mass. % Or more, particularly preferably 70% by mass or more.
- ethylene / polar monomer copolymers examples include ethylene / vinyl acetate copolymers, ethylene / vinyl propionate copolymers, ethylene / vinyl butyrate copolymers, and ethylene / vinyl ester copolymers such as ethylene / vinyl stearate copolymers.
- One kind or two or more kinds selected from a polymer, an ethylene / unsaturated carboxylic acid ester copolymer, an ethylene / unsaturated carboxylic acid copolymer, and the like can be used.
- the ethylene / unsaturated carboxylic acid ester copolymer is a polymer obtained by copolymerizing ethylene and at least one unsaturated carboxylic acid ester.
- a copolymer containing ethylene and an alkyl ester of an unsaturated carboxylic acid can be exemplified.
- the unsaturated carboxylic acid in the unsaturated carboxylic acid ester include acrylic acid, methacrylic acid, ethacrylic acid, crotonic acid, fumaric acid, maleic acid, maleic anhydride, itaconic acid, itaconic anhydride and the like.
- alkyl moiety in the alkyl ester of the unsaturated carboxylic acid examples include those having 1 to 12 carbon atoms, and more specifically, methyl, ethyl, n-propyl, isopropyl, n-butyl, isobutyl, secondary butyl. And alkyl groups such as 2-ethylhexyl and isooctyl.
- the alkyl moiety of the alkyl ester preferably has 1 to 8 carbon atoms.
- a particularly preferred ethylene / unsaturated carboxylic acid ester copolymer is an ethylene / (meth) acrylic acid ester copolymer.
- copolymers examples include ethylene / methyl acrylate copolymer, ethylene / ethyl acrylate copolymer, ethylene / normal butyl acrylate copolymer, ethylene / isobutyl acrylate copolymer, ethylene / They are methyl methacrylate copolymer, ethylene / ethyl methacrylate copolymer, ethylene / normal butyl methacrylate copolymer, and ethylene / isobutyl methacrylate copolymer.
- the ethylene / unsaturated carboxylic acid copolymer is a polymer obtained by copolymerizing ethylene and at least one unsaturated carboxylic acid.
- the unsaturated carboxylic acid ester may be copolymerized.
- a copolymer containing ethylene and an unsaturated carboxylic acid can be exemplified.
- the unsaturated carboxylic acid include acrylic acid, methacrylic acid, ethacrylic acid, crotonic acid, fumaric acid, maleic acid, maleic anhydride, itaconic acid, itaconic anhydride and the like.
- a particularly preferred ethylene / unsaturated carboxylic acid copolymer is an ethylene / (meth) acrylic acid copolymer.
- ethylene / polar monomer copolymers are ethylene / vinyl acetate copolymer, ethylene / (meth) methyl acrylate copolymer, ethylene / (meth) ethyl acrylate copolymer, ethylene / (meth).
- At least one selected from propyl acrylate copolymer, ethylene / (meth) butyl acrylate copolymer, and ethylene / (meth) acrylic acid copolymer is particularly preferably used.
- the above-described resins may be used alone or blended.
- the content of the polar monomer in the ethylene / polar monomer copolymer is preferably 5% by mass or more and 40% by mass or less, more preferably 8% by mass or more and 35% by mass or less, and particularly preferably 8% by mass or more. 30% by mass or less.
- the vinyl acetate content can be measured according to, for example, JIS K7192: 1999.
- the method for producing the ethylene / polar monomer copolymer is not particularly limited, and can be produced by a known method. For example, it can be produced by a conventionally known high pressure autoclave method or tubular method. A commercially available ethylene / polar monomer copolymer may be used.
- the content of all structural units (monomer units) constituting the copolymer is 100 mol. %
- the content of the structural unit derived from the ⁇ -olefin having 3 to 20 carbon atoms is preferably 5 mol% or more. More preferably, it is 10 mol% or more.
- the content of the structural unit derived from the ⁇ -olefin is 15 mol% or more.
- the content of the structural unit derived from the ⁇ -olefin is 15 mol% or more.
- it is less than 50 mol%, Preferably it is 40 mol% or less, Most preferably, it is 30 mol% or less.
- ⁇ -olefin having 3 to 20 carbon atoms examples include propylene, 1-butene, 1-pentene, 1-hexene, 1-heptene, 1-octene, 1-nonene, 1-decene and 1-undecene.
- Linear ⁇ -olefins such as 1-dodecene, 1-tridecene, 1-tetradecene, 1-pentadecene, 1-hexadecene, 1-heptadecene, 1-octadecene, 1-nanodecene, 1-eicocene;
- Examples include branched ⁇ -olefins such as 1-butene, 3-methyl-1-pentene, 4-methyl-1-pentene, 2-ethyl-1-hexene, and 2,2,4-trimethyl-1-pentene. These can be used in combination of two types.
- the number of carbon atoms of the ⁇ -olefin is preferably 3 to 10, more preferably 3 to 8 in view of versatility (cost, mass productivity, or availability).
- the ethylene / ⁇ -olefin copolymer is preferably an ethylene / propylene copolymer, an ethylene / 1-butene copolymer, an ethylene / 4-methyl-1-pentene copolymer, or an ethylene / 1-hexene copolymer.
- These ethylene / ⁇ -olefin copolymers have a constitutional unit content derived from ethylene of 50 mol% or more.
- the proportion of the structural unit derived from ⁇ -olefin is preferably 5% by mole or more when the amount of all structural units (monomer units) constituting each copolymer is 100% by mole. More preferably, it is 10 mol% or more.
- the ethylene / ⁇ -olefin copolymer may be used alone or in combination of two or more.
- the ethylene / ⁇ -olefin copolymer can be produced, for example, by a slurry polymerization method, a solution polymerization method, a bulk polymerization method, or a gas phase polymerization method using a metallocene catalyst.
- the density of the ethylene / ⁇ -olefin copolymer is preferably 850 kg / m 3 or more, more preferably 860 kg / m 3 or more, and particularly preferably 870 kg / m. There are 3 or more.
- the density of the ethylene / ⁇ -olefin copolymer measured according to JIS K7112, is 920 kg / m 3 or less, more preferably 910 kg / m 3 or less.
- the content of the ethylene copolymer (B2) in the adhesive layer (B) is 100% by mass of the total amount of the epoxy group-containing ethylene copolymer (B1) and the ethylene copolymer (B2). 50 mass% or more and 99 mass% or less are preferable, 75 mass% or more and 99 mass% or less are more preferable, 85 mass% or more and 98 mass% or less are more preferable, and 90 mass% or more and 97 mass% or less are especially preferable.
- the content of the ethylene-based copolymer (B2) is within the above range, the performance balance of transparency, adhesiveness, moisture resistance, insulation, flexibility, heat resistance and workability is further improved. can do.
- At least a part of the epoxy group-containing ethylene copolymer (B1) and the ethylene copolymer (B2) in the adhesive layer (B) is graft-modified with a silane coupling agent.
- graft modification of the silane coupling agent to the epoxy group-containing ethylene copolymer (B1) and the ethylene copolymer (B2) is, for example, an epoxy group-containing ethylene copolymer (B1) or an ethylene-based copolymer.
- graft modification method 1 Using a method of reacting the copolymer (B2) with a silane coupling agent having an amino group or an epoxy group under heating (eg, 100 ° C. to 200 ° C.) (graft modification method 1), or using a polymerization initiator And a method of graft-polymerizing a silane coupling agent having a polymerizable group to the epoxy group-containing ethylene copolymer (B1) or ethylene copolymer (B2) (graft modification method 2).
- the amino group or epoxy group in the silane coupling agent reacts with the epoxy group or carboxyl group in the epoxy group-containing ethylene copolymer (B1) or ethylene copolymer (B2).
- a silane coupling agent is grafted to the side chain of the epoxy group-containing ethylene copolymer (B1) or the ethylene copolymer (B2).
- a silane coupling agent having a polymerizable group for example, an epoxy group-containing ethylene copolymer (B1) or ethylene copolymer (B2), a silane coupling agent having a polymerizable group, and a radical polymerization initiator are used as an extruder.
- melt-kneading at a temperature above the melting point of the epoxy group-containing ethylene copolymer (B1) or ethylene copolymer (B2) and above the decomposition temperature of the radical polymerization initiator can be manufactured. These reactions can also be performed in a solution.
- organic peroxides are preferred.
- organic peroxide a known organic peroxide that can be used as a polymerization initiator can be used. Specifically, a diacyl peroxide compound, an alkyl peroxy ester compound, a peroxy dicarbonate compound, a peroxy carbonate can be used. Examples thereof include compounds, peroxyketal compounds, dialkyl peroxide compounds, hydroperoxide compounds, and ketone peroxide compounds.
- dialkyl peroxide compounds are preferable, and 2,5-dimethyl-2,5-di (t-butylperoxy) hexane, 1,3-di (2-t-butylperoxyisopropyl) benzene, di-t- Butyl peroxide, 2,5-dimethyl-2,5-di (t- (butylperoxy) hexyne-3 is more preferred.
- the polymerization initiator is usually 0.1 to 5 parts by mass, preferably 0.5 to 3 parts per 100 parts by mass in total of the epoxy group-containing ethylene copolymer (B1) and the ethylene copolymer (B2). It can be contained in an amount of parts by mass.
- silane coupling agent having a polymerizable group examples include vinyltrimethoxysilane, vinyltriethoxysilane, 3-methacryloxypropylmethyldimethoxysilane, 3-methacryloxypropyltrimethoxysilane, 3-methacryloxypropylmethyldiethoxysilane, Examples include 3-methacryloxypropyltriethoxysilane, 3-acryloxypropylmethyldimethoxysilane, 3-acryloxypropyltrimethoxysilane, 3-acryloxypropylmethyldiethoxysilane, and 3-acryloxypropyltriethoxysilane.
- silane coupling agent having an amino group examples include N- (2-aminoethyl) -3-aminopropyltrimethoxysilane, N- (2-aminoethyl) -3-aminopropylmethyldimethoxysilane, N-2- ( Aminoethyl) -3-aminopropyltriethoxysilane, 3-aminopropyltrimethoxysilane, 3-aminopropyltriethoxysilane, 3-triethoxysilyl-N- (1,3-dimethyl-butylidene) propylamine, N- Examples thereof include phenyl-3-aminopropyltrimethoxysilane, N- (vinylbenzyl) -2-aminoethyl-3-aminopropyltrimethoxysilane hydrochloride, and the like.
- silane coupling agent having an epoxy group examples include 2- (3,4-epoxycyclohexyl) ethyltrimethoxysilane, 3-glycidoxypropylmethyldimethoxysilane, 3-glycidoxypropyltrimethoxysilane, 3-glycid And xylpropylmethyldiethoxysilane, 3-glycidoxypropyltriethoxysilane, and the like.
- the silane coupling agent is usually from 0.01 to 5 mass, preferably from 0.05 to 100 mass parts per 100 mass parts in total of the epoxy group-containing ethylene copolymer (B1) and the ethylene copolymer (B2). It can be contained in an amount of 3 parts by mass, more preferably 0.1 to 2 parts by mass.
- Both the epoxy group-containing ethylene copolymer (B1) and the ethylene copolymer (B2) have a melt flow rate (JIS K7210-1999, 190 ° C., 2160 g load; hereinafter abbreviated as MFR). Is preferably in the range of 0.1 g / 10 min to 50 g / 10 min. Further, it is preferably in the range of 0.5 g / 10 min to 30 g / 10 min, and particularly preferably in the range of 1 g / 10 min to 20 g / 10 min. By selecting a copolymer within this range, it becomes easier to process the sheet required as the multilayer sheet 10 for solar cell encapsulant, and a desired sheet can be obtained. Thereby, when a solar cell module is produced, the favorable adhesiveness and the suppression effect of unnecessary damaging are acquired.
- MFR melt flow rate
- the total content of the epoxy group-containing ethylene copolymer (B1) and the ethylene copolymer (B2) is preferably when the entire adhesive layer (B) is 100% by mass. It is 50 mass% or more, More preferably, it is 65 mass% or more, More preferably, it is 80 mass% or more, Most preferably, it is 90 mass% or more.
- the total content of the epoxy group-containing ethylene copolymer (B1) and the ethylene copolymer (B2) is within the above range, transparency, adhesion, moisture resistance, insulation, flexibility, heat resistance and The performance balance of workability can be further improved.
- the adhesive layer (B) can contain various additives within a range that does not impair the object of the present invention.
- additives include a crosslinking agent, a crosslinking aid, a silane coupling agent, an ultraviolet absorber, a light stabilizer, and an antioxidant.
- Additives are used for resin modification and durability improvement.
- the crosslinking aid can be used as necessary, and is usually 5 parts by mass or less, based on a total of 100 parts by mass of the epoxy group-containing ethylene copolymer (B1) and the ethylene copolymer (B2). Preferably, it can be contained in an amount of 0.1 to 3 parts by mass.
- the silane coupling agent is usually 5 parts by mass or less, preferably 0.02 to 3 parts by mass with respect to 100 parts by mass in total of the epoxy group-containing ethylene copolymer (B1) and the ethylene copolymer (B2). It can be contained in an amount of parts. When the silane coupling agent is contained in the above range, the adhesion between the multilayer sheet and the protective material or solar cell element can be further improved.
- the antioxidant, light stabilizer and ultraviolet absorber are each usually 5 parts by mass or less for a total of 100 parts by mass of the epoxy group-containing ethylene copolymer (B1) and the ethylene copolymer (B2), Preferably, it can be contained in an amount of 0.1 to 3 parts by mass.
- the adhesive layer (B) can contain additives such as a colorant, a light diffusing agent, and a flame retardant as necessary.
- additives such as a colorant, a light diffusing agent, and a flame retardant as necessary.
- the thing similar to what was mentioned by the resin layer (A) can be used.
- the method for producing the multilayer sheet 10 for a solar cell encapsulant according to the present embodiment can be performed by a known method using, for example, a multilayer T-die extruder or a multilayer inflation molding machine.
- a resin composition (A) containing an ethylene / unsaturated carboxylic acid copolymer or its ionomer as a main component, an epoxy group-containing ethylene copolymer (B1), an ethylene / polar monomer copolymer and a density of Resin containing at least one ethylene copolymer (B2) selected from ethylene / ⁇ -olefin copolymers of 920 kg / m 3 or less (excluding epoxy group-containing ethylene copolymer (B1))
- the composition (B) can be obtained by feeding from a main extruder of a multilayer T-die extruder and a hopper of a slave extruder and multilayer extrusion molding into a sheet form from the tip of the T die.
- FIG. 2 is a cross-sectional view schematically showing an example of the structure of the solar cell module 1 according to the embodiment of the present invention.
- the solar cell module 1 according to this embodiment includes at least a substrate 2 on which sunlight enters, a solar cell element 3, a back sheet 4, and the solar cell element 3 sealed between the substrate 2 and the back sheet 4.
- the sealing resin layer 5 comprised by the multilayer sheet 10 for solar cell sealing materials which concerns on this embodiment is provided.
- the solar cell module 1 according to the present embodiment can be produced by fixing the solar cell element 3 sealed with the multilayer sheet 10 for the solar cell sealing material according to the present embodiment on the substrate 2.
- a multilayer for solar cell encapsulant from both sides of the solar cell element 3 such as substrate 2 / multilayer sheet 10 for solar cell encapsulant / solar cell element 3 / multilayer sheet 10 for solar cell encapsulant / backsheet 4.
- the solar cell element 3 formed in advance on the surface of the substrate 2 such as glass or the like sandwiched between the sheets 10 is like a substrate 2 / solar cell element 3 / multilayer sheet 10 for solar cell sealing material / back sheet 4.
- the back sheet 4 can be formed.
- the solar cell module 1 when the solar cell encapsulant multilayer sheet 10 has a three-layer structure of adhesive layer (B) / resin layer (A) / adhesive layer (B), the adhesive layer (B) as the outer layer Is laminated so that one of the two contacts the solar cell element 3 and the other outer layer, the adhesive layer (B), contacts the substrate 2 or the back sheet 4.
- the multilayer sheet 10 for solar cell sealing materials has a two-layer structure of resin layer (A) / adhesive layer (B), the resin layer (A) contacts the solar cell element 3 and the adhesive layer (B Are preferably laminated so as to contact the substrate 2 or the back sheet 4.
- the solar cell element 3 examples include silicon-based materials such as single crystal silicon, polycrystalline silicon, and amorphous silicon, III-V groups such as gallium-arsenic, copper-indium-selenium, copper-indium-gallium-selenium, cadmium-tellurium, and the like. Various solar cell elements such as II-VI compound semiconductor systems can be used.
- the solar cell sealing material multilayer sheet 10 according to the present embodiment is particularly useful for sealing an amorphous silicon solar cell element.
- the plurality of solar cell elements 3 are electrically connected in series via the interconnector 6.
- substrate 2 which comprises the solar cell module 1
- substrate comprised by glass, an acrylic resin, a polycarbonate, polyester, a fluorine-containing resin etc.
- the back sheet 4 is a single or multilayer sheet such as a metal or various thermoplastic resin films, for example, a metal such as tin, aluminum or stainless steel, an inorganic material such as glass, polyester, an inorganic vapor deposition polyester, or a fluorine-containing resin. And a single-layer or multilayer sheet of polyolefin or the like. Good adhesion to the multilayer sheet 10 for solar cell encapsulant according to the present embodiment, the substrate 2 or the backsheet 4 is shown.
- the manufacturing method of the solar cell module 1 is not specifically limited, For example, the following method is mentioned. First, a plurality of solar cell elements 3 electrically connected using the interconnector 6 are sandwiched between the multilayer sheets 10 for solar cell encapsulant, and the multilayer sheet 10 for solar cell encapsulant is further connected to the substrate 2 and the back sheet 4. A laminated body is produced by sandwiching between. Next, the solar cell module 1 is obtained by heating and pressurizing the laminate and bonding the members.
- EMAc1 (A): an ionomer of an ethylene / methacrylic acid copolymer (ethylene content 85 mass%, methacrylic acid content: 15 mass%, 23% zinc neutralization)
- EMAc2 (A): Ionomer of ethylene / methacrylic acid copolymer (ethylene content 85% by mass, methacrylic acid content: 15% by mass, 54% magnesium neutralization)
- EMAc3 A): ionomer of ethylene / methacrylic acid / butyl acrylate copolymer (ethylene content 80%, methacrylic acid content 10%, butyl acrylate 10%, 70% zinc neutralization)
- EMAc1 (A) was added with an antioxidant: pentaerythritol tetrakis [3- (3,5-di-tert-butyl-4-hydroxyphenyl) propionate] (manufactured by BASF, Irganox 1010), ultraviolet absorber: 2- (2H -Benzotriazol-2-yl) -4,6-di-tert-pentylphenol, light stabilizer: bis (2,2,6,6, -tetramethyl-4-piperidyl) sebacate in a predetermined amount of biaxial extruder Was previously melt-kneaded to obtain a stabilizer masterbatch.
- pentaerythritol tetrakis [3- (3,5-di-tert-butyl-4-hydroxyphenyl) propionate] manufactured by BASF, Irganox 1010
- ultraviolet absorber 2- (2H -Benzotriazol-2-yl) -4,6-di-tert-pent
- ⁇ EGMAVA modified composition > Ethylene / glycidyl methacrylate / vinyl acetate copolymer (EGMAVA, manufactured by Sumitomo Chemical Co., Ltd., Bondfast 7B, ethylene content: 83 mass%, glycidyl methacrylate content: 12 mass%, vinyl acetate content: 5 mass %, MFR (190 ° C., 2160 g load): 7 g / 10 min): 49 parts by mass, ethylene / vinyl acetate copolymer (vinyl acetate content: 19% by mass): 49 parts by mass, ⁇ -methacryloxypropyltrimethoxy Silane (manufactured by Shin-Etsu Chemical Co., Ltd., trade name “KBM503”): 1.5 parts by mass and 2,5-dimethyl-2,5-di (t-butylperoxy) hexane (manufactured by Arkema Yoshitomi Corp.) Product name “
- EGMAVA grafted with ⁇ -methacryloxypropyltrimethoxysilane in EGMAVA modified composition 1 (also referred to as EGMAVA modified product 1) is an epoxy group-containing ethylene copolymer (B1) according to this embodiment.
- the ethylene / vinyl acetate copolymer grafted with ⁇ -methacryloxypropyltrimethoxysilane corresponds to the ethylene copolymer (B2) according to this embodiment.
- EVA1 Ethylene / vinyl acetate copolymer (ethylene content: 90% by mass, vinyl acetate content: 10% by mass)
- LDPE1 Low density polyethylene (Mitsui / DuPont Polychemical Co., Ltd., Mirason 68P, density: 918 kg / m 3 )
- LDPE2 Low density polyethylene (Mitsui / DuPont Polychemical Co., Ltd., Mirason 401, density: 920 kg / m 3 )
- EMA1 ethylene methyl acrylate copolymer (ethylene content: 80% by mass, methyl acrylate content: 20% by mass, MFR: 8 g / 10 min)
- EEA1 Ethylene / ethyl acrylate copolymer (ethylene content: 85% by mass, ethyl acrylate content: 15% by mass, MFR: 6 g / 10 min)
- EBA1 Ethylene / but
- a resin composition (B) (compound (B-1)) obtained by dry blending EGMAVA modified composition 1:10 parts by mass and ethylene copolymer EVA1 (B2): 90 parts by mass as outer layer 1 and outer layer 2
- a resin composition obtained by dry blending 90 parts by mass of EMAc1 (A) and 10 parts by mass of a stabilizer masterbatch as an intermediate layer, using a two-type three-layer T-die molding machine at a resin temperature of 180 ° C.
- the multilayer sheet and PET were pulled apart at a tensile speed of 100 mm / min, and the maximum stress was determined as the initial adhesive strength (N / 15 mm). Further, the laminate was stored at 85 ° C. and a humidity of 90% RH for 1000 hours, and the adhesive strength after 500 hours and the adhesive strength after 1000 hours were also determined. The obtained adhesive strength was defined as the PET adhesive strength in each laminate. The obtained results are shown in Table 2.
- Examples 2 to 7, Comparative Examples 1 to 3 A multilayer sheet was prepared in the same manner as in Example 1 except that the blends (B-2 to B-10) shown in Table 1 were used instead of the blends (B-1) of the outer layers 1 and 2. Evaluation similar to 1 was performed. The obtained results are shown in Tables 2 and 3, respectively.
- Example 8 and 9 A stabilizer masterbatch and an intermediate layer were prepared using EMAc2 (A) and EMAc3 (A3) instead of EMAc1 (A), respectively, and the same procedure as in Example 5 was used except that the obtained intermediate layer was used. Each multilayer sheet was produced and evaluated in the same manner as in Example 1. The obtained results are shown in Table 3, respectively.
- Example 5 A single-layer sheet was produced in the same manner as in Example 1 except that the outer layers 1 and 2 were not provided, and the same evaluation as in Example 1 was performed. The obtained results are shown in Table 3.
- the multilayer sheets of Examples 1 to 9 were excellent in the performance balance of transparency, adhesiveness, moisture resistance and insulation.
- the sheets of Comparative Examples 1 to 5 were inferior in the performance balance of transparency, adhesiveness, moisture resistance and insulation.
- a solar cell comprising: a resin layer (A) containing an ethylene / unsaturated carboxylic acid copolymer or its ionomer as a main component; and an adhesive layer (B) provided on one side or both sides of the resin layer (A).
- a multilayer sheet for sealing material The adhesive layer (B) is at least selected from a glycidyl group-containing ethylene copolymer (B1), an ethylene / polar monomer copolymer, and an ethylene / ⁇ -olefin copolymer having a density of 910 kg / m 3 or less.
- a multilayer sheet for a solar cell encapsulant comprising a kind of ethylene copolymer (B2) (excluding the glycidyl group-containing ethylene copolymer (B1)).
- B2 ethylene copolymer
- B1 glycidyl group-containing ethylene copolymer
- the multilayer sheet for solar cell sealing materials whose Haze measured based on JISK7136 is 40% or less. 5.
- the glycidyl group-containing ethylene copolymer (B1) is composed of ethylene / (meth) acrylic acid glycidyl copolymer, ethylene / (meth) acrylic acid glycidyl / vinyl acetate copolymer, and ethylene / (meth) acrylic acid glycidyl /
- the multilayer sheet for solar cell sealing materials containing at least 1 type selected from a (meth) acrylic acid ester copolymer. 6). 1.
- the ethylene / polar monomer copolymer includes at least one selected from an ethylene / vinyl ester copolymer, an ethylene / unsaturated carboxylic acid ester copolymer, and an ethylene / unsaturated carboxylic acid copolymer.
- Multi-layer sheet for materials. 7). 1.
- a solar cell encapsulant in which at least a part of the glycidyl group-containing ethylene copolymer (B1) and the ethylene copolymer (B2) in the adhesive layer (B) is graft-modified with a silane coupling agent Multilayer sheet. 8).
- a multilayer sheet for a solar cell encapsulant wherein the mass ratio of the ethylene copolymer (B2) to the glycidyl group-containing ethylene copolymer (B1) contained in the adhesive layer (B) is 1 or more and 50 or less. . 9. 1. To 8. In the multilayer sheet for solar cell sealing material according to any one of the above, The resin layer (A) is a multilayer sheet for a solar cell encapsulant containing the ionomer of the ethylene / unsaturated carboxylic acid copolymer as a main component. 10. 1. To 9.
- the manufacturing method of the multilayer sheet for solar cell sealing materials including the process of carrying out multilayer extrusion molding of the composition (A) containing ethylene / unsaturated carboxylic acid cop
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Abstract
Description
太陽光発電は、シリコンセル等の半導体(太陽電池素子)を用いて太陽光エネルギーを直接電気エネルギーに変換する。ここで用いられている太陽電池素子は薄く割れやすいうえ、直接外気と接触するとその機能が低下するものが存在する。そのため、太陽電池素子を封止材で挟み、太陽電池素子を保護するとともに、異物の混入や水分等の侵入を防いでいる。また、太陽光を効率よく太陽電池素子に与えるためには、封止材に透明性が求められる。
まず、主成分としてエチレン・酢酸ビニル共重合体を含む太陽電池用封止材は防湿性に劣っていた。そのため、太陽光が入射する側に配置される透明基板やバックシート等の種類、接着条件、太陽電池の使用環境等によっては太陽電池モジュール内に水分が侵入し、太陽電池としての性能を低下させることがあった。
また、エチレン・酢酸ビニル共重合体を含む太陽電池用封止材は体積抵抗率が一般的なポリオレフィン材料に比べて低く、高出力、高性能な太陽電池を保護する材料としては絶縁性の面で不十分となる場合があった。
さらに、本発明者らの検討によれば、エチレン・酢酸ビニル共重合体を含む太陽電池用封止材は、エチレン・酢酸ビニル共重合体中の酢酸ビニルの含有量を減らすと、透湿度が低下して防湿性が良好になったり、体積抵抗率が増加して絶縁性が良好になったりする一方で、透明性や接着性が悪化することが明らかになった。
すなわち、透明性および接着性と、防湿性および絶縁性との間には、トレードオフの関係が存在し、そのトレードオフの関係はポリマーの組成を改良することでは改善できないことを明らかにした。すなわち、本発明者らは、従来の太陽電池用封止材には、透明性、接着性、防湿性および絶縁性をバランスよく向上させるという観点において、改善の余地があることを見出した。
エチレン・不飽和カルボン酸共重合体またはそのアイオノマーを主成分として含有する樹脂層(A)と、上記樹脂層(A)の片面または両面に設けられた接着層(B)と、を備える太陽電池封止材用多層シートであって、
上記接着層(B)は、エポキシ基含有エチレン系共重合体(B1)と、エチレン・極性モノマー共重合体および密度が920kg/m3以下のエチレン・α-オレフィン共重合体から選択される少なくとも一種のエチレン系共重合体(B2)(ただし、上記エポキシ基含有エチレン系共重合体(B1)を除く)と、を含む太陽電池封止材用多層シート。
[2]
上記[1]に記載の太陽電池封止材用多層シートにおいて、
上記樹脂層(A)の両面に上記接着層(B)が設けられた太陽電池封止材用多層シート。
[3]
上記[1]または[2]に記載の太陽電池封止材用多層シートにおいて、
全体の厚みが50μm以上2000μm以下である太陽電池封止材用多層シート。
[4]
上記[1]乃至[3]いずれか一つに記載の太陽電池封止材用多層シートにおいて、
JISK7136に準拠して測定されるHazeが40%以下である太陽電池封止材用多層シート。
[5]
上記[1]乃至[4]いずれか一つに記載の太陽電池封止材用多層シートにおいて、
上記エポキシ基含有エチレン系共重合体(B1)はエチレン・(メタ)アクリル酸グリシジル共重合体、エチレン・(メタ)アクリル酸グリシジル・酢酸ビニル共重合体、およびエチレン・(メタ)アクリル酸グリシジル・(メタ)アクリル酸エステル共重合体から選択される少なくとも一種を含む太陽電池封止材用多層シート。
[6]
上記[1]乃至[5]いずれか一つに記載の太陽電池封止材用多層シートにおいて、
上記エチレン・極性モノマー共重合体は、エチレン・ビニルエステル共重合体、エチレン・不飽和カルボン酸エステル共重合体およびエチレン・不飽和カルボン酸共重合体から選択される少なくとも一種を含む太陽電池封止材用多層シート。
[7]
上記[1]乃至[6]いずれか一つに記載の太陽電池封止材用多層シートにおいて、
上記接着層(B)中の上記エポキシ基含有エチレン系共重合体(B1)および上記エチレン系共重合体(B2)の少なくとも一部はシランカップリング剤によりグラフト変性されている太陽電池封止材用多層シート。
[8]
上記[1]乃至[7]いずれか一つに記載の太陽電池封止材用多層シートにおいて、
上記接着層(B)に含まれるエチレン系共重合体(B2)の含有量は、エポキシ基含有エチレン系共重合体(B1)とエチレン系共重合体(B2)との合計量を100質量%として、50質量%以上99質量%以下である太陽電池封止材用多層シート。
[9]
上記[1]乃至[8]いずれか一つに記載の太陽電池封止材用多層シートにおいて、
上記樹脂層(A)は上記エチレン・不飽和カルボン酸共重合体のアイオノマーを主成分として含有する太陽電池封止材用多層シート。
[10]
上記[1]乃至[9]いずれか一つに記載の太陽電池封止材用多層シートにおいて、
少なくとも一方の面がコロナ処理されていない電気絶縁性樹脂フィルム層を接着するために用いられる太陽電池封止材用多層シート。
[11]
上記[1]乃至[10]いずれか一つに記載の太陽電池封止材用多層シートを製造するための製造方法であって、
エチレン・不飽和カルボン酸共重合体またはそのアイオノマーを主成分として含有する樹脂組成物(A)と、エポキシ基含有エチレン系共重合体(B1)並びにエチレン・極性モノマー共重合体および密度が920kg/m3以下のエチレン・α-オレフィン共重合体から選択される少なくとも一種のエチレン系共重合体(B2)(ただし、上記エポキシ基含有エチレン系共重合体(B1)を除く)を含有する樹脂組成物(B)と、を多層押出成形する工程を含む太陽電池封止材用多層シートの製造方法。
[12]
太陽光が入射する基板と、
太陽電池素子と、
バックシートと、
上記太陽電池素子を上記基板と上記バックシートとの間に封止するための上記[1]乃至[10]いずれか一つに記載の太陽電池封止材用多層シートにより構成された封止樹脂層と、
を備える太陽電池モジュール。
また、本多層シートは合わせガラス用の中間膜としても使用でき、透明性、接着性、防湿性の性能バランスに優れた合わせガラス用中間膜および合わせガラスを提供することができる。
図1は、本発明に係る実施形態の太陽電池封止材用多層シート10の構造の一例を模式的に示した断面図である。
本実施形態に係る太陽電池封止材用多層シート10(以下、多層シートとも呼ぶ。)は太陽電池素子を封止するために用いられるものであり、エチレン・不飽和カルボン酸共重合体またはそのアイオノマーを主成分として含有する樹脂層(A)と、樹脂層(A)の片面または両面に設けられた接着層(B)と、を備える。樹脂層(A)と、接着層(B)以外の層が例えば樹脂層(A)と接着層(B)の間に含まれる形態も本発明の実施形態であるが、樹脂層(A)と接着層(B)が直接接する形態が好ましい。
そして、接着層(B)は、エポキシ基含有エチレン系共重合体(B1)と、エチレン・極性モノマー共重合体および密度が920kg/m3以下のエチレン・α-オレフィン共重合体から選択される少なくとも一種のエチレン系共重合体(B2)(ただし、エポキシ基含有エチレン系共重合体(B1)を除く)と、を含む。
なお、「主成分」とはエチレン・不飽和カルボン酸共重合体またはそのアイオノマーが樹脂層(A)中に60質量%以上含有することを意味する。
また、接着層(B)も樹脂層(A)と同様に、単一の層により構成されていることが好ましいが、共重合体の組成や配合量が異なる複数の層により構成されていてもよい。
また、本実施形態に係る多層シートは、透明性、接着性、防湿性および絶縁性の性能バランスに優れているため、多層シートの全体の厚みを800μm以下と薄くすることができる。
また、樹脂層(A)からなる中間層と、その両面に設けられた接着層(B)からなる外層とを含む3層シートの場合、本実施形態に係る多層シートを構成する樹脂層(A)の一層の厚み(a)と、接着層(B)の一層の厚み(b)との比(a/b)は、1/1~10/1、好ましくは2/1~6/1である。a/bが上記範囲内にあると、透明性、接着性、防湿性、絶縁性、柔軟性、耐熱性および加工性の性能バランスをより一層良好なものとすることができる。外層は上記の厚み比であれば外層の2層のそれぞれの厚みは異なっていてもよい。
透湿度が上記上限値以下である太陽電池封止材用多層シート10は内部に水分を保持し難いため、太陽電池素子や電極の腐食を抑制することができる。その結果、太陽電池モジュールの長期安定性をより一層向上させることができる。
これにより得られる太陽電池モジュールの光発電量をより一層良好なものとすることができる。
樹脂層(A)は、エチレン・不飽和カルボン酸共重合体またはそのアイオノマーを主成分として含有する。
エチレンから導かれる構成単位が上記下限値以上であると、多層シートの耐熱性や機械的強度等をより良好なものとすることができる。また、エチレンから導かれる構成単位が上記上限値以下であると、多層シートの透明性や柔軟性、接着性等をより良好なものとすることができる。
不飽和カルボン酸から導かれる構成単位が上記下限値以上であると、多層シートの透明性や柔軟性、接着性等をより良好なものとすることができる。また、不飽和カルボン酸から導かれる構成単位が上記上限値以下であると、多層シートの加工性をより良好なものとすることができる。
なお、これら不飽和カルボン酸は1種単独で用いてもよいし、2種以上を組み合わせて用いてもよい。
アイオノマーにおけるイオン源としては、リチウム、ナトリウム等のアルカリ金属;カルシウム、マグネシウム、亜鉛、アルミニウム等の多価金属等が挙げられる。
架橋剤はエチレン・不飽和カルボン酸共重合体またはそのアイオノマー100質量部に対し、通常0.1~5質量部、好ましくは0.5~3質量部の量で含有させることができる。
架橋助剤はエチレン・不飽和カルボン酸共重合体またはそのアイオノマー100質量部に対し、通常5質量部以下、好ましくは0.1~3質量部の量で含有させることができる。
シランカップリング剤は、エチレン・不飽和カルボン酸共重合体またはそのアイオノマー100質量部に対し、通常5質量部以下、好ましくは0.02~3質量部の量で含有させることができる。シランカップリング剤が上記範囲で含まれていると、多層シートと、保護材または太陽電池素子等との接着性をより一層向上させることができる。
酸化防止剤として各種ヒンダードフェノール系酸化防止剤やホスファイト系酸化防止剤等が用いられる。
酸化防止剤、光安定剤および紫外線吸収剤は、エチレン・不飽和カルボン酸共重合体またはそのアイオノマー100質量部に対し、各々通常5質量部以下、好ましくは0.1~3質量部の量で含有させることができる。
着色剤としては、顔料、無機化合物、染料等が挙げられ、特に白色の着色剤としては、酸化チタン、酸化亜鉛、炭酸カルシウムが挙げられる。これらの添加剤を含有する多層シートを太陽電池素子の受光側の封止材として用いる場合は、透明性を損なう場合があるが、太陽電池素子の受光側と反対面の封止材として用いる場合には好適に用いられる。
接着層(B)は、エポキシ基含有エチレン系共重合体(B1)と、エチレン・極性モノマー共重合体および密度が920kg/m3以下のエチレン・α-オレフィン共重合体から選択される少なくとも一種のエチレン系共重合体(B2)(ただし、エポキシ基含有エチレン系共重合体(B1)を除く)と、を含有する。
グリシジル基含有エチレン系共重合体としては、例えば、エチレン・(メタ)アクリル酸グリシジル共重合体、エチレン・(メタ)アクリル酸グリシジル・酢酸ビニル共重合体、およびエチレン・(メタ)アクリル酸グリシジル・(メタ)アクリル酸エステル共重合体等から選択される少なくとも一種が挙げられる。
エポキシ基含有エチレン系共重合体(B1)中の(メタ)アクリル酸グリシジル等のモノマーに由来の構成単位の含有割合は、好ましくは2質量%以上30質量%以下、より好ましくは3質量%以上25質量%以下である。
(メタ)アクリル酸グリシジル等のモノマーに由来の構成単位の含有割合が上記下限値以上であると、太陽電池封止材用多層シート10と太陽電池モジュール構成部材(太陽電池素子や基板等)との接着性がより良好になり、また上記上限値以下であると、封止材用多層シートとしての加工性が向上し、加えて太陽電池封止材用多層シート10の透明性と柔軟性もより良好になる。
なお、「(メタ)アクリル酸グリシジル」とは、メタクリル酸グリシジルおよびアクリル酸グリシジルの一方または両方を表す。
エポキシ基含有エチレン系共重合体(B1)における「エチレン由来の構成単位」の占める割合は、好ましくは50質量%以上、より好ましくは65質量%以上、さらに好ましくは70質量%以上、特に好ましくは80質量%以上である。このとき、エポキシ基含有エチレン系共重合体は、エチレンおよび重合性基とエポキシ基を有するモノマー以外の他のモノマー単位をさらに含むことができる。
他のモノマーとしては、酢酸ビニル、プロピオン酸ビニル等のビニルエステル;アクリル酸エステル、メタクリル酸エステル、エタクリル酸エステル、クロトン酸エステル、フマル酸エステル、マレイン酸エステル、無水マレイン酸エステル、イタコン酸エステル、無水イタコン酸エステル等の不飽和カルボン酸エステル等が挙げられる。エステル基としては炭素数1~12のアルキルエステル基を挙げることができ、より具体的には、メチルエステル、エチルエステル、n-プロピルエステル、イソプロピルエステル、n-ブチルエステル、イソブチルエステル、セカンダリーブチルエステル、2-エチルヘキシルエステル、イソオクチルエステル等のアルキルエステル基を例示することができる。
これらの中でも酢酸ビニルおよび(メタ)アクリル酸エステルから選択される少なくとも一種が好ましい。
酢酸ビニル等のビニルエステルに由来の構成単位および(メタ)アクリル酸エステル等の不飽和カルボン酸エステルに由来の構成単位の含有割合は30質量%以下であることが好ましく、20質量%以下であることがより好ましい。これにより、太陽電池封止材用多層シート10の透湿度が低下して防湿性をより一層良好なものとすることができる。
具体的には、エチレンと、不飽和カルボン酸のアルキルエステルとを含む共重合体を例示することができる。
不飽和カルボン酸エステルにおける不飽和カルボン酸としては、例えば、アクリル酸、メタクリル酸、エタクリル酸、クロトン酸、フマル酸、マレイン酸、無水マレイン酸、イタコン酸、無水イタコン酸等が挙げられる。
不飽和カルボン酸のアルキルエステルにおけるアルキル部位としては、炭素数1~12のものを挙げることができ、より具体的には、メチル、エチル、n-プロピル、イソプロピル、n-ブチル、イソブチル、セカンダリーブチル、2-エチルヘキシル、イソオクチル等のアルキル基を例示することができる。本実施形態では、アルキルエステルのアルキル部位の炭素数は、1~8が好ましい。
本実施形態において、特に好ましいエチレン・不飽和カルボン酸エステル共重合体は、エチレン・(メタ)アクリル酸エステル共重合体である。このような共重合体の例としては、エチレン・アクリル酸メチル共重合体、エチレン・アクリル酸エチル共重合体、エチレン・アクリル酸ノルマルブチル共重合体、エチレン・アクリル酸イソブチル共重合体、エチレン・メタクリル酸メチル共重合体、エチレン・メタクリル酸エチル共重合体、エチレン・メタクリル酸ノルマルブチル共重合体、エチレン・メタクリル酸イソブチル共重合体である。
具体的には、エチレンと、不飽和カルボン酸とを含む共重合体を例示することができる。
不飽和カルボン酸としては、例えばアクリル酸、メタクリル酸、エタクリル酸、クロトン酸、フマル酸、マレイン酸、無水マレイン酸、イタコン酸、無水イタコン酸等が挙げられる。
本実施形態において、特に好ましいエチレン・不飽和カルボン酸共重合体は、エチレン・(メタ)アクリル酸共重合体である。
極性モノマーの含有量がこの範囲にあると、太陽電池封止材用多層シート10の接着性、透明性、機械的性質、成膜性のバランスをより一層良好なものとすることができる。酢酸ビニル含有量は、例えば、JIS K7192:1999に準拠して測定することができる。
接着層(B)において、上記エチレン・α-オレフィン共重合体は、1種単独で用いてもよく、2種以上組み合わせて用いてもよい。
JIS K7112に準拠して測定される、エチレン・α-オレフィン共重合体の密度は、920kg/m3以下であり、より好ましくは910kg/m3以下である。エチレン・α-オレフィン共重合体の密度が上記上限値以下であることにより、多層シートの接着性および透明性がより一層良好となる。
ここで、エポキシ基含有エチレン系共重合体(B1)およびエチレン系共重合体(B2)へのシランカップリング剤のグラフト変性は、例えば、エポキシ基含有エチレン系共重合体(B1)やエチレン系共重合体(B2)と、アミノ基またはエポキシ基を有するシランカップリング剤とを加熱下(例えば、100℃~200℃)で反応させる方法(グラフト変性方法1)や、重合開始剤を用いて、エポキシ基含有エチレン系共重合体(B1)やエチレン系共重合体(B2)に、重合性基を有するシランカップリング剤をグラフト重合させる方法(グラフト変性方法2)等がある。
グラフト変性方法1では、シランカップリング剤中のアミノ基またはエポキシ基と、エポキシ基含有エチレン系共重合体(B1)やエチレン系共重合体(B2)中のエポキシ基やカルボキシル基と、が反応することにより、エポキシ基含有エチレン系共重合体(B1)やエチレン系共重合体(B2)の側鎖にシランカップリング剤がグラフトされる。
グラフト変性方法2では、例えば、エポキシ基含有エチレン系共重合体(B1)やエチレン系共重合体(B2)と、重合性基を有するシランカップリング剤と、ラジカル重合開始剤とを、押出機、ニーダー、バンバリーミキサー等を用いて、エポキシ基含有エチレン系共重合体(B1)やエチレン系共重合体(B2)の融点以上、かつラジカル重合開始剤の分解温度以上の温度で溶融混練することにより製造することができる。なお、これらの反応は溶液中で行なうこともできる。
有機過酸化物としては重合開始剤として使用可能な公知の有機過酸化物を用いることができ、具体的には、ジアシルパーオキサイド化合物、アルキルパーオキシエステル化合物、パーオキシジカーボネート化合物、パーオキシカーボネート化合物、パーオキシケタール化合物、ジアルキルパーオキサイド化合物、ハイドロパーオキサイド化合物、ケトンパーオキサイド化合物等が挙げられる。
中でも、ジアルキルパーオキサイド化合物が好ましく、2,5-ジメチル-2,5-ジ(t-ブチルパーオキシ)ヘキサン、1,3-ジ(2-t-ブチルパーオキシイソプロピル)ベンゼン、ジ-t-ブチルパーオキサイド、2,5-ジメチル-2,5-ジ(t-(ブチルパーオキシ)ヘキシン-3がより好ましい。
重合開始剤はエポキシ基含有エチレン系共重合体(B1)と、エチレン系共重合体(B2)との合計100質量部に対し、通常0.1~5質量部、好ましくは0.5~3質量部の量で含有させることができる。
アミノ基を有するシランカップリング剤としては、N-(2-アミノエチル)-3-アミノプロピルトリメトキシシラン、N-(2-アミノエチル)-3-アミノプロピルメチルジメトキシシラン、N-2-(アミノエチル)-3-アミノプロピルトリエトキシシラン、3-アミノプロピルトリメトキシシラン、3-アミノプロピルトリエトキシシラン、3-トリエトキシシリル-N-(1,3-ジメチル-ブチリデン)プロピルアミン、N-フェニル-3-アミノプロピルトリメトキシシラン、N-(ビニルベンジル)-2-アミノエチル-3-アミノプロピルトリメトキシシランの塩酸塩等が挙げられる。
エポキシ基を有するシランカップリング剤としては、2-(3,4-エポキシシクロヘキシル)エチルトリメトキシシラン、3-グリシドキシプロピルメチルジメトキシシラン、3-グリシドキシプロピルトリメトキシシラン、3-グリシドキシプロピルメチルジエトキシシラン、3-グリシドキシプロピルトリエトキシシラン等が挙げられる。
シランカップリング剤は、エポキシ基含有エチレン系共重合体(B1)と、エチレン系共重合体(B2)との合計100質量部に対し、通常0.01~5質量、好ましくは0.05~3質量部、より好ましくは0.1~2質量部の量で含有させることができる。
これらの添加剤については、樹脂層(A)で挙げたものと同様のものを用いることができる。
添加剤は、樹脂の改質や耐久性向上等のために使用される。
シランカップリング剤は、エポキシ基含有エチレン系共重合体(B1)と、エチレン系共重合体(B2)との合計100質量部に対し、通常5質量部以下、好ましくは0.02~3質量部の量で含有させることができる。シランカップリング剤が上記範囲で含まれていると、多層シートと、保護材または太陽電池素子等との接着性をより一層向上させることができる。
酸化防止剤、光安定剤および紫外線吸収剤は、エポキシ基含有エチレン系共重合体(B1)と、エチレン系共重合体(B2)との合計100質量部に対し、各々通常5質量部以下、好ましくは0.1~3質量部の量で含有させることができる。
これらの添加剤については、樹脂層(A)で挙げたものと同様のものを用いることができる。
ここで、樹脂組成物(A)や樹脂組成物(B)には、前述した各種添加剤を添加してもよい。
図2は、本発明に係る実施形態の太陽電池モジュール1の構造の一例を模式的に示した断面図である。
本実施形態に係る太陽電池モジュール1は、少なくとも、太陽光が入射する基板2と、太陽電池素子3と、バックシート4と、太陽電池素子3を基板2とバックシート4との間に封止し、本実施形態に係る太陽電池封止材用多層シート10により構成された封止樹脂層5と、を備える。
本実施形態に係る太陽電池モジュール1は、基板2上に、本実施形態に係る太陽電池封止材用多層シート10により封止された太陽電池素子3を固定することで作製することができる。
太陽電池モジュール1において、太陽電池封止材用多層シート10が接着層(B)/樹脂層(A)/接着層(B)の3層構造である場合は、外層である接着層(B)の一方が太陽電池素子3と当接し、他方の外層である接着層(B)が基板2またはバックシート4と当接するように積層される。また、太陽電池封止材用多層シート10が樹脂層(A)/接着層(B)の2層構造である場合は、樹脂層(A)が太陽電池素子3と当接し、接着層(B)が基板2またはバックシート4と当接するように積層されることが好ましい。
太陽電池モジュール1においては、複数の太陽電池素子3は、インターコネクタ6を介して電気的に直列に接続されている。
バックシート4としては、金属や各種熱可塑性樹脂フィルム等の単体もしくは多層のシートであり、例えば、錫、アルミ、ステンレススチール等の金属、ガラス等の無機材料、ポリエステル、無機物蒸着ポリエステル、フッ素含有樹脂、ポリオレフィン等の1層もしくは多層のシートを例示することができる。本実施形態に係る太陽電池封止材用多層シート10、これらの基板2またはバックシート4に対して良好な接着性を示す。
まず、インターコネクタ6を用いて電気的に接続した複数の太陽電池素子3を太陽電池封止材用多層シート10で挟み、さらにこれら太陽電池封止材用多層シート10を基板2とバックシート4とで挟んで積層体を作製する。次いで、積層体を加熱・加圧して、各部材間を接着することで、太陽電池モジュール1が得られる。
EMAc1(A):エチレン・メタクリル酸共重合体のアイオノマー(エチレン含有量85質量%、メタクリル酸含有量:15質量%、23%亜鉛中和)
EMAc2(A):エチレン・メタクリル酸共重合体のアイオノマー(エチレン含有量85質量%、メタクリル酸含有量:15質量%、54%マグネシウム中和)
EMAc3(A):エチレン・メタクリル酸・アクリル酸ブチル共重合体のアイオノマー(エチレン含有量80%、メタクリル酸含量10%、アクリル酸ブチル10%、70%亜鉛中和)
EMAc1(A)に、酸化防止剤:ペンタエリトリトールテトラキス[3-(3,5-ジ-tert-ブチル-4-ヒドロキシフェニル)プロピオナート](BASF社製、Irganox1010)、紫外線吸収剤:2-(2H-ベンゾトリアゾール-2-イル)-4,6-ジ-tert-ペンチルフェノール、光安定剤:ビス(2,2,6,6,-テトラメチル-4-ピペリジル)セバケートを所定量2軸押し出し機であらかじめ溶融混練して安定化剤マスターバッチを得た。
エチレン・メタクリル酸グリシジル・酢酸ビニル共重合体(EGMAVA、住友化学(株)製、ボンドファースト7B、エチレン含有量:83質量%、メタクリル酸グリシジル含有量:12質量%、酢酸ビニル含有量:5質量%、MFR(190℃、2160g荷重):7g/10分):49質量部、エチレン・酢酸ビニル共重合体(酢酸ビニル含有量:19質量%):49質量部、γ-メタクリロキシプロピルトリメトキシシラン(信越化学工業(株)製、商品名「KBM503」):1.5質量部および2,5-ジメチル-2,5-ジ(t-ブチルパーオキシ)ヘキサン(アルケマ吉富(株)製、商品名「ルペロックス101」):0.5質量部を予め混合し、溶融温度220℃にて単軸押出機でグラフト重合させてEGMAVA変性体組成物1を得た。ここで、EGMAVA変性体組成物1中のγ-メタクリロキシプロピルトリメトキシシランがグラフトされたEGMAVA(EGMAVA変性体1とも呼ぶ。)が本実施形態に係るエポキシ基含有エチレン系共重合体(B1)に相当し、γ-メタクリロキシプロピルトリメトキシシランがグラフトされたエチレン・酢酸ビニル共重合体が本実施形態に係るエチレン系共重合体(B2)に相当する。
EVA1:エチレン・酢酸ビニル共重合体(エチレン含有量:90質量%、酢酸ビニル含有量:10質量%)
LDPE1:低密度ポリエチレン(三井・デュポン・ポリケミカル社製、ミラソン68P、密度:918kg/m3)
LDPE2:低密度ポリエチレン(三井・デュポン・ポリケミカル社製、ミラソン401、密度:920kg/m3)
EMA1:エチレン・アクリル酸メチル共重合体(エチレン含有量:80質量%、アクリル酸メチル含有量:20質量%、MFR:8g/10分)
EEA1:エチレン・アクリル酸エチル共重合体(エチレン含有量:85質量%、アクリル酸エチル含有量:15質量%、MFR:6g/10分)
EBA1:エチレン・アクリル酸ブチル共重合体(エチレン含有量:83質量%、アクリル酸ブチル含有量:17質量%、MFR:7g/10分)
EC1:エチレン・α-オレフィン共重合体(三井化学社製、タフマーDF840、MFR:3.6g/10分、密度:885kg/m3)
EC2:エチレン・α-オレフィン共重合体(三井化学社製、タフマーDF940、MFR:3.6g/10分、密度:893kg/m3)
EC3:エチレン・α-オレフィン共重合体(プライムポリマー社製、エボリューSP0540、MFR:3.8g/10分、密度:903kg/m3)
EC4:エチレン・α-オレフィン共重合体(プライムポリマー社製、エボリューSP2540、MFR:3.8g/10分、密度:924kg/m3)
EGMAVA変性体組成物1:10質量部とエチレン系共重合体のEVA1(B2):90質量部をドライブレンドした樹脂組成物(B)(配合(B-1))を外層1、外層2とし、EMAc1(A)90質量部と安定化剤マスターバッチ10質量部をドライブレンドした樹脂組成物を中間層に用いて、2種3層T-ダイ成形機を用いて、樹脂温度180℃にて、厚み比率を外層1/中間層/外層2=67μm/266μm/67μmにして総厚み400μm(0.4mm)の多層シートを作製した。
(1)接着性評価
真空加熱貼合機(NPC社製二重真空槽貼合機、LM-50×50S)を用いて、3.2mm厚のガラス/得られた多層シート/コロナ処理なしPETの順番に積層させ、加熱温度160℃、加熱時間8分の条件で貼り合わせた。その後、貼り合わせたものを大気中に静置し、自然冷却によって徐冷した。完成した積層体のシート部分に15mm幅のスリットを入れて試験片とし、引張試験機に設置した。引張速度100mm/分で多層シートとPETを引き離し、最大応力を初期の接着強度(N/15mm)として求めた。
また、積層体を85℃、湿度90%RHの条件で1000時間保管し、500時間後の接着強度と、1000時間後の接着強度もそれぞれ求めた。得られた接着強度をそれぞれの積層体におけるPET接着強度とした。得られた結果を表2に示す。
3.2mm厚のガラス/得られた多層シート/3.2mm厚のガラスの順番に積層させ、(1)の接着性評価時と同様の方法で作成した積層体を、スガ試験機社製ヘイズメーターを用いてJIS K7136に準拠して、全光線透過率(単位:%)およびHaze(曇り度、単位:%)を測定した。得られた結果を表2に示す。
カップ法(JIS Z0208準拠、測定雰囲気:40℃×90%RH)により多層シートの透湿度g/(m2・24h)を測定した。得られた結果を表2に示す。
JIS C2139(2008年)に準拠して多層シートの体積固有抵抗率を測定した。得られた結果を表2に示す。
外層1および2の配合(B-1)の代わりに、表1に示す配合(B-2~B-10)を用いた以外は実施例1と同様にして多層シートをそれぞれ作製し、実施例1と同様の評価をそれぞれおこなった。得られた結果を表2および3にそれぞれ示す。
EMAc1(A)の代わりに、EMAc2(A)およびEMAc3(A3)を用いて安定化剤マスターバッチおよび中間層をそれぞれ作製し、得られた中間層を使用した以外は実施例5と同様にして多層シートをそれぞれ作製し、実施例1と同様の評価をそれぞれおこなった。得られた結果を表3にそれぞれ示す。
単軸押出機を用いて、樹脂温度100℃にて、EVA1をシート状に押出成形し、厚み400μm(0.4mm)の樹脂シートを作製し、実施例1と同様の評価をおこなった。得られた結果を表3に示す。
外層1および2を設けない以外は実施例1と同様にして単層シートを作製し、実施例1と同様の評価をおこなった。得られた結果を表3に示す。
1.
エチレン・不飽和カルボン酸共重合体またはそのアイオノマーを主成分として含有する樹脂層(A)と、前記樹脂層(A)の片面または両面に設けられた接着層(B)と、を備える太陽電池封止材用多層シートであって、
前記接着層(B)は、グリシジル基含有エチレン系共重合体(B1)と、エチレン・極性モノマー共重合体および密度が910kg/m3以下のエチレン・α-オレフィン共重合体から選択される少なくとも一種のエチレン系共重合体(B2)(ただし、前記グリシジル基含有エチレン系共重合体(B1)を除く)と、を含む太陽電池封止材用多層シート。
2.
1.に記載の太陽電池封止材用多層シートにおいて、
前記樹脂層(A)の両面に前記接着層(B)が設けられた太陽電池封止材用多層シート。
3.
1.または2.に記載の太陽電池封止材用多層シートにおいて、
全体の厚みが50μm以上2000μm以下である太陽電池封止材用多層シート。
4.
1.乃至3.いずれか一つに記載の太陽電池封止材用多層シートにおいて、
JISK7136に準拠して測定されるHazeが40%以下である太陽電池封止材用多層シート。
5.
1.乃至4.いずれか一つに記載の太陽電池封止材用多層シートにおいて、
前記グリシジル基含有エチレン系共重合体(B1)はエチレン・(メタ)アクリル酸グリシジル共重合体、エチレン・(メタ)アクリル酸グリシジル・酢酸ビニル共重合体、およびエチレン・(メタ)アクリル酸グリシジル・(メタ)アクリル酸エステル共重合体から選択される少なくとも一種を含む太陽電池封止材用多層シート。
6.
1.乃至5.いずれか一つに記載の太陽電池封止材用多層シートにおいて、
前記エチレン・極性モノマー共重合体は、エチレン・ビニルエステル共重合体、エチレン・不飽和カルボン酸エステル共重合体およびエチレン・不飽和カルボン酸共重合体から選択される少なくとも一種を含む太陽電池封止材用多層シート。
7.
1.乃至6.いずれか一つに記載の太陽電池封止材用多層シートにおいて、
前記接着層(B)中の前記グリシジル基含有エチレン系共重合体(B1)および前記エチレン系共重合体(B2)の少なくとも一部はシランカップリング剤によりグラフト変性されている太陽電池封止材用多層シート。
8.
1.乃至7.いずれか一つに記載の太陽電池封止材用多層シートにおいて、
前記接着層(B)に含まれる、前記グリシジル基含有エチレン系共重合体(B1)に対する前記エチレン系共重合体(B2)の質量比が1以上50以下である太陽電池封止材用多層シート。
9.
1.乃至8.いずれか一つに記載の太陽電池封止材用多層シートにおいて、
前記樹脂層(A)は前記エチレン・不飽和カルボン酸共重合体のアイオノマーを主成分として含有する太陽電池封止材用多層シート。
10.
1.乃至9.いずれか一つに記載の太陽電池封止材用多層シートにおいて、
少なくとも一方の面がコロナ処理されていない電気絶縁性樹脂フィルム層を接着するために用いられる太陽電池封止材用多層シート。
11.
1.乃至10.いずれか一つに記載の太陽電池封止材用多層シートを製造するための製造方法であって、
エチレン・不飽和カルボン酸共重合体またはそのアイオノマーを主成分として含有する樹脂組成物(A)と、グリシジル基含有エチレン系共重合体(B1)とエチレン・極性モノマー共重合体および密度が910kg/m3以下のエチレン・α-オレフィン共重合体から選択される少なくとも一種のエチレン系共重合体(B2)(ただし、前記グリシジル基含有エチレン系共重合体(B1)を除く)とを含有する樹脂組成物(B)と、を多層押出成形する工程を含む太陽電池封止材用多層シートの製造方法。
12.
太陽光が入射する基板と、
太陽電池素子と、
バックシートと、
前記太陽電池素子を前記基板と前記バックシートとの間に封止し、1.乃至10.いずれか一つに記載の太陽電池封止材用多層シートにより構成された封止樹脂層と、
を備える太陽電池モジュール。
Claims (12)
- エチレン・不飽和カルボン酸共重合体またはそのアイオノマーを主成分として含有する樹脂層(A)と、前記樹脂層(A)の片面または両面に設けられた接着層(B)と、を備える太陽電池封止材用多層シートであって、
前記接着層(B)は、エポキシ基含有エチレン系共重合体(B1)と、エチレン・極性モノマー共重合体および密度が920kg/m3以下のエチレン・α-オレフィン共重合体から選択される少なくとも一種のエチレン系共重合体(B2)(ただし、前記エポキシ基含有エチレン系共重合体(B1)を除く)と、を含む太陽電池封止材用多層シート。 - 請求項1に記載の太陽電池封止材用多層シートにおいて、
前記樹脂層(A)の両面に前記接着層(B)が設けられた太陽電池封止材用多層シート。 - 請求項1または2に記載の太陽電池封止材用多層シートにおいて、
全体の厚みが50μm以上2000μm以下である太陽電池封止材用多層シート。 - 請求項1乃至3いずれか一項に記載の太陽電池封止材用多層シートにおいて、
JISK7136に準拠して測定されるHazeが40%以下である太陽電池封止材用多層シート。 - 請求項1乃至4いずれか一項に記載の太陽電池封止材用多層シートにおいて、
前記エポキシ基含有エチレン系共重合体(B1)はエチレン・(メタ)アクリル酸グリシジル共重合体、エチレン・(メタ)アクリル酸グリシジル・酢酸ビニル共重合体、およびエチレン・(メタ)アクリル酸グリシジル・(メタ)アクリル酸エステル共重合体から選択される少なくとも一種を含む太陽電池封止材用多層シート。 - 請求項1乃至5いずれか一項に記載の太陽電池封止材用多層シートにおいて、
前記エチレン・極性モノマー共重合体は、エチレン・ビニルエステル共重合体、エチレン・不飽和カルボン酸エステル共重合体およびエチレン・不飽和カルボン酸共重合体から選択される少なくとも一種を含む太陽電池封止材用多層シート。 - 請求項1乃至6いずれか一項に記載の太陽電池封止材用多層シートにおいて、
前記接着層(B)中の前記エポキシ基含有エチレン系共重合体(B1)および前記エチレン系共重合体(B2)の少なくとも一部はシランカップリング剤によりグラフト変性されている太陽電池封止材用多層シート。 - 請求項1乃至7いずれか一項に記載の太陽電池封止材用多層シートにおいて、
前記接着層(B)に含まれるエチレン系共重合体(B2)の含有量は、エポキシ基含有エチレン系共重合体(B1)と、エチレン系共重合体(B2)との合計量を100質量%としたとき、50質量%以上99質量%以下である太陽電池封止材用多層シート。 - 請求項1乃至8いずれか一項に記載の太陽電池封止材用多層シートにおいて、
前記樹脂層(A)は前記エチレン・不飽和カルボン酸共重合体のアイオノマーを主成分として含有する太陽電池封止材用多層シート。 - 請求項1乃至9いずれか一項に記載の太陽電池封止材用多層シートにおいて、
少なくとも一方の面がコロナ処理されていない電気絶縁性樹脂フィルム層を接着するために用いられる太陽電池封止材用多層シート。 - 請求項1乃至10いずれか一項に記載の太陽電池封止材用多層シートを製造するための製造方法であって、
エチレン・不飽和カルボン酸共重合体またはそのアイオノマーを主成分として含有する樹脂組成物(A)と、エポキシ基含有エチレン系共重合体(B1)並びにエチレン・極性モノマー共重合体および密度が920kg/m3以下のエチレン・α-オレフィン共重合体から選択される少なくとも一種のエチレン系共重合体(B2)(ただし、前記エポキシ基含有エチレン系共重合体(B1)を除く)を含有する樹脂組成物(B)と、を多層押出成形する工程を含む太陽電池封止材用多層シートの製造方法。 - 太陽光が入射する基板と、
太陽電池素子と、
バックシートと、
前記太陽電池素子を前記基板と前記バックシートとの間に封止するための請求項1乃至10いずれか一項に記載の太陽電池封止材用多層シートにより構成された封止樹脂層と、
を備える太陽電池モジュール。
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JP2017543226A JP6914841B2 (ja) | 2015-09-29 | 2016-09-26 | 太陽電池封止材用多層シート、太陽電池封止材用多層シートの製造方法および太陽電池モジュール |
EP16851388.5A EP3358629B1 (en) | 2015-09-29 | 2016-09-26 | Multilayer sheet for solar cell sealing material, method for manufacturing multilayer sheet for solar cell sealing material, and solar cell module |
KR1020187009818A KR102579787B1 (ko) | 2015-09-29 | 2016-09-26 | 태양 전지 밀봉재용 다층 시트, 태양 전지 밀봉재용 다층 시트의 제조 방법 및 태양 전지 모듈 |
CN201680056625.7A CN108140682B (zh) | 2015-09-29 | 2016-09-26 | 太阳能电池封装材料用多层片材、太阳能电池封装材料用多层片材的制造方法及太阳能电池模块 |
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CN107502209A (zh) * | 2017-09-21 | 2017-12-22 | 杭州福斯特应用材料股份有限公司 | 一种三层结构的太阳能电池封装胶膜及制备方法 |
KR20200108077A (ko) * | 2018-03-16 | 2020-09-16 | 미쓰이 가가쿠 가부시키가이샤 | 아크릴로나이트릴·뷰타다이엔 고무 조성물 및 당해 조성물층을 포함하는 적층체 |
WO2021125004A1 (ja) * | 2019-12-16 | 2021-06-24 | 三井・ダウポリケミカル株式会社 | 太陽電池封止材用樹脂組成物、太陽電池封止材、太陽電池封止材の製造方法および太陽電池モジュール |
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CN109021900A (zh) * | 2018-07-02 | 2018-12-18 | 江西农业大学 | 一种太阳能电池封装用单组份环氧胶黏剂的制备方法 |
KR102149846B1 (ko) | 2019-11-05 | 2020-09-01 | (주)동신폴리켐 | 굽힘하중 및 단열성 향상구조를 갖는 폴리카보네이트 다층시트 |
EP4019601A4 (en) * | 2019-11-19 | 2023-12-13 | Hangzhou First Applied Material Co., Ltd. | ADHESIVE FILM, ANTI-PID ENCAPSULATION ADHESIVE FILM, ADHESIVE FILM FORMING COMPOSITION, AND PHOTOVOLTAIC MODULE AND LAMINATED GLASS |
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KR102579787B1 (ko) | 2023-09-19 |
EP3358629B1 (en) | 2020-08-26 |
TW201726422A (zh) | 2017-08-01 |
EP3358629A4 (en) | 2019-04-03 |
EP3358629A1 (en) | 2018-08-08 |
CN108140682B (zh) | 2021-07-13 |
JP6914841B2 (ja) | 2021-08-04 |
JPWO2017057217A1 (ja) | 2018-07-12 |
KR20180061221A (ko) | 2018-06-07 |
TWI735468B (zh) | 2021-08-11 |
CN108140682A (zh) | 2018-06-08 |
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