JP5914323B2 - 太陽電池用封止膜及びこれを用いた太陽電池 - Google Patents
太陽電池用封止膜及びこれを用いた太陽電池 Download PDFInfo
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- JP5914323B2 JP5914323B2 JP2012500554A JP2012500554A JP5914323B2 JP 5914323 B2 JP5914323 B2 JP 5914323B2 JP 2012500554 A JP2012500554 A JP 2012500554A JP 2012500554 A JP2012500554 A JP 2012500554A JP 5914323 B2 JP5914323 B2 JP 5914323B2
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- solar cell
- sealing film
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- ethylene
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Images
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- H01L31/04—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof adapted as photovoltaic [PV] conversion devices
- H01L31/042—PV modules or arrays of single PV cells
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- C08L23/02—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers not modified by chemical after-treatment
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- C08L23/08—Copolymers of ethene
- C08L23/0846—Copolymers of ethene with unsaturated hydrocarbons containing other atoms than carbon or hydrogen atoms
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- C08L23/0876—Neutralised polymers, i.e. ionomers
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- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
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- C08L23/0846—Copolymers of ethene with unsaturated hydrocarbons containing other atoms than carbon or hydrogen atoms
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- C09K—MATERIALS FOR MISCELLANEOUS APPLICATIONS, NOT PROVIDED FOR ELSEWHERE
- C09K3/00—Materials not provided for elsewhere
- C09K3/10—Materials in mouldable or extrudable form for sealing or packing joints or covers
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L31/00—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
- H01L31/04—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof adapted as photovoltaic [PV] conversion devices
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- H01L31/048—Encapsulation of modules
- H01L31/0481—Encapsulation of modules characterised by the composition of the encapsulation material
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- C08L2203/20—Applications use in electrical or conductive gadgets
- C08L2203/204—Applications use in electrical or conductive gadgets use in solar cells
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- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
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- C09K2200/00—Chemical nature of materials in mouldable or extrudable form for sealing or packing joints or covers
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- 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
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- Materials Engineering (AREA)
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- Sealing Material Composition (AREA)
- Compositions Of Macromolecular Compounds (AREA)
- Macromonomer-Based Addition Polymer (AREA)
Description
(1)前記(メタ)アクリレート化合物の含有量が、前記エチレン−酢酸ビニル共重合体100質量部に対して、0.1〜1.0質量部である。
(2)前記ハイドロタルサイトの含有量が、前記エチレン−酢酸ビニル共重合体100質量部に対して、0.5〜1.5質量部である。
(3)前記架橋剤の含有量が、前記エチレン‐酢酸ビニル共重合体100質量部に対して、0.1〜2質量部である。
(4)前記架橋助剤の含有量が、前記エチレン‐酢酸ビニル共重合体100質量部に対して、0.1〜2.5質量部である。
(5)前記ハイドロタルサイトが、Mg4.5Al2(OH)13CO3・3.5H2Oである。
(6)前記架橋剤が、有機過酸化物である。
本発明に係る太陽電池用封止膜の好ましい態様は以下の通りである。
(1)前記式(I)におけるR2が、Hである。
本発明において化合物Iは、上記式Iに示すように9〜14個のエチレンオキシ基(−CH2CH2O−(R2がHの場合))又はプロピレンオキシ基(−CH(CH3)CH2O−(R2がCH3の場合))を有し、更に、分子の両末端部分に(メタ)アクリロイル基(本発明において、アクリロイル基又はメタアクリロイル基を意味する)又は(メタ)アクリロイルオキシ基(本発明において、アクリロイルオキシ基又はメタアクリロイルオキシ基を意味する)を有する。
本発明に使用するエチレン−酢酸ビニル共重合体(EVA)における酢酸ビニルの含有量は、EVA100質量部に対して20〜35質量部、さらに22〜30質量部、特に24〜28質量部とするのが好ましい。EVAの酢酸ビニル単位の含有量が低い程、得られる封止膜が硬くなる傾向がある。酢酸ビニルの含有量が20質量部未満では、高温で架橋硬化させる場合に、得られる封止膜の透明性が充分でない恐れがある。また、35質量部を超えると封止膜の硬さが不十分となる場合があり、更にカルボン酸、アルコール、アミン等が発生し封止膜と保護部材等との界面で発泡が生じ易くなる恐れがある。
本発明において、ハイドロタルサイトは、一般にハイドロタルサイト類、ハイドロタルサイト様化合物といわれるものであれば、どのようなものでも良く、天然に産出されるものでも、各種金属塩から合成されるものでも良い。ハイドロタルサイトは、層状構造を持ち、層間にアニオンを取り込む性質を有する。一般に、2価の金属及び3価の金属の水酸化物の塩であり、例えば、下記式(II)で表される。
本発明において架橋剤は、エチレン−酢酸ビニル共重合体の架橋構造を形成することができるものである。架橋剤は、有機過酸化物又は光重合開始剤を用いることが好ましい。
本発明の太陽電池用封止膜は、必要に応じて、さらに架橋助剤を含んでいてもよい。前記架橋助剤は、エチレン−極性モノマー共重合体のゲル分率を向上させ、封止膜の接着性及び耐久性を向上させることができる。
本発明の太陽電池用封止膜は、太陽電池内部の封止性能を考慮すると、優れた接着力を有するのが好ましい。そのために、接着向上剤をさらに含んでいても良い。接着向上剤としては、シランカップリング剤を用いることができる。これにより、優れた接着力を有する太陽電池用封止膜を形成することが可能となる。前記シランカップリング剤としては、γ−クロロプロピルメトキシシラン、ビニルエトキシシラン、ビニルトリス(β−メトキシエトキシ)シラン、γ−メタクリロキシプロピルトリメトキシシラン、ビニルトリアセトキシシラン、γ-グリシドキシプロピルトリメトキシシラン、γ−グリシドキシプロピルトリエトキシシラン、β−(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、ビニルトリクロロシラン、γ−メルカプトプロピルトリメトキシシラン、γ−アミノプロピルトリエトキシシラン、N−β−(アミノエチル)−γ−アミノプロピルトリメトキシシランを挙げることができる。これらシランカップリング剤は、単独で使用しても、又は2種以上組み合わせて使用しても良い。なかでも、γ−メタクリロキシプロピルトリメトキシシランが特に好ましく挙げられる。
本発明の太陽電池用封止膜は、膜の種々の物性(機械的強度、透明性等の光学的特性、耐熱性、耐光性、架橋速度等)の改良あるいは調整のため、必要に応じて、可塑剤、本発明における化合物Iの他のアクリロキシ基含有化合物、メタクリロキシ基含有化合物及び/又はエポキシ基含有化合物などの各種添加剤をさらに含んでいてもよい。
本発明の太陽電池の構造は、本発明の太陽電池用封止膜を用いていれば、特に制限されない。例えば、表面側透明保護部材と裏面側保護部材との間に、本発明の太陽電池用封止膜を介在させて架橋一体化させることにより太陽電池用セルを封止させた構造などが挙げられる。なお、本発明において、太陽電池セルの光が照射される側(受光面側)を「表面側」と称し、太陽電池セルの受光面とは反対面側を「裏面側」と称する。
[実施例1〜12(実施例1〜4、7、8、10:本発明、実施例5、6、9、11、12:参考例)、比較例1〜14]
表1及び表2に示す配合で各材料をロールミルに供給し、70℃で、混練して太陽電池用封止膜組成物を調製した。前記太陽電池用封止膜組成物を、70℃で、カレンダ成形し、放冷後、各太陽電池用封止膜(厚さ0.6mm)を作製した。
(1)カレンダ成形性
前記太陽電池用封止膜組成物をカレンダ成形する際に、混練不良等の問題なく成形できた場合を○、成形し難かった場合を×とした。
ガラス板(FLガラス:厚さ3mm)、上記で作製した各太陽電池用封止膜、及びAl蒸着したポリフッ化ビニル樹脂フィルム(厚さ200μm)をこの順で積層し、真空ラミネータにて90℃で仮圧着した後、加熱し、ゲル化分率90%以上まで架橋させ、酢酸発生量定量用モジュールとした。
上記で作製した各太陽電池用封止膜の100mmx100mmの大きさのサンプルを作製し、真空ラミネータにて90℃で仮圧着した後、加熱し、ゲル化分率90%以上まで架橋させた。
白板ガラス(厚さ;3mm)/各太陽電池用封止膜/白板ガラス(厚さ;3mm)をこの順で積層し、(2)と同様に架橋させたモジュールについて、JIS K 7136(2000年)に従って、ヘイズ値(%)を測定した。その際、ヘイズメーター(日本電色工業(株)製、NDH−2000型)を用いた。
(1)〜(3)の評価がいずれも合格の場合を○とし、(1)の評価のみが×の場合を△、それ以外を×とした。(4)はより好ましい配合を設定するための指標とした。
各サンプルの体積固有抵抗の結果を表1及び表2に示す。実施例1〜12において、EVA100質量部に対して、ハイドロタルサイト0.1〜6.0質量部、及び上記式(I)を満たす(メタ)アクリレート化合物(式(I)中、R1及びR3がCH3、R2がH、nが9又は14のもの)(化合物I)を0.1〜2.0質量部配合した太陽電池用封止膜を評価した。その結果、すべての実施例において、体積固有抵抗、酢酸発生量は合格であった。但し、化合物Iを1.5、及び2.0質量部配合した実施例5、及び6についてはカレンダ成形性が不良であり、化合物Iの配合量は、0.1〜1.0質量部がより好ましいことが示された。また、ハイドロタルサイトを6.0質量部配合した実施例12では、ヘイズ値が10%を越え、透明性が低下していた。従って、ハイドロタルサイトの配合量は、0.1〜1.5質量部が好ましいことが示された。
12 裏面側保護部材
13A 表面側封止膜
13B 裏面側封止膜
14 太陽電池用セル
Claims (5)
- エチレン−酢酸ビニル共重合体、架橋剤、架橋助剤、及びハイドロタルサイトを含む太陽電池用封止膜であって、
更に、下記式(I)
前記(メタ)アクリレート化合物の含有量が、前記エチレン−酢酸ビニル共重合体100質量部に対して、0.1〜1.0質量部であり、
前記ハイドロタルサイトの含有量が、前記エチレン−酢酸ビニル共重合体100質量部に対して、0.5〜1.5質量部であり、
前記架橋剤の含有量が、前記エチレン‐酢酸ビニル共重合体100質量部に対して、0.1〜2質量部であり、
前記架橋助剤の含有量が、前記エチレン‐酢酸ビニル共重合体100質量部に対して、0.1〜2.5質量部であり、
前記ハイドロタルサイトが、Mg4.5Al2(OH)13CO3・3.5H2Oであり、
前記架橋剤が有機過酸化物であることを特徴とする太陽電池用封止膜。 - 前記式(I)におけるR2が、Hである請求項1に記載の太陽電池用封止膜。
- 前記架橋助剤が、トリアリルシアヌレート又はトリアリルイソシアヌレートである請求項1又は2に記載の太陽電池用封止膜。
- 前記架橋剤が、2,5−ジメチル−2,5ジ(tert−ブチルパーオキシ)ヘキサン又は1,1−ビス(tert−ヘキシルパーオキシ)−3,3,5−トリメチルシクロヘキサンである請求項1〜3のいずれか1項に記載の太陽電池用封止膜。
- 請求項1〜4のいずれか1項に記載の太陽電池封止膜を用いたことを特徴とする太陽電池。
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