WO2014208756A1 - 積層体形成用シート、及び積層体の製造方法 - Google Patents
積層体形成用シート、及び積層体の製造方法 Download PDFInfo
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- WO2014208756A1 WO2014208756A1 PCT/JP2014/067281 JP2014067281W WO2014208756A1 WO 2014208756 A1 WO2014208756 A1 WO 2014208756A1 JP 2014067281 W JP2014067281 W JP 2014067281W WO 2014208756 A1 WO2014208756 A1 WO 2014208756A1
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- WIPO (PCT)
- Prior art keywords
- laminate
- vinyl acetate
- eva
- sheet
- forming sheet
- Prior art date
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- 238000004519 manufacturing process Methods 0.000 title claims abstract description 45
- XTXRWKRVRITETP-UHFFFAOYSA-N Vinyl acetate Chemical compound CC(=O)OC=C XTXRWKRVRITETP-UHFFFAOYSA-N 0.000 claims abstract description 17
- 239000000203 mixture Substances 0.000 claims abstract description 17
- 239000003431 cross linking reagent Substances 0.000 claims abstract description 13
- 239000000155 melt Substances 0.000 claims abstract description 6
- 239000005038 ethylene vinyl acetate Substances 0.000 claims description 105
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- OMPJBNCRMGITSC-UHFFFAOYSA-N Benzoylperoxide Chemical compound C=1C=CC=CC=1C(=O)OOC(=O)C1=CC=CC=C1 OMPJBNCRMGITSC-UHFFFAOYSA-N 0.000 description 4
- 239000006087 Silane Coupling Agent Substances 0.000 description 4
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- BRQMAAFGEXNUOL-UHFFFAOYSA-N 2-ethylhexyl (2-methylpropan-2-yl)oxy carbonate Chemical compound CCCCC(CC)COC(=O)OOC(C)(C)C BRQMAAFGEXNUOL-UHFFFAOYSA-N 0.000 description 2
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- QEQBMZQFDDDTPN-UHFFFAOYSA-N (2-methylpropan-2-yl)oxy benzenecarboperoxoate Chemical compound CC(C)(C)OOOC(=O)C1=CC=CC=C1 QEQBMZQFDDDTPN-UHFFFAOYSA-N 0.000 description 1
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- NLBJAOHLJABDAU-UHFFFAOYSA-N (3-methylbenzoyl) 3-methylbenzenecarboperoxoate Chemical compound CC1=CC=CC(C(=O)OOC(=O)C=2C=C(C)C=CC=2)=C1 NLBJAOHLJABDAU-UHFFFAOYSA-N 0.000 description 1
- AGKBXKFWMQLFGZ-UHFFFAOYSA-N (4-methylbenzoyl) 4-methylbenzenecarboperoxoate Chemical compound C1=CC(C)=CC=C1C(=O)OOC(=O)C1=CC=C(C)C=C1 AGKBXKFWMQLFGZ-UHFFFAOYSA-N 0.000 description 1
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- VTEYUPDBOLSXCD-UHFFFAOYSA-N 1,1-bis(tert-butylperoxy)-2-methylcyclohexane Chemical compound CC1CCCCC1(OOC(C)(C)C)OOC(C)(C)C VTEYUPDBOLSXCD-UHFFFAOYSA-N 0.000 description 1
- OTMBZPVYOQYPBE-UHFFFAOYSA-N 1,1-bis(tert-butylperoxy)cyclododecane Chemical compound CC(C)(C)OOC1(OOC(C)(C)C)CCCCCCCCCCC1 OTMBZPVYOQYPBE-UHFFFAOYSA-N 0.000 description 1
- HSLFISVKRDQEBY-UHFFFAOYSA-N 1,1-bis(tert-butylperoxy)cyclohexane Chemical compound CC(C)(C)OOC1(OOC(C)(C)C)CCCCC1 HSLFISVKRDQEBY-UHFFFAOYSA-N 0.000 description 1
- ZFUIKMHIKJFJHF-UHFFFAOYSA-N 1-tert-butylperoxy-3,3,5-trimethylhexane Chemical compound CC(C)CC(C)(C)CCOOC(C)(C)C ZFUIKMHIKJFJHF-UHFFFAOYSA-N 0.000 description 1
- XRDOCCGDIHPQPF-UHFFFAOYSA-N 2,2,4,4-tetramethylheptaneperoxoic acid Chemical compound CCCC(C)(C)CC(C)(C)C(=O)OO XRDOCCGDIHPQPF-UHFFFAOYSA-N 0.000 description 1
- DPGYCJUCJYUHTM-UHFFFAOYSA-N 2,4,4-trimethylpentan-2-yloxy 2-ethylhexaneperoxoate Chemical compound CCCCC(CC)C(=O)OOOC(C)(C)CC(C)(C)C DPGYCJUCJYUHTM-UHFFFAOYSA-N 0.000 description 1
- DMWVYCCGCQPJEA-UHFFFAOYSA-N 2,5-bis(tert-butylperoxy)-2,5-dimethylhexane Chemical compound CC(C)(C)OOC(C)(C)CCC(C)(C)OOC(C)(C)C DMWVYCCGCQPJEA-UHFFFAOYSA-N 0.000 description 1
- CHKCPIUYSMYEEW-UHFFFAOYSA-N 2-(2-cyclohexylpropan-2-ylperoxy)-2-ethylhexanoic acid Chemical compound CCCCC(CC)(C(O)=O)OOC(C)(C)C1CCCCC1 CHKCPIUYSMYEEW-UHFFFAOYSA-N 0.000 description 1
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- OXYZDRAJMHGSMW-UHFFFAOYSA-N 3-chloropropyl(trimethoxy)silane Chemical compound CO[Si](OC)(OC)CCCCl OXYZDRAJMHGSMW-UHFFFAOYSA-N 0.000 description 1
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- MKTOIPPVFPJEQO-UHFFFAOYSA-N 4-(3-carboxypropanoylperoxy)-4-oxobutanoic acid Chemical compound OC(=O)CCC(=O)OOC(=O)CCC(O)=O MKTOIPPVFPJEQO-UHFFFAOYSA-N 0.000 description 1
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- BMOKJBQYCQTSSE-UHFFFAOYSA-N [2,5-dimethyl-5-(2-methylbenzoyl)peroxyhexan-2-yl] 2-methylbenzenecarboperoxoate Chemical compound CC1=CC=CC=C1C(=O)OOC(C)(C)CCC(C)(C)OOC(=O)C1=CC=CC=C1C BMOKJBQYCQTSSE-UHFFFAOYSA-N 0.000 description 1
- JUIBLDFFVYKUAC-UHFFFAOYSA-N [5-(2-ethylhexanoylperoxy)-2,5-dimethylhexan-2-yl] 2-ethylhexaneperoxoate Chemical compound CCCCC(CC)C(=O)OOC(C)(C)CCC(C)(C)OOC(=O)C(CC)CCCC JUIBLDFFVYKUAC-UHFFFAOYSA-N 0.000 description 1
- NOZAQBYNLKNDRT-UHFFFAOYSA-N [diacetyloxy(ethenyl)silyl] acetate Chemical compound CC(=O)O[Si](OC(C)=O)(OC(C)=O)C=C NOZAQBYNLKNDRT-UHFFFAOYSA-N 0.000 description 1
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- 125000003700 epoxy group Chemical group 0.000 description 1
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- FWDBOZPQNFPOLF-UHFFFAOYSA-N ethenyl(triethoxy)silane Chemical compound CCO[Si](OCC)(OCC)C=C FWDBOZPQNFPOLF-UHFFFAOYSA-N 0.000 description 1
- WOXXJEVNDJOOLV-UHFFFAOYSA-N ethenyl-tris(2-methoxyethoxy)silane Chemical compound COCCO[Si](OCCOC)(OCCOC)C=C WOXXJEVNDJOOLV-UHFFFAOYSA-N 0.000 description 1
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- 125000004401 m-toluyl group Chemical group [H]C1=C([H])C(=C([H])C(=C1[H])C([H])([H])[H])C(*)=O 0.000 description 1
- 229910021421 monocrystalline silicon Inorganic materials 0.000 description 1
- XNTUJOTWIMFEQS-UHFFFAOYSA-N octadecanoyl octadecaneperoxoate Chemical compound CCCCCCCCCCCCCCCCCC(=O)OOC(=O)CCCCCCCCCCCCCCCCC XNTUJOTWIMFEQS-UHFFFAOYSA-N 0.000 description 1
- SRSFOMHQIATOFV-UHFFFAOYSA-N octanoyl octaneperoxoate Chemical compound CCCCCCCC(=O)OOC(=O)CCCCCCC SRSFOMHQIATOFV-UHFFFAOYSA-N 0.000 description 1
- 230000003287 optical effect Effects 0.000 description 1
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- 238000002360 preparation method Methods 0.000 description 1
- 230000002265 prevention Effects 0.000 description 1
- 239000001294 propane Substances 0.000 description 1
- KKEYFWRCBNTPAC-UHFFFAOYSA-L terephthalate(2-) Chemical compound [O-]C(=O)C1=CC=C(C([O-])=O)C=C1 KKEYFWRCBNTPAC-UHFFFAOYSA-L 0.000 description 1
- WYKYCHHWIJXDAO-UHFFFAOYSA-N tert-butyl 2-ethylhexaneperoxoate Chemical compound CCCCC(CC)C(=O)OOC(C)(C)C WYKYCHHWIJXDAO-UHFFFAOYSA-N 0.000 description 1
- GQIUQDDJKHLHTB-UHFFFAOYSA-N trichloro(ethenyl)silane Chemical compound Cl[Si](Cl)(Cl)C=C GQIUQDDJKHLHTB-UHFFFAOYSA-N 0.000 description 1
- JXUKBNICSRJFAP-UHFFFAOYSA-N triethoxy-[3-(oxiran-2-ylmethoxy)propyl]silane Chemical compound CCO[Si](OCC)(OCC)CCCOCC1CO1 JXUKBNICSRJFAP-UHFFFAOYSA-N 0.000 description 1
- DQZNLOXENNXVAD-UHFFFAOYSA-N trimethoxy-[2-(7-oxabicyclo[4.1.0]heptan-4-yl)ethyl]silane Chemical compound C1C(CC[Si](OC)(OC)OC)CCC2OC21 DQZNLOXENNXVAD-UHFFFAOYSA-N 0.000 description 1
- YUYCVXFAYWRXLS-UHFFFAOYSA-N trimethoxysilane Chemical compound CO[SiH](OC)OC YUYCVXFAYWRXLS-UHFFFAOYSA-N 0.000 description 1
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- 239000005050 vinyl trichlorosilane Substances 0.000 description 1
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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
- C09J123/00—Adhesives based on homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Adhesives based on derivatives of such polymers
- C09J123/02—Adhesives based on homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Adhesives based on derivatives of such polymers not modified by chemical after-treatment
- C09J123/04—Homopolymers or copolymers of ethene
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- B32B17/00—Layered products essentially comprising sheet glass, or glass, slag, or like fibres
- B32B17/06—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material
- B32B17/10—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin
- B32B17/10005—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing
- B32B17/10009—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing characterized by the number, the constitution or treatment of glass sheets
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- B32B17/06—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material
- B32B17/10—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin
- B32B17/10005—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing
- B32B17/1055—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing characterized by the resin layer, i.e. interlayer
- B32B17/10788—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing characterized by the resin layer, i.e. interlayer containing ethylene vinylacetate
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- B32B37/14—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers
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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
- C09J5/00—Adhesive processes in general; Adhesive processes not provided for elsewhere, e.g. relating to primers
- C09J5/06—Adhesive processes in general; Adhesive processes not provided for elsewhere, e.g. relating to primers involving heating of the applied adhesive
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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
- C09J7/00—Adhesives in the form of films or foils
- C09J7/10—Adhesives in the form of films or foils without carriers
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L31/00—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
- H01L31/04—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof adapted as photovoltaic [PV] conversion devices
- H01L31/042—PV modules or arrays of single PV cells
- H01L31/048—Encapsulation of modules
- H01L31/0481—Encapsulation of modules characterised by the composition of the encapsulation material
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2457/00—Electrical equipment
- B32B2457/12—Photovoltaic modules
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2581/00—Seals; Sealing equipment; Gaskets
-
- 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
- C09J2203/00—Applications of adhesives in processes or use of adhesives in the form of films or foils
- C09J2203/322—Applications of adhesives in processes or use of adhesives in the form of films or foils for the production of solar panels
-
- 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
- C09J2301/30—Additional features of adhesives in the form of films or foils characterized by the chemical, physicochemical or physical properties of the adhesive or the carrier
- C09J2301/304—Additional features of adhesives in the form of films or foils characterized by the chemical, physicochemical or physical properties of the adhesive or the carrier the adhesive being heat-activatable, i.e. not tacky at temperatures inferior to 30°C
-
- 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
-
- 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
- C09J2400/00—Presence of inorganic and organic materials
- C09J2400/10—Presence of inorganic materials
- C09J2400/14—Glass
- C09J2400/143—Glass 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
- C09J2423/00—Presence of polyolefin
- C09J2423/04—Presence of homo or copolymers of ethene
-
- 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
- C09J2431/00—Presence of polyvinyl acetate
-
- 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 laminate-forming sheet mainly composed of an ethylene-vinyl acetate copolymer used for the production of laminates such as laminated glass and solar cells (sealing film for solar cells, interlayer film for laminated glass, etc.)
- the present invention relates to a laminate forming sheet useful for manufacturing a laminate including a step of pressing with a nip roll.
- a sheet (hereinafter also referred to as EVA sheet) mainly composed of an ethylene-vinyl acetate copolymer (hereinafter also referred to as EVA) is inexpensive and has excellent adhesiveness and high transparency. It is used as a laminate-forming sheet such as an interlayer film for laminated glass and a sealing film for solar cells. As shown in FIG. 2, the interlayer film for laminated glass is sandwiched between glass plates 21A and 21B and exhibits functions such as penetration resistance and prevention of scattering of broken glass. As the solar cell sealing film, as shown in FIGS. 3A to 3C, between the solar cell element 34 and the surface-side transparent protective member 31 made of a glass substrate, and / or the solar cell element 34.
- the EVA sheet can improve adhesion, penetration resistance, durability, and the like by crosslinking the copolymer using a crosslinking agent such as an organic peroxide.
- a laminated body such as laminated glass
- a laminate material such as a plurality of glass plates and a laminated body forming sheet are present at the interface between the laminated body forming sheet and the glass plate. It is necessary to discharge air to prevent bubbles from being generated. This is because if air bubbles are present in a laminated body such as laminated glass, performance deterioration and appearance defects may occur due to a decrease in transparency.
- a laminated body such as laminated glass
- a laminated body in which a laminated body forming sheet is sandwiched between a plurality of substrates is put in a vacuum bag, deaerated, and pressed under heating.
- the air in the laminate forming sheet and the interface between the substrate and the laminate forming sheet is removed to the extent that bubbles remain, and then in the main heating and pressurization with a high-temperature and high-pressure container.
- the method (2) using a nip roll is advantageous in that the crimping process can be performed continuously.
- Patent Document 1 in order to streamline the manufacturing process of laminated glass, it is made of a resin having specific viscoelastic properties (glass transition temperature, storage elastic modulus), and an intermediate film having a predetermined range of thickness is used.
- a method is disclosed in which laminated glass is continuously produced by pressure contact with a nip roll.
- Patent Document 2 discloses a method for removing air in a laminated body using a pressure roll (nip roll) as an inexpensive method for manufacturing an amorphous solar cell.
- the method of (2) using a nip roll is used normally. It is preferably used.
- an object of the present invention is a laminate-forming sheet mainly composed of EVA, which can sufficiently remove bubbles in the laminate by a pressurizing step using a nip roll, and can produce a good laminate. It is providing the sheet
- Another object of the present invention is a method for producing a laminate using a laminate-forming sheet mainly composed of EVA, and sufficiently removing bubbles in the laminate by a pressurizing step using a nip roll. It is possible to provide a production method capable of producing a good laminate.
- the laminate in the heating device used before pressurization by the nip roll, the laminate is difficult to be heated uniformly, and a temperature distribution may occur in the central portion and the peripheral portion in the plan view of the laminate. I understood that. Since the viscosity of EVA tends to drop sharply when it reaches a certain temperature, when the temperature distribution occurs in the EVA sheet in the laminate, the viscosity (fluidity) of EVA in the central part and the peripheral part in the plan view of the EVA sheet. Large differences can occur.
- the above object is a laminate forming sheet used in a laminate production method including a step of applying pressure using a nip roll, comprising a composition containing an ethylene-vinyl acetate copolymer and a crosslinking agent, wherein the ethylene -The vinyl acetate content of the vinyl acetate copolymer is 30% by mass or more based on the ethylene-vinyl acetate copolymer, and the melt flow rate of the ethylene-vinyl acetate copolymer (according to JIS-K7210) Is achieved by a laminate-forming sheet characterized by being 5 g / 10 min or less.
- EVA has the vinyl acetate content and the melt flow rate (hereinafter also referred to as MFR) as described above, it is possible to obtain EVA in which the viscosity change with respect to the temperature change in the vicinity of the heating temperature at the time of pressurization by the nip roll is suppressed. it can.
- MFR melt flow rate
- Preferred embodiments of the laminate forming sheet of the present invention are as follows.
- the vinyl acetate content of the ethylene-vinyl acetate copolymer is 30 to 50% by mass with respect to the ethylene-vinyl acetate copolymer. If the vinyl acetate content is too high, the EVA fluidity in the vicinity of the heating temperature during pressurization by the nip roll may become too high, so the above range is preferable.
- the melt flow rate (in accordance with JIS-K7210) of the ethylene-vinyl acetate copolymer is greater than 0 g / 10 minutes and not greater than 5 g / 10 minutes. If the MFR is too small, the EVA fluidity in the vicinity of the heating temperature during pressurization by the nip roll may become too low, so the above range is preferable.
- the viscosity change rate (r) with respect to a temperature change from 60 ° C. to 90 ° C. of the ethylene-vinyl acetate copolymer calculated by the formula (1) is 90% or less. If it has such physical properties, it is possible to sufficiently reduce the probability of bubbles entering in the step of applying pressure using a nip roll. (4) In (3), the viscosity change rate (r) is 80% or less. Furthermore, the probability that air bubbles enter can be lowered. (5) An interlayer film for laminated glass or a sealing film for solar cells. Since it is difficult for the transparency of the laminate to be lowered due to air bubbles, it is optimal for those uses where high transparency is important.
- the above object is also achieved by sandwiching the laminate-forming sheet of the present invention between two or more other laminate materials to obtain a laminate, using the nip roll after heating the laminate. It is achieved by a method for producing a laminate, comprising: a crimping step for crimping by pressing, and a step of further crosslinking and integrating the laminate after the crimping step. Since the method for producing a laminate of the present invention uses the laminate-forming sheet of the present invention, even in the case of an EVA sheet, air bubbles in the laminate are sufficiently removed by a pressure-bonding process in which pressure is applied using a nip roll. And a good laminate can be produced.
- Preferred embodiments of the laminate manufacturing method of the present invention are as follows.
- the pressure-bonding step is a step of passing the laminated body through the heating furnace and then pressing between at least one pair of nip rolls for pressurization.
- the pressure-bonding step is heated so that the temperature of the laminate-forming sheet is 55 to 95 ° C. before pressurization using a nip roll.
- the laminate is a laminated glass or a solar cell.
- the sheet for forming a laminate of the present invention is an EVA sheet
- the change in viscosity with respect to the temperature change in the vicinity of the heating temperature at the time of pressurization is suppressed.
- the removal can be performed sufficiently. Therefore, according to the method for producing a laminate of the present invention, a laminate using an EVA sheet as a laminate-forming sheet can be efficiently used using a continuous pre-bonding step, and appearance defects caused by a decrease in transparency can be obtained. By suppressing the generation, it can be manufactured with a high yield.
- FIG. 3 is a view for explaining preferred viscosity-temperature characteristics of an ethylene-vinyl acetate copolymer constituting the laminate-forming sheet of the present invention.
- the laminate-forming sheet of the present invention is a laminate-forming sheet used in a laminate production method including a step of applying pressure using a nip roll.
- the EVA is composed of a composition containing at least EVA and a crosslinking agent (EVA composition).
- EVA composition a crosslinking agent
- the EVA has a vinyl acetate content of 30% by mass or more based on the EVA, and the EVA melt flow rate (JIS- K7210)) is 5 g / 10 min or less.
- JIS- K7210 EVA melt flow rate
- MFR is measured on condition of 190 degreeC and load 21.18N.
- Such an EVA composition can suppress a change in viscosity with respect to a temperature change in the vicinity of the heating temperature at the time of pressurization by a nip roll. Therefore, even when the laminated body is not heated uniformly before pressurization by the nip roll, and the temperature distribution is generated in the central part and the peripheral part of the laminated body in the plan view, the central part and the peripheral part of the EVA sheet in the planar view. It is difficult for a large difference to occur in the viscosity (fluidity) of EVA in the part. Thereby, by the process of pressurizing using a nip roll, the bubble removal in a laminated body can fully be performed, and it can be set as the laminated body formation sheet which can manufacture a favorable laminated body.
- the content of vinyl acetate in EVA is preferably 30 to 50% by mass, more preferably 30 to 45% by mass, and particularly preferably 30 to 40% by mass with respect to EVA. If the EVA vinyl acetate content is too high, the EVA fluidity in the vicinity of the heating temperature during pressurization by the nip roll may become too high, or the impact resistance and penetration resistance of the resulting laminate may be reduced. is there.
- the MFR of EVA is preferably larger than 0 g / 10 minutes, more preferably 0.1 g / 10 minutes or more. If the EVA MFR is too small, the EVA fluidity in the vicinity of the heating temperature at the time of pressurization by the nip roll is lowered, and it may be necessary to heat to a higher temperature.
- the EVA MFR is preferably less than 4 g / 10 min, more preferably 3 g / 10 min or less, and particularly preferably 2 g / 10 min or less. In the vicinity of the heating temperature at the time of pressurization by the nip roll, the viscosity change with respect to the temperature change can be further suppressed.
- EVA ethylene-vinyl acetate copolymer calculated by the following formula is 90% or less. If EVA has such a narrow viscosity range as described above over a relatively wide temperature range of 60 to 110 ° C., the resin fluidity is less likely to be uneven and bubbles are less likely to enter. In addition, if EVA has the above-mentioned viscosity change rate (r), it is possible to make it more difficult for fluidity unevenness to occur in the pressurizing step with a nip roll having a resin surface temperature of 60 ° C. to 90 ° C. The probability of entering can be made sufficiently low.
- the rate of change in viscosity (r) is the formula (I ′): when the melting point exceeds 60 ° C.
- the viscosity change rate (r) is preferably 80% or less.
- FIG. 4 shows the viscosity-temperature characteristics of EVA. As shown in FIG. 4, the vinyl acetate content is 33% by mass with respect to EVA, the MFR is 1.0 g / 10 min EVA (1), and the vinyl acetate content is 32% by mass with respect to EVA.
- the EVA (2) of 0.2 g / 10 min has a viscosity range of 60 to 110 ° C. within the above range, and the viscosity change rate (r) is 79% and 87%, respectively. Meet the above provisions.
- EVA (3) with a vinyl acetate content of 24% by mass and an MFR of 2.0 g / 10 min with respect to EVA has a viscosity range at 60 to 110 ° C. that is outside the above range, and the rate of change in viscosity (r) (Because the melting point exceeds 60 ° C., calculated by the above formula (I ′)) is also 90%, and the vinyl acetate content is 33% by mass with respect to EVA and MFR is 30 g / 10 min EVA (4 ), The viscosity range at 60 to 110 ° C. is outside the above range, and the viscosity change rate (r) is 94%.
- the viscosities in FIG. 4 were measured using EVA with a viscometer capillograph ID (furnace diameter: ⁇ 9.55 mm, capillary: ⁇ 1.0 ⁇ 10 mm, manufactured by Toyo Seiki Co., Ltd.) at a test speed of 1 mm / min at each temperature. The viscosity of was measured.
- the sheet for forming a laminate of the present invention has high transparency because it can sufficiently remove bubbles in the laminate in the press-bonding process using a nip roll, and it is difficult for the transparency of the laminate to decrease due to bubbles.
- the crosslinking agent used in the EVA composition can form an EVA crosslinked structure, and can improve the adhesiveness, strength, and durability of the laminate forming sheet. Is.
- An organic peroxide is preferably used as the crosslinking agent. Any organic peroxide can be used as long as it decomposes at a temperature of 100 ° C. or higher to generate radicals.
- the organic peroxide is generally selected in consideration of the film formation temperature, the adjustment conditions of the composition, the curing temperature, the heat resistance of the adherend, and the storage stability. In particular, those having a decomposition temperature of 70 hours or more with a half-life of 10 hours are preferred.
- organic peroxide examples include benzoyl peroxide-based curing agents (benzoyl peroxide, 2,5-dimethylhexyl-2,5-bisperoxybenzoate, p-) from the viewpoint of processing temperature and storage stability of the resin.
- benzoyl peroxide-based curing agents benzoyl peroxide, 2,5-dimethylhexyl-2,5-bisperoxybenzoate, p-
- organic peroxides in particular 2,5-dimethyl-2,5di (tert-butylperoxy) hexane, 1,1-bis (tert-hexylperoxy) -3,3,5-trimethylcyclohexane, tert -Butylperoxy-2-ethylhexyl monocarbonate is preferred.
- a laminate-forming sheet having excellent insulating properties can be obtained.
- Such a sheet is effective when used as a solar cell sealing film.
- the content of the organic peroxide is not particularly limited, but is preferably 0.1 to 5 parts by mass, more preferably 0.2 to 3 parts by mass with respect to 100 parts by mass of EVA.
- the EVA composition may further contain a crosslinking aid, if necessary.
- the crosslinking aid can improve the gel fraction of EVA and improve the adhesion and durability of the EVA film.
- the content of the crosslinking aid is generally 10 parts by mass or less, preferably 0.1 to 5 parts by mass, more preferably 0.1 to 2.5 parts by mass with respect to 100 parts by mass of EVA.
- crosslinking aid compound having a radical polymerizable group as a functional group
- examples of the crosslinking aid include trifunctional crosslinking aids such as triallyl cyanurate and triallyl isocyanurate, and (meth) acrylic esters (eg, NK ester) ) Monofunctional or bifunctional crosslinking aids.
- trifunctional crosslinking aids such as triallyl cyanurate and triallyl isocyanurate, and (meth) acrylic esters (eg, NK ester) ) Monofunctional or bifunctional crosslinking aids.
- triallyl cyanurate and triallyl isocyanurate are preferable, and triallyl isocyanurate is particularly preferable.
- the EVA composition may further contain an adhesion improver in order to impart further excellent adhesive force.
- an adhesion improver a silane coupling agent can be used.
- the silane coupling agent include ⁇ -chloropropyltrimethoxysilane, vinyltriethoxysilane, vinyltris ( ⁇ -methoxyethoxy) silane, ⁇ -methacryloxypropyltrimethoxysilane, vinyltriacetoxysilane, and ⁇ -glycidoxypropyl.
- the content of the silane coupling agent is preferably 0.1 to 2 parts by weight, more preferably 0.1 to 0.65 parts by weight, and particularly 0.1 to 0.4 parts by weight with respect to 100 parts by weight of EVA. preferable.
- the EVA composition may use other additives depending on the use of the laminate forming sheet.
- various physical properties such as mechanical properties, optical properties such as adhesion, transparency, heat resistance, light resistance, crosslinking speed, etc.
- various additives such as a plasticizer, an acryloxy group-containing compound, a methacryloxy group-containing compound, an epoxy group-containing compound, an ultraviolet absorber, a light stabilizer, and an anti-aging agent are used as necessary. You may add more.
- the addition amount of various additives is preferably in the range of 5 parts by mass or less with respect to 100 parts by mass of EVA.
- the EVA composition is mixed by heating and kneading the EVA and the cross-linking agent and, if necessary, the above-described various materials with a super mixer (high-speed fluid mixer), a twin-screw kneader, a roll mill, etc., and then extruded. It can be manufactured by a method of forming into a sheet by molding or calendar molding (calendering).
- an embossing roller or an embossing plate may be pressed on the surface to give a concavo-convex pattern on the surface of the sheet.
- the heat-kneading temperature and the molding temperature are preferably temperatures at which the crosslinking agent does not react or hardly reacts. For example, 40 to 90 ° C., particularly 50 to 80 ° C. is preferable.
- the thickness of the EVA sheet is limited, but in the case of the laminate forming sheet of the present invention, the change in the viscosity of the EVA with respect to the temperature change is suppressed. Therefore, the thickness of the laminate forming sheet is not particularly limited, and can be appropriately set depending on the application.
- the thickness of the laminate forming sheet is generally in the range of 50 ⁇ m to 2 mm.
- the laminate-forming sheet of the present invention may be composed of one EVA sheet or may be a multilayer structure in which two or more EVA sheets are laminated.
- the method for producing a laminate of the present invention includes a step of sandwiching a laminate-forming sheet between two or more other laminate materials to obtain a laminate (uncured), and heating the laminate (uncured). Then, a laminate is manufactured by a step of pre-pressing by pressurizing using a nip roll, and then a step of cross-linking and integrating by further heating the laminate (after pre-pressing).
- the method for producing a laminate of the present invention uses the laminate-forming sheet of the present invention, as described above, even with an EVA sheet, the viscosity with respect to temperature change in the vicinity of the heating temperature at the time of pressurization by a nip roll. Change is suppressed. Therefore, air bubbles in the laminated body can be sufficiently removed by the pressure bonding process using the nip roll, and a good laminated body can be manufactured by the subsequent heating and crosslinking process.
- FIG. 1 is a schematic cross-sectional view showing a typical example of a method for producing a laminate according to the present invention.
- a laminate forming sheet 102 is sandwiched between two substrates 101A and 101B to form a laminate (uncured) 120.
- the laminate is passed through the heating furnace 301 while being transported by the transport device 303.
- the heating furnace 301 includes a heater unit 302 and can heat the laminated body forming sheet 102 to a predetermined temperature while the laminated body (uncured) 120 passes through the heating furnace 301.
- the laminate (uncured) 120 is passed between nip rolls 304 composed of two pairs of opposing roll portions.
- the nip roll 304 is a device that continuously pressurizes what passes between the roll portions with a predetermined linear pressure. Thereby, the laminated body (uncured) 120 is pressurized, and the heated laminated body forming sheet 102 is pressure-bonded to the boundary surface between the substrates 101A and 101B to obtain a laminated body (after preliminary pressure bonding) 120 '. At this time, since the laminate-forming sheet 102 is made of EVA having the vinyl acetate content and MFR as described above, the heating furnace 301 causes the laminate (uncured) 120 to have a central portion and a peripheral portion in plan view.
- a conventionally well-known thing can be used for the conveyance apparatus 303, the heating furnace 301, and the nip roll 304.
- FIG. Any method may be used for heating the heater unit 32 of the heating furnace 301. Examples thereof include a hot air heating method and an infrared heating method.
- a heating roll type heating device may be used instead of the heating furnace 301.
- the heating is not particularly limited as long as it is a temperature at which the crosslinking agent contained in the EVA composition of the laminate forming sheet 102 does not react. In consideration of the fluidity of the laminate-forming sheet 102 and the stress relaxation property during pressurization, the laminate-forming sheet 102 is heated so that the temperature of the laminate-forming sheet 102 is in the range of 55 to 95 ° C.
- the temperature is in the range of 65 to 95 ° C, particularly 70 to 95 ° C.
- the temperature difference between the central portion and the peripheral portion in plan view of the laminate forming sheet is preferably 15 ° C. or less.
- the nip roll 304 may be any type and may have a plurality of pairs of nip rolls. Moreover, in order to avoid the temperature fall at the time of pressurization, what was comprised with the heating roll may be used.
- the linear pressure applied by the nip roll 304 is not particularly limited, but is preferably 5 to 100 kN / m, and more preferably 10 to 50 kN / m.
- the layered body (after preliminary pressure bonding) 120 ′ is heated to perform a cross-linking and integration step (heating cross-linking step) to obtain a layered body.
- a conventionally well-known method can be used for a heat-crosslinking process. For example, high-temperature and high-pressure treatment such as autoclave can be used. There is no restriction
- Heating is preferably performed while pressurizing at a pressure of 1.0 ⁇ 10 3 Pa to 5.0 ⁇ 10 7 Pa. At this time, cooling after cross-linking of the laminate is generally performed at room temperature. Since air bubbles are sufficiently removed from the laminate (after pre-compression) 120 ′ by the press-bonding step of applying pressure using a nip roll, a good laminate can be obtained by the heat crosslinking step.
- the method for manufacturing a laminate of the present invention it is possible to sufficiently remove bubbles in the laminate in the pressure-bonding step of applying pressure using a nip roll, and it is difficult to cause a decrease in transparency of the laminate due to bubbles. It is suitable for the production of laminated glass or solar cells that require high transparency.
- the laminated body forming sheet of the present invention is used as the laminated glass intermediate film 22 of the laminated glass shown in FIG.
- Other laminate materials can be produced according to the laminate production method shown in FIG. In other words, a laminated body forming sheet (intermediate film) is sandwiched between two transparent substrates such as glass plates to form a laminated body (uncured), heated, and then pressed using a nip roll. Is preliminarily pressure-bonded by heating and further integrated by crosslinking to produce a laminated glass.
- the transparent substrate examples include green terephthalate (PET), polyethylene naphthalate (PEN), polyethylene butyrate, polymethyl methacrylate, in addition to glass plates such as green glass, silicate glass, inorganic glass plate, and non-colored transparent glass plate.
- a plastic substrate or film such as (PMMA) may be used.
- a glass plate is preferable in terms of heat resistance, weather resistance, impact resistance, and the like.
- the thickness of the transparent substrate is generally about 0.1 to 20 mm.
- the two transparent substrates may be the same or may be used in combination with different base materials.
- the present invention as a solar cell sealing film (front surface side sealing film 33A and / or back surface side sealing film 33B) in the solar cell shown in FIGS. 3 (a) to 3 (c). 1 can be manufactured according to the method for manufacturing a laminate shown in FIG. 1 using the surface-side transparent protective member 31, the solar cell element 34, and the back-side protective member 32 as other laminate materials. . That is, in the case of the solar cell of FIG. 3A, the surface side transparent protective member, the laminate forming sheet (sealing film), the solar cell element (solar cell), the laminate forming sheet (sealing film).
- a back surface side protective member in this order, and in the case of the solar cell of FIG. 3B, between the front surface side transparent protective member having a thin film solar cell element formed on the surface and the back surface side protective member.
- a laminate-forming sheet is sandwiched between the front surface side transparent protective member and the back surface side protective member having a thin film solar cell element formed on the surface.
- a laminate-forming sheet is sandwiched between them to form a laminate (uncured), heated, pre-pressed by pressing with a nip roll, and further crosslinked by heating.
- the solar cell is manufactured by integrating.
- the solar cell element in the case of the solar cell shown in FIG. 3 (a), a monocrystalline or polycrystalline silicon crystal type solar cell is exemplified, and the thin film solar cell shown in FIGS. 3 (b) and (c).
- a thin film silicon system In the case of an element, a thin film silicon system, a thin film amorphous silicon system solar cell, a copper indium selenide (CIS) system solar cell element, etc. are mentioned.
- the surface-side transparent protective member examples include glass substrates such as silicate glass, polyimide substrates, and fluororesin-based transparent substrates.
- a glass substrate is preferable and may be chemically or thermally strengthened.
- the thickness of the transparent substrate is generally 0.1 to 10 mm, preferably 0.3 to 5 mm.
- a plastic film such as polyethylene terephthalate (PET) is preferably used.
- PET polyethylene terephthalate
- a film obtained by laminating a fluorinated polyethylene film, particularly a fluorinated polyethylene film / Al / fluorinated polyethylene film in this order in consideration of heat resistance and wet heat resistance may be used.
- EVA has a vinyl acetate content of 30% by mass or more and an MFR of 5.0 g / 10 min or less, and as described above (see FIG. 4), EVA at 60 ° C. to 110 ° C.
- Example 1 or the range of 70 to 95 ° C.
- Example 2 it was shown that a laminated glass having a good appearance can be produced in a pressure bonding step by pressurization using a nip roll.
- the vinyl acetate content of EVA is 24% by mass
- the viscosity range at 60 ° C. to 110 ° C. is higher than the above range
- the viscosity change rate (r) with respect to the temperature change from the melting point to 90 ° C. is 90%.
- MFR is 30.0 g / 10 min
- viscosity range at 60 ° C. to 110 ° C. is lower than the above range
- a laminated body such as a laminated glass or a solar cell with high productivity by using a sheet for forming a laminated body including EVA that is inexpensive and excellent in adhesiveness and transparency.
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- Photovoltaic Devices (AREA)
- Laminated Bodies (AREA)
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Abstract
Description
従って、本発明の目的は、EVAを主成分とする積層体形成用シートであって、ニップロールを用いて加圧する工程により、積層体内の気泡除去を十分に行うことができ、良好な積層体を製造することができる積層体形成用シートを提供することにある。
(2)前記エチレン-酢酸ビニル共重合体のメルトフローレート(JIS-K7210に準拠する)が、0g/10分より大きく、5g/10分以下である。MFRが小さすぎると、ニップロールによる加圧時の加熱温度近傍におけるEVAの流動性が低くなり過ぎる場合があるため、上記範囲が好ましい。
(3)前記エチレン-酢酸ビニル共重合体の60℃~110℃における粘度範囲が、1.0×104~3.0×105Pa・sであり、且つ下記式(I):
r=(η60℃-η90℃)/η60℃)×100(%)(I)
[ただし、rは粘度変化率を表し、η60℃、及びη90℃は、それぞれ、エチレン-酢酸ビニル共重合体の60℃における粘度、及び90℃における粘度を表す。]
により算出される、前記エチレン-酢酸ビニル共重合体の60℃から90℃の温度変化に対する粘度変化率(r)が、90%以下である。このような物性を有していれば、ニップロールを用いて加圧する工程において気泡が入る確率を十分に低くすることができる。
(4)(3)において、前記粘度変化率(r)が、80%以下である。さらに気泡が入る確率を低くすることができる。
(5)合わせガラス用中間膜又は太陽電池用封止膜である。気泡による積層体の透明性の低下が生じ難いため、透明性が高いことが重要であるこれらの用途に最適である。
(2)前記圧着工程が、ニップロールを用いる加圧の前に、前記積層体形成用シートの温度が55~95℃になるように加熱される。
(3)前記積層体が、合わせガラス又は太陽電池である。
r=(η60℃-η90℃)/η60℃)×100(%)(I)
[ただし、rは粘度変化率を表し、η60℃、及びη90℃は、それぞれ、EVAの60℃における粘度、及び90℃における粘度を表す。]
により算出される、前記エチレン-酢酸ビニル共重合体の60℃から90℃の温度変化に対する粘度変化率(r)が、90%以下であることが好ましい。60~110℃という比較的広い温度範囲において、上記のような狭い粘度範囲を有するEVAであれば、樹脂の流動性にムラが生じ難く、気泡が入り難くなる。また、上記の粘度変化率(r)を有するEVAであれば、60℃~90℃の樹脂表面温度となるニップロールによる加圧工程において、さらに流動性のムラを生じ難くすることができ、気泡が入る確率を十分に低くすることができる。なお、粘度変化率(r)は、融点が60℃を超える場合は、式(I’):
r=(η(融点)-η90℃)/η(融点))×100(%)(I’)
[ただし、η(融点)は、EVAの融点における粘度を表し、その他は式(I)と同じである]
により算出される。
本発明の積層体形成用シートにおいて、EVA組成物に使用する架橋剤は、EVAの架橋構造を形成することができ、積層体形成用シートの接着性、強度、耐久性を向上することができるものである。
本発明の積層体形成用シートにおいて、EVA組成物は、必要に応じて、さらに架橋助剤を含んでいても良い。前記架橋助剤は、EVAのゲル分率を向上させ、EVAフィルムの接着性及び耐久性を向上させることができる。
本発明の積層体形成用シートにおいて、EVA組成物は、更に優れた接着力を付与するために、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。前記シランカップリング剤としては、γ-クロロプロピルトリメトキシシラン、ビニルトリエトキシシラン、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。
本発明の積層体形成用シートにおいて、EVA組成物は、積層体形成用シートの用途に応じて、他の添加剤を使用しても良い。例えば、合わせガラス用中間膜や太陽電池用封止膜として使用する場合、種々の物性(機械的強度、接着性、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、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、エポキシ基含有化合物、紫外線吸収剤、光安定剤、老化防止剤などの各種添加剤を1種又は2種以上添加してもよい。各種添加剤の添加量は、EVA100質量部に対して5質量部以下の範囲が好ましい。
本発明の積層体形成用シートの製造方法は、特に制限はなく、上述のEVA組成物を、従来公知の方法によりシート状に製膜することで製造できる。例えば、EVA及び架橋剤、並びに必要に応じて上述した各種材料を、スーパーミキサー(高速流動混合機)、二軸混練機、ロールミル等により、加熱混練することによりEVA組成物を混合した後、押出成形又はカレンダ成形(カレンダリング)などによりシート状に成形する方法で製造できる。必要に応じて、シート状に成形した後、エンボスローラーやエンボスプレートを表面に押圧し、シートの表面に凹凸形状パターンを付与しても良い。加熱混練温度、成形温度は、架橋剤が反応しない、或いはほとんど反応しない温度とすることが好ましい。例えば、40~90℃、特に50~80℃が好ましい。
本発明の積層体形成用シートを用いて、積層体を製造する方法について、図面を参照しながら説明する。本発明の積層体の製造方法は、積層体形成用シートを、2枚以上の他の積層体材料の間に挟持し、積層体(未硬化)を得る工程、積層体(未硬化)を加熱し、ニップロールを用いて加圧することにより予備圧着させる工程、その後、積層体(予備圧着後)を更に加熱することにより、架橋一体化させる工程により積層体が製造される。本発明の積層体の製造方法は、本発明の積層体形成用シートを用いているので、上述の通り、EVAシートであっても、ニップロールによる加圧時の加熱温度近傍において、温度変化に対する粘度変化が抑制されている。従って、ニップロールによる圧着工程により、積層体内の気泡除去を十分に行うことができ、その後の加熱架橋工程により良好な積層体を製造することができる。
本発明の積層体の製造方法により、合わせガラスを製造する場合、例えば、図2に示す合わせガラスの合わせガラス用中間膜22として本発明の積層体形成用シートを用い、透明基板21A及び21Bを他の積層体材料として、図1に示した積層体の製造方法に従って製造することができる。即ち、2枚のガラス板等の透明基板の間に、積層体形成用シート(中間膜)を挟持して積層体(未硬化)を形成し、それを加熱後、ニップロールを用いて加圧することにより予備圧着し、更に加熱することにより架橋一体化させ、合わせガラスを製造する。
太陽電池を製造する場合、例えば、図3(a)~(c)に示す太陽電池における、太陽電池用封止膜(表面側封止膜33A及び/又は裏面側封止膜33B)として本発明の積層体形成用シートを用い、表面側透明保護部材31、太陽電池素子34、裏面側保護部材32を他の積層体材料として、図1に示した積層体の製造方法に従って製造することができる。即ち、図3(a)の太陽電池の場合は、表面側透明保護部材、積層体形成用シート(封止膜)、太陽電池素子(太陽電池用セル)、積層体形成用シート(封止膜)、及び裏面側保護部材をこの順で積層し、図3(b)の太陽電池の場合は、表面に薄膜太陽電池素子が形成された表面側透明保護部材と、裏面側保護部材との間に、積層体形成用シート(封止膜)を挟持し、図3(c)の太陽電池の場合は、表面側透明保護部材と、表面に薄膜太陽電池素子が形成された裏面側保護部材との間に積層体形成用シート(封止膜)を挟持し、積層体(未硬化)を形成し、それを加熱後、ニップロールを用いて加圧することにより予備圧着し、更に加熱することにより架橋一体化させ、太陽電池を製造する。
1.積層体形成用シートの作製
表1及び表2に記載した配合の組成物をロールミルにて60~70℃で混練し、70℃でカレンダ成形し、積層体形成用シート(厚さ;0.5mm)を作製した。
2.積層体(合わせガラス)の作製
各積層体形成用シートを中間膜として、2枚のガラス板(大きさ:1000mm×1000mm、厚さ:3mm)の間に挟持した積層体(未硬化)を形成し、加熱装置(熱風加熱方式)及びニップロールによる加圧装置を有する圧着装置を用いて(図1参照)、表1及び表2に記載した積層体形成用シート温度になるように加熱した後、予備圧着を行い、次いでオートクレーブにより、温度135℃の条件下で60分間加圧処理して合わせガラスを作製した。なお、積層体形成用シートの温度は、積層体の形成前に温度インジケーターシールを積層体形成用シートの平面視中央部及び周辺部に添付しておき、その指示温度により測定した。
得られた合わせガラスの外観を観察し、気泡の状況を評価した。評価は、作製した合わせガラスの表面に、目視で確認できる気泡が認められない場合を○、気泡が認められる場合を×とした。
3.評価結果
評価結果を表1及び表2に示す。
102 積層体形成用シート
120 積層体(未硬化)
120’ 積層体(予備圧着後)
301 加熱炉
302 ヒーター部
303 搬送装置
304 ニップロール
21A、21B ガラス板
22 合わせガラス用中間膜
31 表面側透明保護部材
32 裏面側保護部材
33A、33B 太陽電池用封止膜
34 太陽電池素子
Claims (10)
- ニップロールを用いて加圧する工程を含む積層体製造方法に用いられる積層体形成用シートであって、
エチレン-酢酸ビニル共重合体及び架橋剤を含む組成物からなり、
前記エチレン-酢酸ビニル共重合体の酢酸ビニル含有率が、前記エチレン-酢酸ビニル共重合体に対して30質量%以上であり、且つ
前記エチレン-酢酸ビニル共重合体のメルトフローレート(JIS-K7210に準拠する)が、5g/10分以下であることを特徴とする積層体形成用シート。 - 前記エチレン-酢酸ビニル共重合体の酢酸ビニル含有率が、前記エチレン-酢酸ビニル共重合体に対して30~50質量%である請求項1に記載の積層体形成用シート。
- 前記エチレン-酢酸ビニル共重合体のメルトフローレート(JIS-K7210に準拠する)が、0g/10分より大きく、5g/10分以下である請求項1又は2に記載の積層体形成用シート。
- 前記エチレン-酢酸ビニル共重合体の60℃~110℃における粘度範囲が、1.0×104~3.0×105Pa・sであり、且つ下記式(I):
r=(η60℃-η90℃)/η60℃)×100(%)(I)
[ただし、rは粘度変化率を表し、η60℃、及びη90℃は、それぞれ、エチレン-酢酸ビニル共重合体の60℃における粘度、及び90℃における粘度を表す。]
により算出される、前記エチレン-酢酸ビニル共重合体の60℃から90℃の温度変化に対する粘度変化率(r)が、90%以下である請求項1~3のいずれか1項に記載の積層体形成用シート。 - 前記粘度変化率(r)が、80%以下である請求項4に記載の積層体形成用シート。
- 合わせガラス用中間膜又は太陽電池用封止膜である請求項1~5のいずれか1項に記載の積層体形成用シート。
- 請求項1~6のいずれか1項に記載の積層体形成用シートを、2枚以上の他の積層体材料の間に挟持し、積層体を得る工程、
前記積層体を、加熱した後、ニップロールを用いて加圧することにより圧着する圧着工程、及び
前記圧着工程後に、前記積層体を更に加熱することにより、架橋一体化させる工程、を含むことを特徴とする積層体の製造方法。 - 前記圧着工程が、前記積層体を搬送しながら加熱炉内を通過させ、その後少なくとも1対のニップロール間を通過させて加圧する工程である請求項7に記載の積層体の製造方法。
- 前記圧着工程が、ニップロールを用いる加圧の前に、前記積層体形成用シートの温度が55~95℃になるように加熱される請求項7又は8に記載の積層体の製造方法。
- 前記積層体が、合わせガラス又は太陽電池である請求項7~9のいずれか1項に記載の製造方法。
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WO2019159852A1 (ja) | 2018-02-14 | 2019-08-22 | 三井・ダウポリケミカル株式会社 | 合わせガラス中間膜または太陽電池封止材用樹脂組成物、合わせガラス中間膜、合わせガラス、太陽電池封止材および太陽電池モジュール |
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EP3015522A4 (en) | 2016-10-05 |
JPWO2014208756A1 (ja) | 2017-02-23 |
CN105339454A (zh) | 2016-02-17 |
EP3015522A1 (en) | 2016-05-04 |
US20160152873A1 (en) | 2016-06-02 |
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