WO2017090521A1 - 太陽電池モジュール - Google Patents
太陽電池モジュール Download PDFInfo
- Publication number
- WO2017090521A1 WO2017090521A1 PCT/JP2016/084233 JP2016084233W WO2017090521A1 WO 2017090521 A1 WO2017090521 A1 WO 2017090521A1 JP 2016084233 W JP2016084233 W JP 2016084233W WO 2017090521 A1 WO2017090521 A1 WO 2017090521A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- solar cell
- surface side
- receiving surface
- sealing layer
- light
- Prior art date
Links
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Images
Classifications
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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
- H01L31/048—Encapsulation of modules
- H01L31/0481—Encapsulation of modules characterised by the composition of the encapsulation material
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- H01B3/00—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties
- H01B3/18—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of organic substances
- H01B3/30—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of organic substances plastics; resins; waxes
- H01B3/44—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of organic substances plastics; resins; waxes vinyl resins; acrylic resins
- H01B3/441—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of organic substances plastics; resins; waxes vinyl resins; acrylic resins from alkenes
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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
- H01L31/02—Details
- H01L31/0224—Electrodes
- H01L31/022408—Electrodes for devices characterised by at least one potential jump barrier or surface barrier
- H01L31/022425—Electrodes for devices characterised by at least one potential jump barrier or surface barrier for solar cells
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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
- H01L31/02—Details
- H01L31/0236—Special surface textures
- H01L31/02366—Special surface textures of the substrate or of a layer on the substrate, e.g. textured ITO/glass substrate or superstrate, textured polymer layer on glass substrate
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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
- H01L31/042—PV modules or arrays of single PV cells
- H01L31/048—Encapsulation of modules
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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
- H01L31/042—PV modules or arrays of single PV cells
- H01L31/048—Encapsulation of modules
- H01L31/0488—Double glass encapsulation, e.g. photovoltaic cells arranged between front and rear glass sheets
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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 solar cell module.
- solar cells are attracting attention as a means of generating energy that is clean and free from depletion.
- a solar cell When a solar cell is used outdoors such as a roof portion of a building, it is generally used in the form of a solar cell module.
- the above solar cell module is generally manufactured by the following procedure. First, the light-receiving surface side protective member / solar cell sealing material / solar cell element / solar cell sealing material / back surface side protective member are laminated in this order. Then, a solar cell module is manufactured by utilizing the lamination method etc. which vacuum-suck these and heat-press them.
- the solar cell module manufactured in this way has weather resistance and is suitable for outdoor use such as a roof portion of a building.
- Patent Document 1 describes an ethylene-vinyl acetate copolymer film as a solar cell sealing film.
- Patent Document 2 describes a solar cell encapsulant made of an ⁇ -olefin copolymer.
- Patent Document 3 describes a resin composition for a solar cell encapsulant containing an ethylene / ⁇ -olefin copolymer.
- the present invention has been made in view of the above circumstances, and provides a solar cell module in which a decrease in output of the solar cell module is suppressed and the sealing layer is thin.
- the present inventors diligently studied to provide a solar cell module in which a decrease in output of the solar cell module is suppressed and the sealing layer is thin. As a result, by controlling the thickness of the sealing layer on the bus bar electrode and the elastic modulus of the solar cell sealing material constituting the sealing layer to a specific range, the solar cell element and wiring can be prevented from being damaged while being sealed. The present inventors have found that a thinner stop layer can be realized, and have reached the present invention.
- the following solar cell module is provided.
- a solar comprising a light-receiving surface side protection member, a back surface-side protection member, a solar cell element, and a sealing layer that seals the solar cell element between the light-receiving surface side protection member and the back surface side protection member.
- a battery module The light-receiving surface side protection member has at least a plurality of fine concave portions and a plurality of fine convex portions on the solar cell element side surface,
- the solar cell element is provided with a bus bar electrode on at least the light receiving surface side surface,
- the sealing layer is provided between the light receiving surface side protective member and the solar cell element, and the light receiving surface side sealing layer is provided between the back surface side protecting member and the solar cell element.
- the solar cell element is sealed between the light receiving surface side sealing layer and the back surface side sealing layer,
- the light-receiving surface side sealing layer contains at least one resin selected from polyolefin resins and ethylene / polar monomer copolymers, The elastic modulus at 23 ° C.
- the solar cell module In the solar cell module according to any one of [1] to [5], The solar cell module whose average thickness (X) of the said light-receiving surface side sealing layer is 0.60 mm or less. [7] In the solar cell module according to any one of [1] to [6], The solar cell sealing material constituting the light-receiving surface side sealing layer is a solar cell module further including a lubricating oil.
- the present invention it is possible to realize a solar cell module in which a decrease in output of the solar cell module is suppressed and the sealing layer is thin.
- FIG. 1 is a cross-sectional view schematically showing one embodiment of the solar cell module of the present invention.
- a solar cell module 10 shown in FIG. 1 includes a light receiving surface side protection member 14, a back surface side protection member 15, a solar cell element 13, and a solar cell element between the light reception surface side protection member 14 and the back surface side protection member 15. And a sealing layer 11 for sealing 13.
- the light receiving surface side protection member 14 has a plurality of fine concave portions 14A and a plurality of fine convex portions 14B on at least the surface of the solar cell element 13, and the solar cell element 13 is provided with a bus bar electrode 17 on at least the surface of the light receiving surface. It has been.
- the sealing layer 11 includes a light receiving surface side sealing layer 11A provided between the light receiving surface side protection member 14 and the solar cell element 13, and a back surface provided between the back surface side protection member 15 and the solar cell element 13.
- the solar cell element 13 is sealed between the light receiving surface side sealing layer 11A and the back surface side sealing layer 11B.
- the light-receiving surface side sealing layer 11 ⁇ / b> A includes at least one resin selected from a polyolefin resin and an ethylene / polar monomer copolymer (hereinafter also referred to as a resin (P)).
- the of the solar cell encapsulant constituting the light receiving surface side sealing layer 11A is 5 MPa or more and 30 MPa or less, preferably 6 MPa or more and 28 MPa or less, more preferably 6 MPa or more and 25 MPa or less, and particularly preferably 8 MPa.
- the pressure is 15 MPa or less.
- the lower limit of the effective thickness of the light-receiving surface side sealing layer 11A represented by (XYZ) is 0.01 mm or more, preferably 0.02 mm or more, more preferably 0.05 mm or more, and further preferably 0.07 mm. As described above, it is particularly preferably 0.08 mm or more.
- the upper limit of the effective thickness of the light-receiving surface side sealing layer 11A represented by (XYZ) is less than 0.25 mm, preferably 0.20 mm or less, more preferably less than 0.20 mm, and still more preferably 0. .18 mm or less, particularly preferably 0.15 mm or less.
- the effective thickness of the light-receiving surface side sealing layer 11A By setting the effective thickness of the light-receiving surface side sealing layer 11A to the above lower limit or more, the solar cell element or the wiring is damaged due to stress when the solar cell module is manufactured or repeatedly used in an environment with a large temperature change. Can be suppressed, and as a result, a decrease in output in the solar cell module can be suppressed. Further, by making the effective thickness of the light receiving surface side sealing layer 11A less than or below the above upper limit value, the sealing layer can be made thinner, and as a result, the thickness is thinner while maintaining the output even after the temperature cycle. A solar cell module can be obtained.
- the average thickness (X) of the light receiving surface side sealing layer 11A is the weight W 1 (g / 100 cm 2 ) of the light receiving surface side sealing layer 11A cut to a size of 10 cm ⁇ 10 cm, and the light receiving surface side sealing.
- W 1 g / 100 cm 2
- D 1 g / cm 3
- the average thickness (X) of the light-receiving surface side sealing layer 11A is preferably 0.60 mm or less from the viewpoint of miniaturization of the module. From the viewpoint of handling, the thickness is preferably 0.40 to 0.60 mm, and more preferably 0.43 to 0.55 mm.
- the lower limit of the elastic modulus at 23 ° C. of the solar cell encapsulant constituting the light-receiving surface side encapsulating layer 11 is 5 MPa or more, preferably 6 MPa or more, more preferably 8 MPa or more.
- the upper limit of the elastic modulus at 23 ° C. of the solar cell sealing material constituting the light-receiving surface side sealing layer 11 is 30 MPa or less, preferably 28 MPa or less, more preferably 25 MPa or less, and further preferably 15 MPa or less.
- the effective thickness of the light receiving surface side encapsulating layer 11A is 0.01 mm or more and less than 0.25 mm, It is preferable because damage to the solar cell element and wiring when used repeatedly in an environment with a large temperature change can be suppressed, and a decrease in output of the solar cell module can be suppressed.
- the elastic modulus at 23 ° C.
- the resin (P) is an ethylene / ⁇ -olefin copolymer
- the elastic modulus can be adjusted to the above range by adjusting the carbon number of the olefin.
- the elastic modulus can be adjusted to the above range by adjusting the content ratio of the structural unit derived from the polar monomer and the kind of the polar monomer.
- the solar cell encapsulant may further contain a lubricating oil.
- the content of the lubricating oil is preferably 5 parts by mass or more and 30 parts by mass or less with respect to 100 parts by mass in total of the resin (P) and the lubricating oil.
- a conventionally known lubricating oil can be used as the lubricating oil.
- the lubricating oil include paraffinic oil and hydrocarbon synthetic oil.
- paraffinic oil examples include paraffinic process oil (for example, Diana Process Oil (registered trademark) (manufactured by Idemitsu Kosan)), liquid paraffin (for example, Moresco White (registered trademark) (manufactured by MORESCO)), and the like.
- paraffinic process oil for example, Diana Process Oil (registered trademark) (manufactured by Idemitsu Kosan)
- liquid paraffin for example, Moresco White (registered trademark) (manufactured by MORESCO)
- hydrocarbon-based synthetic oil examples include ethylene / ⁇ -olefin co-oligomers (for example, Lucant (registered trademark) manufactured by Mitsui Chemicals) and poly- ⁇ -olefins (for example, SpectraSyn (registered trademark) manufactured by ExxonMobil). ))
- paraffinic oil is preferable, and paraffinic process oil is more preferable.
- the average thickness (Y) of the bus bar electrode 17 can be measured from a photograph of a cross section of the bus bar electrode 17 taken with a scanning electron microscope or the like. Specifically, a cross section of the bus bar electrode 17 is photographed, 10 arbitrary portions are selected from the obtained photograph, and the thicknesses of these portions are measured. An average thickness (Y) of the bus bar electrode 17 can be obtained by adding up all the thicknesses and dividing the sum by 10.
- the apparent thickness Z 2 of the light-receiving-surface-side protection member 14 is a thickness of the convex portion 14B of the light receiving surface side protective member 14, for example, measure 10 points, can be an average value.
- the lower limit of the effective thickness of the back side sealing layer 11B is preferably 0.01 mm or more, more preferably 0.02 mm or more, still more preferably 0.05 mm or more, still more preferably 0.07 mm or more, and particularly preferably 0. 0.08 mm or more.
- the upper limit of the effective thickness of the back side sealing layer 11B is preferably less than 0.25 mm, more preferably 0.20 mm or less, still more preferably less than 0.20 mm, even more preferably 0.18 mm or less, and particularly preferably 0. .15 mm or less.
- the effective thickness of the back surface side sealing layer 11B can be measured by the same procedure as the effective thickness of the light receiving surface side sealing layer 11A.
- the average thickness of the back surface side sealing layer 11B is A [mm]
- the average thickness of the bus bar electrode 17 on the back surface side is B [mm]
- a plurality of back surface side protection members 15 are provided on the solar cell element 13 side surface.
- the effective thickness of the back-side sealing layer 11B is expressed by (ABC). .
- Each average thickness can be measured by the same method as the measurement of the effective thickness of the light-receiving surface side sealing layer 11A.
- the solar cell module 10 includes a plurality of solar cell elements 13 electrically connected by an interconnector 16.
- FIG. 1 shows an example in which the solar cell elements 13 are connected in series, the solar cell elements 13 may be connected in parallel.
- the light receiving surface side protection member 14 and the back surface side protection member 15 sandwich the solar cell element 13, and the sealing layer 11 is filled between these protection members and the plurality of solar cell elements 13.
- the sealing layer 11 includes a light receiving surface side sealing layer 11A and a back surface side sealing layer 11B.
- the light receiving surface side sealing layer 11A is in contact with an electrode formed on the light receiving surface of the solar cell element 13.
- the back side sealing layer 11B is in contact with the electrode formed on the back side of the solar cell element 13.
- the electrode is a current collecting member formed on each of the light receiving surface and the back surface of the solar cell element 13 and includes a finger electrode, a bus bar electrode, a back electrode layer, and the like which will be described later.
- the back side sealing layer 11B may be the same as or different from the thickness of the light receiving side sealing layer 11A, but is preferably 0.60 mm or less from the viewpoint of miniaturization of the module. From the viewpoint of handling, it is preferably 0.40 to 0.60 mm, and more preferably 0.43 to 0.55 mm.
- the sealing layer 11 is formed from a solar cell sealing material S made of a resin composition.
- the solar cell encapsulant S is preferably in the form of a sheet, and may be cross-linked as necessary or non-cross-linked.
- the solar cell sealing material S used for forming the sealing layer 11 will be described.
- the solar cell sealing material S is composed of a pair of a first solar cell sealing material S1 that forms the light-receiving surface side sealing layer 11A and a second solar cell sealing material S2 that forms the back surface side sealing layer 11B. May be.
- the solar cell sealing material S may be used as a general term for the first solar cell sealing material S1 and the second solar cell sealing material S2.
- the solar cell encapsulant S is preferably composed of a resin composition containing at least one resin (P) selected from polyolefin resins and ethylene / polar monomer copolymers.
- the first solar cell sealing material S1 constituting the light-receiving surface side sealing layer 11A preferably includes a polyolefin resin as the resin (P), and the first solar cell sealing material S1 and the second solar cell seal More preferably, both of the stoppers S2 contain a polyolefin resin.
- the content of the resin (P) in the light receiving surface side sealing layer 11A (first solar cell sealing material S1) is the light receiving surface side sealing layer 11A (first solar cell sealing material S1).
- the total is 100% by mass, it is preferably 50% by mass or more, more preferably 70% by mass or more, further preferably 80% by mass or more, and particularly preferably 90% by mass or more.
- crosslinking characteristic, can be obtained.
- content of the said resin (P) in the back surface side sealing layer 11B (2nd solar cell sealing material S2) in this embodiment is back surface side sealing layer 11B (2nd solar cell sealing material S2).
- the total is 100% by mass, it is preferably 50% by mass or more, more preferably 70% by mass or more, further preferably 80% by mass or more, and particularly preferably 90% by mass or more.
- polystyrene resins examples include ethylene / ⁇ -olefin copolymers, low density ethylene resins, medium density ethylene resins, ultra low density ethylene resins, propylene (co) polymers, and 1-butene (co).
- the first solar cell sealing material S1 preferably contains an ethylene / ⁇ -olefin copolymer as a polyolefin resin. Thereby, the light-receiving surface side sealing layer 11A containing the ethylene / ⁇ -olefin copolymer can be formed.
- the second solar cell encapsulating material S2 may be formed from the same composition as the first solar cell encapsulating material S1, or may be formed from a different composition.
- the ethylene / ⁇ -olefin copolymer contained in the solar cell encapsulant S is more preferably an ethylene / ⁇ -olefin copolymer composed of ethylene and an ⁇ -olefin having 3 to 20 carbon atoms.
- ⁇ -olefin ⁇ -olefins having 3 to 20 carbon atoms can be used singly or in combination of two or more. Among these, ⁇ -olefins having 10 or less carbon atoms are preferable, and ⁇ -olefins having 3 to 8 carbon atoms are particularly preferable.
- ⁇ -olefins include propylene, 1-butene, 1-pentene, 1-hexene, 3-methyl-1-butene, 3,3-dimethyl-1-butene, 4-methyl-1- Examples include pentene, 1-octene, 1-decene, and 1-dodecene. Of these, propylene, 1-butene, 1-pentene, 1-hexene, 4-methyl-1-pentene and 1-octene are preferable because of their availability.
- the ethylene / ⁇ -olefin copolymer may be a random copolymer or a block copolymer, but a random copolymer is preferred from the viewpoint of flexibility.
- an ethylene / ⁇ -olefin copolymer satisfying at least one of the following a1) to a4) is preferably used.
- the content ratio of the structural unit derived from ethylene is 80 to 90 mol%, and the content ratio of the structural unit derived from the ⁇ -olefin having 3 to 20 carbon atoms is 10 to 20 mol%.
- the density measured according to ASTM D1505 is 0.865 to 0.884 g / cm 3 .
- the Shore A hardness measured according to ASTM D2240 is 60 to 85.
- the ethylene / ⁇ -olefin copolymer used for the solar cell encapsulant S preferably satisfies any two of the above a1) to a4), and satisfies any three of the above a1) to a4). More preferably, it is particularly preferable to satisfy the above three a1), a3) and a4). It is particularly preferable to satisfy all of the above a1) to a4).
- a1) to a4) will be described.
- the proportion of structural units derived from an ⁇ -olefin having 3 to 20 carbon atoms (hereinafter also referred to as “ ⁇ -olefin unit”) contained in the ethylene / ⁇ -olefin copolymer is preferably 10 to 20 mol%. More preferably, it is 12 to 20 mol%, further preferably 12 to 18 mol%, particularly preferably 13 to 18 mol%.
- ⁇ -olefin unit By setting the content of the ⁇ -olefin unit to 10 mol% or more, a highly transparent sealing layer 11 tends to be obtained.
- the flexibility is high, it is possible to further suppress the occurrence of cracking of the solar cell element 13 and chipping of the thin film electrode.
- the ⁇ -olefin unit content is 20 mol% or less, a sheet that is easily formed into a sheet and has good blocking resistance can be obtained, and heat resistance can be improved by crosslinking.
- melt flow rate (MFR) of the ethylene / ⁇ -olefin copolymer measured at 190 ° C. under a load of 2.16 kg is usually 0.1 to 50 g / 10 min, preferably Is 2 to 50 g / 10 min, more preferably 10 to 50 g / 10 min, still more preferably 10 to 40 g / 10 min, particularly preferably 12 to 27 g / 10 min, and most preferably 15 to 25 g / 10 min. Minutes.
- the MFR of the ethylene / ⁇ -olefin copolymer is adjusted by adjusting the polymerization temperature, polymerization pressure, and the molar ratio of the ethylene and ⁇ -olefin monomer concentrations to the hydrogen concentration in the polymerization system, which will be described later. Can be adjusted.
- the MFR is 2 g / 10 min or more, preferably the MFR is 10 g / 10 min or more, the fluidity of the resin composition containing the ethylene / ⁇ -olefin copolymer is improved and the productivity at the time of sheet extrusion molding is improved. Can be made.
- the MFR is 50 g / 10 min or less, the molecular weight increases, and therefore, adhesion to a roll surface such as a chill roll can be suppressed. Therefore, peeling is unnecessary, and a sheet having a uniform thickness can be formed. Furthermore, since it becomes a resin composition with “koshi”, a thick sheet of 0.1 mm or more can be easily formed.
- the crosslinking characteristic at the time of laminate molding of the solar cell module is improved, it is possible to sufficiently crosslink and suppress a decrease in heat resistance.
- the MFR is 27 g / 10 min or less, the draw-down during sheet molding can be further suppressed, a wide sheet can be formed, the cross-linking characteristics and heat resistance are further improved, and the best solar cell encapsulant sheet Can be obtained.
- the MFR is 0.1 g / 10 min or more and 10 g / 10.
- a sheet can also be obtained by extrusion molding using a resin composition of less than 5 minutes, preferably 0.5 g / 10 minutes or more and less than 8.5 g / 10 minutes.
- a resin composition having an MFR of 0.1 g / 10 min or more and less than 10 g / 10 min is used. It is also possible to produce a sheet by extrusion molding at a molding temperature of 170 to 250 ° C. while performing a crosslinking treatment. When the MFR is within this range, it is preferable in that the laminating apparatus can be prevented from being soiled by the molten resin that protrudes when the sheet is laminated with the solar cell element.
- the density of the ethylene / ⁇ -olefin copolymer measured according to ASTM D1505 is 0.865 to 0.884 g / cm 3 , preferably 0.866 to 0.883 g / cm 3 , more preferably 0. .866 to 0.880 g / cm 3 , more preferably 0.867 to 0.880 g / cm 3 .
- the density of the ethylene / ⁇ -olefin copolymer can be adjusted by a balance between the content ratio of ethylene units and the content ratio of ⁇ -olefin units.
- the crystallinity is increased and a high density ethylene / ⁇ -olefin copolymer can be obtained.
- the content ratio of the ethylene unit is lowered, the crystallinity is lowered and an ethylene / ⁇ -olefin copolymer having a low density can be obtained.
- the density of the ethylene / ⁇ -olefin copolymer is 0.884 g / cm 3 or less, transparency and flexibility can be improved.
- the density of the ethylene / ⁇ -olefin copolymer is 0.865 g / cm 3 or more, it becomes easy to form a sheet, a sheet having good blocking resistance can be obtained, and heat resistance can be improved. .
- the Shore A hardness of the ethylene / ⁇ -olefin copolymer measured in accordance with ASTM D2240, is 60 to 85, preferably 62 to 83, more preferably 62 to 80, and still more preferably 65 to 80. .
- the Shore A hardness of the ethylene / ⁇ -olefin copolymer can be adjusted by controlling the content ratio and density of the ethylene unit in the ethylene / ⁇ -olefin copolymer within the numerical range described below. That is, an ethylene / ⁇ -olefin copolymer having a high ethylene unit content and a high density has a high Shore A hardness.
- an ethylene / ⁇ -olefin copolymer having a low content of ethylene units and a low density has a low Shore A hardness.
- Shore A hardness is 60 or more, a sheet that is easily formed into a sheet and has good blocking resistance can be obtained, and the heat resistance can also be improved.
- Shore A hardness is 85 or less, transparency and flexibility can be improved and sheet molding can be facilitated.
- the ethylene / ⁇ -olefin copolymer can be produced using various metallocene compounds shown below as catalysts.
- the metallocene compound for example, the metallocene compounds described in JP-A-2006-077261, JP-A-2008-231265, JP-A-2005-314680 and the like can be used.
- a metallocene compound having a structure different from the metallocene compounds described in these patent documents may be used, or two or more metallocene compounds may be used in combination.
- the polymerization of the ethylene / ⁇ -olefin copolymer can be carried out by any of the conventionally known gas phase polymerization methods and liquid phase polymerization methods such as slurry polymerization methods and solution polymerization methods. Preferably, it is carried out by a liquid phase polymerization method such as a solution polymerization method.
- ethylene / polar monomer copolymer examples include ethylene / (meth) ethyl acrylate copolymer, ethylene / (meth) methyl acrylate copolymer, ethylene / (meth) propyl propyl copolymer, ethylene / (Meth) butyl acrylate copolymer, ethylene / (meth) acrylic acid hexyl copolymer, ethylene / (meth) acrylic acid-2-hydroxyethyl copolymer, ethylene / (meth) acrylic acid-2-hydroxypropyl Copolymer, ethylene / (meth) acrylic acid glycidyl copolymer, ethylene / dimethyl maleate copolymer, ethylene / diethyl maleate copolymer, ethylene / dimethyl fumarate copolymer, ethylene / diethyl fumarate copolymer Ethylene / unsaturated carboxylic acid ester copolymer such as
- the ethylene / polar monomer copolymer is preferably an ethylene / unsaturated carboxylic acid copolymer and a salt thereof, an ethylene / vinyl ester copolymer, an ethylene / unsaturated copolymer because of its balance between availability and performance.
- the content of the polar monomer unit in the ethylene / polar monomer copolymer is preferably 8% by mass to 40% by mass, more preferably 10% by mass to 35% by mass, and still more preferably 13% by mass to 35% by mass. % Or less.
- the content of the polar monomer is within this range, the balance of crosslinkability, flexibility, weather resistance, and transparency is further improved.
- ethylene / vinyl acetate copolymer is preferable, and the content ratio of the structural unit derived from vinyl acetate is preferably 26% by mass to 40% by mass, more preferably 29% by mass to 35% by mass.
- -A vinyl acetate copolymer can be used most suitably.
- the solar cell encapsulant S may contain one or more selected from a silane coupling agent; a crosslinking agent such as a photocrosslinking initiator and an organic peroxide, in addition to the resin (P) described above.
- a silane coupling agent such as a photocrosslinking initiator and an organic peroxide
- the content of the silane coupling agent is, for example, preferably 0.1 to 5 parts by weight and more preferably 0.1 to 4 parts by weight with respect to 100 parts by weight of the resin (P).
- the content of the cross-linking agent is preferably 0.05 to 5 parts by weight, and more preferably 0.1 to 3 parts by weight with respect to 100 parts by weight of the resin (P).
- a conventionally known silane coupling agent can be used and is not particularly limited. Specifically, vinyltriethoxysilane, vinyltrimethoxysilane, vinyltris ( ⁇ -methoxyethoxysilane), ⁇ -glycidoxypropyltrimethoxysilane, ⁇ -aminopropyltriethoxysilane, ⁇ -methacryloxypropyltrimethoxysilane Etc. can be used.
- one or more selected from ⁇ -glycidoxypropylmethoxysilane, ⁇ -aminopropyltriethoxysilane, ⁇ -methacryloxypropyltrimethoxysilane, vinyltriethoxysilane, and the like, which have good adhesiveness, are mentioned. It is done.
- the organic peroxide is used as a radical initiator when graft-modifying the silane coupling agent and the resin (P), and further, when the crosslinking reaction occurs during the lamination of the solar cell module of the resin (P). Used as an agent.
- graft-modifying the resin (P) with a silane coupling agent the solar cell module 10 having good adhesion to the light-receiving surface side protection member 14, the back surface side protection member 15, the solar cell element 13, and the electrode is obtained. .
- the solar cell module 10 excellent in heat resistance and adhesiveness can be obtained by crosslinking the resin (P).
- organic peroxides can be used. Specific examples include dilauroyl peroxide, 1,1,3,3-tetramethylbutylperoxy-2-ethylhexanoate, dibenzoyl peroxide, t-amylperoxy-2-ethylhexanoate, t -Butylperoxy-2-ethylhexanoate, t-butylperoxyisobutyrate, t-butylperoxymaleic acid, 1,1-di (t-amylperoxy) -3,3,5-trimethylcyclohexane 1,1-di (t-amylperoxy) cyclohexane, t-amylperoxyisononanoate, t-amylperoxynormal octoate, 1,1-di (t-butylperoxy) -3,3, 5-trimethylcyclohexane, 1,1-di (t-butylperoxy) cyclohexane
- dilauroyl peroxide t-butyl peroxyisopropyl carbonate, t-butyl peroxyacetate, t-butyl peroxyisononanoate, t-butyl peroxy-2-ethylhexyl carbonate, t-butyl peroxybenzoate, etc.
- these can also be used individually by 1 type or in combination of 2 or more types.
- photocrosslinking initiator examples include benzophenone, benzophenone derivatives, thioxanthone, thioxanthone derivatives, benzoin, benzoin derivatives, ⁇ -hydroxyalkylphenones, ⁇ -aminoalkylphenols, acylphosphinoxides, alkylphenylgluoxy
- benzophenone, benzophenone derivatives, thioxanthone, thioxanthone derivatives benzoin, benzoin derivatives, ⁇ -hydroxyalkylphenones, ⁇ -aminoalkylphenols, acylphosphinoxides, alkylphenylgluoxy
- acylphosphinoxides alkylphenylgluoxy
- benzophenone, benzophenone derivatives, benzoin, benzoin derivatives, ⁇ -hydroxyalkylphenones, oxime esters, and anthraquinone derivatives are preferable in terms of better crosslinkability, benzophenone, benzophenone derivatives, and anthraquinone derivatives are more preferable, benzophenone, A benzophenone derivative is most preferable because of good transparency.
- 2-hydroxybenzophenone is used as an ultraviolet absorber as will be described later, and has a function of converting light into heat energy.
- the photocrosslinking initiator of this embodiment is preferably a benzophenone derivative that does not have a hydroxyl group at the 2-position.
- benzophenone and benzophenone derivatives include benzophenone, 4-phenylbenzophenone, 4-phenoxybenzophenone, 4,4-bis (diethylamino) benzophenone, methyl o-benzoylbenzoate, 4-methylbenzophenone, 2,4,6-trimethyl Examples include benzophenone.
- Preferred examples of the anthraquinone derivative include 2-methylanthraquinone, 2-ethylanthraquinone, 2-t-butylanthraquinone, 1-chloroanthraquinone and the like. These photocrosslinking initiators can be used singly or in combination of two or more.
- the solar cell encapsulant S preferably contains at least one additive selected from the group consisting of ultraviolet absorbers, light stabilizers, and heat stabilizers.
- the amount of these additives is preferably 0.005 to 5 parts by weight per 100 parts by weight of the resin (P).
- the blending amount of the additive is within the above range, the effect of improving resistance to high temperature and humidity, heat cycle resistance, weather resistance stability, and heat resistance stability is sufficiently ensured, and a solar cell sealing material It is preferable because the transparency of S and the decrease in adhesion with the light-receiving surface side protection member 14, the back surface side protection member 15, the solar cell element 13, the electrode, and aluminum can be prevented.
- the ultraviolet absorber examples include 2-hydroxy-4-normal-octyloxybenzophenone, 2-hydroxy-4methoxybenzophenone, 2,2-dihydroxy-4-methoxybenzophenone, 2-hydroxy-4-methoxy- Benzophenone ultraviolet absorbers such as 4-carboxybenzophenone and 2-hydroxy-4-N-octoxybenzophenone; 2- (2-hydroxy-3,5-di-t-butylphenyl) benzotriazole, 2- (2- Benzotrialisol ultraviolet absorbers such as hydroxy-5-methylphenyl) benzotriazole; salicylic acid ester ultraviolet absorbers such as phenylsalicylate and p-octylphenylsalicylate are used. These ultraviolet absorbers can be used singly or in combination of two or more.
- Examples of the light stabilizer include bis (2,2,6,6-tetramethyl-4-piperidyl) sebacate, poly [ ⁇ 6- (1,1,3,3-tetramethylbutyl) amino-1,3, 5-triazine-2,4-diyl ⁇ ⁇ (2,2,6,6-tetramethyl-4-piperidyl) imino ⁇ hexamethylene ⁇ (2,2,6,6-tetramethyl-4-piperidyl) imino ⁇ And the like are preferably used, such as hindered amine-based and hindered piperidine-based compounds. These light stabilizers can be used alone or in combination of two or more.
- heat-resistant stabilizers include tris (2,4-di-tert-butylphenyl) phosphite, bis [2,4-bis (1,1-dimethylethyl) -6-methylphenyl] ethyl ester.
- Phosphorous acid tetrakis (2,4-di-tert-butylphenyl) [1,1-biphenyl] -4,4′-diylbisphosphonite, and bis (2,4-di-tert-butylphenyl) Phosphite heat stabilizers such as pentaerythritol diphosphite; lactone heat stabilizers such as the reaction product of 3-hydroxy-5,7-di-tert-butyl-furan-2-one and o-xylene; 3,3 ′, 3 ′′, 5,5 ′, 5 ′′ -hexa-tert-butyl-a, a ′, a ′′-(methylene-2,4,6-triyl) tri-p-cresol, 1,3 , 5-Trimethyl- 2,4,6-tris (3,5-di-tert-butyl-4-hydroxyphenyl) benzylbenzene, pentaerythritol tetra
- various components other than the components described in detail above can be appropriately contained as long as the object of the present invention is not impaired.
- various resins other than the resin (P) and / or various rubbers, plasticizers, lubricating oils, fillers, pigments, dyes, antistatic agents, antibacterial agents, antifungal agents, flame retardants, crosslinking aids, and dispersions One or more additives selected from agents and the like can be appropriately contained.
- the amount of the crosslinking aid is 0.05 to 5 parts by weight with respect to 100 parts by weight of the resin (P). It is preferable because it can improve heat resistance, mechanical properties, and adhesiveness.
- crosslinking aid As the crosslinking aid, conventionally known ones generally used for the resin (P) can be used. Such a crosslinking aid is a compound having two or more double bonds in the molecule. Specifically, monoacrylates such as t-butyl acrylate, lauryl acrylate, cetyl acrylate, stearyl acrylate, 2-methoxyethyl acrylate, ethyl carbitol acrylate, methoxytripropylene glycol acrylate; t-butyl methacrylate, lauryl methacrylate, cetyl methacrylate Monomethacrylate such as stearyl methacrylate, methoxyethylene glycol methacrylate, methoxypolyethylene glycol methacrylate; 1,4-butanediol diacrylate, 1,6-hexanediol diacrylate, 1,9-nonanediol diacrylate, neopentyl glycol diacrylate , Diethylene glyco
- a diallyl compound such as diallyl phthalate; a triallyl compound; an oxime such as p-quinonedioxime and pp′-dibenzoylquinonedioxime; and a maleimide such as phenylmaleimide.
- triacrylates such as diacrylate, dimethacrylate, divinyl aromatic compound, trimethylolpropane triacrylate, tetramethylolmethane triacrylate, pentaerythritol triacrylate; trimethylolpropane trimethacrylate , Trimethacrylates such as trimethylolethane trimethacrylate; tetraacrylates such as pentaerythritol tetraacrylate and tetramethylolmethane tetraacrylate; cyanurates such as triallyl cyanurate and triallyl isocyanurate; diallyl compounds such as diallyl phthalate; triallyl compound: p -Oximes such as quinonedioxime and pp'-dibenzoylquinonedioxime; males such as phenylmaleimide It is a mid. Further, among these, triallyl isocyanurate is particularly prefer
- the sheet surface may be embossed.
- embossing reduces the storage elastic modulus of the solar cell sealing material S, the solar cell element 13 becomes a cushion for the solar cell element 13 and the like when the solar cell sealing material S and the solar cell element 13 are laminated. Can be further prevented.
- the light-receiving surface side protective member 14 is not particularly limited, but is positioned on the outermost layer of the solar cell module, and therefore, long-term reliability in outdoor exposure of the solar cell module including weather resistance, water repellency, contamination resistance, mechanical strength, and the like. It is preferable to have performance for ensuring the property. Moreover, in order to utilize sunlight effectively, it is preferable that it is a highly transparent sheet
- the light receiving surface side protection member 14 include a glass plate and a resin film.
- the resin constituting the resin film include polyester resin, fluororesin, acrylic resin, cyclic olefin (co) polymer, and ethylene-vinyl acetate copolymer.
- the light-receiving surface side protection member 14 has a plurality of fine concave portions 14A and a plurality of fine convex portions 14B on at least the solar cell element 13 side surface. Thereby, the adhesiveness of the light-receiving surface side protection member 14 and the light-receiving surface side sealing layer 11A can be improved. In addition, the reflectance can be reduced by scattering light, and an antiglare effect can be imparted to the solar cell module.
- the plurality of fine concave portions 14A and the plurality of fine convex portions 14B can be formed using a conventionally known method.
- a method of directly imparting irregularities to the surface of the light-receiving surface side protective member 14 using a physical method or a chemical method a method of forming an irregular reflection layer having an irregular surface on the surface of the light-receiving surface side protective member 14, etc.
- Examples of the method of directly imparting irregularities to the surface of the light-receiving surface side protection member 14 using a physical method or a chemical method include embossing, pressing, and laser patterning.
- a method for forming the irregular reflection layer having an uneven surface on the surface of the light receiving surface side protection member 14 for example, a method of applying a composition containing an organic binder and inorganic particles on the surface of the light receiving surface side protection member 14 Alternatively, a method of transferring a composition containing an organic binder and inorganic particles on the surface of another base material onto the surface of the light-receiving surface side protective member 14 may be used.
- a method of forming a plurality of fine concave portions 14A and a plurality of fine convex portions 14B by embossing the surface is preferable.
- Basis weight thickness Z 1 of the light-receiving surface side protection member 14 is preferably 1mm or more 5mm or less, and more preferably 2mm or more 4mm or less.
- the depth (Z) of the recess 14A of the light-receiving surface side protection member 14 is preferably 0.02 mm to 0.5 mm, and more preferably 0.04 mm to 0.1 mm.
- the back surface side protection member 15 does not need to be transparent and is not particularly limited. However, since the back surface side protection member 15 is located on the outermost layer of the solar cell module 10, the weather resistance, mechanical strength, etc. Various characteristics are required. Therefore, the back surface side protection member 15 may be made of the same material as the light receiving surface side protection member 14. That is, the above-described various materials used as the light receiving surface side protection member 14 can also be used as the back surface side protection member 15. In particular, a polyester resin and glass can be preferably used. Moreover, since the back surface side protection member 15 does not presuppose passage of sunlight, the transparency calculated
- a reinforcing plate may be attached to increase the mechanical strength of the solar cell module 10 or to prevent distortion and warpage due to temperature change.
- a reinforcing plate for example, a steel plate, a plastic plate, an FRP (glass fiber reinforced plastic) plate or the like can be preferably used.
- the solar cell element 13 used in the solar cell module 10 is not particularly limited as long as it can generate power using the photovoltaic effect of the semiconductor.
- FIG. 1 shows an example in which a crystalline solar cell element is used as the solar cell element 13, but a compound semiconductor (III-III group, II-VI group, etc.) solar cell element, wet solar cell element, organic semiconductor A solar cell element or the like can also be used.
- Crystalline solar cell elements are formed of single crystal, polycrystal, amorphous (amorphous) silicon, etc. Among these, polycrystal is used from the viewpoint of balance between power generation performance and cost. Those formed of shaped silicon are more preferred.
- the average thickness of the solar cell element 13 (excluding the thickness of the current collecting electrode) is usually 0.3 mm or more and 0.5 mm or less. However, from the viewpoint of cost reduction and thinning, the thickness of the solar cell element 13 is preferably 0.01 mm or more and 0.5 mm or less, and more preferably 0.01 mm or more and 0.3 mm or less. In the solar cell module 10 of this embodiment, even if the thickness of the solar cell element 13 is thin as described above, the solar cell element 13 can be prevented from being damaged. In addition, the average thickness of the solar cell element 13 can be measured from a photograph of a cross section of the solar cell element 13 taken with a scanning electron microscope or the like.
- the solar cell element is usually provided with a collecting electrode for taking out the generated electricity.
- Examples of current collecting electrodes include bus bar electrodes, finger electrodes, and the like.
- the current collecting electrode has a structure in which the current collecting electrode is disposed on both the front surface and the back surface of the solar cell element.
- the current collecting electrode is disposed on the light receiving surface, it is required to dispose the power collecting efficiency as much as possible.
- FIG. 2 is a plan view schematically showing one configuration example of the light receiving surface and the back surface of the solar cell element 13.
- FIG. 2 an example of the configuration of the light receiving surface 22A and the back surface 22B of the solar cell element 13 is shown.
- the bus bar electrode 34A Connected to the bus bar electrode 34A.
- a conductive layer (back electrode) 36 is formed on the entire back surface 22B of the solar cell element 22, and charges are collected from the conductive layer 36 on the back surface 22B.
- a bus bar electrode 34B connected to the connector 16 (FIG. 1) is formed.
- the line width of the finger electrode 32 is, for example, about 0.2 mm; the line width of the bus bar electrode 34A is, for example, about 2 to 3 mm; and the line width of the bus bar electrode 34B is, for example, about 5 to 7 mm.
- the average thickness (Y) of the bus bar electrode is not particularly limited, but is preferably 0.02 mm to 0.6 mm, and more preferably 0.04 mm to 0.5 mm.
- the average thickness (Y) of the bus bar electrode is not less than the above lower limit value, the generated electricity can be collected more efficiently.
- the average thickness (Y) of the bus bar electrodes is not more than the above upper limit value, a solar cell module having a thinner thickness can be obtained.
- the average thickness of the finger electrode is not particularly limited, but is preferably 0.01 mm or more and 0.1 mm or less, more preferably 0.02 mm or more and 0.07 mm or less.
- the average thickness of the finger electrodes is not less than the above lower limit value, the generated electricity can be collected more efficiently.
- the average thickness of the finger electrodes is not more than the above upper limit value, a thinner solar cell module can be obtained.
- the average thickness (Y) of the bus bar electrode when the average thickness (Y) of the bus bar electrode is different between the light receiving surface 22A and the back surface 22B of the solar cell element 13, light is received using the average thickness (Y) of the bus bar electrode on the light receiving surface 22A side.
- the effective thickness of the surface side sealing layer 11A is determined. Thereby, damage to the solar cell element 13 can be suppressed more reliably.
- the interconnector 16 is made of, for example, copper foil. Although the average thickness of the interconnector 16 is not specifically limited, For example, it is 0.15 mm or more and 1.0 mm or less. Further, the width of the interconnector 16 may be approximately the same as that of the bus bar electrode.
- the finger electrode 32, the bus bar electrode 34A, and the bus bar electrode 34B preferably include a metal having high conductivity.
- highly conductive metals include gold, silver, and copper.
- Silver, a silver compound, an alloy containing silver, and the like are preferable from the viewpoint of high conductivity and corrosion resistance.
- the conductive layer 36 contains not only a highly conductive metal but also a highly light reflective component such as aluminum from the viewpoint of reflecting the light received by the light receiving surface and improving the photoelectric conversion efficiency of the solar cell element. It is preferable.
- the conductive material paint containing the above highly conductive metal is applied to the light receiving surface 22A or the back surface 22B of the solar cell element 22 by, for example, screen printing. Then, it is formed by drying and baking as necessary.
- the manufacturing method of the solar cell module 10 is (i) the light-receiving surface side protection member 14, the first solar cell sealing material S1, the solar cell element 13, the second solar cell sealing material S2, and the back surface side protection member. 15 are stacked in this order to form a stacked body, and (ii) the obtained stacked body is subjected to pressurization and heating or light irradiation to be integrated.
- step (i) when the solar cell encapsulating material S is embossed, it is preferable to arrange the surface on which the uneven shape (embossed shape) is formed on the solar cell element 13 side.
- step (ii) the laminate obtained in step (i) is integrated (sealed) by heating and pressurizing using a vacuum laminator or a hot press according to a conventional method.
- the laminated body obtained in the step (i) is photocrosslinked by irradiating light such as ultraviolet rays and integrated (sealed).
- the solar cell sealing material S has high cushioning properties, damage to the solar cell element can be prevented.
- the deaeration property is good, there is no air entrainment, and a high-quality product can be manufactured with a high yield.
- the elastic modulus of the solar cell sealing material constituting the light-receiving surface side sealing layer was measured as follows. A 1-mm thick solar cell encapsulating sheet having the same composition as the solar cell encapsulating sheets of Examples and Comparative Examples was prepared. Then, the elastic modulus of the sheet was measured according to JIS K7161 using an autograph (manufactured by Shimadzu Corporation: AGS-J) under the conditions of the chuck interval: 40 mm and the tensile speed: 1 mm / min. The temperature of the measurement environment was 23 ° C. and 50% Rh.
- Example 1 Production of solar cell encapsulating sheet Ethylene / ⁇ -olefin copolymer 1 ( ⁇ -olefin: 1-butene, content ratio of ⁇ -olefin units: in the same manner as in Synthesis Example 1 of WO 2012/060086: 14 mol%, ethylene unit content: 86 mol%, Shore A hardness: 70, MFR: 4.0 g / 10 min, density: 0.870 g / cm 3 ).
- the elastic modulus at 23 ° C. of the obtained solar cell encapsulating sheet was 10 MPa.
- the average thickness of the said solar cell sealing sheet was 0.60 mm.
- each member used in the solar cell module is as follows.
- white plate float glass (3.2 mm thick heat-treated glass with embossing) manufactured by Asahi Glass Fabricate Co., Ltd. was used.
- the depth (Z) of the concave portion of the light receiving surface side protection member was 0.05 mm.
- As the solar cell element a cell having a bus bar silver electrode having a thickness of 0.35 mm (single crystal cell, 5 cm ⁇ 3 cm, manufactured by Shinsung Solar Co., Ltd.) in the center on the light receiving surface side was connected in series.
- each cell was connected in series using a copper ribbon electrode.
- the copper ribbon electrode is a copper foil whose surface is coated with eutectic solder.
- a silica-deposited PET back sheet was used as the back side protective member.
- the solar cell back surface sealing material the same solar cell sealing sheet as the light receiving surface was used.
- the solar cell module was produced by the following procedure. First, the obtained solar cell sealing sheet is set between the light-receiving surface side protective member and the solar cell element, and the solar cell back surface sealing material is set between the solar cell element and the back surface side protective member, and laminated. Got the body. Next, a cut of about 2 cm was made in a part of the back surface side protection member, and the positive terminal and the negative terminal of the solar cell element were taken out.
- the obtained laminate was vacuum laminated using a vacuum laminator (manufactured by NPC: LM-110 ⁇ 160-S) at a hot plate temperature of 150 ° C., a vacuum time of 3 minutes, and a pressurization time of 15 minutes.
- the layer formed of the solar cell sealing sheet is the light-receiving surface side sealing layer.
- the average thickness of the light-receiving surface side sealing layer was 0.60 mm.
- the light-receiving surface side sealing layer and the back surface-side protection member that protruded from the light-receiving surface-side protection member were cut, an end surface sealing sheet was applied to the end of the light-receiving surface-side protection member, and an aluminum frame was attached.
- the notch portion of the terminal portion taken out from the back surface side protective member was cured by applying RTV silicone.
- the solar cell module was obtained by the above method.
- the average thickness of the light-receiving surface side sealing layer formed by the solar cell sealing sheet was 0.60 mm.
- the obtained solar cell module was put into a temperature cycle tester (manufactured by ESPEC Co., Ltd., PSL-2J), and a temperature cycle test was performed 200 cycles in accordance with JIS C8917.
- a temperature cycle tester manufactured by ESPEC Co., Ltd., PSL-2J
- a temperature cycle test was performed 200 cycles in accordance with JIS C8917.
- AM air mass
- PVS-116i-S manufactured by Nisshinbo Mechatronics was used for the IV evaluation.
- the evaluation results were classified as follows. The results are shown in Table 1.
- the output maintenance rate means 100 ⁇ (output of solar cell module after 200 cycles of temperature cycle test) / (output of solar cell module before temperature cycle test).
- Output maintenance rate is 95% or more: ⁇
- Output maintenance ratio is 90% or more and less than 95%:
- Output maintenance rate is less than 90%: ⁇
- Example 1 Comparative Example 1 and Reference Example 1
- a solar cell module was prepared in the same manner as in Example 1 except that the average thickness of the solar cell sealing sheet was changed and the average thickness (X) of the light-receiving surface side sealing layer was changed to the value shown in Table 1.
- the output retention rate was measured. The results are shown in Table 1.
- Example 4 Instead of ethylene / ⁇ -olefin copolymer 1, ethylene / ⁇ -olefin copolymer 1 ( ⁇ -olefin: 1-butene, ⁇ -olefin unit content: 14 mol%, ethylene unit content: 86 mol% , Shore A hardness: 70, MFR: 4.0 g / 10 min, density: 0.870 g / cm 3 ) 80 parts by mass of Lucant HC-40 manufactured by Mitsui Chemicals, Ltd., which is a lubricant for adjusting the elastic modulus
- a solar cell encapsulating sheet was produced in the same manner as in Example 2 except that 20 parts by mass was added.
- the elastic modulus at 23 ° C. of the obtained solar cell encapsulating sheet was 6 MPa.
- the solar cell module was produced like Example 1, and the output maintenance factor was measured. The results are shown in Table 1.
- Example 5 Instead of the ethylene / ⁇ -olefin copolymer 1, an ethylene / ⁇ -olefin copolymer 2 ( ⁇ -olefin: 1-octene, ⁇ ) synthesized in the same manner as in Synthesis Example 3 of International Publication No. 2012/046456 -Content of olefin unit: 11 mol%, content of ethylene unit: 89 mol%, Shore A hardness: 84, MFR: 48 g / 10 min, density: 0.884 g / cm 3 ) Similarly, a solar cell encapsulating sheet was produced. The elastic modulus at 23 ° C. of the obtained solar cell encapsulating sheet was 28 MPa. And the solar cell module was produced like Example 1, and the output maintenance factor was measured. The results are shown in Table 1.
- the density D 1 of the light-receiving surface side sealing layer was measured according to ASTM D1505.
- the average thickness (Y) of the bus bar electrode and the average thickness of the semiconductor element were calculated from photographs taken with a scanning electron microscope. Specifically, a cross section of the bus bar electrode and the semiconductor element was photographed, and 10 arbitrary portions were selected from the obtained photographs, and the thicknesses of the bus bar electrode and the semiconductor element at those portions were measured, respectively. Then, the total thickness of all bus bar electrodes divided by 10 is defined as the average bus bar electrode thickness (Y), and the total thickness of all semiconductor elements divided by 10 is the average thickness of the semiconductor elements. Say it.
- the weight per unit area is determined by using the weight W 2 (g / 100 cm 2 ) of the light-receiving surface side protection member cut to a size of 10 cm ⁇ 10 cm and the density D 2 (g / cm 3 ) of the light-receiving surface side protection member.
- Z 1 W 2 / (D 2 ⁇ 10) was calculated.
- the apparent thickness Z 2 [mm] of the light-receiving surface side protection member was measured at the convex portion using a dial gauge (MODEL H manufactured by Peacock).
- the density D 1 of the light-receiving surface side protective member was measured in accordance with ASTM D1505.
- each of the solar cell modules of Examples 1 to 5 had an output retention rate of 95% or more, and it was confirmed that the output decrease of the solar cell module was suppressed.
- the solar cell modules of Comparative Examples 1 to 3 each had an output retention rate of less than 90%, and it was confirmed that the output of the solar cell module was significantly reduced. Further, even when compared with the solar cell module of the reference example having an effective thickness of 0.30 mm, it can be seen that the solar cell modules of Examples 1 to 5 have a sufficient output reduction preventing function. That is, in Examples 1 to 5, it was confirmed that a decrease in output was suppressed and a solar cell module with a thin sealing layer was realized.
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Abstract
Description
しかしながら、本発明者らの検討によれば、従来の太陽電池モジュールでは、太陽電池封止材の厚さを薄くすると、太陽電池モジュールの作製時や、温度変化が大きい環境下で繰り返し使用した際に、応力によって太陽電池素子や配線に破損が起き、太陽電池モジュールの出力低下が起こりやすくなることが明らかになった。
受光面側保護部材と、裏面側保護部材と、太陽電池素子と、上記受光面側保護部材と上記裏面側保護部材との間に上記太陽電池素子を封止する封止層と、を備える太陽電池モジュールであって、
上記受光面側保護部材は少なくとも上記太陽電池素子側表面に複数の微細な凹部および複数の微細な凸部を有し、
上記太陽電池素子には少なくとも受光面側表面にバスバー電極が設けられており、
上記封止層が上記受光面側保護部材と上記太陽電池素子との間に設けられた受光面側封止層と、上記裏面側保護部材と上記太陽電池素子との間に設けられた裏面側封止層と、を有し、上記受光面側封止層と上記裏面側封止層との間に上記太陽電池素子が封止されており、
上記受光面側封止層はポリオレフィン系樹脂およびエチレン・極性モノマー共重合体から選択される少なくとも一種の樹脂を含み、
上記受光面側封止層を構成する太陽電池封止材の23℃における弾性率が5MPa以上30MPa以下であり、
上記受光面側封止層の平均厚さをX[mm]とし、受光面側の上記バスバー電極の平均厚さをY[mm]とし、上記凹部の深さをZ[mm]としたとき、
(X-Y-Z)で表される上記受光面側封止層の実効厚みが0.01mm以上0.25mm未満である太陽電池モジュール。
[2]
上記[1]に記載の太陽電池モジュールにおいて、
上記バスバー電極の平均厚さ(Y)が0.02mm以上0.6mm以下である太陽電池モジュール。
[3]
上記[1]または[2]に記載の太陽電池モジュールにおいて、
上記凹部の深さ(Z)が0.02mm以上0.5mm以下である太陽電池モジュール。
[4]
上記[1]乃至[3]のいずれか一つに記載の太陽電池モジュールにおいて、
上記受光面側封止層に含まれる上記樹脂がエチレン・α-オレフィン共重合体を含む太陽電池モジュール。
[5]
上記[1]乃至[4]のいずれか一つに記載の太陽電池モジュールにおいて、
上記太陽電池素子の平均厚さが0.01mm以上0.5mm以下である太陽電池モジュール。
[6]
上記[1]乃至[5]のいずれか一つに記載の太陽電池モジュールにおいて、
上記受光面側封止層の平均厚さ(X)が0.60mm以下である太陽電池モジュール。
[7]
上記[1]乃至[6]のいずれか一つに記載の太陽電池モジュールにおいて、
上記受光面側封止層を構成する上記太陽電池封止材は潤滑油をさらに含む太陽電池モジュール。
受光面側保護部材14は少なくとも太陽電池素子13側表面に複数の微細な凹部14Aおよび複数の微細な凸部14Bを有し、太陽電池素子13には少なくとも受光面側表面にバスバー電極17が設けられている。封止層11は受光面側保護部材14と太陽電池素子13との間に設けられた受光面側封止層11Aと、裏面側保護部材15と太陽電池素子13との間に設けられた裏面側封止層11Bと、を有し、受光面側封止層11Aと裏面側封止層11Bとの間に太陽電池素子13が封止されている。受光面側封止層11Aはポリオレフィン系樹脂およびエチレン・極性モノマー共重合体から選択される少なくとも一種の樹脂(以下、樹脂(P)とも呼ぶ。)を含む。
受光面側封止層11Aを構成する太陽電池封止材の23℃における弾性率が5MPa以上30MPa以下であり、好ましくは6MPa以上28MPa以下であり、さらに好ましくは6MPa以上25MPa以下、特に好ましくは8MPa以上15MPa以下である。
受光面側封止層11Aの平均厚さをX[mm]とし、受光面側のバスバー電極17の平均厚さをY[mm]とし、凹部14Aの深さをZ[mm]としたとき、(X-Y-Z)で表される受光面側封止層11Aの実効厚みの下限が0.01mm以上、好ましくは0.02mm以上、より好ましくは0.05mm以上、さらに好ましくは0.07mm以上、特に好ましくは0.08mm以上である。また、(X-Y-Z)で表される受光面側封止層11Aの実効厚みの上限が0.25mm未満、好ましくは0.20mm以下、より好ましくは0.20mm未満、さらに好ましくは0.18mm以下、特に好ましくは0.15mm以下である。
また、受光面側封止層11Aの実効厚みを上記上限値未満または以下とすることにより、封止層の薄膜化を実現でき、その結果、温度サイクル後も出力を維持しつつ厚みがより薄い太陽電池モジュールを得ることができる。
太陽電池封止材の23℃における弾性率を上記範囲とするには、例えば、樹脂(P)がエチレン・α-オレフィン共重合体の場合、α-オレフィンに由来する構成単位の含有割合やα-オレフィンの炭素数を調整することにより弾性率を上記範囲に調整することができる。樹脂(P)がエチレン・極性モノマー共重合体の場合、極性モノマーに由来する構成単位の含有割合や極性モノマーの種類を調整することにより弾性率を上記範囲に調整することができる。
潤滑油は、従来公知の潤滑油を用いることができる。潤滑油としては、例えば、パラフィン系オイル、炭化水素系合成油等が挙げられる。
パラフィン系オイルとしては、例えば、パラフィン系プロセスオイル(例えば、ダイアナプロセスオイル(登録商標)(出光興産社製))、流動パラフィン(例えば、モレスコホワイト(登録商標)(MORESCO社製))等が挙げられる。
上記炭化水素系合成油としては、例えば、エチレン・α-オレフィンコオリゴマー(例えば、三井化学社製のルーカント(登録商標))、ポリ-α-オレフィン(例えば、エクソンモービル社製のSpectraSyn(登録商標))等が挙げられる。
これらの中でも、パラフィン系オイルが好ましく、パラフィン系プロセスオイルがより好ましい。
まず受光面側保護部材14を10cm×10cmの大きさにカットしたものの重量W2(g/100cm2)と、受光面側保護部材14の密度D2(g/cm3)とを用いて、受光面側保護部材14の目付け厚さZ1=W2/(D2×10)を算出する。
次に、受光面側保護部材14の見掛け厚さZ2[mm]を、ダイヤルゲージ等の膜厚計を用いて凸部14Bで測定する。ここで、受光面側保護部材14の見掛け厚さZ2は、受光面側保護部材14の凸部14Bでの厚みであり、例えば、10点測定し、その平均値とすることができる。
そして、凹部14Aの深さ(Z)は、Z=Z2-Z1により算出することができる。
ここで、裏面側封止層11Bの実効厚みは、受光面側封止層11Aの実効厚みと同様の手順で測定することができる。すなわち、裏面側封止層11Bの平均厚さをA[mm]とし、裏面側のバスバー電極17の平均厚さをB[mm]とし、裏面側保護部材15が太陽電池素子13側表面に複数の微細な凹部および複数の微細な凸部を有する場合はその凹部の深さをC[mm]としたとき、裏面側封止層11Bの実効厚みは(A-B-C)で表される。各平均厚さは、受光面側封止層11Aの実効厚みの測定と同様の方法で測定できる。
また、本実施形態における裏面側封止層11B(第二太陽電池封止材S2)中の上記樹脂(P)の含有量は、裏面側封止層11B(第二太陽電池封止材S2)全体を100質量%としたとき、好ましくは50質量%以上、より好ましくは70質量%以上、さらに好ましくは80質量%以上、特に好ましくは90質量%以上である。これにより、接着性、耐熱性、柔軟性、架橋特性等の諸特性のバランスにより優れた裏面側封止層11Bを得ることができる。
a2)ASTM D1238に準拠し、190℃、2.16kg荷重の条件で測定されるMFRが0.1~50g/10分である。
a3)ASTM D1505に準拠して測定される密度が0.865~0.884g/cm3である。
a4)ASTM D2240に準拠して測定されるショアA硬度が60~85である。
エチレン・α-オレフィン共重合体に含まれる、炭素数3~20のα-オレフィンに由来する構成単位(以下、「α-オレフィン単位」とも記す)の割合は、好ましくは10~20mol%であり、より好ましくは12~20mol%、さらに好ましくは12~18mol%、特に好ましくは13~18mol%である。α-オレフィン単位の含有割合を10mol%以上にすることで、高透明性の封止層11が得られる傾向にある。また、柔軟性が高いため、太陽電池素子13の割れや、薄膜電極のカケ等の発生をより一層抑制することができる。一方、α-オレフィン単位の含有割合が20mol%以下であると、シート化しやすく耐ブロッキング性が良好なシートを得ることができ、また、架橋させることで耐熱性を向上させることができる。
ASTM D1238に準拠し、190℃、2.16kg荷重の条件で測定されるエチレン・α-オレフィン共重合体のメルトフローレ-ト(MFR)は、通常0.1~50g/10分であり、好ましくは2~50g/10分であり、より好ましくは10~50g/10分であり、さらに好ましくは10~40g/10分、特に好ましくは12~27g/10分、最も好ましくは15~25g/10分である。エチレン・α-オレフィン共重合体のMFRは、後述する重合反応の際の重合温度、重合圧力、並びに重合系内のエチレンおよびα-オレフィンのモノマー濃度と水素濃度のモル比率等を調整することにより、調整することができる。
MFRが0.1g/10分以上10g/10分未満であると、カレンダー成形によってシートを製造することができる。MFRが0.1g/10分以上10g/10分未満であると、エチレン・α-オレフィン共重合体を含む樹脂組成物の流動性が低いため、シートを電池素子とラミネートする際にはみ出した溶融樹脂によるラミネート装置の汚れを防止できる点で好ましい。
MFRが2g/10分以上、好ましくはMFRが10g/10分以上であると、エチレン・α-オレフィン共重合体を含む樹脂組成物の流動性が向上し、シート押出成形時の生産性を向上させることができる。
MFRが50g/10分以下であると、分子量が大きくなるため、チルロール等のロール面への付着を抑制できるため、剥離を不要とし、均一な厚みのシートに成形することができる。さらに、「コシ」がある樹脂組成物となるため、0.1mm以上の厚いシートを容易に成形することができる。また、太陽電池モジュールのラミネート成形時の架橋特性が向上するため、十分に架橋させて、耐熱性の低下を抑制することができる。
MFRが27g/10分以下であると、さらに、シート成形時のドローダウンを抑制でき幅の広いシートを成形でき、また架橋特性および耐熱性がさらに向上し、最も良好な太陽電池封止材シートを得ることができる。
なお後述する太陽電池モジュールのラミネート工程において樹脂組成物の架橋処理を行わない場合は、溶融押出工程において有機過酸化物の分解の影響が小さいため、MFRが0.1g/10分以上10g/10分未満、好ましくは0.5g/10分以上8.5g/10分未満の樹脂組成物を用い、押出成形によってシートを得ることもできる。樹脂組成物の有機過酸化物含有量が0.15重量部以下である場合には、MFRが0.1g/10分以上10g/10分未満の樹脂組成物を用い、シラン変性処理、または微架橋処理を行いつつ170~250℃の成形温度で押出成形によってシートを製造することもできる。MFRがこの範囲にあるとシートを太陽電池素子とラミネートする際にはみ出した溶融樹脂によるラミネート装置の汚れを防止できる点で好ましい。
ASTM D1505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0.865~0.884g/cm3であり、好ましくは0.866~0.883g/cm3、より好ましくは0.866~0.880g/cm3、さらに好ましくは0.867~0.880g/cm3である。エチレン・α-オレフィン共重合体の密度は、エチレン単位の含有割合とα-オレフィン単位の含有割合とのバランスにより調整することができる。すなわち、エチレン単位の含有割合を高くすると結晶性が高くなり、密度の高いエチレン・α-オレフィン共重合体を得ることができる。一方、エチレン単位の含有割合を低くすると結晶性が低くなり、密度の低いエチレン・α-オレフィン共重合体を得ることができる。エチレン・α-オレフィン共重合体の密度が0.884g/cm3以下であると、透明性及び柔軟性を向上させることができる。一方、エチレン・α-オレフィン共重合体の密度が0.865g/cm3以上であると、シート化しやすくなり、耐ブロッキング性が良好なシートが得られ、また、耐熱性を向上させることができる。
ASTM D2240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ショアA硬度は60~85であり、好ましくは62~83、より好ましくは62~80、さらに好ましくは65~80である。エチレン・α-オレフィン共重合体のショアA硬度は、エチレン・α-オレフィン共重合体のエチレン単位の含有割合や密度を後述の数値範囲に制御することにより、調整することができる。すなわち、エチレン単位の含有割合が高く、密度が高いエチレン・α-オレフィン共重合体は、ショアA硬度が高くなる。一方、エチレン単位の含有割合が低く、密度が低いエチレン・α-オレフィン共重合体は、ショアA硬度が低くなる。ショアA硬度が60以上であると、シート化しやすく耐ブロッキング性が良好なシートが得られ、さらに耐熱性も向上させることができる。一方、ショアA硬度が85以下であると、透明性及び柔軟性を向上させるとともに、シート成形を容易にすることができる。
これらの中でもエチレン・酢酸ビニル共重合体が好ましく、酢酸ビニルに由来する構成単位の含有割合が、好ましくは26質量%以上40質量%以下、より好ましくは29質量%以上35質量%以下であるエチレン・酢酸ビニル共重合体を最も好適に用いることができる。
シランカップリング剤の含有量は、例えば、樹脂(P)100重量部に対して0.1~5重量部とすることが好ましく、0.1~4重量部とすることがより好ましい。
架橋剤の含有量は、例えば、樹脂(P)100重量部に対して0.05~5重量部とすることが好ましく、0.1~3重量部にすることがより好ましい。
ベンゾフェノン誘導体の中でも2―ヒドロキシベンゾフェノンは、後述するように紫外線吸収剤として用いられ、光を熱エネルギーに変換する作用を有する。本実施形態の光架橋開始剤は、2位に水酸基を有しないベンゾフェノン誘導体が望ましい。
ベンゾフェノンおよびベンゾフェノン誘導体の好ましい例として、ベンゾフェノン、4-フェニルベンゾフェノン、4-フェノキシベンゾフェノン、4,4-ビス(ジエチルアミノ)ベンゾフェノン、o-ベンゾイル安息香酸メチル、4-メチルベンゾフェノン、2,4,6-トリメチルベンゾフェノン等を挙げることができる。
アントラキノン誘導体の好ましい例として、2-メチルアントラキノン、2-エチルアントラキノン、2-t-ブチルアントラキノン、1-クロロアントラキノン等を挙げることができる。
これらの光架橋開始剤は一種単独で又は二種以上を組み合わせて用いることもできる。
樹脂フィルムを構成する樹脂としては、ポリエステル樹脂、フッ素樹脂、アクリル樹脂、環状オレフィン(共)重合体、エチレン-酢酸ビニル共重合等が挙げられる。
受光面側保護部材14の表面に物理的方法または化学的方法を用いて凹凸を直接付与する方法としては、エンボス加工、プレス加工、レーザパターニング加工等が挙げられる。
受光面側保護部材14の表面上に凹凸面を備えた乱反射層を形成する方法としては、例えば、有機バインダと無機粒子とを含む組成物を受光面側保護部材14の表面上に塗布する方法、または、有機バインダと無機粒子とを含む組成物を他の基材の表面上に塗布したものを受光面側保護部材14の表面上に転写する方法等が挙げられる。
これらの中でも受光面側保護部材14の表面に所望の形状を有する複数の微細な凹部14Aおよび複数の微細な凸部14Bを容易に形成することが可能なことから、受光面側保護部材14の表面をエンボス加工することにより複数の微細な凹部14Aおよび複数の微細な凸部14Bを形成する方法が好ましい。
なお、太陽電池素子13の平均厚さは、太陽電池素子13の断面を走査型電子顕微鏡等で撮影した写真から測定することができる。具体的には太陽電池素子13の断面を撮影し、得られた写真から、任意の部位を10個選択し、それらの部位の厚みをそれぞれ測定する。そして全ての厚みを積算して10で除したものを太陽電池素子13の平均厚さとすることができる。
フィンガー電極32の線幅は、例えば0.2mm程度であり;バスバー電極34Aの線幅は、例えば2~3mm程度であり;バスバー電極34Bの線幅は、例えば5~7mm程度である。
工程(ii)において、工程(i)で得られた積層体を常法に従って真空ラミネーター、又は熱プレスを用いて加熱及び加圧して一体化(封止)する。あるいは工程(ii)において、工程(i)で得られた積層体に対し、紫外線等の光を照射することにより光架橋して一体化(封止)する。
封止において、太陽電池封止材Sは、クッション性が高いため、太陽電池素子の損傷を防止することができる。また、脱気性が良好であるため空気の巻き込みもなく、高品質の製品を歩留り良く製造することができる。
実施例および比較例において、受光面側封止層を構成する太陽電池封止材の弾性率は以下のように測定した。実施例および比較例の太陽電池封止シートと同様の組成の厚み1mmの太陽電池封止シートを準備した。そして、当該シートの弾性率をJIS K7161に準拠し、オートグラフ(島津製作所製:AGS-J)を用いて、チャック間:40mm、引張速度:1mm/minの条件で測定した。また、測定環境の温度は23℃、50%Rhとした。
1.太陽電池封止シートの作製
国際公開第2012/060086号の合成例1と同様の方法で、エチレン・α-オレフィン共重合体1(α-オレフィン:1-ブテン、α-オレフィン単位の含有割合:14mol%、エチレン単位の含有割合:86mol%、ショアA硬度:70、MFR:4.0g/10分、密度:0.870g/cm3)を合成した。次いで、上記エチレン・α-オレフィン共重合体100質量部に対し、シランカップリング剤としてγ-メタクリロキシプロピルトリメトキシシランを0.4質量部、架橋剤としてt-ブチルパーオキシ-2-エチルヘキシルカーボネートを0.8質量部、架橋助剤としてトリアリルイソシアヌレートを1.2質量部、紫外線吸収剤として2-ヒドロキシ-4-ノルマル-オクチルオキシベンゾフェノンを0.4質量部、光安定化剤としてビス(2,2,6,6-テトラメチル-4-ピペリジル)セバケートを0.2質量部、および耐熱安定剤1としてトリス(2,4-ジ-tert-ブチルフェニル)ホスファイト0.1質量部、耐熱安定剤2としてオクタデシル-3-(3,5-ジ-tert-ブチル-4-ヒドロキシフェニル)プロピオネート0.1質量部を配合し、押出成形機を用い、ダイス温度105℃の条件下で樹脂組成物をシート状に溶融押出し、冷却ロールにて冷却固化後、巻き取り、太陽電池封止シートとした。得られた太陽電池封止シートの23℃における弾性率は10MPaであった。また、当該太陽電池封止シートの平均厚みは0.60mmであった。
太陽電池モジュールに用いた各部材は、以下の通りである。
受光面側保護部材としては、旭硝子ファブリテック社製の白板フロートガラス(3.2mm厚みのエンボス付き熱処理ガラス)を用いた。受光面側保護部材の凹部の深さ(Z)は0.05mmであった。
太陽電池素子としては、受光面側の中央に0.35mm厚みのバスバー銀電極を有するセル(Shinsung Solar社製の単結晶セル、5cm×3cm)を18セル直列接続したものを用いた。ここで、各セルは、銅リボン電極を用いて直列接続した。銅リボン電極は銅箔に共晶ハンダを表面コートしたものである。
裏面側保護部材としては、シリカ蒸着PET系バックシートを用いた。
太陽電池裏面封止材としては、受光面と同じ太陽電池封止シートを用いた。
太陽電池モジュールは、以下の手順で作製した。
まず、得られた太陽電池封止シートを受光面側保護部材と太陽電池素子との間にセットし、太陽電池裏面封止材を太陽電池素子と裏面側保護部材との間にセットし、積層体を得た。次いで、裏面側保護部材の一部に約2cmの切り込みを入れ、太陽電池素子のプラス端子とマイナス端子を取り出した。次いで、真空ラミネーター(NPC社製:LM-110x160-S)を用いて、得られた積層体を熱板温度150℃、真空時間3分、加圧時間15分にて真空ラミネートした。ここで、太陽電池封止シートにより形成された層が受光面側封止層である。また、受光面側封止層の平均厚さは0.60mmであった。
次いで、受光面側保護部材からはみ出した受光面側封止層、裏面側保護部材をカットし、受光面側保護部材の端部には端面封止シートを付与して、アルミフレームを取り付けた。次いで、裏面側保護部材から取り出した端子部分の切れ込み部位はRTVシリコーンを付与して硬化させた。以上の方法により、太陽電池モジュールを得た。ここで、上記太陽電池封止シートにより形成された受光面側封止層の平均厚さは0.60mmであった。
得られた太陽電池モジュールを、温度サイクル試験機(エスペック社製、PSL-2J)に投入し、JIS C8917に準拠し、温度サイクル試験を200サイクル実施した。AM(エアマス)1.5クラスAの光強度分布を有するキセノン光源を用いて、200サイクル前後の太陽電池モジュールのIV特性をそれぞれ評価した。IV評価には日清紡メカトロニクス社製のPVS-116i-Sを用いた。評価結果は、以下の通りに分類した。結果を表1に示す。なお、出力維持率は、100×(温度サイクル試験を200サイクル実施した後の太陽電池モジュールの出力)/(温度サイクル試験前の太陽電池モジュールの出力)を意味する。
出力維持率が95%以上:○
出力維持率が90%以上95%未満:△
出力維持率が90%未満:×
太陽電池封止シートの平均厚みを変化させ、受光面側封止層の平均厚さ(X)を表1に示す値にした以外は、実施例1と同様にして太陽電池モジュールをそれぞれ作製し、出力維持率をそれぞれ測定した。結果を表1に示す。
エチレン・α-オレフィン共重合体1の代わりに、エチレン・α-オレフィン共重合体1(α-オレフィン:1-ブテン、α-オレフィン単位の含有割合:14mol%、エチレン単位の含有割合:86mol%、ショアA硬度:70、MFR:4.0g/10分、密度:0.870g/cm3)80質量部に、弾性率を調整するために潤滑油である三井化学社製ルーカントHC-40を20質量部加えたものを用いた以外は実施例2と同様にして太陽電池封止シートを作製した。得られた太陽電池封止シートの23℃における弾性率は6MPaであった。そして、実施例1と同様にして太陽電池モジュールを作製し、出力維持率を測定した。結果を表1に示す。
エチレン・α-オレフィン共重合体1の代わりに、国際公開第2012/046456号の合成例3と同様の方法で合成したエチレン・α-オレフィン共重合体2(α-オレフィン:1-オクテン、α-オレフィン単位の含有割合:11mol%、エチレン単位の含有割合:89mol%、ショアA硬度:84、MFR:48g/10分、密度:0.884g/cm3)を用いた以外は実施例2と同様にして太陽電池封止シートを作製した。得られた太陽電池封止シートの23℃における弾性率は28MPaであった。そして、実施例1と同様にして太陽電池モジュールを作製し、出力維持率を測定した。結果を表1に示す。
エチレン・α-オレフィン共重合体1の代わりに、国際公開第2012/060086号の合成例2と同様の方法で合成したエチレン・α-オレフィン共重合体3(α-オレフィン:1-ブテン、α-オレフィン単位の含有割合:18mol%、エチレン単位の含有割合82mol%、ショアA硬度:60、MFR:9.5g/10分、密度:0.865g/cm3)80質量部に、弾性率を調整するために潤滑油である三井化学社製ルーカントHC-40を20質量部加えたものを用いた以外は実施例2と同様にして太陽電池封止シートを作製した。得られた太陽電池封止シートの23℃における弾性率は4MPaであった。そして、実施例1と同様にして太陽電池モジュールを作製し、出力維持率を測定した。結果を表1に示す。
エチレン・α-オレフィン共重合体1の代わりに、国際公開第2012/060086号の合成例7と同様の方法で合成したエチレン・α-オレフィン共重合体4(α-オレフィン:1-ブテン、α-オレフィン単位の含有割合:11mol%、エチレン単位の含有割合:89mol%、ショアA硬度:86、MFR:4.0g/10分、密度:0.885g/cm3)を用いた以外は実施例2と同様にして太陽電池封止シートを作製した。得られた太陽電池封止シートの23℃における弾性率は32MPaであった。そして、実施例1と同様にして太陽電池モジュールを作製し、出力維持率を測定した。結果を表1に示す。
1.受光面側封止層の平均厚さ(X)
受光面側封止層を10cm×10cmの大きさにカットしたものの重量W1(g/100cm2)と、受光面側封止層の密度D1(g/cm3)とを用いて、X=W1/(D1×10)により算出した。
ここで、受光面側封止層の密度D1はASTM D1505に準拠して測定した。
バスバー電極の平均厚さ(Y)および半導体素子の平均厚さは走査型電子顕微鏡で撮影した写真から算出した。具体的にはバスバー電極および半導体素子の断面を撮影し、得られた写真から、任意の部位を10個選択し、それらの部位におけるバスバー電極および半導体素子の厚みをそれぞれ測定した。そして、全てのバスバー電極の厚みを積算して10で除したものをバスバー電極の平均厚さ(Y)とし、全ての半導体素子の厚みを積算して10で除したものを半導体素子の平均厚さとした。
まず受光面側保護部材を10cm×10cmの大きさにカットしたものの重量W2(g/100cm2)と、受光面側保護部材の密度D2(g/cm3)とを用いて、目付け厚さZ1=W2/(D2×10)を算出した。
次に、受光面側保護部材の見掛け厚さZ2[mm]を、ダイヤルゲージ(ピーコック社製MODEL H)を用いて凸部で測定した。ここで、受光面側保護部材の見掛け厚さZ2は、受光面側保護部材の凸部での厚みを10点測定し、その平均値とした。
そして、凹部の深さ(Z)は、Z=Z2-Z1により算出した。
ここで、受光面側保護部材の密度D1はASTM D1505に準拠して測定した。
また、実効厚みが0.30mmである参考例の太陽電池モジュールと比較しても、実施例1~5の太陽電池モジュールは十分な出力低下防止機能を有することがわかる。すなわち、実施例1~5では出力低下が抑制され、かつ、封止層の厚みが薄い太陽電池モジュールを実現できていることが確認できた。
Claims (7)
- 受光面側保護部材と、裏面側保護部材と、太陽電池素子と、前記受光面側保護部材と前記裏面側保護部材との間に前記太陽電池素子を封止する封止層と、を備える太陽電池モジュールであって、
前記受光面側保護部材は少なくとも前記太陽電池素子側表面に複数の微細な凹部および複数の微細な凸部を有し、
前記太陽電池素子には少なくとも受光面側表面にバスバー電極が設けられており、
前記封止層が前記受光面側保護部材と前記太陽電池素子との間に設けられた受光面側封止層と、前記裏面側保護部材と前記太陽電池素子との間に設けられた裏面側封止層と、を有し、前記受光面側封止層と前記裏面側封止層との間に前記太陽電池素子が封止されており、
前記受光面側封止層はポリオレフィン系樹脂およびエチレン・極性モノマー共重合体から選択される少なくとも一種の樹脂を含み、
前記受光面側封止層を構成する太陽電池封止材の23℃における弾性率が5MPa以上30MPa以下であり、
前記受光面側封止層の平均厚さをX[mm]とし、受光面側の前記バスバー電極の平均厚さをY[mm]とし、前記凹部の深さをZ[mm]としたとき、
(X-Y-Z)で表される前記受光面側封止層の実効厚みが0.01mm以上0.25mm未満である太陽電池モジュール。 - 請求項1に記載の太陽電池モジュールにおいて、
前記バスバー電極の平均厚さ(Y)が0.02mm以上0.6mm以下である太陽電池モジュール。 - 請求項1または2に記載の太陽電池モジュールにおいて、
前記凹部の深さ(Z)が0.02mm以上0.5mm以下である太陽電池モジュール。 - 請求項1乃至3のいずれか一項に記載の太陽電池モジュールにおいて、
前記受光面側封止層に含まれる前記樹脂がエチレン・α-オレフィン共重合体を含む太陽電池モジュール。 - 請求項1乃至4のいずれか一項に記載の太陽電池モジュールにおいて、
前記太陽電池素子の平均厚さが0.01mm以上0.5mm以下である太陽電池モジュール。 - 請求項1乃至5のいずれか一項に記載の太陽電池モジュールにおいて、
前記受光面側封止層の平均厚さ(X)が0.60mm以下である太陽電池モジュール。 - 請求項1乃至6のいずれか一項に記載の太陽電池モジュールにおいて、
前記受光面側封止層を構成する前記太陽電池封止材は潤滑油をさらに含む太陽電池モジュール。
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US20190267296A1 (en) * | 2018-02-26 | 2019-08-29 | D2Solar LLC | Preventing solar cell stress fractures by controlling encapsulant thickness |
JP2020123663A (ja) * | 2019-01-30 | 2020-08-13 | パナソニック株式会社 | 太陽電池モジュール |
JP2021039984A (ja) * | 2019-08-30 | 2021-03-11 | パナソニック株式会社 | 太陽電池モジュール、太陽電池モジュール作製方法 |
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JP7285994B1 (ja) | 2022-06-23 | 2023-06-02 | ジョジアン ジンコ ソーラー カンパニー リミテッド | 光起電力モジュール |
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