Encapsulating material for solar cell and solar cell module

Patent metadata

Field	Value
Publication number	US-9349895-B2
Application number	US-201113882218-A
Country	US
Kind code	B2
Filing date	Oct 31, 2011
Priority date	Nov 2, 2010
Publication date	May 24, 2016
Grant date	May 24, 2016

Abstract

An encapsulating material for solar cell excellent in a balance among properties including transparency, flexibility, adhesiveness, heat resistance, appearance, crosslinking properties, electrical properties and calender moldability. The encapsulating material includes an ethylene/α-olefin copolymer satisfying the following requirements: (a1) the content ratio of structural units derived from ethylene is from 80 to 90 mol % and the content ratio of structural units derived from α-olefin having 3 to 20 carbon atoms is from 10 to 20 mol %; (a2) MFR is equal to or more than 2 g/10 minutes and less than 10 g/10 minutes as measured under the conditions of a temperature of 190 degrees centigrade and a load of 2.16 kg in accordance with ASTM D1238; (a3) the density is from 0.865 to 0.884 g/cm 3 as measured in accordance with ASTM D1505; and (a4) the shore A hardness is from 60 to 85 as measured in accordance with ASTM D2240.

First claim

The invention claimed is:

1. A solar cell module comprising:
a transparent surface protective member;
a back surface protective member;
a solar cell element; and
an encapsulating layer for encapsulating said solar cell element between said transparent surface protective member and said back surface protective member to be formed by crosslinking an encapsulating material for solar cell,
wherein the encapsulating layer is in direct contact with at least one side of the solar cell element, and
the encapsulating material for solar cell comprises an ethylene/α-olefin copolymer satisfying the following requirements (a1) to (a4) and (a11):
(a1) the content ratio of structural units derived from ethylene is from 80 to 90 mol % and the content ratio of structural units derived from α-olefin having 3 to 20 carbon atoms is from 10 to 20 mol %;
(a2) MFR is equal to or more than 2 g/10 minutes and less than 10 g/10 minutes as measured under the conditions of a temperature of 190 degrees centigrade and a load of 2.16 kg in accordance with ASTM D1238;
(a3) the density is from 0.865 to 0.884 g/cm 3 as measured in accordance with ASTM D1505;
(a4) the shore A hardness is from 60 to 85 as measured in accordance with ASTM D2240; and
(a11) the extracted amount of said ethylene/α-olefin copolymer in methyl acetate is equal to or less than 5.0 weight %.

2. The solar cell module according to claim 1 , wherein the encapsulating material for solar cell further satisfies the following requirement (a5):
(a5) the volume resistivity is from 1.0×10 13 to 1.0×10 18 Ω·cm as measured at a temperature of 100 degrees centigrade with an applied voltage of 500V in accordance with JIS K6911.

3. The solar cell module according to claim 1 , wherein said ethylene/α-olefin copolymer further satisfies the following requirement (a6):
(a6) the content of aluminum element in said ethylene/α-olefin copolymer is from 10 to 500 ppm.

4. The solar cell module according to claim 2 , wherein said ethylene/α-olefin copolymer further satisfies the following requirement (a6):
(a6) the content of aluminum element in said ethylene/α-olefin copolymer is from 10 to 500 ppm.

5. The solar cell module according to claim 1 , wherein the encapsulating material for solar cell further contains organic peroxide having a one-minute half-life temperature in the range of 100 to 170 degrees centigrade in an amount of 0.1 to 3 weight parts, based on 100 weight parts of said ethylene/α-olefin copolymer.

6. The solar cell module according to claim 1 , wherein said ethylene/α-olefin copolymer is polymerized in the presence of a catalyst for olefin polymerization comprising a metallocene compound, and at least one compound selected from the group consisting of an organic aluminumoxy compound and an organic aluminum compound.

7. The solar cell module according to claim 1 , wherein the encapsulating material for solar cell comprises an ethylene resin composition containing a silane coupling agent in an amount of 0.1 to 5 weight parts, based on 100 weight parts of said ethylene/α-olefin copolymer.

8. The solar cell module according to claim 7 , wherein said ethylene resin composition further comprises at least one kind selected from the group consisting of an ultraviolet absorber, a heat-resistant stabilizer and a hindered amine type light stabilizer in an amount of 0.005 to 5 weight parts, based on 100 weight parts of said ethylene/α-olefin copolymer.

9. The solar cell module according to claim 7 , wherein said ethylene resin composition further comprises a crosslinking aid in an amount of 0.05 to 5 weight parts, based on 100 weight parts of said ethylene/α-olefin copolymer.

10. The solar cell module according to claim 1 , the encapsulating material for solar cell is obtained by melt-kneading said ethylene/α-olefin copolymer and an additive and then calender-molding the melt-kneaded mixture at the calender molder in a sheet form.

11. The solar cell module according to claim 1 , wherein, for said ethylene/α-olefin copolymer,
(a7) the B value determined from the 13 C-NMR spectrum and the following equation (1) is from 0.9 to 1.5, and
(a8) the intensity ratio of Tαβ to Tαα (Tαβ/Tαα) in the 13 C-NMR spectrum is equal to or less than 1.5:
B Value=[ P OE ]/(2 ×[P O ]×[P E ])  (1)

wherein, in the equation (1), [P E ] represents the molar fraction of structural units derived from ethylene contained in said ethylene/α-olefin copolymer; [P O ] represents the molar fraction of structural units derived from α-olefin having 3 to 20 carbon atoms contained in said ethylene/α-olefin copolymer; and [P OE ] represents the molar fraction of an α-olefin/ethylene chain contained in the total dyad chain.

12. The solar cell module according to claim 1 , wherein (a9) the molecular weight distribution (Mw/Mn) of said ethylene/α-olefin copolymer is in the range of 1.2 to 3.5 as measured by gel permeation chromatography (GPC).

13. The solar cell module according to claim 1 , wherein (a10) the content ratio of chlorine ion of said ethylene/α-olefin copolymer is equal to or less than 2 ppm as detected from an extract subjected to solid-phase extraction by ion chromatography.

14. The solar cell module according to claim 1 , wherein the encapsulating material for solar cell is in a sheet form.

Assignees

• Ikenaga Shigenobu
• Takeuchi Fumito
• Watanabe Keiji
• Ito Tomoaki
• Mitsui Chemicals Inc
• Mitsui Chemicals Tohcello Inc

Inventors

• Ikenaga Shigenobu
• Takeuchi Fumito
• Watanabe Keiji
• Ito Tomoaki

Classifications

• C08F4/65912

  in combination with an organoaluminium compound · CPC title

• C08F4/65908

  in combination with an ionising compound other than alumoxane, e.g. (C6F5)4B-X+ · CPC title

• H10F19/00

  Integrated devices, or assemblies of multiple devices, comprising at least one photovoltaic cell covered by group H10F10/00, e.g. photovoltaic modules · CPC title

• H10F19/804 Primary

  Materials of encapsulations · CPC title

• C09D123/0815

  Copolymers of ethene with aliphatic 1-olefins · CPC title