Solar cell sealing material, and solar cell module prepared by using same

Patent metadata

Field	Value
Publication number	US-9447272-B2
Application number	US-201113812378-A
Country	US
Kind code	B2
Filing date	Jul 28, 2011
Priority date	Jul 28, 2010
Publication date	Sep 20, 2016
Grant date	Sep 20, 2016

Abstract

Provided are a solar cell encapsulant material which facilitates production of solar cell modules, which does not require a crosslinking step and which is excellent in heat resistance and others, and a solar cell module produced by the use of the encapsulant material. The solar cell encapsulant material comprises a resin composition (C) that contains an olefin-based polymer (A) satisfying the following requirement (a) and an olefin-based polymer (B) satisfying the following requirement (b). (a) The crystal melting peak temperature of the polymer, as measured at a heating rate of 10° C./min in differential scanning calorimetry, is lower than 100° C. (b) The extrapolated onset temperature of melting of the polymer, as measured at a heating rate of 10° C./min in differential scanning calorimetry, is 100° C. or higher.

First claim

The invention claimed is:

1. A solar cell encapsulant material comprising a resin composition comprising a first olefin-based polymer and a second olefin-based polymer,
wherein a crystal melting peak temperature of the first olefin-based polymer, as measured at a heating rate of 10° C./min in differential scanning calorimetry, is from 30 to 95° C.;
an extrapolated onset temperature of melting of the second olefin-based polymer, as measured at a heating rate of 10° C./min in differential scanning calorimetry, is 100 to 130° C.
a difference between the crystal melting peak temperature of the first olefin-based polymer and the extrapolated onset temperature of melting of the second olefin-based polymer is 35° C. or higher; and
wherein a ratio by mass of the first olefin-based polymer to the second olefin-based polymer in the resin composition is in a range of 99:1 to 50:50,
wherein the first olefin-based polymer is an α-olefin random copolymer that comprises units of an α-olefin and units of a monomer other than the α-olefin, and
wherein a content of units from the α-olefin in the α-olefin random copolymer is from 2 to 40 mol %, relative to the total monomer units in the α-olefin random copolymer.

2. The solar cell encapsulant material according to claim 1 , wherein the second olefin-based polymer is an ethylene-α-olefin block copolymer.

3. The solar cell encapsulant material according to claim 1 , wherein the resin composition further comprises at least one additive selected from the group consisting of a silane coupling agent, an antioxidant, a UV absorbent, and a weather-resistant stabilizer.

4. The solar cell encapsulant material according to claim 1 , wherein the solar cell encapsulant material has a laminate configuration.

5. The solar cell encapsulant material according to claim 4 , wherein the laminate configuration comprises at least two layers, wherein at least two of the layers differ from each other in a storage elastic modulus in dynamic viscoelasticity measurement at an oscillation frequency of 10 Hz and at a temperature of 20° C.

6. The solar cell encapsulant material according to claim 5 , wherein the layers that differ from each other in the storage elastic modulus comprise a first layer and a second layer,
wherein the storage elastic modulus of the first layer is less than 100 MPa; and
the storage elastic modulus of the second layer is 100 MPa or higher.

7. The solar cell encapsulant material according to claim 6 , wherein the laminate configuration of the at least two layers is a two-type three-layer configuration of the first layer/the second layer/the first layer.

8. The solar cell encapsulant material of claim 6 , wherein the storage elastic modulus of the first layer is from 5 to 50 MPa and the storage elastic modulus of the second layer is from 200 to 800 MPa.

9. A solar cell module comprising the solar cell encapsulant material of claim 1 .

10. The solar cell encapsulant material of claim 1 ,
wherein the units of the α-olefin in the α-olefin random copolymer are units of an α-olefin selected from the group consisting of propylene, 1-butene, 1-pentene, 1-hexene, 1-heptene, 1-octene, 1-nonene, 1-decene, 3-methyl-butene-1, 4-methyl-pentene-1, and a combination thereof.

11. The solar cell encapsulant material of claim 10 ,
wherein the units of the α-olefin in the α-olefin random copolymer are units of an α-olefin selected from the group consisting of propylene, 1-butene, 1-hexene 1-octene, and a combination thereof.

12. The solar cell encapsulant material of claim 1 ,
wherein a content of units from the α-olefin in the α-olefin random copolymer is from 3 to 30 mol %, relative to the total monomer units in the α-olefin random copolymer.

13. The solar cell encapsulant material of claim 1 ,
wherein a content of units from the α-olefin in the α-olefin random copolymer is from 5 to 25 mol %, relative to the total monomer units in the α-olefin random copolymer.

14. A solar cell encapsulant material comprising a resin composition comprising a first olefin-based polymer and a second olefin-based polymer,
wherein a crystal melting peak temperature of the first olefin-based polymer, as measured at a heating rate of 10° C./min in differential scanning calorimetry, is from 30 to 95° C.;
an extrapolated onset temperature of melting of the second olefin-based polymer, as measured at a heating rate of 10° C./min in differential scanning calorimetry, is 100 to 130° C.
a difference between the crystal melting peak temperature of the first olefin-based polymer and the extrapolated onset temperature of melting of the second olefin-based polymer is 35° C. or higher; and
wherein a ratio by mass of the first olefin-based polymer to the second olefin-based polymer in the resin composition is in a range of 99:1 to 50:50,
wherein the second olefin-based polymer is an ethylene-octene multi-block copolymer.

Assignees

• Taniguchi Kouichirou
• Otsuka Michiko
• Nishioka Jun
• Dainippon Printing Co Ltd

Inventors

• Taniguchi Kouichirou
• Otsuka Michiko
• Nishioka Jun

Classifications

• B32B27/08

  of synthetic resin · CPC title

• C08L53/00 Primary

  Compositions of block copolymers containing at least one sequence of a polymer obtained by reactions only involving carbon-to-carbon unsaturated bonds; Compositions of derivatives of such polymers · CPC title

• B32B27/36

  comprising polyesters · CPC title

• C09K2200/0617

  Polyalkenes · CPC title

• C09K3/10

  {Materials in mouldable or extrudable form} for sealing or packing joints or covers (filling pastes C09D5/34) · CPC title