Laminate for solar cell and solar cell module produced using same

Patent metadata

Field	Value
Publication number	US-9660118-B2
Application number	US-201113989957-A
Country	US
Kind code	B2
Filing date	Nov 29, 2011
Priority date	Nov 30, 2010
Publication date	May 23, 2017
Grant date	May 23, 2017

Abstract

Provided are a laminate for solar cells, which facilitates production of solar cell modules, which does not require a crosslinking step and which is excellent in transparency, moisture-proofness, sealability and handleability (rigidity), and a solar cell module produced by the use of the laminate. The laminate for solar cells has a resin layer (I)-1 or a resin layer (I)-2 as at least one outermost layer thereof, and has a resin layer (II) that contains an etylene-based polymer (C) satisfying a specific requirement and a nucleating agent (D). The resin layer (I)-1 is a resin layer containing an ethylene/α-olefin random copolymer (A) satisfying a specific requirement, and an ethylene/α-olefin block copolymer (B) satisfying a specific requirement. The resin layer (I)-2 is a resin layer containing a silane-modified etylene-based resin (X).

First claim

The invention claimed is:

1. A laminate, comprising:
an outermost resin layer, and
a second resin layer that comprises 30%-99.9% by mass of an ethylene-based polymer and 0.01%-3.0% by mass of a nucleating agent, each based on the mass of the second resin layer,
wherein the outermost resin layer comprises:
an ethylene/α-olefin random copolymer having a heat of crystal fusion of from 0 to 70 J/g as measured at a heating rate of 10° C./min in differential scanning calorimetry and an ethylene/α-olefin block copolymer having a crystal melting peak temperature of from 100 to 145° C. as measured at a heating rate of 10° C./min in differential scanning calorimetry and a heat of crystal fusion of from 5 to 70 J/g,

wherein a crystal melting peak temperature of the ethylene-based polymer of the second resin layer, as measured at a heating rate of 10° C./min in differential scanning calorimetry, is from 100 to 145° C., and a heat of crystal fusion of the ethylene-based polymer of the second resin layer is from 120 to 190 J/g, and
wherein a ratio of thickness of the second resin layer to a total thickness of the laminate is 0.2 to 0.6.

2. The laminate according to claim 1 , wherein a content of the nucleating agent in the second resin layer is from 0.05% by mass to 1% by mass.

3. The laminate according to claim 1 , wherein the second resin layer further comprises an olefin-miscible resin selected from the group consisting of a petroleum resin, a terpene resin, a coumarone-indene resin, a rosin resin, and any hydrogenated derivative thereof.

4. The laminate according to claim 3 , wherein a softening temperature of the olefin-miscible resin is from 80° C. to [Tc(C)+5° C.], in which Tc(C) is a crystallization peak temperature of the ethylene-based polymer of the second resin layer measured at a cooling rate of 10° C./min in differential scanning calorimetry.

5. The laminate according to claim 1 , wherein the ethylene-based resin of the second resin layer comprises from 0.1 to 3.0% by mass of at least one α-olefin selected from the group consisting of butene-1, hexene-1, and octene-1.

6. The laminate according to claim 1 , wherein the second resin layer further comprises a cyclic olefin-based resin.

7. The laminate according to claim 1 , wherein a storage elastic modulus of the outermost resin layer is smaller than a storage elastic modulus of the second resin layer, measured through dynamic viscoelasticity measurement at a oscillation frequency of 10 Hz and at a temperature of 20° C.

8. The laminate according to claim 7 , wherein the storage elastic modulus of the outermost resin layer is at most 100 MPa, and the storage elastic modulus of the second resin layer is more than 100 MPa.

9. The laminate according to claim 1 , wherein a water vapor permeability of the laminate having a total thickness of 0.3 mm, as measured at a temperature of 40° C. and at a relative humidity of 90%, is at most 3.0 g/(m 2 ·24 hours).

10. The laminate according to claim 1 , wherein a storage elastic modulus of the laminate, as measured through dynamic viscoelasticity measurement at a oscillation frequency of 10 Hz and at a temperature of 20° C., is from 100 to 1000 MPa.

11. The laminate according to claim 1 ,
wherein a storage elastic modulus of the laminate having a total thickness of 0.3 mm, as measured through dynamic viscoelasticity measurement at a oscillation frequency of 10 Hz and at a temperature of 20° C., is from 300 to 700 MPa,
a water vapor permeability of the laminate having a total thickness of 0.3 mm, as measured at a temperature of 40° C. and at a relative humidity of 90%, is at most 3.0 g/(m 2 ·24 hours), and
a total light transmission of the laminate having a total thickness of 0.3 mm is at least 85%.

12. The laminate according to claim 1 , wherein a total light transmission of the laminate having a thickness of 0.3 mm is at least 85%, as measured according to JIS K7105.

13. The laminate according to claim 1 , wherein the outermost resin layer, the second resin layer, or both 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.

14. The laminate according to claim 1 , further comprising a third resin layer,
wherein either the third resin layer comprises an ethylene/α-olefin random copolymer having a heat of crystal fusion of from 0 to 70 J/g as measured at a heating rate of 10° C./min in differential scanning calorimetry and an ethylene/α-olefin block copolymer having a crystal melting peak temperature of from 100 to 145° C. as measured at a heating rate of 10° C./min in differential scanning calorimetry and a heat of crystal fusion of from 5 to 70 J/g, or the third resin layer comprises a silane-modified ethylene-based resin.

15. The laminate according to claim 1 , suitable for adhering to and protecting a solar cell element.

16. A solar cell module, comprising:
the laminate of claim 1 .

17. The laminate according to claim 1 , wherein a ratio of the thickness of the second resin layer to a total thickness of the laminate is 0.35 to 0.55.

18. A laminate, comprising:
an outermost resin layer, and
a second resin layer that comprises 30%-99.9% by mass of an ethylene-based polymer and 0.01%-3.0% by mass of a nucleating agent, each based on the mass of the second resin layer,
wherein the outermost resin layer comprises:
a silane-modified ethylene-based resin and a polyethylene-based resin as the main ingredient thereof,

wherein a crystal melting peak temperature of the ethylene-based polymer of the second resin layer, as measured at a heating rate of 10° C./min in differential scanning calorimetry, is from 100 to 145° C., and a heat of crystal fusion of the ethylene-based polymer of the second resin layer is from 120 to 190 J/g, and
wherein a ratio of the thickness of the second resin layer to a total thickness of the laminate is 0.2 to 0.6.

19. The laminate according to claim 18 , wherein a content of the nucleating agent in the second resin layer is from 0.05% by mass to 1.0% by mass.

20. The laminate according to claim 18 , wherein the second resin layer further comprises an olefin-miscible resin selected from the group consisting of a petroleum resin, a terpene resin, a coumarone-indene resin, a rosin resin, and any hydrogenated derivative thereof.

Assignees

• Taniguchi Kouichirou
• Tanaka Kazuya
• Dainippon Printing Co Ltd

Inventors

• Taniguchi Kouichirou
• Tanaka Kazuya

Classifications

• B32B2307/544

  Torsion strength; Torsion stiffness · CPC title

• C08L53/00

  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

• B32B2307/7246

  Water vapor barrier · CPC title

• B32B2307/7265

  Non-permeable · CPC title

• B32B2307/412

  Transparent · CPC title