Polyester film and method for producing the same, back sheet for solar cell, and solar cell module

Patent metadata

Field	Value
Publication number	US-9831376-B2
Application number	US-201414495258-A
Country	US
Kind code	B2
Filing date	Sep 24, 2014
Priority date	Mar 26, 2012
Publication date	Nov 28, 2017
Grant date	Nov 28, 2017

Abstract

A polyester film containing a polyester support having a terminal carboxylic acid value of from 3 to 20 eq/ton and IV of from 0.65 to 0.9 dL/g, and a conductive layer having a surface specific resistance of from 10 6 to 10 14 Ω per square with an in-plane distribution of from 0.1 to 20% exhibits an improvement in withstand voltage.

First claim

What is claimed is:

1. A polyester film comprising a polyester support that has a terminal carboxylic acid value, AV of from 3 to 20 eq/ton and IV of from 0.65 to 0.9 dL/g, and a conductive layer that is provided at least one surface of the polyester support,
the conductive layer having a surface specific resistance R0 of from 10 6 to 10 14 Ω per square, and
the surface specific resistance R0 of the conductive layer having an in-plane distribution of from 1% to 20%,
wherein the conductive layer has a thickness distribution of from 0.1 to 10%.

2. The polyester film according to claim 1 , wherein the polyester support contains at least one layer of a polyester layer that contains as a major component a polyester component that satisfies at least one of the following conditions (A) and (B):
condition (A): the polyester component is a polyester composition that contains a polyester and an terminal blocking agent in an amount of from 0.1 to 10% by mass based on the polyester, and
condition (B): the polyester component is a CHDM polyester that contains a structure derived from 1,4-cyclohexanedimethanol, CHDM in an amount of from 0.1 to 20% by mol or from 80 to 100% by mol based on a diol component.

3. The polyester film according to claim 2 , which has, as the outermost layer of the polyester support on the side where the conductive layer is provided, a polyester layer that contains as a major component a polyester component that satisfies at least one of the conditions (A) and (B).

4. The polyester film according to claim 2 , wherein the polyester component satisfies the condition (A).

5. The polyester film according to claim 4 , wherein the terminal blocking agent has a weight average molecular weight of from 200 to 100,000.

6. The polyester film according to claim 4 , wherein the terminal blocking agent is a carbodiimide compound.

7. The polyester film according to claim 4 , wherein the terminal blocking agent is a carbodiimide compound having a carbodiimide group, and having a cyclic structure in which two nitrogen atoms in the carbodiimide group are bonded via a linking group.

8. The polyester film according to claim 2 , wherein the terminal blocking agent is a cyclic carbodiimide compound.

9. The polyester film according to claim 1 , wherein the conductive layer contains an organic conductive agent.

10. The polyester film according to claim 1 , wherein the conductive layer has a thickness of from 0.01 to 50 μm.

11. The polyester film according to claim 1 , which comprises a readily adhesive layer having a thickness unevenness of from 0.1 to 10% on at least one surface of the polyester support.

12. The polyester film according to claim 1 , wherein the polyester support is formed by extruding a molten material of a composition containing a polyester and a terminal blocking agent from a die, and then solidifying the composition by cooling with air blow having an air blow amount with a modulation of from 0.1 to 10%.

13. The polyester film according to claim 1 , wherein the conductive layer is formed by coating a coating liquid for a conductive layer, and then drying the coating liquid at an outlet port of a drying zone by applying a temperature distribution of from 0.1 to 10° C.

14. The polyester film according to claim 1 , which is wound up into a roll form.

15. A back sheet for a solar cell module, comprising a polyester film comprising a polyester support that has a terminal carboxylic acid value, AV of from 3 to 20 eq/ton and IV of from 0.65 to 0.9 dL/g, and a conductive layer that is provided at least one surface of the polyester support,
the conductive layer having a surface specific resistance R0 of from 10 6 to 10 14 Ω per square, and
the surface specific resistance R0 of the conductive layer having an in-plane distribution of from 1% to 20%,
wherein the conductive layer has a thickness distribution of from 0.1 to 10%.

16. A solar cell module comprising the back sheet for a solar cell module, which comprises a polyester film comprising a polyester support that has a terminal carboxylic acid value, AV of from 3 to 20 eq/ton and IV of from 0.65 to 0.9 dL/g, and a conductive layer that is provided at least one surface of the polyester support,
the conductive layer having a surface specific resistance R0 of from 10 6 to 10 14 Ω per square, and
the surface specific resistance R0 of the conductive layer having an in-plane distribution of from 1% to 20%,
wherein the conductive layer has a thickness distribution of from 0.1 to 10%.

17. A method for producing a polyester film comprising:
extruding a molten material of a polyester composition from a die and solidifying the composition by cooling, so as to produce a polyester support that has a terminal carboxylic acid value, AV of from 3 to 20 eq/ton and IV of from 0.65 to 0.9 dL/g; and
forming a conductive layer on at least one surface of the polyester support,
the conductive layer having a surface specific resistance R0 of from 10 6 to 10 14 Ω per square,
the surface specific resistance R0 of the conductive layer having an in-plane distribution of from 1% to 20%, and
the polyester support being cooled with air blow having an air blow amount with a modulation of from 0.5% to 10%,
wherein the conductive layer has a thickness distribution of from 0.1 to 10%.

18. The method for producing a polyester film according to claim 17 , wherein the polyester composition is a composition that contains as a major component a polyester component that satisfies at least one of the following conditions (A) and (B):
condition (A): the polyester component is a polyester composition that contains a polyester and a terminal blocking agent in an amount of from 0.1 to 10% by mass based on the polyester, and
condition (B): the polyester component is a CHDM polyester that contains a structure derived from 1,4-cyclohexanedimethanol, CHDM in an amount of from 0.1 to 20% by mol or from 80 to 100% by mol of a diol component.

19. The method for producing a polyester film according to claim 18 , wherein the polyester component satisfies the condition (A).

20. The method for producing a polyester film according to claim 17 , which comprises:
coating a coating liquid for a conductive layer on at least one surface of the polyester support; and
conveying the polyester support having the coating liquid for a conductive layer coated thereon, in a drying zone, so as to form the conductive layer, and
a temperature distribution of from 0.1 to 10° C. is applied at an outlet port of the drying zone.

Assignees

• Fujifilm Corp

Inventors

• Hashimoto Kiyokazu

Classifications

• B05D3/0254

  After-treatment · CPC title

• C08G63/199

  Acids or hydroxy compounds containing cycloaliphatic rings · CPC title

• B05D3/002

  Pretreatement · CPC title

• C08L67/03

  the dicarboxylic acids and dihydroxy compounds having the carboxyl- and the hydroxy groups directly linked to aromatic rings · CPC title

• C09D5/24

  Electrically-conducting paints {(conductive materials H01B1/00)} · CPC title