POLYESTER FILM, METHOD FOR PRODUCING THE SAME, BACK SHEET FOR SOLAR CELLS, AND SOLAR CELL MODULE

• US 20120070615A1
• Filed: 08/29/2011
• Published: 03/22/2012
• Est. Priority Date: 09/17/2010
• Status: Abandoned Application

• Current Assignee: Fujifilm Corporation (Fujifilm Holdings Corporation)
• Original Assignee: Fujifilm Corporation (Fujifilm Holdings Corporation)
• Inventors: SHI, Zemin, FUJITA, Akihide, YAMADA, Akira
• Application Number:
  US13/220,588
• Publication Number:
  US 20120070615A1
• Time in Patent Office: Days
• US Class Current: 428/143
• CPC Class Codes: B29B 7/483 the other mixing parts being discs perpendicular to the screw axis
• CPC Class Codes: B29B 7/489 Screws B29B7/482 takes precedence
• CPC Class Codes: B29B 7/72 Measuring, controlling or regulating
• CPC Class Codes: B29B 7/826 Apparatus therefor
• CPC Class Codes: B29B 7/845 Venting, degassing or removing evaporated components in devices with rotary stirrers
• CPC Class Codes: B29B 7/86 for working at sub- or superatmospheric pressure B01F33/70 takes precedence
• CPC Class Codes: B29C 2948/92152 Thickness
• CPC Class Codes: B29C 2948/92447 Moulded article
• CPC Class Codes: B29C 2948/92514 Pressure
• CPC Class Codes: B29C 2948/92704 Temperature
• CPC Class Codes: B29C 2948/92895 Barrel or housing
• CPC Class Codes: B29C 2948/92923 Calibration, after-treatment or cooling zone
• CPC Class Codes: B29C 48/08 flexible, e.g. films
• CPC Class Codes: B29C 48/37 Gear pumps
• CPC Class Codes: B29C 48/40 using two or more parallel screws or at least two parallel non-intermeshing screws, e.g. twin screw extruders
• CPC Class Codes: B29C 48/402 the screws having intermeshing parts
• CPC Class Codes: B29C 48/54 with additional forward-feeding elements
• CPC Class Codes: B29C 48/55 having reverse-feeding elements
• CPC Class Codes: B29C 48/57 provided with kneading disc-like elements, e.g. with oval-shaped elements
• CPC Class Codes: B29C 48/693 Substantially flat filters mounted at the end of an extruder screw perpendicular to the feed axis
• CPC Class Codes: B29C 48/767 : through a degassing opening of a barrel
• CPC Class Codes: B29C 48/91 : Heating, e.g. for cross linking
• CPC Class Codes: B29C 48/914 : cooling drums
• CPC Class Codes: B29C 48/917 : by applying pressurised gas to the surface of the flat article
• CPC Class Codes: B29C 55/143 : firstly parallel to the direction of feed and then transversely thereto
• CPC Class Codes: B29K 2067/00 : Use of polyesters or derivatives thereof, as moulding material
• CPC Class Codes: B29K 2067/003 : PET, i.e. poylethylene terephthalate
• CPC Class Codes: C08G 63/85 : Germanium, tin, lead, arsenic, antimony, bismuth, titanium, zirconium, hafnium, vanadium, niobium, tantalum, or compounds thereof C08G63/823 takes precedence
• CPC Class Codes: C08J 2367/02 : Polyesters derived from dicarboxylic acids and dihydroxy compounds; C08J2367/06 takes precedence
• CPC Class Codes: C08J 5/18 : Manufacture of films or sheets
• CPC Class Codes: H01L 31/0481 : characterised by the composition of the encapsulation material
• CPC Class Codes: H01L 31/049 : Protective back sheets
• CPC Class Codes: Y02E 10/50 : Photovoltaic [PV] energy
• CPC Class Codes: Y10T 428/24372 : Particulate matter

Abstract

Provided is a method for producing a polyester film, including: subjecting a polyester raw material resin, which contains a titanium compound and has an intrinsic viscosity of from 0.71 to 1.00, to melt extrusion using a twin-screw extruder which includes a cylinder; two screws disposed inside the cylinder; and a kneading disk unit disposed in at least a portion of a region extending from a 10%-position to a 65%-position of screw length with respect to an upstream end of the screws in a resin extrusion direction as a starting point, at a maximum shear rate generated inside the twin-screw extruder of from 10 sec⁻¹ to 2000 sec⁻¹;

• • forming an unstretched film by cooling and solidifying the melt extruded polyester resin on a cast roll; subjecting the unstretched film to biaxial stretching in a longitudinal direction and a lateral direction; and heat fixing the stretched film formed by biaxial stretching.

Claims

1. A method for producing a polyester film, the method comprising:

subjecting a polyester raw material resin, which contains a titanium compound as a polymerization catalyst and has an intrinsic viscosity of from 0.71 to 1.00, to melt extrusion using a twin-screw extruder which includes a cylinder;

two screws disposed inside the cylinder; and

a kneading disk unit disposed in at least a portion of a region extending from a 10%-position to a 65%-position of screw length with respect to an upstream end of the screws in a resin extrusion direction as a starting point, at a maximum shear rate (γ

) generated inside the twin-screw extruder of from 10 sec<sup>−

1</sup> to 2000 sec<sup>−

1</sup>;

forming an unstretched film by cooling and solidifying the melt extruded polyester resin on a cast roll;

subjecting the unstretched film to biaxial stretching in a longitudinal direction and a lateral direction; and

heat fixing the stretched film formed by biaxial stretching.

2. The method for producing a polyester film according to claim 1, wherein the melt extrusion comprises using a kneading disk unit having a length of from 1% to 30% in a longitudinal direction of the screw.

3. The method for producing a polyester film according to claim 1, wherein the melt extrusion further comprises performing suction through vents provided on the cylinder of the twin-screw extruder.

4. The method for producing a polyester film according to claim 1, wherein the twin-screw extruder comprises, in a downstream of the cylinder in the resin extrusion direction, a gear pump for extrusion control which controls an extrusion output of the resin and a filter for foreign material removal which removes foreign materials from the resin.

5. The method for producing a polyester film according to claim 1, wherein forming of the unstretched film comprises cooling and solidification in a region in which a temperature of the polyester resin that is melt extruded from the twin-screw extruder is from 140°

C. to 230°

C., at an average cooling rate in a range of from 230°

C./min to 500°

C./min.

6. The method for producing a polyester film according to claim 1, further comprising, after the heat fixing, subjecting the heat fixed stretched film to a relaxation treatment in the longitudinal direction and the lateral direction of the film.

7. The method for producing a polyester film according to claim 6, wherein the relaxation treatment is performed in the longitudinal direction of the stretched film by clamping two edges in the width direction of the stretched film using clips installed in a pair of flexurally movable clip chains to which plural chain links are linked in a cyclic form, causing the stretched film to have a bendable structure between the clips, running the clips along guide rails to cause displacement of the bending angle of the chain links, and thereby shortening the distance between clips in the clip run direction.

8. The method for producing a polyester film according to claim 1, wherein an amount of terminal carboxylic acid groups in the polyester raw material resin is from 8 eq/ton to 25 eq/ton.

9. The method for producing a polyester film according to claim 1, wherein the polyester raw material resin contains recovered waste of a polyester resin in an amount of from 0% by mass to 15% by mass relative to a total mass of the polyester raw material resin.

10. The method for producing a polyester film according to claim 1, wherein the titanium compound is an organic chelate titanium complex.

11. A polyester film produced by the method for producing a polyester film according to claim 1.

12. The polyester film according to claim 11, which comprises titanium atoms derived from a polymerization catalyst and has an intrinsic viscosity of from 0.71 to 1.00, and wherein time taken for breaking elongation obtainable after a heat-moisture treatment in an atmosphere at a temperature of 120°

C. and a relative humidity of 100%, to reach 50% relative to the breaking elongation prior to the heat-moisture treatment, is from 65 hours to 150 hours.

13. The polyester film according to claim 11, wherein the amount of foreign materials having a protrusion height from the film surface of 0.5 μ

m or more is from 1 to 100 pieces/100 cm², and the surface roughness Ra is from 20 nm to 200 nm.

14. A back sheet for a solar cell, comprising the polyester film according to claim 11.

15. A solar cell module comprising the polyester film according to claim 11.