ENCAPSULATING MATERIAL FOR SOLAR CELL AND SOLAR CELL MODULE

• US 20130167911A1
• Filed: 10/07/2011
• Published: 07/04/2013
• Est. Priority Date: 10/08/2010
• Status: Active Grant

• Current Assignee: Mitsui Chemicals Tohcello Incorporated (Mitsui Chemicals)
• Original Assignee: Mitsui Chemicals Incorporated (Mitsui Chemicals)
• Inventors: Ikenaga, Shigenobu, Takeuchi, Fumito, Tokuhiro, Jun, Yarimizu, Kazuhiro, Watanabe, Keiji, Murofushi, Takanobu, Ito, Tomoaki, Maruko, Nobuhiro
• Granted Patent: US 8,772,625 B2
• Time in Patent Office: Days
• US Class Current: 136/251
• CPC Class Codes: C08F 210/08 Butenes
• CPC Class Codes: C08F 210/14 Monomers containing five or more carbon atoms
• CPC Class Codes: C08F 210/16 Copolymers of ethene with alpha-alkenes, e.g. EP rubbers
• CPC Class Codes: C08F 2500/03 Narrow molecular weight distribution, i.e. Mw/Mn < 3
• CPC Class Codes: C08F 2500/08 Low density, i.e. < 0.91 g/cm3
• CPC Class Codes: C08F 2500/12 Melt flow index or melt flow ratio
• CPC Class Codes: C08F 4/65908 in combination with an ionising compound other than alumoxane, e.g. (C6F5)4B-X+
• CPC Class Codes: C08F 4/65912 in combination with an organoaluminium compound
• CPC Class Codes: C08F 4/6592 containing at least one cyclopentadienyl ring, condensed or not, e.g. an indenyl or a fluorenyl ring
• CPC Class Codes: C08F 4/65925 two cyclopentadienyl rings being mutually non-bridged
• CPC Class Codes: C08L 2312/08 by silane
• CPC Class Codes: C09D 123/0815 Copolymers of ethene with aliphatic 1-olefins
• CPC Class Codes: C09K 2200/0617 Polyalkenes
• CPC Class Codes: C09K 2200/062 Polyethylene
• CPC Class Codes: C09K 3/10 Materials in mouldable or extrudable form for sealing or packing joints or covers filling pastes C09D5/34
• CPC Class Codes: H01L 31/0481 characterised by the composition of the encapsulation material
• CPC Class Codes: Y02B 10/10 Photovoltaic [PV]
• CPC Class Codes: Y02E 10/50 Photovoltaic [PV] energy

Abstract

Disclosed is an encapsulating material for solar cell containing an ethylene/α-olefin copolymer satisfying the following requirements (a1) to (a4): (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 from 10 to 50 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/cm³ 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.

Claims

1. An encapsulating material for solar cell comprising an ethylene/α

-olefin copolymer satisfying the following requirements (a1) to (a4);

(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 from 10 to 50 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/cm³ 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.

2. The encapsulating material for solar cell 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×

10¹³ to 1.0×

10¹⁸ Ω

·

cm as measured at a temperature of 100 degrees centigrade with an applied voltage of 500V in accordance with JIS K6911.

3. The encapsulating material for solar cell 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 encapsulating material for solar cell 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 encapsulating material for solar cell according to claim 1, wherein MFR of said ethylene/α

-olefin copolymer is from 10 to 27 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.

6. The encapsulating material for solar cell according to claim 1, wherein organic peroxide having a one-minute half-life temperature in the range of 100 to 170 degrees centigrade is further contained in an amount of 0.005 to 5 weight parts, based on 100 weight parts of said ethylene/α

-olefin copolymer.

7. The encapsulating material for solar cell 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.

8. The encapsulating material for solar cell according to claim 1, comprising an ethylene resin composition containing a silane coupling agent in an amount of 0.1 to 5 weight parts and a crosslinking agent in an amount of 0.1 to 3 weight parts, based on 100 weight parts of said ethylene/α

-olefin copolymer.

9. The encapsulating material for solar cell according to claim 8, 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.

10. The encapsulating material for solar cell according to claim 8, 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.

11. The encapsulating material for solar cell according to claim 1, obtained by melt-kneading said ethylene/α

-olefin copolymer and an additive, and then extrusion-molding the melt-kneaded mixture in a sheet form.

12. The encapsulating material for solar cell according to claim 1, wherein, for said ethylene/α

-olefin copolymer, (a7) the B value determined from the ¹³C-NMR spectrum and the following equation (1) is from 0.9 to 1.5, and

(a8) the intensity ratio of Tα

β

to Tα

α

(Tα

β

/Tα

α

) in the ¹³C-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.

13. The encapsulating material for solar cell 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).

14. The encapsulating material for solar cell 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.

15. The encapsulating material for solar cell according to claim 1, wherein (a11) the extracted amount of said ethylene/α

-olefin copolymer in methyl acetate is equal to or less than 5.0 weight %.

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

17. 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 said encapsulating material for solar cell according to claim 1.

18. (canceled)

19. (canceled)

20. (canceled)