成果報告書詳細
管理番号20110000000330
タイトル*平成22年度中間年報 太陽光発電システム次世代高性能技術の開発 ロールツーロールプロセスを可能とする封止材一体型保護シートの研究開発 
公開日2011/7/28
報告書年度2010 - 2010
委託先名積水化学工業株式会社
プロジェクト番号P07015
部署名新エネルギー部
和文要約和文要約等以下本編抜粋:1. 共同研究の内容及び成果等 1.1共同研究の内容 「ロールツーロールプロセスを可能とする封止材一体型保護シートの研究開発」では、太陽電池素子をラミネートする工程のプロセス革新を目的に研究開発を行っている。具体的には、真空プレス機によるバッチ方式の従来工程を、ロールツーロールプロセスによる連続生産可能なロールラミネート方式への置き換える事で、生産性を2倍以上にしてコストを大幅に改善することを目的にしている。 真空プレス機を用いた従来工法では、ガラスなどの表面保護層/封止材/光電変換素子/封止材/バックシート等の裏面保護材を積層する工程を前工程として行った後にプレスすることから保護材と封止材の接着はプレス工程内で同時に実施される。一方でロールラミネート工法では、素材の積層とラミネートを同時に行うためには、保護層と封止材があらかじめ一体化されている必要がある。
英文要約 Novel Hybrid Material Based on A Combination of Encapsulants and Transparent Glazing Layers for A Roll-to-Roll Manufacturing
A novel hybrid material based on a combination of encapsulants and transparent glazing layers is reported. It can be applied to a wide variety of roll-to-roll manufacturing for PV modules even at low processing temperatures. Furthermore, fabrication of the a-Si PV module via roll-to-roll process can be done under ambient conditions. No vacuum pressing techniques are required. A hybrid material, comprising a transparent flexible outer layer exposed to the environment and attached directly a thermoplastic encapsulation layer, has been successfully prepared via co-extrusion process. Moreover the sophisticated equipment was successfully designed and manufactured for roll-to-roll manufacturing of PV modules.
1. Encapsulants
We are offering a thermoplastic polymer which has an adhesion property as an encapsulant for PV modules. It allows us to encapsulate PV modules less time. We also added UV absorber and other chemicals for long term stability. The relationship between the encapsulant formulation and the durability properties was investigated.
2. Transparent Glazing Layers
While glass is sometimes used for a glazing on a PV module, thermoplastic polymers are often used due to their increased impact resistance and lower weight. The glazing for a flexible photovoltaic module must have extended durability under solar radiation, high transmittance of solar energy, good dirt release performance, the ability to withstand high temperature used to form the module without deformation and discoloration. We are proposing a flexible durable film as a transparent glazing layer for a PV module. The flexible durable film must be thick enough to support the glazing weight in the PV module, and can vary with the type of durable film.
3. Combination of Encapsulant/Protection Film
Multilayer laminates often result in a misbalance of properties, are expensive, or difficult to handle or process. In particular a photovoltaic front sheet, a good interlayer adhesion is needed. In addition, the inner layers may not be fully durable over the life of the laminate without additional protection. Co-extrusion process is applied to make a combination of encapsulants and transparent glazing layers. The properties of the layers such as thickness, planarity are researched to achieve a roll lamination. A lamination of these combined materials could potentially be done in a roll-to-roll process.
4. Lamination Technique
No roll-to-roll lamination technique for manufacturing PV modules has been achieved. Our fundamental research for a high speed lamination allowed us to customize the roll-to-roll lamination system for manufacturing PV modules. The sophisticated lamination equipment was successfully designed and manufactured. In general, the lamination of the two or more materials is accomplished less than a second and several seconds. Where vacuum lamination is utilized, the process can take about 5 to about 15 minutes. We are going to make a lamination technique in the next investigation.
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