成果報告書詳細
管理番号20120000000546
タイトル*平成23年度中間年報 太陽エネルギー技術研究開発/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2012/6/20
報告書年度2011 - 2011
委託先名積水化学工業株式会社
プロジェクト番号P0715
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:
「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。
英文要約Title:A Novel Hybrid Material Based on A Combination of Encapsulants and Transparent Glazing Layers for A Roll-to-Roll Manufacturing
An innovative PV module production process has been studied. It can help to improve the productivity and reduce the production cost dramatically. A roll-to-roll basis, continuous lamination process is employed for the PV module manufacturing process. In the prior art multilayer films are constructions, which provide several performances separately. These performances include weathering resistance, water vapor barrier, encapsulation and electrical insulation. Up until the present technology, such as vacuum pressing lamination manufacturing often result in a complicated handling process. In this study we have designed the new roll-to-roll module manufacturing facility. It can be applied to a wide variety of roll-to-roll manufacturing for PV modules, such as a fabrication of the flexible a-Si PV modules. We are conducting four parts of developments, 1)encapsulant, 2)glazing layer 3)hybrid material based on a combination of encapsulants and transparent glazing layers and 4)roll-to-roll lamination process.
1) The development of encapsulant
Most of the present CIS- or CIGS-based PV modules employ ZnO as the conducting front contact electrodes. We have conducted stability studies for the ZnO electrode on glass using accelerated stress tests that include DH with developing encapsulants and standard EVA polymers. The results show much less degradation of ZnO with developing encapsulants than that of standard EVA polymers.
2) The development of hybrid materials based on a combination of encapsulants and transparent glazing layers
We have conducted several accelerated stress tests for a-Si modules with the developing hybrid materials based on a combination of encapsulants and transparent glazing layers as well. But we did not have expecting performance of these modules. The results showed a degradation of one of the important properties. In this period we have been improving these properties by changing the design of the materials.
3) The development of the roll-to-roll lamination process
The lamination condition has been investigated by using the sophisticated roll-to-roll manufacturing facility. We have acquired a suitable lamination technique for flexible a-Si modules and we are going to make a mass production technique in the next step.
4)The development of the ultra gas barrier materials
Hybrid coatings on PEN substrates exhibit good planarity as equal as Ra=1.0nm. The excellent properties can be obtained by synergistic effect through the combination of vapor-deposited inorganic oxide layers and hybrid polymer based coating layers. Two stacks of each layer enable us to achieve less than 10-4 g/m2day of barrier properties.
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