成果報告書詳細
管理番号20130000000653
タイトル*平成24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2014/5/9
報告書年度2012 - 2012
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
英文要約A Novel Hybrid Material Based on A Combination of Encapsulants and Transparent Glazing Layers for A Roll-to-Roll Manufacturing.(FY2010-FY2014) FY2012 Annual Report

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 have been conducting five parts of developments, 1)encapsulant, 2)protection sheet, 3)hybrid material based on a combination of encapsulants and transparent glazing layers, 4)roll-to-roll lamination process and 5)encapsulant for rigid PVs.
1) The development of the encapsulant
The special chemicals were incorporated into our current encapsulant in order to modify an adequate viscoelastic property at a higher temperature. The new encapsulant has a good thermal stability at a higher temperature region as same as the conventional EVA encapsulant has. At the same time it enables us to do a faster lamination.
2) The development of the protection sheet
Novel moisture barrier sheet has been fabricated by roll-to-roll depositing machine.
First the smoothing hybrid barrier layer was printed on the substrate by roll to roll printing. And then the inorganic barrier layer was deposited on the hybrid barrier layer under the vacuum condition. This process of alternating hybrid and inorganic layers can be repeated a number of times to ensure that the total water vapor permeability is reduced to the desired level. A few stacks of each layer enable us to achieve less than 10-4 g/m2day of barrier properties and high 87% in transmittance.
3) The 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 the encapsulant and the transparent glazing layer. But the delamination between them was occurred during the damp heat test. In this period we have been improving the adhesive property between the encapsulant and the transparent glazing layer by changing the design of the materials.
4) The development of the roll-to-roll lamination process
We have been able to achieve the 3m/min of lamination speed by using the sophisticated roll-to-roll manufacturing facility. But a curing issue was remained. We have changed the design of the current module structure to the adequate construction.
5) The development of the new encapsulant for rigid PVs
The developing new polyolefin type of encapsulant has a better moisture barrier property and insulation property than the conventional cross-linked EVA has. It reveals that the new developing encapsulant is superior to the conventional one in terms of the Pmax in the damp heat condition.
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