成果報告書詳細
管理番号20110000000364
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  超ハイガスバリア太陽電池部材の研究開発 
公開日2011/6/29
報告書年度2010 - 2010
委託先名三菱樹脂株式会社
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
太陽光発電システムの普及にはモジュールコストの低減が不可欠である。その中で今後普及が見込める薄膜シリコンやCIS系の太陽電池では製造プロセスの製造コスト比率が大きくその低減が望まれている。
PV2030の技術開発ロードマップにおいても重要技術開発項目として言及されており、高生産性セルモジュール生産プロセスによる革新的コスト低減が太陽光発電の普及拡大のため極めて重要である。
また、高生産性のセルモジュール生産プロセス実現のためにはロールto ロールプロセスといわれる連続プロセスが必要となる。
本事業では、屋外で使用可能なプラスチック基材と蒸着膜の組み合わせにより10~6 g/(m2・d)以下となる耐久性、超ハイガスバリアフィルムを開発することを目指す。
平成22年度実施内容と成果
本事業では、エンジニアリングプラスチックとナノ粒子の配合設計、共押出、コーティングの組み合わせにより、耐久性を向上させた耐久性基材を開発する。また、バリア性の向上としてCat~CVD法を応用したガスバリア層を成膜することにより、超ハイガスバリア性を達成する。
平成22年度は、以下の内容を実施した。
英文要約Title: Research and development of Solar energy technology/
Development of next generation high efficient solar photovoltaic system/
Research and development of super-high gas barrier materials for solar battery.
The following results were achieved in FY2010 for each development themes.
1. Development of a high gas barrier film with Cat-CVD layers and its producing technology.
 In order to develop an ultra high gas barrier film with Cat-CVD layers, the gas barrier properties of those thin films were evaluated.
 In this study, hexamethyldisilazane was used as a material gas for Cat-CVD process. Water vapor transmission rate of the gas barrier films with Cat-CVD layers were measured by the bag method. By optimizations of process gases, layer thickness and process parameters, we could confirm the improvement of gas barrier properties. In addition, a try of high rate deposition was implemented. Compared with the normal deposition condition, we could enhance the deposition rate with keeping the high gas barrier property of 10-3 g/m2/day.
2. Development of weather-resistant back sheet and front sheet.
 Ultraviolet filters and moisture barrier layers are most important for improvement PV durability. We investigated the influence of ultraviolet protection treatment on optical properties of PV front sheets and worked on the optimization of moisture barrier films to the mechanical strength of PV back sheets.
2-1 Influence of ultraviolet protection treatment
Three different UV protection treatment samples were prepared; (1) UV-1 protection treating at polyester substrate, (2) UV-2 protection treating at polyester substrate and (3) Plain polyester film compounded UV absorbent additives. UV absorbance spectrum of PV front sheet with each of above UV filters was measured after 85oC x 85%RH 1000hrs test and SWOM test. UV-1 protection treated film show the highest retention in both tests.
2-2 Optimization of moisture barrier films
 Four kinds of back sheets were formed by laminating using proper polyurethane adhesives.
 Three barrier samples: laminating weather-resistant film and moisture barrier film (from 10-3 order to 10-1 moisture barrier sample), and non Barrier sample. After 85oC x 85%RH 2000hrs test, the tensile strength of both back sheets was measured. Tensile strength of barrier samples retains high value and that of non barrier sample drastically decreased. We have found that order of moisture barrier is closely related the retention ratio of mechanical strength.
3. Development of high weather and heat-resistant base film
In order to achieve high weather and heat-resistant film with the low thermal expansion coefficient and low thermal shrinkage, we investigated various plastic films and other materials with heat-resistant property, and tried to make the composite film.
 Evaluations of basic properties were implemented for various plastic films and other materials. We selected one base film and some kinds of composite materials. After optimized the combinations of the film and composite materials, two of noble composite films (Composite film-A and Composite film-B) showed low thermal expansion coefficient and thermal shrinkage.
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