JP2018061333A - Terminal box for solar power generation, solar cell - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a terminal box for photovoltaic power generation and a solar cell including the same, which can increase the degree of freedom in designing a photovoltaic power generation system, work efficiency in installing a system, and power generation efficiency.SOLUTION: A terminal box for photovoltaic power generation comprises a resin composition having a specific gravity of 1.5 g/cmor less and a Vicat softening point of 155°C or more, and has a bypass diode and an inverter inside, and a solar cell comprises the same.SELECTED DRAWING: Figure 1

Description

  The present invention relates to a terminal box for solar power generation and a solar battery.

Generally, a solar power generation system is configured by connecting power generation panels in series.
The direct current generated by each power generation panel is collected in a current collection box, and then converted into alternating current through a power conditioner having an inverter function.
In a photovoltaic power generation system, if a panel with poor power generation efficiency occurs due to factors such as the series connection of panels, the power generation efficiency is reduced due to factors such as being in the shade or the surface of the panel being dirty. There are things to do. Therefore, a terminal box in which a bypass diode having a function of bypassing a panel with reduced power generation efficiency is usually attached to each panel.

  Here, it is difficult to operate the power conditioner with an efficient system when the input voltage is mainly determined and the installation area such as the roof of a house is small. In order to solve this problem, a micro inverter that can be installed for each panel has been used in recent years.

  As the exterior body of the micro inverter, a metal case having excellent heat dissipation is used so as to withstand the heat generated by the inverter. However, since the power generation efficiency of the photovoltaic power generation panel decreases when the panel temperature increases, it is not preferable to directly attach the solar power generation panel to the back side of the panel in the case of a metal case whose outer surface also becomes high temperature.

  Under such circumstances, there is a method of installing a micro inverter with a gap between the panel (see Patent Document 1). In addition, a method of installing a micro inverter between the cells of the panel has been proposed (see Patent Document 2).

Japanese Patent No. 3357808 JP 2004-241753 A

  However, the method of Patent Document 1 has a problem that the degree of freedom of installation of the micro inverter is limited and the working efficiency is extremely deteriorated, and the method of Patent Document 2 originally has a space where a panel can be installed. By installing an inverter in the panel, the ratio of the panel installation area to the panel installable area becomes small, so that the power generation efficiency may be lowered as a whole.

  SUMMARY OF THE INVENTION An object of the present invention is to provide a solar power generation terminal box capable of increasing the degree of freedom of design of a solar power generation system, work efficiency in system installation, and power generation efficiency, and a solar cell including the same. And

  In order to solve the above-described problem advantageously, the inventors have come up with the integration of a box containing a bypass diode and a box containing a micro inverter.

  When examined, in the case of the resin material used in the conventional junction box, it is difficult to withstand the heat generation of the inverter, and in the case of the metal case used in the micro inverter, the installation location is limited as described above. It was found that the work efficiency was poor, it was difficult to maintain the insulation required for the junction box, and the weight increased with the increase in size.

  In the first place, since the terminal box that houses the bypass diode and micro inverter is installed outdoors, it was thought that it would be beneficial to provide such characteristics as not cracking even at low temperatures and not rusting when exposed to sea breeze. .

  The gist of the present invention made by the inventors is as follows.

The terminal box for photovoltaic power generation of the present invention is made of a resin composition having a specific gravity of 1.5 g / cm ³ or less and a Vicat softening point of 155 ° C. or more, and has a bypass diode and an inverter inside. And

Here, in the terminal box for photovoltaic power generation of the present invention, it is preferable that the resin composition has a tensile strength retention of 80% or more before and after 3000 hours exposure in an environment of temperature 85 ° C. and humidity 85%. .
Moreover, in the solar power generation terminal box of the present invention, the volume is preferably 300 cm ³ or more.
Furthermore, in the terminal box for photovoltaic power generation according to the present invention, a rib having a thickness of 1 mm or more is provided in the inside to partition a region occupied by the circuit of the bypass diode and a region occupied by the circuit of the inverter. preferable.
Furthermore, it is preferable that the terminal box for photovoltaic power generation of the present invention includes a container and a lid, and the unevenness difference of the outer surface of the lid is 3 mm or less.

  The solar cell of the present invention is characterized in that the high-performance terminal box for photovoltaic power generation and the photovoltaic power generation panel are directly attached via an adhesive.

  ADVANTAGE OF THE INVENTION According to this invention, the solar power generation terminal box which can raise the design freedom of a solar power generation system, the work efficiency in installation of a system, and power generation efficiency, and a solar cell provided with the same can be provided. .

(A) is a perspective view which shows an example of the terminal box for solar power generation of this embodiment. (B) is a perspective view which shows an example of the solar cell of this embodiment.

  Hereinafter, modes for carrying out the present invention (hereinafter also referred to as “the present embodiment”) will be described in detail with reference to the drawings. The following embodiments are examples for explaining the present invention, and the present invention is not limited to the following embodiments, and various modifications can be made within the scope of the gist of the present invention.

(Terminal box for photovoltaic power generation)
FIG. 1A is a perspective view showing an example of a terminal box for photovoltaic power generation according to this embodiment.
The terminal box 1 for photovoltaic power generation of this embodiment consists of a resin composition, and has the bypass diode 2 and the inverter 3 inside.
Here, the resin composition has a specific gravity of 1.5 g / cm ³ or less and a Vicat softening point of 155 ° C. or more.

  According to the photovoltaic power generation terminal box 1 of the present embodiment, by placing the bypass diode 2 and the inverter (particularly, the micro inverter) 3 in one box, points such as the arrangement of the solar cell panel 6 and the junction box 1 are provided. Therefore, the design freedom of the photovoltaic power generation system can be increased, and the work efficiency in the installation of the photovoltaic power generation system can be increased in terms of the arrangement of the bypass diode 2 and the inverter 3 near the solar battery panel. it can.

  Moreover, in the terminal box 1 for photovoltaic power generation of this embodiment, since members, such as a bypass diode 2 and an inverter 3, will be put together compactly in a system, the space which can install a solar panel is maximized. It becomes possible to use, and the power generation efficiency in the solar power generation system can be increased.

  Conventionally, a metal case that can withstand heat generation during operation and can efficiently dissipate heat has been used as a case for housing the micro inverter 3. When the micro inverter 3 is placed in a resin case There has been no report on the practicality of. In this respect, the standard for the exterior body and the like of the micro inverter 3 has not been determined at present.

The bypass diode 2 included in the solar power generation terminal box 1 of the present embodiment is not particularly limited, and may be appropriately determined according to the purpose and application.
The inverter 3 included in the solar power generation terminal box 1 of the present embodiment is not particularly limited and may be appropriately determined according to the purpose and application, but the micro inverter 3 is preferable from the viewpoint of compactness. .

  More specifically, the solar power generation terminal box 1 of the present embodiment includes a container 1B and a lid 1L as shown in FIG.

The shape of the terminal box for photovoltaic power generation according to this embodiment is not particularly limited, and may be appropriately determined according to the purpose and application. As shown in FIG. The shape may be matched.
The shape of the internal space of the terminal box 1 is not particularly limited, but from the viewpoint of facilitating the arrangement of the bypass diode 2 and the inverter 3, it is preferably a column having a rectangular bottom, as shown in FIG. Thus, it is more preferable that it is a rectangular parallelepiped.
The external shapes of the container 1B and the lid 1L are not particularly limited. As shown in FIG. 1A, the external shape of the container 1B may be a bowl shape, and the external shape of the lid 1L is the same as that of the container 1B. Although it is not particularly limited as long as it can be fitted, it may be flat.

  Although it does not specifically limit as a dimension of the terminal box 1, For example, when an external appearance is a rectangular parallelepiped, it may be 150-200 mm long x 100-200 mm wide x 20-40 mm in height.

In the present embodiment, considering that the terminal box 1 is attached to the photovoltaic power generation panel 6 to form a solar cell (described later), it is preferable that the unevenness difference on the outer surface of the lid 1L is smaller. Is preferably 3 mm or less, and more preferably 2 mm or less.
The outer surface of the lid refers to a surface facing outward from the box when the lid and the container are fitted together. In addition, the uneven | corrugated difference of the outer surface of the lid | cover 1L means the distance between both outermost ends about the thickness direction (direction which fits the lid | cover 1L to the container 1B) of the lid | cover 1L.

In the present embodiment, a rib 4 is provided inside the terminal box 1 to divide a region occupied by the circuit of the bypass diode 2 and a region occupied by the circuit of the inverter 3. The rib 4 allows the circuit of the bypass diode 2 and the circuit of the inverter 3 to exist independently.
The height of the rib 4 is not particularly limited, but may be 20 to 80% of the height of the container 1B.
The thickness of the rib 4 is preferably 1 mm or more, more preferably 1.5 to 2.5 mm, from the viewpoint of heat insulation and easy moldability.

  The wall thickness of the container 1B and the lid 1L of the terminal box 1 may be the same over all locations, may vary depending on the location, may be 1.5 to 3.0 mm on average, and is heat resistant. From this viewpoint, the thickness is preferably 2.0 to 3.0 mm.

Volume PV terminal box 1 of this embodiment, to secure the inner space of the box than the predetermined order, from the viewpoint of suppressing heat accumulation inside the box, is preferably 300 cm ³ or more, in 320 cm ³ or more More preferably.

  Hereinafter, it describes about the detail of the resin composition used by this embodiment.

The specific gravity of the resin composition used in the present embodiment is 1.5 g / cm ³ or less and more preferably 1.2 g / cm ³ or less from the viewpoint of facilitating adhesion to the panel using an adhesive. preferable.

  The Vicat softening point of the resin composition of the present embodiment is 155 ° C. or higher, preferably 160 ° C. or higher, and preferably 180 ° C. or lower so that it can withstand the heat generated from the electronic circuit. More preferably, it is 170 ° C. or lower.

  The resin composition used in the present embodiment may include a resin component and other components. Here, the resin component preferably includes a polyphenylene ether resin from the viewpoint of heat resistance and the like.

  More specifically, the resin composition of the present embodiment includes (A) polyphenylene ether, (B) a styrene resin, and (C) a hydrogenated block copolymer. It is preferable that a phosphoric ester compound, (E) polyolefin, (F) other additives are included.

（式（Ｉ）及び式（ＩＩ）中、Ｒ^１，Ｒ^２，Ｒ^３，Ｒ^４，Ｒ^５及びＲ^６は、各々独立に、水素原子、炭素数１〜４のアルキル基、炭素数６〜９のアリール基、又はハロゲン原子を表す。ただし、Ｒ^５及びＲ^６は、同時に水素ではない。） -(A) Polyphenylene ether-
(A) The polyphenylene ether is a homopolymer or copolymer containing a repeating unit represented by the following formula (I) and / or the following formula (II).

(In formula (I) and formula (II), R ¹ , R ² , R ³ , R ⁴ , R ⁵ and R ⁶ are each independently a hydrogen atom, an alkyl group having 1 to 4 carbon atoms, or 6 carbon atoms. Represents an aryl group of ˜9 or a halogen atom, provided that R ⁵ and R ⁶ are not hydrogen at the same time.

  Examples of the homopolymer of polyphenylene ether include poly (2,6-dimethyl-1,4-phenylene) ether, poly (2-methyl-6-ethyl-1,4-phenylene) ether, and poly (2,6 -Diethyl-1,4-phenylene) ether, poly (2-ethyl-6-n-propyl-1,4-phenylene) ether, poly (2,6-di-n-propyl-1,4-phenylene) ether Poly (2-methyl-6-n-butyl-1,4-phenylene) ether, poly (2-ethyl-6-isopropyl-1,4-phenylene) ether, poly (2-methyl-6-chloroethyl-1) , 4-phenylene) ether, poly (2-methyl-6-hydroxyethyl-1,4-phenylene) ether, poly (2-methyl-6-chloroethyl-1,4-phenyle) ) Ether and the like.

  Examples of the copolymer of polyphenylene ether include a copolymer of 2,6-dimethylphenol and 2,3,6-trimethylphenol, a copolymer of 2,6-dimethylphenol and o-cresol, 2, Examples include copolymers of 6-dimethylphenol, 2,3,6-trimethylphenol and o-cresol.

  Among these polyphenylene ethers, poly (2,6-dimethyl-1,4-phenylene) ether is preferable from the viewpoint of availability and economy, and is described in JP-A-63-301222 and the like. Polyphenylene ether containing 2- (dialkylaminomethyl) -6-methylphenylene ether unit or 2- (N-alkyl-N-phenylaminomethyl) -6-methylphenylene ether unit as a partial structure is also preferably used. .

  The polyphenylene ether (A) may be a modified polyphenylene ether partially or entirely modified with an unsaturated carboxylic acid or derivative thereof. The modified polyphenylene ether can be produced, for example, by melt-kneading and reacting polyphenylene ether with an unsaturated carboxylic acid or a derivative thereof in the presence or absence of a radical initiator. Or it can manufacture also by dissolving polyphenylene ether, unsaturated carboxylic acid, and its derivative (s) in the organic solvent in the presence or absence of a radical initiator, and making it react under a solution.

  The unsaturated carboxylic acid or derivative thereof is not particularly limited, and examples thereof include maleic acid, fumaric acid, itaconic acid, halogenated maleic acid, cis-4-cyclohexene-1,2-dicarboxylic acid, and endo-cis-bischromo ( 2,2,1) -5-heptene-2,3-dicarboxylic acid and the like, and anhydrides, esters and amides of these dicarboxylic acids. As the saturated carboxylic acid, a compound that can be thermally decomposed at the reaction temperature at the time of producing the modified polyphenylene ether to become a derivative that can be used in this embodiment can also be used. Specific examples include malic acid and citric acid. These may be used alone or in combination of two or more.

The content of (A) polyphenylene ether in the resin composition is not particularly limited, but is preferably in the range of 65 to 98 mass% with respect to the total of 100 mass% of (A) to (D) above. 70-97 are more preferable, 70-95 mass% is further more preferable, 75-93 mass% is still more preferable, 80-90 mass% is especially preferable.
When the content of polyphenylene ether in the total 100% by mass of the above (A) to (D) is 65% by mass or more, the heat resistant temperature does not become too low and long-term heat resistance can be improved. Further, if the polyphenylene ether content in the total 100% by mass of the above (A) to (D) is 98% by mass or less, the melt viscosity at the time of extrusion does not become too high, and the productivity can be further stabilized. .

-(B) Styrenic resin-
(B) The styrene resin is a polymer obtained by polymerizing a styrene compound or a styrene compound and a compound copolymerizable with the styrene compound in the presence or absence of a rubbery polymer. Say. The styrene compound is not particularly limited, and examples thereof include styrene, α-methylstyrene, 2,4-dimethylstyrene, monochlorostyrene, p-methylstyrene, p-tert-butylstyrene, and ethylstyrene. Among these, styrene is preferable from the viewpoint of compatibility with polyphenylene ether.

  The compound copolymerizable with the styrenic compound is not particularly limited, and examples thereof include methacrylic acid esters such as methyl methacrylate and ethyl methacrylate; unsaturated nitrile compounds such as acrylonitrile and methacrylonitrile; acids such as maleic anhydride. An anhydride etc. are mentioned. These are used with styrenic compounds. The amount of the copolymerizable compound is not particularly limited, but is preferably 20% by mass or less, more preferably 15% by mass or less, based on the total amount with the styrenic compound.

  The rubbery polymer is not particularly limited, and examples thereof include conjugated diene rubbers, copolymers of conjugated dienes and aromatic vinyl compounds, and ethylene-propylene copolymer rubbers.

  Specific examples of the styrene resin include polystyrene, rubber reinforced polystyrene, styrene-acrylonitrile copolymer (AS resin), rubber reinforced styrene-acrylonitrile copolymer (ABS resin), and other styrene copolymers. .

  Although content of the styrene resin (B) in a resin composition is not specifically limited, It is preferable that it is the range of 1-25 mass% with respect to a total of 100 mass% of said (A)-(D). 1 to 15% by mass is more preferable, and 1 to 10% by mass is more preferable. In particular, when a connection structure is used under conditions where long-term heat resistance is required, the content of polystyrene in the total of 100% by mass of (A) to (D) is preferably in the range of 1 to 25% by mass. More preferably, it is the range of 3-10 mass%.

-(C) Hydrogenated block copolymer-
(C) A hydrogenated block copolymer is a hydrogenated block copolymer of a block copolymer obtained by copolymerizing at least styrene and a diene compound. The hydrogenated block copolymer may be copolymerized with other monomers as long as the performance is not affected. The hydrogenation rate of the unsaturated bond derived from the diene compound is preferably 60% or more, more preferably 80% or more, and still more preferably 95% or more.
The hydrogenation rate can be measured with a nuclear magnetic resonance apparatus (NMR).

In the hydrogenated block copolymer, when the styrene block chain is represented by “S” and the diene compound block chain is represented by “B”, examples of the structure of the hydrogenated block copolymer include SBS, S— BSB, (SB-) 4-Si, SBS-BSS, etc. are mentioned. The microstructure of the diene compound polymer block (for example, 1,2-vinyl bond, 1,4-vinyl bond, etc.) is not particularly limited, and can be arbitrarily selected. Usually, the 1,2-vinyl bond is in the range of 2 to 60%, preferably 8 to 40%, based on the total bond of the diene compound polymer.
The 1,2-vinyl bond can be measured by a nuclear magnetic resonance apparatus (NMR).

  (C) The ratio of the styrene polymer block of the hydrogenated block copolymer to the entire copolymer is not particularly limited, but is preferably 25 to 80% by mass, and preferably 30 to 50% by mass from the viewpoint of impact resistance. Is more preferable.

  (C) The hydrogenated block copolymer preferably has at least one styrene block chain having a number average molecular weight of 15,000 or more, more preferably 20,000 to 50,000. More preferably, the number average molecular weight of all styrene block chains is 15,000 or more. (C) Although the number average molecular weight of a hydrogenated block copolymer is not specifically limited, Preferably it is 80,000 or more, More preferably, it is 150,000-400,000. Here, the number average molecular weight can be determined by measuring by gel permeation chromatography (GPC) using tetrahydrofuran as a mobile phase, calibrating with polystyrene having a known molecular weight and converting. (C) A hydrogenated block copolymer may be used individually by 1 type, and may use 2 or more types together.

  Although content of (C) hydrogenated block copolymer in a resin composition is not specifically limited, It is the range of 1-20 mass% with respect to a total of 100 mass% of said (A)-(D). It is preferably 3 to 10% by mass, more preferably 3 to 8% by mass. When the content of the hydrogenated block copolymer is 1% by mass or more, sufficient impact strength can be obtained. Moreover, by setting it as 20 mass% or less, not only the outstanding impact resistance but the fall of the impact resistance retention after heat aging can be prevented.

（式（ＩＩＩ）及び式（ＩＶ）中、Ｑ^１，Ｑ^２，Ｑ^３及びＱ^４は、各々独立して、炭素数１〜６のアルキル基を表し、Ｒ^７及びＲ^８は、各々独立して、水素原子又はメチル基を表す。ｎは１以上の整数を表し、ｎ^１及びｎ^２は、各々独立して、０〜２の整数を表し、ｍ^１，ｍ^２，ｍ^３及びｍ^４は、各々独立して、０〜３の整数を表す。） -(D) Phosphate ester compound-
By including the (D) phosphate ester compound in the resin composition, flame retardancy can be improved.
The (D) phosphate ester compound used as necessary in the present embodiment is not particularly limited, and (A) an organic phosphate ester usually used as a flame retardant for polyphenylene ether can be used.
Among these, the condensed phosphate ester represented by the following formula (III) or the following formula (IV) is preferable.

(In Formula (III) and Formula (IV), Q ¹ , Q ² , Q ³ and Q ⁴ each independently represent an alkyl group having 1 to 6 carbon atoms, and R ⁷ and R ⁸ are each independently A hydrogen atom or a methyl group, n represents an integer of 1 or more, n ¹ and n ² each independently represents an integer of 0 to 2, m ¹ , m ² , m ³ and m ⁴ each independently represents an integer of 0 to 3.)

  Condensed phosphate ester may be used individually by 1 type, and may use 2 or more types together.

  In the condensed phosphate esters represented by formula (III) and formula (IV), n is an integer of 1 or more, preferably an integer of 1 to 3, respectively.

Among these, in formula (III), m ¹ , m ² , m ³ , m ⁴ , n ¹ and n ² are all 0, and R ⁷ and R ⁸ are methyl groups; In formula (III), Q ¹ , Q ² , Q ³ , Q ⁴ , R ⁷ and R ⁸ are all methyl groups, n ¹ and n ² are 0, and m ¹ , m ² , m ³ And m ⁴ are each independently a condensed phosphate ester having an integer of 1 to 3, and a condensed phosphate ester in which n is 1 to 3 is preferable. Among these, it is more preferable that the phosphoric acid ester in which n is 1 is 50% by mass or more in the component (D).
Commercially available products can be used for these flame retardants, and examples thereof include trade names “CR-741”, “CR733S”, “PX-200” and the like manufactured by Daihachi Chemical Co., Ltd. Specifically, bisphenol A bisdiphenyl phosphate and resorcin bisdikyryl phosphate are particularly preferable as the phosphate ester compounds.

  The content of the phosphate ester (D) in the resin composition is not particularly limited, and varies depending on the flame retardancy level desired for the connection structure, but with respect to the total of 100% by mass of the above (A) to (D). It is preferable that it is the range of 3-20 mass%, 5-15 mass% is more preferable, and 5-20 mass% is further more preferable. When the phosphate ester content is 3% by mass or more, sufficient combustibility can be obtained. Moreover, if it is 20 mass% or less, not only a flame retardance but sufficient heat resistance can be obtained, and the outstanding physical property balance can be obtained.

-(E) Polyolefin-
By including polyolefin in the resin composition, the heat resistance can be further improved.
The (E) polyolefin used as necessary in the present embodiment is not particularly limited, and for example, low density polyethylene, high density polyethylene, linear low density polyethylene, polypropylene, ethylene-propylene copolymer, ethylene- Examples include butene copolymers, ethylene-octene copolymers, and ethylene-acrylic acid ester copolymers.
Among these, low density polyethylene and ethylene-propylene copolymer are preferable from the viewpoint of heat resistance.
Here, the ethylene-propylene copolymer, ethylene-butene copolymer, ethylene-octene copolymer, and ethylene-acrylic acid ester copolymer are generally amorphous or low crystalline copolymers.
These copolymers may be copolymerized with other monomers as long as the performance is not affected. Although the component ratio of ethylene and propylene, butene, or octene is not specifically limited, Usually, the component ratio of propylene, butene, or octene in a copolymer is the range of 5-50 mol%, respectively. These polyolefins may be used individually by 1 type, and may use 2 or more types together.

  (E) For polyolefin, the melt flow rate (MFR) measured at a cylinder temperature of 230 ° C. according to ASTM D-1238 is not particularly limited, but is preferably 0.1 to 50 g / 10 min. More preferably, it is 2 to 20 g / 10 minutes. (E) By making MFR of polyolefin into the said numerical range, compatibility with (C) component can be improved.

  The content of the (E) polyolefin in the resin composition is not particularly limited, but from the viewpoint of dispersibility in the component (A) and the component (B), the total content of the above (A) to (D) is 100% by mass. On the other hand, the range is preferably 0.5 to 5% by mass, more preferably 0.1 to 3% by mass, and still more preferably 0.5 to 2% by mass.

-(F) Other additives-
In order to further impart properties such as fluidity and heat resistance of the resin composition, (F) other additives may be added to the resin composition.
(F) Other additives include, but are not particularly limited to, reinforcing agents (glass fibers, glass flakes, kaolin clay, talc and other inorganic fillers, other fibrous reinforcing agents, etc.), plasticizers, antioxidants, Various stabilizers, antistatic agents, mold release agents, dyes and pigments, other resins, flame retardants other than component (D) and flame retardant aids (hydroxides such as magnesium hydroxide and aluminum hydroxide containing crystal water) Zinc borate compound; zinc stannate compound; inorganic silicon compounds such as silica, kaolin clay, talc, etc.).

The resin composition has a tensile strength retention of 80% or more, more preferably 85% or more before and after 3000 hours exposure in an environment of temperature 85 ° C. and humidity 85%.
In addition, the retention rate of the said tensile strength can be measured by the method of description of the below-mentioned Example.

  The production method of the resin composition is not particularly limited, and a known production method suitable for each may be used. When polyphenylene ether powder is used, the total barrel length of the twin screw extruder is set to 100%. Sometimes it is preferred that the length of 45-75% from the upstream side of the barrel is the unmelted mixing zone. Here, the unmelted mixing zone refers to a zone in which the melting of the polyphenylene ether powder is suppressed and the polyphenylene ether powder is not completely melted and conveyed to the downstream side of the barrel while being mixed with other raw materials. Say. The ratio of the unmelted mixing zone length to the barrel length is not particularly limited, but is preferably 50 to 70%, and more preferably 60 to 70%.

  From the viewpoint of maintaining the physical properties of the resin composition, production stability, etc., the ratio of the unmelted mixing zone length to the barrel total length is preferably 45% or more. From the viewpoint of sufficiently melt-kneading the resin composition and securing the addition zone from the vacuum degassing zone and the second supply port, the ratio of the unmelted kneading zone length to the barrel total length is 75% or less. It is preferable.

  For the extrusion screw in the unmelted mixing zone, use a feed screw element such as a single threaded screw element or a double threaded screw element, so that it is difficult to take a share and has a good powder component conveying efficiency. Is preferred. In particular, from the viewpoint of improving the efficiency of conveying powder components, a single positive screw having a ratio (L / D) of the length (L) of the screw element to the screw diameter (D) of 1.0 to 3.0 It is preferable to use an element or a double threaded screw element.

  A melt-kneading zone for sufficiently kneading the polyphenylene ether powder and other raw materials is provided after the unmelted mixing zone. The ratio of the melt-kneading zone length to the total barrel length is not particularly limited, but is preferably 5 to 30%, more preferably 8 to 20%. Here, the melt-kneading zone is a kneading disc R (a combination of 3 to 7 discs with a twist angle of 15 to 75 degrees, L / D of 0.5 to 2. 0 positive screw element), kneading disk N (neutral screw element with L / D of 0.5-2.0, combining 3 to 7 disks at a twist angle of 90 degrees), kneading disk L (reverse screw screw element having L / D of 0.5 to 1.0 in which 3 to 7 disks are combined at a twist angle of 15 to 75 degrees), reverse screw screw (L / D is 0.5 to 1.0, two reverse screw screw elements), SME screw (notched to the positive screw screw to improve kneadability, L / D is 0.5 to 1.5 Screw elements such as Crew elements) and ZME screws (screw elements having a L / D of 0.5 to 1.5 with a notch in the reverse screw screw to improve kneading properties), etc. A zone that is incorporated and kneaded. The melt-kneading zone can be divided and provided in two or more places as necessary. Even when two or more melt-kneading zones are provided, the ratio of the total length of the melt-kneading zones to the total barrel length is preferably 5 to 30%. For the remaining screw elements other than the unmelted mixing zone and the melt-kneading zone, it is preferable to use a feed screw element such as a double threaded screw element having an L / D of 0.5 to 3.0.

  After the melt-kneading zone, it is preferable to provide a vacuum degassing zone for removing volatile components and decomposition products from the molten resin. It is preferable that the screw in the vacuum degassing zone has a screw configuration that is less likely to be sheared by using a feed screw element such as a double threaded screw screw. The vacuum degassing zone is preferably provided with a decompression vent and decompressed to −600 mmHg or less. Two or more decompression vent ports may be installed in the vacuum degassing zone. Furthermore, a 2nd supply port can be provided as needed, and a flame retardant, an impact modifier, an additive, an inorganic filler, etc. can also be added. As the screw of the second supply port, it is preferable to use a feed screw element such as two regular screw screws.

  The barrel temperature of the unmelted mixing zone is not particularly limited, but is preferably set to 280 ° C. or lower. More preferably, the barrel of the first supply port of the raw material is water-cooled and the first 30% of the barrel length is set to a barrel temperature of 200 ° C. or lower. The barrel temperature from the melt kneading zone to the extruder outlet is preferably set to 240 to 330 ° C, more preferably 250 to 300 ° C, and further preferably 260 to 290 ° C. By setting the barrel temperature to 330 ° C. or lower, the deterioration of the resin can be prevented. By setting the barrel temperature to less than 240 ° C, the polyphenylene ether powder can be melted moderately, deterioration of mechanical properties can be prevented, the torque during extrusion does not become too high, and the extruder stops due to torque over. Can be prevented.

  Although the screw speed of an extruder is not specifically limited, It is preferable that it is 150-600 rpm, It is more preferable that it is 200-500 rpm, It is further more preferable that it is 300-450 rpm. By setting the screw rotation speed to 150 rpm or more, the polyphenylene ether powder and other raw materials can be sufficiently kneaded. By setting the screw rotation speed to 600 rpm or less, it is possible to suppress an extreme increase in the resin temperature and to prevent a deterioration in the performance of the extruder.

  In the method for producing a resin composition, the temperature of the resin composition extruded from the outlet of the die is not particularly limited, but is preferably controlled to be less than 380 ° C. By setting the resin temperature to 380 ° C. or lower, it is possible to prevent the resin from being deteriorated or decomposed, and to prevent mechanical properties, impact resistance after exposure to heat, and the like from decreasing. The temperature of the resin composition is more preferably 320 to 370 ° C, and further preferably 330 to 360 ° C.

  In order to keep the resin temperature below 380 ° C, the length of unmelted mixing zone and melting zone, screw configuration, barrel set temperature, screw rotation speed, etc. are adjusted appropriately according to the quantity ratio and type of resin composition do it.

  In the method for producing a resin composition, the method for supplying the (D) phosphate ester compound is not particularly limited, and a known method may be used.

  When the phosphate ester compound is a liquid, (A) polyphenylene ether powder, (B) styrene resin, and (C) hydrogenated block copolymer are fed from the first raw material supply port on the upstream side of the extruder. After feeding, it is preferable to perform side feed from the second raw material supply port on the downstream side of the first raw material supply port. More preferably, (A) a method in which a second raw material supply port is provided in an unmelted mixing zone where the polyphenylene ether powder is not melted and side feed is performed therefrom. (D) When supplying the phosphoric ester compound from the unmelted mixing zone, the kneading disc R (combined 3 to 7 discs with a twist angle of 15 to 75 degrees within a range in which the polyphenylene ether is not melted, L / It is preferable to mix (A) the polyphenylene ether powder and the liquid (D) phosphate ester compound using a positive screw element having a D of 1.0 to 1.5.

  The method for side-feeding the liquid (D) phosphate ester compound is not particularly limited, and can be fed from the injection nozzle to the side of the extruder using, for example, a gear pump or a plunger pump.

  (D) When the phosphate ester compound is solid, it may be supplied together with other components from the first supply port on the upstream side of the extruder, or provided downstream from the first supply port. Alternatively, side feeding may be performed from the supply port.

(Manufacturing method of high-performance terminal box for photovoltaic power generation)
The method for producing a high-performance terminal box for photovoltaic power generation is not particularly limited, and examples thereof include injection molding and molding by cutting from a thick plate, and injection molding is preferred from the viewpoint of mass productivity.
In particular, when manufacturing junction boxes, there are few weld lines generated when molten resin merges from multiple directions in injection molding, and sufficient pressure was applied to flow ends such as nails and thin-walled portions and difficult-to-flow portions. It is preferable to select a resin-filled gate position that can be filled in a state from the viewpoint of impact resistance and dimensional accuracy. In addition, in order to ensure fitting and joining with connectors and other parts, it is necessary to make the terminal box into a shape that does not easily cause sink marks or warpage that impairs the surface smoothness and dimensional accuracy of the terminal box. From the viewpoint of attachment to the substrate, it is preferable.

(Solar cell)
FIG. 1B is a perspective view showing an example of the solar cell of the present embodiment.
In the solar cell 10 of this embodiment, a photovoltaic power generation high-functional terminal box 1 and a photovoltaic power generation panel 6 are directly attached via an adhesive 5.

In the present embodiment, from the viewpoint of power generation efficiency, it is preferable that the high-functionality terminal box 1 for solar power generation is attached to the back surface (shade side surface) of the solar power generation panel 6.
Moreover, the position in the solar power generation panel 6 to which the high-function terminal box 1 for solar power generation is attached is not particularly limited, and may be appropriately determined according to the purpose and application.

  Moreover, the thickness of the layer made of the adhesive 5 formed between the high-performance terminal box 1 for photovoltaic power generation and the photovoltaic power generation panel 6 may be 0.1 to 1.0 mm, and the cost of the adhesive is low. From the viewpoint, it is preferably 0.1 to 0.5 mm.

  The adhesive 5 is not particularly limited and may be appropriately selected depending on the purpose and application, and a silicon-based adhesive having a property that hardly affects the resin such as deterioration is preferable.

  The manufacturing method of the solar cell may be a method well known to those skilled in the art, and the terminal box can be appropriately attached to the panel.

  EXAMPLES Hereinafter, although this invention is demonstrated based on an Example and a comparative example, this invention is not limited to these.

The raw materials used in the examples described later are as follows.
-(A) Polyphenylene ether ("PPE" in Table 1)-
Poly-2,6-dimethyl-1,4-phenylene ether. Reduced viscosity measured with a chloroform solution at 30 ° C .: 0.48 dL / g.
-(B) Styrenic resin (in Table 1, "PS")-
Rubber Reinforced Polystyrene (High Impact Polystyrene, HIPS): Product name “H9405” manufactured by PS Japan
-(C) Hydrogenated block copolymer-
It has two styrene block chains having a number average molecular weight of 41,000, a 1,2-vinyl structure of 33% S-B-S-B structure, a styrene polymer block of 33% by mass, a butadiene unit hydrogenation rate of 99 %, A hydrogenated styrene block copolymer having a number average molecular weight of about 250,000.
-(D) Phosphate ester compound-
Condensed phosphate ester: Daihachi Chemicals, trade name “CR-741”

The raw materials used in the comparative examples described below are as follows.
Polycarbonate resin ("PC" in Table 1) (manufactured by SABIC, trade name "Lexan (registered trademark) EXL9330")
Acrylonitrile-butadiene-styrene resin (“ABS” in Table 1) (trade name “Stylac (registered trademark) VA58” manufactured by Asahi Kasei Chemicals Corporation)
-Impact resistant polystyrene resin (in Table 1, "HIPS") (manufactured by PS Japan, trade name "PSJ-polystyrene H8672")
Glass fiber reinforced polyamide resin (in Table 1, “PA / GF”) (manufactured by DuPont, trade name “Zytel (registered trademark) FR50”)
Glass fiber reinforced polybutylene terephthalate resin (in Table 1, “PBT / GF”) (manufactured by SABIC, trade name “Valox (registered trademark) 4521”)
・ Metal (Metal type: Stainless steel SUS304)

  The measuring method of the physical property of the resin composition obtained by the below-mentioned Example and comparative example is as follows.

(A) Specific gravity The specific gravity (g / cm ³ ) of the obtained resin composition was measured according to ISO 1183 by cutting out a test piece from an injection-molded dumbbell piece. The results are shown in Table 1.

(B) Vicat softening point The Vicat softening point (° C) of the obtained resin composition was cut out from a dumbbell piece molded by injection molding, in accordance with ISO306, the heating rate: 120 ° C / hr, load: Measurement was performed under conditions of 1 kg. The results are shown in Table 1.

(C) High-temperature and high-humidity environment test An ISO dumbbell test piece injection-molded from the obtained resin composition was exposed to a constant temperature and humidity chamber at 85 ° C. and humidity 85% for 3500 hours, and then at a temperature 23 ° C. and humidity 50%. A tensile test was carried out after standing for 24 hours in the environment. The results are shown in Table 1.
○: Tensile strength retention is 80% or more ×: Tensile strength retention is less than 80%

(D) Low-temperature steel ball drop test A 3 mm-thick injection-molded test piece produced from the obtained resin composition was tested according to the test method of ISO6603-2. The conditions of a support ring diameter of 40 mm, a striker diameter of 20 mm, a weight of 2.5 kg, and a height of 987 mm were used. The results are shown in Table 1.
○: No complete through hole occurred in the test piece ×: Complete through hole occurred in the test piece

(E) Insulation test The obtained resin composition was subjected to an IEC 60093 test (room temperature) and a CTI test in UL 746A. The results are shown in Table 1.
In the CTI test, classification by PLC is performed, PLC0 is 600V ≦ tracking index, PLC1 is 400V ≦ tracking index V <600V, PLC2 is 250V ≦ tracking index V <400V, PLC3 Is 175V ≦ tracking index V <250V, PLC4 is 100V ≦ tracking index V <175V, and PLC5 is tracking index V <100V. If the PLC value is small, tracking is less likely to occur, which is preferable.
○: The surface resistivity was 10 ¹⁶ in the IEC 60093 test and the PLC was 0 to 2 in the CTI test. ×: The surface resistivity was 10 ¹⁶ in the IEC 60093 test, but the PLC was 3 to 5 in the CTI test.

  The measuring method of the physical property of the terminal box for photovoltaic power generation obtained by the below-mentioned Example and comparative example is as follows.

(1) Thermal deformation test The obtained terminal box was taken out of an oven at 120 ° C. for 1 hour and then left at room temperature for 1 hour, and then the presence or absence of deformation in the appearance of the box was visually observed. The results are shown in Table 1.
○: No deformation ×: Deformation

(2) Thermal insulation test The thermal conductivity at room temperature of the obtained terminal box was measured in accordance with ASTM D5930.
○: More than 0.5 (W / (m · K)) ×: 0.5 (W / (m · K)) or more

(3) Panel adhesion test After thinly applying an adhesive to the outer surface of the lid of the obtained terminal box, the applied part was adhered to the glass plate, and then left at room temperature for 1 day with the glass plate side up The adhesion between the lid and the glass was evaluated.
○: No float or the like with glass ×: Float or the like is seen in glass and test product

Example 1
(A) Polyphenylene ether, (B) Styrene when the above material is melt-kneaded using a screw twin screw extruder ("ZSK58MC", manufactured by Werner & Pfleiderer, Germany) with a screw diameter of 58 mm and a 13-barrel decompression vent. After supplying the resin, (C) hydrogenated block copolymer, and (E) polyolefin from the first supply port in the barrel 1 on the upstream side with respect to the flow direction of the extruder, (D) the phosphate ester compound Was extruded from an injection nozzle on the side of the extruder using a gear pump from a second supply port downstream of the first supply port. The extruded strand was cut by cooling to obtain a resin composition pellet.
Test pieces were appropriately prepared from the resin composition pellets, and the physical properties were evaluated as described above.

The screw configuration of the extruder was 65% of the total barrel length as an unmelted mixing zone and 12% of the remaining 35% of the barrel length as a melt-kneading zone. A vacuum degassing zone was provided in the barrel 11 to reduce and degas at -670 mmHg. A second supply port for supplying a phosphate ester compound was provided in the barrel 12.
Barrel set temperature is barrel 1: water cooling, barrel 2: 100 ° C., barrel 3: 150 ° C., barrel 4, 5: 200 ° C., barrel 6: 250 ° C., barrel 7 to barrel 10: 280 ° C., barrel 11 to barrel 13 : Extrusion was performed under the conditions of 270 ° C., die set temperature: 320 ° C., screw rotation speed: 400 rpm, discharge amount: 300 kg / hour.
In the unmelted mixing zone, a single positive screw screw (L / D = 1.0) and two positive screw screws were used. In the melt-kneading zone, a kneading disc R (a positive screw element with L / D = 1.0, which is a combination of 5 discs with a twist angle of 45 degrees), and a kneading disc N (5 discs) A combination of a screw screw element with L / D = 1.0 and a reverse screw screw element (two reverse screw elements with L / D = 0.52) combined at a twist angle of 90 degrees was used.
Between the vacuum degassing zone and the phosphate ester compound supply port, a reverse screw screw (two reverse screw screw elements with L / D = 0.52) was used to supply the phosphate ester compound. In the zone, a kneading disk R (L / D = 1.0) and an SME screw (L / D = 0.69) were used.

A terminal box for photovoltaic power generation having a structure as shown in FIG. 1A was produced using the resin composition pellets.
About the structure of the produced terminal box for photovoltaic power generation, the external shape is a rectangular parallelepiped, the dimensions are 200 mm long × 150 mm wide × 30 mm high, the unevenness of the outer surface of the lid is 2 mm, The height was 50% of the container height, the rib thickness was 2.5 mm, the container and lid wall thickness was 2.5 mm, and the terminal box volume was 900 cm ³ . .
Moreover, the thickness of the layer which consists of an adhesive agent is 0.2 mm, and Shin-Etsu Chemical KE45 was used as an adhesive agent.
Each physical property of this solar power generation terminal box was evaluated as described above.

(Example 2, Comparative Examples 1-7)
Except for the conditions shown in Table 1, a resin composition pellet was obtained in the same manner as in Example 1 to produce a terminal box for photovoltaic power generation.

  ADVANTAGE OF THE INVENTION According to this invention, the solar power generation terminal box which can raise the design freedom of a solar power generation system, the work efficiency in installation of a system, and power generation efficiency, and a solar cell provided with the same can be provided. .

DESCRIPTION OF SYMBOLS 1 Terminal box for photovoltaic power generation 1B Container 1L Lid 2 Bypass diode 3 Inverter 4 Rib 5 Adhesive 6 Solar cell panel 10 Solar cell

Claims (6)

A terminal box for photovoltaic power generation, comprising a resin composition having a specific gravity of 1.5 g / cm ³ or less and a Vicat softening point of 155 ° C. or more, and having a bypass diode and an inverter therein.   The high-functional terminal box for photovoltaic power generation according to claim 1, wherein the resin composition has a tensile strength retention of 80% or more before and after 3000 hours exposure at a temperature of 85 ° C and a humidity of 85%. The high-functional terminal box for photovoltaic power generation according to claim 1, wherein the volume is 300 cm ³ or more.   The high-function terminal box for photovoltaic power generation according to claim 1, wherein a rib having a thickness of 1 mm or more is provided inside to divide a region occupied by the circuit of the bypass diode and a region occupied by the circuit of the inverter. . A container and a lid,
The high-functional terminal box for photovoltaic power generation according to claim 1, wherein the unevenness difference of the outer surface of the lid is 3 mm or less.   The solar cell with which the highly functional terminal box for solar power generation of Claim 1 and a solar power generation panel are directly affixed through the adhesive agent.

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