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WO2012090674A1 - Surface material for solar battery, coating material for solar battery, and solar battery module - Google Patents

Surface material for solar battery, coating material for solar battery, and solar battery module Download PDF

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Publication number
WO2012090674A1
WO2012090674A1 PCT/JP2011/078490 JP2011078490W WO2012090674A1 WO 2012090674 A1 WO2012090674 A1 WO 2012090674A1 JP 2011078490 W JP2011078490 W JP 2011078490W WO 2012090674 A1 WO2012090674 A1 WO 2012090674A1
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Prior art keywords
solar cell
surface material
cerium oxide
fluororesin
solar battery
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French (fr)
Japanese (ja)
Inventor
有賀 広志
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AGC Inc
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Asahi Glass Co Ltd
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    • HELECTRICITY
    • H10SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
    • H10FINORGANIC SEMICONDUCTOR DEVICES SENSITIVE TO INFRARED RADIATION, LIGHT, ELECTROMAGNETIC RADIATION OF SHORTER WAVELENGTH OR CORPUSCULAR RADIATION
    • H10F19/00Integrated devices, or assemblies of multiple devices, comprising at least one photovoltaic cell covered by group H10F10/00, e.g. photovoltaic modules
    • H10F19/80Encapsulations or containers for integrated devices, or assemblies of multiple devices, having photovoltaic cells
    • H10F19/804Materials of encapsulations
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02EREDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E10/00Energy generation through renewable energy sources
    • Y02E10/50Photovoltaic [PV] energy

Definitions

  • the present invention relates to a solar cell surface material, a solar cell coating material, and a solar cell module.
  • Fluororesin especially ethylene-tetrafluoroethylene copolymer (ETFE) has been noted for its weather resistance and is used as a surface material instead of glass in flexible solar cells.
  • the ETFE film used as the surface material of the solar cell is made of a material such as an ethylene-vinyl acetate copolymer (EVA), a modified polyethylene, or polybutyl vinyl (PVB) that serves as a filler for enclosing the solar cell.
  • EVA ethylene-vinyl acetate copolymer
  • PVB polybutyl vinyl
  • the film is heat laminated at 135 to 160 ° C. without using an adhesive.
  • a fluororesin film such as an ETFE film does not have sufficient adhesion to a filler such as EVA as it is.
  • Patent Document 1 describes that a fluorine resin attached to a transparent electrode of a solar cell is subjected to corona discharge treatment and oxygen atoms and nitrogen atoms are introduced into the surface of the fluorine resin.
  • Patent Document 2 describes that a fluororesin is subjected to a discharge treatment in an atmosphere containing methane gas and carbon dioxide in a rare gas.
  • Patent Document 3 describes that a fluororesin is subjected to a discharge treatment in an atmosphere containing a polymerizable unsaturated compound gas and carbon dioxide in an inert gas.
  • Patent Document 4 describes that a fluororesin is subjected to a discharge treatment in an inert gas atmosphere containing an organic compound having a functional group.
  • a discharge treatment in an inert gas atmosphere containing an organic compound having a functional group.
  • Patent Document 5 describes that a high-molecular ultraviolet absorber having a molecular weight of 300 or more is added to a fluororesin film. This high molecular weight UV absorber is inferior in heat resistance and cannot withstand the temperature (200 ° C. or more) at the time of molding the fluororesin.
  • the fluororesin film is immersed in an organic solvent in which a high-molecular UV absorber is dissolved, and the UV absorber is vaporized by a dyeing method in which the UV absorber is contained.
  • a method is described in which a high-molecular ultraviolet absorber is added to the fluororesin film by a thermal diffusion method in which the fluororesin film is exposed and impregnated with the ultraviolet absorber.
  • Patent Document 6 describes an invention in which an ultraviolet absorber is added to a surface coating material composed of a laminate of a fluororesin film and EVA, and in the examples, it is described that an ultraviolet absorber is added to EVA.
  • examples of the ultraviolet absorber include inorganic ultraviolet absorbers such as titanium oxide, zinc oxide and tin oxide, and high molecular weight ultraviolet absorbers.
  • Patent Document 7 describes that a fluorine resin laminated with EVA contains titanium oxide particles for the purpose of preventing EVA deterioration and surface contamination.
  • the present invention has been made in view of the above problems, and although it is excellent in weather resistance, as it is, it is composed of a fluororesin film having poor adhesion to a filler such as EVA, but the filler and It is an object of the present invention to provide a surface material for a solar cell that is excellent in the adhesion of the solar cell, can maintain the adhesion for a long period of time, and does not adversely affect the power generation efficiency of the solar cell.
  • Another object of the present invention is to provide a solar cell module that has excellent durability and does not impair power generation efficiency by having a solar cell coating material that can be used stably for a long period of time.
  • the present invention employs the following configuration.
  • a solar cell surface material comprising a fluororesin film having a surface subjected to glow discharge treatment and containing an ultraviolet absorber containing cerium oxide.
  • the ultraviolet absorber includes cerium oxide particles and a coating layer that covers a surface of the cerium oxide particles, and the coating layer includes silicon oxide.
  • a solar cell coating material wherein the surface material for a solar cell according to any one of [1] to [9] and a filler made of an organic resin are laminated.
  • the solar cell coating material according to [10] wherein the surface side of the solar cell surface material that has been subjected to the glow discharge treatment is laminated so as to be in contact with the filler.
  • a solar cell having one or more thin-film photoelectric conversion layers is provided inside, and at least one surface side of the solar cell is for the solar cell according to any one of [10] to [12].
  • the solar cell surface material of the present invention is excellent in adhesiveness with a filler encapsulating solar cells, can maintain the adhesiveness for a long time, and does not adversely affect the power generation efficiency of the solar cell.
  • the covering material for solar cells of the present invention is constituted by laminating the surface material for solar cells and the filler of the present invention, it can be used stably for a long period of time, and the power generation efficiency of the solar cells is adversely affected. Don't give.
  • the solar cell module of the present invention has excellent durability and high power generation efficiency by having a solar cell coating material that can be used stably for a long period of time.
  • FIG. 1 It is a schematic sectional drawing which shows one Embodiment of the solar cell module of this invention. It is an example of the relationship between the wavelength of the solar cell module of this invention, and collection efficiency. It is a figure which shows the light transmittance of the surface material for solar cells of Example 1.
  • FIG. 2 It is a figure which shows the light transmittance of the surface material for solar cells of Example 2.
  • FIG. 2 It is a figure which shows the light transmittance of the surface material for solar cells of Example 3.
  • FIG. It is a figure which shows the light transmittance of the surface material for solar cells of the comparative example 1.
  • FIG. 1 shows the light transmittance of the surface material for solar cells of Example 1.
  • the surface material for a solar cell of the present invention is made of a fluororesin film whose surface is modified by glow discharge treatment, and contains an ultraviolet absorber containing cerium oxide in a dispersed manner.
  • the ultraviolet absorber preferably has cerium oxide particles and a coating layer that covers the surface of the cerium oxide particles, and the coating layer preferably contains silicon oxide.
  • the surface material for solar cells of the present invention preferably has a light transmittance of 80% or more at 400 nm and a light transmittance of 70% or less at 300 nm as the surface material itself.
  • fluororesin examples of the fluororesin constituting the surface material for solar cells include ethylene-tetrafluoroethylene copolymer (hereinafter also referred to as “ETFE”), polytrifluoroethylene chloride (PCTFE), ethylene-trifluorochloride.
  • ETFE ethylene-tetrafluoroethylene copolymer
  • PCTFE polytrifluoroethylene chloride
  • Highly transparent fluororesin such as ethylene copolymer (ECTFE), tetrafluoroethylene-perfluoroalkyl vinyl ether copolymer (PFA), tetrafluoroethylene-hexafluoropropylene copolymer (FEP), or these A mixture is mentioned.
  • ECTFE ethylene copolymer
  • PFA tetrafluoroethylene-perfluoroalkyl vinyl ether copolymer
  • FEP tetrafluoroethylene-hexafluoropropylene copolymer
  • ETFE a fluororesin mainly composed of ETFE having a ratio of ETFE in the resin component of 80% by mass or more, preferably 90% by mass or more, and particularly preferably 100% by mass.
  • ETFE is a copolymer of ethylene (hereinafter referred to as “E”) and tetrafluoroethylene (hereinafter referred to as “TFE”), or a copolymerizable in addition to a repeating unit based on E and TFE. It is a copolymer containing repeating units based on these monomers.
  • the ratio (molar ratio) between the repeating unit based on TFE and the repeating unit based on E in ETFE is preferably 70/30 to 30/70, more preferably 65/35 to 40/60, and 60/40 to 40/60. Is particularly preferred. Unless otherwise specified, “to” indicating the numerical range described above is used to mean that the numerical values described before and after it are used as a lower limit value and an upper limit value, and hereinafter “to” Used with meaning. In addition to the repeating units based on E and TFE, when containing repeating units based on other monomers that are copolymerizable, the content of the repeating units based on other monomers is in the total repeating units of ETFE.
  • it is preferably 0.1 mol% or more, more preferably 0.5 to 30 mol%, particularly preferably 0.5 to 20 mol%.
  • functions such as high solubility, water repellency, oil repellency, and adhesion to the substrate are imparted without impairing the physical properties of ETFE. Is possible.
  • Examples of other monomers include other fluoroolefins other than TFE, other olefins other than E, and vinyl monomers.
  • Examples of other fluoroolefins include C2-C3 fluoroolefins such as chlorotrifluoroethylene, hexafluoropropylene, vinylidene fluoride, and vinyl fluoride.
  • fluorovinyl monomers such as (perfluoroalkyl) ethylene, are mentioned.
  • Examples of other olefins include propylene and isobutylene.
  • Examples of vinyl monomers include vinyl ether, allyl ether, carboxylic acid vinyl ester, carboxylic acid allyl ester, and the like.
  • Examples of the vinyl ether include cycloalkyl vinyl ethers such as cyclohexyl vinyl ether; alkyl vinyl ethers such as nonyl vinyl ether, 2-ethylhexyl vinyl ether, hexyl vinyl ether, ethyl vinyl ether, n-butyl vinyl ether, and t-butyl vinyl ether.
  • Examples of allyl ethers include alkyl allyl ethers such as ethyl allyl ether and hexyl allyl ether.
  • Examples of the carboxylic acid vinyl ester include vinyl esters of carboxylic acids such as acetic acid, butyric acid, pivalic acid, benzoic acid, and propionic acid.
  • carboxylic acid allyl ester examples include allyl esters of the above carboxylic acids.
  • a vinyl ester of a carboxylic acid having a branched alkyl group may be used.
  • Specific examples include “Beoba-9” and “Beoba-10” (both manufactured by Shell Chemical Co., Ltd.).
  • the other copolymer monomers may be used alone or in combination of two or more.
  • Examples of the resin other than ETFE in the fluororesin mainly composed of ETFE include, for example, hexafluoropropylene-tetrafluoroethylene copolymer, perfluoro (alkyl vinyl ether) -tetrafluoroethylene copolymer, and tetrafluoroethylene.
  • -Fluororesin such as hexafluoropropylene-vinylidene fluoride copolymer and chlorotrifluoroethylene-ethylene copolymer.
  • the fluororesin mainly composed of ETFE may contain a resin other than the fluororesin.
  • the other resins may be used alone or in combination of two or more.
  • the surface material for a solar cell of the present invention comprises a fluororesin film whose surface is modified by glow discharge treatment.
  • a glow discharge treatment by polymerizing a polymerizable gas, a plasma polymerization treatment for introducing a polymer containing oxygen atoms and nitrogen atoms and not containing fluorine onto the fluororesin film; Non-polymerizable plasma treatment in which nitrogen atoms are introduced may be mentioned.
  • the introduced oxygen atom or nitrogen atom provides adhesion to the filler.
  • Both the plasma polymerization treatment and the non-polymerization plasma treatment are plasma treatments using glow discharge caused by ionized plasma.
  • a high-frequency electromagnetic field composed of a high frequency, a pulse wave, a microwave, or the like is formed between the discharge electrode and the counter electrode in an atmosphere where a predetermined gas exists, and is disposed between the discharge electrode and the counter electrode.
  • Glow discharge treatment is performed on the surface of the fluororesin film.
  • a nitrogen atmosphere is preferable in terms of running cost.
  • the oxygen concentration in the nitrogen atmosphere is preferably 100 ppm or less, more preferably 90 ppm or less, and further preferably 60 ppm or less. The lower the oxygen concentration, the easier it is to obtain a fluororesin film that can maintain adhesion for a long period of time by surface treatment.
  • carbon dioxide gas and / or hydrogen gas may be introduced in addition to nitrogen gas.
  • Carbon dioxide gas serves as an oxygen supply source for introducing oxygen functional groups such as hydroxy groups on the surface of the fluororesin.
  • the hydrogen gas functions as a hydrogen supply source for introducing amino groups on the surface of the fluororesin.
  • the total introduction amount of carbon dioxide gas and / or hydrogen gas is preferably 10 mol% or less when the total amount of both is 100 mol%. If the total introduction amount of carbon dioxide gas and hydrogen gas is 10 mol% or less with respect to 100 mol% of nitrogen gas, fluorine oligomers and fluorine low molecular weight substances, which are specific actions of nitrogen plasma gas, are introduced from the surface. Easy to get rid of effect. Helium gas and argon gas can also be turned into plasma and glow discharge is possible, and the above-described discharge effect is easily obtained. However, these gases are expensive.
  • a mixed gas atmosphere composed of a polymerizable unsaturated compound gas and a carbon oxide gas is preferable.
  • methane gas and ethane gas classified as saturated hydrocarbons represented by C 4 H 2n + 2 are also preferable because plasma polymerization is performed in a mixed gas with a carbon oxide gas.
  • the polymerizable unsaturated compound gas include a compound gas having a double bond such as ethylene gas and propylene gas.
  • the carbon oxide gas include carbon dioxide gas and carbon monoxide gas. In the saturated hydrocarbon represented by C 4 H 2n + 2 , methane and ethane are preferable, and methane is more preferable.
  • the atmospheric pressure when performing the glow discharge treatment is preferably near atmospheric pressure. That is, 500 to 800 Torr is preferable, and 700 to 780 Torr is more preferable. If the pressure is 500 Torr or more, it is easy to suppress mixing of gases other than the introduced gas into the discharge part. If the pressure is 800 Torr or less, it is easy to suppress the plasma-treated gases from colliding with each other and reducing the surface treatment effect of the film.
  • the atmosphere temperature during the glow discharge treatment is not particularly limited and is preferably 0 to 60 ° C, more preferably 10 to 40 ° C.
  • the electric field applied to the discharge electrode and the counter electrode is preferably a pulsed electric field (hereinafter referred to as “pulse electric field”) having a voltage rise time of 10 ⁇ sec or less. If the voltage rise time is 10 ⁇ sec or less, the discharge state can be prevented from shifting to arc discharge, and the glow discharge treatment can be performed stably.
  • the voltage rise time of the pulse voltage is more preferably 5 ⁇ sec or less. As the voltage rise time is shorter, the gas is more easily ionized and becomes plasma, and glow discharge is more likely to occur. However, the voltage rise time is a time during which the voltage change is continuously positive.
  • the voltage fall time of the applied electric field is preferably as short as the voltage rise time, and the rise time and the fall time are preferably set to the same time.
  • the voltage fall time is a time during which the voltage change is continuously negative.
  • the waveform of the pulse electric field is not particularly limited, and examples thereof include an impulse waveform, a square waveform, and a modulation waveform. Further, when the frequency exceeds 20 kHz, a sine wave is likely to be formed.
  • the pulse duration in the pulse electric field is preferably 0.5 to 200 ⁇ sec, more preferably 1 to 10 ⁇ sec. If the pulse duration is 0.5 ⁇ sec or more, the discharge becomes more stable. If the pulse duration is 200 ⁇ s or less, it is easy to suppress the transition of glow discharge to arc discharge.
  • the pulse duration can be adjusted by the frequency of the electric field pulse. However, the pulse duration is the time during which the pulses are continuous. For example, if each pulse is an intermittent pulse that is separated, the pulse duration is the same as the pulse width time. When a plurality of pulses are continuous, the pulse duration is the same as the sum of the pulse width times of the series of continuous pulses.
  • the electric field strength of the applied electric field is preferably 10 to 1,000 kV / cm, more preferably 100 to 300 kV / cm. If the electric field strength is 10 kV / cm or more, the gas is easily turned into plasma by glow discharge. If the electric field strength is 1000 kV / cm or less, it is easy to suppress the occurrence of arc discharge.
  • the frequency of the pulse voltage is preferably 0.5 to 100 kHz, more preferably 5 to 50 kHz. When the frequency of the pulse voltage is 0.5 kHz or more, the discharge density of the glow discharge is improved and the time required for the surface treatment is shortened. If the frequency of the pulse voltage is 100 kHz or less, the discharge state can be prevented from shifting to arc discharge, and the glow discharge treatment can be performed stably.
  • the glow discharge treatment using a pulsed electric field is preferably performed a plurality of times with an interval of 0.01 seconds or more.
  • the discharge density of each glow discharge treatment that is, the discharge density between each discharge electrode and the counter electrode is preferably 40 to 200 W ⁇ min / m 2 , and preferably 60 to 180 W ⁇ min / m 2. More preferred. If the discharge density of each glow discharge treatment is 40 W ⁇ min / m 2 or more, nitrogen functional groups and oxygen functional groups are easily introduced. Further, when the discharge density is less than that, the number of functional groups to be introduced is extremely small. If the discharge density of each glow discharge treatment is 200 W ⁇ min / m 2 or less, the adhesion obtained by the surface treatment can be easily maintained for a long period of time.
  • the increase in the temperature of the fluororesin film to be treated is reduced, and the temperature once increased between each discharge treatment is reduced. Therefore, the movement of the oligomer component to the surface layer due to heat is suppressed.
  • the amount of oligomer components generated due to the breakage of the carbon-carbon bond of the fluororesin on the surface layer is reduced. Therefore, the oligomer component is reduced on the surface layer of the fluororesin film, and oxygen atoms and nitrogen atoms are easily introduced into the fluororesin itself, not into the oligomer component having a weak binding force.
  • a known electrode structure can be freely adopted as the structure of the discharge electrode and the counter electrode used for the glow discharge.
  • a curved electrode or a flat electrode is used as the counter electrode.
  • the distance between both electrodes is preferably 0.5 to 10 mm.
  • By setting the thickness to 0.5 mm or more it is easy to dispose a fluororesin film between both electrodes.
  • by setting it as 10 mm or less it is easy to obtain discharge with stable discharge and high discharge density.
  • a single metal such as copper or aluminum, an alloy such as stainless steel or brass, or the like can be used.
  • a solid dielectric In order to prevent the occurrence of arc discharge, it is preferable to coat a solid dielectric on at least one opposing surface side of both electrodes. In order to create a better plasma state, a solid dielectric should be placed on both electrodes.
  • a metal oxide such as silicon dioxide, aluminum oxide, zirconium dioxide, titanium dioxide. Synthetic resins such as polytetrafluoroethylene and polyethylene terephthalate, and glass can also be used.
  • a solid dielectric having a relative dielectric constant of 10 or more (relative dielectric constant in an environment at 25 ° C., the same shall apply hereinafter). Examples of the solid dielectric having a relative dielectric constant of 10 or more include metal oxides such as zirconium dioxide and titanium dioxide, and double oxides such as barium titanate.
  • Titanium dioxide is known as a ferroelectric, and in the case of a titanium dioxide single composition, the relative dielectric constant differs depending on the crystal structure, and the relative dielectric constant is about 80 for the rutile crystal structure. Further, a dielectric composition having a relative dielectric constant of about 2000 to 18500 is obtained by using a mixed composition of at least one selected from metal oxides such as Ba, Sr, Pb, Ca, Mg, and Zr and titanium dioxide. The body is obtained. That is, the relative dielectric constant can be changed depending on the type and ratio of other oxides to be mixed and the crystallinity. Titanium dioxide alone has a drastic compositional change in a heating environment, restricts the use environment, and is difficult to handle when formed as a film on an electrode. Therefore, it is preferable to use a mixed composition composed of 5 to 50% by mass of titanium dioxide and 50 to 95% by mass of aluminum oxide with improved thermal stability.
  • Zirconium dioxide when used alone, has a relative dielectric constant of about 12 and is advantageous for generating a discharge plasma at a low voltage. Moreover, it is good also as a mixed composition with another metal oxide.
  • the relative dielectric constant can be changed depending on the type and ratio of other oxides to be mixed and the crystallinity.
  • Zirconium oxide is preferably mixed with yttrium oxide (Y 2 O 3 ), calcium carbonate (CaCO 3 ), magnesium oxide (MgO), or the like because it is stabilized by preventing expansion and contraction due to crystal transformation.
  • Y 2 O 3 yttrium oxide
  • CaCO 3 calcium carbonate
  • MgO magnesium oxide
  • at least 70% by mass is zirconium oxide, and the proportion of the other oxides is preferably within 30% by mass.
  • a zirconium oxide film to which 4 to 20% by mass of yttrium oxide is added is preferable because the relative dielectric constant is about 8 to 16.
  • the thickness of the solid dielectric on the discharge electrode side is appropriately determined depending on the thickness of the substrate to be processed and the applied voltage, but is preferably 0.01 to 4 mm. If it is too thick, a high voltage is required to generate plasma discharge. If it is too thin, dielectric breakdown occurs when voltage is applied, and arc discharge occurs.
  • the solid dielectric on the counter electrode side supports the fluororesin film, it is familiar with the fluororesin film and is preferably a soft material.
  • silicon rubber is effective.
  • the surface material for a solar cell of the present invention contains an ultraviolet absorber.
  • an ultraviolet absorber is contained in the surface material, not in the filler.
  • the ultraviolet absorbent in the present invention is characterized by containing cerium oxide. If it is cerium oxide, it does not have a photocatalytic action like titanium oxide, so even if it is contained in the fluororesin film, the fluororesin film is discolored to reduce the light transmittance or reduce the mechanical strength. Does not cause such problems. Further, as will be apparent from the examples described later, cerium oxide absorbs less light in a wavelength region of 350 nm or more, which has high collection efficiency in power generation by a solar cell. On the other hand, ultraviolet rays on the low wavelength side (especially less than 350 nm) that have a large influence on the functional group have sufficient absorbency.
  • the functional group in the discharge-treated fluororesin can be protected from ultraviolet rays without substantially impairing the power generation efficiency.
  • zinc oxide and the like are also known as ultraviolet absorbers that do not have a photocatalytic action.
  • zinc oxide has a large absorption with respect to light of 350 to 360 nm that can obtain a certain degree of collection efficiency in power generation of a solar cell. For this reason, if zinc oxide is used as a UV absorber for a solar cell surface material, sufficient power generation efficiency cannot be obtained.
  • Cerium oxide is easily dissolved by hydrogen fluoride generated by the decomposition of the fluororesin. Therefore, in order to obtain higher weather resistance, it is preferable to use composite particles in which the surface of the cerium oxide particles is covered with a coating layer for protecting from hydrogen fluoride.
  • a coating layer containing silicon oxide is preferable, and a silicon oxide having a silicon oxide ratio of 60% by mass or more, preferably 80% by mass or more, particularly preferably 100% by mass in the coating layer as a main component.
  • a coating layer is preferred.
  • other components contained in the coating layer include aluminum oxide remaining on the surface of the coating layer derived from aluminum sulfate (aggregating agent) used during the production of the composite particles.
  • the composite particle in which the surface of the cerium oxide particle is covered with a coating layer for protecting from hydrogen fluoride is a cerium oxide-silica composite in which the surface of the cerium oxide particle is covered with silicon oxide (ie, silica).
  • silicon oxide ie, silica
  • the CeO 2 : SiO 2 mass ratio of the cerium oxide-silica composite particles in which the surface of the cerium oxide particles is covered with silica is preferably 30:70 to 80:20, and 40:60 to 70: 30 is more preferable.
  • the mass ratio of the CeO 2 and SiO 2 is cerium oxide - a ratio between CeO 2 and SiO 2 in the entire particles of the silica complex. When the ratio of silica is increased, the weather resistance is improved.
  • a silicon oxide is an amorphous silica (namely, amorphous silica) which does not have crystallinity.
  • amorphous silica include amorphous silica obtained by hydrolyzing sodium silicate. That is, the composite particle in which the surface of the cerium oxide particle is covered with a coating layer for protecting from hydrogen fluoride is preferably a cerium oxide-amorphous silica composite in which the surface of the cerium oxide particle is covered with amorphous silica.
  • the particles of the cerium oxide-amorphous silica composite are preferably secondary particles in which a plurality of particles in which primary particles of cerium oxide are coated with amorphous silica are aggregated and the amorphous silica is fused together.
  • the distribution of the secondary particle diameter of the cerium oxide-amorphous silica composite particles measured by a laser diffraction particle size distribution analyzer is preferably 95% by mass or more in the range of 1 to 30 ⁇ m. More preferably, it is in the range of 10 ⁇ m.
  • the average secondary particle diameter of the cerium oxide-amorphous silica composite particles measured by a laser diffraction particle size distribution analyzer is preferably 2 to 8 ⁇ m, and particularly preferably 1 to 5 ⁇ m.
  • the average particle diameter (average primary particle diameter) measured by SEM (scanning electron microscope) of the cerium oxide particles in the cerium oxide-amorphous silica composite is such that the necessary ultraviolet absorbing ability is obtained and the solar cell In power generation, the thickness is preferably 10 to 250 nm from the viewpoint of obtaining high transparency with respect to light of 400 nm or more, which can obtain a certain degree of high collection efficiency.
  • the average primary particle size here is the particle size of the cerium oxide particles.
  • the method for producing particles of the cerium oxide-amorphous silica composite in which the surface of the cerium oxide particles is covered with amorphous silica is not limited to the above method.
  • cerium oxide particles are synthesized, and water glass or ethyl silicate is synthesized therewith.
  • a method of performing silica coating using as a material may be used.
  • a flocculant such as aluminum sulfate is used to facilitate filtration of the silica-coated insoluble cerium compound dispersed in water.
  • aluminum sulfate aluminum oxide derived from aluminum ions attached to the surface remains on the surface of the coating layer, but there is no particular problem in performance.
  • the surface of the ultraviolet absorber containing cerium oxide (that is, cerium oxide particles or cerium oxide particles having a coating layer containing silica) is subjected to a hydrophobic treatment.
  • a hydrophobic treatment thereby, the dispersibility in a fluororesin film improves.
  • the fluororesin comes into contact with the screw and the cylinder many times, but the shearing at that time can be kept low by hydrophobization, Resin coloring is suppressed.
  • the degree of hydrophobicity is preferably 40 to 75% of the degree of methanol hydrophobicity.
  • Methanol hydrophobicity is an index indicating the hydrophobicity of particles.
  • the measurement method is as follows. That is, 50 cc of distilled water is put into a 300 cc beaker, and 5 g of particles are added while stirring well. If the particles are evenly dispersed, the particles are very familiar with distilled water and the degree of methanol hydrophobization is 0%. If the particles are not uniformly dispersed, methanol is gradually added dropwise until the particles are uniformly dispersed in the aqueous solution.
  • the preferred degree of methanol hydrophobicity required differs depending on the type of fluororesin, and in the case of ETFE, it is preferably 40 to 70%.
  • reactive organosilicon compounds include tetraalkoxysilanes such as tetraethoxysilane and tetramethoxysilane, isobutyltrimethoxysilane, hexyltrimethoxysilane, and (3,3,3-trifluoropropyl) trimethoxysilane.
  • silicone oils such as trialkoxysilanes, dimethyl silicone oil, methyl hydrogen silicone oil, and phenylmethyl silicone oil. Of these, isobutyltrimethoxysilane, hexyltrimethoxysilane, dimethyl silicone oil, and phenylmethyl silicone oil are preferable. .
  • the required amount of the reactive organosilicon compound used for the hydrophobization treatment is the size of the specific surface area of the cerium oxide-amorphous silica composite. Is proportional to When the amount of the reactive organosilicon compound is small, the cerium oxide-amorphous silica composite particles may turn black or brown when kneaded with the fluororesin. When there are many reactive organosilicon compounds, the aggregate which consists of a reactive organosilicon compound appears as a lump, and the film external appearance may worsen.
  • the reactive organosilicon compound is silicone oil
  • alkoxysilane such as isobutyltrimethoxysilane.
  • the content of the UV absorber containing cerium oxide in the surface material is determined in consideration of the balance between the UV absorbing ability required from the viewpoint of maintaining adhesion and the transmittance of light having a wavelength that contributes to power generation.
  • the transmittance of 300 nm of the surface material is preferably as low as possible from the viewpoint of improving adhesion, and therefore it is necessary to contain a sufficient amount of the ultraviolet absorber.
  • the content is too large, the absorption characteristic of cerium oxide becomes remarkable, and the transmittance around 400 nm, which particularly affects the power generation efficiency, is lowered.
  • the ultraviolet absorber containing cerium oxide is preferably contained so that the transmittance at 400 nm of the surface material is 80% or more and the transmittance at 300 nm is 20 to 70%. Further, it is more preferable that the surface material be contained so that the transmittance at 400 nm is 85% or more and the transmittance at 300 nm is 20 to 50%.
  • the surface material having the preferable light transmission characteristics can be easily obtained. Specifically, it is preferable to contain an ultraviolet absorber so that the amount of cerium oxide per unit area in the surface material is 0.1 to 2 g / m 2 . Further, although depending on the thickness of the film and the amount of the coating layer, the ratio of the amount of cerium oxide to the whole surface material is preferably in the range of 0.1 to 2% by mass.
  • the surface material contains other UV absorbers, pigments, carbon black, carbon fibers, silicon carbide, glass fibers, mica, cross-linking agents, and fillers. May be.
  • the thickness of the surface material is preferably 10 to 300 ⁇ m, more preferably 20 to 250 ⁇ m, and particularly preferably 25 to 200 ⁇ m. If it exists in this range, the handling of the film at the time of discharge processing will be easy, and the wrinkle by discharge will not generate
  • the covering material for solar cells of the present invention is a laminate of the surface material of the present invention and a filler made of an organic resin.
  • the surface material and the filler are laminated so that the surface of the surface material subjected to the discharge treatment is in contact with the filler.
  • the filler for the solar battery covers at least the unevenness of the internal element having the solar battery cell, and functions as an adhesive between the internal element and the surface material. Therefore, light resistance, adhesiveness, and heat resistance are required.
  • an ethylene copolymer is preferable, and an ethylene-vinyl acetate copolymer (hereinafter referred to as EVA), an ethylene-ethyl acrylate copolymer (EEA), and an ethylene-methyl acrylate (EMA) and polybutyl vinylal (PVB).
  • EVA ethylene-vinyl acetate copolymer
  • EAA ethylene-ethyl acrylate copolymer
  • EMA ethylene-methyl acrylate
  • PVB polybutyl vinylal
  • blended the crosslinking material with polyethylene (henceforth PE) is also mentioned.
  • the filler in the solar cell of the present invention preferably contains one or more of EVA, EEA, EMA and PVB.
  • the filler is preferably cross-linked so as to be resistant to high temperature use environments. When the filler is EVA, crosslinking with an organic peroxide is preferred.
  • crosslinking treatment is preferably performed in a state “after hot pressing” in the step of joining the solar battery cell to the solar battery covering material when the solar battery module is manufactured.
  • Crosslinking may be performed using a crosslinking agent such as isocyanate or melamine.
  • ⁇ Solar cell module> An embodiment of the solar cell module of the present invention will be described with reference to FIG.
  • a filler 2a and a surface material 3a are sequentially laminated on the light incident side of the solar battery cell 1, and a covering material 4a is constituted by the filler 2a and the surface material 3a.
  • the filler 2b and the surface material 3b are sequentially laminated on the side opposite to the light incident side of the solar battery cell, and the covering material 4b is configured by the filler 2b and the surface material 3b.
  • At least one of the surface material 3a and the surface material 3b is the surface material for solar cells of the present invention.
  • the coating material 4a and the coating material 4b is the solar cell coating material of the present invention.
  • the surface material 3a disposed on the light incident side is the surface material for solar cells of the present invention, that is, the coating material 4a is the coating material for solar cells of the present invention.
  • both the surface material 3a and the surface material 3b are the solar cell surface material of the present invention, that is, both the coating material 4a and the coating material 4b are the solar cell coating material of the present invention.
  • Solar cell 1 has one or more thin film photoelectric conversion layers between a pair of conductive layers.
  • a cell in which a plurality of thin film photoelectric conversion layers having different wavelength regions from which high collection efficiency is obtained is widely used.
  • FIG. 2 shows an amorphous silicon-germanium (a-Si) thin film photoelectric conversion layer with high collection efficiency for light on the short wavelength side as a top cell and amorphous silicon-germanium (with high collection efficiency for light on the long wavelength side).
  • the collection efficiency obtained in a cell in which a thin film photoelectric conversion layer of (a-SiGe) is a bottom cell and a laminate of a top cell and a bottom cell is disposed between a pair of conductive layers is shown.
  • the overall collection efficiency is a value obtained by combining the collection efficiencies of the top cell and the bottom cell.
  • the collection efficiency at a wavelength of 300 to 400 nm is almost equal to the collection efficiency of the top cell alone.
  • the transmittance curve of the surface material of the present invention decreases very closely with the collection efficiency curve of the amorphous silicon (a-Si) thin film photoelectric conversion layer of FIG. Show the trend. Therefore, the solar cell module of the present invention easily maintains high power generation efficiency particularly when it has a thin film photoelectric conversion layer of amorphous silicon (a-Si). Similarly, in other solar cells that generate power in a wide wavelength range of 350 to 1500 nm, for example, called CIGS, it is easy to maintain high power generation efficiency.
  • permeability curve of the surface material of this invention has low transmittance
  • hydrophobized silica-coated cerium oxide particles 100 g was added to 1900 g of ETFE resin (manufactured by Asahi Glass Co., Ltd., Full-on ETFE: 88AX), and after stirring well, hydrophobized silica with a biaxial extruder Master batch pellets containing 5% coated cerium oxide particles (2.95% cerium oxide) were prepared.
  • the extrusion conditions were a cylinder temperature of 310 ° C and a head temperature of 320 ° C.
  • the pellets and ETFE resin pellets containing no silica-coated cerium oxide particles are put in a polypropylene bag at a ratio of 1: 9 and shaken vigorously by hand 10 times. Mixed. This was molded with a T die having a cylinder temperature and a die temperature of 320 ° C. to obtain an ETFE film having a width of 550 mm and a thickness of 50 ⁇ m.
  • the surface of the ETFE film was discharged.
  • a plasma processing apparatus RD550 manufactured by Sekisui Chemical Co., Ltd. was used.
  • the discharge electrode a ceramic dielectric (solid dielectric) layer having a thickness of 1 mm on a carbon steel plate having a length of 100 mm in the transport direction of the ETFE film and a length of 650 mm in the width direction of the ETFE film and a thickness of 20 mm. The one provided with was used.
  • covered the silicon rubber of thickness 2mm was used for the metal roll surface with a diameter of 30 cm, and roll temperature was hold
  • the flow rate of nitrogen gas to be introduced was 50 L / min, and the gas was introduced for 2 minutes, and it was confirmed that the oxygen concentration was 100 ppm. Thereafter, while introducing nitrogen gas, the output voltage of the high frequency power source is 450 V, the output current is 5.4 A, the processing power is 2.43 kW, and the ETFE film is transported at 6 m / min, so that the discharge density is 623 W ⁇ min / A glow discharge treatment of m 2 was performed. The frequency was 40 kHz. Therefore, the waveform of the pulse electric field is close to a sine wave.
  • the discharge density was calculated by the following formula (1).
  • Example 2 An ETFE film was obtained in the same manner as in Example 1 except that the mixing ratio of the masterbatch pellets and ETFE resin containing no silica-coated cerium oxide particles (Asahi Glass Co., Ltd., Fullon ETFE: 88AX) was 1: 4. Further, the surface was discharged in the same manner as in Example 1 to obtain the surface material of Example 2.
  • Example 3 An ETFE film was obtained in the same manner as in Example 1 except that the mixing ratio of the masterbatch pellets and the ETFE resin containing no silica-coated cerium oxide particles (Asahi Glass Co., Ltd., Fullon ETFE: 88AX) was 1:19. Further, the surface was discharged in the same manner as in Example 1 to obtain the surface material of Example 3.
  • Example 4 An ETFE film was molded in the same manner as in Example 1, and the gas composition introduced from the gas inlet was 99 vol% argon, 0.3 vol% carbon dioxide, 0.7 vol% methane, and a gas flow rate of 20 l / Example 1 except that the output voltage of the high-frequency power source was 110 V, the output current was 2.2 A, the processing power was 2.42 W, the transport speed of the ETFE film was 1 m / min, and the discharge density was 372 W ⁇ min / m 2.
  • the surface material of Example 4 was obtained in the same manner as described above.
  • Example 5 An ETFE film was obtained in the same manner as in Example 2, and the surface was discharged in the same manner as in Example 4 to obtain the surface material of Example 5.
  • Example 6 An ETFE film was obtained in the same manner as in Example 3, and the surface was discharged in the same manner as in Example 4 to obtain the surface material of Example 6.
  • the transmittance of the surface material of each example is very close to the collection efficiency curve of the amorphous silicon (a-Si) thin film photoelectric conversion layer of FIG. 2 from the wavelength of 400 nm to 300 nm. Showed a decreasing trend.
  • the surface material of Comparative Example 2 had a transmittance of about 360 nm or less, which was a characteristic that had to substantially affect the power generation efficiency of the solar cell.
  • Tables 2 to 5 in Examples 1 to 6, the adhesion after the weathering test was maintained well compared to any of Comparative Examples 1 to 4.
  • the surface material for solar cell of the present invention has excellent adhesion to the filler used for the coating material for solar cell, can maintain the adhesion for a long time, and adversely affects the power generation efficiency of the solar cell. Therefore, it is useful for a solar cell coating material and for a solar cell module.

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Abstract

Provided is a surface material for a solar battery, which has excellent adhesion to a filler, can maintain the adhesion for a long period, and does not affect the power generation efficiency of the solar battery. Also provided are a coating material formed by overlaying the surface material and the filler, and a solar battery module using the coating material. An UV absorber including cerium oxide is contained in a fluororesin film the surface of which is treated by means of glow discharge treatment.

Description

太陽電池用表面材、太陽電池用被覆材及び太陽電池モジュールSurface material for solar cell, coating material for solar cell, and solar cell module

 本発明は、太陽電池用表面材、太陽電池用被覆材及び太陽電池モジュールに関する。 The present invention relates to a solar cell surface material, a solar cell coating material, and a solar cell module.

 フッ素樹脂、とりわけエチレン-テトラフルオロエチレン系共重合体(ETFE)は、その耐候性が注目され、フレキシブル太陽電池において、ガラスに代わる表面材として使用されている。該太陽電池の表面材として用いられるETFEフィルムは、太陽電池セルを内包する充填材となる、エチレン-酢酸ビニル系共重合体(EVA)、変性ポリエチレン、ポリブチルビニラール(PVB)などの材料と、接着剤を用いずに135~160℃で熱ラミネートされる。
 しかし、ETFEフィルム等のフッ素樹脂フィルムは、そのままでは、EVA等の充填材との密着性が充分でない。
Fluororesin, especially ethylene-tetrafluoroethylene copolymer (ETFE), has been noted for its weather resistance and is used as a surface material instead of glass in flexible solar cells. The ETFE film used as the surface material of the solar cell is made of a material such as an ethylene-vinyl acetate copolymer (EVA), a modified polyethylene, or polybutyl vinyl (PVB) that serves as a filler for enclosing the solar cell. The film is heat laminated at 135 to 160 ° C. without using an adhesive.
However, a fluororesin film such as an ETFE film does not have sufficient adhesion to a filler such as EVA as it is.

 フッ素樹脂フィルムと他の部材との密着性向上を目的として、フッ素樹脂を放電処理する表面改質技術が知られている。
 例えば、特許文献1には、太陽電池の透明電極に貼り付けるフッ素樹脂にコロナ放電処理を施し、フッ素樹脂表面に酸素原子と窒素原子を導入することが記載されている。また、特許文献2には、希ガス中にメタンガスと二酸化炭素を含む雰囲気下で、フッ素樹脂を放電処理することが記載されている。また、特許文献3には、不活性ガス中に重合性不飽和化合物ガスと二酸化炭素を含む雰囲気下で、フッ素樹脂を放電処理することが記載されている。また、特許文献4には、官能基を有する有機化合物を含む不活性ガス雰囲気下で、フッ素樹脂を放電処理することが記載されている。
 しかし、これらの放電処理では、フッ素樹脂のEVA等に対する密着性を充分に向上させることは困難であった。また、仮に処理直後の密着性が向上しても、その密着性は長期間維持できなかった。
For the purpose of improving the adhesion between the fluororesin film and other members, a surface modification technique for discharging the fluororesin is known.
For example, Patent Document 1 describes that a fluorine resin attached to a transparent electrode of a solar cell is subjected to corona discharge treatment and oxygen atoms and nitrogen atoms are introduced into the surface of the fluorine resin. Patent Document 2 describes that a fluororesin is subjected to a discharge treatment in an atmosphere containing methane gas and carbon dioxide in a rare gas. Patent Document 3 describes that a fluororesin is subjected to a discharge treatment in an atmosphere containing a polymerizable unsaturated compound gas and carbon dioxide in an inert gas. Patent Document 4 describes that a fluororesin is subjected to a discharge treatment in an inert gas atmosphere containing an organic compound having a functional group.
However, in these discharge treatments, it has been difficult to sufficiently improve the adhesion of the fluororesin to EVA or the like. Even if the adhesion immediately after the treatment was improved, the adhesion could not be maintained for a long time.

 フッ素樹脂フィルムとEVA等との密着性を長期間維持し難い原因として、フッ素樹脂フィルムを透過した紫外線によるEVA等の劣化が知られている。この紫外線によるEVA等の劣化を防ぐため、紫外線吸収剤を用いる方法が提案されている。
 例えば、特許文献5では、分子量300以上の高分子の紫外線吸収剤をフッ素樹脂フィルムに添加することが記載されている。この高分子の紫外線吸収剤は耐熱性に劣り、フッ素樹脂の成形時の温度(200度以上)に耐えることができない。そこで、同文献では、フッ素樹脂をフィルムとして成形した後に、高分子の紫外線吸収剤を溶解した有機溶剤にフッ素樹脂フィルムを浸漬して紫外線吸収剤を含有させる染色法、あるいは紫外線吸収剤の蒸気にフッ素樹脂フィルムを晒して紫外線吸収剤を含浸させる熱拡散法などにより、高分子の紫外線吸収剤をフッ素樹脂フィルムに添加する方法が記載されている。
As a cause that it is difficult to maintain the adhesion between the fluororesin film and EVA or the like for a long period of time, deterioration of EVA or the like due to ultraviolet rays transmitted through the fluororesin film is known. In order to prevent the deterioration of EVA or the like due to ultraviolet rays, a method using an ultraviolet absorber has been proposed.
For example, Patent Document 5 describes that a high-molecular ultraviolet absorber having a molecular weight of 300 or more is added to a fluororesin film. This high molecular weight UV absorber is inferior in heat resistance and cannot withstand the temperature (200 ° C. or more) at the time of molding the fluororesin. Therefore, in this document, after forming a fluororesin as a film, the fluororesin film is immersed in an organic solvent in which a high-molecular UV absorber is dissolved, and the UV absorber is vaporized by a dyeing method in which the UV absorber is contained. A method is described in which a high-molecular ultraviolet absorber is added to the fluororesin film by a thermal diffusion method in which the fluororesin film is exposed and impregnated with the ultraviolet absorber.

 また、特許文献6には、フッ素樹脂フィルムとEVAの積層体からなる表面被覆材に紫外線吸収剤を添加する発明が記載され、実施例では、EVAの方に紫外線吸収剤を添加したことが記載されている。特許文献6において、紫外線吸収剤としては、酸化チタン、酸化亜鉛、酸化スズ等の無機系紫外線吸収剤、及び高分子量紫外線吸収剤が挙げられている。
 また、特許文献7には、EVAの劣化と表面汚染の防止を目的として、EVAと積層するフッ素樹脂に酸化チタン粒子を含有させることが記載されている。
Patent Document 6 describes an invention in which an ultraviolet absorber is added to a surface coating material composed of a laminate of a fluororesin film and EVA, and in the examples, it is described that an ultraviolet absorber is added to EVA. Has been. In Patent Document 6, examples of the ultraviolet absorber include inorganic ultraviolet absorbers such as titanium oxide, zinc oxide and tin oxide, and high molecular weight ultraviolet absorbers.
Patent Document 7 describes that a fluorine resin laminated with EVA contains titanium oxide particles for the purpose of preventing EVA deterioration and surface contamination.

日本特開2004-055970号公報Japanese Unexamined Patent Application Publication No. 2004-055570 日本特開平05-043721号公報Japanese Unexamined Patent Publication No. 05-043721 日本特開平10-273546号公報Japanese Unexamined Patent Publication No. 10-273546 日本特開平05-092530号公報Japanese Unexamined Patent Publication No. 05-092530 日本特許第2756082号公報Japanese Patent No. 2756082 日本特許第3135477号公報Japanese Patent No. 3135477 日本特開平10-30030号公報Japanese Unexamined Patent Publication No. 10-30030

 しかし、特許文献5のように高分子の紫外線吸収剤をフッ素樹脂フィルムに添加しても、10年以上にわたり、その紫外線吸収性能を維持できるとは考えにくい。なぜなら、フッ素樹脂と紫外線吸収剤のような炭化水素系の材料とは相溶性に乏しいため、フッ素樹脂から紫外線吸収剤が揮散してしまうと考えられるからである。特に、太陽電池の表面温度は、夏場には70℃以上となるため、なおさら揮発しやすいと考えられる。そのため、EVAとの密着性を長期間維持する効果は期待できない。
 また、一方、特許文献6のように、フッ素樹脂フィルムより内側となるEVAの方に紫外線吸収剤を添加するのであれば、高分子量の紫外線吸収剤を用いても、揮散が抑制され、紫外線吸収性能は、ある程度維持できると考えられる。しかしながら、本発明者が検討した結果、EVAの方に紫外線吸収剤を添加する方法では、紫外線吸収剤の種類にかかわらず、フッ素樹脂フィルムとEVAとの密着性を長期間維持できないことがわかった。
 また、特許文献7のように、EVAと積層するフッ素樹脂に酸化チタン粒子を含有させると、酸化チタンの光触媒作用により、フッ素樹脂フィルムが変色して光線透過率が低下する、機械的強度が低下する等の問題が生じる。
However, even if a polymer ultraviolet absorber is added to the fluororesin film as in Patent Document 5, it is unlikely that the ultraviolet absorption performance can be maintained for over 10 years. This is because it is considered that the ultraviolet absorbent is volatilized from the fluororesin because the fluororesin and the hydrocarbon-based material such as the ultraviolet absorbent are poorly compatible. In particular, since the surface temperature of the solar cell is 70 ° C. or higher in summer, it is considered that it is more likely to volatilize. Therefore, the effect of maintaining the adhesion with EVA for a long time cannot be expected.
On the other hand, if a UV absorber is added to EVA inside the fluororesin film as in Patent Document 6, even if a high molecular weight UV absorber is used, volatilization is suppressed and UV absorption is achieved. The performance can be maintained to some extent. However, as a result of investigation by the present inventors, it has been found that the method of adding an ultraviolet absorber to EVA cannot maintain the adhesion between the fluororesin film and EVA for a long period regardless of the type of the ultraviolet absorber. .
Further, as in Patent Document 7, when titanium oxide particles are contained in a fluororesin laminated with EVA, the photocatalytic action of titanium oxide causes the fluororesin film to discolor and light transmittance is reduced, and mechanical strength is reduced. Problems occur.

 本発明は、上記課題に鑑みなされたものであり、耐候性に優れるものの、そのままではEVA等の充填材との密着性に乏しいフッ素樹脂のフィルムで構成されているにもかかわらず、充填材との密着性に優れ、かつ、その密着性を長期間維持でき、しかも太陽電池の発電効率に悪影響を与えない太陽電池用表面材を提供することを課題とする。
 また、充填材との密着性を長期間維持できる太陽電池用表面材と充填材とを積層することによって、長期間安定して使用でき、しかも太陽電池の発電効率に悪影響を与えない太陽電池用被覆材を提供することを課題とする。
 また、長期間安定して使用できる太陽電池用被覆材を有することにより、耐久性に優れ、しかも発電効率が損なわれない太陽電池モジュールを提供することを課題とする。
The present invention has been made in view of the above problems, and although it is excellent in weather resistance, as it is, it is composed of a fluororesin film having poor adhesion to a filler such as EVA, but the filler and It is an object of the present invention to provide a surface material for a solar cell that is excellent in the adhesion of the solar cell, can maintain the adhesion for a long period of time, and does not adversely affect the power generation efficiency of the solar cell.
In addition, for solar cells that can be used stably for a long period of time without adversely affecting the power generation efficiency of the solar cell by laminating the filler and the surface material for solar cell that can maintain the adhesion with the filler for a long period of time It is an object to provide a covering material.
Another object of the present invention is to provide a solar cell module that has excellent durability and does not impair power generation efficiency by having a solar cell coating material that can be used stably for a long period of time.

 上記の課題を達成するために、本発明は以下の構成を採用した。
 [1]表面にグロー放電処理を施したフッ素樹脂のフィルムからなり、酸化セリウムを含む紫外線吸収剤を含有することを特徴とする太陽電池用表面材。
 [2]前記紫外線吸収剤は、酸化セリウム粒子と、該酸化セリウム粒子の表面を被覆する被覆層を有し、該被覆層は酸化ケイ素を含む[1]に記載の太陽電池用表面材。
 [3]400nmにおける光透過率が80%以上、300nmにおける光透過率が70%以下とされている[1]又は[2]に記載の太陽電池用表面材。
 [4]前記フッ素樹脂は、エチレン-テトラフルオロエチレン系共重合体を含む[1]から[3]のいずれかに一項に記載太陽電池用表面材。
 [5]前記被覆層において酸化ケイ素が占める割合が60質量%以上である[2]から[4]のいずれか一項に記載の太陽電池用表面材。
 [6]前記酸化セリウム粒子の表面を被覆する酸化ケイ素が不定型シリカである[2]から[5]のいずれか一項に記載の太陽電池用表面材。
 [7]前記した酸化セリウム粒子の表面を不定型シリカにより被覆した酸化セリウム-不定型シリカ複合体の酸化セリウムの粒子の平均一次粒子径が10~250nmである[6]に記載の太陽電池用表面材。
 [8]前記表面材における酸化セリウムの含有割合が0.1~2質量%である[1]から[7]のいずれか一項に記載の太陽電池用表面材。
 [9]前記酸化セリウム粒子、または前記被覆層を有する酸化セリウム粒子の表面に疎水化処理が施されている[2]から[8]のいずれか一項に記載の太陽電池用表面材。
 [10][1]から[9]のいずれか一項に記載の太陽電池用表面材と、有機樹脂よりなる充填材とが積層されたことを特徴とする太陽電池用被覆材。
 [11]前記太陽電池用表面材のグロー放電処理を施した面側が前記充填材と接するように積層された[10]に記載の太陽電池用被覆材。
 [12]前記充填材は、エチレン-酢酸ビニル共重合体を含む[10]又は[11]に記載の太陽電池用被覆材。
 [13]内部に、1以上の薄膜光電変換層を有する太陽電池セルを備え、該太陽電池セルの少なくとも一方の面側が、[10]から[12]のいずれか一項に記載の太陽電池用被覆材で被覆されていることを特徴とする太陽電池モジュール。
 [14]前記太陽電池セルが、アモルファスシリコン(a-Si)の薄膜光電変換層を有する[13]に記載の太陽電池モジュール。
In order to achieve the above object, the present invention employs the following configuration.
[1] A solar cell surface material comprising a fluororesin film having a surface subjected to glow discharge treatment and containing an ultraviolet absorber containing cerium oxide.
[2] The solar cell surface material according to [1], wherein the ultraviolet absorber includes cerium oxide particles and a coating layer that covers a surface of the cerium oxide particles, and the coating layer includes silicon oxide.
[3] The solar cell surface material according to [1] or [2], wherein the light transmittance at 400 nm is 80% or more and the light transmittance at 300 nm is 70% or less.
[4] The solar cell surface material according to any one of [1] to [3], wherein the fluororesin includes an ethylene-tetrafluoroethylene-based copolymer.
[5] The solar cell surface material according to any one of [2] to [4], wherein a ratio of silicon oxide in the coating layer is 60% by mass or more.
[6] The surface material for a solar cell according to any one of [2] to [5], wherein the silicon oxide covering the surface of the cerium oxide particles is amorphous silica.
[7] The solar cell according to [6], wherein the average primary particle diameter of the cerium oxide particles of the cerium oxide-amorphous silica composite in which the surface of the cerium oxide particles is coated with amorphous silica is 10 to 250 nm. Surface material.
[8] The solar cell surface material according to any one of [1] to [7], wherein a content ratio of cerium oxide in the surface material is 0.1 to 2% by mass.
[9] The solar cell surface material according to any one of [2] to [8], wherein a surface of the cerium oxide particles or the cerium oxide particles having the coating layer is subjected to a hydrophobic treatment.
[10] A solar cell coating material, wherein the surface material for a solar cell according to any one of [1] to [9] and a filler made of an organic resin are laminated.
[11] The solar cell coating material according to [10], wherein the surface side of the solar cell surface material that has been subjected to the glow discharge treatment is laminated so as to be in contact with the filler.
[12] The solar cell coating material according to [10] or [11], wherein the filler includes an ethylene-vinyl acetate copolymer.
[13] A solar cell having one or more thin-film photoelectric conversion layers is provided inside, and at least one surface side of the solar cell is for the solar cell according to any one of [10] to [12]. A solar cell module which is covered with a covering material.
[14] The solar cell module according to [13], wherein the solar cell has a thin film photoelectric conversion layer of amorphous silicon (a-Si).

 本発明の太陽電池用表面材は、太陽電池セルを内包する充填材との密着性に優れ、かつ、その密着性を長期間維持でき、しかも太陽電池の発電効率に悪影響を与えない。また、本発明の太陽電池用被覆材は、本発明の太陽電池用表面材と充填材とを積層して構成されるため、長期間安定して使用でき、しかも太陽電池の発電効率に悪影響を与えない。また、本発明の、太陽電池モジュールは、長期間安定して使用できる太陽電池用被覆材を有することにより、耐久性に優れ、かつ高い発電効率が得られる。 The solar cell surface material of the present invention is excellent in adhesiveness with a filler encapsulating solar cells, can maintain the adhesiveness for a long time, and does not adversely affect the power generation efficiency of the solar cell. Moreover, since the covering material for solar cells of the present invention is constituted by laminating the surface material for solar cells and the filler of the present invention, it can be used stably for a long period of time, and the power generation efficiency of the solar cells is adversely affected. Don't give. Moreover, the solar cell module of the present invention has excellent durability and high power generation efficiency by having a solar cell coating material that can be used stably for a long period of time.

本発明の太陽電池モジュールの一実施形態を示す概略断面図である。It is a schematic sectional drawing which shows one Embodiment of the solar cell module of this invention. 本発明の太陽電池モジュールの波長と収集効率との関係の一例である。It is an example of the relationship between the wavelength of the solar cell module of this invention, and collection efficiency. 実施例1の太陽電池用表面材の光線透過率を示す図である。It is a figure which shows the light transmittance of the surface material for solar cells of Example 1. FIG. 実施例2の太陽電池用表面材の光線透過率を示す図である。It is a figure which shows the light transmittance of the surface material for solar cells of Example 2. FIG. 実施例3の太陽電池用表面材の光線透過率を示す図である。It is a figure which shows the light transmittance of the surface material for solar cells of Example 3. FIG. 比較例1の太陽電池用表面材の光線透過率を示す図である。It is a figure which shows the light transmittance of the surface material for solar cells of the comparative example 1. FIG. 比較例2の太陽電池用表面材の光線透過率を示す図である。It is a figure which shows the light transmittance of the surface material for solar cells of the comparative example 2. FIG.

<太陽電池用表面材>
 本発明の太陽電池用表面材は、表面がグロー放電処理により改質されているフッ素樹脂のフィルムからなり、当該フィルムの内部に酸化セリウムを含む紫外線吸収剤を分散含有することを特徴とする。
 本発明の太陽電池用表面材において、前記紫外線吸収剤は、酸化セリウム粒子と、該酸化セリウム粒子の表面を被覆する被覆層を有し、該被覆層は酸化ケイ素を含んでいるのが好ましい。
 また、本発明の太陽電池用表面材は、表面材自身として、400nmにおける光透過率が80%以上、300nmにおける光透過率が70%以下とされているのが好ましい。
<Surface material for solar cell>
The surface material for a solar cell of the present invention is made of a fluororesin film whose surface is modified by glow discharge treatment, and contains an ultraviolet absorber containing cerium oxide in a dispersed manner.
In the surface material for a solar cell of the present invention, the ultraviolet absorber preferably has cerium oxide particles and a coating layer that covers the surface of the cerium oxide particles, and the coating layer preferably contains silicon oxide.
The surface material for solar cells of the present invention preferably has a light transmittance of 80% or more at 400 nm and a light transmittance of 70% or less at 300 nm as the surface material itself.

[フッ素樹脂]
 太陽電池用表面材を構成するフッ素樹脂としては、エチレン-テトラフルオロエチレン系共重合体(以下、「ETFE」ともいう。)、ポリ三フッ化塩化エチレン樹脂(PCTFE)、エチレン-三フッ化塩化エチレン共重合体(ECTFE)、四フッ化エチレン-パーフルオロアルキルビニルエーテル共重合体(PFA)、四フッ化エチレン-六フッ化プロピレン共重合体(FEP)などの高透明フッ素樹脂、或いは、これらの混合物が挙げられる。
[Fluororesin]
Examples of the fluororesin constituting the surface material for solar cells include ethylene-tetrafluoroethylene copolymer (hereinafter also referred to as “ETFE”), polytrifluoroethylene chloride (PCTFE), ethylene-trifluorochloride. Highly transparent fluororesin such as ethylene copolymer (ECTFE), tetrafluoroethylene-perfluoroalkyl vinyl ether copolymer (PFA), tetrafluoroethylene-hexafluoropropylene copolymer (FEP), or these A mixture is mentioned.

 これらの中でも、樹脂成分に占めるETFEの割合が80質量%以上、好ましくは90質量%以上、特に好ましくは100質量%であるETFEを主成分とするフッ素樹脂が好ましい。
 ETFEは、エチレン(以下、「E」という。)とテトラフルオロエチレン(以下、「TFE」という。)との共重合体、またはEとTFEに基づく繰返し単位に加えて、共重合可能な、その他の単量体に基づく繰返し単位を含有する共重合体である。
Among these, a fluororesin mainly composed of ETFE having a ratio of ETFE in the resin component of 80% by mass or more, preferably 90% by mass or more, and particularly preferably 100% by mass is preferable.
ETFE is a copolymer of ethylene (hereinafter referred to as “E”) and tetrafluoroethylene (hereinafter referred to as “TFE”), or a copolymerizable in addition to a repeating unit based on E and TFE. It is a copolymer containing repeating units based on these monomers.

 ETFE中のTFEに基づく繰返し単位とEに基づく繰返し単位の比率(モル比)は、70/30~30/70が好ましく、65/35~40/60がより好ましく、60/40~40/60が特に好ましい。
 上記した数値範囲を示す「~」とは、特段の定めがない限り、その前後に記載された数値を下限値及び上限値として含む意味で使用され、以下本明細書において「~」は、同様の意味をもって使用される。
 EとTFEに基づく繰返し単位に加えて、共重合可能な、その他の単量体に基づく繰返し単位を含有する場合、その他の単量体に基づく繰返し単位の含有量は、ETFEの全繰返し単位に対して、0.1モル%以上が好ましく、0.5~30モル%がより好ましく、0.5~20モル%が特に好ましい。ETFEの共単量体に基づく繰り返し単位の含有量がこの範囲にあると、ETFEの物性を損なうことなく、高い溶解性、撥水性、撥油性、基材に対する接着性などの機能を付与することが可能になる。
The ratio (molar ratio) between the repeating unit based on TFE and the repeating unit based on E in ETFE is preferably 70/30 to 30/70, more preferably 65/35 to 40/60, and 60/40 to 40/60. Is particularly preferred.
Unless otherwise specified, “to” indicating the numerical range described above is used to mean that the numerical values described before and after it are used as a lower limit value and an upper limit value, and hereinafter “to” Used with meaning.
In addition to the repeating units based on E and TFE, when containing repeating units based on other monomers that are copolymerizable, the content of the repeating units based on other monomers is in the total repeating units of ETFE. On the other hand, it is preferably 0.1 mol% or more, more preferably 0.5 to 30 mol%, particularly preferably 0.5 to 20 mol%. When the content of the repeating unit based on the comonomer of ETFE is within this range, functions such as high solubility, water repellency, oil repellency, and adhesion to the substrate are imparted without impairing the physical properties of ETFE. Is possible.

 その他の単量体としては、TFE以外の他のフルオロオレフィン、E以外の他のオレフィン、ビニル系モノマーなどが挙げられる。
 他のフルオロオレフィンとしては、例えば、クロロトリフルオロエチレン、ヘキサフルオロプロピレン、フッ化ビニリデン、フッ化ビニルなどの炭素数2~3のフルオロオレフィンが挙げられる。また、(パーフルオロアルキル)エチレンなどのフルオロビニルモノマーが挙げられる。
 他のオレフィンとしては、例えば、プロピレン、イソブチレンなどが挙げられる。
 ビニル系単量体としては、例えば、ビニルエーテル、アリルエーテル、カルボン酸ビニルエステル、カルボン酸アリルエステルなどが挙げられる。
Examples of other monomers include other fluoroolefins other than TFE, other olefins other than E, and vinyl monomers.
Examples of other fluoroolefins include C2-C3 fluoroolefins such as chlorotrifluoroethylene, hexafluoropropylene, vinylidene fluoride, and vinyl fluoride. Moreover, fluorovinyl monomers, such as (perfluoroalkyl) ethylene, are mentioned.
Examples of other olefins include propylene and isobutylene.
Examples of vinyl monomers include vinyl ether, allyl ether, carboxylic acid vinyl ester, carboxylic acid allyl ester, and the like.

 ビニルエーテルとしては、例えば、シクロヘキシルビニルエーテルなどのシクロアルキルビニルエーテル;ノニルビニルエーテル、2-エチルヘキシルビニルエーテル、ヘキシルビニルエーテル、エチルビニルエーテル、n-ブチルビニルエーテル、t-ブチルビニルエーテルなどのアルキルビニルエーテルが挙げられる。
 アリルエーテルとしては、例えば、エチルアリルエーテル、ヘキシルアリルエーテルなどのアルキルアリルエーテルが挙げられる。
 カルボン酸ビニルエステルとしては、酢酸、酪酸、ピバリン酸、安息香酸、プロピオン酸などのカルボン酸のビニルエステルなどが挙げられる。カルボン酸アリルエステルとしては前記カルボン酸のアリルエステルなどが挙げられる。また、分枝状アルキル基を有するカルボン酸のビニルエステルを用いてもよい。具体的には、商品名「ベオバ-9」、「ベオバ-10」(いずれもシェル化学社製)などが挙げられる。
 前記他の共重合単量体は、1種を単独で使用してもよく、2種以上を併用してもよい。
Examples of the vinyl ether include cycloalkyl vinyl ethers such as cyclohexyl vinyl ether; alkyl vinyl ethers such as nonyl vinyl ether, 2-ethylhexyl vinyl ether, hexyl vinyl ether, ethyl vinyl ether, n-butyl vinyl ether, and t-butyl vinyl ether.
Examples of allyl ethers include alkyl allyl ethers such as ethyl allyl ether and hexyl allyl ether.
Examples of the carboxylic acid vinyl ester include vinyl esters of carboxylic acids such as acetic acid, butyric acid, pivalic acid, benzoic acid, and propionic acid. Examples of the carboxylic acid allyl ester include allyl esters of the above carboxylic acids. Alternatively, a vinyl ester of a carboxylic acid having a branched alkyl group may be used. Specific examples include “Beoba-9” and “Beoba-10” (both manufactured by Shell Chemical Co., Ltd.).
The other copolymer monomers may be used alone or in combination of two or more.

 ETFEを主成分とするフッ素樹脂におけるETFE以外の他の樹脂としては、例えば、ヘキサフルオロプロピレン-テトラフルオロエチレン系共重合体、パーフルオロ(アルキルビニルエーテル)-テトラフルオロエチレン系共重合体、テトラフルオロエチレン-ヘキサフルオロプロピレン-フッ化ビニリデン系共重合体、クロロトリフルオロエチレン-エチレン共重合体などのフッ素樹脂が挙げられる。また、ETFEを主成分とするフッ素樹脂には、フッ素樹脂以外の樹脂が含有されていてもよい。
 前記他の樹脂は、1種を単独で使用してもよく、2種以上を併用してもよい。
Examples of the resin other than ETFE in the fluororesin mainly composed of ETFE include, for example, hexafluoropropylene-tetrafluoroethylene copolymer, perfluoro (alkyl vinyl ether) -tetrafluoroethylene copolymer, and tetrafluoroethylene. -Fluororesin such as hexafluoropropylene-vinylidene fluoride copolymer and chlorotrifluoroethylene-ethylene copolymer. The fluororesin mainly composed of ETFE may contain a resin other than the fluororesin.
The other resins may be used alone or in combination of two or more.

[放電処理]
 本発明の太陽電池用表面材は、表面がグロー放電処理により改質されたフッ素樹脂のフィルムからなる。
 グロー放電処理としては、重合性ガスを重合させることにより、酸素原子及び窒素原子を含みフッ素を含まないポリマーをフッ素樹脂フィルム上に導入するプラズマ重合処理、及び、重合を伴わずに、酸素原子や窒素原子を導入する非重合性のプラズマ処理が挙げられる。
 何れの場合も、導入される酸素原子や窒素原子により、充填材に対する密着力が付与される。
[Discharge treatment]
The surface material for a solar cell of the present invention comprises a fluororesin film whose surface is modified by glow discharge treatment.
As the glow discharge treatment, by polymerizing a polymerizable gas, a plasma polymerization treatment for introducing a polymer containing oxygen atoms and nitrogen atoms and not containing fluorine onto the fluororesin film; Non-polymerizable plasma treatment in which nitrogen atoms are introduced may be mentioned.
In any case, the introduced oxygen atom or nitrogen atom provides adhesion to the filler.

 プラズマ重合処理及び非重合性のプラズマ処理は、何れも、プラズマ化されたイオンによるグロー放電を利用するプラズマ処理である。具体的には、所定のガスが存在する雰囲気中において放電電極と対向電極の間に、高周波、パルス波、マイクロ波等からなる高周波電磁界を形成させ、放電電極と対向電極の間に配置したフッ素樹脂フィルムの表面にグロー放電処理を施す。 Both the plasma polymerization treatment and the non-polymerization plasma treatment are plasma treatments using glow discharge caused by ionized plasma. Specifically, a high-frequency electromagnetic field composed of a high frequency, a pulse wave, a microwave, or the like is formed between the discharge electrode and the counter electrode in an atmosphere where a predetermined gas exists, and is disposed between the discharge electrode and the counter electrode. Glow discharge treatment is performed on the surface of the fluororesin film.

 非重合性のプラズマ処理を行う場合の雰囲気としては、そのランニングコストの面から窒素雰囲気が好ましい。窒素雰囲気における酸素濃度は100ppm以下であることが好ましく、90ppm以下であることがより好ましく、60ppm以下であることがさらに好ましい。酸素濃度が低い程、表面処理によって、密着性を長期間維持できるフッ素樹脂フィルムが得られやすい。
 窒素雰囲気においては、窒素ガスに加えて炭酸ガスおよび/または水素ガスを導入してもよい。炭酸ガスは、フッ素樹脂表面に、ヒドロキシ基などの酸素官能基を導入する酸素供給源として働く。水素ガスは、フッ素樹脂表面に、アミノ基を導入する水素供給源として働く。
 炭酸ガスおよび/または水素ガスの合計の導入量は両者合計で、窒素ガスを100モル%としたとき、10モル%以下であることが好ましい。炭酸ガスおよび水素ガスの合計の導入量が、窒素ガス100モル%に対して10モル%以下であれば、窒素プラズマガスの特異的な作用である、フッ素オリゴマーやフッ素低分子量体をその表面から取り除くという効果を得やすい。
 ヘリウムガスやアルゴンガスもプラズマ化してグロー放電が可能であり、上記の放電の効果も得やすい。ただし、これらのガスは高価である。
As an atmosphere in the case of performing non-polymerizable plasma treatment, a nitrogen atmosphere is preferable in terms of running cost. The oxygen concentration in the nitrogen atmosphere is preferably 100 ppm or less, more preferably 90 ppm or less, and further preferably 60 ppm or less. The lower the oxygen concentration, the easier it is to obtain a fluororesin film that can maintain adhesion for a long period of time by surface treatment.
In a nitrogen atmosphere, carbon dioxide gas and / or hydrogen gas may be introduced in addition to nitrogen gas. Carbon dioxide gas serves as an oxygen supply source for introducing oxygen functional groups such as hydroxy groups on the surface of the fluororesin. The hydrogen gas functions as a hydrogen supply source for introducing amino groups on the surface of the fluororesin.
The total introduction amount of carbon dioxide gas and / or hydrogen gas is preferably 10 mol% or less when the total amount of both is 100 mol%. If the total introduction amount of carbon dioxide gas and hydrogen gas is 10 mol% or less with respect to 100 mol% of nitrogen gas, fluorine oligomers and fluorine low molecular weight substances, which are specific actions of nitrogen plasma gas, are introduced from the surface. Easy to get rid of effect.
Helium gas and argon gas can also be turned into plasma and glow discharge is possible, and the above-described discharge effect is easily obtained. However, these gases are expensive.

 プラズマ重合処理を行う場合の雰囲気としては、重合性不飽和化合物ガスと炭素酸化物ガスからなる混合ガス雰囲気が好ましい。また、C2n+2で表記される飽和炭化水素に分類されるメタンガスやエタンガスも、炭素酸化物ガスとの混合ガス中でプラズマ重合を行うため好ましい。
 重合性不飽和化合物ガスとしては、エチレンガス、プロピレンガスなどの二重結合を有する化合物ガスが挙げられる。また、炭素酸化物ガスとしては、炭酸ガス、一酸化炭素ガスが挙げられる。
 また、C2n+2で表記される飽和炭化水素ではメタン、エタンが好ましく、より好ましいのはメタンである。この飽和炭化水素、あるいは重合性不飽和化合物ガス、そして炭素酸化物ガスを使用したプラズマ重合処理を行う場合、これらのガスを、高価ではあるが、ヘリウムガスやアルゴンガス中に混合してプラズマ重合を行うことが好ましい。これにより、炭素、水素、酸素、窒素からなる不規則な構造を有する重合度の低いポリマー重合層ができやすくなり、フッ素ポリマーに対する強固な密着性を得やすくなる。一方、これらのガスを窒素ガス中に混合すれば、低コストでプラズマ重合処理を行うことができる。
As an atmosphere in the case of performing the plasma polymerization treatment, a mixed gas atmosphere composed of a polymerizable unsaturated compound gas and a carbon oxide gas is preferable. Further, methane gas and ethane gas classified as saturated hydrocarbons represented by C 4 H 2n + 2 are also preferable because plasma polymerization is performed in a mixed gas with a carbon oxide gas.
Examples of the polymerizable unsaturated compound gas include a compound gas having a double bond such as ethylene gas and propylene gas. Examples of the carbon oxide gas include carbon dioxide gas and carbon monoxide gas.
In the saturated hydrocarbon represented by C 4 H 2n + 2 , methane and ethane are preferable, and methane is more preferable. When performing plasma polymerization using this saturated hydrocarbon, polymerizable unsaturated compound gas, and carbon oxide gas, these gases are mixed with helium gas or argon gas, but plasma polymerization is performed. It is preferable to carry out. Thereby, it becomes easy to form a polymer polymerization layer having an irregular structure composed of carbon, hydrogen, oxygen, and nitrogen and having a low polymerization degree, and it becomes easy to obtain strong adhesion to the fluoropolymer. On the other hand, if these gases are mixed in nitrogen gas, plasma polymerization can be performed at low cost.

 グロー放電処理を行う際の雰囲気圧力は、大気圧近傍が好ましい。すなわち、500~800Torrが好ましく、700~780Torrがより好ましい。圧力が500Torr以上であれば、導入ガス以外のガスが放電部に混入することを抑制しやすい。圧力が800Torr以下であれば、プラズマ化されたガス同士が衝突し、フィルムの表面処理効果が低下することを抑制しやすい。
 グロー放電処理を行う際の雰囲気温度は特に制限されず、0~60℃が好ましく、10~40℃がより好ましい。
The atmospheric pressure when performing the glow discharge treatment is preferably near atmospheric pressure. That is, 500 to 800 Torr is preferable, and 700 to 780 Torr is more preferable. If the pressure is 500 Torr or more, it is easy to suppress mixing of gases other than the introduced gas into the discharge part. If the pressure is 800 Torr or less, it is easy to suppress the plasma-treated gases from colliding with each other and reducing the surface treatment effect of the film.
The atmosphere temperature during the glow discharge treatment is not particularly limited and is preferably 0 to 60 ° C, more preferably 10 to 40 ° C.

 放電電極と対向電極に印加する電界は、電圧立ち上がり時間が10μ秒以下のパルス化された電界(以下、「パルス電界」という。)であることが好ましい。電圧立ち上がり時間が10μ秒以下であれば、放電状態がアーク放電に移行することを抑制でき、安定してグロー放電処理が行える。パルス電圧の電圧立ち上がり時間は、5μ秒以下がより好ましい。電圧立ち上がり時間が短いほど、ガスが効率良く電離してプラズマ化されやすく、グロー放電を発生させやすくなる。ただし、電圧立ち上がり時間とは、電圧変化が連続して正である時間をいう。
 印加する電界の電圧立ち下がり時間は、電圧立ち上がり時間と同様に短いことが好ましく、立ち上がり時間と立ち下がり時間を同じ時間に設定することが好ましい。ただし、電圧立ち下がり時間とは、電圧変化が連続して負である時間をいう。
 パルス電界の波形は、特に限定されず、インパルス波形、方形波形、変調波形などが挙げられる。また、周波数が20kHzを超えると正弦波の形になりやすい。
The electric field applied to the discharge electrode and the counter electrode is preferably a pulsed electric field (hereinafter referred to as “pulse electric field”) having a voltage rise time of 10 μsec or less. If the voltage rise time is 10 μsec or less, the discharge state can be prevented from shifting to arc discharge, and the glow discharge treatment can be performed stably. The voltage rise time of the pulse voltage is more preferably 5 μsec or less. As the voltage rise time is shorter, the gas is more easily ionized and becomes plasma, and glow discharge is more likely to occur. However, the voltage rise time is a time during which the voltage change is continuously positive.
The voltage fall time of the applied electric field is preferably as short as the voltage rise time, and the rise time and the fall time are preferably set to the same time. However, the voltage fall time is a time during which the voltage change is continuously negative.
The waveform of the pulse electric field is not particularly limited, and examples thereof include an impulse waveform, a square waveform, and a modulation waveform. Further, when the frequency exceeds 20 kHz, a sine wave is likely to be formed.

 パルス電界におけるパルス継続時間は、0.5~200μ秒が好ましく、1~10μ秒が好ましい。パルス継続時間が0.5μ秒以上であれば、放電がより安定なものとなる。パルス継続時間が200μ秒以下であれば、グロー放電がアーク放電に移行することを抑制しやすい。パルス継続時間は、電界パルスの周波数により調節できる。ただし、パルス継続時間とは、パルスが連続している時間をいう。
 例えば、1つ1つのパルスが離れている間欠型のパルスである場合、パルス継続時間はパルス幅時間と同じである。また、複数のパルスが連続している場合、パルス継続時間はその一連の連続したパルスのパルス幅時間の合計と同じである。
The pulse duration in the pulse electric field is preferably 0.5 to 200 μsec, more preferably 1 to 10 μsec. If the pulse duration is 0.5 μsec or more, the discharge becomes more stable. If the pulse duration is 200 μs or less, it is easy to suppress the transition of glow discharge to arc discharge. The pulse duration can be adjusted by the frequency of the electric field pulse. However, the pulse duration is the time during which the pulses are continuous.
For example, if each pulse is an intermittent pulse that is separated, the pulse duration is the same as the pulse width time. When a plurality of pulses are continuous, the pulse duration is the same as the sum of the pulse width times of the series of continuous pulses.

 印加する電界の電界強度は、10~1,000kV/cmが好ましく、100~300kV/cmが好ましい。電界強度が10kV/cm以上であれば、グロー放電によりガスをプラズマ化しやすい。電界強度が1000kV/cm以下であれば、アーク放電が発生することを抑制しやすい。
 パルス電圧の周波数は、0.5~100kHzが好ましく、5~50kHzがより好ましい。パルス電圧の周波数が0.5kHz以上であれば、グロー放電の放電密度が向上し、表面処理に要する時間が短くなる。パルス電圧の周波数が100kHz以下であれば、放電状態がアーク放電に移行することを抑制でき、安定してグロー放電処理が行える。
The electric field strength of the applied electric field is preferably 10 to 1,000 kV / cm, more preferably 100 to 300 kV / cm. If the electric field strength is 10 kV / cm or more, the gas is easily turned into plasma by glow discharge. If the electric field strength is 1000 kV / cm or less, it is easy to suppress the occurrence of arc discharge.
The frequency of the pulse voltage is preferably 0.5 to 100 kHz, more preferably 5 to 50 kHz. When the frequency of the pulse voltage is 0.5 kHz or more, the discharge density of the glow discharge is improved and the time required for the surface treatment is shortened. If the frequency of the pulse voltage is 100 kHz or less, the discharge state can be prevented from shifting to arc discharge, and the glow discharge treatment can be performed stably.

 パルス電界によるグロー放電処理は、0.01秒以上の間隔を空けて複数回行うことが好ましい。
 各々のグロー放電処理の放電密度、つまり各々の放電電極と対向電極の間の放電密度は、40~200W・分/mであることが好ましく、60~180W・分/mであることがより好ましい。各々のグロー放電処理の放電密度が40W・分/m以上であれば、窒素官能基や酸素官能基が導入されやすい。また、放電密度がそれ未満では、導入される官能基の数は極めて少ない。各々のグロー放電処理の放電密度が200W・分/m以下であれば、表面処理により得られる密着性を長期間維持しやすい。
 パルス電界によるグロー放電処理とすることにより、処理対象のフッ素樹脂のフィルムの温度の上昇が小さくなり、また各放電処理間で一旦上昇した温度が低下する。そのため、熱によるオリゴマー成分の表層への移動が抑制される。加えて、各グロー放電処理の放電密度、およびその総和を抑制することにより、表層でのフッ素樹脂の炭素-炭素結合の切断によるオリゴマー成分の生成量が低減される。そのため、フッ素樹脂フィルムの表層ではオリゴマー成分が少なくなり、酸素原子や窒素原子が、結合力の弱いオリゴマー成分にではなく、フッ素樹脂自体に導入されやすくなる。
The glow discharge treatment using a pulsed electric field is preferably performed a plurality of times with an interval of 0.01 seconds or more.
The discharge density of each glow discharge treatment, that is, the discharge density between each discharge electrode and the counter electrode is preferably 40 to 200 W · min / m 2 , and preferably 60 to 180 W · min / m 2. More preferred. If the discharge density of each glow discharge treatment is 40 W · min / m 2 or more, nitrogen functional groups and oxygen functional groups are easily introduced. Further, when the discharge density is less than that, the number of functional groups to be introduced is extremely small. If the discharge density of each glow discharge treatment is 200 W · min / m 2 or less, the adhesion obtained by the surface treatment can be easily maintained for a long period of time.
By performing glow discharge treatment using a pulsed electric field, the increase in the temperature of the fluororesin film to be treated is reduced, and the temperature once increased between each discharge treatment is reduced. Therefore, the movement of the oligomer component to the surface layer due to heat is suppressed. In addition, by suppressing the discharge density and the total sum of each glow discharge treatment, the amount of oligomer components generated due to the breakage of the carbon-carbon bond of the fluororesin on the surface layer is reduced. Therefore, the oligomer component is reduced on the surface layer of the fluororesin film, and oxygen atoms and nitrogen atoms are easily introduced into the fluororesin itself, not into the oligomer component having a weak binding force.

 グロー放電に用いる放電電極及び対向電極の構造は、既知の電極構造が自由に採用できる。例えば、対向電極としては、曲面型、平板型の電極が用いられる。電界集中によるアーク放電が発生するのを防止するため、電極間の距離が一定となる平行平板型電極を採用するのが好ましい。両電極間の距離は、0.5~10mmとするのが好ましい。0.5mm以上とすることにより、両電極間にフッ素樹脂のフィルムを配置しやすい。また、10mm以下とすることにより、放電が安定し、かつ、放電密度の高い放電を得やすい。
 両電極の材質としては、銅、アルミニウム等の金属単体、ステンレス、黄銅等の合金等を使用することができる。
A known electrode structure can be freely adopted as the structure of the discharge electrode and the counter electrode used for the glow discharge. For example, a curved electrode or a flat electrode is used as the counter electrode. In order to prevent arc discharge due to electric field concentration, it is preferable to employ a parallel plate type electrode in which the distance between the electrodes is constant. The distance between both electrodes is preferably 0.5 to 10 mm. By setting the thickness to 0.5 mm or more, it is easy to dispose a fluororesin film between both electrodes. Moreover, by setting it as 10 mm or less, it is easy to obtain discharge with stable discharge and high discharge density.
As a material for both electrodes, a single metal such as copper or aluminum, an alloy such as stainless steel or brass, or the like can be used.

 アーク放電が発生するのを防止するため、両電極の少なくとも一方の対向面側に、固体誘電体を被覆することが好ましい。より良好なプラズマ状態を作るためには、固体誘電体を双方の電極に配するのがよい。
 放電電極側に用いる固体誘電体の材質としては、二酸化珪素、酸化アルミニウム、二酸化ジルコニウム、二酸化チタン等の金属酸化物を使用することが好ましい。ポリテトラフルオロエチレン、ポリエチレンテレフタレート等の合成樹脂、ガラス等を使用することもできる。
 中でも比誘電率10以上(25℃環境下の比誘電率、以下同じ。)の固体誘電体を用いることが好ましい。比誘電率10以上の固体誘電体としては、二酸化ジルコニウム、二酸化チタン等の金属酸化物、チタン酸バリウム等の複酸化物等が挙げられる。
In order to prevent the occurrence of arc discharge, it is preferable to coat a solid dielectric on at least one opposing surface side of both electrodes. In order to create a better plasma state, a solid dielectric should be placed on both electrodes.
As the material of the solid dielectric used on the discharge electrode side, it is preferable to use a metal oxide such as silicon dioxide, aluminum oxide, zirconium dioxide, titanium dioxide. Synthetic resins such as polytetrafluoroethylene and polyethylene terephthalate, and glass can also be used.
In particular, it is preferable to use a solid dielectric having a relative dielectric constant of 10 or more (relative dielectric constant in an environment at 25 ° C., the same shall apply hereinafter). Examples of the solid dielectric having a relative dielectric constant of 10 or more include metal oxides such as zirconium dioxide and titanium dioxide, and double oxides such as barium titanate.

 二酸化チタンは強誘電体として知られており、二酸化チタン単独組成の場合、結晶構造で比誘電率が異なり、ルチル型結晶構造で比誘電率80程度である。また、Ba、Sr、Pb、Ca、Mg、Zr等の金属の酸化物から選ばれた少なくとも1種以上と二酸化チタンとの混合組成とすることにより、比誘電率が約2000~18500である誘電体が得られる。すなわち、比誘電率は、混合する他の酸化物の種類や割合、結晶性によって変えることが出来る。
 二酸化チタンは、単独では加熱環境下における組成変化が激しく、使用環境が制限され、電極上に皮膜として形成する場合の取扱が困難である。そのため、二酸化チタン5~50質量%、酸化アルミニウム50~95質量%からなる混合組成となし、熱的安定性を改良して用いることが好ましい。
Titanium dioxide is known as a ferroelectric, and in the case of a titanium dioxide single composition, the relative dielectric constant differs depending on the crystal structure, and the relative dielectric constant is about 80 for the rutile crystal structure. Further, a dielectric composition having a relative dielectric constant of about 2000 to 18500 is obtained by using a mixed composition of at least one selected from metal oxides such as Ba, Sr, Pb, Ca, Mg, and Zr and titanium dioxide. The body is obtained. That is, the relative dielectric constant can be changed depending on the type and ratio of other oxides to be mixed and the crystallinity.
Titanium dioxide alone has a drastic compositional change in a heating environment, restricts the use environment, and is difficult to handle when formed as a film on an electrode. Therefore, it is preferable to use a mixed composition composed of 5 to 50% by mass of titanium dioxide and 50 to 95% by mass of aluminum oxide with improved thermal stability.

 二酸化ジルコニウムは、単独の場合、比誘電率は約12程度であり、低い電圧で放電プラズマを発生させるのに有利である。また、他の金属酸化物との混合組成としてもよい。比誘電率は、混合する他の酸化物の種類や割合、結晶性によって変えることが出来る。
 酸化ジルコニウムは酸化イットリウム(Y)、炭酸カルシウム(CaCO)、酸化マグネシウム(MgO)等を混合すると、結晶変態による膨張、収縮を防止し安定化されるので好ましい。
 他の酸化物との混合組成とする場合、少なくとも70質量%は酸化ジルコニウムとし、他の酸化物の割合は30質量%以内とすることが好ましい。例えば、酸化イットリウムが4~20質量%添加された酸化ジルコニウム被膜は比誘電率が8~16程度となるため好ましい。
Zirconium dioxide, when used alone, has a relative dielectric constant of about 12 and is advantageous for generating a discharge plasma at a low voltage. Moreover, it is good also as a mixed composition with another metal oxide. The relative dielectric constant can be changed depending on the type and ratio of other oxides to be mixed and the crystallinity.
Zirconium oxide is preferably mixed with yttrium oxide (Y 2 O 3 ), calcium carbonate (CaCO 3 ), magnesium oxide (MgO), or the like because it is stabilized by preventing expansion and contraction due to crystal transformation.
In the case of a mixed composition with other oxides, at least 70% by mass is zirconium oxide, and the proportion of the other oxides is preferably within 30% by mass. For example, a zirconium oxide film to which 4 to 20% by mass of yttrium oxide is added is preferable because the relative dielectric constant is about 8 to 16.

 放電電極側の固体誘電体の厚みは、処理される基材の厚みや印加電圧によって適宜決定されるが、0.01~4mmであることが好ましい。厚すぎるとプラズマ放電を発生するのに高電圧を要し、薄すぎると電圧印加時に絶縁破壊が起こり、アーク放電が発生するためである。 The thickness of the solid dielectric on the discharge electrode side is appropriately determined depending on the thickness of the substrate to be processed and the applied voltage, but is preferably 0.01 to 4 mm. If it is too thick, a high voltage is required to generate plasma discharge. If it is too thin, dielectric breakdown occurs when voltage is applied, and arc discharge occurs.

 対向電極側の固体誘電体は、フッ素樹脂のフィルムを支持するため、フッ素樹脂のフィルムとよくなじみ、柔らかい材質が好ましい。例えばシリコンゴムなどが有効である。 Since the solid dielectric on the counter electrode side supports the fluororesin film, it is familiar with the fluororesin film and is preferably a soft material. For example, silicon rubber is effective.

[紫外線吸収剤]
 本発明の太陽電池用表面材は、紫外線吸収剤を含有する。本発明者が検討した結果、グロー放電処理によって得られる酸素原子や窒素原子を含む官能基、特に窒素原子を含む官能基は、紫外線に対する耐性が低いことがわかった。すなわち、これらの官能基が紫外線によって破壊されることが、経時による密着性の低下をもたらしていることを見出した。したがって、表面材と充填材とが安定に積層した被覆材を得るためには、充填材を紫外線から保護するだけでは足りず、放電処理したフッ素樹脂における上記官能基も紫外線から保護すべきことを見出した。そのため本発明では、充填材にではなく、表面材に紫外線吸収剤を含有させることとした。
[Ultraviolet absorber]
The surface material for a solar cell of the present invention contains an ultraviolet absorber. As a result of studies by the present inventors, it has been found that functional groups containing oxygen atoms and nitrogen atoms, particularly functional groups containing nitrogen atoms, obtained by glow discharge treatment have low resistance to ultraviolet rays. That is, it has been found that the destruction of these functional groups by ultraviolet rays causes a decrease in adhesion over time. Therefore, in order to obtain a coating material in which the surface material and the filler are stably laminated, it is not only necessary to protect the filler from ultraviolet rays, and the functional groups in the discharge-treated fluororesin should also be protected from ultraviolet rays. I found it. Therefore, in the present invention, an ultraviolet absorber is contained in the surface material, not in the filler.

 本発明における紫外線吸収剤は、酸化セリウムを含有することを特徴とする。酸化セリウムであれば、酸化チタンのような光触媒作用を有しないため、フッ素樹脂フィルムに含有させても、フッ素樹脂フィルムを変色させて光線透過率が低下させたり、機械的強度を低下させたりする等の問題を生じない。
 また、後述の実施例から明らかなように、酸化セリウムは、太陽電池の発電において収集効率の高い350nm以上の波長領域の光については吸収が少ない。一方、官能基に対する影響が大きい低波長側の紫外線(特に350nm未満)については、十分な吸収性を備える。そのため、発電効率を実質的に損なうことなく、放電処理したフッ素樹脂における官能基を紫外線から保護することができる。
 たとえば、酸化亜鉛なども、光触媒作用を有しない紫外線吸収剤として知られているが、酸化亜鉛の場合、太陽電池の発電において、ある程度高い収集効率が得られる350~360nmの光に対する吸収が大きい。そのため、酸化亜鉛を紫外線吸収剤として太陽電池用表面材に用いると、充分な発電効率が得られない。
The ultraviolet absorbent in the present invention is characterized by containing cerium oxide. If it is cerium oxide, it does not have a photocatalytic action like titanium oxide, so even if it is contained in the fluororesin film, the fluororesin film is discolored to reduce the light transmittance or reduce the mechanical strength. Does not cause such problems.
Further, as will be apparent from the examples described later, cerium oxide absorbs less light in a wavelength region of 350 nm or more, which has high collection efficiency in power generation by a solar cell. On the other hand, ultraviolet rays on the low wavelength side (especially less than 350 nm) that have a large influence on the functional group have sufficient absorbency. Therefore, the functional group in the discharge-treated fluororesin can be protected from ultraviolet rays without substantially impairing the power generation efficiency.
For example, zinc oxide and the like are also known as ultraviolet absorbers that do not have a photocatalytic action. However, zinc oxide has a large absorption with respect to light of 350 to 360 nm that can obtain a certain degree of collection efficiency in power generation of a solar cell. For this reason, if zinc oxide is used as a UV absorber for a solar cell surface material, sufficient power generation efficiency cannot be obtained.

 酸化セリウムは、フッ素樹脂が分解することにより発生するフッ化水素により溶解しやすい。そのため、より高い耐候性を得るためには、酸化セリウム粒子の表面をフッ化水素から保護するための被覆層で覆った複合粒子とすることが好ましい。
 被覆層としては、酸化ケイ素を含む被覆層が好ましく、被覆層に占める酸化ケイ素の割合が60質量%以上、好ましくは80質量%以上、特に好ましくは100質量%である酸化ケイ素を主成分とする被覆層が好ましい。
 被覆層に含まれる他の成分としては、複合粒子製造時に使用する硫酸アルミニウム(凝集剤)に由来して、被覆層表面に残留する酸化アルミニウム等が挙げられる。
Cerium oxide is easily dissolved by hydrogen fluoride generated by the decomposition of the fluororesin. Therefore, in order to obtain higher weather resistance, it is preferable to use composite particles in which the surface of the cerium oxide particles is covered with a coating layer for protecting from hydrogen fluoride.
As the coating layer, a coating layer containing silicon oxide is preferable, and a silicon oxide having a silicon oxide ratio of 60% by mass or more, preferably 80% by mass or more, particularly preferably 100% by mass in the coating layer as a main component. A coating layer is preferred.
Examples of other components contained in the coating layer include aluminum oxide remaining on the surface of the coating layer derived from aluminum sulfate (aggregating agent) used during the production of the composite particles.

 すなわち、酸化セリウム粒子の表面をフッ化水素から保護するための被覆層で覆った複合粒子は、酸化セリウム粒子の表面を酸化ケイ素(すなわち、シリカ)で覆った酸化セリウム-シリカ複合体であることが好ましい。その場合、酸化セリウム粒子の表面をシリカにより覆った酸化セリウム-シリカ複合体の粒子のCeO:SiOの質量比が30:70~80:20であることが好ましく、40:60~70:30であることがより好ましい。ここにおいて、前記CeOとSiOとの質量比は、酸化セリウム-シリカ複合体の粒子の全体におけるCeOとSiOとの割合である。シリカの比率が高くなれば耐候性は向上するが、シリカの量が多過ぎると、このシリカに吸着する水も増えるため、フィルム成型時に発泡スジを生ずることがある。
 また、酸化ケイ素は、結晶性を有しない無定形のシリカ(すなわち、不定形シリカ)であることが好ましい。不定形シリカの具体例としては、たとえばケイ酸ナトリウムを加水分解して得られる不定形シリカが挙げられる。
 すなわち、酸化セリウム粒子の表面をフッ化水素から保護するための被覆層で覆った複合粒子は、酸化セリウム粒子の表面を不定形シリカで覆った酸化セリウム-不定形シリカ複合体であることが好ましい。
That is, the composite particle in which the surface of the cerium oxide particle is covered with a coating layer for protecting from hydrogen fluoride is a cerium oxide-silica composite in which the surface of the cerium oxide particle is covered with silicon oxide (ie, silica). Is preferred. In that case, the CeO 2 : SiO 2 mass ratio of the cerium oxide-silica composite particles in which the surface of the cerium oxide particles is covered with silica is preferably 30:70 to 80:20, and 40:60 to 70: 30 is more preferable. Here, the mass ratio of the CeO 2 and SiO 2 is cerium oxide - a ratio between CeO 2 and SiO 2 in the entire particles of the silica complex. When the ratio of silica is increased, the weather resistance is improved. However, if the amount of silica is too large, water adsorbed on the silica also increases, which may cause foaming streaks during film molding.
Moreover, it is preferable that a silicon oxide is an amorphous silica (namely, amorphous silica) which does not have crystallinity. Specific examples of the amorphous silica include amorphous silica obtained by hydrolyzing sodium silicate.
That is, the composite particle in which the surface of the cerium oxide particle is covered with a coating layer for protecting from hydrogen fluoride is preferably a cerium oxide-amorphous silica composite in which the surface of the cerium oxide particle is covered with amorphous silica. .

 酸化セリウム-不定形シリカ複合体の粒子は、酸化セリウムの一次粒子が不定形シリカで被覆された粒子が複数集合し、不定形シリカ同士が融着した二次粒子であることが好ましい。酸化セリウム-不定形シリカ複合体の粒子のレーザ回折式粒度分布測定装置により測定した二次粒子径の分布は、その95質量%以上が粒径1~30μmの範囲にあることが好ましく、2~10μmの範囲にあることがより好ましい。また、酸化セリウム-不定形シリカ複合体の粒子のレーザ回折式粒度分布測定装置により測定した平均二次粒子径は、2~8μmであることが好ましく、1~5μmであることが特に好ましい。
 また、酸化セリウム-不定形シリカ複合体中の酸化セリウム粒子のSEM(走査型電子顕微鏡)により測定した平均粒子径(平均一次粒子径)は、必要な紫外線吸収能を得、かつ、太陽電池の発電において、ある程度高い収集効率が得られる400nm以上の光に対して高い透明性を得る観点から10~250nmであることが好ましい。ここにおける平均一次粒子径は、酸化セリウム粒子の粒子径である。
 酸化セリウム粒子の表面を不定形シリカで覆った酸化セリウム-不定形シリカ複合体の粒子の製造方法としては、たとえば、特開平9-118610号公報、特許第3981483号公報に記載されているように、不溶性セリウム化合物粒子(例えばCe(OH))の水分散液に、ケイ酸塩溶液を撹拌しながら滴下し、シリカ被覆不溶性セリウム化合物を得て、その後、乾燥し、さらに焼成する方法が挙げられる。この製造方法は、総て液層中で反応を完結させる方法である。よって、粉砕・焼成後の粒子径は0.5~10μm程度に分布しているが、酸化セリウム自体の粒子径は220nm前後と小さいため、太陽電池の発電において、ある程度高い収集効率が得られる400nm以上の光に対して非常に高い透明性が得られる。
The particles of the cerium oxide-amorphous silica composite are preferably secondary particles in which a plurality of particles in which primary particles of cerium oxide are coated with amorphous silica are aggregated and the amorphous silica is fused together. The distribution of the secondary particle diameter of the cerium oxide-amorphous silica composite particles measured by a laser diffraction particle size distribution analyzer is preferably 95% by mass or more in the range of 1 to 30 μm. More preferably, it is in the range of 10 μm. The average secondary particle diameter of the cerium oxide-amorphous silica composite particles measured by a laser diffraction particle size distribution analyzer is preferably 2 to 8 μm, and particularly preferably 1 to 5 μm.
In addition, the average particle diameter (average primary particle diameter) measured by SEM (scanning electron microscope) of the cerium oxide particles in the cerium oxide-amorphous silica composite is such that the necessary ultraviolet absorbing ability is obtained and the solar cell In power generation, the thickness is preferably 10 to 250 nm from the viewpoint of obtaining high transparency with respect to light of 400 nm or more, which can obtain a certain degree of high collection efficiency. The average primary particle size here is the particle size of the cerium oxide particles.
As a method for producing particles of a cerium oxide-amorphous silica composite in which the surface of cerium oxide particles is covered with amorphous silica, for example, as described in JP-A-9-118610 and JP-A-3981483 A method in which a silicate solution is dropped into an aqueous dispersion of insoluble cerium compound particles (for example, Ce (OH) 4 ) while stirring to obtain a silica-coated insoluble cerium compound, followed by drying and further firing. It is done. This production method is a method for completing the reaction in the liquid layer. Therefore, although the particle size after pulverization / firing is distributed in the range of about 0.5 to 10 μm, the particle size of cerium oxide itself is as small as around 220 nm. Very high transparency can be obtained for the above light.

 酸化セリウム粒子の表面を不定形シリカで覆った酸化セリウム-不定形シリカ複合体の粒子の製造方法は、上記方法に限定されず、例えば、酸化セリウム粒子を合成し、これに水ガラスやエチルシリケートを材料としてシリカ被覆を行う方法であってもよい。
 酸化セリウムの表面を不定形シリカで覆った酸化セリウム-不定形シリカ複合体の製造にあたっては、水に分散しているシリカ被覆不溶性セリウム化合物の濾過を容易にするために、硫酸アルミニウム等の凝集剤を使用することができる。硫酸アルミニウムを凝集剤として使用した場合、表面に付着したアルミニウムイオン由来の酸化アルミニウムが被覆層表面に残留するが、性能上特に差し支えない。
The method for producing particles of the cerium oxide-amorphous silica composite in which the surface of the cerium oxide particles is covered with amorphous silica is not limited to the above method. For example, cerium oxide particles are synthesized, and water glass or ethyl silicate is synthesized therewith. A method of performing silica coating using as a material may be used.
In the production of a cerium oxide-amorphous silica composite in which the surface of cerium oxide is covered with amorphous silica, a flocculant such as aluminum sulfate is used to facilitate filtration of the silica-coated insoluble cerium compound dispersed in water. Can be used. When aluminum sulfate is used as a flocculant, aluminum oxide derived from aluminum ions attached to the surface remains on the surface of the coating layer, but there is no particular problem in performance.

 また、酸化セリウムを含む紫外線吸収剤(すなわち、酸化セリウム粒子、あるいはシリカを含む被覆層を有する酸化セリウム粒子)は、表面を疎水化処理されていることが好ましい。これにより、フッ素樹脂フィルム内での分散性が向上する。また、酸化セリウムを含む紫外線吸収剤を、フッ素樹脂に分散させる工程において、フッ素樹脂は、スクリュー、シリンダーと何回も接触することになるが、疎水化によりその際のせん断が低く抑えられるため、樹脂の着色が抑制される。疎水化の程度は、メタノール疎水化度を40~75%とすることが好ましい。
 メタノール疎水化度は粒子の疎水性を示す指標である。その測定方法は次のとおりである。すなわち、300ccのビーカーに蒸留水50ccを入れ、5gの粒子を良く撹拌させながら投入する。粒子が均一に分散されれば、この粒子は蒸留水ときわめてなじみがよく、メタノール疎水化度は0%である。粒子が均一に分散しない場合、水溶液に粒子が均一に分散されるまでメタノールを徐々に滴下する。ちょうど均一に分散されるまでのメタノール総添加量M(単位:cc)からメタノール疎水化度D(単位:%)は次式によって求められる。
   D=100M/(M+50)
Moreover, it is preferable that the surface of the ultraviolet absorber containing cerium oxide (that is, cerium oxide particles or cerium oxide particles having a coating layer containing silica) is subjected to a hydrophobic treatment. Thereby, the dispersibility in a fluororesin film improves. In addition, in the step of dispersing the ultraviolet absorber containing cerium oxide in the fluororesin, the fluororesin comes into contact with the screw and the cylinder many times, but the shearing at that time can be kept low by hydrophobization, Resin coloring is suppressed. The degree of hydrophobicity is preferably 40 to 75% of the degree of methanol hydrophobicity.
Methanol hydrophobicity is an index indicating the hydrophobicity of particles. The measurement method is as follows. That is, 50 cc of distilled water is put into a 300 cc beaker, and 5 g of particles are added while stirring well. If the particles are evenly dispersed, the particles are very familiar with distilled water and the degree of methanol hydrophobization is 0%. If the particles are not uniformly dispersed, methanol is gradually added dropwise until the particles are uniformly dispersed in the aqueous solution. The methanol hydrophobization degree D (unit:%) is determined by the following formula from the total methanol addition amount M (unit: cc) until it is evenly dispersed.
D = 100M / (M + 50)

 フッ素樹脂の種類により要求される好ましいメタノール疎水化度は若干異なり、ETFEの場合は40~70%であることが好ましく、ヘキサフルオロプロピレン-テトラフルオロエチレン系共重合体またはパーフルオロ(アルキルビニルエーテル)-テトラフルオロエチレン系共重合体の場合は60~75%であることが好ましく、テトラフルオロエチレン-ヘキサフルオロプロピレン-フッ化ビニリデン系共重合体の場合は40~70%であることが好ましい。 The preferred degree of methanol hydrophobicity required differs depending on the type of fluororesin, and in the case of ETFE, it is preferably 40 to 70%. Hexafluoropropylene-tetrafluoroethylene copolymer or perfluoro (alkyl vinyl ether)- In the case of a tetrafluoroethylene copolymer, it is preferably 60 to 75%, and in the case of a tetrafluoroethylene-hexafluoropropylene-vinylidene fluoride copolymer, it is preferably 40 to 70%.

 酸化セリウムを含む紫外線吸収剤の表面を疎水化処理するためには、酸基または加水分解性基がケイ素原子に直接結合している反応性の有機ケイ素化合物で処理することが好ましい。
 反応性の有機ケイ素化合物としては、たとえばテトラエトキシシラン、テトラメトキシシランなどのテトラアルコキシシラン類、イソブチルトリメトキシシラン、ヘキシルトリメトキシシラン、(3,3,3-トリフルオロプロピル)トリメトキシシランなどのトリアルコキシシラン類、ジメチルシリコーンオイル、メチル水素シリコーンオイル、フェニルメチルシリコーンオイルなどのシリコーンオイル類が挙げられ、これらのうちイソブチルトリメトキシシラン、ヘキシルトリメトキシシラン、ジメチルシリコーンオイル、フェニルメチルシリコーンオイルが好ましい。
In order to hydrophobize the surface of the ultraviolet absorber containing cerium oxide, it is preferable to treat with a reactive organosilicon compound in which an acid group or a hydrolyzable group is directly bonded to a silicon atom.
Examples of reactive organosilicon compounds include tetraalkoxysilanes such as tetraethoxysilane and tetramethoxysilane, isobutyltrimethoxysilane, hexyltrimethoxysilane, and (3,3,3-trifluoropropyl) trimethoxysilane. Examples include silicone oils such as trialkoxysilanes, dimethyl silicone oil, methyl hydrogen silicone oil, and phenylmethyl silicone oil. Of these, isobutyltrimethoxysilane, hexyltrimethoxysilane, dimethyl silicone oil, and phenylmethyl silicone oil are preferable. .

 酸化セリウムを含む紫外線吸収剤が酸化セリウム-不定形シリカ複合体である場合、疎水化処理に用いる反応性の有機ケイ素化合物の必要量は、酸化セリウム-不定形シリカ複合体の比表面積の大きさに比例する。反応性の有機ケイ素化合物が少ない場合には、酸化セリウム-不定形シリカ複合体粒子がフッ素樹脂との混練時に黒色または茶色に変色することがある。反応性の有機ケイ素化合物が多い場合には、反応性の有機ケイ素化合物からなる凝集体がブツとなって現れ、フィルム外観が悪くなることがある。
 反応性の有機ケイ素化合物がシリコーンオイルである場合、前記紫外線吸収剤に対して、1~10質量%のシリコーンオイルで処理することが適切であり、イソブチルトリメトキシシランのようなアルコキシシランで処理する場合には、前記紫外線吸収剤に対して、8~20質量%のアルコキシシランで処理することが適切である。
When the ultraviolet absorber containing cerium oxide is a cerium oxide-amorphous silica composite, the required amount of the reactive organosilicon compound used for the hydrophobization treatment is the size of the specific surface area of the cerium oxide-amorphous silica composite. Is proportional to When the amount of the reactive organosilicon compound is small, the cerium oxide-amorphous silica composite particles may turn black or brown when kneaded with the fluororesin. When there are many reactive organosilicon compounds, the aggregate which consists of a reactive organosilicon compound appears as a lump, and the film external appearance may worsen.
When the reactive organosilicon compound is silicone oil, it is appropriate to treat with 1 to 10% by mass of silicone oil with respect to the ultraviolet absorber, and with alkoxysilane such as isobutyltrimethoxysilane. In this case, it is appropriate to treat with 8 to 20% by mass of alkoxysilane with respect to the ultraviolet absorber.

 表面材中の酸化セリウムを含む紫外線吸収剤の含有量は、密着性の維持の観点から要求される紫外線吸収能と、発電に寄与する波長の光の透過性とのバランスを考慮して決定される。
 すなわち、表面材の300nmの透過率は、密着性向上の観点から低ければ低いほど好ましいので、充分な量の紫外線吸収剤を含有させる必要がある。一方、含有量が多すぎると、酸化セリウム特有の吸収が顕著となり、特に発電効率に影響を与える400nm付近の透過率が落ちてしまう。
 酸化セリウムを含む紫外線吸収剤は、表面材の400nmにおける透過率が80%以上で、かつ300nmの透過率が20~70%となるように含有させることが好ましい。また、表面材の400nmにおける透過率が85%以上で、かつ300nmの透過率が20~50%となるように含有させることがより好ましい。
The content of the UV absorber containing cerium oxide in the surface material is determined in consideration of the balance between the UV absorbing ability required from the viewpoint of maintaining adhesion and the transmittance of light having a wavelength that contributes to power generation. The
That is, the transmittance of 300 nm of the surface material is preferably as low as possible from the viewpoint of improving adhesion, and therefore it is necessary to contain a sufficient amount of the ultraviolet absorber. On the other hand, if the content is too large, the absorption characteristic of cerium oxide becomes remarkable, and the transmittance around 400 nm, which particularly affects the power generation efficiency, is lowered.
The ultraviolet absorber containing cerium oxide is preferably contained so that the transmittance at 400 nm of the surface material is 80% or more and the transmittance at 300 nm is 20 to 70%. Further, it is more preferable that the surface material be contained so that the transmittance at 400 nm is 85% or more and the transmittance at 300 nm is 20 to 50%.

 酸化セリウムを含有する紫外線吸収剤を用いれば、上記好ましい光透過特性を有する表面材を容易に得ることができる。具体的には、表面材における単位面積あたりの酸化セリウム量が、0.1~2g/mとなるように、紫外線吸収剤を、含有させることが好ましい。
 また、フィルムの厚みや、被覆層の量により異なるが、表面材全体に対する酸化セリウム量の割合が、0.1~2質量%の範囲であることが好ましい。
If the ultraviolet absorber containing cerium oxide is used, the surface material having the preferable light transmission characteristics can be easily obtained. Specifically, it is preferable to contain an ultraviolet absorber so that the amount of cerium oxide per unit area in the surface material is 0.1 to 2 g / m 2 .
Further, although depending on the thickness of the film and the amount of the coating layer, the ratio of the amount of cerium oxide to the whole surface material is preferably in the range of 0.1 to 2% by mass.

[その他の成分等]
 表面材には、酸化セリウムを含む紫外線吸収剤の他、他の紫外線吸収剤、顔料、カーボンブラック、カーボンファイバ、炭化ケイ素、ガラスファイバ、マイカ、架橋剤などの添加剤、充填物が含有されていてもよい。
 表面材の厚みは、10~300μmが好ましく、20~250μmがより好ましく、25~200μmが特に好ましい。この範囲にあれば、放電処理時のフィルムのハンドリングが容易であり、放電によるシワも発生しにくい。
[Other ingredients]
In addition to UV absorbers containing cerium oxide, the surface material contains other UV absorbers, pigments, carbon black, carbon fibers, silicon carbide, glass fibers, mica, cross-linking agents, and fillers. May be.
The thickness of the surface material is preferably 10 to 300 μm, more preferably 20 to 250 μm, and particularly preferably 25 to 200 μm. If it exists in this range, the handling of the film at the time of discharge processing will be easy, and the wrinkle by discharge will not generate | occur | produce easily.

<太陽電池用被覆材>
 本発明の太陽電池用被覆材は、上記本発明の表面材と有機樹脂よりなる充填材との積層体である。表面材と充填材とは、表面材の放電処理を施した側が充填材と接するようにして積層される。
 太陽電池の充填材は、少なくとも太陽電池セルを有する内部素子の凹凸を被覆し、かつ、内部素子と表面材の接着剤としての働きを有する。そのため、耐光性、接着性、耐熱性が要求される。これらの要求を満たす有機樹脂としては、エチレン系共重合体が好ましく、エチレン-酢酸ビニル共重合体(以下、EVAという。)、エチレン-エチルアクリレート共重合体(EEA)、及びエチレン-メチルアクリレート(EMA)、ポリブチルビニラール(PVB)が挙げられる。また、ポリエチレンに架橋材を配合したもの(以下、PEという。)も挙げられる。本発明の太陽電池における充填材は、EVA、EEA、EMA及びPVBの何れか一以上を含むことが好ましい。
 充填材は、高温の使用環境に耐性を備えるよう、架橋されるようにされることが好ましい。充填材がEVAの場合、有機過酸化物による架橋が好ましい。通常、かかる架橋処理は、太陽電池モジュールを製造する際の太陽電池セルに太陽電池用被覆材に接合する工程の「熱プレス後」の状態で行なうのが好ましい。
 架橋は、イソシアネート、メラミン等の架橋剤を用いて行ってもよい。
<Solar cell coating>
The covering material for solar cells of the present invention is a laminate of the surface material of the present invention and a filler made of an organic resin. The surface material and the filler are laminated so that the surface of the surface material subjected to the discharge treatment is in contact with the filler.
The filler for the solar battery covers at least the unevenness of the internal element having the solar battery cell, and functions as an adhesive between the internal element and the surface material. Therefore, light resistance, adhesiveness, and heat resistance are required. As an organic resin satisfying these requirements, an ethylene copolymer is preferable, and an ethylene-vinyl acetate copolymer (hereinafter referred to as EVA), an ethylene-ethyl acrylate copolymer (EEA), and an ethylene-methyl acrylate ( EMA) and polybutyl vinylal (PVB). Moreover, what mix | blended the crosslinking material with polyethylene (henceforth PE) is also mentioned. The filler in the solar cell of the present invention preferably contains one or more of EVA, EEA, EMA and PVB.
The filler is preferably cross-linked so as to be resistant to high temperature use environments. When the filler is EVA, crosslinking with an organic peroxide is preferred. Usually, such a crosslinking treatment is preferably performed in a state “after hot pressing” in the step of joining the solar battery cell to the solar battery covering material when the solar battery module is manufactured.
Crosslinking may be performed using a crosslinking agent such as isocyanate or melamine.

<太陽電池モジュール>
 本発明の太陽電池モジュールの一実施形態を、図1を用いて説明する。図1の太陽電池モジュール10は、太陽電池セル1の光入射側に、充填材2aと表面材3aとが順次積層されており、充填材2aと表面材3aとで被覆材4aが構成されている。
 同様に、太陽電池セルの光入射側と反対側に、充填材2bと表面材3bとが順次積層されており、充填材2bと表面材3bとで被覆材4bが構成されている。
 表面材3aと表面材3bの少なくとも一方は、本発明の太陽電池用表面材である。すなわち、被覆材4aと被覆材4bの少なくとも一方は、本発明の太陽電池用被覆材である。
 特に、光入射側に配置される表面材3aが本発明の太陽電池用表面材であること、すなわち、被覆材4aが本発明の太陽電池用被覆材であることが好ましい。
 表面材3aと表面材3bの双方が、本発明の太陽電池用表面材であること、すなわち、被覆材4aと被覆材4bの双方が本発明の太陽電池用被覆材であることが最も好ましい。
<Solar cell module>
An embodiment of the solar cell module of the present invention will be described with reference to FIG. In the solar cell module 10 of FIG. 1, a filler 2a and a surface material 3a are sequentially laminated on the light incident side of the solar battery cell 1, and a covering material 4a is constituted by the filler 2a and the surface material 3a. Yes.
Similarly, the filler 2b and the surface material 3b are sequentially laminated on the side opposite to the light incident side of the solar battery cell, and the covering material 4b is configured by the filler 2b and the surface material 3b.
At least one of the surface material 3a and the surface material 3b is the surface material for solar cells of the present invention. That is, at least one of the coating material 4a and the coating material 4b is the solar cell coating material of the present invention.
In particular, it is preferable that the surface material 3a disposed on the light incident side is the surface material for solar cells of the present invention, that is, the coating material 4a is the coating material for solar cells of the present invention.
It is most preferable that both the surface material 3a and the surface material 3b are the solar cell surface material of the present invention, that is, both the coating material 4a and the coating material 4b are the solar cell coating material of the present invention.

 太陽電池セル1は、一対の導電層の間に、1以上の薄膜光電変換層を有する。発電効率を高めるため、高い収集効率が得られる波長領域の異なる複数の薄膜光電変換層を積層したセルが広く用いられている。
 図2に、短波長側の光に対して収集効率が高いアモルファスシリコン(a-Si)の薄膜光電変換層をトップセルとし、長波長側の光に対して収集効率が高いアモルファスシリコン-ゲルマニウム(a-SiGe)の薄膜光電変換層をボトムセルとし、トップセルとボトムセルの積層体を一対の導電層の間に配置したセルにおいて得られる収集効率を示す。図2に示すように、全体の収集効率は、トップセルとボトムセルの各々の収集効率を総合した値となる。また、波長300~400nmの収集効率は、ほぼトップセル単独の収集効率と等しい。
Solar cell 1 has one or more thin film photoelectric conversion layers between a pair of conductive layers. In order to increase the power generation efficiency, a cell in which a plurality of thin film photoelectric conversion layers having different wavelength regions from which high collection efficiency is obtained is widely used.
FIG. 2 shows an amorphous silicon-germanium (a-Si) thin film photoelectric conversion layer with high collection efficiency for light on the short wavelength side as a top cell and amorphous silicon-germanium (with high collection efficiency for light on the long wavelength side). The collection efficiency obtained in a cell in which a thin film photoelectric conversion layer of (a-SiGe) is a bottom cell and a laminate of a top cell and a bottom cell is disposed between a pair of conductive layers is shown. As shown in FIG. 2, the overall collection efficiency is a value obtained by combining the collection efficiencies of the top cell and the bottom cell. The collection efficiency at a wavelength of 300 to 400 nm is almost equal to the collection efficiency of the top cell alone.

 後述の実施例に示すように、波長400nmから300nmにかけて、本発明の表面材の透過率曲線は、図2のアモルファスシリコン(a-Si)の薄膜光電変換層の収集効率曲線と極めて近似した減少傾向を示す。そのため、本発明の太陽電池モジュールは、特にアモルファスシリコン(a-Si)の薄膜光電変換層を有する場合に、高い発電効率を維持しやすい。同様に、それ以外の例えばCIGS系と呼ばれる、350~1500nmの広い波長域で発電する太陽電池においても、高い発電効率を維持しやすい。
 また、本発明の表面材の透過率曲線は、低波長の紫外線ほど透過率が低いため、表面材の放電処理された面における官能基を充分に保護できる。
 したがって、本発明の太陽電池モジュールは、発電効率と耐久性の何れにおいても優れている。
As shown in the examples described later, from the wavelength of 400 nm to 300 nm, the transmittance curve of the surface material of the present invention decreases very closely with the collection efficiency curve of the amorphous silicon (a-Si) thin film photoelectric conversion layer of FIG. Show the trend. Therefore, the solar cell module of the present invention easily maintains high power generation efficiency particularly when it has a thin film photoelectric conversion layer of amorphous silicon (a-Si). Similarly, in other solar cells that generate power in a wide wavelength range of 350 to 1500 nm, for example, called CIGS, it is easy to maintain high power generation efficiency.
Moreover, since the transmittance | permeability curve of the surface material of this invention has low transmittance | permeability as the ultraviolet-ray of a low wavelength, it can fully protect the functional group in the surface by which the discharge treatment of the surface material was carried out.
Therefore, the solar cell module of the present invention is excellent in both power generation efficiency and durability.

 以下に、上記実施形態の具体例を実施例として説明する。なお、本発明は、以下の実施例に限定されるものではない。
 以下の記載において、%は、特に断りのないかぎり質量%を意味する。
Specific examples of the above embodiment will be described below as examples. The present invention is not limited to the following examples.
In the following description, “%” means “% by mass” unless otherwise specified.

<表面材の作成>
[実施例1]
 フェニルメチルシリコーンオイル(東レダウコーニング社製、SH510)を、2-プロパノール(以下、IPAと記す。)に溶解し、フェニルメチルシリコーンオイルの2%IPA溶液の500gを調製した。そこに、シリカ被覆酸化セリウム粒子(大東化成工業社製、SC6832。シリカ被覆酸化セリウム粒子の全体におけるCeOとSiOとAlの割合は次の通り。CeO:65%、SiO:32%、Al:3%)の100gをゆっくり攪拌しながら添加した。その後この液を真空にて乾燥し、表面がフェニルメチルシリコーンオイルで疎水化されたシリカ被覆酸化セリウム粒子の110gを得た。
<Creation of surface material>
[Example 1]
Phenylmethyl silicone oil (manufactured by Toray Dow Corning, SH510) was dissolved in 2-propanol (hereinafter referred to as IPA) to prepare 500 g of a 2% IPA solution of phenylmethyl silicone oil. Silica-coated cerium oxide particles (manufactured by Daito Kasei Kogyo Co., Ltd., SC6832. The ratio of CeO 2 , SiO 2 and Al 2 O 3 in the entire silica-coated cerium oxide particles is as follows. CeO 2 : 65%, SiO 2 : 32%, Al 2 O 3 : 3%) was added with slow stirring. Thereafter, this liquid was dried under vacuum to obtain 110 g of silica-coated cerium oxide particles whose surface was hydrophobized with phenylmethylsilicone oil.

 ETFE樹脂(旭硝子社製、フルオンETFE:88AX)の1900gに、上記の疎水化されたシリカ被覆酸化セリウム粒子の100gを添加し、よく攪拌後、2軸の押し出し機にて、疎水化されたシリカ被覆酸化セリウム粒子を5%(酸化セリウムとして2.95%)含有するマスターバッチのペレットを作成した。押出条件は、シリンダー温度310℃、ヘッド温度320℃とした。
 続いて、前記ペレットと、シリカ被覆酸化セリウム粒子を含まないETFE樹脂のペレット(旭硝子社製、フルオンETFE:88AX)を1:9の比率でポリプロピレン製の袋に入れ、手で激しく10回振る方法で混合した。これを、シリンダー温度、ダイ温度を320℃としたTダイにて成型し、幅550mm、厚さ50μmのETFEフィルムを得た。
100 g of the above-mentioned hydrophobized silica-coated cerium oxide particles was added to 1900 g of ETFE resin (manufactured by Asahi Glass Co., Ltd., Full-on ETFE: 88AX), and after stirring well, hydrophobized silica with a biaxial extruder Master batch pellets containing 5% coated cerium oxide particles (2.95% cerium oxide) were prepared. The extrusion conditions were a cylinder temperature of 310 ° C and a head temperature of 320 ° C.
Subsequently, the pellets and ETFE resin pellets containing no silica-coated cerium oxide particles (Asahi Glass Co., Ltd., Fullon ETFE: 88AX) are put in a polypropylene bag at a ratio of 1: 9 and shaken vigorously by hand 10 times. Mixed. This was molded with a T die having a cylinder temperature and a die temperature of 320 ° C. to obtain an ETFE film having a width of 550 mm and a thickness of 50 μm.

 次に、ETFEフィルムの表面を放電処理した。装置としては、積水化学社製のプラズマ処理装置、RD550を使用した。放電電極としては、ETFEフィルムの搬送方向の長さが100mm、ETFEフィルムの幅方向の長さが650mmで、厚みが20mmの炭素鋼板上に、厚みが1mmのセラミック誘電体(固体誘電体)層を設けたものを用いた。また、対向電極としては、直径30cmの金属ロール表面に、厚さ2mmのシリコンゴムを被覆したロール電極を使用し、ロール温度を循環水によって15℃に保持した。ガス導入口から導入するガスは、純度99.99%以上が保証された窒素ガスを用いた。 Next, the surface of the ETFE film was discharged. As an apparatus, a plasma processing apparatus RD550 manufactured by Sekisui Chemical Co., Ltd. was used. As the discharge electrode, a ceramic dielectric (solid dielectric) layer having a thickness of 1 mm on a carbon steel plate having a length of 100 mm in the transport direction of the ETFE film and a length of 650 mm in the width direction of the ETFE film and a thickness of 20 mm. The one provided with was used. Moreover, as a counter electrode, the roll electrode which coat | covered the silicon rubber of thickness 2mm was used for the metal roll surface with a diameter of 30 cm, and roll temperature was hold | maintained at 15 degreeC with the circulating water. Nitrogen gas with a purity of 99.99% or more was used as the gas introduced from the gas inlet.

 導入する窒素ガスの流量を50L/分とし、2分間導入し、酸素濃度が100ppmとなっていることを確認した。その後、窒素ガスを導入しながら、高周波電源の出力電圧を450V、出力電流を5.4Aとし、処理電力2.43kWとして、ETFEフィルムを6m/分で搬送することで、放電密度623W・分/mのグロー放電処理を行った。周波数は40kHzとした。そのため、パルス電界の波形は正弦波に近いものとなった。
 放電密度は、下式(1)で算出した。
  (放電密度)=(I×V)/(v×d)   (1)
 ただし、式(1)中、Iは高周波電源の出力電流(単位:A)、Vは高周波電源の出力電圧(単位:V)、vはETFEフィルムの搬送速度(単位:m/分)、dは処理幅、すなわち放電電極によって処理されるETFEフィルムの幅方向の長さである。
The flow rate of nitrogen gas to be introduced was 50 L / min, and the gas was introduced for 2 minutes, and it was confirmed that the oxygen concentration was 100 ppm. Thereafter, while introducing nitrogen gas, the output voltage of the high frequency power source is 450 V, the output current is 5.4 A, the processing power is 2.43 kW, and the ETFE film is transported at 6 m / min, so that the discharge density is 623 W · min / A glow discharge treatment of m 2 was performed. The frequency was 40 kHz. Therefore, the waveform of the pulse electric field is close to a sine wave.
The discharge density was calculated by the following formula (1).
(Discharge density) = (I × V) / (v × d) (1)
However, in Formula (1), I is the output current (unit: A) of a high frequency power supply, V is the output voltage (unit: V) of a high frequency power supply, v is the conveyance speed (unit: m / min) of an ETFE film, d Is the treatment width, that is, the length in the width direction of the ETFE film treated by the discharge electrode.

[実施例2]
 前記マスターバッチのペレットと、シリカ被覆酸化セリウム粒子を含まないETFE樹脂(旭硝子社製、フルオンETFE:88AX)の混合比率を1:4としたほかは、実施例1と同様にしてETFEフィルムを得、さらに、実施例1と同様にして表面を放電処理し、実施例2の表面材を得た。
[Example 2]
An ETFE film was obtained in the same manner as in Example 1 except that the mixing ratio of the masterbatch pellets and ETFE resin containing no silica-coated cerium oxide particles (Asahi Glass Co., Ltd., Fullon ETFE: 88AX) was 1: 4. Further, the surface was discharged in the same manner as in Example 1 to obtain the surface material of Example 2.

[実施例3]
 前記マスターバッチのペレットと、シリカ被覆酸化セリウム粒子を含まないETFE樹脂(旭硝子社製、フルオンETFE:88AX)の混合比率を1:19としたほかは、実施例1と同様にしてETFEフィルムを得、さらに、実施例1と同様にして表面を放電処理し、実施例3の表面材を得た。
[Example 3]
An ETFE film was obtained in the same manner as in Example 1 except that the mixing ratio of the masterbatch pellets and the ETFE resin containing no silica-coated cerium oxide particles (Asahi Glass Co., Ltd., Fullon ETFE: 88AX) was 1:19. Further, the surface was discharged in the same manner as in Example 1 to obtain the surface material of Example 3.

[比較例1]
 前記マスターバッチのペレットを使用せず、シリカ被覆酸化セリウム粒子を含まないETFE樹脂(旭硝子社製、フルオンETFE:88AX)のみを用いたほかは、実施例1と同様にしてETFEフィルムを得、さらに、実施例1と同様にして表面を放電処理し、比較例1の表面材を得た。
[Comparative Example 1]
An ETFE film was obtained in the same manner as in Example 1 except that only the ETFE resin (Asahi Glass Co., Ltd., Full-on ETFE: 88AX) containing no silica-coated cerium oxide particles was used without using the masterbatch pellets. The surface was discharged in the same manner as in Example 1 to obtain the surface material of Comparative Example 1.

[比較例2]
 ETFE樹脂(旭硝子社製、フルオンETFE:88AX)に、紫外線吸収剤として、有機系の紫外線吸収剤であるチヌビン479(BASF社)を、配合後の樹脂全体に対して1.5%となるように配合し、シリンダー温度、ダイ温度を320℃としたTダイにて成型し、幅550mm、厚さ50μmのETFEフィルムを得た。得られたフィルムを実施例1と同様にして表面を放電処理し、比較例2の表面材を得た。
[Comparative Example 2]
ETFE resin (manufactured by Asahi Glass Co., Ltd., Full-on ETFE: 88AX), tinuvin 479 (BASF), which is an organic UV absorber, is used as the UV absorber so that the total amount of the resin after compounding becomes 1.5%. And an ETFE film having a width of 550 mm and a thickness of 50 μm was obtained. The surface of the obtained film was discharged in the same manner as in Example 1 to obtain the surface material of Comparative Example 2.

[実施例4]
 実施例1と同様にしてETFEフィルムを成型し、さらに、ガス導入口から導入するガス組成を、アルゴン99体積%、二酸化炭素0.3体積%、メタン0.7体積%、ガス流量20リットル/分とし、高周波電源の出力電圧を110V、出力電流を2.2A、処理電力2.42W、ETFEフィルムの搬送速度を1m/分、放電密度372W・分/mとしたほかは、実施例1と同様にして放電処理し、実施例4の表面材を得た。
[Example 4]
An ETFE film was molded in the same manner as in Example 1, and the gas composition introduced from the gas inlet was 99 vol% argon, 0.3 vol% carbon dioxide, 0.7 vol% methane, and a gas flow rate of 20 l / Example 1 except that the output voltage of the high-frequency power source was 110 V, the output current was 2.2 A, the processing power was 2.42 W, the transport speed of the ETFE film was 1 m / min, and the discharge density was 372 W · min / m 2. The surface material of Example 4 was obtained in the same manner as described above.

[実施例5]
 実施例2と同様にしてETFEフィルムを得、さらに、実施例4と同様にして表面を放電処理し、実施例5の表面材を得た。
[Example 5]
An ETFE film was obtained in the same manner as in Example 2, and the surface was discharged in the same manner as in Example 4 to obtain the surface material of Example 5.

[実施例6]
 実施例3と同様にしてETFEフィルムを得、さらに、実施例4と同様にして表面を放電処理し、実施例6の表面材を得た。
[Example 6]
An ETFE film was obtained in the same manner as in Example 3, and the surface was discharged in the same manner as in Example 4 to obtain the surface material of Example 6.

[比較例3]
 比較例1と同様にしてETFEフィルムを得、さらに、実施例4と同様にして表面を放電処理し、比較例3の表面材を得た。
[Comparative Example 3]
An ETFE film was obtained in the same manner as in Comparative Example 1, and the surface was discharged in the same manner as in Example 4 to obtain the surface material of Comparative Example 3.

[比較例4]
 比較例2と同様にしてETFEフィルムを得、さらに、実施例4と同様にして表面を放電処理し、比較例4の表面材を得た。
[Comparative Example 4]
An ETFE film was obtained in the same manner as in Comparative Example 2, and the surface was discharged in the same manner as in Example 4 to obtain the surface material of Comparative Example 4.

<評価>
[透過率曲線]
 実施例1~3、比較例1、2の表面材の透過率曲線を、図3~7に示す。
 なお、透過率曲線は、島津製作所社製の紫外可視近赤外分光光度計UV-3600装置を用いて測定した。
<Evaluation>
[Transmissivity curve]
The transmittance curves of the surface materials of Examples 1 to 3 and Comparative Examples 1 and 2 are shown in FIGS.
The transmittance curve was measured using an ultraviolet-visible near-infrared spectrophotometer UV-3600 apparatus manufactured by Shimadzu Corporation.

[濡れ指数]
 各実施例、比較例の表面材について、JIS K6768に準拠した濡れ試験方法により濡れ指数を求めた。結果を表1に示す。
[Wetting index]
About the surface material of each Example and the comparative example, the wetting index was calculated | required with the wetting test method based on JISK6768. The results are shown in Table 1.

Figure JPOXMLDOC01-appb-T000001
Figure JPOXMLDOC01-appb-T000001

[EVAに対する初期密着力]
 7cm×15cmのサイズに切り取った、実施例1~6および比較例1~4の表面材を2枚使用し、各々の放電処理面を内側としてEVAの膜(ブリヂストン社製、2540)を挟み込み、145℃×15分、面圧力:1MPaにて熱プレスを行い、3層の積層体を得た。EVAの膜と一方の表面材との間の密着力をテンシロンにて測定し、初期密着力を測定した。条件は、180度剥離、剥離速度:50mm/分とした。結果を表2、3に示す。
[Initial adhesion to EVA]
Two pieces of the surface materials of Examples 1 to 6 and Comparative Examples 1 to 4 cut to a size of 7 cm × 15 cm were used, and EVA films (made by Bridgestone, 2540) were sandwiched between the respective discharge treated surfaces, Hot pressing was performed at 145 ° C. for 15 minutes and a surface pressure of 1 MPa to obtain a three-layer laminate. The adhesion between the EVA film and one surface material was measured with Tensilon, and the initial adhesion was measured. The conditions were 180 degree peeling and peeling speed: 50 mm / min. The results are shown in Tables 2 and 3.

[EVAに対する耐候試験後の密着力]
 前記したEVAに対する初期密着力の評価と同様にして3層の積層体を複数得た。これを促進耐候性試験装置(スガ試験機:サンシャイン300)に投入し、ブラックパネル温度を63℃とし、光照射のみに48分間暴露した後に、光照射と降雨に12分間暴露する合計60分間のサイクルを繰り返した。サイクルの繰り返しを2500時間、5000時間、7500時間まで繰り返した後のEVAと一方の表面材との間の密着力を、各々初期密着力と同様にして測定した。結果を表2、3に示す。
[Adhesion after weathering test for EVA]
A plurality of three-layer laminates were obtained in the same manner as the evaluation of the initial adhesion strength to EVA described above. This was put into an accelerated weathering test apparatus (Suga tester: Sunshine 300), the black panel temperature was 63 ° C., and after exposure to light irradiation only for 48 minutes, exposure to light irradiation and rainfall for 12 minutes totaled 60 minutes. The cycle was repeated. The adhesion force between EVA and one surface material after repeating the cycle up to 2500 hours, 5000 hours, and 7500 hours was measured in the same manner as the initial adhesion force. The results are shown in Tables 2 and 3.

Figure JPOXMLDOC01-appb-T000002
Figure JPOXMLDOC01-appb-T000002

Figure JPOXMLDOC01-appb-T000003
Figure JPOXMLDOC01-appb-T000003

[変性PEに対する初期密着力]
 7cm×15cmのサイズに切り取った、実施例1~6および比較例1~4の表面材を2枚使用し、各々の放電処理面を内側として太陽電池充填材用の変性PEの膜(大日本印刷社製変性ポリエチレンシート、Z68)を挟み込み、145℃×15分、面圧力:1MPaにて熱プレスを行い、3層の積層体を得た。変性PEと一方の表面材との間の密着力をテンシロンにて測定し、初期密着力を測定した。条件は、180度剥離、剥離速度:50mm/分とした。結果を表4、5に示す。
[Initial adhesion to modified PE]
Two surface materials of Examples 1 to 6 and Comparative Examples 1 to 4 cut to a size of 7 cm × 15 cm were used, and a modified PE film for solar cell fillers (Dainippon) A modified polyethylene sheet (Z68) manufactured by Printing Co., Ltd. was sandwiched and subjected to hot pressing at 145 ° C. for 15 minutes and a surface pressure of 1 MPa to obtain a three-layer laminate. The adhesion between the modified PE and one surface material was measured with Tensilon, and the initial adhesion was measured. The conditions were 180 degree peeling and peeling speed: 50 mm / min. The results are shown in Tables 4 and 5.

[変性PEに対する耐候試験後の密着力]
 前記した変性PEに対する初期密着力の評価と同様にして3層の積層体を複数得た。これを促進耐候性試験装置(スガ試験機:サンシャイン300)に投入し、ブラックパネル温度を63℃とし、光照射のみに48分間暴露した後に、光照射と降雨に12分間暴露する合計60分間のサイクルを繰り返した。サイクルの繰り返しを2500時間、5000時間、7500時間まで繰り返した後の変性PEと一方の表面材との間の密着力を、各々初期密着力と同様にして測定した。結果を表4、5に示す。
[Adhesion after weathering test for modified PE]
A plurality of three-layer laminates were obtained in the same manner as in the evaluation of the initial adhesion strength to the modified PE described above. This was put into an accelerated weathering test apparatus (Suga tester: Sunshine 300), the black panel temperature was 63 ° C., and after exposure to light irradiation only for 48 minutes, exposure to light irradiation and rainfall for 12 minutes totaled 60 minutes. The cycle was repeated. The adhesion between the modified PE and one surface material after repeating the cycle up to 2500 hours, 5000 hours, and 7500 hours was measured in the same manner as the initial adhesion force. The results are shown in Tables 4 and 5.

Figure JPOXMLDOC01-appb-T000004
Figure JPOXMLDOC01-appb-T000004

Figure JPOXMLDOC01-appb-T000005
Figure JPOXMLDOC01-appb-T000005

 図3~5に示すように、実施例の表面材の透過率は、何れも、波長400nmから300nmにかけて、図2のアモルファスシリコン(a-Si)の薄膜光電変換層の収集効率曲線と極めて近似した減少傾向を示した。
 これに対して、比較例2の表面材は360nm以下の透過率がほぼゼロであり、太陽電池の発電効率に実質的な影響を与えざるを得ない特性であった。
 表2~5に示すように、実施例1~6では、比較例1~4の何れと比較しても、耐候試験後の密着力が良好に維持されていた。
As shown in FIGS. 3 to 5, the transmittance of the surface material of each example is very close to the collection efficiency curve of the amorphous silicon (a-Si) thin film photoelectric conversion layer of FIG. 2 from the wavelength of 400 nm to 300 nm. Showed a decreasing trend.
On the other hand, the surface material of Comparative Example 2 had a transmittance of about 360 nm or less, which was a characteristic that had to substantially affect the power generation efficiency of the solar cell.
As shown in Tables 2 to 5, in Examples 1 to 6, the adhesion after the weathering test was maintained well compared to any of Comparative Examples 1 to 4.

 本発明の太陽電池用表面材は、太陽電池用被覆材に用いられる充填材との密着性に優れ、かつ、その密着性を長期間維持でき、しかも太陽電池の発電効率に悪影響を与えることがないので、太陽電池用被覆材用として、また太陽電池モジュール用として有用である。
 なお、2010年12月27日に出願された日本特許出願2010-289675号の明細書、特許請求の範囲、図面及び要約書の全内容をここに引用し、本発明の開示として取り入れるものである。
The surface material for solar cell of the present invention has excellent adhesion to the filler used for the coating material for solar cell, can maintain the adhesion for a long time, and adversely affects the power generation efficiency of the solar cell. Therefore, it is useful for a solar cell coating material and for a solar cell module.
The entire contents of the specification, claims, drawings and abstract of Japanese Patent Application No. 2010-289675 filed on Dec. 27, 2010 are incorporated herein as the disclosure of the present invention. .

1…太陽電池セル、2a,2b…充填材、3a,3b…表面材、4a,4b…被覆材、
10…太陽電池モジュール
DESCRIPTION OF SYMBOLS 1 ... Solar cell, 2a, 2b ... Filler, 3a, 3b ... Surface material, 4a, 4b ... Covering material,
10 ... Solar cell module

Claims (14)

 表面にグロー放電処理を施したフッ素樹脂のフィルムからなり、酸化セリウムを含む紫外線吸収剤を含有することを特徴とする太陽電池用表面材。 A surface material for a solar cell comprising a film of a fluororesin having a surface subjected to glow discharge treatment and containing an ultraviolet absorber containing cerium oxide.  前記紫外線吸収剤は、酸化セリウム粒子と、該酸化セリウム粒子の表面を被覆する被覆層を有し、該被覆層は酸化ケイ素を含む請求項1に記載の太陽電池用表面材。 2. The solar cell surface material according to claim 1, wherein the ultraviolet absorber has a cerium oxide particle and a coating layer covering a surface of the cerium oxide particle, and the coating layer contains silicon oxide.  400nmにおける光透過率が80%以上、300nmにおける光透過率が70%以下とされている請求項1又は2に記載の太陽電池用表面材。 The solar cell surface material according to claim 1 or 2, wherein the light transmittance at 400 nm is 80% or more and the light transmittance at 300 nm is 70% or less.  前記フッ素樹脂は、エチレン-テトラフルオロエチレン系共重合体を含む請求項1から3のいずれか一項に記載の太陽電池用表面材。 The solar cell surface material according to any one of claims 1 to 3, wherein the fluororesin contains an ethylene-tetrafluoroethylene copolymer.  前記被覆層において酸化ケイ素が占める割合が60質量%以上である請求項2から4のいずれか一項に記載の太陽電池用表面材。 The surface material for a solar cell according to any one of claims 2 to 4, wherein a ratio of silicon oxide in the coating layer is 60% by mass or more.  前記酸化セリウム粒子の表面を被覆する酸化ケイ素が不定型シリカである請求項2から5のいずれか一項に記載の太陽電池用表面材。 The solar cell surface material according to any one of claims 2 to 5, wherein the silicon oxide covering the surface of the cerium oxide particles is amorphous silica.  前記した酸化セリウム粒子の表面を不定型シリカにより被覆した酸化セリウム-不定型シリカ複合体の酸化セリウムの粒子の平均一次粒子径が10~250nmである請求項6に記載の太陽電池用表面材。 The surface material for a solar cell according to claim 6, wherein the average primary particle diameter of the cerium oxide particles of the cerium oxide-amorphous silica composite in which the surface of the cerium oxide particles is coated with amorphous silica is 10 to 250 nm.  前記表面材における酸化セリウムの含有割合が0.1~2質量%である請求項1から7のいずれか一項に記載の太陽電池用表面材。 The solar cell surface material according to any one of claims 1 to 7, wherein a content ratio of cerium oxide in the surface material is 0.1 to 2 mass%.  前記酸化セリウム粒子、または前記被覆層を有する酸化セリウム粒子の表面に疎水化処理が施されている請求項2から8のいずれか一項に記載の太陽電池用表面材。 The surface material for a solar cell according to any one of claims 2 to 8, wherein a surface of the cerium oxide particles or the cerium oxide particles having the coating layer is subjected to a hydrophobic treatment.  請求項1から9のいずれか一項に記載の太陽電池用表面材と、有機樹脂よりなる充填材とが積層されたことを特徴とする太陽電池用被覆材。 A solar cell coating material, wherein the surface material for a solar cell according to any one of claims 1 to 9 and a filler made of an organic resin are laminated.  前記太陽電池用表面材のグロー放電処理を施した面側が前記充填材と接するように積層された請求項10に記載の太陽電池用被覆材。 The solar cell coating material according to claim 10, wherein the solar cell surface material is laminated so that a surface on which the glow discharge treatment is performed is in contact with the filler.  前記充填材は、エチレン-酢酸ビニル共重合体を含む請求項10又は11に記載の太陽電池用被覆材。 The solar cell coating material according to claim 10 or 11, wherein the filler includes an ethylene-vinyl acetate copolymer.  内部に、1以上の薄膜光電変換層を有する太陽電池セルを備え、該太陽電池セルの少なくとも一方の面側が、請求項10から12のいずれか一項に記載の太陽電池用被覆材で被覆されていることを特徴とする太陽電池モジュール。 A solar battery cell having one or more thin-film photoelectric conversion layers is provided therein, and at least one surface side of the solar battery cell is covered with the coating material for a solar battery according to any one of claims 10 to 12. A solar cell module characterized by comprising:  前記太陽電池セルが、アモルファスシリコン(a-Si)の薄膜光電変換層を有する請求項13に記載の太陽電池モジュール。 14. The solar cell module according to claim 13, wherein the solar cell has a thin film photoelectric conversion layer of amorphous silicon (a-Si).
PCT/JP2011/078490 2010-12-27 2011-12-08 Surface material for solar battery, coating material for solar battery, and solar battery module Ceased WO2012090674A1 (en)

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