JP5821677B2 - Adhesive composition for laminated sheet and back surface protective sheet for solar cell - Google Patents

Description

  The present invention relates to an adhesive composition for laminated sheets and a back surface protective sheet for solar cells.

  In recent years, for outdoor industrial applications, for example, multi-layer (composite) films used for barrier materials, roofing materials, solar panel materials, window materials, outdoor flooring materials, lighting protection materials, automobile members, signboards, stickers, etc. Multilayer (composite) laminates have been put to practical use. A multilayer laminate is obtained by laminating (laminating) metal materials, plastic materials, and the like. Examples of the metal-based material include metal foils such as aluminum, copper, and steel plates, metal plates, and metal vapor deposition films. Examples of the plastic material include plastic films such as polypropylene, polyvinyl chloride, polyester, fluororesin, and acrylic resin, plastic films having a surface formed with an inorganic oxide layer such as a plastic sheet, a plastic plate, and a silica vapor deposition film. . Conventionally, polyepoxy adhesives and polyurethane adhesives are known as adhesives used for joining metal materials and plastic materials.

  Patent Document 1 describes a solar cell back surface sealing sheet comprising a laminate in which at least two or more layers of substrates are bonded together with a polyurethane-based adhesive. More specifically, condition 1: laminate strength after storage at 105 ° C., 1.05 atm, 168 hours in a HAST chamber, which is an accelerated evaluation apparatus using pressurized steam, is at least 1 N / I 5 mm or more, condition 2: additional It has hydrolysis resistance that satisfies the condition that no floating occurs between base materials due to delamination after storage at 105 ° C, 1.05 atm, and 168 hours in a HAST chamber, which is an accelerated evaluation apparatus using pressurized steam. A polyurethane adhesive containing an adhesive is described. Specifically, a plurality of polyurethane adhesives in which a crosslinking agent is combined for each of the six types of polyols A to F are proposed (see claims 2 to 11 of Patent Document 1).

Patent Document 2 describes a solar cell module backsheet comprising a laminate in which at least two substrates are bonded together with an acrylic adhesive. More specifically, it contains an acrylic polymer obtained by polymerizing a monomer component containing a monomer represented by the general formula (I) as an acrylic adhesive having hydrolysis resistance, insulation resistance, and moisture barrier properties. An acrylic adhesive has been proposed (see claim 2 of Patent Document 2).
^{_{CH 2 = C (R 1)}} -CO-OZ (I)
In the formula, R ¹ represents a hydrogen atom or a methyl group, and Z represents a hydrocarbon group having 4 to 25 carbon atoms.

  In addition, although it is the patent document published after the previous application used as the basis of a priority, in patent documents 3 and 4, it is suitable for the use used for the sheet | seat which bonded the untreated surface of the plastic film, and another base material. Adhesive compositions are described.

International Publication No. 2007-148754 JP 2009-246360 A JP 2011-105819 A JP 2011-1111519 A

  In order to maintain the adhesive stably over a long period of time under severe outdoor conditions, it is important that the adhesive strength is stable over time. In recent years, as in Patent Documents 3 and 4, the development of an adhesive that can favorably bond an untreated plastic surface such as a polyester film that does not undergo surface treatment to other base materials has been actively conducted. . This is because the manufacturing process can be shortened by not performing the surface treatment, so that the cost can be reduced. However, on the other hand, the surface treatment technology that has been utilized conventionally is also utilized, the original performance of the adhesive composition is further enhanced, and there is a high need for an adhesive composition having synergistically superior adhesive properties. It has become.

  The present invention has been made in view of the above background, and the object of the present invention is to provide a high adhesive force between various sheet-like members, particularly between layers including a surface treatment layer of a plastic film, and a high temperature and high humidity environment. An object of the present invention is to provide a laminated sheet adhesive composition suitable for the production of a solar cell back surface protective sheet and a solar cell back surface protective sheet, which can maintain high adhesive force even when exposed to the bottom.

As a result of intensive studies to solve the above problems, the present inventors have found that the above problems can be solved by the following adhesive composition for laminated sheets, and have completed the present invention.
That is, the adhesive composition for laminated sheets according to the present invention is an adhesive composition for laminated sheets comprising an acrylic polyol (A) and a polyisocyanate (B), and the acrylic polyol (A). The number average molecular weight is 10,000 to 100,000, the hydroxyl value is 1 to 100 mgKOH / g, and the glass transition temperature (Tg) is more than 10 ° C. and not more than 50 ° C. The equivalent ratio NCO / OH between the hydroxyl group derived from the polyol (A) and the isocyanate group derived from the polyisocyanate (B) is from 0.1 to 10.
Preferable examples of the polyisocyanate (B) include those containing a polyisocyanate derived from an alicyclic diisocyanate or an aliphatic diisocyanate. The adhesive composition for laminated sheets of the above aspect is used in the production of a back surface protective sheet for solar cells having two or more sheet-like members, and is at least one of the adhesive layers for joining the sheet-like members together. It is used suitably for the use which forms a part.

Moreover, the back surface protection sheet for solar cells which concerns on this invention is the adhesive layer formed from the adhesive composition for laminated sheets of the said aspect, and two or more sheet-like members laminated | stacked via the said adhesive layer. It comprises.

According to the present invention, high adhesive strength is exhibited between various sheet-like members, particularly between layers including a surface treatment layer of a plastic film, and high adhesive strength can be maintained even when exposed to a high temperature and high humidity environment. There exists an outstanding effect that the adhesive composition for laminated sheets suitable for manufacture of a back surface protection sheet, and the back surface protection sheet for solar cells can be provided.

  Hereinafter, embodiments of the present invention will be described in detail. In addition, as long as it agree | coincides with the meaning of this invention, other embodiment can also belong to the category of this invention. In the present specification, the description “any number A to any number B” means a range larger than the numbers A and A but smaller than the numbers B and B. In addition, the expression “(meth) acrylo” described in the present specification and claims includes both the compound read as “acrylo” and the compound read as “methacrylo”. The same definition is applied to “(meth) acryl” and “(meth) acrylate”.

<Acrylic polyol (A)>
As the acrylic polyol (A), a copolymer of a hydroxyl group-containing mono (meth) acrylate monomer and a mono (meth) acrylate monomer not containing a hydroxyl group is preferably used. The hydroxyl group-containing mono (meth) acrylate monomer is a monomer containing one (meth) acryloyl group and one or more hydroxyl groups in one molecule. Preferred examples include mono (meth) acrylic acid ester monomers obtained by reaction of dihydric alcohols with (meth) acrylic acid, ε-caprolactone-modified (meth) acrylic monomers, and the like.
If the number average molecular weight of the acrylic polyol (A) is about the same, an ester bond is formed on the portion not involved in the copolymerization of the mono (meth) acrylate monomer, that is, the (meth) acrylic acid portion, from the viewpoint of improving the adhesive strength. The number of carbons of the moiety bonded via the moiety (part such as an alkyl group or alkenyl group; hereinafter referred to as “side chain part”) is preferably 1 to 17, more preferably 1 to 9, and more preferably 1 More preferably, it is ~ 3. The side chain portion will form the side chain of the acrylic polyol (A) after copolymerization. The carbon number of the side chain portion of the mono (meth) acrylate monomer is generally about 1 to 30, but if the number average molecular weight of the acrylic polyol (A) is about the same, the side chain portion is The shorter, the longer the main chain of the acrylic polyol (A). As a result, it is considered that the mechanical properties (specifically, the elongation rate) of the adhesive layer after curing are improved and the adhesive force is improved.

  Examples of mono (meth) acrylic acid ester monomers obtained from dihydric alcohols include 2-hydroxyethyl (meth) acrylate, hydroxypropyl (meth) acrylate, 1,4-butanediol mono (meth) acrylate, ( And poly) ethylene glycol mono (meth) acrylate.

  Furthermore, mono (meth) acrylic acid ester monomers obtained from trihydric or higher alcohols such as 2,3-dihydroxypropyl (meth) acrylate can also be used as hydroxyl-containing mono (meth) acrylate monomers. .

As the mono (meth) acrylate monomer not containing a hydroxyl group, conventionally known radically polymerizable monomers can be appropriately selected and used. Suitable examples include, for example, n-butyl (meth) acrylate, isobutyl (meth) acrylate, tert-butyl (meth) acrylate, 2-ethylhexyl (meth) acrylate, n-octyl (meth) acrylate, lauryl (meth) acrylate Long chain (meth) acrylic monomers represented by alkyl (meth) acrylate monomers such as tridecyl (meth) acrylate and stearyl (meth) acrylate, and acrylonitrile.
Furthermore, in addition to the above-mentioned hydroxyl group-containing (meth) acrylate monomer and mono (meth) acrylate monomer not containing a hydroxyl group, other monomers such as (meth) acrylic acid, maleic acid, maleic anhydride and other carboxyl group-containing Monomers, anhydrides thereof, or vinyl monomers such as styrene can be copolymerized. The hydroxyl group-containing (meth) acrylate monomer and the mono (meth) acrylate monomer that does not contain a hydroxyl group may be used independently or in combination of two or more compounds. The same applies to the case of using other monomers.

  In the present invention, the number average molecular weight of the acrylic polyol (A) needs to be 10,000 to 100,000. Furthermore, it is preferable that it is 10,000-70,000, and it is more preferable that it is 25,000-50,000.

A laminated sheet formed by laminating two or more sheet-like members using the adhesive composition for laminated sheets of the present invention (hereinafter also referred to as “adhesive composition”), for example, a back protective sheet for solar cells, It is obtained through the following steps. The adhesive composition is applied to the bonding surface of one sheet-like member and dried. Next, another sheet-like member is superimposed on the adhesive layer, and the adhesive layer is cured in a process called “aging” in which it is stored for about 2 days to 1 week in an environment of 40 ° C. to 60 ° C. To obtain a laminated sheet.
When the number average molecular weight of the acrylic polyol is less than 10,000, the cohesive force of the adhesive layer before the aging process tends to be insufficient, and the adhesive force before the aging process may be reduced. In the case of industrial production, the laminated body wound up in a roll is usually aged with the winding core in the vertical direction. If the adhesive strength before the aging process is small, the winding tends to collapse during aging, which is not suitable for industrial production. On the other hand, if it is less than 10,000, the cohesive force after the aging process tends to be insufficient, and accordingly, the heat-and-moisture resistance is lowered, and delamination or the like may occur.
Further, when the number average molecular weight of the acrylic polyol exceeds 100,000, the viscosity of the adhesive is increased, and there is a tendency that the coating property is deteriorated or the wettability to the sheet-like member is lowered. There is a possibility that the adhesive force before the process is reduced. Although the initial adhesive force is increased by aging as compared with that before aging, it is gradually lowered by a subsequent heat and heat resistance test, and may be lower than the lower limit of use after 3000 hours.

  The number average molecular weight in the present invention is a value obtained by gel permeation chromatography (GPC) and converted to polystyrene. More specifically, the number average molecular weight in the present invention indicates a value obtained by the measurement method described in the examples described later. Similarly, the glass transition temperature and the NCO / OH equivalent ratio show values obtained by the method described in Examples described later.

The hydroxyl value of the acrylic polyol (A) is determined by the content of the hydroxyl group-containing mono (meth) acrylate monomer. In the present invention, the hydroxyl value needs to be 1 to 40 mgKOH / g. Furthermore, 4-40 mgKOH / g is more preferable. If it is less than 1 mgKOH / g, the crosslinking with the isocyanate curing agent tends to be reduced, and the heat and moisture resistance may be reduced. Moreover , when it exceeds 40 mgKOH / g, although the adhesive force before aging can be expressed, the crosslinking density tends to be high after aging, and sufficient adhesive force cannot be expressed. There is a risk of power loss.

  Moreover, in this invention, the glass transition point (Tg) of acrylic polyol (A) needs to exceed 10 degreeC and 50 degrees C or less for the reason mentioned later. Furthermore, it exceeds 10 degreeC and 30 degrees C or less is more preferable.

<Polyisocyanate (B)>
The polyisocyanate (B) is, for example, a compound derived from a known diisocyanate, and a known compound can be used without limitation. For example, 2,4-tolylene diisocyanate (alias: 2,4-TDI), 2,6-tolylene diisocyanate (alias: 2,6-TDI), xylylene diisocyanate (alias: XDI), diphenylmethane diisocyanate (alias: MDI), isophorone diisocyanate, 1,5-naphthalene diisocyanate, hexamethylene diisocyanate (also known as HDI), bis (4-isocyanatocyclohexyl) methane, or hydrogenated diphenylmethane diisocyanate. Nurate body, trimethylolpropane adduct body, biuret type, prepolymer having isocyanate residue (low polymer obtained from diisocyanate and polyol), isocyanate residue Uretdione body, allophanate body, or their complexes, and blocked isocyanates. Polyisocyanate (B) can be used alone or in combination of two or more.

The polyisocyanate (B) is preferably a polyisocyanate derived from an alicyclic diisocyanate or an aliphatic diisocyanate from the viewpoint of viscoelasticity of the cured coating film after crosslinking. More specifically, examples of the alicyclic diisocyanate include isophorone diisocyanate and methyl-2,6-cyclohexane diisocyanate. Examples of the aliphatic diisocyanate include hexamethylene diisocyanate and pentamethylene diisocyanate. Also, diisocyanate nurate, trimethylolpropane adduct, biuret type, prepolymer having isocyanate residue (low polymer obtained from diisocyanate and polyol) which is a derivative of the above-mentioned alicyclic diisocyanate and aliphatic diisocyanate compound. Uretdione bodies having an isocyanate residue, allophanate bodies, or a complex thereof.
In addition, when importance is attached to the speed of curing, an isocyanate having an aromatic ring, such as xylylene diisocyanate (also known as XDI), but having an alkylene group between the NCO and the aromatic ring may be used. preferable. A high curing rate is preferable in that the aging time can be shortened.

Moreover, it is preferable that the isocyanate group density | concentration in polyisocyanate (B) is 5 to 30 weight%. In addition, the isocyanate group density | concentration in polyisocyanate (B) can be calculated | required by the titration method. Titration was evaluated by n-butylamine / hydrochloric acid titration method. Specifically, after dissolving the sample in dry toluene, an excess n-dibutylamine solution was added and reacted, the remaining n-dibutylamine was back titrated with hydrochloric acid, the inflection point on the titration curve was taken as the end point, The isocyanate group content was calculated from the titration amount up to the end point.

The amount of the polyisocyanate (B) used is determined by the NCO / OH equivalent ratio of the hydroxyl group derived from the acrylic polyol (A) and the isocyanate group derived from the polyisocyanate (B). 0.1-10. More preferably, the NCO / OH equivalent ratio is 0.5-6. If it is less than 0.1, the adhesive strength after indoor and outdoor exposure tends to decrease. On the other hand, if it exceeds 10, the adhesive strength after the initial aging tends to decrease. NCO / OH equivalent ratio was performed using the following numerical formula (1).

NCO / OH ratio = necessary amount of polyisocyanate (parts by weight) × (561 / OH value) × (NCO% / (42 × 100)) × (100 / polyol amount (solid content weight)) Formula (1)

  The present inventors have found that an adhesive composition for laminated sheets having surprisingly excellent characteristics can be obtained by satisfying all of the following conditions. That is, the acrylic polyol (A) having the above-mentioned (i) a specific range of number average molecular weight, (ii) a specific range of hydroxyl values, and (iii) a specific range of glass transition temperature (Tg), (Iv) By satisfying all the conditions that the equivalent ratio NCO / OH between the hydroxyl group derived from the acrylic polyol (A) and the isocyanate group derived from the polyisocyanate (B) is within the specific range described above, Shows high adhesive strength between sheet-like members, especially between plastic film surface treatment layers, maintains high adhesive strength even when exposed to high-temperature and high-humidity environments, and makes it possible to manufacture a back protection sheet for solar cells It has been found that an adhesive composition can be provided. The reason will be described below.

When a plastic film whose surface is treated by corona discharge or the like is laminated as compared with a case where a plastic film having an untreated surface is laminated, an added value corresponding to an increase in the manufacturing process is required. In the adhesive force, a higher adhesive force is required than when a plastic film whose surface is not processed is laminated.
If the Tg of the acrylic polyol is too low, the adhesive layer formed from the adhesive composition is soft because the adhesive layer before aging is still insufficiently cured. And the adhesive force of a certain amount can be expressed between sheet-like members by the softness. However, even if the adhesive layer is sufficiently cured after aging, the adhesive layer lacks cohesive force due to the low Tg of the raw acrylic polyol, and it tends to be difficult to ensure a large adhesive force. Furthermore, when the laminate is placed under high temperature and high humidity for a long time, the adhesive force tends to gradually decrease due to insufficient cohesive force of the adhesive layer.
On the other hand, if the Tg of the acrylic polyol is too high, the wettability to the substrate tends to be insufficient. Although the adhesive strength after aging is somewhat larger than before aging, the cured adhesive layer after crosslinking becomes too hard, and thus the adhesive strength after the aging process tends to deteriorate.
In the present invention, the reason why the above-mentioned excellent effect was obtained is that the Tg of the acrylic polyol is not too low and not too high (specifically, it is over 10 ° C. and 50 ° C. or less), Furthermore, by making the specific hydroxyl value, the specific NCO / OH equivalent ratio, and the specific number average molecular weight range synergistically make use of the activity of acrylic polyol movement at the molecular movement level, This is considered to be due to the fact that the wettability and anchoring performance of the can were improved. In particular, by controlling the NCO / OH equivalent ratio in the range of 0.1 to 10, particularly in the range of 0.5 to 6, an appropriate balance of the degree of crosslinking can be realized and high adhesive strength can be exhibited after the aging process. I think. Moreover, it has surprisingly been found that a high adhesive force can be expressed even before aging. Furthermore, it has been found that a high adhesive force can be maintained after the aging process and after being placed under high temperature and high humidity.

  The adhesive composition for laminated sheets of the present invention preferably contains a silane coupling agent from the viewpoint of improving the adhesive strength when a metal foil, a metal plate, a metal vapor-deposited film or the like is used as a substrate.

  Examples of the silane coupling agent include, but are not limited to, vinyl silanes such as vinyl tris (β-methoxyethoxy) silane, vinylethoxysilane, and vinyltrimethoxysilane; γ- (meth) acryloxypropyl (Meth) acryloxysilanes such as trimethoxysilane, γ- (meth) acryloxypropyltriethoxysilane, and γ- (meth) acryloxypropyldimethoxymethylsilane; β- (3,4-epoxycyclohexyl) ethyltri Methoxysilane, β- (3,4-epoxycyclohexyl) methyltrimethoxysilane, β- (3,4-epoxycyclohexyl) ethyltriethoxysilane, β- (3,4-epoxycyclohexyl) methyltriethoxysilane, γ- Glycidoxypropyltrimethoxy And epoxy silanes such as γ-glycidoxypropyltriethoxysilane; N-β (aminoethyl) γ-aminopropyltrimethoxysilane, N-β (aminoethyl) γ-aminopropyltriethoxysilane, N- β (aminoethyl) γ-aminopropylmethyldiethoxysilane, γ-aminopropyltriethoxysilane, γ-aminopropyltrimethoxysilane, N-phenyl-γ-aminopropyltrimethoxysilane, and N-phenyl-γ- Aminosilanes such as aminopropyltriethoxysilane; and thiosilanes such as γ-mercaptopropyltrimethoxysilane and γ-mercaptopropyltriethoxysilane. These may be used alone or in any combination of two or more.

  The addition amount of the silane coupling agent is preferably 0.1 to 5 parts by weight, and more preferably 1 to 3 parts by weight with respect to 100 parts by weight of the acrylic polyol (A). If it is less than 0.1 parts by weight, the effect of improving the adhesive strength to the metal foil by adding a silane coupling agent is poor, and even if it is added in excess of 5 parts by weight, no further improvement in performance may be observed. is there.

  The adhesive composition for laminated sheets of the present invention may be a so-called two-liquid mixed type adhesive in which the main agent and the curing agent are mixed at the time of use, or one liquid in which the main agent and the curing agent are mixed in advance. It may be a type of adhesive. Furthermore, you may use the acrylic polyol (A) and polyisocyanate (B) which concern on this invention by multiple types each independently. Furthermore, you may use the main ingredient and hardening | curing agent other than this invention independently by a single type or multiple types, respectively. Usually, the main agent contains an acrylic polyol (A), a silane coupling agent, an organic solvent, and other additives, and the curing agent contains a polyisocyanate (B), an organic solvent, and other additives.

  As other additives, the adhesive for laminated sheets of the present invention includes a tackifier, a reaction accelerator, a leveling agent, a phosphorus-based or phenol-based antioxidant, an ultraviolet ray without departing from the spirit of the present invention. Various additives such as stabilizers, metal deactivators, flame retardants, plasticizers, organic and inorganic pigments can be blended.

  When using a metal layer (metal foil, metal plate, etc.) as a sheet-like member, in order to improve the metal adhesion of the adhesive composition for laminated sheets of the present invention, phosphoric acid compounds such as phosphoric acid, metaphosphoric acid, Pyrophosphoric acid, phosphorous acid, esters thereof and the like can be added.

  Moreover, the adhesive composition for laminated sheets of the present invention is preferably used as an adhesive for producing a back protective sheet for solar cells, and can also be used as an anchor coating agent for solar cell laminated sheets. In that case, it is preferable to add an antiblocking agent.

  In addition, known additives for adhesives can be blended without limitation without departing from the spirit of the present invention. For example, a reaction accelerator can be used. Specifically, metal catalysts such as dibutyltin diacetate, dibutyltin dilaurate, dioctyltin dilaurate, dibutyltin dimaleate; 1,8-diaza-bicyclo (5,4,0) undecene-7, 1,5-diazabicyclo ( 4,3,0) nonene-5,6-dibutylamino-1,8-diazabicyclo (5,4,0) undecene-7 and other tertiary amines; reactive tertiary amines such as triethanolamine It is done. As the reaction accelerator, one kind or two or more kinds of reaction accelerators can be used.

  Furthermore, for the purpose of improving the laminate appearance, a known leveling agent or antifoaming agent can be added to the main agent.

  Examples of leveling agents include polyether-modified polydimethylsiloxane, polyester-modified polydimethylsiloxane, aralkyl-modified polymethylalkylsiloxane, polyester-modified hydroxyl group-containing polydimethylsiloxane, polyetherester-modified hydroxyl group-containing polydimethylsiloxane, and acrylic copolymers. , Methacrylic copolymers, polyether-modified polymethylalkylsiloxanes, acrylic acid alkyl ester copolymers, methacrylic acid alkyl ester copolymers, lecithin, or mixtures thereof.

  Examples of the antifoaming agent include known resins such as silicone resins, silicone solutions, copolymers of alkyl vinyl ethers, alkyl acrylates and alkyl methacrylates, or mixtures thereof. When a leveling agent and an antifoaming agent are added, one type of compound may be used independently, or two or more types of compounds may be used in any combination.

  Further, as a known additive used in the present invention, a known additive is used for the purpose of further suppressing yellowing of the adhesive due to ultraviolet rays such as the sun over time, and yellowing of the adhesive due to heat such as solar heat. Phosphorous and phenolic antioxidants, UV stabilizers, and metal deactivators can be incorporated into the main agent. These may be used alone or in any combination of two or more. The phosphorus-based or phenol-based antioxidant, UV stabilizer, and metal deactivator used in the present invention have a range of 0.05 to 5 parts by weight with respect to 100 parts by weight of the solid content of the acrylic polyol (A). Preferably, it is 0.1 to 1 part by weight. If the added amount is less than 0.05 weight, a sufficient yellowing suppression effect may not be obtained, and if it is more than 5 parts by weight, the adhesive force of the adhesive may be greatly deteriorated.

  As the curing agent, in addition to the polyisocyanate (B), any known oxazoline compound such as 2,5-dimethyl-2-oxazoline or 2,2 may be used as long as the effects of the present invention are not impaired. -(1,4-butylene) -bis (2-oxazoline) or a hydrazide compound such as isophthalic acid dihydrazide, sebacic acid dihydrazide, or adipic acid dihydrazide may be included.

  Examples of the solvent used in the present invention include esters such as ethyl acetate, butyl acetate and cellosolve acetate; ketones such as acetone, methyl ethyl ketone, isobutyl ketone, methyl isobutyl ketone and cyclohexanone; ethers such as tetrahydrofuran and dioxane; Aromatic hydrocarbons such as toluene and xylene; halogenated hydrocarbons such as methylene chloride and ethylene chloride; dimethyl sulfoxide, dimethyl sulfoamide and the like. These may be used alone or in any combination of two or more.

  The nonvolatile content (solid content) of the adhesive of the present invention is preferably in the range of 10 to 50% by weight. This adhesive agent can adjust solid content using the solvent which was illustrated above.

Next, an example of a method for producing a back protective sheet for solar cells using the adhesive composition for laminated sheets of the present invention and an example of the back protective sheet for solar cells will be described. The manufacturing method and structure of the back surface protection sheet for solar cells are not limited to the following examples, and various manufacturing methods and structures can be adopted according to the purpose and needs.

  A simple solar cell module has a configuration in which a filler and a glass plate are sequentially laminated on both sides of a solar cell which is a solar cell element. Since a glass plate is excellent in transparency, weather resistance, and scratch resistance, it is still generally used as a sealing sheet on the solar light receiving surface side. However, on the non-light-receiving surface side that does not require transparency, from the viewpoint of cost, safety, and workability, backside protection sheets for solar cells other than glass plates have been developed by various companies, and these are being replaced by glass plates. .

  As a back surface protection sheet for solar cells, a plastic film such as a polyester film, a plastic film with a metal layer in which a vapor deposition layer of a metal oxide or a nonmetal oxide is provided on a polyester film, a metal foil such as an aluminum foil, a silicon nitride layer There are those with laminated plastic films. Each sheet-like member to be laminated can be joined using the adhesive composition for laminated sheets of the present invention. The back surface protection sheet for solar cells having a multilayer structure can impart various performances due to the multilayer structure. For example, insulating properties can be imparted by using a polyester film, weather resistance can be imparted by using a fluorine-based film, and water vapor barrier properties can be imparted by using an aluminum foil. What kind of solar cell back surface protection sheet is used can be appropriately selected depending on the product and application in which the solar cell module is used.

Examples of the plastic film include polyester resin films such as polyethylene terephthalate and polynaphthalene terephthalate, polyethylene resin films, polypropylene resin films, polyvinyl chloride resin films, polycarbonate resin films, polysulfone resin films, and poly (meta ) Acrylic resin film, polyvinyl fluoride, polyvinylidene fluoride, polychlorotrifluoroethylene, polyethylene tetrafluoroethylene, polytetrafluoroethylene, tetrafluoroethylene perfluoroalkyl vinyl ether copolymer, tetrafluoroethylene-hexafluoropropylene copolymer Examples thereof include a fluorine resin film such as a coalescence.
A film in which these plastic films are used as a support and are coated with an acrylic or fluorine-based paint, a multilayer film in which polyvinylidene fluoride, an acrylic resin, or the like is laminated by coextrusion can be used. Furthermore, you may use the sheet-like member by which multiple said plastic films were laminated | stacked through the urethane type adhesive bond layer.
The above plastic film has a so-called wrinkled state where the surface is subjected to physical treatment such as corona discharge, plasma treatment, flame treatment, etc., chemical treatment for modifying the film surface with acid or alkali, etc. What is made an easily bonding surface by mat processing etc. to make can be used suitably. Of course, it goes without saying that the adhesive composition for laminated sheets of the present invention may be applied to a surface untreated material.

  Examples of the metal foil include aluminum foil and copper foil. Examples of the metal oxide or non-metal inorganic oxide to be deposited include oxides such as silicon, aluminum, magnesium, calcium, potassium, tin, sodium, boron, titanium, lead, zirconium, and yttrium.

  Among these, polyethylene terephthalate, polynaphthalene terephthalate, etc. that have resistance to temperature in order to satisfy performance such as weather resistance, water vapor permeability, electrical insulation, mechanical properties, mounting workability when used as a solar cell module Polyester-based resin film, polycarbonate-based resin film, and plastic film or aluminum on which a metal oxide having a water vapor barrier property or a non-metallic inorganic oxide is deposited in order to prevent a decrease in output due to the influence of water on the solar battery cell A back protective sheet for solar cells, in which a metal foil such as a foil and a fluorine resin film with good weather resistance are laminated in order to prevent appearance defects due to light deterioration, is preferable.

  Moreover, in order to protect the solar cell module from damage due to voltage application, the solar cell back surface protection sheet is required to have a partial discharge voltage of 700 V or 1000 V in addition to the power generation capacity of the solar cell, and has electrical insulation or Many configurations that improve the partial discharge voltage by including a foam layer are employed. Since the electrical insulation as a method for improving the partial discharge voltage depends on the thickness of the film or the foamed layer, the film or the foamed layer tends to be a pressure film. In recent years, a configuration using about 100 μm to about 300 μm has been adopted.

The adhesive layer is formed by, for example, applying an adhesive composition to one side of a sheet-like member such as one plastic film, volatilizing the solvent, and then bonding the other laminate substrate to room temperature or applying pressure. It is obtained by curing under heat. Alternatively, an adhesive composition is applied to any one sheet-like member, heat-cured, an adhesive layer is formed, an adhesive layer is formed, and then another sheet-like member forming coating liquid is applied. However, it can be manufactured by forming another sheet-like member by heat or active energy rays. As an apparatus for applying the adhesive composition to a sheet-like member, a comma coater, a dry laminator, a roll knife coater, a die coater, a roll coater, a bar coater, a gravure roll coater, a reverse roll coater, a blade coater, a gravure coater, a micro Examples include a gravure coater. The amount of adhesive applied to the surface of the laminate substrate is preferably about 0.1 to 50 g / m ^{2 in} terms of dry. More preferably about 1 to 50 g / ^{m 2.} As a laminate base material, an arbitrary base material can be selected in any number depending on the application, and when making a multilayer structure of three or more layers, all or a part of each layer is bonded. The adhesive composition according to the present invention can be used.
As a coating liquid for forming a sheet-like member, a polyester resin solution, a polyethylene resin solution, a polypropylene resin solution, a polyvinyl chloride resin solution, a polycarbonate resin solution, or a polysulfone resin solution that can be used for forming a plastic film Poly (meth) acrylic resin solution, fluorine resin solution and the like are preferable examples.
Various manufacturing methods can be selected or further combined in consideration of performance, price, productivity and the like required for the back surface protection sheet for solar cells.

<Example>
EXAMPLES Hereinafter, although an Example demonstrates this invention further in detail, a following example does not restrict | limit the right range of this invention at all. In addition, each evaluation in an Example followed the following method. In the examples, parts are parts by weight,% is% by weight, and the hydroxyl value is mgKOH / g. The number average molecular weight, glass transition temperature, and hydroxyl value were determined as follows.

<Number average molecular weight>
For the measurement of the number average molecular weight, GPC (gel permeation chromatography) “HPC-8020” manufactured by Tosoh Corporation was used, and tetrahydrofuran was used as the solvent. The number average molecular weight was calculated in terms of standard polystyrene.

<Glass transition temperature (Tg)>
The glass transition temperature (Tg) was measured using DSC “RDC220” manufactured by Seiko Instruments Inc. A sample obtained by drying the polycarbonate urethane polyol A-1 to A-14 solution synthesized by the following method, about 10 mg was weighed into an aluminum pan, set in a DSC apparatus, cooled to −100 ° C. with liquid nitrogen, and then 10 ° C. / The glass transition temperature was determined from the DSC chart obtained by raising the temperature in min.

<Hydroxyl value>
Regarding the hydroxyl value, about 2 g of a sample was dissolved in about 10 ml of pyridine, 5 ml of a mixed solution having a previously prepared volume ratio of acetic anhydride / pyridine of 15/85 was added, and the mixture was allowed to stand for 20 hours. Thereafter, 1 ml of water and 10 ml of ethanol were added, and titration was performed with 0.1 N potassium hydroxide (ethanol solution). Phenolphthalein was used as an indicator.

<Production of acrylic polyol (A)> (Synthesis Example A-1)
A 4-necked flask equipped with a condenser, a nitrogen inlet tube, a dropping funnel, and a thermometer was charged with 100 parts by weight of ethyl acetate, heated to 80 ° C., 42.7 parts by weight of butyl acrylate, and 55.5 weights of ethyl methacrylate. Part, 1.8 parts by weight of 2-hydroxyethyl acrylate, and 2.0 parts by weight of azobisisobutylnitrile in advance were added dropwise over 2 hours from the dropping funnel. Thereafter, the reaction was carried out for 1 hour, followed by adding 0.2 parts by weight of azobisisobutylnitrile and reacting for 1 hour until the monomer conversion reached 98% or more, and then cooled. Then, ethyl acetate was added to obtain a solution having a solid content of 50%.

(Synthesis Examples A-2 to A-18) Synthesis Examples A-2 to A-18 shown in Table 1 were performed in the same manner as Synthesis Example 1 except that the molecular weight was adjusted by the addition amount of the polymerization initiator azobisisobutylnitrile. An acrylic polyol was obtained. In addition, about synthesis example A-15, it is an acrylic polyol of the composition shown as the synthesis example 1 in patent document 2. FIG. Abbreviations in Table 1 are as follows.
BA: butyl acrylate, EMA: ethyl methacrylate, EA: ethyl acrylate, St: styrene, CHMA: cyclohexyl methacrylate, 2EHA: 2-ethylhexyl acrylate, HEA: 2-hydroxyethyl acrylate, 4HBA: 4-hydroxybutyl acrylate

<Composition example of adhesive composition> (Examples 1 to 13 and Comparative Examples 1 to 6) Polyisocyanate (B) as a curing agent with respect to 100 parts by weight of the acrylic polyol (A) as a main ingredient in terms of solid content Are mixed at a mixing ratio shown in Table 2, and glycidyl group-containing silane coupling agent ("KBM-403" manufactured by Shin-Etsu Chemical Co., Ltd.) is added as an additive at 3.0 parts by weight, and dioctyltin dilaurate ("Neostan U -810 "(manufactured by Nitto Kasei Co., Ltd.) was added in an amount of 0.01 part by weight, and the solid content was further adjusted to 30% with ethyl acetate.

<Example of production of laminated film 1>
Using each adhesive composition of Examples 1 to 13 and Comparative Examples 1 to 6, a dry coating amount of the adhesive composition was applied to the corona-treated surface of a polyester film [Toray Industries, Lumirror X-10S, thickness 50 μm]. : It apply | coated with the dry laminator in the quantity used as 4-5 g / m < ² >. And after volatilizing a solvent, it laminated | stacked on the corona treatment surface of another polyester film [Toray Industries, Lumirror X-10S, thickness 50micrometer]. Then, the adhesive agent was hardened by performing the hardening process (aging) for 3 days at 40 degreeC, and the laminated | multilayer film 1 was produced.

<Example of production of laminated film 2>
Using the adhesive compositions of Examples 1 to 4 and Comparative Examples 2 and 3 , a laminated film 2 having a configuration of [corona-treated polyester film / adhesive layer / aluminum foil] according to the method for producing the laminated film 1 described above. Was made.

<Example of production of laminated film 3>
Using the adhesive compositions of Examples 1 to 4 and Comparative Examples 2 and 3 , according to the method for producing the laminated film 1 described above, the vapor deposition layer of the silica vapor deposition polyester film was in contact with the adhesive layer, and [corona A laminated film 3 having a configuration of [treated polyester film / adhesive layer / silica vapor-deposited polyester film] was produced.

In Tables 2 and 3, the combinations of the main agent and the curing agent in Examples 1 to 13 and Comparative Examples 1 to 6, and the initial adhesive strength of the laminated film 1 at 85 ° C. and a humidity of 85%, 1000 hours, 2000 hours And adhesion after 3000 hours exposure.

In Tables 4 and 5, the initial adhesive strength and the laminated films 2 and 3 using Examples 1 to 4 and Comparative Examples 1 to 3 are 1000 hours, 2000 hours, and 3000 in an atmosphere of 85 ° C. and 85% humidity. Indicates the adhesive strength after time exposure. A specific evaluation method will be described below.

<Adhesion test before and after aging>
Prior to aging and after aging, the laminated films 1, 2, and 3 were each cut into a size of 200 mm x 15 mm, and allowed to stand in an environment of 25 ° C and 65% humidity for 6 hours, and then tested according to ASTM-D1876-61. According to the method, a T-type peel test was performed using a tensile tester at a load rate of 300 mm / min in an environment of 25 ° C. and a humidity of 65%. The peel strength (N / 15 mm width) between the PET film / PET film, between the PET film / aluminum foil, and between the PET film / silica vapor-deposited polyester film is shown as an average value of five test pieces.
<Adhesion test after wet heat resistance test>
Each of the laminated bodies after aging was cut into a size of 200 mm × 15 mm, and allowed to stand for 1000 hours, 2000 hours, and 3000 hours in an environment of 85 ° C. and 85% humidity. Then, after standing for 6 hours in an environment of 25 ° C. and a humidity of 65%, in accordance with the test method of ASTM-D1876-61, using a tensile tester, the load speed is 300 mm in an environment of 25 ° C. and a humidity of 65%. A T-type peel test was conducted at / min. The peel strength (N / 15 mm width) between the PET film / PET film, between the PET film / aluminum foil, and between the PET film / silica vapor-deposited polyester film is shown as an average value of five test pieces.

<Evaluation criteria>
[Adhesion test before aging]
◎ Excellent in practical use: 3N / 15mm or more ○ Practical range: 2-3N / 15mm
△ Practical use lower limit: 1-2N / 15mm
× Not practical: Less than 1N / 15mm
[Test after aging, Adhesion test after wet heat resistance test]
◎ Excellent in practical use: 5N / 15mm or more ○ Practical range: 4-5N / 15mm
△ Practical lower limit: 2-4N / 15mm
× Not practical: Less than 2N / 15mm

  As shown in Table 3, the adhesive compositions of the examples were found to have excellent adhesive strength both before aging and after aging. Moreover, it turned out that the outstanding adhesive force is obtained after a heat-and-moisture resistance test. Since the adhesive strength can be maintained over a long period of time, the adhesive compositions of the examples are particularly suitable for long-term wet heat resistance for outdoor use.

  In JIS C 8917 (environmental test method and durability test method for crystalline solar cell module), a moisture resistance test B-2 is defined, which is to endure for 1000 hours at 85 ° C. and 85% humidity. It is known as a harsh test method. In this example, it is shown that the adhesive strength can be maintained over a long period of 1000 hours exceeding 1000 hours, and it can be said that the adhesive composition of the present invention has sufficient long-term wet heat resistance.

  In such a long-term moisture and heat resistance test, the back protection sheet for solar cells retains sufficient interlayer adhesion strength (laminate strength) and does not generate delamination between sheet layers, thereby protecting solar cell elements and maintaining power generation efficiency. Furthermore, it can contribute to the extension of the lifetime of the solar cell. Extending the lifetime of solar cells leads to the spread of solar cell systems and contributes to environmental conservation from the viewpoint of securing energy other than fossil fuels.

  The adhesive composition according to the present invention is a multilayer laminated material for outdoor industrial applications such as buildings (barrier material, outer wall material, wall barrier agent, roofing material, solar cell panel material (back surface protection sheet for solar cell, solar cell surface protection sheet). ), Window materials, outdoor flooring materials, certification protective materials, automobile members, etc.) can provide strong adhesive strength. In addition, it is possible to suppress a decrease in adhesive strength over time due to hydrolysis or the like during outdoor exposure, and to maintain strong adhesive strength over a long period of time.

  Comparative Example 1 is an example in which the acrylic polyol (A) has a glass transition temperature of −20 ° C. and lower than 10 ° C. As a result of the evaluation, even in the case of the surface-treated polyester film, a result that only an adhesive force of about 3 (N / 15 mm) can be obtained was obtained.

  Comparative Example 2 is an example in which the glass transition temperature of the acrylic polyol (A) is 55 ° C. and higher than 50 ° C. As a result of the evaluation, since there was almost no wettability to the base material, the initial adhesive force was extremely small, and the result was further reduced in the wet heat resistance test.

  Comparative Example 3 is an example in which the acrylic polyol (A) has a number average molecular weight of 6,000 and less than 10,000. As a result of the evaluation, it was found that the adhesive force before the aging process was insufficient and the adhesive force before the aging process was extremely small. In the case of industrial production, the roll-shaped laminated body is aged with the winding core in the vertical direction. If the adhesive strength before the aging process is extremely small, the winding tends to collapse during aging, which is not suitable for industrial production.

  In Comparative Example 4, the number average molecular weight of the acrylic polyol (A) is 120,000, which is an example larger than 100,000. As a result of the evaluation, it was found that the wettability to the PET film was insufficient and sufficient adhesive force could not be obtained before aging. As in Comparative Example 3, the winding tends to collapse during aging and is not suitable for industrial production. In addition, after the moist heat resistance test, no decrease in the adhesive strength was observed by the moist heat resistance test, but it was found to be inferior to the examples because the original adhesive strength was low.

  In Comparative Example 5, the acrylic polyol (A) has an OH value of 110.0, which is larger than 100. As a result of the evaluation, it was found that cross-linking was excessive and a very hard cured coating film was obtained, resulting in poor adhesion.

  Comparative Example 6 is an example in which the amount of polyisocyanate (B) is NCO / OH = 12. As a result of the evaluation, it was found that the reaction with the acrylic polyol (A) progressed before the coating, and the gel material was generated, so that the coating could not be performed.

The adhesive composition for laminated sheets according to the present invention is used for joining adherends of the same or different materials, and is suitable for joining, for example, a multilayer laminate of a plastic material and a metal material. Used. Of course, it is also suitable for joining plastic materials and metal materials. The adhesive composition for laminated sheets according to the present invention can maintain a high adhesive force even when exposed to a high temperature and high humidity environment. Therefore, multilayer laminated materials for outdoor industrial applications such as buildings (barrier materials, outer wall materials, roofing materials, solar cell panel materials (back surface protection sheets for solar cells, solar cell surface protection sheets), window materials, outdoor flooring materials, lighting protection It is suitable as an adhesive for materials, automobile members, and the like. Since the adhesive strength over time can be maintained over a long period of time, it is particularly suitable for uses where environmental resistance has been strongly demanded, for example, for forming a back protective sheet for solar cells. Moreover, it is suitable also for formation of the surface protection sheet for solar cells. In addition, the adhesive composition for laminated sheets according to the present invention exhibits a high adhesive force particularly between the layers including the surface treatment layer of the plastic film, but it is suitable for a surface untreated material (including a surface untreated plastic film). Can also be suitably applied.

Claims (3)

An adhesive composition for a laminated sheet comprising an acrylic polyol (A) and a polyisocyanate (B),
The acrylic polyol (A) has a number average molecular weight of 10,000 to 100,000,
And a hydroxyl value is 1-40 mgKOH / g, Furthermore, glass transition temperature (Tg) exceeds 10 degreeC and is 50 or less,
The polyisocyanate (B) is at least one selected from the group consisting of a TMP adduct modification of hexamethylene diisocyanate, an allophanate modification of hexamethylene diisocyanate and an isocyanurate modification of isophorone diisocyanate,
The adhesive composition for laminated sheets, wherein an equivalent ratio NCO / OH between a hydroxyl group derived from the acrylic polyol (A) and an isocyanate group derived from the polyisocyanate (B) is 0.1 to 10. Used for the production of a back surface protection sheet for solar cells comprising two or more sheet-like members,
The sheet-shaped members together claim 1 laminated sheet for adhesive composition according used in applications for forming at least a portion of the adhesive layer for bonding. The back surface protection for solar cells which comprised the adhesive bond layer formed from the adhesive composition for laminated sheets of Claim 1 or 2 and the sheet-like member of the at least 2 layer laminated | stacked through the said adhesive bond layer. Sheet.