JP2006190867A - Solar cell encapsulant - Google Patents
Solar cell encapsulant Download PDFInfo
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- JP2006190867A JP2006190867A JP2005002252A JP2005002252A JP2006190867A JP 2006190867 A JP2006190867 A JP 2006190867A JP 2005002252 A JP2005002252 A JP 2005002252A JP 2005002252 A JP2005002252 A JP 2005002252A JP 2006190867 A JP2006190867 A JP 2006190867A
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B17/00—Layered products essentially comprising sheet glass, or glass, slag, or like fibres
- B32B17/06—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material
- B32B17/10—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin
- B32B17/10005—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing
- B32B17/1055—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing characterized by the resin layer, i.e. interlayer
- B32B17/10743—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing characterized by the resin layer, i.e. interlayer containing acrylate (co)polymers or salts thereof
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Abstract
【課題】 太陽電池封止材の透明性や柔軟性等に実質的に悪影響を及ぼすことなく特定の添加剤を配合することによって赤外線に基づく太陽電池素子の温度上昇を抑制し、太陽電池の発電効率の低下を抑制する処方を提供する。
【解決手段】 不飽和カルボン酸単位含有量が4重量%以上であって、融点が85℃以上のエチレン・不飽和カルボン酸共重合体もしくはそのアイオノマー(A)及び少なくとも1200〜3000nmの波長領域の赤外線を遮蔽する透過波長選択剤(B)を含有し、エチレン・不飽和カルボン酸共重合体もしくはそのアイオノマー(A)100重量部に対する透過波長選択剤(B)の配合割合が0.01〜10重量部である樹脂組成物からなる太陽電池封止材、及びそれを用いた太陽電池モジュール。
【選択図】 なし
PROBLEM TO BE SOLVED: To suppress an increase in temperature of a solar cell element based on infrared rays by blending a specific additive without substantially adversely affecting the transparency and flexibility of a solar cell encapsulant, and generating power of the solar cell A prescription that suppresses the decrease in efficiency is provided.
An ethylene / unsaturated carboxylic acid copolymer having an unsaturated carboxylic acid unit content of 4% by weight or more and a melting point of 85 ° C. or higher, or an ionomer (A) thereof, and at least a wavelength region of 1200 to 3000 nm. It contains a transmission wavelength selection agent (B) that shields infrared rays, and the blending ratio of the transmission wavelength selection agent (B) to 100 parts by weight of the ethylene / unsaturated carboxylic acid copolymer or its ionomer (A) is 0.01 to 10%. The solar cell sealing material which consists of a resin composition which is a weight part, and a solar cell module using the same.
[Selection figure] None
Description
本発明は、温度上昇に基づく発電効率の低下を抑制する太陽電池封止材に関する。とくには、集光型太陽電池モジュールの封止材として有用な太陽電池封止材に関する。 The present invention relates to a solar cell encapsulant that suppresses a decrease in power generation efficiency based on a temperature rise. In particular, it is related with the solar cell sealing material useful as a sealing material of a concentrating solar cell module.
無尽蔵な自然エネルギーを利用し、二酸化炭素の削減やその他の環境問題の改善が図れる水力発電、風力発電並びに太陽光発電などが脚光を浴びている。このうち太陽光発電は、太陽電池モジュールの発電効率等の性能向上が著しい一方、価格の低下が進んだこと、国や自治体が住宅用太陽光発電システム導入促進事業を進めてきたことから、近年その普及が著しく進んでいる。しかしながら更なる普及には一層の低コスト化が必要であり、そのため発電効率の一層の向上に向けた研究も日夜続けられている。 Hydroelectric power generation, wind power generation, and solar power generation, which use inexhaustible natural energy to reduce carbon dioxide and improve other environmental problems, are in the spotlight. Among these, solar power generation has seen remarkable improvements in performance, such as power generation efficiency of solar cell modules, but the price has declined and the national and local governments have promoted the introduction of residential solar power generation systems. Its spread is remarkably advanced. However, further cost reduction is necessary for further dissemination, and research for further improvement of power generation efficiency is continued day and night.
一般に太陽電池は高温時に発電効率が低下することが従来から問題になっており、とくに集光型太陽電池は温度が上昇しやすく、発電効率の低下が大きいと考えられている。 In general, it has been a problem that the power generation efficiency of solar cells decreases at a high temperature. In particular, it is considered that the temperature of a concentrating solar cell is likely to increase, and the power generation efficiency is greatly decreased.
そこで本発明の目的は、太陽電池封止材の透明性や柔軟性等に実質的に悪影響を及ぼすことなく特定の添加剤を配合し、もって太陽電池素子の温度上昇を抑制し、発電効率の改善を図ることにある。 Therefore, an object of the present invention is to blend specific additives without substantially adversely affecting the transparency and flexibility of the solar cell encapsulant, thereby suppressing the temperature rise of the solar cell element and improving the power generation efficiency. The goal is to improve.
すなわち本発明は、不飽和カルボン酸単位含有量が4重量%以上であって、融点が85℃以上のエチレン・不飽和カルボン酸共重合体もしくはそのアイオノマー(A−1)及び少なくとも1200〜3000nmの波長領域の赤外線を遮蔽する透過波長選択剤(B)を含有し、エチレン・不飽和カルボン酸共重合体もしくはそのアイオノマー(A−1)100重量部に対する透過波長選択剤(B)の配合割合が0.01〜10重量部である樹脂組成物(C)からなる太陽電池封止材に関する。また透過波長選択剤(B)としては、金属酸化物、金及び銀から選ばれる少なくとも1種の無機物が好ましく、とくに酸化インジウム、酸化錫、酸化亜鉛、酸化マグネシウム、酸化アンチモン及びこれらの2種以上の金属が複合化された金属酸化物から選ばれる金属酸化物が好ましい。 That is, the present invention is an ethylene / unsaturated carboxylic acid copolymer having an unsaturated carboxylic acid unit content of 4% by weight or more and a melting point of 85 ° C. or higher, or its ionomer (A-1), and at least 1200 to 3000 nm. It contains a transmission wavelength selection agent (B) that shields infrared rays in the wavelength region, and the blending ratio of the transmission wavelength selection agent (B) to 100 parts by weight of the ethylene / unsaturated carboxylic acid copolymer or its ionomer (A-1) is It is related with the solar cell sealing material which consists of a resin composition (C) which is 0.01-10 weight part. The transmission wavelength selector (B) is preferably at least one inorganic material selected from metal oxides, gold and silver, in particular indium oxide, tin oxide, zinc oxide, magnesium oxide, antimony oxide and two or more of these. A metal oxide selected from metal oxides in which these metals are combined is preferred.
本発明はまた、上記樹脂組成物(C)の層と、不飽和カルボン酸単位含有量が4重量%以上であって、融点が85℃以上のエチレン・不飽和カルボン酸共重合体もしくはそのアイオノマー(A−2)を含有し、透過波長選択剤(B)を含有しない樹脂組成物(D)の層とが積層されてなる太陽電池封止材に関する。 The present invention also provides a layer of the resin composition (C), an ethylene / unsaturated carboxylic acid copolymer having an unsaturated carboxylic acid unit content of 4% by weight or more and a melting point of 85 ° C. or higher, or an ionomer thereof. It is related with the solar cell sealing material by which the layer of the resin composition (D) which contains (A-2) and does not contain a transmission wavelength selection agent (B) is laminated | stacked.
上記(A−1)及び(A−2)としては、いずれもアイオノマー又はエチレン・不飽和カルボン酸共重合体とアイオノマーのブレンドであって、平均中和度が1〜30%のものが好ましい。 As (A-1) and (A-2), both are ionomers or blends of ethylene / unsaturated carboxylic acid copolymers and ionomers, and those having an average neutralization degree of 1 to 30% are preferable.
本発明の太陽電池封止材は、太陽光中の発電に関わる波長領域の光線の透過を実質的に妨げることなく、発電に寄与しないが太陽電池素子の温度上昇の原因となる1200nm以上の波長の赤外線を選択的に遮蔽することができるので、太陽電池モジュールにおける太陽電池素子の温度上昇が抑制され、発電効率の低下を抑制することができる。とくに集光型太陽電池の封止材として本発明のものを使用すると、発電効率の改善効果が顕著に表れる。本発明の太陽電池封止材はまた、太陽電池素子に対して、あるいは上部保護材としてガラス、下部基板保護材として金属などを使用する場合はこれら保護材に対して、架橋剤やシランカップリング剤を使用しなくても優れた接着性を示し、また透明性、耐熱性においても優れている。とくに成分(A−1)又は(A−1)と(A−2)として、選択されたアイオノマーを使用することにより、例えば、150℃における貯蔵弾性率が103Pa以上、好ましくは5×103Pa以上で、光線透過率が85%以上、好ましくは90%以上の封止材料を容易に得ることができる。また架橋剤の使用が省略できるので、太陽電池モジュール製造工程における生産性を著しく高めることが可能であり、太陽電池モジュールの製造コストを大幅に低減させることが可能である。 The solar cell encapsulant of the present invention has a wavelength of 1200 nm or more that does not contribute to power generation but does not contribute to power generation without substantially impeding transmission of light in the wavelength region related to power generation in sunlight. Therefore, the temperature rise of the solar cell element in the solar cell module can be suppressed, and the decrease in power generation efficiency can be suppressed. In particular, when the material of the present invention is used as a sealing material for concentrating solar cells, the effect of improving the power generation efficiency is remarkably exhibited. The solar cell encapsulant of the present invention also has a crosslinking agent or silane coupling for the solar cell element, or when using glass as the upper protective material and metal as the lower substrate protective material. Excellent adhesion without using any agent, and excellent in transparency and heat resistance. In particular, by using selected ionomers as the components (A-1) or (A-1) and (A-2), for example, the storage elastic modulus at 150 ° C. is 10 3 Pa or more, preferably 5 × 10. A sealing material having a light transmittance of 85% or more, preferably 90% or more can be easily obtained at 3 Pa or more. Moreover, since the use of a crosslinking agent can be omitted, the productivity in the solar cell module manufacturing process can be remarkably increased, and the manufacturing cost of the solar cell module can be greatly reduced.
本発明の太陽電池封止材は、エチレン・不飽和カルボン酸共重合体又はそのアイオノマー(A−1)を主成分とし、少なくとも1200〜3000nmの波長領域の赤外線を遮蔽する透過波長選択剤(B)を含有する樹脂組成物(C)から構成される。前記エチレン・不飽和カルボン酸共重合体又はそのアイオノマー(A−1)は、不飽和カルボン酸単位含有量が4重量%以上、好ましくは5〜20重量%のエチレン・不飽和カルボン酸共重合体又はそのアイオノマーであって、DSCによる融点が85℃以上、好ましくは90〜110℃のものである。かかる共重合体又はそのアイオノマーは、エチレン・酢酸ビニル共重合体の場合のように、コモノマー含量の高いエチレン共重合体を使用しなくても優れた透明性を有しているという利点がある。 The solar cell encapsulating material of the present invention comprises an ethylene / unsaturated carboxylic acid copolymer or its ionomer (A-1) as a main component, and a transmission wavelength selector (B) that shields infrared rays in a wavelength region of at least 1200 to 3000 nm. ) Containing the resin composition (C). The ethylene / unsaturated carboxylic acid copolymer or its ionomer (A-1) has an unsaturated carboxylic acid unit content of 4% by weight or more, preferably 5 to 20% by weight. Or an ionomer thereof having a melting point by DSC of 85 ° C. or higher, preferably 90 to 110 ° C. Such a copolymer or its ionomer has an advantage of having excellent transparency without using an ethylene copolymer having a high comonomer content, as in the case of an ethylene / vinyl acetate copolymer.
ここに不飽和カルボン酸としては、アクリル酸、メタクリル酸、マレイン酸、無水マレイン酸などであり、とくにアクリル酸又はメタクリル酸が好ましい。上記エチレン・不飽和カルボン酸共重合体としては、柔軟性付与に効果的であるところから、ビニルエステルや(メタ)アクリル酸エステルなどが共重合されたものを使用してもよいが、一般的にはこれら共重合成分を含むものは融点が低くなるので、多量に含有するものは使用できない。 Here, examples of the unsaturated carboxylic acid include acrylic acid, methacrylic acid, maleic acid, maleic anhydride, and acrylic acid or methacrylic acid is particularly preferable. As the above-mentioned ethylene / unsaturated carboxylic acid copolymer, a copolymer obtained by copolymerizing vinyl ester or (meth) acrylic acid ester may be used since it is effective for imparting flexibility. Since those containing these copolymer components have a low melting point, those containing a large amount cannot be used.
本発明におけるエチレン・不飽和カルボン酸共重合体のアイオノマーとしては、その金属種として、リチウム、ナトリウムなどのアルカリ金属、カルシウム、マグネシウム、亜鉛、アルミニウムなどの多価金属などを例示することができる。このようなアイオノマーを使用する利点は、透明性、高温における貯蔵弾性率が高いことである。アイオノマーとしては、例えば中和度が80%以下程度のものを使用することが望ましいが、ガラスあるいは太陽電池素子に対する接着性や柔軟性等を勘案すると、あまり中和度の高いものを使用するのは得策ではなく、例えば中和度が60%以下、とくに30%以下のものを使用するのが好ましい。 Examples of the ionomer of the ethylene / unsaturated carboxylic acid copolymer in the present invention include alkali metals such as lithium and sodium, and polyvalent metals such as calcium, magnesium, zinc and aluminum. The advantage of using such an ionomer is transparency and high storage modulus at high temperatures. For example, it is desirable to use an ionomer having a degree of neutralization of about 80% or less. However, in view of adhesiveness and flexibility to glass or solar cell elements, an ionomer having a high degree of neutralization is used. Is not a good idea. For example, it is preferable to use those having a neutralization degree of 60% or less, particularly 30% or less.
不飽和カルボン酸単位含有量が4重量%より少ないような上記共重合体又はそのアイオノマーを使用した場合には透明性が優れたものが得られず、また太陽電池素子などに対する接着性についても不充分なものとなる。また不飽和カルボン酸単位含有量が大きくなると、透明性に関してはより優れたものが得られるが、その含有量が大きくなりすぎると融点が低くなり、また吸湿性が増すなどの問題がでてくる。本発明においては融点が85℃以上のものと規定しているため、その含有量には限度がある。 When the above copolymer having an unsaturated carboxylic acid unit content of less than 4% by weight or an ionomer thereof is used, a product having excellent transparency cannot be obtained, and adhesion to a solar cell element or the like is not good. It will be enough. Further, when the unsaturated carboxylic acid unit content is increased, more excellent transparency can be obtained. However, when the content is too large, the melting point is lowered and the hygroscopicity is increased. . In this invention, since melting | fusing point is prescribed | regulated as 85 degreeC or more, there exists a limit in the content.
本発明においては、上記共重合体やアイオノマーとして、融点が85℃より低いものを使用した場合には耐熱性が充分でなく、また太陽電池モジュールを加熱圧着法で製造するときに、封止材料が必要以上に流れ出してバリを生じる恐れがあるので好ましくない。 In the present invention, when a copolymer or ionomer having a melting point lower than 85 ° C. is used, the heat resistance is not sufficient, and when a solar cell module is produced by a thermocompression bonding method, a sealing material is used. Is not preferable because it may flow out more than necessary and cause burrs.
上記共重合体やアイオノマー(A−1)としては、透明性、接着性及び耐熱性のバランスを考慮すると、不飽和カルボン酸単位含有量が5〜20重量%、好ましくは7〜17重量%のエチレン・不飽和カルボン酸共重合体のアイオノマーであって、中和度が1〜30%、好ましくは5〜20%、融点が90〜110℃、好ましくは92〜105℃のものを使用するのがとくに好ましい。あるいは不飽和カルボン酸単位含有量が5〜20重量%、好ましくは7〜17重量%、融点が90〜110℃のエチレン・不飽和カルボン酸共重合体と、不飽和カルボン酸単位含有量が5〜20重量%、好ましくは7〜17重量%、融点が90〜110℃のエチレン・不飽和カルボン酸共重合体アイオノマーのブレンドであって、後者アイオノマーの金属成分と両者の不飽和カルボン酸成分を勘案した平均中和度が1〜30%、好ましくは5〜20%のものを使用するのがとくに好ましい。上記アイオノマーのみを使用する場合にも、不飽和カルボン酸単位含有量が1重量%以上異なる2種以上のアイオノマーを併用するのが望ましく、また後者のように共重合体とアイオノマーをブレンドして用いる場合にも、不飽和カルボン酸単位含有量が1重量%以上異なるものを使用するのが好ましい。後者の場合の例として、例えば融点が90〜105℃のエチレン・不飽和カルボン酸共重合体20〜95重量部、好ましくは50〜80重量部と、不飽和カルボン酸酸単位含有量が該共重合体より1重量%以上少なく、融点が1℃以上高いアイオノマー80〜5重量部、好ましくは50〜20重量部のブレンドのようなものを例示することができる。 The copolymer or ionomer (A-1) has an unsaturated carboxylic acid unit content of 5 to 20% by weight, preferably 7 to 17% by weight, considering the balance of transparency, adhesiveness and heat resistance. Use an ionomer of an ethylene / unsaturated carboxylic acid copolymer having a neutralization degree of 1 to 30%, preferably 5 to 20%, and a melting point of 90 to 110 ° C, preferably 92 to 105 ° C. Is particularly preferred. Alternatively, an ethylene / unsaturated carboxylic acid copolymer having an unsaturated carboxylic acid unit content of 5 to 20% by weight, preferably 7 to 17% by weight and a melting point of 90 to 110 ° C., and an unsaturated carboxylic acid unit content of 5 A blend of an ethylene / unsaturated carboxylic acid copolymer ionomer having a melting point of 90 to 110 ° C., comprising a metal component of the latter ionomer and an unsaturated carboxylic acid component of both. It is particularly preferable to use those having an average degree of neutralization of 1 to 30%, preferably 5 to 20%. Even when only the above ionomer is used, it is desirable to use two or more kinds of ionomers having an unsaturated carboxylic acid unit content of 1% by weight or more in combination. Further, as in the latter case, a copolymer and an ionomer are blended and used. Even in this case, it is preferable to use those having an unsaturated carboxylic acid unit content different by 1% by weight or more. Examples of the latter case include, for example, 20 to 95 parts by weight, preferably 50 to 80 parts by weight of an ethylene / unsaturated carboxylic acid copolymer having a melting point of 90 to 105 ° C., and the unsaturated carboxylic acid unit content is the same. Examples include a blend of 80 to 5 parts by weight, preferably 50 to 20 parts by weight of an ionomer that is 1% by weight or more lower than the polymer and has a melting point of 1 ° C. or more.
上記共重合体又はそのアイオノマー(A−1)としてはまた、190℃、2160g荷重におけるメルトフローレート(MFR)(JIS K7210−1999、以下同じ)が0.1〜500g/10分、とくに1〜200g/10分のものを使用するのが好ましい。MFRが低いものを使用した場合には、若干低めの融点のものを使用しても上記のような封止材料の流れによるトラブルが生じ難いという利点はあるが、過度にMFRの低いものを使用すると加工性が悪くなる。一方、過度にMFRの高すぎるものを使用すると、モジュール作成時に端部からはみ出してラミネート内に付着する量が多くなり、それを取り除く作業に手間がかかり、生産効率が悪くなる。 The copolymer or its ionomer (A-1) also has a melt flow rate (MFR) at 190 ° C. under a load of 2160 g (JIS K7210-1999, the same shall apply hereinafter) of 0.1 to 500 g / 10 min. It is preferable to use the one with 200 g / 10 minutes. When using a material with a low MFR, there is an advantage that even if a material with a slightly lower melting point is used, there is an advantage that troubles due to the flow of the sealing material as described above hardly occur, but a material with an excessively low MFR is used. Then, workability deteriorates. On the other hand, if an excessively high MFR is used, the amount that protrudes from the end when adhering to the module and increases in the laminate increases, and it takes time and effort to remove it, resulting in poor production efficiency.
本発明においては、上記エチレン・不飽和カルボン酸共重合体もしくはそのアイオノマー(A−1)を主成分とし、これと少なくとも1200〜3000nmの波長領域の赤外線を遮蔽する透過波長選択剤(B)を、(A−1)100重量部に対して、(B)を0.01〜10重量部の割合で配合した樹脂組成物を太陽電池封止材として使用するものである。上記透過波長選択剤(B)としては、金属酸化物、金及び銀から選ばれる少なくとも1種の無機物を使用するのが好ましく、とりわけ酸化インジウム、酸化錫、酸化亜鉛、酸化マグネシウム及び酸化アンチモンから選ばれる金属酸化物を使用するかあるいはインジウム、錫、亜鉛、マグネシウム及びアンチモンから選ばれる2種以上の金属の複合酸化物を使用するのが好ましい。上記無機物としてはまた、少量の添加で太陽電池封止材中によく分散し、赤外線を効率よく吸収するために、またエチレン・不飽和カルボン酸共重合体もしくはそのアイオノマー(A−1)の透明性を損なわないために、その粒径が1μm以下、好ましくは500nm以下程度の超微粉を使用するのが好ましい。エチレン・不飽和カルボン酸共重合体もしくはそのアイオノマー(A−1)にこのような透過波長選択剤(B)を適量配合した樹脂組成物を太陽電池封止材として使用することにより、太陽電池素子の温度上昇が抑制され、発電効率の低下を抑制することができる。 In the present invention, a transmission wavelength selective agent (B) that contains the ethylene / unsaturated carboxylic acid copolymer or its ionomer (A-1) as a main component and shields infrared rays in the wavelength region of at least 1200 to 3000 nm. (A-1) The resin composition which mix | blended (B) in the ratio of 0.01-10 weight part with respect to 100 weight part is used as a solar cell sealing material. As the transmission wavelength selective agent (B), it is preferable to use at least one inorganic material selected from metal oxides, gold and silver, and particularly selected from indium oxide, tin oxide, zinc oxide, magnesium oxide and antimony oxide. It is preferable to use a metal oxide or a composite oxide of two or more metals selected from indium, tin, zinc, magnesium and antimony. As the inorganic material, it is well dispersed in a solar cell encapsulant with a small amount of addition, and absorbs infrared rays efficiently. Also, an ethylene / unsaturated carboxylic acid copolymer or its ionomer (A-1) is transparent. In order not to impair the properties, it is preferable to use ultrafine powder having a particle size of 1 μm or less, preferably about 500 nm or less. By using, as a solar cell encapsulant, a resin composition in which an appropriate amount of such a transmission wavelength selective agent (B) is blended with an ethylene / unsaturated carboxylic acid copolymer or its ionomer (A-1), a solar cell element Temperature rise is suppressed, and a decrease in power generation efficiency can be suppressed.
本発明の太陽電池封止材を構成する樹脂組成物には、必要に応じ、種々の添加剤を配合することができる。このような添加剤として具体的には、シランカップリング剤、紫外線吸収剤、ヒンダードフェノール系やホスファイト系の酸化防止剤、ヒンダードアミン系の光安定剤、光拡散剤、難燃剤、変色防止剤などを例示することができる。 Various additives can be blended in the resin composition constituting the solar cell encapsulant of the present invention, if necessary. Specific examples of such additives include silane coupling agents, UV absorbers, hindered phenol-based and phosphite-based antioxidants, hindered amine-based light stabilizers, light diffusing agents, flame retardants, and discoloration inhibitors. Etc. can be illustrated.
シランカップリング剤は、封止材の保護材や太陽電池素子等に対する接着性を向上させるのに有用であり、その例としては、アミノ基又はエポキシ基とともに、アルコキシ基のような加水分解可能な基を有する化合物を挙げることができる。シランカップリング剤として具体的には、N−(β−アミノエチル)−γ−アミノプロピルトリメトキシシラン、N−(β−アミノエチル)−γ−アミノプロピルメチルジメトキシシラン、γ−アミノプロピルトリエトキシシラン、γ−グリシドキシプロピルトリメトキシシラン、γ−メタクリロキシプロピルトリメトキシシランなどを例示することができる。シランカップリング剤は、エチレン・不飽和カルボン酸共重合体もしくはそのアイオノマー(A−1)100重量部に対し、0.1〜5重量部程度配合することが望ましい。 A silane coupling agent is useful for improving the adhesion of a sealing material to a protective material, a solar cell element, and the like. Examples thereof include an amino group or an epoxy group and a hydrolyzable like an alkoxy group. The compound which has group can be mentioned. Specific examples of the silane coupling agent include N- (β-aminoethyl) -γ-aminopropyltrimethoxysilane, N- (β-aminoethyl) -γ-aminopropylmethyldimethoxysilane, and γ-aminopropyltriethoxy. Examples include silane, γ-glycidoxypropyltrimethoxysilane, γ-methacryloxypropyltrimethoxysilane, and the like. The silane coupling agent is desirably blended in an amount of about 0.1 to 5 parts by weight with respect to 100 parts by weight of the ethylene / unsaturated carboxylic acid copolymer or its ionomer (A-1).
本発明の太陽電池封止材に添加することができる紫外線吸収剤としては、ベンゾフェノン系、ベンゾトリアゾール系、トリアジン系、サリチル酸エステル系など各種タイプのものを挙げることができる。ベンゾフェノン系紫外線吸収剤としては、例えば、2−ヒドロキシ−4−メトキシベンゾフェノン、2−ヒドロキシ−4−メトキシ−2’−カルボキシベンゾフェノン、2−ヒドロキシ−4−オクトキシベンゾフェノン、2−ヒドロキシ−4−n−ドデシルオキシベンゾフェノン、2−ヒドロキシ−4−n−オクタデシルオキシベンゾフェノン、2−ヒドロキシ−4−ベンジルオキシベンゾフェノン、2−ヒドロキシ−4−メトキシ−5−スルホベンゾフェノン、2−ヒドロキシ−5−クロロベンゾフェノン、2,4−ジヒドロキシベンゾフェノン、2,2’−ジヒドロキシ−4−メトキシベンゾフェノン、2,2’−ジヒドロキシ−4,4’−ジメトキシベンゾフェノン、2,2’,4,4’−テトラヒドロキシベンゾフェノンなどを挙げることができる。 Examples of the ultraviolet absorber that can be added to the solar cell encapsulant of the present invention include various types such as benzophenone-based, benzotriazole-based, triazine-based, and salicylic acid ester-based materials. Examples of the benzophenone-based UV absorber include 2-hydroxy-4-methoxybenzophenone, 2-hydroxy-4-methoxy-2′-carboxybenzophenone, 2-hydroxy-4-octoxybenzophenone, 2-hydroxy-4-n. -Dodecyloxybenzophenone, 2-hydroxy-4-n-octadecyloxybenzophenone, 2-hydroxy-4-benzyloxybenzophenone, 2-hydroxy-4-methoxy-5-sulfobenzophenone, 2-hydroxy-5-chlorobenzophenone, 2 , 4-dihydroxybenzophenone, 2,2′-dihydroxy-4-methoxybenzophenone, 2,2′-dihydroxy-4,4′-dimethoxybenzophenone, 2,2 ′, 4,4′-tetrahydroxybenzophenone, etc. It is possible.
ベンゾトリアゾール系紫外線吸収剤としては、ヒドロキシフェニル置換ベンゾトリアゾール化合物であって、例えば、2−(2−ヒドロキシ−5−メチルフェニル)ベンゾトリアゾール、2−(2−ヒドロキシ−5−t−ブチルフェニル)ベンゾトリアゾール、2−(2−ヒドロキシ−3,5−ジメチルフェニル)ベンゾトリアゾール、2−(2−メチル−4−ヒドロキシフェニル)ベンゾトリアゾール、2−(2−ヒドロキシ−3−メチル−5−t−ブチルフェニル)ベンゾトリアゾール、2−(2−ヒドロキシ−3,5−ジ−t−アミルフェニル)ベンゾトリアゾール、2−(2−ヒドロキシ−3,5−ジ−t−ブチルフェニル)ベンゾトリアゾール、などを挙げることができる。またトリアジン系紫外線吸収剤としては、2−[4,6−ビス(2,4−ジメチルフェニル)−1,3,5−トリアジン−2−イル]−5−(オクチルオキシ)フェノール、2−(4,6−ジフェニル−1,3,5−トリアジン−2−イル)−5−(ヘキシルオキシ)フェノールなどを挙げることができる。サリチル酸エステル系としては、フェニルサリチレート、p−オクチルフェニルサリチレートなどを挙げることができる。 The benzotriazole ultraviolet absorber is a hydroxyphenyl-substituted benzotriazole compound, for example, 2- (2-hydroxy-5-methylphenyl) benzotriazole, 2- (2-hydroxy-5-t-butylphenyl) Benzotriazole, 2- (2-hydroxy-3,5-dimethylphenyl) benzotriazole, 2- (2-methyl-4-hydroxyphenyl) benzotriazole, 2- (2-hydroxy-3-methyl-5-t- Butylphenyl) benzotriazole, 2- (2-hydroxy-3,5-di-t-amylphenyl) benzotriazole, 2- (2-hydroxy-3,5-di-t-butylphenyl) benzotriazole, and the like. Can be mentioned. Examples of triazine ultraviolet absorbers include 2- [4,6-bis (2,4-dimethylphenyl) -1,3,5-triazin-2-yl] -5- (octyloxy) phenol, 2- ( And 4,6-diphenyl-1,3,5-triazin-2-yl) -5- (hexyloxy) phenol. Examples of salicylic acid esters include phenyl salicylate and p-octylphenyl salicylate.
本発明の太陽電池封止材は、上記したエチレン・不飽和カルボン酸共重合体もしくはそのアイオノマー(A−1)及び透過波長選択剤(B)を必須成分として含有し、任意にシランカップリング剤、紫外線吸収剤などの添加剤を配合した樹脂組成物(C)の単層構成で使用することができる。しかしながら樹脂組成物(C)の層と、不飽和カルボン酸単位含有量が4重量%以上であって、融点が85℃以上のエチレン・不飽和カルボン酸共重合体もしくはそのアイオノマー(A−2)を必須成分として含有し、任意にシランカップリング剤、紫外線吸収剤などの添加剤を配合した樹脂組成物(D)の層とからなる積層体として使用することができる。樹脂組成物(D)は、透過波長選択剤(B)を含有していない以外は樹脂組成物(C)で説明したのと全く同様の原料及び配合量のものを使用することができる。とくに(A−1)と(A−2)は実質的に同一のものを使用するのが好ましく、またその他添加剤の種類や配合量も実質的に同一にするのが好ましい。上記積層体においては、樹脂組成物(C)の層と樹脂組成物(D)の層の厚み比率[C]/[D]は、1/99〜90/10の範囲とするのが好ましい。樹脂組成物(C)における透過波長選択剤(B)は、樹脂組成物(C)を単層で使用する場合、あるいは樹脂組成物(C)の層と樹脂組成物(D)の層の積層体として使用する場合は、(C)層の厚みに応じて、前記した範囲内で適正な割合で配合すればよい。 The solar cell encapsulant of the present invention contains the above-described ethylene / unsaturated carboxylic acid copolymer or its ionomer (A-1) and a transmission wavelength selective agent (B) as essential components, and optionally a silane coupling agent. In addition, it can be used in a single layer configuration of the resin composition (C) containing an additive such as an ultraviolet absorber. However, a layer of the resin composition (C), an ethylene / unsaturated carboxylic acid copolymer having an unsaturated carboxylic acid unit content of 4% by weight or more and a melting point of 85 ° C. or more, or an ionomer thereof (A-2) Can be used as a laminate comprising a layer of the resin composition (D) optionally containing additives such as a silane coupling agent and an ultraviolet absorber. As the resin composition (D), the same raw materials and blending amounts as those described for the resin composition (C) can be used except that the resin composition does not contain the transmission wavelength selective agent (B). In particular, it is preferable to use substantially the same (A-1) and (A-2), and it is preferable that the types and amounts of other additives are substantially the same. In the laminate, the thickness ratio [C] / [D] of the resin composition (C) layer and the resin composition (D) layer is preferably in the range of 1/99 to 90/10. The transmission wavelength selection agent (B) in the resin composition (C) is used when the resin composition (C) is used as a single layer, or a laminate of the resin composition (C) layer and the resin composition (D) layer. When using as a body, according to the thickness of (C) layer, what is necessary is just to mix | blend in an appropriate ratio within the above-mentioned range.
本発明の太陽電池封止材を用い、太陽電池素子を上下の保護材で固定することにより太陽電池モジュールを製作することができる。このような太陽電池モジュールとしては、種々のタイプのものを例示することができる。例えば上部透明保護材/封止材/太陽電池素子/封止材/下部保護材のように太陽電池素子の両側から封止材で挟む構成のもの、下部基板保護材の内周面上に形成させた太陽電池素子上に封止材と上部透明保護材を形成させるような構成のもの、上部透明保護材の内周面上に形成させた太陽電池素子、例えばフッ素樹脂系透明保護材上にアモルファス太陽電池素子をスパッタリング等で作成したものの上に封止材と下部保護材を形成させるような構成のものなどを挙げることができる。 A solar cell module can be produced by fixing the solar cell element with upper and lower protective materials using the solar cell encapsulant of the present invention. Examples of such solar cell modules include various types. For example, the upper transparent protective material / encapsulant / solar cell element / encapsulant / lower protective material sandwiched between the solar cell elements from both sides, formed on the inner peripheral surface of the lower substrate protective material A solar cell element formed on the inner peripheral surface of the upper transparent protective material, for example, a fluororesin-based transparent protective material. The thing of the structure which forms a sealing material and a lower protective material on what created the amorphous solar cell element by sputtering etc. can be mentioned.
太陽電池素子としては、単結晶シリコン、多結晶シリコン、アモルファスシリコンなどのシリコン系、ガリウムー砒素、銅ーインジウムーセレン、カドミウムーテルルなどのIIIーV族やIIーVI族化合物半導体系等の各種太陽電池素子を用いることができる。本発明の太陽電池封止材は、とくにシリコン系太陽電池素子の封止材として有用である。 Solar cell elements include single-crystal silicon, polycrystalline silicon, amorphous silicon, and other silicon systems, and gallium-arsenic, copper-indium-selenium, cadmium-tellurium, and other III-V group and II-VI group compound semiconductor systems. Various solar cell elements can be used. The solar cell sealing material of the present invention is particularly useful as a sealing material for silicon-based solar cell elements.
太陽電池モジュールを構成する上部保護材としては、ガラス、アクリル樹脂、ポリカーボネート、ポリエステル、フッ素含有樹脂などを例示することができる。下部保護材としては、金属や各種熱可塑性樹脂フィルムなどの単体もしくは多層のシートであり、例えば、錫、アルミ、ステンレススチールなどの金属、ガラス等の無機材料、ポリエステル、無機物蒸着ポリエステル、フッ素含有樹脂、ポリオレフィンなどの1層もしくは多層の保護材を例示することができる。本発明の太陽電池封止材は、これらの上部又は下部保護材に対して良好な接着性を示す。 Examples of the upper protective material constituting the solar cell module include glass, acrylic resin, polycarbonate, polyester, and fluorine-containing resin. The lower protective material is a single or multilayer sheet such as metal or various thermoplastic resin films, for example, metals such as tin, aluminum, and stainless steel, inorganic materials such as glass, polyester, inorganic vapor deposition polyester, fluorine-containing resin And a single-layer or multilayer protective material such as polyolefin. The solar cell encapsulant of the present invention exhibits good adhesion to these upper or lower protective materials.
本発明の太陽電池封止材は、通常、シート状で使用される。樹脂組成物(C)からなる単層のシート状太陽電池封止材は、T−ダイ押出機、カレンダー成形機などを使用する公知のシート成形法によって製造することができる。例えばエチレン・不飽和カルボン酸共重合体もしくはそのアイオノマー(A−1)に、透過波長選択剤(B)、必要に応じて添加されるシランカップリング剤、紫外線吸収剤、酸化防止剤、光安定剤等の添加剤を予めドライブレンドしてT−ダイ押出機のホッパーから供給し、シート状に押出成形することによって得ることができる。勿論、これらドライブレンドに際して、一部又は全部の添加剤は、マスターバッチの形で使用することができる。またT−ダイ押出やカレンダー成形において、予めエチレン・不飽和カルボン酸共重合体もしくはそのアイオノマー(A−1)に一部又は全部の添加剤を、一軸押出機、二軸押出機、バンバリーミキサー、ニーダーなどを用いて溶融混合して得た樹脂組成物を使用することもできる。また樹脂組成物(C)の層と樹脂組成物(D)の層とからなる積層シート状太陽電池封止材は、上記したのと同様な条件で共押出法によって製造するか、あるいはそれぞれの単層シートを作成した後それらを積層することによって製造することができる。シート厚みは、単層シートの場合0.1〜1mm程度、積層シートの場合は、樹脂組成物(C)の層が0.01〜1mm程度、樹脂組成物(D)の層が0.05〜1mm程度で、総厚みを0.1〜2mm程度とするのが好ましい。 The solar cell encapsulant of the present invention is usually used in a sheet form. The single-layer sheet-like solar cell encapsulant made of the resin composition (C) can be produced by a known sheet molding method using a T-die extruder, a calendar molding machine, or the like. For example, a transmission wavelength selector (B), a silane coupling agent, an ultraviolet absorber, an antioxidant, and a light stabilizer, which are added to an ethylene / unsaturated carboxylic acid copolymer or its ionomer (A-1) as necessary. An additive such as an agent can be dry blended in advance, supplied from a hopper of a T-die extruder, and extruded into a sheet. Of course, in these dry blends, some or all of the additives can be used in the form of a masterbatch. In addition, in T-die extrusion and calendering, a part or all of the additive is previously added to the ethylene / unsaturated carboxylic acid copolymer or its ionomer (A-1), a single screw extruder, a twin screw extruder, a Banbury mixer, A resin composition obtained by melt mixing using a kneader or the like can also be used. Moreover, the laminated sheet-like solar cell encapsulant composed of the resin composition (C) layer and the resin composition (D) layer is produced by a coextrusion method under the same conditions as described above, or It can be manufactured by creating single layer sheets and then laminating them. In the case of a single layer sheet, the sheet thickness is about 0.1 to 1 mm. In the case of a laminated sheet, the resin composition (C) layer is about 0.01 to 1 mm, and the resin composition (D) layer is 0.05. It is preferable that the total thickness is about 0.1 to 2 mm.
太陽電池モジュールの製造に当たっては、本発明の封止材料のシートを予め作っておき、封止材料が溶融する温度で圧着するという従来同様の方法によって、すでに述べたような構成のモジュールを形成することができる。この場合、封止材料に有機過酸化物を含有させる必要がないので、封止材料のシート成形を高温で生産性よく行うことができるとともに、モジュールの形成においても2段階の接着工程を経る必要はなく、高温度で短時間に完結することができる。本発明の封止材は、太陽電池素子の受光側に使用するのが好ましい。また樹脂組成物(C)の層と樹脂組成物(D)の層からなる積層シート状太陽電池封止材を使用する場合には、樹脂組成物(D)の層が太陽電池素子に当接するように、また樹脂組成物(C)の層が表面保護材に当接するようにするのがよい。さらに本発明の封止材料を押出コーティングすることによって太陽電池素子や上部保護材あるいは下部保護材と積層する方法を採用すれば、わざわざシート成形することなく一段階で太陽電池モジュールを製造することが可能である。したがって本発明の封止材料を使用すれば、モジュールの生産性を格段に改良することができる。 In manufacturing a solar cell module, a sheet having the above-described configuration is formed by a method similar to the conventional method in which a sheet of the sealing material of the present invention is prepared in advance and pressure-bonded at a temperature at which the sealing material melts. be able to. In this case, since it is not necessary to contain an organic peroxide in the sealing material, it is possible to perform sheet molding of the sealing material at a high temperature with high productivity, and it is also necessary to go through a two-step bonding process in forming the module. It can be completed in a short time at a high temperature. It is preferable to use the sealing material of this invention for the light-receiving side of a solar cell element. Moreover, when using the lamination sheet-like solar cell sealing material which consists of a layer of the resin composition (C) and a resin composition (D), the layer of the resin composition (D) contacts a solar cell element. In addition, the layer of the resin composition (C) is preferably in contact with the surface protective material. Furthermore, if a method of laminating with the solar cell element, the upper protective material or the lower protective material by extrusion coating the sealing material of the present invention is adopted, a solar cell module can be manufactured in one step without bothering to form a sheet. Is possible. Therefore, if the sealing material of this invention is used, the productivity of a module can be improved significantly.
以下、実施例及び比較例により本発明をさらに詳細に説明する。尚、実施例及び比較例に用いた原料及び物性の評価方法は以下の通りである。 Hereinafter, the present invention will be described in more detail with reference to Examples and Comparative Examples. In addition, the raw material used for the Example and the comparative example and the evaluation method of a physical property are as follows.
1.原料
(1)エチレン・不飽和カルボン酸共重合体及びアイオノマー
EMAA:エチレン・メタクリル酸共重合体(メタクリル酸単位含量15重量%、メルトフローレート(190℃、2160g荷重、JIS K7210−1999、以下同じ)25g/10分)
IO−Zn:メタクリル酸単位含量15重量%のエチレン・メタクリル酸共重合体の亜鉛アイオノマー(亜鉛中和度21%、メルトフローレート16g/10分)
(2)透過波長選択剤
ITO:錫ドープ酸化インジウム、平均粒径30nm
(3)シランカップリング剤:γ−メタクリロキシプロピルトリメトキシシラン(商品名:KBM503、信越化学(株)製)
1. Raw material (1) Ethylene / unsaturated carboxylic acid copolymer and ionomer EMAA: Ethylene / methacrylic acid copolymer (methacrylic acid unit content 15% by weight, melt flow rate (190 ° C., 2160 g load, JIS K7210-1999, the same applies hereinafter) ) 25g / 10min)
IO-Zn: Zinc ionomer of ethylene / methacrylic acid copolymer having a methacrylic acid unit content of 15% by weight (zinc neutralization degree 21%, melt flow rate 16 g / 10 min)
(2) Transmission wavelength selection agent ITO: tin-doped indium oxide, average particle size 30 nm
(3) Silane coupling agent: γ-methacryloxypropyltrimethoxysilane (trade name: KBM503, manufactured by Shin-Etsu Chemical Co., Ltd.)
[実施例1]
事前に10重量%の上記ITOを含有する上記EMAAのマスターバッチ(MB)を用意した。上記EMAAペレット3500g、ITOのマスターバッチ(MB)1500g及び上記シランカップリング剤(商品名:KBM503)5gを混合し、含浸のため一昼夜放置した。得られた含浸ペレットを、30mmφインフレーションフィルム成形機を用いて、加工温度180℃にて混練、成形して0.05mm厚みのフィルム(c−1)を作成した。
[Example 1]
A master batch (MB) of the EMAA containing 10% by weight of the ITO was prepared in advance. 3500 g of the above EMAA pellets, 1500 g of ITO masterbatch (MB) and 5 g of the above silane coupling agent (trade name: KBM503) were mixed and left overnight for impregnation. The resulting impregnated pellets were kneaded and molded at a processing temperature of 180 ° C. using a 30 mmφ inflation film molding machine to produce a 0.05 mm thick film (c-1).
一方で、上記EMAAペレット5000g及び上記シランカップリング剤5gを混合し、同様に含浸のため一昼夜放置した。得られた含浸ペレットを、40mmφシート成形機にて厚み0.5mmのシート(d)を作成した。 On the other hand, 5000 g of the EMAA pellets and 5 g of the silane coupling agent were mixed and left for a whole day and night for impregnation. A sheet (d) having a thickness of 0.5 mm was prepared from the obtained impregnated pellets using a 40 mmφ sheet molding machine.
3mm厚みの青色ガラス2枚の間に上記で作成した0.05mmフィルム(c−1)(ITO3%含有)と0.5mmシート(d)(ITO未添加)を挟み、150℃×15分で真空貼り合わせ機にて貼り合わせを行い、紫外線分光光度計にて可視光線領域である650nmの透過率を、また赤外分光光度計にて赤外線領域である2000nm(5000cm−1)の透過率を測定した。結果を表1に示す。 Between 2 sheets of 3 mm thick blue glass, the 0.05 mm film (c-1) prepared above (containing 3% ITO) and a 0.5 mm sheet (d) (without ITO added) are sandwiched at 150 ° C. for 15 minutes. Bonding is performed with a vacuum bonding machine, and a transmittance of 650 nm that is a visible light region is measured with an ultraviolet spectrophotometer, and a transmittance of 2000 nm (5000 cm −1 ) that is an infrared region is measured with an infrared spectrophotometer. It was measured. The results are shown in Table 1.
[実施例2]
上記EMAAペレット4850g、10重量%の上記ITOを含むMB150g及び上記シランカップリング剤(商品名:KBM503)5gを混合し、含浸のため一昼夜放置した。得られた含浸ペレットを、40mmφシート成形機にて厚み0.5mmのシート(c−2)を作成した。3mm厚みの青色ガラス2枚の間に得られた0.5mmシート(c−2)を挟み、150℃×15分で真空貼り合わせ機にて貼り合わせを行い、紫外線分光光度計にて可視光線領域である650nmの透過率を、また赤外分光光度計にて赤外線領域である2000nm(5000cm−1)の透過率を測定した。結果を表1に示す。
[Example 2]
4850 g of the EMAA pellets, 150 g of MB containing 10% by weight of the ITO, and 5 g of the silane coupling agent (trade name: KBM503) were mixed and left overnight for impregnation. A sheet (c-2) having a thickness of 0.5 mm was prepared from the obtained impregnated pellets using a 40 mmφ sheet molding machine. A 0.5 mm sheet (c-2) obtained between two 3 mm-thick blue glasses is sandwiched and bonded with a vacuum bonding machine at 150 ° C. for 15 minutes, and visible light is measured with an ultraviolet spectrophotometer. The transmittance at 650 nm as the region and the transmittance at 2000 nm (5000 cm −1 ) as the infrared region were measured with an infrared spectrophotometer. The results are shown in Table 1.
[実施例3]
上記IO−Znペレット4850g、10重量%の上記ITOを含むMB150g及び上記シランカップリング剤(商品名:KBM503)5gを混合し、含浸のため一昼夜放置した。得られた含浸ペレットを、40mmφシート成形機にて厚み0.5mmのシート(c−3)を作成した。3mm厚みの青色ガラス2枚の間に得られた0.5mmシート(c−3)を挟み、150℃×15分で真空貼り合わせ機にて貼り合わせを行い、紫外線分光光度計にて可視光線領域である650nmの透過率を、また赤外分光光度計にて赤外線領域である2000nm(5000cm−1)の透過率を測定した。結果を表1に示す。
[Example 3]
4150 g of the IO-Zn pellets, 150 g of MB containing 10% by weight of the ITO, and 5 g of the silane coupling agent (trade name: KBM503) were mixed and left overnight for impregnation. A sheet (c-3) having a thickness of 0.5 mm was prepared from the obtained impregnated pellets using a 40 mmφ sheet molding machine. A 0.5 mm sheet (c-3) obtained between two 3 mm-thick blue glasses is sandwiched and bonded with a vacuum bonding machine at 150 ° C. for 15 minutes, and visible light is measured with an ultraviolet spectrophotometer. The transmittance at 650 nm as the region and the transmittance at 2000 nm (5000 cm −1 ) as the infrared region were measured with an infrared spectrophotometer. The results are shown in Table 1.
[比較例1]
3mm厚みの青色ガラス2枚の間に実施例1で使用した0.5mmシート(d)を挟み、150℃×15分で真空貼り合わせ機にて貼り合わせを行い、紫外線分光光度計にて可視光線領域である650nmの透過率を、また赤外分光光度計にて赤外線領域である2000nm(5000cm−1)の透過率を測定した。結果を表1に示す。
[Comparative Example 1]
The 0.5 mm sheet (d) used in Example 1 was sandwiched between two 3 mm-thick blue glasses, bonded at 150 ° C. for 15 minutes with a vacuum bonding machine, and visible with an ultraviolet spectrophotometer. The transmittance at 650 nm, which is the light region, and the transmittance at 2000 nm (5000 cm −1 ), which is the infrared region, were measured using an infrared spectrophotometer. The results are shown in Table 1.
Claims (13)
The solar cell module according to claim 12, wherein the solar cell sealing material is used on a light receiving side of a solar cell element.
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