May.2012
PV Module Material
TOYOBO CO.,LTD.
Industrial Films Operating Department
Contents
１．Overview of Toyobo
２．Toyobo’s technologies and the development
for PV components
３．Proposal of Toyobo products for PV Backsheet
components
４．Toyobo’s polymer 「TOYOBO GS Catalyst®」
５．Pet film for PV Backsheet 「SHINEBEAM®」
６． Enhanced EVA adhesion coated Film
７．SHINEBEAM - Milky White type ８．SHINEBEAM - Transparent type ９．SHINEBEAM - Cavity White type １０．Enhanced EVA adhesion coated Film（Black type）
2
１．Toyobo Profile
Company name :TOYOBO Co.
Founded
:1882
Employee
:3,124(Consolidate 11,181)
Business
Film/Functional resin
Packaging , Industrial , Industrial lamination ,
Engineering plastics , fine chemicals
Industrial Material
Automobile fabric , super-fabric , functional filter etc
Life science
Bio , Pharmaceutical , Medical filter ,
Medical device , aqua-filer
Fabric
Functional material , fabric , textile
Others
Engineering etc
3
２．TOYOBO Technologies and PV material
TOYOBO Technologies
Resin Technologies
PV Backsheet material
・Properties control technologies
・Catalyst technologies
・Polymerization technologies
Hydrolysis resistant
Polyester Film
・Film-forming technologies
Film Technologies
Enhanced EVA
adhesion coated Film
・Easy-adhesive Coating technologies
High Barrier PET Film
・Barrier Coating technologies
4
３．Proposal for PV Backsheet composition
①Structure of Photovoltaic Device
Frame
PV cell
Glass
Lead Frame
EVA
＜構造概図（
Backsheet
Terminal Box
Terminal Cable
②Alternative Proposal
Sealing Material (EVA)
Polyester Film
EVA Resin
Weather Proof Film
： Backsheet structure
Adhesive
Layer
Sealing Material (EVA)
EVA Adhesive Polyester Film
Moisture of Barrier (Al・PET)
High Barrier Polyester Film
Fluoride Film
Hydrolysis Resistant Polyester Film
Fluoride Film alternation ⇒ 「SHINEBEAM」
EVA Adhesive improvement ⇒ ｢EVA Adhesive PET Film」
Moisture of Barrier ⇒ 「Ecosyal」
5
４．Toyobo’s polymer
① Catalyst Review
Currently, Antimony catalysts represented by Sb2O3 are
used for over 95% of polymerization of polyester in the
world.
With the rising demands for environmental protection,
it will become the subject of regulation.
Need the solution to dispose heavy metals
Thanks to the accumulated technologies of polyester
polymerization for over 65 years, Toyobo developed the
heavy metal free aluminum catalyst, which is the world’s
first breakthrough technology in history.
「ＴＯＹＯＢＯ ＧＳ Ｃａｔａｌｙｓｔ®」was developed.
6
４．Toyobo’s polymer
② Characteristic
Type of Resin
Hydrolysis
Thermal oxidation
degradability
Resin using TOYOBO GS CatalystⓇ
0.021
0.01
Resin using antimony Catalyst
0.064
0.18
Testing Condition
130℃×6ｈｒ
230℃×15 min
airborne
(%BB)
GS resin has high hydrolysis resistance and low thermal oxidation degradability.
%BB ： “Percent broken bonds of ester bonds” value: the lower, the better
Calculated from the equation, % BB (%) = 0.245(IVff-1.47 – IVfi-1.47)
【Journal of Applied Polymer Science, 42, 1041 (1991)】
7
５．TOYOBO Backsheet material
①TOYOBO Hydrolysis Resistant Polyester Film （SHINEBEAM）
SHINEBEAM is PET Film developed for PV that has the following
characteristics, which is recommended to be used as Protective Films
for the Backsheet of PV Module.
TOYOBO SHINEBEAM
・Hydrolysis resistance is improved dramatically
・Heat life is improved
・No heavy-metal Sb (antimony) content as polymerization
・Transparent and White type
8
６． Enhanced EVA adhesion coated Film
Conventional Structure（TPT）
Fluoro Polymer Film（25,38μm）
PVF、PVDF、ETFE
Normal PET Film
(188,250μm)
Proposal Structure
Fluoro Polymer Film（25,38μm）
PVF、PVDF、ETFE
TOYOBO SHINEBEAM
Proposal Structure
EVA Adhesion coating
(below 1μm)
Type
Q1A15
Thickness
Color
Characteristic
Transpa High Adhesiveness to EVA
50μm
High Hydrolysis Resistance
And others rent
RTI：120～125℃（in process）
Flame Class：ＶＴＭ-2（in process）
Q3215
White
50μm
And others
Q1215
50μm
Transpar High Hydrolysis Resistance
RTI：120～125℃
And others ent
High Hydrolysis Resistance
UV Resistance
RTI：120～125℃
Flame Class：ＶＴＭ-2
Flame Class：ＶＴＭ-2
9
６．Enhanced EVA adhesion coated Film
(3)Coating Effect
Creating a sample configuration below.
Glass
EVA
Measuring the force
necessary to peel the layers
after endurance test.
Enhanced EVA adhesion layer
Peeled surface
PET Film
Peel Strength（N/cm） 180°peeling
85℃ 85%RH
Surface treatment
Initial
1000hr
2000hr
non-coat
10
8
－*
Corona treated
60
9
－*
Adhesion coated
60 over
20 over
10 over
＊It was impossible to measure.
The test results indicate great effective adhesion durability.
10
７．SHINEBEAM - Milky White Conventional Structure（TPT）
Fluoro Polymer Film（25,38μm）
PVF、PVDF、ETFE
Normal PET Film
(188,250μm)
Proposal Structure
Fluoro Polymer Film（25,38μm）
PVF、PVDF、ETFE
TOYOBO SHINEBEAM
Proposal Structure
Type
Q1A15
EVA side
Thickness
Color
Characteristic
Transpa High Adhesiveness to EVA
50μm
High Hydrolysis Resistance
And others rent
RTI：120～125℃（in process）
Flame Class：ＶＴＭ-2（in process）
Q3215
White
50μm
And others
Q1215
50μm
Transpar High Hydrolysis Resistance
RTI：120～125℃
And others ent
High Hydrolysis Resistance
UV Resistance
RTI：120～125℃
Flame Class：ＶＴＭ-2
Flame Class：ＶＴＭ-2
11
７．SHINEBEAM - Milky White TE Retention Rate after UV Test
Retention Elongation at break (%)
100
80
60
40
Q3215-50μm
General PET
PVF
20
0
0
20
40
60
80
Process time(h)
100
Test condition
Irradiation intensity : 1000W／㎡
Temperature ： 65℃／50％ＲＨ
Exposed time ： 100hr.
12
７．SHINEBEAM - Milky White Color Change after UV Test （⊿b*）
30
Q3215-50μm
General PET
PVF
25
⊿b*
20
15
10
5
0
0
20
40
60
Process time(hr)
80
100
Test condition
Irradiation intensity : 1000W／㎡
Temperature ： 65℃／50％ＲＨ
Exposed time ： １00hr.
13
８．SHINEBEAM - Transparent Conventional Structure（TPT）
Fluoro Polymer Film（25,38μm）
PVF、PVDF、ETFE
Normal PET Film
(188,250μm)
Fluoro Polymer Film（25,38μm）
PVF、PVDF、ETFE
Proposal Structure
TOYOBO SHINEBEAM
Proposal Structure
Type
Thickness
Q1215
125,188,
250μm
Q2215
125,188,
250μm
Color
Characteristic
Transpare High Hydrolysis Resistance
nt
RTI：125℃
Flame Class：VTM-2
Density：1.4
White
High Reflectivity
High Insulation
RTI：105℃
Density：1.1
14
８．SHINEBEAM - Transparent Evaluation of backsheet after
85℃×85%RH×3000hr Damp Heat Test
PVF / Normal PET/ PVF
SHINE BEAM (White) / SHINE BEAM (Transparent)
Embrittlement
and yellowing
Holding its structure
backsheet
Cells
EVA
Glass
Degradation of general PET
laminated with PVF
No peeling off recognizable
SHINEBEAM represents excellent durability
Modules are assembled and tested at AIST Highly Reliable PV Module Development and Evaluation Consortium.
15
８．SHINEBEAM - Transparent Water Vapor Transmission Rate
Comparison of WVTR to other materials
水蒸気透過率
Water Vapor
Transmission(g/㎡/d)
Rate (g/㎡/d)
100
SHINEBEAM Q1 （Transparent）
SHINEBEAM Q2 （Cavity）
SHINEBEAM Q3 （Milky White）
PVF (1)
PVF (2)
PVDF
フッ素系フィルム
Fluorine
Polymer
10
1
0
50
100
150
200
250
300
厚み
(μm)(μm)
Thickness
SHINEBEAM is excellent compared to the fluoropolymer film.
16
８．Hydrolysis Resistance of SHINEBEAM
Highly Accelerated Stress Test：121℃ 100%Rh
SHINEBEAM Q1215 (Transparent)
SHINEBEAM Q2215 (Cavity White)
SHINEBEAM Q3215 (Milky White)
General PET
PVF
PVDF
Retention of Elongation at break (%)
120
100
80
60
40
20
0
0
20
40
60
Process Time (hr)
17
80
100
８．Hydrolysis Resistance of SHINEBEAM
Damp Heat Test：85℃ 85%Rh
Retention of Elongation at break (%)
120
SHINEBEAM Q1215（Transparent）
SHINEBEAM Q2215（Cavity White）
SHINEBEAM Q3215（Milky White）
General PET
PVF
PVDF
100
80
60
40
20
0
0
500
1000
1500
2000
2500
3000
3500
4000
Process Time (hr)
*Q3215（Milky White Type） is examining.
18
９．SHINEBEAM - Cavity White type Conventional Structure（TPT）
Fluoro Polymer Film（25,38μm）
PVF、PVDF、ETFE
Normal PET Film
(188,250μm)
Fluoro Polymer Film（25,38μm）
PVF、PVDF、ETFE
Proposal Structure
Proposal Structure
Type
SHINEBEAM
Thickness
Color
Q1215
125,188,
250μm
Transparent
Q2215
125,188,
250μm
White
19
Characteristic
High hydrolysis resistance
RTI(UL746B)：125℃
Flame class(UL94)：VTM-2
High reflectivity
High insulation
RTI(UL746B)：105℃（UL取得）
Density：1.1
９．SHINEBEAM - Cavity White type （１）Characteristic of SHINEBEAM White
< Sectional drawing>
←Skin layer
←Cavity layer
←Skin layer
(Coating layer for EVA)
・Superior Hydrolysis resistance
・Long Heat Life
・Heavy Metal Free (Antimony Free)
・High Reflectivity （Wavelength：400～1200nm)
・Light Resistance
・High Insulation properties
・Better Die Cut performance
(Thanks to numerous voids contained in the film, SHINEBEAM White offers about 20% better than die cutcutability.)
20
９．Reflectance of SHINEBEAM
Spectrum reflectance
SHINE BEAM White(Q2 Cavity)
SHINE BEAM White（Q3 Milky white）
Competitor A PET
Competitor C PET
Competitor D PET
PVF
PVDF
1
Reflectance (%) Alumina
0.9
0.8
0.7
0.6
0.5
0.4
0.3
0.2
0.1
0
250
500
750
1000
1250
1500
1750
Wavelength （nm)
The reflectance in the infrared domain of
SHINEBEAM cavity white is high in a white film
21
2000
９．Power performance of SHINEBEAM cavity white type
Reflectance (%) vs Alumina
Evaluation of power performance of polycrystalline silicone single cell module
with backsheets varying in reflectance
SHINEBEAM Q2 (Cavity white)
Semitransparent film
Black film
TPT
100%
3.8
3.7
Pmax (W)
80%
60%
3.6
40%
3.5
20%
3.4
0%
400
500
600
700
800
900
1000
SHINEBEAM Q2
1100
Wavelength (nm)
Semitransparent
film
Black film
TPT
Output electricity is higher than
module with TPT
Reflectance ： Black ＜Semitransparent ＜TPT ＜
SHINEBEAM cavity white
SHINEBEAM cavity white type：Higher reflectance ⇒ Higher output electricity
22
22
９．Insulation of SHINEBEAM -Partial DischargePartial discharge test
Maximum permissible system voltage, Usys
Maximum Permissible System
Voltage（VDC）
1400
Q1（Transparent Type）
Q2（Cavity white type）
Q3（Milky white Type）
1200
1100
990
1000
935
800
600
400
200
0
0
50
100
150
200
250
Film Thickness（μm）
Tested：TUV Rheinland Japan Ltd.Global Technology Assessment Center
Test spec.：IEC 60664-1:207 Clause 6.1.3.5
23
300
９． Lineup and characteristic of SHINEBEAM
Lineup and characteristic comparison
SHINEBEAM
Type
Color
Thickness
（μm）
Hydrolysis
Resistance
Anti UV
Reflectance
Insulation
Flame
class
UL94
RTI
UL746B
Q1***
Transparent
50,125,
188,250
◎
△
－
○
VTM-2
5050-79μm：
120℃
8080-275μm：
125℃
Q2***
White
(Cavity)
50,125,250
△
○
◎
◎
－
105℃
Q3***
Milky white
(non-cavity)
50,75,
125,250
○
◎
△
○
VTM-2
Same as Q1
◎：Excellent ○：good △：Standard ×：Poor
24
１０．Enhanced EVA adhesion coated Film（Black type）
Characteristic
◆ Adhesive property with EVA is GOOD.
◆ It is possible to produce backsheets with unification color design.
◆ It improves the generation efficiency for amorphous silicone
photovoltaic by a heat storage effect.
Application
EVA adhesive
coated layer (black)
TOYOBO PET Film
PET Film
PVF,PVDF,
HR-PET etc.
25
１０．Enhanced EVA adhesion coated Film（Black type）
Enhanced EVA adhesion coated black film “TR809”
【Property】
Item
Thickness
Total Light Transmittance
Tensile Strength
TR809
Test Method
μm
50
JIS C-2318
%
0.6
JIS K-7105
MPa
MD
179
JIS C-2318
MPa
TD
252
JIS C-2318
%
MD
175
JIS C-2318
%
TD
108
JIS C-2318
Heat Shrinkage
%
MD
0.2
JIS C-2318
（150℃30min.）
%
TD
0.0
JIS C-2318
N/cm
Standard/fast
type EVA
80 over
TOYOBO
Method*
Tensile Elongation
Adhesion Property
with EVA
＊Above data is typical, not guaranteed.
＊Adhesion property is not guaranteed for all EVA.
26
All Rights Reserved