Glass laminate and method for producing glass laminate
Patent Information
- Authority / Receiving Office
- WO · WO
- Patent Type
- Applications
- Current Assignee / Owner
- AGC INC
- Filing Date
- 2025-12-02
- Publication Date
- 2026-06-25
Smart Images
Figure JP2025042048_25062026_PF_FP_ABST
Abstract
Description
Glass laminate and method for manufacturing glass laminate
[0001] The present disclosure relates to a glass laminate and a method for manufacturing a glass laminate.
[0002] In recent years, laminated glass has been widely used in various fields such as architectural applications. In addition, in recent years, the development of a solar cell module in which a solar power generation cell is encapsulated inside the laminated glass has been underway.
[0003] Patent Document 1 discloses a technique related to laminated glass. In the laminated glass disclosed in Patent Document 1, a strip-shaped edge protection material is provided on the side end surfaces of the first glass plate and the second glass plate.
[0004] International Publication No. 2014 / 098160
[0005] Since laminated glass has an intermediate film provided between two glass plates, in an environment with high humidity, moisture in the atmosphere may penetrate from the end face of the laminated glass into the interior of the laminated glass, and the intermediate film may deteriorate. In particular, when a solar power generation cell is encapsulated inside the laminated glass, the solar power generation cell may deteriorate due to the infiltrated moisture. For example, by providing a strip-shaped edge protection material (sealing material) on the side end face of the laminated glass, it is possible to suppress the infiltration of moisture into the laminated glass (see Patent Document 1).
[0006] However, when providing a strip-shaped sealing material on the side end face of the laminated glass, it is necessary to heat the sealing material to a high temperature to give it shape followability. Further, after the sealing material is provided on the side end face of the laminated glass, the sealing material needs to have a predetermined hardness at the use temperature. That is, by having the sealing material have a predetermined hardness, deformation of the sealing material under the actual use environment at the end of the laminated glass is suppressed and durability is improved.
[0007] In view of the above problems, an object of the present disclosure is to provide a glass laminate capable of realizing shape followability of a sealing material at high temperature and rigidity at use temperature, and effectively suppressing the infiltration of moisture from the end of the laminated glass into the interior of the laminated glass, and a method for manufacturing the glass laminate.
[0008] One aspect of this disclosure, such a glass laminate and a method for manufacturing the glass laminate, is as follows.
[0009] [1] A glass laminate comprising: a first glass plate; a second glass plate disposed opposite to the first glass plate; an interlayer disposed between the first glass plate and the second glass plate; and a butyl-based sealant provided around the end of the laminated glass, wherein the melt viscosity of the sealant at 120°C is 0.6 kPa·s or more and 7.0 kPa·s or less, and the JIS A hardness of the sealant at 25°C is 50 to 90.
[0010] [2] The glass laminate according to [1], wherein the storage modulus of the sealing material at 25°C is 10 MPa or more and 60 MPa or less.
[0011] [3] The glass laminate according to [1] or [2], wherein the sealing material further contains a desiccant, and the moisture absorption amount of the sealing material is 0.1% by mass or more and 10% by mass or less.
[0012] [4] The glass laminate according to any one of [1] to [3], wherein the thickness of the sealing material at the end face of the laminated glass is 0.4 mm or more and 10 mm or less.
[0013] [5] The glass laminate according to any one of [1] to [4], wherein an adhesive layer is formed between the end face of the laminated glass and the sealing material.
[0014] [6] The glass laminate according to any one of [1] to [5], wherein a photovoltaic cell is sealed between the first glass plate and the second glass plate of the laminated glass.
[0015] [7] The glass laminate according to any one of [1] to [6], wherein the sealing material is provided around the end side of the laminated glass so as to cover the end surface of the laminated glass.
[0016] [8] The glass laminate according to any one of [1] to [6], wherein the sealing material has a substantially U-shaped cross-section and is provided around the end side of the laminated glass so as to cover the end surface of the laminated glass and so as to cover the periphery of the end side of the main surface of the first glass plate and the periphery of the end side of the main surface of the second glass plate.
[0017] [9] The glass laminate according to any one of [1] to [8], wherein the sealing material is provided between the first glass plate and the second glass plate.
[0018]
[10] The glass laminate according to any one of [1] to [6], wherein, when the glass laminate is viewed in plan, the first glass plate is configured to be smaller in the in-plane direction than the second glass plate, and the sealing material is provided so as to cover the periphery of the end side of the main surface of the first glass plate opposite to the interlayer, the end face of the first glass plate, and the periphery of the interlayer.
[0019]
[11] The glass laminate according to any one of [1] to [6], wherein, when the glass laminate is viewed in plan, the first glass plate is configured to be smaller in the in-plane direction than the second glass plate, and the sealing material is provided to cover the periphery of the end side of the main surface of the first glass plate opposite to the interlayer, the end surface of the first glass plate, the periphery of the interlayer, and the periphery of the end side of the main surface of the second glass plate on the interlayer side.
[0020]
[12] The glass laminate according to any one of [1] to [6], wherein, when the glass laminate is viewed in plan, the first glass plate is configured to be smaller in the in-plane direction than the second glass plate, and the sealing material is provided so as to cover the periphery of the end side of the main surface of the first glass plate opposite to the interlayer, the end face of the first glass plate, the periphery of the interlayer, the periphery of the end side of the main surface of the second glass plate on the interlayer side, and the end face of the second glass plate.
[0021]
[13] The glass laminate according to any one of [1] to [6], wherein, when the glass laminate is viewed in plan, the first glass plate is configured to be smaller in the in-plane direction than the second glass plate, and the sealing material is provided so as to cover the periphery of the end side of the main surface of the first glass plate opposite to the interlayer, the end face of the first glass plate, the periphery of the interlayer, the periphery of the end side of the main surface of the second glass plate on the interlayer side, the end face of the second glass plate, and the periphery of the end side of the main surface of the second glass plate opposite to the interlayer.
[0022]
[14] The glass laminate according to any one of [1] to [6], wherein, when the glass laminate is viewed in plan, the first glass plate is configured to be smaller in the in-plane direction than the second glass plate, and the sealing material is provided to cover the end face of the first glass plate and the periphery of the interlayer.
[0023]
[15] The glass laminate according to any one of [1] to
[14] , wherein the weight-average molecular weight of the sealing material is 200,000 or more and 250,000 or less.
[0024]
[16] A method for manufacturing a glass laminate, comprising the steps of: preparing a laminated glass having a first glass plate, a second glass plate disposed opposite to the first glass plate, and an interlayer disposed between the first glass plate and the second glass plate; and providing a butyl-based sealant around the end of the laminated glass, wherein the melt viscosity of the sealant at 120°C is 0.6 kPa·s or more and 7.0 kPa·s or less, and the JIS A hardness of the sealant at 25°C is 50 to 90.
[0025]
[17] The method for manufacturing a glass laminate according to
[16] , wherein the step of providing the sealing material comprises filling the area around the end of the laminated glass with a molten sealing material and cooling the filled sealing material.
[0026]
[18] A method for manufacturing a glass laminate according to
[17] , wherein an adhesive layer is applied around the end of the laminated glass, and then the molten sealing material is filled around the end of the laminated glass.
[0027] This disclosure provides a glass laminate that achieves shape conformability at high temperatures and rigidity at the operating temperature of the sealing material, and can effectively suppress the intrusion of moisture from the edges of the laminated glass into the interior of the laminated glass, as well as a method for manufacturing the glass laminate.
[0028] This is a front view showing an example of the configuration of a glass laminate according to the embodiment. This is a cross-sectional view taken along the cutting line II-II in Figure 1. This is a cross-sectional view for explaining the manufacturing method of the glass laminate according to the embodiment. This is a front view showing another example of the configuration of a glass laminate according to the embodiment. This is a cross-sectional view taken along the cutting line V-V in Figure 4. This is a cross-sectional view for explaining another manufacturing method of the glass laminate according to the embodiment. This is a front view showing another example of the configuration of a glass laminate according to the embodiment. This is a cross-sectional view taken along the cutting line VIII-VIII in Figure 6. This is a cross-sectional view for explaining another manufacturing method of the glass laminate according to the embodiment. This is a cross-sectional view showing another example of the configuration of a glass laminate according to the embodiment. This is a cross-sectional view showing another example of the configuration of a glass laminate according to the embodiment. This is a cross-sectional view showing another example of the configuration of a glass laminate according to the embodiment. This is a cross-sectional view showing another example of the configuration of a glass laminate according to the embodiment. This is a cross-sectional view showing another example of the configuration of a glass laminate according to the embodiment.
[0029] The embodiments will now be described with reference to the drawings. Figure 1 is a front view showing an example of the configuration of a glass laminate according to the embodiment. Figure 2 is a cross-sectional view taken along the cutting line II-II in Figure 1.
[0030] As shown in Figures 1 and 2, the glass laminate 1 according to this embodiment comprises laminated glass 10 and a butyl-based sealant 21 provided around the end of the laminated glass 10. The glass laminate 1 according to this embodiment can be suitably used as a building material such as window glass in buildings.
[0031] As shown in Figure 2, the laminated glass 10 comprises a first glass plate 11, a second glass plate 12, and an interlayer 13 placed between the first glass plate 11 and the second glass plate 12. The laminated glass 10 is constructed by stacking the first glass plate 11, the interlayer 13, and the second glass plate 12 in the thickness direction, and the first glass plate 11 and the second glass plate 12 are bonded to each other using the interlayer 13.
[0032] The thickness of the first glass plate 11 and the second glass plate 12 is, for example, 1 mm or more and 12 mm or less. For example, chemically strengthened glass may be used as the first glass plate 11 and the second glass plate 12. When chemically strengthened glass is used, the first glass plate 11 and the second glass plate 12 can be made lighter while maintaining their strength. In this embodiment, air-cooled tempered glass may also be used as the first glass plate 11 and the second glass plate 12.
[0033] The interlayer 13 is positioned so as to be sandwiched between the first glass plate 11 and the second glass plate 12. The thickness of the interlayer 13 is, for example, 0.4 mm or more and 10 mm or less. The interlayer 13 may be made of EVA (ethylene-vinyl acetate copolymer) resin, PVB (polyvinyl butyral) resin, ionomer resin, COP (cycloolefin polymer), polyurethane, PVC (polyvinyl chloride), POE (polyolefin elastomer), TPO (olefin-based thermoplastic elastomer), etc. Alternatively, the interlayer 13 may be made by combining these materials.
[0034] In this embodiment, a photovoltaic cell 18 may be sealed between the first glass plate 11 and the second glass plate 12 of the laminated glass 10. The photovoltaic cell 18 can be made using photovoltaic cells such as silicon-based monocrystalline type, silicon-based polycrystalline type, amorphous silicon type, thin-film silicon type, CIGS type, organic thin-film type, dye-sensitized type, or perovskite type. The photovoltaic cell 18 may be made using multiple power generation cells. For example, a single-sided light-receiving type photovoltaic cell may be used as the photovoltaic cell 18. In this case, the light-receiving surface of the photovoltaic cell 18 is positioned on the outside. For example, if the first glass plate 11 is positioned on the outdoor side and the second glass plate 12 is positioned on the indoor side, the light-receiving surface of the photovoltaic cell 18 is positioned on the first glass plate 11 side. Alternatively, a double-sided light-receiving type photovoltaic cell may be used as the photovoltaic cell 18.
[0035] For example, when forming laminated glass 10, the first glass plate 11, interlayer 13, photovoltaic cell 18, interlayer 13, and second glass plate 12 are stacked in that order, and the laminated body is heated and pressurized to bond them together, thereby forming the laminated glass 10. At this time, the interlayer 13 placed on both sides of the photovoltaic cell 18 is heated and melted, so in the finished laminated glass 10 there is only one layer of interlayer 13, and the photovoltaic cell 18 is sealed inside the interlayer 13.
[0036] Furthermore, if the photovoltaic cell 18 is a perovskite type photovoltaic cell or a thin-film silicon type photovoltaic cell, that is, if the photovoltaic cell 18 is made of a thin film, the photovoltaic cell 18 may be formed directly on at least one surface of the first glass plate 11 and the second glass plate 12. Also, although the example configuration shown in Figure 1 shows a configuration in which the photovoltaic cell 18 is provided on almost the entire surface of the laminated glass 10, the position and area on which the photovoltaic cell 18 is provided can be arbitrarily determined. In addition, in this embodiment, the photovoltaic cell 18 may be omitted.
[0037] As shown in Figure 1, the sealing material 21 is provided around the end of the laminated glass 10 so as to surround it. Specifically, as shown in Figure 2, the sealing material 21 is provided around the end of the laminated glass so as to cover the end face 15 of the laminated glass.
[0038] In this embodiment, the material constituting the sealing material 21 is a material having a melt viscosity of 0.6 kPa·s or more and 7.0 kPa·s or less at 120°C. Furthermore, the sealing material 21 is a material having a JIS A hardness of 50 to 90 at 25°C. In other words, by using a material constituting the sealing material 21 with a melt viscosity of 0.6 kPa·s or more and 7.0 kPa·s or less at 120°C, the shape conformability of the sealing material 21 at high temperatures can be improved. Therefore, the workability when applying the sealing material 21 to the end face 15 of the laminated glass can be improved. Furthermore, the material constituting the sealing material 21 is a material having a JIS A hardness of 50 to 90 at 25°C. Therefore, after applying the sealing material 21 to the end face 15 of the laminated glass 10, the sealing material 21 can be made to have a predetermined rigidity at the operating temperature of the glass laminate 1. Therefore, the intrusion of moisture from the end of the laminated glass into the interior of the laminated glass can be effectively suppressed.
[0039] The thickness of the sealing material 21 at the end face 15 of the laminated glass 10 is preferably 0.4 mm or more and 10 mm or less, more preferably 0.8 mm or more and 8 mm or less, and even more preferably 1 mm or more and 7 mm or less.
[0040] In this embodiment, an adhesive layer (primer layer) may be formed between the end face 15 of the laminated glass 10 and the sealant 21. That is, after applying the adhesive layer to the end face 15 of the laminated glass 10, the molten sealant 21 may be filled into the end face 15 of the laminated glass 10. By providing an adhesive layer (primer layer) in this way, the adhesive strength between the end face 15 of the laminated glass and the sealant 21 can be increased. Here, the adhesive layer (primer layer) is not particularly limited as long as it is a glass / resin adhesive. For example, urethane adhesives, polyester adhesives, epoxy adhesives, α-cyanoacrylate adhesives, acrylic adhesives, etc., containing compounds having hydrolyzable silyl groups can be used.
[0041] The thermoplastic resin composition constituting the sealing material 21 is hydrophobic, while the first glass plate 11 and the second glass plate 12 (hereinafter collectively referred to as glass plates) are hydrophilic. Therefore, it is required that adhesion between the two be ensured, but as long as adhesion between the two can be ensured, various adhesives can be used.
[0042] For example, from the viewpoint of weather resistance and adhesion, a urethane adhesive made from a polyol that does not contain an aromatic ring structure in its main chain, a non-yellowing isocyanate, and a derivative of the non-yellowing isocyanate may be used. The urethane adhesive only needs to contain at least a polyol and an isocyanate, and may also contain a silane coupling agent as needed to ensure adhesion to the glass plate. The polyol may be a polyester polyol or a polyacrylic polyol, in addition to the polyol that does not contain an aromatic ring structure in its main chain as described above, or a urethane resin obtained by reacting a polyol with a non-yellowing isocyanate. The isocyanate may be a non-yellowing isocyanate or a derivative of the non-yellowing isocyanate. Therefore, the urethane adhesive comprises at least one of polyester polyols, polyacrylic polyols, polyols that do not contain an aromatic ring structure in their main chain, and urethane resins obtained by reacting a polyol with a non-yellowing isocyanate, and at least one non-yellowing isocyanate and a derivative of a non-yellowing isocyanate, and may further contain a silane coupling agent or the like as needed. Note that polyol means a polyfunctional alcohol having one or more hydroxyl groups in one molecule.
[0043] In this context, it is preferable that the polyol contained in the urethane adhesive has a glass transition temperature (Tg) higher than 20°C. This ensures initial strength during bonding and allows for stable adhesion without gaps forming when bonding high-temperature butyl rubber and glass plates. Furthermore, it is preferable that the molecular weight of the polyol be within the range of 2,000 to 50,000. This ensures long-term reliability such as heat resistance and weather resistance. In addition, it is preferable that the acid value of the polyol be less than 3 KOH mg / g. This ensures the stability and workability of the adhesive solution. The acid value is the number of mg of potassium hydroxide required to neutralize the free fatty acids present in 1 g of polyol, and indicates the degree of purity of the polyol; a lower value indicates a higher degree of purity.
[0044] Also, a silane coupling agent can be added to the adhesive as needed. As described above, the silane coupling agent is used to enhance the adhesion to glass. Examples of the silane coupling agent include epoxy silanes such as 3-glycidoxypropyltrimethoxysilane and 3-glycidoxypropyltriethoxysilane, and amino silanes such as 3-aminopropyltrimethoxysilane, 3-aminoethoxysilane, and 3-triethoxysilyl-N-(1,3-dimethyl-butylidene)propylamine. Further, additives such as antioxidants, wetting agents, and defoaming agents, and organic solvents may be added to the above adhesive as needed.
[0045] Next, the material constituting the sealing material 21 will be described in detail. In the present embodiment, a butyl-based thermoplastic resin can be used for the sealing material 21. The JIS A hardness of the sealing material 21 at 25°C is preferably 50 to 90, more preferably 60 to 85, and even more preferably 65 to 85.
[0046] At this time, the butyl-based thermoplastic resin may contain a butyl rubber, a crystalline polyolefin, a desiccant, and an inorganic filler. That is, it is preferable to use a resin material containing a butyl rubber so that sufficient low moisture permeability can be obtained as the sealing material 21. Further, it is preferable to add a material that contributes to increasing the hardness, such as a crystalline polyolefin, so that sufficient shape retention characteristics can be obtained as the sealing material 21.
[0047] The ratio of the butyl rubber to the total amount of the butyl rubber and the crystalline polyolefin in the sealing material 21 is preferably 50 to 98% by mass. If it is 50% by mass or more, the elastic modulus at room temperature can be increased. If it is 98% by mass or less, the melt viscosity at high temperatures can be reduced.
[0048] The ratio of the crystalline polyolefin to the total amount of the butyl rubber and the crystalline polyolefin in the sealing material 21 is preferably 2 to 50% by mass, more preferably 5 to 40% by mass, even more preferably 7 to 20% by mass, and most preferably 8 to 15% by mass. If the ratio of the crystalline polyolefin is 2% by mass or more, the hardness of the butyl rubber can be increased. If it is 50% by mass or less, the characteristics of the butyl rubber are likely to be exhibited.
[0049] As the desiccant contained in the thermoplastic resin, zeolite, alumina, silica gel, etc. can be used, and zeolite is preferable because of its high moisture absorption performance in a low humidity region. The moisture absorption amount of the sealing material 21 is preferably 0.1 to 10% by mass, more preferably 1 to 10% by mass, and still more preferably 2 to 8% by mass. Here, the moisture absorption amount of the sealing material 21 is the mass ratio of the moisture absorbed by the sealing material 21 to the weight of the sealing material 21.
[0050] As the inorganic filler contained in the thermoplastic resin, those usually used as inorganic fillers such as calcium carbonate, talc, mica, carbon black, etc. can be used alone or in combination of two or more kinds. At this time, the ratio of the inorganic filler to the total 100 parts by weight of the butyl rubber and the crystalline polyolefin is preferably 200 parts by mass or less.
[0051] In the present embodiment, the butyl rubber contained in the thermoplastic resin preferably contains two kinds of materials, a material on the high molecular weight side constituting the high molecular weight butyl rubber and a material on the low molecular weight side constituting the low molecular weight butyl rubber.
[0052] The ratio of the high molecular weight butyl rubber to the total weight of the sealing material 21 is preferably 15 to 35% by mass, and more preferably 20 to 30% by mass. If it is 15% by mass or more, the elastic modulus at room temperature can be increased. If it is 35% by mass or less, the melt viscosity at high temperature can be reduced. Also, the ratio of the low molecular weight butyl rubber to the total weight of the sealing material 21 is preferably 15 to 35% by weight, more preferably 16 to 30% by weight, and still more preferably 17 to 25% by weight. If it is 15% by weight or more, the melt viscosity at high temperature can be reduced. If it is 35% by weight or less, the elastic modulus at room temperature can be increased.
[0053] The high molecular weight butyl rubber and the low molecular weight butyl rubber have substantially the same chemical structure but different molecular weights. Because the chemical structures are the same, the gas permeability, chemical resistance, etc. are the same, but due to the different molecular weights, the physical properties such as melt viscosity and elastic modulus are different. The high molecular weight butyl rubber is a block-shaped solid and exhibits characteristics as an elastomer. On the other hand, the low molecular weight butyl rubber is a viscous liquid and exhibits characteristics as an adhesive.
[0054] In the sealing material 21 used in this embodiment, the differences in physical properties due to the molecular weight of butyl rubber are utilized to increase fluidity at high temperatures (reduce melt viscosity) while maintaining the elastic modulus at room temperature. The details are explained below.
[0055] To reduce melt viscosity, the molecular weight of the high molecular weight butyl rubber has a significant influence. Therefore, when selecting a high molecular weight butyl rubber, it is preferable to use a material with a lower molecular weight within the range that exhibits the physical properties of high molecular weight butyl rubber (elastomerity, high elasticity). Specifically, it is preferable to use a high molecular weight butyl rubber with a weight-average molecular weight of 200,000 to 650,000, more preferably a material with a weight-average molecular weight of 250,000 to 550,000, and even more preferably a material with a weight-average molecular weight of 300,000 to 500,000.
[0056] When a butyl rubber with a lower molecular weight is selected as the high molecular weight butyl rubber, a decrease in the elastic modulus at room temperature may occur. Therefore, in order to reduce the melt viscosity and maintain the elastic modulus at room temperature, it is preferable to select a material with a higher molecular weight within the range that exhibits the physical properties (high viscosity) of a low molecular weight butyl rubber. Specifically, it is preferable to use a material with a weight-average molecular weight of 30,000 to 150,000 as the low molecular weight butyl rubber, more preferably a material with a weight-average molecular weight of 40,000 to 120,000, and even more preferably a material with a weight-average molecular weight of 50,000 to 100,000.
[0057] For the sealing material 21, the use of two or more types of butyl rubber is preferable to improve the elastic modulus at room temperature and ensure tackiness. It is preferable to use a butyl rubber material as the sealing material 21 with a weight-average molecular weight of 200,000 or more and 250,000 or less. It is more preferable to use a material with a weight-average molecular weight of 202,000 or more and 240,000 or less, and even more preferable to use a material with a weight-average molecular weight of 205,000 or more and 235,000 or less.
[0058] By using such materials, the melt viscosity of the encapsulant 21 at 120°C can be set to 0.6 kPa·s or more and 7.0 kPa or less, and the JIS A hardness at 25°C can be set to 50 to 90. Therefore, the elastic modulus at room temperature can be maintained while reducing the melt viscosity at high temperatures. In other words, if the melt viscosity of the thermoplastic resin used in the encapsulant 21 at 120°C is set within the range of 0.6 kPa·s or more and 7.0 kPa·s or less, molding is possible even at temperatures below 120°C.
[0059] Furthermore, the glass laminate 1 is actually used only after the sealant 21 has cooled and solidified, completing the glass laminate 1, and the temperature at which it is used is generally around 25°C, at room temperature. Therefore, by setting the JIS A hardness of the sealant 21 at 25°C to 50-90, the sealant 21 can be made to have a predetermined rigidity at the operating temperature of the glass laminate 1. Consequently, it is possible to effectively suppress the intrusion of moisture from the edges of the laminated glass into the interior of the laminated glass.
[0060] Furthermore, in this embodiment, it is preferable that the sealing material 21 has an appropriate modulus of elasticity at room temperature. Therefore, the storage modulus of elasticity at 25°C of the thermoplastic resin used as the sealing material 21 is preferably 10 MPa or more and 60 MPa or less, more preferably 12 MPa or more and 55 MPa or less, and even more preferably 15 MPa or more and 45 MPa or less.
[0061] Next, a method for manufacturing a glass laminate according to this embodiment will be described. Figure 3 is a cross-sectional view illustrating the method for manufacturing a glass laminate according to this embodiment.
[0062] When manufacturing the glass laminate 1 according to this embodiment, first, a laminated glass 10 is prepared as shown in the left diagram of Figure 3. The laminated glass 10 described above can be used as the laminated glass 10.
[0063] Next, as shown in the right-hand diagram of Figure 3, a butyl-based sealant 21 is provided around the end of the laminated glass 10. The sealant 21 can be made of a material having a melt viscosity of 0.6 kPa·s or more and 7.0 kPa·s or less at 120°C, and a JIS A hardness of 50 to 90 at 25°C. The sealant 21 described above can be used.
[0064] In this embodiment, the molten sealant 21 is filled around the end side (i.e., the end face 15) of the laminated glass 10, and the filled sealant 21 is cooled to provide the sealant 21 to the end face 15 of the laminated glass 10. Alternatively, in this embodiment, after filling the end face 15 of the laminated glass 10 with the molten sealant 21, the filled sealant 21 may be compressed by pressurizing it. By compressing the filled sealant 21 in this way, the sealing performance of the sealant 21 is further improved.
[0065] In this embodiment, an adhesive layer (primer layer) may be applied to the end face 15 of the laminated glass 10, and then the molten sealant 21 may be filled into the end face 15 of the laminated glass 10. By providing an adhesive layer (primer layer) in this way, the adhesive strength between the end face 15 of the laminated glass and the sealant 21 can be increased. The materials described above can be used for the adhesive layer (primer layer).
[0066] By using the manufacturing method described above, the glass laminate according to this embodiment can be manufactured.
[0067] Next, other configuration examples of the glass laminate according to this embodiment will be described. Figure 4 is a front view showing another configuration example of the glass laminate according to this embodiment. Figure 5 is a cross-sectional view taken along the cutting line V-V in Figure 4.
[0068] In this embodiment, the cross-sectional shape of the sealing material 22 may be substantially U-shaped (see Figure 5), as shown in the glass laminate 2 in Figures 4 and 5. That is, the sealing material 22 may be provided around the end side of the laminated glass 10 so as to cover the end face 15 of the laminated glass 10, and also so as to cover the periphery of the end side of the main surface 31 of the first glass plate 11 and the periphery of the end side of the main surface 32 of the second glass plate 12.
[0069] Figure 6 is a cross-sectional view illustrating the manufacturing method of the glass laminate 2 shown in Figures 4 and 5. As shown in Figure 6, when manufacturing the glass laminate 2 shown in Figures 4 and 5, first, laminated glass 10 is prepared as shown in the left diagram of Figure 6. The laminated glass described above can be used for the laminated glass 10.
[0070] Next, as shown in the center view of Figure 6, a butyl-based sealant 22 is applied around the end of the laminated glass 10. Specifically, the molten sealant 22 is filled around the end of the laminated glass 10 (i.e., the end face 15). Then, a mold 40 is placed around the end of the laminated glass 10, and the sealant 22 is pressed using the mold 40 to mold it so that the sealant 22 covers the end of the main surface 31 of the first glass plate 11 and the end of the main surface 32 of the second glass plate 12. After that, the mold 40 is removed from the end of the laminated glass 10, and a glass laminate 2 as shown in the right view of Figure 6 can be manufactured.
[0071] In the glass laminate 2 shown in Figures 4 to 6, the sealing material 22 is made of a material having a melt viscosity of 0.6 kPa·s to 7.0 kPa·s at 120°C and a JIS A hardness of 50 to 90 at 25°C. Therefore, the sealing material 22 can achieve shape conformability at high temperatures and sealing performance at the operating temperature, effectively suppressing the intrusion of moisture from the edges of the laminated glass into the interior of the laminated glass.
[0072] In particular, in the glass laminate 2 shown in Figures 4 and 5, a sealing material 22 is provided so as to cover the end side of the main surface 31 of the first glass plate 11 and the end side of the main surface 32 of the second glass plate 12, which can more effectively suppress moisture from entering the interior of the laminated glass 10 from the edges of the laminated glass 10.
[0073] Next, other configuration examples of the glass laminate according to this embodiment will be described. Figure 7 is a front view showing another configuration example of the glass laminate according to this embodiment. Figure 8 is a cross-sectional view taken along the cutting line VIII-VIII in Figure 7.
[0074] In this embodiment, as shown in Figures 7 and 8, a sealing material 23 may be provided between the first glass plate 11 and the second glass plate 12. In other words, the sealing material 23 may be provided so as to surround the interlayer 13 around the end of the laminated glass 10.
[0075] Figure 9 is a cross-sectional view illustrating the manufacturing method of the glass laminate 3 shown in Figures 7 and 8. As shown in Figure 9, when manufacturing the glass laminate 3 shown in Figures 7 and 8, first, as shown in step S1 of Figure 9, the first glass plate 11 is prepared.
[0076] Next, as shown in step S2, the interlayer 13 is placed on the first glass plate 11. At this time, the photovoltaic cells 18 may be placed between the interlayers 13. Furthermore, the sealing material 23 is placed on the first glass plate 11. The sealing material 23 is provided so as to surround the interlayer 13 around the edge of the first glass plate 11. When placing the sealing material 23, it may be placed in a molten state or in a solid state (at room temperature).
[0077] Next, as shown in step S3, the second glass plate 12 is placed on the interlayer 13 and the sealant 23. Then, the laminate containing the first glass plate 11, the interlayer 13, the photovoltaic cell 18, the sealant 23, and the second glass plate 12 is heated and pressurized to form laminated glass 10 (glass laminate 3) (step S4). At this time, as the laminate is heated and pressurized, the interlayer 13 melts and the first glass plate 11 and the second glass plate 12 are bonded together by the interlayer 13. Also, the sealant 23 melts and seals the edges of the laminated glass 10 with the sealant 23.
[0078] In the glass laminate 3 shown in Figures 7 to 9, the sealing material 23 is made of a material having a melt viscosity of 0.6 kPa·s to 7.0 kPa·s at 120°C and a JIS A hardness of 50 to 90 at 25°C. Therefore, the sealing material can achieve shape conformability at high temperatures and sealing performance at the operating temperature, effectively suppressing the intrusion of moisture from the edges of the laminated glass into the interior of the laminated glass.
[0079] In this embodiment, the glass laminate 3 shown in Figures 7 and 8 may be combined with the glass laminate shown in Figures 1 and 2. That is, a sealing material 23 may be provided between the first glass plate 11 and the second glass plate 12, and a sealing material 21 may be provided to cover the end face 15 of the laminated glass.
[0080] Furthermore, in this embodiment, the glass laminate 3 shown in Figures 7 and 8 may be combined with the glass laminates shown in Figures 4 and 5. That is, a sealing material 23 may be provided between the first glass plate 11 and the second glass plate 12, and a sealing material 22 may be provided so as to cover the end face 15 of the laminated glass 10 and so as to cover the periphery of the end side of the main surface 31 of the first glass plate 11 and the periphery of the end side of the main surface 32 of the second glass plate 12.
[0081] Next, other configuration examples of the glass laminate according to this embodiment will be further described. Figures 10 to 14 are cross-sectional views showing other configuration examples of the glass laminate according to this embodiment. In the configuration examples shown in Figures 10 to 14, when the glass laminates 4 to 8 are viewed from above, the first glass plate 11 is smaller in the in-plane direction than the second glass plate 12. In other words, the length of each side of the first glass plate 11 is shorter than the length of each side of the second glass plate that corresponds to each side of the first glass plate 11. In this configuration, a sealing material may be provided as follows in this embodiment.
[0082] For example, as shown in the glass laminate 4 in Figure 10, the sealing material 24 may be provided so as to cover the periphery of the end side of the main surface 31 of the first glass plate 11 opposite to the interlayer 13, the end face 16 of the first glass plate 11, and the periphery 19 of the interlayer 13.
[0083] Furthermore, as shown in Figure 11, the sealing material 25 may be provided so as to cover the periphery of the end side of the main surface 31 of the first glass plate 11 opposite to the interlayer 13, the end surface 16 of the first glass plate 11, the periphery 19 of the interlayer 13, and the periphery of the end side of the main surface 33 of the second glass plate 12 on the interlayer 13 side.
[0084] Furthermore, as shown in Figure 12, the sealing material 26 may be provided so as to cover the periphery of the end side of the main surface 31 of the first glass plate 11 opposite to the interlayer 13, the end face 16 of the first glass plate 11, the periphery 19 of the interlayer 13, the periphery of the end side of the main surface 33 of the second glass plate 12 on the interlayer 13 side, and the end face 17 of the second glass plate 12.
[0085] Furthermore, as shown in Figure 13, the sealing material 27 may be provided so as to cover the periphery of the end side of the main surface 31 of the first glass plate 11 opposite to the interlayer 13, the end face 16 of the first glass plate 11, the periphery 19 of the interlayer 13, the periphery of the end side of the main surface 33 of the second glass plate 12 on the interlayer 13 side, the end face 17 of the second glass plate 12, and the periphery of the end side of the main surface 32 of the second glass plate 12 opposite to the interlayer 13.
[0086] Furthermore, as shown in Figure 14, the sealing material 28 may be provided so as to cover the end face 16 of the first glass plate 11 and the periphery 19 of the interlayer 13.
[0087] In the glass laminates 4 to 8 shown in Figures 10 to 14, the sealing materials 24 to 28 are made of materials having a melt viscosity of 0.6 kPa·s to 7.0 kPa·s at 120°C and a JIS A hardness of 50 to 90 at 25°C. Therefore, the sealing material can be made to conform to the shape at high temperatures and to maintain sealing performance at the operating temperature, effectively suppressing the intrusion of moisture from the edges of the laminated glass into the interior of the laminated glass.
[0088] Furthermore, in the glass laminates 4 to 8 shown in Figures 10 to 14, the first glass plate 11 is configured to be smaller in the in-plane direction than the second glass plate 12. With this configuration, the adhesive surfaces of the sealing materials 24 to 28 can be visually confirmed from the main surface 32 side of the second glass plate 12, so the adhesion state of the sealing materials 24 to 28 can be accurately confirmed.
[0089] When manufacturing the glass laminates 4 to 8 shown in Figures 10 to 14, the same method as the manufacturing method for the glass laminate shown in Figure 6 can be used. That is, butyl-based sealants 24 to 28 are placed around the end side of the laminated glass 10. Then, a mold is placed around the end side of the laminated glass 10, and the sealants 24 to 28 are pressed and molded using the mold. After that, the glass laminates 4 to 8 shown in Figures 10 to 14 can be manufactured by removing the mold from the end side of the laminated glass 10. The mold used should have a shape corresponding to the sealants 24 to 28 of the glass laminates 4 to 8 shown in Figures 10 to 14.
[0090] In this embodiment, the butyl-based sealant 24 to 28 may also be applied to the main surface 31 side of the first glass plate 11, thereby providing the sealant 24 to 28 around the end side of the laminated glass 10.
[0091] Next, we will describe some examples.
[0092] <Sealing Material> First, compositions 1 to 3 were prepared as materials to constitute the sealing material. Of the materials to constitute the sealing material, two types of high molecular weight butyl rubber were prepared: regular butyl rubber (IIR-1) with a weight-average molecular weight of 360,000 and regular butyl rubber (IIR-2) with a weight-average molecular weight of 430,000. In addition, two types of low molecular weight butyl rubber were prepared: polyisobutylene (PIB-B) with a weight-average molecular weight of 97,000 and polyisobutylene (PIB-C) with a weight-average molecular weight of 70,000.
[0093] In addition, as a crystalline polyolefin, low-density polyethylene (LDPE) with a melt flow rate (MFR) of 14 g / 10 min (according to JIS K6922-2) and a melting point of 106°C was prepared.
[0094] As a tackifier, a hydrogenated DCPD (dicyclopentadiene) type hydrocarbon resin with a softening point of 125°C was prepared. As inorganic fillers, talc with an average particle size of 4 μm and HAF (High Abrasion Furnace) type carbon black were prepared. Zeolite powder 4A and zeolite powder 3A were prepared as drying agents. A phenolic type antioxidant was prepared as an additive. Compositions 1 to 3 were prepared by kneading each material in the proportions shown in Table 1 and dispersing them uniformly.
[0095]
[0096] Furthermore, the hardness (25°C), storage modulus (25°C), melt viscosity (120°C), moisture absorption, and weight-average molecular weight of compositions 1 to 3 prepared as described above were measured using the following method.
[0097] The hardness of compositions 1 to 3 at 25°C was measured using a Type A hardness tester in accordance with JIS A hardness (JIS K7215-1986). For the storage modulus (E') at 25°C, a dynamic viscoelasticity measuring device DVA-200 manufactured by IT Measurement Co., Ltd. was used. The temperature was raised at 5°C / min in constant-speed heating mode, and measurements were taken with a sample measuring 20 mm in length, 5 mm in width, and 0.6 mm in thickness, with a strain of 0.1%, a static / dynamic ratio of 2, and a frequency of 1 Hz, to determine the storage modulus (E') at 25°C.
[0098] The melt viscosity at 120°C was measured using a Capillograph 1C manufactured by Toyo Seiki Seisakusho Co., Ltd. A capillary with a length of 10 mm and a diameter of 2 mm was used. A furnace with a body diameter of 9.55 mm was used. The melt viscosity at 150°C and a shear rate of 100 / s was used as the baseline.
[0099] To determine the amount of moisture absorbed, the sealing material was molded to a thickness of approximately 1 mm, placed in a constant temperature and humidity chamber at 60°C and 90% humidity, and stored until the weight increase ceased. The amount of moisture absorbed was determined from the difference between the initial weight and the weight after complete moisture absorption.
[0100] Weight-average molecular weight was measured using a size exclusion chromatography system manufactured by Tosoh Corporation (main unit: HLC-8220GPC, RI detector guard column: TSKgen Guardcolumn SuperHZ-L, columns: TSKgen SuperHZ2000, TSKgel SuperHZ2500, TSKgel SuperHZ4000), with THF solvent and polystyrene standard samples as references.
[0101] Table 2 shows the measurement results for hardness (25°C), storage modulus E' (25°C), melt viscosity η (120°C), moisture absorption, and weight-average molecular weight of compositions 1 to 3. As shown in Table 2, the measurement results for compositions 1 and 2 fell within the range of the present invention. On the other hand, the measurement results for composition 3 fell outside the range of the present invention.
[0102]
[0103] <Glass Laminate> Next, a glass laminate was fabricated using the following method. Two 150mm x 150mm float glass sheets (3mm thick), a 100mm x 100mm perovskite solar cell film cell (manufactured by Saule), and an interlayer (manufactured by Tosoh Nicchem Co., Ltd.: EVA G7055) were prepared. The float glass, interlayer, perovskite solar cell film cell, interlayer, and float glass were then stacked in that order, and the laminate was heated and pressurized to form a laminated glass. The heating and pressing conditions were a temperature of 120°C and a pressure of 10kPa.
[0104] Then, a primer was applied to the periphery (outer circumference) of the end side of the laminated glass, and the periphery of the end side of the laminated glass was sealed with a sealant. The primer used was a polyurethane adhesive consisting of an acrylic polyol, a hexamethylene diisocyanate-based polyisocyanate, and a silane coupling agent. The sealant used was either the sealant according to composition example 1 or the sealant according to composition example 2. The sealing structure was one of the structures shown in Figures 2, 5, or 8. Table 3 shows the composition of the samples according to Examples 1 to 6. Examples 1 to 5 are examples, and Example 6 is a comparative example.
[0105] (Example 1) In the sample for Example 1, the sealing material according to Composition Example 1 was used as the sealing material. The sealing structure was as shown in Figure 2. The sealing depth was 4 mm. Here, the sealing depth corresponds to the thickness of the sealing material at the end face of the laminated glass.
[0106] (Example 2) In the sample for Example 2, the sealing material for composition example 1 was used as the sealing material. The sealing structure was as shown in Figure 5. The sealing depth was 4 mm. Here, the sealing depth corresponds to the thickness of the sealing material at the end face of the laminated glass.
[0107] (Example 3) In the sample according to Example 3, the sealing material according to Composition Example 1 was used as the sealing material. The sealing structure was as shown in Figure 8. The sealing depth was 4 mm. In the sample according to Example 3, the sealing depth refers to the depth to which the sealing material 23 shown in Figure 8 is sealed inside the laminated glass.
[0108] (Example 4) In the sample for Example 4, the sealing material for composition example 2 was used. The sealing structure was as shown in Figure 2. The sealing depth was 4 mm.
[0109] (Example 5) In the sample for Example 5, the sealing material for composition example 2 was used. The sealing structure was as shown in Figure 2. The sealing depth was 6 mm.
[0110] (Example 6) As a sample for Example 6, a sample was prepared in which no sealing material was applied around the edges of the laminated glass.
[0111] <Sample Evaluation> Samples from Examples 1 to 6 were subjected to a durability test by being left in an environment of 85°C and 85% humidity for 1000 hours. After the durability test, the power generation performance, appearance changes, and interlayer moisture content of each sample were examined. For power generation performance, the FF value of each sample was determined by calculating the curve factor from the current-voltage characteristics of the solar cell using a solar simulator. A sample was considered acceptable if the calculated FF value was 50% or more of the initial FF value. For appearance changes, each sample was visually inspected, and it was considered acceptable if there was no clouding, peeling, or deformation. For interlayer moisture content, each sample was disassembled after the durability test, and the moisture content of the interlayer at a position 20 mm from the edge of the photovoltaic cell was measured. A sample was considered acceptable if the moisture content was 0.5 wt% or less. Moisture content was measured using a Karl Fischer moisture meter (main unit CA-200, vaporization unit VA-200, manufactured by Mitsubishi Chemical Analytic Corporation). The evaluation results for each sample are shown in Table 3.
[0112]
[0113] As shown in Table 3, in the samples from Examples 1 to 5, the power generation performance, appearance changes, and interlayer moisture content were good in each sample after the durability test. In contrast, in the sample from Example 6, the power generation performance decreased after the durability test, the interlayer became cloudy, and the interlayer moisture content became 2%. In other words, in the sample from Example 6, since no sealing material was provided around the edges of the laminated glass, it is thought that moisture penetrated into the interior of the laminated glass from the edges, resulting in the interlayer moisture content becoming 2%. As a result, the interlayer became cloudy, and the perovskite solar cell film cell deteriorated due to moisture, leading to a decrease in power generation performance.
[0114] Based on these results, it can be said that by providing a sealing material around the edges of the laminated glass, as in the samples in Examples 1 to 5, it was possible to effectively suppress the intrusion of moisture into the interior of the laminated glass from the edges.
[0115] Although the present invention has been described above in accordance with the above embodiments, the present invention is not limited to the configuration of the above embodiments, and of course includes various modifications, alterations, and combinations that can be made by a person skilled in the art within the scope of the claims of the present patent application.
[0116] This application claims priority based on Japanese Patent Application No. 2024-223835, filed on 19 December 2024, and incorporates all of its disclosures herein.
[0117] 1, 2, 3, 4, 5, 6, 7, 8 Glass laminate 10 Laminated glass 11 First glass plate 12 Second glass plate 13 Interlayer 15, 16, 17 End face 18 Photovoltaic cell 19 Surroundings 21, 22, 23, 24, 25, 26, 27, 28 Sealing material 31, 32, 33 Main surface 40 Formwork
Claims
1. A glass laminate comprising: a first glass plate; a second glass plate disposed opposite to the first glass plate; an interlayer disposed between the first glass plate and the second glass plate; and a butyl-based sealant provided around the end of the laminated glass, wherein the melt viscosity of the sealant at 120°C is 0.6 kPa·s or more and 7.0 kPa·s or less; and the JIS A hardness of the sealant at 25°C is 50 to 90.
2. The glass laminate according to claim 1, wherein the storage modulus of the sealing material at 25°C is 10 MPa or more and 60 MPa or less.
3. The glass laminate according to claim 1 or 2, wherein the sealing material further contains a desiccant, and the moisture absorption amount of the sealing material is 0.1% by mass or more and 10% by mass or less.
4. The glass laminate according to claim 1 or 2, wherein the thickness of the sealing material at the end face of the laminated glass is 0.4 mm or more and 10 mm or less.
5. The glass laminate according to claim 1 or 2, wherein an adhesive layer is formed between the end face of the laminated glass and the sealing material.
6. The glass laminate according to claim 1 or 2, wherein a photovoltaic cell is sealed between the first glass plate and the second glass plate of the laminated glass.
7. The glass laminate according to claim 1 or 2, wherein the sealing material is provided around the end side of the laminated glass so as to cover the end surface of the laminated glass.
8. The glass laminate according to claim 1 or 2, wherein the sealing material has a substantially U-shaped cross-section and is provided around the end side of the laminated glass so as to cover the end surface of the laminated glass and so as to cover the periphery of the end side of the main surface of the first glass plate and the periphery of the end side of the main surface of the second glass plate.
9. The glass laminate according to claim 1 or 2, wherein the sealing material is provided between the first glass plate and the second glass plate.
10. The glass laminate according to claim 1 or 2, wherein, when the glass laminate is viewed from above, the first glass plate is configured to be smaller in the in-plane direction than the second glass plate, and the sealing material is provided to cover the periphery of the end side of the main surface of the first glass plate opposite to the interlayer, the end face of the first glass plate, and the periphery of the interlayer.
11. The glass laminate according to claim 1 or 2, wherein, when the glass laminate is viewed from above, the first glass plate is configured to be smaller in the in-plane direction than the second glass plate, and the sealing material is provided to cover the periphery of the end side of the main surface of the first glass plate opposite to the interlayer, the end surface of the first glass plate, the periphery of the interlayer, and the periphery of the end side of the main surface of the second glass plate on the interlayer side.
12. The glass laminate according to claim 1 or 2, wherein, when the glass laminate is viewed in plan, the first glass plate is configured to be smaller in the in-plane direction than the second glass plate, and the sealing material is provided so as to cover the periphery of the end side of the main surface of the first glass plate opposite to the interlayer, the end face of the first glass plate, the periphery of the interlayer, the periphery of the end side of the main surface of the second glass plate on the interlayer side, and the end face of the second glass plate.
13. The glass laminate according to claim 1 or 2, wherein, when the glass laminate is viewed from above, the first glass plate is configured to be smaller in the in-plane direction than the second glass plate, and the sealing material is provided to cover the periphery of the end side of the main surface of the first glass plate opposite to the interlayer, the end face of the first glass plate, the periphery of the interlayer, the periphery of the end side of the main surface of the second glass plate on the interlayer side, the end face of the second glass plate, and the periphery of the end side of the main surface of the second glass plate opposite to the interlayer.
14. The glass laminate according to claim 1 or 2, wherein, when the glass laminate is viewed from above, the first glass plate is configured to be smaller in the in-plane direction than the second glass plate, and the sealing material is provided to cover the end face of the first glass plate and the periphery of the interlayer.
15. The glass laminate according to claim 1 or 2, wherein the weight-average molecular weight of the sealing material is 200,000 or more and 250,000 or less.
16. A method for manufacturing a glass laminate, comprising the steps of: preparing a laminated glass having a first glass plate, a second glass plate arranged opposite to the first glass plate, and an interlayer disposed between the first glass plate and the second glass plate; and providing a butyl-based sealant around the end of the laminated glass, wherein the melt viscosity of the sealant at 120°C is 0.6 kPa·s or more and 7.0 kPa·s or less, and the JIS A hardness of the sealant at 25°C is 50 to 90.
17. The method for manufacturing a glass laminate according to claim 16, wherein the step of providing the sealing material comprises the steps of filling the molten sealing material around the end side of the laminated glass and cooling the filled sealing material.
18. A method for manufacturing a glass laminate according to claim 17, wherein an adhesive layer is applied around the end of the laminated glass, and then the molten sealing material is filled around the end of the laminated glass.