Multilayer terionomer encapsulant layers and solar cell laminates comprising the same

1. A solar cell pre-lamination assembly comprising a bi-layer film or sheet and a solar cell component formed of one or a plurality of electronically interconnected solar cells, wherein,

the solar cell component has a light-receiving side that faces a light source and a back side that is opposite from the light source;

the bi-layer film or sheet consists of a first surface sub-layer and a second surface sub-layer;

the first surface sub-layer consists essentially of a terionomer;

the second surface sub-layer consists essentially of a high melting point polymer comprising an ionomer;

the terionomer is an acid terpolymer that is about 5% to about 90% neutralized with one or more metal ions, based on the total carboxylic acid content of the acid terpolymer, and comprises repeat units derived from an α-olefin, about 5 to about 15 wt % of an α,β-ethylenically unsaturated carboxylic acid having 3 to 8 carbons, and about 15 to about 40 wt % of an α,β-ethylenically unsaturated carboxylic acid ester having 4 to 12 carbons, based on the total weight of the acid terpolymer; and

the high melting point polymer has a melting point of at least about 80° C.

2. The assembly of claim 1 , wherein the acid terpolymer is about 10% to about 50% neutralized with a metal ion selected from the group consisting of sodium, lithium, magnesium, zinc, and mixtures of two of more thereof, based on the total carboxylic acid content of the acid terpolymer, and comprises about 7 to 11 wt % of repeat units of the α,β-ethylenically unsaturated carboxylic acid and about 20 to about 30 wt % of repeat units of the α,β-ethylenically unsaturated carboxylic acid ester, based on the total weight of the acid terpolymer; and wherein the high melting point polymer is an ionomer having a melting point of at least 90° C.

3. The assembly of claim 1 , wherein the terionomer is poly(ethylene-co-butyl acrylate-co-methacrylic acid) that is about 20% to about 40% neutralized with zinc, based on its total carboxylic acid content.

4. The assembly of claim 1 , wherein the terionomer is a poly(ethylene-co-butyl acrylate-co-methacrylic acid) that is about 20% to about 40% neutralized with zinc, based on its total carboxylic acid content.

5. The assembly of claim 1 , wherein the solar cell is selected from the group consisting of multi-crystalline solar cells, thin film solar cells, compound semiconductor solar cells, amorphous silicon solar cells, and combinations of two or more.

6. The assembly of claim 1 , which comprises a front encapsulant layer positioned next to the light-receiving side of the solar cell component and a back encapsulant layer positioned next to the back side of the solar cell component, wherein the front encapsulant layer is formed of the bi-layer film or sheet and the back encapsulant layer is formed of a polymeric material selected from the group consisting of acid copolymers, ionomers, ethylene vinyl acetates, poly(vinyl acetals) (including acoustic grade poly(vinyl acetals), polyurethanes, polyvinylchlorides, polyethylenes, polyolefin block elastomers, poly(α-olefin-co-α,β-ethylenically unsaturated carboxylic acid ester) copolymers, silicone elastomers, epoxy resins, and combinations thereof.

7. A solar cell pre-lamination assembly comprising (a) a solar cell component formed of one or a plurality of electronically interconnected solar cells and having a light-receiving side that faces a light source and a back side that is opposite from the light source; (b) a front encapsulant layer positioned next to the light-receiving side of the solar cell component; and (c) a back encapsulant layer positioned next to the back side of the solar cell component, (i) wherein each of the front encapsulant layer and back encapsulant layer is formed of a bi-layer film or sheet consisting of a first surface sub-layer consisting essentially of a terionomer and a second surface sub-layer consisting essentially of a high melting point polymer comprising an ionomer having a melting point of at least about 80° C.; and (ii) wherein the terionomer is an acid terpolymer that is about 5% to about 90% neutralized with one or more metal ions, based on the total carboxylic acid content of the acid terpolymer, and comprises repeat units derived from an α-olefin, about 5 to about 15 wt% of an α,β-ethylenically unsaturated carboxylic acid having 3 to 8 carbons, and about 15 to about 40 wt% of an α,β-ethylenically unsaturated carboxylic acid ester having 4 to 12 carbons, based on the total weight of the acid terpolymer.

8. The assembly of claim 6 , further comprising an incident layer positioned next to the front encapsulant layer and a backing layer positioned to the back encapsulant layer.

9. The assembly of claim 8 , wherein the incident layer is selected from the group consisting of (i) glass sheets, (ii) polymeric sheets formed of polycarbonates, acrylics, polyacrylates, cyclic polyolefins, polystyrenes, polyamides, polyesters, fluoropolymers, or combinations of two or more thereof, and (iii) polymeric films formed of polyesters, polycarbonate, polyolefins, norbornene polymers, polystyrene, styrene-acrylate copolymers, acrylonitrile-styrene copolymers, polysulfones, nylons, polyurethanes, acrylics, cellulose acetates, cellophane, poly(vinyl chlorides), fluoropolymers, or combinations of two or more thereof.

10. The assembly of claim 8 , wherein the backing layer is selected from (i) glass sheets, (ii) polymeric sheets, (iii) polymeric films, (iv) metal sheets, and (v) ceramic plates, and wherein the polymeric sheets comprise or are formed of polycarbonates, acrylics, polyacrylates, cyclic polyolefins, polystyrenes, polyamides, polyesters, fluoropolymers, or combinations or two or more thereof; and the polymeric films comprise or are formed of polyesters, polycarbonates, polyolefins, norbornene polymers, polystyrenes, styrene-acrylate copolymers, acrylonitrile-styrene copolymers, polysulfones, nylons, polyurethanes, acrylics, cellulose acetates, cellophanes, poly(vinyl chlorides), fluoropolymers, or combinations of two or more thereof.

11. The assembly of claim 1 , consisting essentially of, from a top side that faces the light source to a bottom side that is opposite from the light source, (i) an incident layer that is positioned next to, (ii) a front encapsulant layer that is positioned next to, (iii) the solar cell component that is positioned next to, (iv) a back encapsulant layer that is positioned next to, (v) a backing layer, wherein the front encapsulant layer or the back encapsulant layers, or both, is formed of the bi-layer film or sheet.

12. A process comprising: (i) providing a solar cell pre-lamination assembly and (ii) laminating the assembly to form a solar cell module, wherein the assembly is as recited in claim 1 .

13. The process of claim 12 , wherein the laminating step is conducted by subjecting the assembly to heat.

14. The process of claim 13 , wherein the laminating step further comprises subjecting the assembly to vacuum or pressure.

15. A solar cell module produced from a solar cell pre-lamination assembly as claimed in claim 1 .

16. The solar cell module of claim 15 , wherein at least about 75% of the 180° peel strength between the bi-layer film or sheet and its adjacent layer(s) is maintained after the module has been conditioned for 1000 hours at a temperature of about 85° C. and a relative humidity of about 85%.

17. The solar cell pre-lamination assembly of claim 1 wherein the high melting point polymer is a polymer selected from the group consisting of acid copolymers, ionomers, poly(ethylene-co-vinyl acetates), thermoplastic polyurethanes, poly(vinyl chlorides), polyethylenes, poly(α-olefin-co-α,β-ethylenically unsaturated carboxylic acid ester) copolymers, polyesters, and epoxy resins.

18. The solar cell pre-lamination assembly of claim 1 , wherein the high melting point polymer is an acid copolymer.

19. The solar cell pre-lamination assembly of claim 1 , wherein the high melting point polymer is an ionomer of an acid copolymer that comprises copolymerized units of an α-olefin and an α,β-ethylenically unsaturated carboxylic acid and is neutralized to a level of about 1% to about 90%, based on the total carboxylic acid content of the acid copolymer.

20. The solar cell pre-lamination assembly of claim 1 , wherein the high melting point polymer is an ionomer of an acid copolymer that comprises copolymerized units of an α-olefin and an α,β-ethylenically unsaturated carboxylic acid and is neutralized with metallic ion selected from the group consisting of sodium, zinc, magnesium, and lithium to a level of about 10% to about 40%, based on the total carboxylic acid content of the acid copolymer.

21. The solar cell pre-lamination assembly of claim 1 , wherein the α-olefin is ethylene, the α,β-ethylenically unsaturated carboxylic acid is selected from the group consisting of acrylic acids, methacrylic acids, itaconic acids, maleic acids, maleic anhydrides, fumaric acids, monomethyl maleic acids, and mixtures of two or more thereof, and the α,β-ethylenically unsaturated carboxylic acid ester is selected from the group consisting of methyl acrylates, methyl methacrylates, ethyl acrylates, ethyl methacrylates, isopropyl acrylates, isopropyl methacrylates, butyl acrylates, butyl methacrylates, and mixtures of two or more thereof.

22. The solar cell pre-lamination assembly of claim 1 , wherein the α-olefin is ethylene, the α,β-ethylenically unsaturated carboxylic acid is selected from the group consisting of acrylic acids, methacrylic acids, and mixtures of two or more thereof, and the α,β-ethylenically unsaturated carboxylic acid ester is selected from the group consisting of methyl acrylates and butyl acrylates.

23. The solar cell pre-lamination assembly of claim 2 , wherein the α-olefin is ethylene, the α,β-ethylenically unsaturated carboxylic acid is selected from the group consisting of acrylic acids, methacrylic acids, itaconic acids, maleic acids, maleic anhydrides, fumaric acids, monomethyl maleic acids, and mixtures of two or more thereof, and the α,β-ethylenically unsaturated carboxylic acid ester is selected from the group consisting of methyl acrylates, methyl methacrylates, ethyl acrylates, ethyl methacrylates, isopropyl acrylates, isopropyl methacrylates, butyl acrylates, butyl methacrylates, and mixtures of two or more thereof.

24. The solar cell pre-lamination assembly of claim 2 , wherein the α-olefin is ethylene, the α,β-ethylenically unsaturated carboxylic acid is selected from the group consisting of acrylic acids, methacrylic acids, and mixtures of two or more thereof, and the α,β-ethylenically unsaturated carboxylic acid ester is selected from the group consisting of methyl acrylates and butyl acrylates.