Edge sealants having balanced properties
View Patent ↗A sealant composition for use in two-pane or multi-pane insulating glass or solar modules, the sealant composition including: a) an olefinic polymer having a number average molecular weight from about 100 D to about 700,000 D, preferably from about 100 D to about 300,000 D; b) a modified olefinic polymer; c) a fine-particle inert filler; d) at least one of a desiccant and a water scavenger, and e) an aging resistor. The sealant composition has a tensile strength greater than 20 PSI, preferably greater than 50 PSI, a lap shear strength greater than 20 PSI, preferable greater than 40 PSI, and the tensile and lap shear strengths balanced such that the sealant fails cohesively before failing adhesively.
1. A sealant composition comprising:
a) an olefinic polymer;
b) a silane modified olefinic polymer;
c) a carbon black having a primary particle size in the range of 50 nm to 60 nm that results in the sealant composition having a volume resistivity of >10 10 Ohm·cm, wherein the carbon black is oxidatively post-treated by a furnace process and included in an amount of up to 20% by weight of the total sealant composition;
d) at least one of a desiccant and a water scavenger; and
e) an aging resistor; and
wherein a tensile strength and a lap shear strength of the sealant composition is balanced such that the sealant fails cohesively before failing adhesively.
2. The sealant composition of claim 1 wherein the sealant composition has a tensile strength greater than 20 PSI and a lap shear strength greater than 20 PSI.
3. The sealant composition of claim 1 wherein the sealant composition has a tensile strength greater than 50 PSI and a lap shear strength greater than 40 PSI.
4. The sealant composition of claim 1 wherein the sealant composition chemically reacts with a polar surface containing at least one of alkoxy groups and hydroxyl (—OH) groups, wherein the hydroxyl groups are present on the surface of glass or poly(vinyl alcohol) (PVA).
5. The sealant composition of claim 1 wherein the sealant composition has an endothermic enthalpy for a peak of approximately 100-140° C. of less than 50 J/g after four (4) weeks of aging under 85% relative humidity and 85° C.
6. The sealant composition of claim 1 wherein the sealant composition has an endothermic enthalpy for a peak of approximately 100-140° C. of less than 30 J/g, after four (4) weeks of aging under 85% relative humidity and 85° C.
7. The sealant composition of claim 1 wherein the sealant composition has a moisture vapor transmission rate (MVTR) less than 0.7 g/m 2 /day at 38° C. and 100% relative humidity for a 0.060 to 0.080 inch thick sample of the sealant composition.
8. The sealant composition of claim 1 wherein the sealant composition has a moisture vapor transmission rate (MVTR) less than 0.4 g/m 2 /day at 38° C. and 100% relative humidity for a 0.060 to 0.080 inch thick sample of the sealant composition.
9. The sealant composition of claim 1 wherein the sealant composition has a moisture vapor transmission rate (MVTR) less than 15 g/m 2 /day at 85° C. and 100% relative humidity for a 0.060 to 0.080 inch thick sample of the sealant composition.
10. The sealant composition of claim 1 wherein the sealant composition has a moisture vapor transmission rate (MVTR) less than 8 g/m 2 /day at 85° C. and 100% relative humidity for a 0.060 to 0.080 inch thick sample of the sealant composition.
11. The sealant composition of claim 1 wherein the sealant composition has a melt volume index (MVI) less than 50 cm 3 /10 minutes at 130° C. and 10 kg load through a 0.0823 inch diameter orifice.
12. The sealant composition of claim 1 wherein the sealant composition exhibits a first viscosity when a first shear force is applied to the sealant composition and a second viscosity when a second shear force is applied to the sealant composition.
13. The sealant composition of claim 12 wherein the first viscosity of the sealant composition is greater than the second viscosity and the first shear force is less than the second shear force.
14. The sealant composition of claim 1 wherein the olefinic polymers are present in the sealant composition in an amount from about 20% to about 60% by weight of the total sealant composition.
15. The sealant composition of claim 1 wherein the olefinic polymers are present in the sealant composition in an amount from about 30% to about 50% by weight of the total sealant composition.
16. The sealant composition of claim 1 wherein the silane modified olefinic polymer is present in the sealant composition in an amount from about 2% to about 35% by weight of the total sealant composition.
17. The sealant composition of claim 1 wherein the silane modified olefinic polymer is present in the sealant composition in an amount from about 5% to about 25% by weight of the total sealant composition.
18. The sealant composition of claim 1 wherein the carbon black is present in the sealant composition in an amount from about 5% to 20% by weight of the total sealant composition.
19. The sealant composition of claim 1 wherein the at least one of the desiccant and water scavenger is present in the sealant composition in an amount from about 2.5% to about 25% by weight of the total sealant composition.
20. The sealant composition of claim 1 wherein the at least one of the desiccant and water scavenger is present in the sealant composition in an amount from about 10% to about 15% by weight of the total sealant composition.
21. The sealant composition of claim 1 wherein the aging resistor is present in the sealant composition in an amount up to about 3% by weight of the total sealant composition.
22. A solar module comprising:
a first substrate having a hydroxyl group;
a second substrate having at least one of a hydroxyl group and an alkoxy group;
at least one photovoltaic cell disposed between the first and second substrates; and
a sealant in contact with the first and second substrates to form a moisture vapor barrier to hinder moisture vapor from reaching the at least one photovoltaic cell, wherein the sealant includes:
a) an olefinic polymer;
b) a silane modified olefinic polymer;
c) a carbon black having a primary particle size in the range of 50 nm to 60 nm that results in the sealant composition having a volume resistivity of >10 10 Ohm·cm, wherein the carbon black is oxidatively post-treated by a furnace process and included in an amount of up to 20% by weight of the total sealant composition;
d) at least one of a desiccant and a water scavenger; and
e) an aging resistor;
wherein a tensile strength and a lap shear strength of the sealant is balanced such that the sealant fails cohesively before failing adhesively and wherein the sealant has a tensile strength greater than 20 PSI and a lap shear strength greater than 20 PSI.
23. The solar module of claim 22 wherein the sealant chemically reacts with the hydroxyl group present on the polar surface of the first substrate and at least one of the alkoxy groups and the hydroxyl (—OH) groups present on the polar surface of the second substrate.
24. The solar module of claim 22 wherein the sealant has an endothermic enthalpy for a peak of approximately 100-140° C. of less than 50 J/g after four (4) weeks of aging under 85% relative humidity and 85° C.
25. The solar module of claim 22 wherein the sealant has an endothermic enthalpy for a peak of approximately 100-140° C. of less than 30 J/g after four (4) weeks of aging under 85% relative humidity and 85° C.
26. The solar module of claim 22 wherein the sealant has a moisture vapor transmission rate (MVTR) less than 0.7 g/m 2 /day at 38° C. and 100% relative humidity for a 0.060 to 0.080 inch thick sample.
27. The solar module of claim 22 wherein the sealant has a moisture vapor transmission rate (MVTR) less than 0.4 g/m 2 /day, at 38° C. and 100% relative humidity for a 0.060 to 0.080 inch thick sample.
28. The solar module of claim 22 wherein the sealant has a moisture vapor transmission rate (MVTR) less than 15 g/m 2 /day at 85° C. and 100% relative humidity for a 0.060 to 0.080 inch thick sample.
29. The solar module of claim 22 wherein the sealant has a moisture vapor transmission rate (MVTR) less than 8 g/m 2 /day, at 85° C. and 100% relative humidity for a 0.060 to 0.080 inch thick sample.
30. The solar module of claim 22 wherein the sealant has a melt volume index (MVI) less than 50 cm 3 /10 minutes at 130° C. and 10 kg load through a 0.0823 inch diameter orifice.
31. The solar module of claim 22 wherein the sealant exhibits a first viscosity when a first shear force is applied to the sealant and a second viscosity when a second shear force is applied to the sealant.
32. The solar module of claim 31 wherein the first viscosity of the sealant is greater than the second viscosity and the first shear force is less than the second shear force.
33. The solar module of claim 22 wherein the olefinic polymer of the sealant is present in an amount from about 30% to about 60% by weight of the sealant, the modified olefinic polymer is present in an amount from about 2% to about 35% by weight of the sealant, the at least one of the desiccant and water scavenger is present in an amount from about 2.5% to about 25% by weight of the sealant, the aging resistor is present in an amount from about 0% to about 3% by weight of the sealant.
34. The solar module of claim 22 wherein the olefinic polymer of the sealant is present in an amount from about 30% to about 50% by weight of the sealant, the modified olefinic polymer is present in an amount from about 5% to about 25% by weight of the sealant, the at least one of the desiccant and water scavenger is present in an amount from about 10% to about 15% by weight of the sealant, the aging resistor is present in an amount from about 0% to about 3% by weight of the sealant.
35. A sealant composition comprising:
a) an olefinic polymer;
b) a silane modified olefinic polymer; wherein the silane modified olefinic polymer includes a reactive group that chemically reacts with a polar surface including at least one of alkoxy groups and hydroxyl (—OH) groups to form a bond that is greater than the cohesive strength of the sealant composition;
c) a carbon black having a primary particle size in the range of 50 nm to 60 nm that results in the sealant composition having a volume resistivity of >10 10 Ohm·cm, wherein the carbon black is oxidatively post-treated by a furnace process and included in an amount of up to 20% by weight of the total sealant composition;
d) at least one of a desiccant and a water scavenger; and
e) an aging resistor, and
wherein the sealant composition has a tensile strength greater than 20 PSI and a lap shear strength greater than 20 PSI.
36. The sealant composition of claim 35 wherein the tensile strength of the sealant composition is greater than 50 PSI.
37. The sealant composition of claim 35 wherein the lap shear strength of the sealant composition is greater than 40 PSI.
38. The sealant composition of claim 35 wherein the sealant composition has an endothermic enthalpy for a peak of approximately 100-140° C. of less than 50 J/g after four (4) weeks of aging under 85% relative humidity and 85° C.
39. The sealant composition of claim 35 wherein the sealant composition has an endothermic enthalpy for a peak of approximately 100-140° C. of less than 30 J/g after four (4) weeks of aging under 85% relative humidity and 85° C.
40. The sealant composition of claim 35 wherein the sealant composition has a moisture vapor transmission rate (MVTR) less than 0.7 g/m 2 /day at 38° C. and 100% relative humidity for a 0.060 to 0.080 inch thick sample.
41. The sealant composition of claim 35 wherein the sealant composition has a moisture vapor transmission rate (MVTR) less than 0.4 g/m 2 /day at 38° C. and 100% relative humidity for a 0.060 to 0.080 inch thick sample.
42. The sealant composition of claim 35 wherein the sealant composition has a moisture vapor transmission rate (MVTR) less than 15 g/m 2 /day at 85° C. and 100% relative humidity for a 0.060 to 0.080 inch thick sample.
43. The sealant composition of claim 35 the sealant composition has a moisture vapor transmission rate (MVTR) less than 8 g/m 2 /day at 85° C. and 100% relative humidity for a 0.060 to 0.080 inch thick sample.
44. The sealant composition of claim 35 wherein the sealant composition has a melt volume index (MVI) less than 50 cm 3 /10 minutes at 130° C. and 10 kg load through 0.0823 inch diameter orifice.
45. The sealant composition of claim 35 wherein the sealant composition exhibits a first viscosity when a first shear force is applied to the sealant composition and a second viscosity when a second shear force is applied to the composition.
46. The sealant composition of claim 45 wherein the first viscosity of the sealant composition is greater than the second viscosity and the first shear force is less than the second shear force.
47. The sealant composition of claim 35 wherein the olefinic polymer of the sealant composition is present in an amount from about 30% to 60% by weight of the total sealant composition, the modified olefinic polymer is present in an amount from about 2% to about 35% by weight of the total sealant composition, the at least one of the desiccant and water scavenger is present in an amount from about 2.5% to about 25% by weight of the total sealant composition, the aging resistor is present in an amount from about 0% to about 3% by weight of the total sealant composition.
48. The sealant composition of claim 35 wherein the olefinic polymer of the sealant composition is present in an amount from about 30% to about 50% by weight of the total sealant composition, the modified olefinic polymer is present in an amount from about 5% to about 25% by weight of the total sealant composition, the at least one of the desiccant and water scavenger is present in an amount from about 10% to about 15% by weight of the total sealant composition, the aging resistor is present in an amount from about 0% to about 3% by weight of the total sealant composition.
49. A sealant disposed between a first substrate and a second substrate, the sealant configured to inhibit the transmission of moisture to a moisture sensitive material disposed between the first and second substrates, the sealant comprising:
an olefinic polymer;
at least one of a silane modified APAO and a silane modified polyisobutylene;
a carbon black having a primary particle size in the range of 50 nm to 60 nm that results in the sealant composition having a volume resistivity of >10 10 Ohm·cm, wherein the carbon black is oxidatively post-treated by a furnace process and included in an amount of up to 20% by weight of the total sealant composition;
a filler including a calcium carbonate or a silicate;
at least one of a water scavenger and a desiccant; and
an aging resistor;
wherein the at least one of the silane modified APAO and the silane modified polyisobutylene includes a reactive group that chemically bonds with the reactive group of the first and second substrates to form a bond that is greater than the cohesive strength of the sealant.
50. The sealant of claim 49 wherein the olefinic polymer includes a polyisobutylene in an amount from about 30% to about 60% by weight of the total sealant composition, the at least one of the silane modified APAO and the silane modified polyisobutylene is included in an amount from about 2% to about 35% by weight of the total sealant composition, the at least one of the water scavenger and the desiccant is included in an amount from about 2.5% to about 25% by weight of the total sealant composition, and the aging resistor is included in an amount from 0.1% to about 3% by weight of the total sealant composition.
51. The sealant of claim 49 wherein the olefinic polymer includes a polyisobutylene in an amount from about 30% to about 50% by weight of the total sealant composition.
52. The sealant of claim 49 wherein the at least one of the silane modified APAO and the silane modified polyisobutylene is included in an amount from about 5% to about 25% by weight of the total sealant composition.
53. The sealant of claim 49 wherein the sealant is oxidatively stable after 4000 hrs. of exposure to temperatures greater than 110° C.
54. The sealant of claim 49 wherein the aging resistor includes a phenol antioxidant.