Multilayer composite films and articles prepared therefrom
View Patent ↗The present invention is an optically transparent laminate film comprising: at least three layers of film, wherein at least two of the at least three layers comprise ionomeric films, and wherein the film can be suitable for use in a photovoltaic cell or in packaging.
1. A solar cell module prepared from a sandwich comprising:
(a) at least one solar cell,
(b) a transparent encapsulant material disposed adjacent to at least one surface of the solar cell which comprises a laminate article comprising:
(i) a first outer layer comprising a first ionomer;
(ii) a core layer unit comprising at least one polymer layer positioned such that a first surface of the core layer unit is in direct contact with at least one surface of the first outer layer;
(iii) a second outer layer comprising a second ionomer positioned such that a second surface of the core layer unit is in direct contact with at least one surface of the second outer layer;
(A) wherein the at least one core layer polymer is a non-ionomeric polymer selected from the group consisting of: ethylene acid copolymers, ethylene acrylate copolymers and blends thereof, and
(B) wherein the measured transmittance at 500 nm for the laminate is greater than the expectation value of the transmittance calculated from the transmittance of the three individual layers in their non laminated state weighted by their thicknesses in the laminate,
(c) a front support layer formed of light transmitting material, and
(d) a backskin layer,
wherein the at least one solar cell and transparent encapsulant material are disposed between the front support layer and the backskin layer.
2. The solar cell module of claim 1 wherein the first and second ionomers comprise identical compositions.
3. The solar cell module of claim 1 wherein the optical transmittance of the laminate material of light of 500 nm wavelength is greater than 85%.
4. The solar cell module of claim 1 wherein the laminate article shows a DMA transition temperature of greater than 65° C. at 1 Hz.
5. The solar cell module of claim 4 wherein the core layer polymer shows a DMA transition temperature of less than 40° C. at 1 Hz when not laminated to the outer layers.
6. The solar cell module of claim 1 wherein the core layer polymer is a laminate.
7. The solar cell module of claim 1 wherein the first and second ionomers independently comprise copolymers obtained by the copolymerization of ethylene and an ethylenically unsaturated C 3 -C 8 carboxylic acid.
8. The solar cell module of claim 1 wherein the first and second ionomers independently are ionomer copolymers obtained by the copolymerization of ethylene and from about 8 wt % to about 25 wt % of ethylenically unsaturated C 3 -C 8 carboxylic acid, based on the total weight of the copolymer.
9. The solar cell module of claim 1 wherein the first and second ionomers independently are ionomer copolymers obtained by the copolymerization of ethylene and from about 14 wt % to about 19 wt % of acrylic acid or methacrylic acid, based on the total weight of the copolymer.
10. The solar cell module of claim 1 comprising a plurality of interconnected solar cells.
11. A solar cell module prepared from a sandwich comprising:
(a) at least one solar cell,
(b) a transparent encapsulant material disposed adjacent to at least one surface of the solar cell which comprises a laminate article comprising:
(i) a first outer layer that comprises a first ionomer;
(ii) a core layer unit comprised of at least one core layer polymer located with a first surface next to a surface of the first outer layer; and
(iii) a second outer layer that comprises a second ionomer located next to a second surface of the core layer unit,
wherein the core layer polymer is selected from the group consisting of: ethylene acid copolymers, ethylene acrylate copolymers and blends thereof, and
wherein the value of the transition temperature under tensile conditions at 1 Hz by DMA for the laminate material is greater than the value of the transition temperature under tensile conditions at 1 Hz by DMA of the core layer polymer measured under identical conditions and not in the laminate,
(c) a front support layer formed of light transmitting material, and
(d) a backskin layer disposed,
wherein the at least one solar cell and transparent encapsulant material are disposed between the front support layer and the backskin layer.
12. The solar cell module of claim 11 wherein the first and second ionomers are the same.
13. The solar cell module of claim 12 wherein the laminate article has a DMA transition temperature of greater than 65° C. at 1 Hz.
14. The solar cell module of claim 13 wherein the core layer polymer has a DMA transition temperature of less than 40° C. at 100 Hz when not laminated to the outer layers.
15. The solar cell module of claim 11 wherein the first and second ionomers independently comprise copolymers obtained by the copolymerization of ethylene and an ethylenically unsaturated C 3 -C 8 carboxylic acid.
16. The solar cell module of claim 15 wherein the first and second ionomers independently comprise copolymers obtained by the copolymerization of ethylene and from about 8 wt % to about 25 wt % of ethylenically unsaturated C 3 -C 8 carboxylic acid, based on the total weight of the copolymer.
17. The solar cell module of claim 16 wherein the first and second ionomers independently are ionomer copolymers obtained by the copolymerization of ethylene and about 14 wt % to about 19 wt % of acrylic acid or methacrylic acid, based on the total weight of the copolymer.
18. A solar cell module prepared from a sandwich comprising:
(a) a front support layer formed of light transmitting material,
(b) at least one solar cell,
(c) a transparent encapsulant laminate positioned adjacent to at least one surface of the solar cell(s), and
(d) a backskin layer,
wherein the transparent encapsulant laminate comprises:
(A) two outer films layers of ionomer copolymer obtained by the copolymerization of ethylene and an about 8 wt % to about 25 wt % of ethylenically unsaturated C 3 -C 8 carboxylic acid, based on the total weight of the copolymer, and
(B) at least one layer of polymer selected from the group consisting of ethylene acid copolymers, ethylene acrylate copolymers and blends thereof, between the outer films layer of ionomer copolymer.
19. The solar cell module of claim 18 wherein the polymer is selected from the ethylene acid copolymers.
20. The solar cell module of claim 18 wherein polymer is selected from the ethylene acrylate copolymers.
21. The solar cell module of claim 18 wherein the ionomer copolymer is obtained by the copolymerization of ethylene and from about 14 wt % to about 19 wt % of acrylic acid or methacrylic acid, based on the total weight of the copolymer.
22. The solar cell module of claim 18 wherein the front support layer is glass.
23. The solar cell module of claim 18 wherein the transparent encapsulant laminate has a total thickness 40.0 mil or less.
24. The solar cell module of claim 18 wherein the transparent encapsulant laminate has a total thickness 20.0 mil or less.
25. The solar cell module of claim 24 wherein (i) the encapsulant laminate is a three-layer structure wherein the at least one layer of polymer is a core layer of the polymer, (ii) the thickness of the outer films layers is each independently about 50% or less of the thickness of the core layer, and (iii) the ethylenically unsaturated C 3 -C 8 carboxylic acid is selected from the group consisting of acrylic acid and methacrylic acid.
26. The solar cell module of claim 18 wherein the transparent encapsulant laminate has a total thickness of 10.0 mil or less.
27. The solar cell module of claim 26 wherein (i) the encapsulant laminate is a three-layer structure wherein the at least one layer of polymer is a core layer of the polymer, (ii) the thickness of the outer films layers is each independently about 50% or less of the thickness of the core layer, and (iii) the ethylenically unsaturated C 3 -C 8 carboxylic acid is selected from the group consisting of acrylic acid and methacrylic acid.
28. The solar cell module of claim 1 wherein the transparent encapsulant laminate has a total thickness of 20.0 mil or less.
29. The solar cell module of claim 28 wherein (i) the encapsulant laminate is a three-layer structure wherein the at least one layer of polymer is a core layer of the polymer, (ii) the thickness of the outer films layers is each independently about 50% or less of the thickness of the core layer, and (iii) the ethylenically unsaturated C 3 -C 8 carboxylic acid is selected from the group consisting of acrylic acid and methacrylic acid.
30. The solar cell module of claim 18 wherein (i) the ethylenically unsaturated C 3 -C 8 carboxylic acid is either acrylic acid or methacrylic acid, (ii) the first transparent encapsulant laminate transmits at least about 85% of the incident light and/or has a haze of less than about 6%, and (iii) the at least one solar cell comprises a plurality of interconnected solar cells.
31. The solar cell module of claim 18 wherein (i) the ethylenically unsaturated C 3 -C 8 carboxylic acid is either acrylic acid or methacrylic acid, (ii) the first transparent encapsulant laminate has a transition temperature as measured by DMA of 65° C. or more at 1 Hz, and (iii) the at least one solar cell comprises a plurality of interconnected solar cells.
32. The solar cell module of claim 18 wherein (i) the ethylenically unsaturated C 3 -C 8 carboxylic acid is either acrylic acid or methacrylic acid, (ii) the first transparent encapsulant laminate transmits at least about 85% of the incident light and/or has a haze of less than about 6%, (iii) the first transparent encapsulant laminate has a transition temperature as measured by DMA of 65° C. or more at 1 Hz, (iv) the at least one solar cell comprises a plurality of interconnected solar cells, and (v) the front support layer is glass.
33. The solar cell module of claim 32 wherein the transparent encapsulant laminate has a total thickness of 20.0 mil or less.
34. The solar cell module of claim 26 wherein (i) the encapsulant laminate is a three-layer structure wherein the at least one layer of polymer is a core layer of the polymer, and (ii) the thickness of the outer films layers is each independently about 50% or less of the thickness of the core layer.
35. The solar cell module of claim 34 wherein the polymer is selected from the ethylene acid copolymers.
36. The solar cell module of claim 34 wherein polymer is selected from the ethylene acrylate copolymers.
37. A solar cell module prepared from a sandwich comprising in order:
(a) a front support layer formed of light transmitting material,
(b) a transparent encapsulant laminate,
(c) at least one solar cell,
(d) an encapsulant or seal layer, and
(e) a backsheet layer;
wherein the transparent encapsulant laminate comprises:
(A) two outer films layers of ionomer copolymer obtained by the copolymerization of ethylene and an about 8 wt % to about 25 wt % of ethylenically unsaturated C 3 -C 8 carboxylic acid, based on the total weight of the copolymer, and
(B) at least one layer of polymer selected from the group consisting of ethylene acid copolymers, ethylene acrylate copolymers and blends thereof, between the outer films layer of ionomer copolymer.
38. The solar cell module of claim 37 wherein the polymer is selected from the ethylene acid copolymers.
39. The solar cell module of claim 37 wherein polymer is selected from the ethylene acrylate copolymers.
40. The solar cell module of claim 37 wherein the ionomer copolymer is obtained by the copolymerization of ethylene and from about 14 wt % to about 19 wt % of acrylic acid or methacrylic acid, based on the total weight of the copolymer.
41. The solar cell module of claim 37 wherein (i) the encapsulant laminate is a three-layer structure wherein the at least one layer of polymer is a core layer of the polymer, (ii) the thickness of the outer films layers is each independently about 50% or less of the thickness of the core layer, and (iii) the ethylenically unsaturated C 3 -C 8 carboxylic acid is selected from the group consisting of acrylic acid and methacrylic acid.
42. The solar cell module of claim 41 wherein (1) the first transparent encapsulant laminate transmits at least about 85% of the incident light and/or has a haze of less than about 6%, and (ii) the at least one solar cell comprises a plurality of interconnected solar cells.
43. The solar cell module of claim 41 wherein (i) the first transparent encapsulant laminate has a transition temperature as measured by DMA of 65° C. or more at 1 Hz, and (ii) the at least one solar cell comprises a plurality of interconnected solar cells.
44. The solar cell module of claim 41 wherein (i) the first transparent encapsulant laminate transmits at least about 85% of the incident light and/or has a haze of less than about 6%, (ii) the first transparent encapsulant laminate has a transition temperature as measured by DMA of 65° C. or more at 1 Hz, (iii) the at least one solar cell comprises a plurality of interconnected solar cells, (iv) the front support layer is glass, (v) the transparent encapsulant laminate has a total thickness of 20.0 mil or less.
45. A solar cell module prepared from a sandwich comprising in order:
(a) a front support layer formed of light transmitting material,
(b) a first transparent encapsulant laminate,
(c) at least one solar cell,
(d) a second encapsulant laminate, and
(e) a backsheet layer;
wherein the first transparent encapsulant laminate and the second encapsulant laminate each comprise:
(A) two outer films layers of ionomer copolymer obtained by the copolymerization of ethylene and an about 8 wt % to about 25 wt % of ethylenically unsaturated C 3 -C 8 carboxylic acid, based on the total weight of the copolymer, and
(B) at least one layer of polymer selected from the group consisting of ethylene acid copolymers, ethylene acrylate copolymers and blends thereof, between the outer films layer of ionomer copolymer.
46. The solar cell module of claim 45 wherein the polymer is selected from the ethylene acid copolymers.
47. The solar cell module of claim 45 wherein polymer is selected from the ethylene acrylate copolymers.
48. A solar cell module prepared from a sandwich comprising in order:
(a) a front support layer formed of light transmitting material,
(b) a transparent encapsulant laminate,
(c) at least one solar cell, and
(d) an encapsulant or seal layer, which also comprises a backsheet layer;
wherein the transparent encapsulant laminate comprises:
(A) two outer films layers of ionomer copolymer obtained by the copolymerization of ethylene and an about 8 wt % to about 25 wt % of ethylenically unsaturated C 3 -C 8 carboxylic acid, based on the total weight of the copolymer, and
(B) at least one layer of polymer selected from the group consisting of ethylene acid copolymers, ethylene acrylate copolymers and blends thereof, between the outer films layer of ionomer copolymer.