Articles such as safety laminates and solar cell modules containing high melt flow acid copolymer compositions

a technology of acid copolymer composition and safety laminate, which is applied in the direction of transportation and packaging, chemistry apparatus and processes, synthetic resin layered products, etc., can solve the problem of complicating the lamination process

Inactive Publication Date: 2008-08-21
PERFORMANCE MATERIALS NA INC
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Benefits of technology

[0028]The invention is also directed to an improved polymeric composition comprising an acid copolymer composition and an additive, wherein (i) the acid copolymer composition comprises a copolymer of an alpha olefin and about 1 to about 30 wt % of an alpha,beta-ethylenically unsaturated carboxylic acid having 3 to 8 carbons, based on the total weight of the acid copolymer, (ii) the acid copolymer has a Melt Index of about 75 to about 600 g / 10 min and (iii) the additive is selected from the group consisting of silane coupling agent, organic peroxide, and combinations thereof. The invention is also directed to shaped articles comprising this polymeric composition. Preferably the shaped article is a polymeric film or sheet. Preferably the film or sheet is a multilayer film or sheet comprising one surface layer formed of the polymeric composition. Preferably the multilayer film or sheet comprises two surface layers with both being formed of the polymeric composition. One preferred embodiment is a solar cell or solar cell pre-laminate.

Problems solved by technology

The use of such low melt flow acid copolymer resins requires higher lamination temperatures (i.e., 130° C.-170° C.) and therefore may complicate the lamination process.

Method used

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Examples

Experimental program
Comparison scheme
Effect test

examples

[0134]The following Examples and are intended to be illustrative of the invention, and are not intended in any way to limit the scope of the invention.

Methods

[0135]The following methods are used in the Examples presented hereafter.

Melt Index

[0136]Melt Index (MI) is measured by ASTM D1238 at 190° C. and a 2160 g load. A similar ISO test is ISO 1133.

I. Lamination Process 1:

[0137]The laminate layers described below are stacked (laid up) to form the pre-laminate assembly described within the examples. For the assembly containing a film layer as the incident or back-sheet layer, a cover glass sheet is placed over the film layer. The pre-laminate assembly is then placed within a Meier ICOLAM 10 / 08 laminator (Meier Vakuumtechnik GmbH, Bocholt, Germany). The lamination cycle includes an evacuation step (vacuum of 3 in. Hg) of 5.5 minutes and a pressing stage (pressure of 1000 mb) of 5.5 minutes at a temperature of 115° C. For Examples 9,11, 41 and 43 only, an additional step at 145° C. for ...

examples 1-15

[0139]The 12×12 in (305×305 mm) laminate structures described below in Table 1 are assembled and laminated by Lamination Process 1, above.

TABLE 1Laminate StructuresExampleLayer 1Layer 2Layer 3Layer 4Layer 51, 16Glass 1HMFAC 1HMFAC 1Glass 12, 17Glass 1HMFAC 2Glass 13, 18Glass 2HMFAC 3PET 1HMFAC 3Glass 24, 19Glass 3HMFAC 4EVAHMFAC 4Glass 15, 20Glass 1HMFAC 5HMFAC 5PET 26, 21Glass 2HMFAC 6Glass 27, 22Glass 1HMFAC 7PET 38, 23Glass 1HMFAC 8EBAHMFAC 8Glass 19, 24Glass 1HMFAC 9Glass 110, 25 Glass 2HMFAC 10PET 4PVBPET 111, 26 Glass 1HMFAC 12HMFAC 11HMFAC 12Glass 112, 27 Glass 2HMFAC 13EBAHMFAC 13PET 513, 28 Glass 1HMFAC 14PET 6HMFAC 14Glass 114, 29 Glass 3HMFAC 15PET 1HMFAC 15Glass 215, 30 Glass 1HMFAC 16HMFAC 16Glass 1

[0140]HMFAC 1 is a 20 mil (0.51 mm) thick embossed sheet of Acid Copolymer A, a poly(ethylene-co-methacrylic acid) containing 15 wt % of polymerized residues of methacrylic acid and having a MI of 100 g / 10 min.

[0141]HMFAC 2 is a 60 mil (−1.52 mm) thick embossed tri-layer shee...

examples 16-30

[0168]The 12×12 in (305×305 mm) laminate structures described above in Table 1 are assembled and laminated by Lamination Process 2, above.

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Abstract

A polymeric film or sheet comprising an acid copolymer composition comprising acid copolymer of an alpha olefin and about 1 to about 30 wt % of alpha,beta-ethylenically unsaturated carboxylic acid having 3 to 8 carbons, based on the total weight of the acid copolymer composition, wherein the acid copolymer has a Melt Index of about 75 to about 600 g/10 min. The acid copolymer composition preferably comprises an additive selected from the group consisting of silane coupling agent, organic peroxide, and combinations thereof. In addition, an article comprising an interlayer formed of the polymeric film or sheet and an additional layer selected from the group consisting of glass, other polymeric interlayer sheets, polymeric film layers, and metal films or sheets. Examples of articles include safety windows and solar cells.

Description

CROSS-REFERENCE TO RELATED APPLICATION[0001]This application claims priority to U.S. Provisional Appln. No. 60 / 901510, filed on Feb. 15, 2007, which is incorporated herein by reference in its entirety.FIELD OF THE INVENTION[0002]The invention relates to polymeric films or sheets comprising acid copolymer compositions, and their use in articles such as safety laminates and solar cell modules.BACKGROUND OF THE INVENTION[0003]Glass laminated products have contributed to society for almost a century. Beyond the well known, every day automotive safety glass used in windshields, laminated glass is used in all forms of the transportation industry. Safety glass is characterized by high impact and penetration resistance and does not scatter glass shards and debris when shattered.[0004]Safety glass typically consists of a sandwich of two glass sheets or panels bonded together with an interlayer of a polymeric sheet. One or both of the glass sheets may be replaced with optically clear rigid po...

Claims

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Application Information

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Patent Type & Authority Applications(United States)
IPC IPC(8): H01L31/0216B32B37/00B32B17/10
CPCY10T428/269B32B17/10036B32B17/10697B32B17/10853B32B27/06B32B2367/00C08J2323/08B32B27/08B32B17/10743B32B17/10C08J5/18B32B17/10018B32B27/308Y10T156/1054Y10T428/31938Y10T428/31645Y10T428/31692Y10T428/31667Y02E10/50B32B17/10005C08L23/08B32B37/00H01L31/04
Inventor HAYES, RICHARD ALLENSAMUELS, SAM LOUISHALL, MATTHEW SCOTT
Owner PERFORMANCE MATERIALS NA INC
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