Polyolefin Photovoltaic Backsheet Comprising a Stabilized Polypropylene Layer

Abstract

Polyolefin photovoltaic (PV) backsheets comprise a polypropylene layer stabilized with (A) at least one hindered amine with 2,2,6,6-tetraalkylpiperdine or 2,2,6,6-tetraakylpiperazinone, either or both in combination with a triazine moiety, (B) a thioester, and, optionally, (C) at least one hindered hydroxybenzoate, and/or (D) an ortho hydroxyl triazine compound. These PV backsheets exhibit a low flame spread index of <100 without the use of FR agents, and the polypropylene layer exhibits good weatherability while providing the required long term heat aging performance necessary for PV modules.

Description

FIELD OF THE INVENTION[0001]This invention relates to photovoltaic (PV) modules or cells. In one aspect the invention relates to PV module backsheets while in another aspect, the invention relates to PV module backsheets comprising polypropylene. In yet another aspect the invention relates to PV module backsheets comprising polypropylene and an additive package for stabilizing the backsheet against UV / visible light degradation and heat aging while imparting flame resistance without the use of flame retardant additives.BACKGROUND OF THE INVENTION[0002]U.S. Pat. Nos. 7,759,417, 6,051,164, 6,867,250 and U.S. Pat. No. 6,843,939 teach protection of polyolefins against degradation by UV / visible light, heat and oxidation through the use of various (1) hindered amine light stabilizers (HALS) such as ortho-tris-aryl triazine light absorbers, hindered hydroxyl benzoates, nickel quenchers (e.g., nickel phenolate), etc., and (2) antioxidants such as hindered phenol, hindered arylalkyl phosphite...

AI Technical Summary

Benefits of technology

[0011]Optionally, one of the layers of the PV backsheet described in the above embodiments can comprise at least one of (1) a non-halogenated organic or inorganic compound, (2) a halogenated, nonphosphorus organic compound, (3) a halogenated phosphorous compound, or (4) an anti-drip agent. These PV backsheets exhibit a low flame spread index of <100, and good weatherability while providing the required long term heat aging performance necessary for a successful PV module.

Problems solved by technology

However, these references do not teach that HALS and / or antioxidants impart flame resistance to a polyolefin.

However, thioester used in the presence of HALS can also decrease effectiveness of the HALS due to its interaction with the degradation byproducts of the thioester.

This results in poor weathering of the polyolefin (Polymeric Materials Encyclopedia: P, Vol. 8, 1996, p.

Some flame retardants (FR), such as halogenated FR, that are typically used to achieve effective low flame spread, also commonly have a deleterious effect on the UV stability provided by HALS (Robert L. Gray, Robert E. Lee and Brent M. Sanders, Journal of Vinyl and Additive Technology, Vol. 2, Issue 1, pages 63-68, March 1996).

However, typically, both FR and NOR HALS are needed to achieve flame retardancy (see, for example, U.S. Pat. No. 5,393,812) Useful inorganic FR typically require very high loadings (up to 60 weight percent (wt %)) of the composition to be effective, and they can negatively impact the mechanical properties or the processability of the composition and / or an article made from the composition.

However, these additives are known to cause discoloration of polypropylene (Aubert M, et al, Polymer Degradation and Stability, 96 (2011) 328-333) and there is no evidence for good long term heat aging (LTHA) which is critical for certification of PV modules.

Similarly, BASF discloses other organic-based FR agents such as AZO or AZONOR (described, for example, in US 2010 / 0144935) but these too do not provide good LTHA or UV stabilization.

An organic-based FR comprising phosphinic acids, salts and ester additives (see, for example, U.S. Pat. No. 8,097,753, 7,485,745 and US 2007 / 0213563) can achieve good flame retardancy but this too does not provide UV or LTHA stabilization.

Other non-halogenated flame retardant agents can provide some flame retardancy and UV stability, but impart a high degree of yellowness (as recorded by the yellowness index) and do not provide significant LTHA stabilization.

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