WO2011047194A1 - Edge sealants having balanced properties - Google Patents
Edge sealants having balanced properties Download PDFInfo
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- WO2011047194A1 WO2011047194A1 PCT/US2010/052733 US2010052733W WO2011047194A1 WO 2011047194 A1 WO2011047194 A1 WO 2011047194A1 US 2010052733 W US2010052733 W US 2010052733W WO 2011047194 A1 WO2011047194 A1 WO 2011047194A1
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- WIPO (PCT)
- Prior art keywords
- sealant
- sealant composition
- composition
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- weight
- Prior art date
Links
- 239000000565 sealant Substances 0.000 title claims abstract description 282
- 239000000203 mixture Substances 0.000 claims abstract description 214
- 239000011521 glass Substances 0.000 claims abstract description 76
- 230000032683 aging Effects 0.000 claims abstract description 41
- 229920000642 polymer Polymers 0.000 claims abstract description 36
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims abstract description 31
- 239000002274 desiccant Substances 0.000 claims abstract description 20
- 239000000945 filler Substances 0.000 claims abstract description 20
- 239000002516 radical scavenger Substances 0.000 claims abstract description 16
- 239000010419 fine particle Substances 0.000 claims abstract 5
- 229910000077 silane Inorganic materials 0.000 claims description 32
- BLRPTPMANUNPDV-UHFFFAOYSA-N Silane Chemical compound [SiH4] BLRPTPMANUNPDV-UHFFFAOYSA-N 0.000 claims description 28
- 230000005540 biological transmission Effects 0.000 claims description 23
- -1 silane modified APAO Chemical class 0.000 claims description 16
- 239000006229 carbon black Substances 0.000 claims description 14
- 239000000758 substrate Substances 0.000 claims description 10
- 229920002367 Polyisobutene Polymers 0.000 claims description 9
- 125000002887 hydroxy group Chemical group [H]O* 0.000 claims description 9
- 125000003545 alkoxy group Chemical group 0.000 claims description 7
- 239000004372 Polyvinyl alcohol Substances 0.000 claims description 6
- 239000000155 melt Substances 0.000 claims description 6
- 229920002451 polyvinyl alcohol Polymers 0.000 claims description 6
- 239000000463 material Substances 0.000 claims description 5
- 238000000034 method Methods 0.000 claims description 5
- VTYYLEPIZMXCLO-UHFFFAOYSA-L Calcium carbonate Chemical compound [Ca+2].[O-]C([O-])=O VTYYLEPIZMXCLO-UHFFFAOYSA-L 0.000 claims description 4
- 230000008569 process Effects 0.000 claims description 4
- 230000004888 barrier function Effects 0.000 claims description 3
- 229910000019 calcium carbonate Inorganic materials 0.000 claims description 2
- 239000002808 molecular sieve Substances 0.000 claims description 2
- URGAHOPLAPQHLN-UHFFFAOYSA-N sodium aluminosilicate Chemical group [Na+].[Al+3].[O-][Si]([O-])=O.[O-][Si]([O-])=O URGAHOPLAPQHLN-UHFFFAOYSA-N 0.000 claims description 2
- BPQQTUXANYXVAA-UHFFFAOYSA-N Orthosilicate Chemical compound [O-][Si]([O-])([O-])[O-] BPQQTUXANYXVAA-UHFFFAOYSA-N 0.000 claims 1
- ISWSIDIOOBJBQZ-UHFFFAOYSA-N Phenol Chemical compound OC1=CC=CC=C1 ISWSIDIOOBJBQZ-UHFFFAOYSA-N 0.000 claims 1
- 239000003963 antioxidant agent Substances 0.000 claims 1
- 230000003078 antioxidant effect Effects 0.000 claims 1
- 230000000052 comparative effect Effects 0.000 description 28
- 150000004756 silanes Chemical class 0.000 description 24
- 125000006850 spacer group Chemical group 0.000 description 24
- 229920001296 polysiloxane Polymers 0.000 description 11
- 150000001875 compounds Chemical class 0.000 description 10
- 238000004519 manufacturing process Methods 0.000 description 10
- 230000001070 adhesive effect Effects 0.000 description 9
- 125000000484 butyl group Chemical group [H]C([*])([H])C([H])([H])C([H])([H])C([H])([H])[H] 0.000 description 9
- 235000019241 carbon black Nutrition 0.000 description 9
- 238000002425 crystallisation Methods 0.000 description 9
- 230000008025 crystallization Effects 0.000 description 9
- 239000000126 substance Substances 0.000 description 8
- 238000012360 testing method Methods 0.000 description 8
- 230000008901 benefit Effects 0.000 description 7
- 238000007789 sealing Methods 0.000 description 7
- 229920001169 thermoplastic Polymers 0.000 description 7
- 239000004416 thermosoftening plastic Substances 0.000 description 7
- 239000000853 adhesive Substances 0.000 description 6
- 238000006243 chemical reaction Methods 0.000 description 6
- 239000007789 gas Substances 0.000 description 5
- 239000002184 metal Substances 0.000 description 5
- 229910052751 metal Inorganic materials 0.000 description 5
- 239000004698 Polyethylene Substances 0.000 description 4
- 238000004458 analytical method Methods 0.000 description 4
- 229920005549 butyl rubber Polymers 0.000 description 4
- 229920002943 EPDM rubber Polymers 0.000 description 3
- 230000007774 longterm Effects 0.000 description 3
- 239000004014 plasticizer Substances 0.000 description 3
- 229920000573 polyethylene Polymers 0.000 description 3
- 239000004590 silicone sealant Substances 0.000 description 3
- 229920006132 styrene block copolymer Polymers 0.000 description 3
- GWEVSGVZZGPLCZ-UHFFFAOYSA-N Titan oxide Chemical compound O=[Ti]=O GWEVSGVZZGPLCZ-UHFFFAOYSA-N 0.000 description 2
- 229910052782 aluminium Inorganic materials 0.000 description 2
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 2
- 229920013640 amorphous poly alpha olefin Polymers 0.000 description 2
- 239000011230 binding agent Substances 0.000 description 2
- 230000033228 biological regulation Effects 0.000 description 2
- 230000001143 conditioned effect Effects 0.000 description 2
- 238000010276 construction Methods 0.000 description 2
- 239000013078 crystal Substances 0.000 description 2
- 230000006735 deficit Effects 0.000 description 2
- 230000032798 delamination Effects 0.000 description 2
- 238000000113 differential scanning calorimetry Methods 0.000 description 2
- 238000009792 diffusion process Methods 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 239000005329 float glass Substances 0.000 description 2
- 239000012943 hotmelt Substances 0.000 description 2
- 239000011261 inert gas Substances 0.000 description 2
- 238000009413 insulation Methods 0.000 description 2
- 238000002844 melting Methods 0.000 description 2
- 230000008018 melting Effects 0.000 description 2
- 230000003287 optical effect Effects 0.000 description 2
- 229920003023 plastic Polymers 0.000 description 2
- 239000004033 plastic Substances 0.000 description 2
- 229920001083 polybutene Polymers 0.000 description 2
- 229920001021 polysulfide Polymers 0.000 description 2
- 239000005077 polysulfide Substances 0.000 description 2
- 150000008117 polysulfides Polymers 0.000 description 2
- 238000012545 processing Methods 0.000 description 2
- 230000002787 reinforcement Effects 0.000 description 2
- 150000004760 silicates Chemical class 0.000 description 2
- 229910052814 silicon oxide Inorganic materials 0.000 description 2
- 239000012815 thermoplastic material Substances 0.000 description 2
- 230000007704 transition Effects 0.000 description 2
- 239000005995 Aluminium silicate Substances 0.000 description 1
- OYPRJOBELJOOCE-UHFFFAOYSA-N Calcium Chemical compound [Ca] OYPRJOBELJOOCE-UHFFFAOYSA-N 0.000 description 1
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 1
- 239000004831 Hot glue Substances 0.000 description 1
- 239000005062 Polybutadiene Substances 0.000 description 1
- 239000004743 Polypropylene Substances 0.000 description 1
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 1
- 239000002318 adhesion promoter Substances 0.000 description 1
- 238000004026 adhesive bonding Methods 0.000 description 1
- 235000012211 aluminium silicate Nutrition 0.000 description 1
- 150000001412 amines Chemical class 0.000 description 1
- 239000012965 benzophenone Substances 0.000 description 1
- 150000008366 benzophenones Chemical class 0.000 description 1
- 150000001565 benzotriazoles Chemical class 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- 239000011575 calcium Substances 0.000 description 1
- 229910052791 calcium Inorganic materials 0.000 description 1
- 235000010216 calcium carbonate Nutrition 0.000 description 1
- AXCZMVOFGPJBDE-UHFFFAOYSA-L calcium dihydroxide Chemical compound [OH-].[OH-].[Ca+2] AXCZMVOFGPJBDE-UHFFFAOYSA-L 0.000 description 1
- 239000000920 calcium hydroxide Substances 0.000 description 1
- 229910001861 calcium hydroxide Inorganic materials 0.000 description 1
- 235000011116 calcium hydroxide Nutrition 0.000 description 1
- 235000012241 calcium silicate Nutrition 0.000 description 1
- 239000003054 catalyst Substances 0.000 description 1
- 239000004020 conductor Substances 0.000 description 1
- 238000001723 curing Methods 0.000 description 1
- 230000007547 defect Effects 0.000 description 1
- 150000001993 dienes Chemical class 0.000 description 1
- 230000004069 differentiation Effects 0.000 description 1
- 230000003203 everyday effect Effects 0.000 description 1
- 238000001125 extrusion Methods 0.000 description 1
- 238000011049 filling Methods 0.000 description 1
- 238000009472 formulation Methods 0.000 description 1
- 239000008236 heating water Substances 0.000 description 1
- BHEPBYXIRTUNPN-UHFFFAOYSA-N hydridophosphorus(.) (triplet) Chemical class [PH] BHEPBYXIRTUNPN-UHFFFAOYSA-N 0.000 description 1
- 238000009434 installation Methods 0.000 description 1
- NLYAJNPCOHFWQQ-UHFFFAOYSA-N kaolin Chemical compound O.O.O=[Al]O[Si](=O)O[Si](=O)O[Al]=O NLYAJNPCOHFWQQ-UHFFFAOYSA-N 0.000 description 1
- 239000000391 magnesium silicate Substances 0.000 description 1
- 235000012243 magnesium silicates Nutrition 0.000 description 1
- 239000010445 mica Substances 0.000 description 1
- 229910052618 mica group Inorganic materials 0.000 description 1
- 230000005012 migration Effects 0.000 description 1
- 238000013508 migration Methods 0.000 description 1
- 239000002480 mineral oil Substances 0.000 description 1
- 235000010446 mineral oil Nutrition 0.000 description 1
- 238000013008 moisture curing Methods 0.000 description 1
- 238000012544 monitoring process Methods 0.000 description 1
- 239000000615 nonconductor Substances 0.000 description 1
- 230000000149 penetrating effect Effects 0.000 description 1
- 230000035515 penetration Effects 0.000 description 1
- 230000035699 permeability Effects 0.000 description 1
- 150000002989 phenols Chemical class 0.000 description 1
- 230000010399 physical interaction Effects 0.000 description 1
- 239000002985 plastic film Substances 0.000 description 1
- 229920006255 plastic film Polymers 0.000 description 1
- 229920002857 polybutadiene Polymers 0.000 description 1
- 229920001155 polypropylene Polymers 0.000 description 1
- 229920002635 polyurethane Polymers 0.000 description 1
- 239000004814 polyurethane Substances 0.000 description 1
- 239000011164 primary particle Substances 0.000 description 1
- 238000005086 pumping Methods 0.000 description 1
- 230000005855 radiation Effects 0.000 description 1
- FZHAPNGMFPVSLP-UHFFFAOYSA-N silanamine Chemical class [SiH3]N FZHAPNGMFPVSLP-UHFFFAOYSA-N 0.000 description 1
- LIVNPJMFVYWSIS-UHFFFAOYSA-N silicon monoxide Chemical class [Si-]#[O+] LIVNPJMFVYWSIS-UHFFFAOYSA-N 0.000 description 1
- 230000006641 stabilisation Effects 0.000 description 1
- 238000011105 stabilization Methods 0.000 description 1
- 229910001220 stainless steel Inorganic materials 0.000 description 1
- 239000010935 stainless steel Substances 0.000 description 1
- 230000035882 stress Effects 0.000 description 1
- 239000000454 talc Substances 0.000 description 1
- 229910052623 talc Inorganic materials 0.000 description 1
- 150000003568 thioethers Chemical class 0.000 description 1
- 239000004408 titanium dioxide Substances 0.000 description 1
- 235000010215 titanium dioxide Nutrition 0.000 description 1
- 238000009281 ultraviolet germicidal irradiation Methods 0.000 description 1
- 238000009423 ventilation Methods 0.000 description 1
- 239000004711 α-olefin Substances 0.000 description 1
Classifications
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L23/00—Details of semiconductor or other solid state devices
- H01L23/28—Encapsulations, e.g. encapsulating layers, coatings, e.g. for protection
- H01L23/29—Encapsulations, e.g. encapsulating layers, coatings, e.g. for protection characterised by the material, e.g. carbon
- H01L23/293—Organic, e.g. plastic
- H01L23/295—Organic, e.g. plastic containing a filler
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
- C08K3/00—Use of inorganic substances as compounding ingredients
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
- C08K3/00—Use of inorganic substances as compounding ingredients
- C08K3/34—Silicon-containing compounds
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L101/00—Compositions of unspecified macromolecular compounds
- C08L101/02—Compositions of unspecified macromolecular compounds characterised by the presence of specified groups, e.g. terminal or pendant functional groups
- C08L101/10—Compositions of unspecified macromolecular compounds characterised by the presence of specified groups, e.g. terminal or pendant functional groups containing hydrolysable silane groups
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L23/00—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L23/00—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers
- C08L23/02—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers not modified by chemical after-treatment
-
- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09K—MATERIALS FOR MISCELLANEOUS APPLICATIONS, NOT PROVIDED FOR ELSEWHERE
- C09K3/00—Materials not provided for elsewhere
- C09K3/10—Materials in mouldable or extrudable form for sealing or packing joints or covers
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L31/00—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
- H01L31/04—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof adapted as photovoltaic [PV] conversion devices
- H01L31/042—PV modules or arrays of single PV cells
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L23/00—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers
- C08L23/26—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers modified by chemical after-treatment
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L2924/00—Indexing scheme for arrangements or methods for connecting or disconnecting semiconductor or solid-state bodies as covered by H01L24/00
- H01L2924/0001—Technical content checked by a classifier
- H01L2924/0002—Not covered by any one of groups H01L24/00, H01L24/00 and H01L2224/00
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
- Y02E10/00—Energy generation through renewable energy sources
- Y02E10/50—Photovoltaic [PV] energy
Definitions
- This invention relates to an edge seal for manufacturing two- pane or multi-pane insulating glass or solar modules, there being provided a sealant having balanced cohesive and adhesive properties to ensure strong adhesive bonding to the glass surfaces and weaker, yet still strong, internal cohesive strength, to prevent delamination of the edge seal from the substrate.
- the spacer consists primarily of metal (usually aluminum), is located in the edge area of the glass panes, and has the function of maintaining the two glass panes at the desired distance apart.
- a desiccant e.g. a molecular sieve
- the spacer is provided with small apertures (longitudinal perforation) on the side facing the interpane space. This arrangement prevents moisture from condensing on the inside of the glass panes at low ambient temperatures and impairing the transparency of the insulating glass unit.
- a seal based on polyisobutylene and/or butyl rubber is provided between the sides of the spacer that face the glass panes and the inner surfaces of the glass panes.
- This seal is generally known as the primary seal.
- the function of the primary seal is during production of the insulating glass panes, to be a kind of "assembly aid" while the glass panes are being joined to the spacer, which has been pre-coated with primary sealant, in order to hold the assembly together during the next production stages, and later, during the service life of the insulating glass unit, to form a water-vapor barrier that prevents moisture from penetrating from the exterior inwards into the interpane space, and, if the insulating glass unit is filled with gas, to prevent loss of this gas outwards from the interpane space.
- the secondary sealant As the outward-facing edge of the spacer is a few millimeters inside of the outside edges of the glass panes, a "channel" is formed into which the secondary sealant, as it is generally known, is injected.
- the main purpose of the secondary seal is to elastically bond the edge of the insulating glass unit (glass panes and spacer) and also to form a seal - which is to some extent an additional seal - against water and water vapor from the outside and gas from the inside (interpane space).
- the secondary seal consists of room- temperature-curing, two-part sealants and/or adhesives based on polysulfide, polyurethane or silicone.
- One-part systems for example based on silicone, or a hot-melt butyl adhesive applied while hot, are also possible.
- metal spacers used there have the disadvantage of being good heat conductors and thus having a negative influence on an insulating glass pane's desirable low K-value, which, in the case of double- or multi-pane insulating glass, has been improved substantially in recent years by filling the interpane space with inert gas and using glass panes coated with low-emission (low-E) layers.
- low-E low-emission
- the DE 196 24 236 A1 describes a hot-melt adhesive composition for insulating glass, containing a mixture of at least one reactive binder based on silane-functional polyisobutylene, hydrogenated polybutadiene and/or poly-a-olefins, and a non-reactive binder from the group comprising the butyl rubbers, poly-a-olefins, diene polymers, polybutene or styrene block copolymers, which composition may be used as 1 - or 2-part adhesive/sealant in the production of insulating glasses. No separate spacers comprising metal or plastic profiles are needed here, and no additional, secondary sealants.
- the DE 198 21 355 A1 describes a sealing compound for use in the production of multi-pane insulating glass; the compound contains silane- modified butyl rubber and serves as spacer between the individual panes of the multi-pane insulating glass. Here too, no secondary sealant is needed.
- thermoplastic material used combines the function of the spacer with that of the primary seal, as it is called. It also contains the desiccant.
- TPS thermoplastic spacer
- the outward-facing edge of the spacer is a few millimeters inside of the outer edges of the glass panes, and the remaining space is filled by the secondary seal, as it is called, which bonds the units elastically.
- the TPS system has, over the past ten years, proved to be completely unproblematic in insulating-glass fenestration applications.
- the main reason may be assumed to be the lack of adhesion between the TPS sealant and the secondary seal, and the inadequate adhesion - based only on predominantly physical interactions - of the TPS sealant to the glass. This bond may be easily weakened to a greater or lesser extent by substances migrating into the glass/TPS sealant interface.
- a sealant composition having a) an olefinic polymer, b) a silane modified olefinic polymer, c) a filler, d) a desiccant or a water scavenger, and e) an aging resistor.
- a tensile strength and a lap shear strength of the sealant composition is balanced such that the sealant fails cohesively before failing adhesively.
- the sealant composition has a tensile strength greater than 20 PSI and a lap shear strength greater than 20 PSI.
- the sealant composition has a tensile strength greater than 50 PSI and a lap shear strength greater than 40 PSI.
- the sealant composition chemically reacts with a polar surface containing at least one of alkoxy groups and hydroxyl (-OH) groups such as, but not limited to, glass and polyvinyl alcohol) (PVA).
- a polar surface containing at least one of alkoxy groups and hydroxyl (-OH) groups such as, but not limited to, glass and polyvinyl alcohol) (PVA).
- the sealant composition has an endothermic enthalpy for a peak approximately 100-140C less than 50 J/g upon four (4) weeks aging under 85% relative humidity 85°C.
- the sealant composition an endothermic enthalpy for a peak approximately 100-140C less than 30 J/g, upon four (4) weeks aging under 85% relative humidity 85°C.
- the sealant composition has a moisture vapor transmission (MVT) less than 0.7 g/m 2 /day at 38 °C and 100% relative humidity for 0.060 to 0.080 inch thick samples.
- VTT moisture vapor transmission
- the sealant composition has a moisture vapor transmission (MVT) less than 0.4 g/m 2 /day at 38 °C and 100% relative humidity for 0.060 to 0.080 inch thick samples.
- VTT moisture vapor transmission
- the sealant composition has a moisture vapor transmission (MVT) less than 15 g/m 2 /day at 85°C and 100% relative humidity for 0.060 to 0.080 inch thick samples.
- VTT moisture vapor transmission
- the sealant composition has a moisture vapor transmission (MVT) less than 8 g/m 2 /day at 85°C and 100% relative humidity for 0.060 to 0.080 inch thick samples.
- VTT moisture vapor transmission
- 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.
- 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.
- the first viscosity of the sealant composition is greater than the second viscosity and the first shear force is a less than force than the second shear force.
- the olefinic polymers are present in the composition in an amount from about 30% to about 60% by weight of the total composition.
- the olefinic polymers are present in the composition in an amount from about 40% to about 50% by weight of the total composition.
- the silane modified olefinic polymer is present in the composition in an amount from about 2% to about 35% by weight of the total composition.
- the silane modified olefinic polymer is present in the composition in an amount from about 5% to about 25% by weight of the total composition.
- the filler is present in the composition in an amount from about 5% to about 40% by weight of the total composition.
- the filler is present in the composition in an amount from about 10% to about 30% by weight of the total composition.
- the desiccant or water scavenger is present in the composition in an amount from about 2.5% to about 25% by weight of the total composition.
- the desiccant or water scavenger is present in the composition in an amount from about 10% to about 15% by weight of the total composition.
- the aging resistor is present in the composition in an amount from about 0% to about 3% by weight of the total composition.
- FIG. 1 is a bar chart depicting the lap shear strength of an example of the sealant composition and the comparative example
- FIG. 2 is a bar chart depicting the lap shear strength of an example of the sealant composition having variable silane content
- FIG. 3 is a graph illustrating DSC scans for the comparative example as a function of damp heat aging time
- FIG. 4 is a graph illustrating DSC scans for an example of the sealant composition as a function of damp het aging time
- FIG. 5 is a illustration depicting crystallized and un crystallized polymer chains
- FIG. 6 is a bar chart depicting the lap shear strength of an example of the sealant composition and the comparative example
- FIG. 7 is a bar chart depicting the tensile strength of an example of the sealant composition having variable silane content.
- FIG. 8 is a graph illustrating DSC scans for the comparative example as a function of aging time.
- Example 1 Comparative (prior art)
- test insulating-glass panes measuring 500 x 350 mm and constructed as 4 mm float glass / 16 mm interpane space / 4 mm float glass plus the edge seal consisting in the one instance of:
- an EPDM profile of the kind typically employed for glazing applications and having a plasticizer content of about 20% mineral oil is bonded using a one-part silicone sealant with a high silicone-plasticizer content, said profile thus being brought into direct contact with the edge-seal sealants.
- the test panes prepared in this way were then exposed to a weathering-cycle test (-20 °C / + 80 °C at 95 - 100% rel. humidity, 8 hours per cycle, 3 cycles per day).
- test pane 1 After only about 4-5 weeks of the weathering-cycle test, test pane 1 ) showed deformation, i.e. movement, of the thermoplastic spacer profile into the interpane space. This was caused by the incompatibility reactions (plasticizer migration from the EPDM profile and the one-part silicone sealant).
- Test pane 2 by contrast, showed no impairment of the edge seal whatsoever even after more than 50 weeks of the weathering-cycle test.
- the glass adhesion and the edge seal showed no recognizable impairment whatsoever after more than 4,000 hours of irradiation with UV lamps (Ultra-violet) and temperatures at the pane surfaces of up to 1 10 °C.
- An edge seal that can withstand stresses of this kind is thus suitable not only for insulating-glass applications in particularly demanding situations, e.g. frameless glazing in facades or roofs (known as structural glazing), but also, for example, for the edge seal in solar modules.
- the edge seal must not show any electrical conductivity, as this can cause fault current or short circuits between the contacts.
- silicone-based secondary seal this is no problem, since silicones typically show very high volume resistivities, mostly > 10 14 Ohm-cm, and thus fall within the category of electrical insulators.
- butyl sealants with a high filler content of carbon black - as in the case of the reactive butyl compound described here - have volume resistivities of ⁇ 10 6 Ohm-cm, meaning that the compound would be electrically conductive. Reducing the carbon black content admittedly increases the volume resistivity, but also brings many disadvantages.
- a high carbon black content in a butyl sealant is to make the mixture particularly stable toward high temperatures and UV irradiation. If the carbon black content were to be substantially reduced because of the volume resistivity, this would no longer be the case and the butyl sealing compound would no longer show the required long-term stability for applications in the field of solar modules, i.e. for applications involving high temperatures and solar radiation.
- a specialty carbon black in place of the carbon blacks generally used in butyl sealants, however, it is possible to obtain a reactive butyl compound that has all the required properties.
- Example 3 A specialty carbon black of this kind is used in the following example.
- Example 3 A specialty carbon black of this kind is used in the following example.
- the sealing compound is a hot-melt sealant that contains Vestoplast 206, a silane grafted amorphous poly alpha olefin (APAO), that chemically reacts with glass hydroxyl (-OH) groups or alkoxy groups in the presence of water resulting in the formation of a covalent bond.
- APAO silane grafted amorphous poly alpha olefin
- the inability of silanes to chemically bond with glass may result in delamination.
- This sealant- glass chemical bonding is very important with respect to the long-term solar module water resistance, as one of the common failure modes is the water ingress into the module through the passage (opening) near glass-sealant interface.
- a comparative example, commercially available from a manufacturer of edge sealants was used to compare the performance of the sealant composition.
- the progression of sealant-glass reaction was quantified using 180° lap shear analyses. 1 "X1 ", 1 .7 mm samples were sandwiched in between two glass plates (1 "X3"). This sandwich was conditioned at 240 °F for ⁇ 30 min and compressed to 1 .22 mm final thickness. These lap shear samples were aged for a month in 85 °C - 85 % relative humidity (damp heat) chamber to monitor lap shear values and failure modes. The reported lap shear is an average of at least 3 specimens pulled at 4 inch/min (the peak value is reported as the lap shear).
- FIG. 1 shows the lap shears for the sealant composition of the present invention and the comparative example as a function of 85 °C - 85 % relative humidity aging time. It was observed that the sealant composition lap shears were always higher than the comparative example during one month aging study. This indicated that the sealant composition adhesion bond to glass was much stronger than that of the comparative example. Furthermore, while the comparative example exhibited adhesive or partially adhesive failures the sealant composition always failed cohesively indicating a better balance of cohesive and adhesive properties.
- FIG. 2 shows the lap shear values for the sealant composition with different silane contents as a function of 85 °C - 85 % relative humidity aging time.
- Initially (roughly up to day 5) there was not any significant difference in lap shears (adhesion to glass) for the sealant composition, the sealant composition with no silanes, the sealant composition with non reactive silanes, and the sealant composition with twice as much silanes.
- the sealant composition and the sealant composition with twice as much silane had significantly higher lap shear strengths (adhesion to glass) than the sealant composition without silanes and the sealant composition with non reactive silanes.
- This ladder study confirmed that the presence of silanes led to the increase in adhesion to glass with time via sealant (silanes) glass surface chemical bonding.
- FIG. 3 shows the sample DSC scans for the comparative example as a function of damp heat aging time.
- Day 1 aged samples showed an endothermic melting peak (onset around 100 °C). This melting peak observed to expand upon aging (FIG. 3) indicating the crystallinity build up. This peak corresponds to the polyethylene (low density and/or linear low density), which is more likely the carrier of the comparative example silanes. Once these silanes crystallize, they cannot diffuse towards glass and react to build up the chemical adhesion to glass. Thermal analyses of the sealant composition silanes did not reveal any significant crystallization upon aging (see FIG. 4). This non- crystallization tendency was more likely the reason behind higher the sealant composition lap shears (adhesion to glass).
- the moisture-cure-potential of the sealant composition makes it suitable to covalently react with glass.
- the progression of this reaction was quantified using 180° lap shear analyses.
- One inch by one inch, 1 .7 mm thick samples were sandwiched in between two glass plates (1 "X3"). This sandwich was conditioned at 240 °F for ⁇ 30 min and compressed to 1 .22 mm final thickness.
- Tensile samples were dog-bone shaped, the gauge dimensions being 1 .5 inch X 8 mm.
- These lap shear and tensile samples were aged for a month in 85 °C - 85 % relative humidity chamber to monitor lap shear values.
- the reported lap shear is an average of at least 3 specimens pulled at 4 inch/min (the peak value is reported as the lap shear) tested at room temperature.
- FIG. 5 shows the lap shears for the sealant composition and the comparative example as a function of 85 °C - 85 % relative humidity aging time. It was observed that the sealant composition lap shears were always higher than comparative example during one month aging study. This indicated that the sealant composition adhesion bond to glass was much stronger than that of comparative example.
- FIG. 6 shows the lap shear values for the sealant composition with different silane contents as a function of 85 °C - 85 % relative humidity aging time.
- Initially (roughly up to day 5) there was not any significant difference in lap shears (adhesion to glass) for the sealant composition, the sealant composition with no silanes, the sealant composition with non reactive silanes, and a sealant composition with twice the silane content.
- the sealant composition and the sealant composition with twice the silane content had significantly higher lap shear strengths (adhesion to glass) than the sealant composition without silanes and the sealant composition with non reactive silanes.
- FIG. 7 shows the tensile strengths for the sealant composition with different silane contents as a function of 85 °C - 85 % relative humidity aging time.
- Tensile strength is the representation of the cohesive strength within the sealant. It was clearly seen that the tensile strength (cohesive strength) of the subject sealant composition was higher than that of the comparative example.
- the melt flow index for the subject sealant composition was 25 ⁇ 5 g/10 min at 130 °C; while that for the comparative example was 0 (the material did not go through the column). This indicated that the subject sealant composition flows much better during processing (pumping) at normal processing temperatures.
- the subject sealant composition showed low moisture vapor transmission (MVT) of 4.5 g/m 2 day at 85 °C/100% relative humidity, compared to the comparative example MVT of 1 1 .57 g/m 2 day.
- FIG. 8 shows the sample DSC scans for the subject sealant composition and the comparative example (day 0 and 2 weeks aged samples).
- the comparative example 2 weeks aged samples showed ice-to-water transition peak around 0 °C.
- the presence of free water in edge seal may not be acceptable from a mechanical performance point of view.
- the comparative example tape showed the propensity towards rapid crystallization upon aging (See the peak around 1 10 °C).
- This peak corresponds to the crystallized polyethylene (low density and/or linear low density), which is likely the carrier of the silanes. Once these silanes crystallize, they cannot diffuse towards glass and react to build up the chemical adhesion to glass.
- Thermal analyses of the subject sealant composition silanes did not reveal any significant crystallization upon aging. This non-crystallization tendency was more likely the reason behind the higher lap shears (adhesion to glass) of the subject sealant.
- the olefinic polymers may include, for example, polyethylene, polypropylene, polybutene, polyisobutene, butyl rubber (polyisobutene-isoprene), styrene block copolymers, and modified forms of styrene block copolymers.
- the olefinic polymers have number average molecular weights of 100 - 700,000 Da, and preferably have number average molecular weights of 100 - 300,000 Da.
- the silanes may include, for example, DFDA-5451 NT (silane grafted PE available from Dow Chemical of Midland, Ml), DFDA-5481 NT (moisture curing catalyst from Dow Chemical of Midland, Ml), amorphous poly alpha olefins (such as but not restricted to VESTOPLAST 206 and VESTOPLAST 2412 available from Evonik Degussa GmbH of Marl, Germany), alkoxy silanes, and amino silanes.
- DFDA-5451 NT silane grafted PE available from Dow Chemical of Midland, Ml
- DFDA-5481 NT moisture curing catalyst from Dow Chemical of Midland, Ml
- amorphous poly alpha olefins such as but not restricted to VESTOPLAST 206 and VESTOPLAST 2412 available from Evonik Degussa GmbH of Marl, Germany
- alkoxy silanes such as but not restricted to VESTOPLAST 206 and VESTOPLAST 2412 available
- the inert fillers may include, for example, ground and precipitated chalks, silicates, silicon oxides, C black, CaCO3, Ca(OH)2, and titanium dioxide.
- the silicates may include, for example, talc, kaolin, mica, silicon oxide, silicas, and calcium or magnesium silicates.
- the aging resistors may include, for example, hindered phenols, hindered amines, thioethers, mercapto compounds, phosphorous esters, benzotriazoles, benzophenones, and antizonants.
- sealant composition of the present invention exhibits the following characteristics:
- e reacts with polar surfaces containing hydroxyl (-OH) groups such as glass and polyvinyl alcohol) (PVA) and/or alkoxy groups;
- hydroxyl (-OH) groups such as glass and polyvinyl alcohol) (PVA) and/or alkoxy groups;
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Abstract
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.
Description
EDGE SEALANTS HAVING BALANCED PROPERTIES
CROSS-REFERENCE TO RELATED PATENT APPLICATIONS
[0001] This patent application claims the benefit of U.S. Provisional Patent Application No. 61/251 ,517, filed on October 14, 2009, and is a continuation-in-part of co-pending U.S. Patent Application No. 12/679,250, filed on March 19, 2010, which claims the benefit of International Application No. PCT/DE/2008/001564, filed on September 22, 2008, which claims the benefit of German priority document DE/10 2007 045 104.2, filed on September 20, 2007. The contents of the above applications are incorporated herein by reference in their entirety.
FIELD
[0002] This invention relates to an edge seal for manufacturing two- pane or multi-pane insulating glass or solar modules, there being provided a sealant having balanced cohesive and adhesive properties to ensure strong adhesive bonding to the glass surfaces and weaker, yet still strong, internal cohesive strength, to prevent delamination of the edge seal from the substrate.
BACKGROUND
[0003] The construction of insulating glass units comprising two-pane or multi-pane glass is known. In addition to the glass panes, it is standard practice to use sealants and/or adhesives, spacers and desiccants or water scavengers for this purpose. Solar-module glazing (both photovoltaic solar
modules and solar modules for heating water) is assembled in the same way, except that the two glass panes can be replaced partially or completely by sheet metal and/or plastic film.
[0004] The spacer consists primarily of metal (usually aluminum), is located in the edge area of the glass panes, and has the function of maintaining the two glass panes at the desired distance apart. A desiccant (e.g. a molecular sieve) is contained additionally within the hollow spacer in order to keep the air or gas trapped between the panes dry. To enable the desiccant to absorb moisture at all, the spacer is provided with small apertures (longitudinal perforation) on the side facing the interpane space. This arrangement prevents moisture from condensing on the inside of the glass panes at low ambient temperatures and impairing the transparency of the insulating glass unit.
[0005] Between the sides of the spacer that face the glass panes and the inner surfaces of the glass panes, a seal based on polyisobutylene and/or butyl rubber is provided. This seal is generally known as the primary seal. The function of the primary seal is during production of the insulating glass panes, to be a kind of "assembly aid" while the glass panes are being joined to the spacer, which has been pre-coated with primary sealant, in order to hold the assembly together during the next production stages, and later, during the service life of the insulating glass unit, to form a water-vapor barrier that prevents moisture from penetrating from the exterior inwards into the interpane space, and, if the insulating glass unit is filled with gas, to prevent loss of this gas outwards from the interpane space.
[0006] As the outward-facing edge of the spacer is a few millimeters inside of the outside edges of the glass panes, a "channel" is formed into which the secondary sealant, as it is generally known, is injected. The main purpose of the secondary seal is to elastically bond the edge of the insulating glass unit (glass panes and spacer) and also to form a seal - which is to some extent an additional seal - against water and water vapor from the outside and gas from the inside (interpane space). As a rule, the secondary seal consists of room- temperature-curing, two-part sealants and/or adhesives based on polysulfide, polyurethane or silicone. One-part systems, for example based on silicone, or a hot-melt butyl adhesive applied while hot, are also possible.
[0007] The systems described above, however, also have certain disadvantages. During production of the insulating glass units, a large number of materials have to be processed in a series of complicated and cost-intensive stages, some of which take place simultaneously.
[0008] As far as the thermal insulation properties of the edge seal are concerned, metal spacers used there have the disadvantage of being good heat conductors and thus having a negative influence on an insulating glass pane's desirable low K-value, which, in the case of double- or multi-pane insulating glass, has been improved substantially in recent years by filling the interpane space with inert gas and using glass panes coated with low-emission (low-E) layers.
[0009] Particularly as a consequence of the second disadvantage, increasing numbers of insulating glass systems have become available recently
which, in place of aluminum as spacer, use: prefabricated stainless steel profiles (lower wall thickness possible and hence reduced heat flow); or prefabricated plastic profiles; or prefabricated thermoplastic profiles; or extrusion compound comprising thermoplastic materials extruded directly onto one of the glass panes. On account of the improved thermal insulation properties in the edge seal, these systems are also known as "warm-edge systems". Examples of the above may be found in EP 517 067 A2, examples and application machinery for in EP 714 964 A1 , EP 176 388 A1 and EP 823 531 A2.
[0010] The DE 196 24 236 A1 describes a hot-melt adhesive composition for insulating glass, containing a mixture of at least one reactive binder based on silane-functional polyisobutylene, hydrogenated polybutadiene and/or poly-a-olefins, and a non-reactive binder from the group comprising the butyl rubbers, poly-a-olefins, diene polymers, polybutene or styrene block copolymers, which composition may be used as 1 - or 2-part adhesive/sealant in the production of insulating glasses. No separate spacers comprising metal or plastic profiles are needed here, and no additional, secondary sealants.
[0011] The DE 198 21 355 A1 describes a sealing compound for use in the production of multi-pane insulating glass; the compound contains silane- modified butyl rubber and serves as spacer between the individual panes of the multi-pane insulating glass. Here too, no secondary sealant is needed.
[0012] Particularly those spacers extruded directly onto one of the glass panes also overcome the problems relating to the manufacturing process.
As a result, insulating glass panes can be made using an automated process which is much more flexible and more productive.
[0013] In the field of solar module manufacture, too, applying the spacer directly onto the module edges in this manner has proved to offer many advantages. Compared, for example, with the manual or semi-automatic fitting of pre-extruded butyl tapes, this solution brings not only optical advantages but also productivity advantages; in addition, it makes for a more reliable long-term barrier against water-vapor penetration and gas leakage. The EP 1 615 272 A1 (or DE 10 2004 032 604 A1 ) contains a description of an exemplary method and device for assembling solar modules.
[0014] The thermoplastic material used combines the function of the spacer with that of the primary seal, as it is called. It also contains the desiccant. The TPS system (TPS = thermoplastic spacer) is an example of such a system.
[0015] With these systems, too, the outward-facing edge of the spacer is a few millimeters inside of the outer edges of the glass panes, and the remaining space is filled by the secondary seal, as it is called, which bonds the units elastically.
[0016] Where silicone is used as the secondary sealant in combination with a thermoplastic spacer such as the TPS system, it has been found that insulating glass units, including those filled with inert gas, can be manufactured substantially more reliably and retain their gastightness in the edge seal even after a large number of weathering cycles (EP 916 801 A2). It is very difficult to
obtain equally low gas-leakage rates when using metallic spacers combined with a standard primary seal and a silicone-based secondary seal.
[0017] Combined with polysulfide as secondary sealant, the TPS system has, over the past ten years, proved to be completely unproblematic in insulating-glass fenestration applications.
[0018] However, particularly in cases where silicone is used as a secondary sealant, there is a disadvantage that can, in certain cases, manifest itself as an optical defect within the insulating glass units. A combination of:
a) materials (e.g. weather seal, EPDM glazing profiles, etc.) which, due to external influences, are not compatible with the insulating-glass edge seal, and
b) construction errors in the glazing area of the insulating glass units, caused by inadequate planning (poor ventilation/drainage of the glass rebate), and c) extreme exposure (particularly high temperatures at the insulating glass pane and in the edge seal) due to the situation of the installation can cause deformation or movement of the thermoplastic spacer profile into the interpane space. This phenomenon is also known in German as the "Girlanden-Effekt". Depending on the quality of the TPS sealant used, (formulation/production process), there are marked differences in susceptibility to the external influences described under points a) to c). Where silicone is used as secondary sealant, the main reason may be assumed to be the lack of adhesion between the TPS sealant and the secondary seal, and the inadequate adhesion - based only on
predominantly physical interactions - of the TPS sealant to the glass. This bond may be easily weakened to a greater or lesser extent by substances migrating into the glass/TPS sealant interface.
[0019] Proposals for creating a connection of such kind between the TPS and the silicone secondary seal as to achieve mechanical anchorage or a frictional connection by way of a specially shaped cross-section for the extruded TPS profile (DE 102 04 174 A1 ) unfortunately cannot be implemented due to the impossibility of obtaining a suitably shaped die for extruding such a profile cross- section. Another problem with this proposal that has not been solved is exactly how to join up the beginning and the end of the spacer profile extruded onto the glass pane. For a normal rectangular cross-section, this has been described and solved in the EP 823 531 A2. A further difficulty with this proposal is encountered while applying the secondary sealant and consists in how to completely fill the partially convex voids within the TPS strand without incorporating any air bubbles. All in all, therefore, this proposal is one that cannot be implemented as such in an everyday production process, and accordingly does not establish the desired objective.
[0020] Attempts to achieve chemical adhesion between the TPS sealant and the silicone sealant by selective addition of traditional, silane-based adhesion promoters to one and/or both sealants also fail. To this end, it is desirable to use grades and quantities which unfortunately have a negative influence on other desired properties, for example the working consistency of the
TPS sealant, or which later on cause fogging in the insulating glass when the unit has been installed.
SUMMARY
[0021] A sealant composition is provided having a) an olefinic polymer, b) a silane modified olefinic polymer, c) a filler, d) a desiccant or a water scavenger, and e) an aging resistor. A tensile strength and a lap shear strength of the sealant composition is balanced such that the sealant fails cohesively before failing adhesively.
[0022] In one example of the present invention, the sealant composition has a tensile strength greater than 20 PSI and a lap shear strength greater than 20 PSI.
[0023] In another example of the present invention, the sealant composition has a tensile strength greater than 50 PSI and a lap shear strength greater than 40 PSI.
[0024] In yet another example of the present invention, the sealant composition chemically reacts with a polar surface containing at least one of alkoxy groups and hydroxyl (-OH) groups such as, but not limited to, glass and polyvinyl alcohol) (PVA).
[0025] In yet another example of the present invention, the sealant composition has an endothermic enthalpy for a peak approximately 100-140C less than 50 J/g upon four (4) weeks aging under 85% relative humidity 85°C.
[0026] In yet another example of the present invention, the sealant composition an endothermic enthalpy for a peak approximately 100-140C less than 30 J/g, upon four (4) weeks aging under 85% relative humidity 85°C.
[0027] In yet another example of the present invention, the sealant composition has a moisture vapor transmission (MVT) less than 0.7 g/m2/day at 38 °C and 100% relative humidity for 0.060 to 0.080 inch thick samples.
[0028] In yet another example of the present invention, the sealant composition has a moisture vapor transmission (MVT) less than 0.4 g/m2/day at 38 °C and 100% relative humidity for 0.060 to 0.080 inch thick samples.
[0029] In yet another example of the present invention, the sealant composition has a moisture vapor transmission (MVT) less than 15 g/m2/day at 85°C and 100% relative humidity for 0.060 to 0.080 inch thick samples.
[0030] In yet another example of the present invention, the sealant composition has a moisture vapor transmission (MVT) less than 8 g/m2/day at 85°C and 100% relative humidity for 0.060 to 0.080 inch thick samples.
[0031] In yet another example of the present invention, the sealant composition has a melt volume index (MVI) less than 50 cm3/10 minutes at 130°C and 10 kg load through a 0.0823 inch diameter orifice.
[0032] In yet another example of the present invention, 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.
[0033] In yet another example of the present invention, the first viscosity of the sealant composition is greater than the second viscosity and the first shear force is a less than force than the second shear force.
[0034] In yet another example of the present invention, the olefinic polymers are present in the composition in an amount from about 30% to about 60% by weight of the total composition.
[0035] In yet another example of the present invention, the olefinic polymers are present in the composition in an amount from about 40% to about 50% by weight of the total composition.
[0036] In yet another example of the present invention, the silane modified olefinic polymer is present in the composition in an amount from about 2% to about 35% by weight of the total composition.
[0037] In yet another example of the present invention, the silane modified olefinic polymer is present in the composition in an amount from about 5% to about 25% by weight of the total composition.
[0038] In yet another example of the present invention, the filler is present in the composition in an amount from about 5% to about 40% by weight of the total composition.
[0039] In yet another example of the present invention, the filler is present in the composition in an amount from about 10% to about 30% by weight of the total composition.
[0040] In yet another example of the present invention, the desiccant or water scavenger is present in the composition in an amount from about 2.5% to about 25% by weight of the total composition.
[0041] In yet another example of the present invention, the desiccant or water scavenger is present in the composition in an amount from about 10% to about 15% by weight of the total composition.
[0042] In yet another example of the present invention, the aging resistor is present in the composition in an amount from about 0% to about 3% by weight of the total composition.
[0043] Further features and advantages of the present invention will become apparent by reference to the following description and appended drawings wherein like reference numbers refer to the same component, element or feature.
DRAWINGS
[0044] The drawings described herein are for illustration purposes only and are not intended to limit the scope of the present disclosure in any way.
[0045] FIG. 1 is a bar chart depicting the lap shear strength of an example of the sealant composition and the comparative example;
[0046] FIG. 2 is a bar chart depicting the lap shear strength of an example of the sealant composition having variable silane content;
[0047] FIG. 3 is a graph illustrating DSC scans for the comparative example as a function of damp heat aging time;
[0048] FIG. 4 is a graph illustrating DSC scans for an example of the sealant composition as a function of damp het aging time;
[0049] FIG. 5 is a illustration depicting crystallized and un crystallized polymer chains;
[0050] FIG. 6 is a bar chart depicting the lap shear strength of an example of the sealant composition and the comparative example;
[0051] FIG. 7 is a bar chart depicting the tensile strength of an example of the sealant composition having variable silane content; and
[0052] FIG. 8 is a graph illustrating DSC scans for the comparative example as a function of aging time.
DETAILED DESCRIPTION
[0053] The invention is explained in detail below by reference to embodiment and a comparative example.
Example 1 : Comparative (prior art)
[0055] To one long edge in each case of test insulating-glass panes measuring 500 x 350 mm and constructed as 4 mm float glass / 16 mm interpane space / 4 mm float glass plus the edge seal consisting in the one instance of:
1 ) the sealing compound of the comparative example 1 as thermoplastic spacer and a conventional 2-part silicone as secondary sealant, and in the other instance of
2) the sealing compound according to example 2 of the invention as thermoplastic spacer and the same conventional 2-part silicone as in 1 ) as secondary sealant,
an EPDM profile of the kind typically employed for glazing applications and having a plasticizer content of about 20% mineral oil is bonded using a one-part silicone sealant with a high silicone-plasticizer content, said profile thus being brought into direct contact with the edge-seal sealants. The test panes prepared in this way were then exposed to a weathering-cycle test (-20 °C / + 80 °C at 95 - 100% rel. humidity, 8 hours per cycle, 3 cycles per day).
[0056] After only about 4-5 weeks of the weathering-cycle test, test pane 1 ) showed deformation, i.e. movement, of the thermoplastic spacer profile into the interpane space. This was caused by the incompatibility reactions (plasticizer migration from the EPDM profile and the one-part silicone sealant).
[0057] Test pane 2), by contrast, showed no impairment of the edge seal whatsoever even after more than 50 weeks of the weathering-cycle test.
[0058] Similarly, the glass adhesion and the edge seal showed no recognizable impairment whatsoever after more than 4,000 hours of irradiation with UV lamps (Ultra-violet) and temperatures at the pane surfaces of up to 1 10 °C.
[0059] An edge seal that can withstand stresses of this kind is thus suitable not only for insulating-glass applications in particularly demanding situations, e.g. frameless glazing in facades or roofs (known as structural glazing), but also, for example, for the edge seal in solar modules.
[0060] In addition to the first application of a strand of reactive butyl compound, it is also possible to apply a second strand of butyl before the solar module is pressed. This is a particularly useful solution in cases where the electrical contacts of the photovoltaic cells contained in the module are made to pass through the edge seal to the outside. After the first strand has been applied, the contacts - usually in the form of thin tape - are channeled to the exterior and the second butyl strand is then extruded directly on top of the first one. The contacts are thereby embedded in the butyl compound, thus ensuring that in the finished solar module, the contact leads across the edge seal to the outside are gastight and impermeable to water vapor. Since the contacts are usually in the form of non-insulated metal tapes, the edge seal must not show any electrical conductivity, as this can cause fault current or short circuits between the contacts. In the case of a silicone-based secondary seal, this is no problem, since silicones typically show very high volume resistivities, mostly > 1014 Ohm-cm, and thus fall within the category of electrical insulators. However, butyl
sealants with a high filler content of carbon black - as in the case of the reactive butyl compound described here - have volume resistivities of < 106 Ohm-cm, meaning that the compound would be electrically conductive. Reducing the carbon black content admittedly increases the volume resistivity, but also brings many disadvantages. Aside from mechanical reinforcement and viscosity regulation, the purpose of a high carbon black content in a butyl sealant is to make the mixture particularly stable toward high temperatures and UV irradiation. If the carbon black content were to be substantially reduced because of the volume resistivity, this would no longer be the case and the butyl sealing compound would no longer show the required long-term stability for applications in the field of solar modules, i.e. for applications involving high temperatures and solar radiation. By using a specialty carbon black in place of the carbon blacks generally used in butyl sealants, however, it is possible to obtain a reactive butyl compound that has all the required properties. It transpired that by selecting an oxidatively post-treated carbon black made by the furnace process and having a primary-particle size in the 50 - 60 nm range, a carbon black had been found which not only permitted filler contents of up to 20 wt.% for the reactive butyl compound, which are necessary for stabilization, mechanical reinforcement and viscosity regulation, but simultaneously result in a volume resistivity of > 1010 Ohm-cm, which is fully adequate for the electrical insulating effect required of the reactive butyl sealing compound.
[0061] A specialty carbon black of this kind is used in the following example.
Example 3:
[0062] The sealing compound is a hot-melt sealant that contains Vestoplast 206, a silane grafted amorphous poly alpha olefin (APAO), that chemically reacts with glass hydroxyl (-OH) groups or alkoxy groups in the presence of water resulting in the formation of a covalent bond. The inability of silanes to chemically bond with glass may result in delamination. This sealant- glass chemical bonding is very important with respect to the long-term solar module water resistance, as one of the common failure modes is the water ingress into the module through the passage (opening) near glass-sealant interface.
[0063] A comparative example, commercially available from a manufacturer of edge sealants was used to compare the performance of the sealant composition. The progression of sealant-glass reaction was quantified using 180° lap shear analyses. 1 "X1 ", 1 .7 mm samples were sandwiched in between two glass plates (1 "X3"). This sandwich was conditioned at 240 °F for ~ 30 min and compressed to 1 .22 mm final thickness. These lap shear samples were aged for a month in 85 °C - 85 % relative humidity (damp heat) chamber to monitor lap shear values and failure modes. The reported lap shear is an average of at least 3 specimens pulled at 4 inch/min (the peak value is reported
as the lap shear). Heat as well as damp heat aged samples (approximately 3 - 5 mg) were characterized using differential scanning calorimetry (standard mode, TA instruments) to monitor the presence of free water in samples and crystallization behavior. Samples were equilibrated at -90 °C and ramped to 200 °C at 10 °C/min.
[0064] FIG. 1 shows the lap shears for the sealant composition of the present invention and the comparative example as a function of 85 °C - 85 % relative humidity aging time. It was observed that the sealant composition lap shears were always higher than the comparative example during one month aging study. This indicated that the sealant composition adhesion bond to glass was much stronger than that of the comparative example. Furthermore, while the comparative example exhibited adhesive or partially adhesive failures the sealant composition always failed cohesively indicating a better balance of cohesive and adhesive properties.
[0065] FIG. 2 shows the lap shear values for the sealant composition with different silane contents as a function of 85 °C - 85 % relative humidity aging time. Initially (roughly up to day 5) there was not any significant difference in lap shears (adhesion to glass) for the sealant composition, the sealant composition with no silanes, the sealant composition with non reactive silanes, and the sealant composition with twice as much silanes. However, as these samples aged in damp heat chamber, it was observed that the sealant composition and the sealant composition with twice as much silane had significantly higher lap shear strengths (adhesion to glass) than the sealant composition without silanes
and the sealant composition with non reactive silanes. This ladder study confirmed that the presence of silanes led to the increase in adhesion to glass with time via sealant (silanes) glass surface chemical bonding.
[0066] FIG. 3 shows the sample DSC scans for the comparative example as a function of damp heat aging time. Day 1 aged samples showed an endothermic melting peak (onset around 100 °C). This melting peak observed to expand upon aging (FIG. 3) indicating the crystallinity build up. This peak corresponds to the polyethylene (low density and/or linear low density), which is more likely the carrier of the comparative example silanes. Once these silanes crystallize, they cannot diffuse towards glass and react to build up the chemical adhesion to glass. Thermal analyses of the sealant composition silanes did not reveal any significant crystallization upon aging (see FIG. 4). This non- crystallization tendency was more likely the reason behind higher the sealant composition lap shears (adhesion to glass).
[0067] Crystallization often involves the orientation of polymer chains resulting in the oriented structures (crystals) (see FIG. 5). Once these crystals are formed, the polymer chains get locked and are not mobile. A chemical reaction involves the diffusion of reactive species toward each other followed by orientation and then reaction. In case of solar edge sealant applications, glass is the stationary surface. Hence the sealant (silane) - glass reaction proceeds only through the diffusion of reactive silanes towards the glass surface. However, upon crystallization, these silanes are locked in place, cannot diffuse (unless melted or dissolved), and hence cannot migrate to the surface to react with glass.
[0068] The sealant composition and the comparative example were also tested for cohesive and adhesive properties. The moisture-cure-potential of the sealant composition makes it suitable to covalently react with glass. The progression of this reaction was quantified using 180° lap shear analyses. One inch by one inch, 1 .7 mm thick samples were sandwiched in between two glass plates (1 "X3"). This sandwich was conditioned at 240 °F for ~ 30 min and compressed to 1 .22 mm final thickness. Tensile samples were dog-bone shaped, the gauge dimensions being 1 .5 inch X 8 mm. These lap shear and tensile samples were aged for a month in 85 °C - 85 % relative humidity chamber to monitor lap shear values. The reported lap shear is an average of at least 3 specimens pulled at 4 inch/min (the peak value is reported as the lap shear) tested at room temperature.
[0069] Heat as well as damp heat aged samples (approximately 3 - 5 mg) were characterized using differential scanning calorimetry (standard mode, TA Instruments Q200 DSC) to monitor the presence of free water in samples and crystallization behavior. Samples were equilibrated at -90 °C and ramped to 200 °C at 10 °C/min.
[0070] Melt flow index values were collected at 130 °C for the sealant composition and the comparative example samples. A 0.823 mm diameter cylindrical column was preheated to 130 °C followed by inserting the sample to be tested into this column. A 0.1 kg piston attached to 9.9 kg weight (total 10 kg weight) was inserted at the top end and the material exiting the bottom end was collected.
[0071] Mocon moisture vapor permeability equipment (Permatarn- w 3/33) was used to monitor the water transmission through the samples (5 cm diameter and 1 .5 mm thick circular samples).
[0072] FIG. 5 shows the lap shears for the sealant composition and the comparative example as a function of 85 °C - 85 % relative humidity aging time. It was observed that the sealant composition lap shears were always higher than comparative example during one month aging study. This indicated that the sealant composition adhesion bond to glass was much stronger than that of comparative example.
[0073] FIG. 6 shows the lap shear values for the sealant composition with different silane contents as a function of 85 °C - 85 % relative humidity aging time. Initially (roughly up to day 5) there was not any significant difference in lap shears (adhesion to glass) for the sealant composition, the sealant composition with no silanes, the sealant composition with non reactive silanes, and a sealant composition with twice the silane content. However, as these samples aged in damp heat chamber, it was observed that the sealant composition and the sealant composition with twice the silane content had significantly higher lap shear strengths (adhesion to glass) than the sealant composition without silanes and the sealant composition with non reactive silanes. This ladder study proved that the presence of reactive silanes led to the increase in adhesion to glass with time. Although, the sealant composition and the sealant composition with twice the silane content showed insignificant differences in lap shear strengths, it
should be noted that this study was conducted for only one month, and upon monitoring the progression further, a differentiation may be seen.
[0074] Lap shear values for the subject sealant composition with different silane contents as a function of 85 °C - 85 % relative humidity aging time; A: subject composition with twice the silane content, B: subject composition, C: subject composition with non-reactive silanes, and D: subject composition with no silanes.
[0075] FIG. 7 shows the tensile strengths for the sealant composition with different silane contents as a function of 85 °C - 85 % relative humidity aging time. Tensile strength is the representation of the cohesive strength within the sealant. It was clearly seen that the tensile strength (cohesive strength) of the subject sealant composition was higher than that of the comparative example.
[0076] The melt flow index for the subject sealant composition was 25 ± 5 g/10 min at 130 °C; while that for the comparative example was 0 (the material did not go through the column). This indicated that the subject sealant composition flows much better during processing (pumping) at normal processing temperatures.
[0077] The subject sealant composition showed low moisture vapor transmission (MVT) of 4.5 g/m2day at 85 °C/100% relative humidity, compared to the comparative example MVT of 1 1 .57 g/m2day.
[0078] FIG. 8 shows the sample DSC scans for the subject sealant composition and the comparative example (day 0 and 2 weeks aged samples). The comparative example 2 weeks aged samples showed ice-to-water transition
peak around 0 °C. The presence of free water in edge seal may not be acceptable from a mechanical performance point of view. Also, the comparative example tape showed the propensity towards rapid crystallization upon aging (See the peak around 1 10 °C). This peak corresponds to the crystallized polyethylene (low density and/or linear low density), which is likely the carrier of the silanes. Once these silanes crystallize, they cannot diffuse towards glass and react to build up the chemical adhesion to glass. Thermal analyses of the subject sealant composition silanes did not reveal any significant crystallization upon aging. This non-crystallization tendency was more likely the reason behind the higher lap shears (adhesion to glass) of the subject sealant.
[0079] DSC scans for the subject sealant composition and the comparative example (day 0 and 2 weeks aged samples). The comparative example 2 weeks aged samples showed ice-to-water transition peak around 0 °C.
[0080] The following are examples of the sealant composition of the present invention:
Example 4:
[0081] The olefinic polymers may include, for example, polyethylene, polypropylene, polybutene, polyisobutene, butyl rubber (polyisobutene-isoprene), styrene block copolymers, and modified forms of styrene block copolymers. The olefinic polymers have number average molecular weights of 100 - 700,000 Da, and preferably have number average molecular weights of 100 - 300,000 Da.
[0082] The silanes may include, for example, DFDA-5451 NT (silane grafted PE available from Dow Chemical of Midland, Ml), DFDA-5481 NT (moisture curing catalyst from Dow Chemical of Midland, Ml), amorphous poly alpha olefins (such as but not restricted to VESTOPLAST 206 and VESTOPLAST 2412 available from Evonik Degussa GmbH of Marl, Germany), alkoxy silanes, and amino silanes.
[0083] The inert fillers may include, for example, ground and precipitated chalks, silicates, silicon oxides, C black, CaCO3, Ca(OH)2, and
titanium dioxide. The silicates may include, for example, talc, kaolin, mica, silicon oxide, silicas, and calcium or magnesium silicates. The aging resistors may include, for example, hindered phenols, hindered amines, thioethers, mercapto compounds, phosphorous esters, benzotriazoles, benzophenones, and antizonants.
[0084] The sealant composition of the present invention exhibits the following characteristics:
a) a tensile strength (the peak value on engineering stress-strain curve) of greater than 20 PSI;
b) a tensile strength (the peak value on engineering stress-strain curve) of greater than 50 PSI;
c) a lap shear strength greater than 20 PSI that fails cohesively;
d) a lap shear strength greater than 40 PSI that fails cohesively;
e) reacts with polar surfaces containing hydroxyl (-OH) groups such as glass and polyvinyl alcohol) (PVA) and/or alkoxy groups;
f) an endothermic enthalpy for a peak (DSC run at 10 C/min, TA instruments Q 200 equipment) approximately 100-140 C less than 50 J/g upon 4 weeks aging under 85% relative humidity 85°C;
g) an endothermic enthalpy for a peak (DSC run at 10 C/min, TA instruments Q 200 equipment) approximately 100 - 140°C less than 30 J/g upon 4 weeks aging under 85% relative humidity 85°C;
h) a moisture vapor transmission less than 0.7 g/m2day at 38°C and 100% relative humidity for .060 to 0.080 inch thick samples;
i) a moisture vapor transmission less than 0.4 g/m2day at 38°C and
100% relative humidity for .060 to 0.080 inch thick samples; j) a moisture vapor transmission less than 15 g/m2day at 85°C and 100% relative humidity for 0.060 to 0.080 inch thick samples as tested using
Mocon Permatron-W® model 3/33;
k) a moisture vapor transmission less than 8 g/m2day at 85°C and 100% relative humidity for 0.060 to 0.080 inch thick samples as tested using
Mocon Permatron-W® model 3/33;
I) a melt volume index less than 50 cm3/10 min at 130°C and 10 kg load through 0.0823 inch diameter orifice;
m) a high viscosity under low shear and a lower viscosity under high shear.
[0085] The description of the invention is merely exemplary in nature and variations that do not depart from the gist of the invention are intended to be within the scope of the invention. Such variations are not to be regarded as a departure from the spirit and scope of the invention.
Claims
1 . A sealant composition comprising:
a) an olefinic polymer;
b) a silane modified olefinic polymer;
c) a filler;
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 at least one of the hydroxyl groups includes glass or polyvinyl alcohol) (PVA).
5. The sealant composition of claim 1 wherein the sealant composition has an endothermic enthalpy for a peak approximately 100-140C less than 50 J/g upon four (4) weeks aging under 85% relative humidity 85°C.
6. The sealant composition of claim 1 wherein the sealant composition has an endothermic enthalpy for a peak approximately 100-140C less than 30 J/g, upon four (4) weeks aging under 85% relative humidity 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/m2/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/m2/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/m2/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/m2/day at 85°C and 100% relative humidity for a 0.060 to 0.080 inch thick sample of the sealant composition.
1 1 . The sealant composition of claim 1 wherein the sealant compostion has a melt volume index (MVI) less than 50 cm3/10 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 filler is present in the sealant composition in an amount from about 5% to about 55% by weight of the total sealant composition.
19. The sealant composition of claim 1 wherein the filler is present in the sealant composition in an amount from about 20% to about 50% 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 2.5% to about 25% by weight of the total sealant composition.
21 . 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.
22. 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.
23. 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;
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 filler;
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 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.
24. The solar module of claim 23 wherein the sealant chemically reacts with a polar surface of at least one of the first and second substrates including at least one of the alkoxy groups and the hydroxyl (-OH) groups.
25. The solar module of claim 23 wherein the sealant has an endothermic enthalpy for a peak approximately 100-140C less than 50 J/g upon four (4) weeks aging under 85% relative humidity 85°C.
26. The solar module of claim 23 wherein the sealant has an endothermic enthalpy for a peak approximately 100-140C less than 30 J/g upon four (4) weeks aging under 85% relative humidity 85°C.
27. The solar module of claim 23 wherein the sealant has a moisture vapor transmission rate (MVTR) less than 0.7 g/m2/day at 38 °C and 100% relative humidity for a 0.060 to 0.080 inch thick sample.
28. The solar module of claim 23 wherein the sealant has a moisture vapor transmission rate (MVTR) less than 0.4 g/m2/day, at 38 °C and 100% relative humidity for a 0.060 to 0.080 inch thick sample.
29. The solar module of claim 23 wherein the sealant has a moisture vapor transmission rate (MVTR) less than 15 g/m2/day at 85°C and 100% relative humidity for a 0.060 to 0.080 inch thick sample.
30. The solar module of claim 23 wherein the sealant has a moisture vapor transmission rate (MVTR) less than 8 g/m2/day, at 85°C and 100% relative humidity for a 0.060 to 0.080 inch thick sample.
31 . The solar module of claim 23 wherein the sealant has a melt volume index (MVI) less than 50 cm3/10 minutes at 130°C and 10 kg load through a 0.0823 inch diameter orifice.
32. The solar module of claim 23 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.
33. The solar module of claim 32 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.
34. The solar module of claim 23 wherein the olefinic polymer of the sealant is present in the sealant in an amount from about 30% to about 60% by weight of the total sealant, the modified olefinic polymer is present in the sealant in an amount from about 2% to about 35% by weight of the total sealant, the fine- particle inert filler is present in the sealant in an amount from about 5% to about 55% by weight of the total sealant, the at least one of the desiccant and water scavenger is present in the sealant in the amount from about 2.5% to about 25% by weight of the total sealant, the aging resistor is present in the sealant in the amount from about 0% to about 3% by weight of the total sealant.
35. The solar module of claim 23 wherein the olefinic polymer of the sealant is present in the sealant in an amount from about 30% to about 50% by weight of the total sealant, the modified olefinic polymer is present in the sealant in an amount from about 5% to about 25% by weight of the total sealant, the fine- particle inert filler is present in the sealant in an amount from about 10% to about 30% by weight of the total sealant, the at least one of the desiccant and water scavenger is present in the sealant in the about 10% to about 15% by weight of the total sealant, the aging resistor is present in the sealant in the amount from about 0% to about 3% by weight of the total sealant.
36. A sealant composition comprising:
a) an olefinic polymer;
b) a silane modified olefinic polymer;
c) a filler;
d) at least one of a desiccant and a water scavenger; and
e) an aging resistor, and
wherein the silane modified olefinic polymer includes a reactive group that chemically reacts with a polar surface including at least one of the alkoxy groups and the hydroxyl (-OH) groups to form a bond that is greater than the cohesive strength of the sealant composition and wherein the sealant composition has a tensile strength greater than 20 PSI and a lap shear strength greater than 20 PSI.
37. The sealant composition of claim 36 wherein the tensile strength of the sealant composition is greater than 50 PSI.
38. The sealant composition of claim 36 wherein the lap shear strength of the sealant composition is greater than 40 PSI.
39. The sealant composition of claim 36 wherein the sealant composition has an endothermic enthalpy for a peak approximately 100-140C less than 50 J/g upon four (4) weeks aging under 85% relative humidity 85°C.
40. The sealant composition of claim 36 wherein the sealant composition has an endothermic enthalpy for a peak approximately 100-140C less than 30 J/g upon four (4) weeks aging under 85% relative humidity 85°C.
41 . The sealant composition of claim 36 wherein the sealant composition has a moisture vapor transmission rate (MVTR) less than 0.7 g/m2/day at 38 °C and 100% relative humidity for a 0.060 to 0.080 inch thick sample.
42. The sealant composition of claim 36 wherein the sealant composition has a moisture vapor transmission rate (MVTR) less than 0.4 g/m2/day at 38 °C and 100% relative humidity for a 0.060 to 0.080 inch thick sample.
43. The sealant composition of claim 36 wherein the sealant composition has a moisture vapor transmission rate (MVTR) less than 15 g/m2/day at 85 °C and 100% relative humidity for a 0.060 to 0.080 inch thick sample.
44. The sealant composition of claim 36 the sealant composition has a moisture vapor transmission rate (MVTR) less than 8 g/m2/day at 85 °C and 100% relative humidity for a 0.060 to 0.080 inch thick sample.
45. The sealant composition of claim 36 wherein the sealant composition has a melt volume index (MVI) less than 50 cm3/10 minutes at 130°C and 10 kg load through 0.0823 inch diameter orifice.
46. The sealant composition of claim 36 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.
47. The sealant composition of claim 46 wherein the first viscosity of the sealant composition is greater than the second viscosity and the first shear force that is less than the second shear force.
48. The sealant composition of claim 36 wherein the olefinic polymer of the sealant composition is present in the sealant composition in an amount from about 30% to about 60% by weight of the total sealant composition, the 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, the fine-particle inert filler is present in the sealant composition in an amount from about 5% to about 40% by weight of the total sealant composition, the at least one of the desiccant and water scavenger is present in the sealant composition in the amount from about 2.5% to about 25% by weight of the total sealant composition, the aging resistor is present in the sealant composition in the amount from about 0% to about 3% by weight of the total sealant composition.
49. The sealant composition of claim 36 wherein the olefinic polymer of the sealant composition is present in the sealant composition in an amount from about 30% to about 50% by weight of the total sealant composition, the 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, the fine-particle inert filler is present in the sealant composition in an amount from about 10% to about 30% by weight of the total sealant composition, the at least one of the desiccant and water scavenger is present in the sealant composition in the about 10% to about 15% by weight of the total sealant composition, the aging resistor is present in the sealant composition in the amount from about 0% to about 3% by weight of the total sealant composition.
50. 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 polymers or combinations thereof;
at least one of a silane modified APAO and a silane modified polyisobutylene;
a carbon black;
a filler;
at least one of a water scavenger and a desiccant; and
an aging resistor, and
wherein the at least one of a silane modified APAO and a 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.
51 . The sealant of claim 50 wherein the carbon black is included in an amount up to about 20% by weight.
52. The sealant of claim 50 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 filler is included in an amount from about 5% to about 47% 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.
53. The sealant of claim 50 wherein the olefinic polymer includes a polyisobutylene in an amount from about 30% to about 50% of the total sealant composition.
54. The sealant of claim 50 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% of the total sealant composition.
55. The sealant of claim 50 wherein the carbon black is oxidatively post treated by a furnace process and included in an amount from 5 to 20% by weight of the total sealant composition, and wherein the sealant has a volume resistivity of greater than 1 x106 ohms-cm.
56. The sealant of claim 50 wherein the carbon black is oxidatively post treated by a furnace process and included in an amount from 5 to 20% by weight of the total sealant composition, and wherein the sealant has a volume resistivity of greater than 1 x1010 ohms-cm.
57. The sealant of claim 50 wherein the at least one of the water scavenger and the desiccant is a molecular sieve included in an amount from about 2.5% to about 30% of the total sealant composition.
58. The sealant of claim 50 wherein the sealant is oxidatively stable after 4000 hrs of exposure to temperatures greater than 1 10 C.
59. The sealant of claim 50 wherein the filler includes calcium carbonate or a silicate.
60. The sealant of claim 50 wherein a combination of the carbon black and the filler is included in an amount from about 10% to about 50%.
61 . The sealant of claim 50 wherein the aging resistor includes a phenol antioxidant.
Priority Applications (5)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN201080056583.XA CN102742005B (en) | 2009-10-14 | 2010-10-14 | There is the edge sealant of the character of balance |
| JP2012534372A JP2013509455A (en) | 2009-10-14 | 2010-10-14 | Edge sealant with balanced properties |
| US13/501,943 US9115272B2 (en) | 2007-09-20 | 2010-10-14 | Edge sealants having balanced properties |
| KR1020127012184A KR101780631B1 (en) | 2009-10-14 | 2010-10-14 | Edge sealants having balanced properties |
| EP10824122.5A EP2489069A4 (en) | 2009-10-14 | 2010-10-14 | Edge sealants having balanced properties |
Applications Claiming Priority (4)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US25151709P | 2009-10-14 | 2009-10-14 | |
| US61/251,517 | 2009-10-14 | ||
| US12/679,250 | 2010-03-19 | ||
| US67925010A | 2010-10-18 | 2010-10-18 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| WO2011047194A1 true WO2011047194A1 (en) | 2011-04-21 |
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Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| PCT/US2010/052733 WO2011047194A1 (en) | 2007-09-20 | 2010-10-14 | Edge sealants having balanced properties |
Country Status (5)
| Country | Link |
|---|---|
| EP (1) | EP2489069A4 (en) |
| JP (1) | JP2013509455A (en) |
| KR (1) | KR101780631B1 (en) |
| CN (1) | CN102742005B (en) |
| WO (1) | WO2011047194A1 (en) |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US10961392B2 (en) | 2018-03-30 | 2021-03-30 | Dow Silicones Corporation | Condensation curable compositions |
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| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN107474768B (en) * | 2017-07-11 | 2020-05-22 | 浙江福斯特新材料研究院有限公司 | Solar thin film battery pack edge sealant |
| CN110499124A (en) * | 2019-08-28 | 2019-11-26 | 浙江福斯特新材料研究院有限公司 | It is used to form composition, its application and photovoltaic module in photovoltaic art of sealant |
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- 2010-10-14 CN CN201080056583.XA patent/CN102742005B/en active Active
- 2010-10-14 EP EP10824122.5A patent/EP2489069A4/en not_active Withdrawn
- 2010-10-14 KR KR1020127012184A patent/KR101780631B1/en active IP Right Grant
- 2010-10-14 WO PCT/US2010/052733 patent/WO2011047194A1/en active Application Filing
- 2010-10-14 JP JP2012534372A patent/JP2013509455A/en active Pending
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| US20020010272A1 (en) * | 1998-04-27 | 2002-01-24 | Mahdi Syed Z. | Cure on demand adhesives and window module with cure on demand adhesive thereon |
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Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US10961392B2 (en) | 2018-03-30 | 2021-03-30 | Dow Silicones Corporation | Condensation curable compositions |
Also Published As
| Publication number | Publication date |
|---|---|
| CN102742005B (en) | 2016-04-20 |
| EP2489069A4 (en) | 2017-05-03 |
| CN102742005A (en) | 2012-10-17 |
| KR20120099675A (en) | 2012-09-11 |
| KR101780631B1 (en) | 2017-09-21 |
| JP2013509455A (en) | 2013-03-14 |
| EP2489069A1 (en) | 2012-08-22 |
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