Classifications

• • H—ELECTRICITY
  • H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
  • H10W—GENERIC PACKAGES, INTERCONNECTIONS, CONNECTORS OR OTHER CONSTRUCTIONAL DETAILS OF DEVICES COVERED BY CLASS H10
  • H10W74/00—Encapsulations, e.g. protective coatings
  • H10W74/40—Encapsulations, e.g. protective coatings characterised by their materials
  • H10W74/47—Encapsulations, e.g. protective coatings characterised by their materials comprising organic materials, e.g. plastics or resins
• • H—ELECTRICITY
  • H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
  • H10W—GENERIC PACKAGES, INTERCONNECTIONS, CONNECTORS OR OTHER CONSTRUCTIONAL DETAILS OF DEVICES COVERED BY CLASS H10
  • H10W74/00—Encapsulations, e.g. protective coatings
  • H10W74/40—Encapsulations, e.g. protective coatings characterised by their materials
• • 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
  • C08K3/01—Use of inorganic substances as compounding ingredients characterized by their specific function
  • C08K3/013—Fillers, pigments or reinforcing additives
• • 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
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
  • C08L51/00—Compositions of graft polymers in which the grafted component is obtained by reactions only involving carbon-to-carbon unsaturated bonds; Compositions of derivatives of such polymers
  • C08L51/06—Compositions of graft polymers in which the grafted component is obtained by reactions only involving carbon-to-carbon unsaturated bonds; Compositions of derivatives of such polymers grafted on to homopolymers or copolymers of aliphatic hydrocarbons containing only one carbon-to-carbon double bond
• • C—CHEMISTRY; METALLURGY
  • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
  • C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
  • C09J123/00—Adhesives based on homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Adhesives based on derivatives of such polymers
  • C09J123/02—Adhesives based on homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Adhesives based on derivatives of such polymers not modified by chemical after-treatment
• • H—ELECTRICITY
  • H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
  • H10F—INORGANIC SEMICONDUCTOR DEVICES SENSITIVE TO INFRARED RADIATION, LIGHT, ELECTROMAGNETIC RADIATION OF SHORTER WAVELENGTH OR CORPUSCULAR RADIATION
  • H10F19/00—Integrated devices, or assemblies of multiple devices, comprising at least one photovoltaic cell covered by group H10F10/00, e.g. photovoltaic modules
  • H10F19/80—Encapsulations or containers for integrated devices, or assemblies of multiple devices, having photovoltaic cells
• • H—ELECTRICITY
  • H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
  • H10W—GENERIC PACKAGES, INTERCONNECTIONS, CONNECTORS OR OTHER CONSTRUCTIONAL DETAILS OF DEVICES COVERED BY CLASS H10
  • H10W74/00—Encapsulations, e.g. protective coatings
  • H10W74/40—Encapsulations, e.g. protective coatings characterised by their materials
  • H10W74/47—Encapsulations, e.g. protective coatings characterised by their materials comprising organic materials, e.g. plastics or resins
  • H10W74/473—Encapsulations, e.g. protective coatings characterised by their materials comprising organic materials, e.g. plastics or resins 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
  • C08K3/02—Elements
  • C08K3/04—Carbon
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
  • C08L2203/00—Applications
  • C08L2203/20—Applications use in electrical or conductive gadgets
  • C08L2203/204—Applications use in electrical or conductive gadgets use in solar cells
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
  • C08L2312/00—Crosslinking
  • C08L2312/08—Crosslinking by silane
• • 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

• edge sealants have the property of having a low rate of moisture vapor transmission, or MVT.
• molecular sieves include, but are not limited to, aluminosilicate minerals, clays, porous glasses, microporous charcoals, zeolites, active carbons, or synthetic compounds that have open structures through which small molecules, such as water can diffuse.
• the sealant composition exhibits a water break through time of greater than 5 hr and a steady state moisture vapor transmission rate of less than 40 g.m2/day for a 0.030 inch thick sample of the sealant composition tested at 85 C and 100% relative humidity.
• a combination of the calcium oxide and the molecular sieve is included in an amount greater than about 10% by weight and the sealant composition exhibits a water break through time of greater than 5 hr and a steady state moisture vapor transmission rate of less than 40 g.m2/day for a 0.030 inch thick sample of the sealant composition tested at 85 C and 100% relative humidity.
• the sealant composition further includes at least one of a clay, a calcium sulfate, and a silica gel.
• the sealant composition exhibits exhibit a water break through time of greater than 5 hr and a steady state moisture vapor transmission rate of less than 40 g.m2/day for a 0.030 inch thick sample of the sealant composition tested at 85 C and 100% relative humidity.
• the sealant composition further includes at least one of a clay, a calcium sulfate, and a silica gel.
• a combination of the calcium oxide, the molecular sieve, and the sealant composition exhibits a water break through time of greater than 10 hr and steady state moisture vapor transmission rate of less than 30 g.m2/day for a 0.030 inch thick sample of the sealant composition tested at 85 C and 100% relative humidity.
• the sealant composition exhibits less than about 15 gm/((m A 2) * day) moisture vapor transmission rate at steady state for a 0.030 inch thick sample of the sealant composition tested at 85 C and 100% relative humidity.
• the sealant includes balanced properties that keep swelling of the sealant to a predetermined amount upon reaction of the calcium oxide with water.
• the olefinic polymer includes at least one of a polyethylene, a polypropylene, a polybutene, a polyisobutene, a butyl rubber (polyisobutene-isoprene), styrene block copolymers, and modified forms of styrene block copolymers, wherein the olefinic polymers have a Number average molecular weight of 100 - 700, 000 Da.
• the silane modified polyolefins include at least one of an amorphous poly alpha olefin, a silane grafted PE, a moisture curing catalyst, an alkoxy silane, and an amino silane.
• the fillers include at least one of a ground chalk, a precipitated chalk, a silicate, a silicon oxide, CaCO3, Ca(OH)2, and titanium dioxide.
• the silicate is selected from the group comprising talc, kaolin, mica, silicon oxide, silicas, and calcium or magnesium silicates.
• the aging resistors include at least one of hindered phenols, hindered amines, thioethers, mercapto compounds, phosphorous esters, benzotriazoles, benzophenones, and antizonants.
• FIG. 1 is a top view of an embodiment of a solar module having a border seal composition according to the principles of the present invention
• FIG. 3 is a graph of moisture vapor transmission rate with time of a sealant composition that includes calcium oxide at 20% by weight
• FIG. 4 is a graph of moisture vapor transmission rate with time of a sealant composition that includes type 3A molecular sieves at 20% by weight.
• an exemplary solar module employing a sealant composition according to the principles of the present invention is generally indicated by reference number 10.
• the solar module 10 may take various forms without departing from the scope of the present invention and generally includes at least one photovoltaic cell 12 located within a chamber 13 defined by a first substrate 14 and a second substrate 16.
• the solar module 10, however, may be a thermoelectric solar module, hybrid solar module, or other light collecting assembly without departing from the scope of the present invention. While a plurality of photovoltaic cells 12 are illustrated, it should be appreciated that any number of photovoltaic cells 12 may be employed.
• photovoltaic devices 12 that may be employed include organic semiconductor cells having conjugate polymers as well as dye-sensitized metal oxides including wet metal oxides and solid metal oxides.
• the photovoltaic device 12 may be either rigid or flexible.
• the photovoltaic cells 12 are linked either in series or in parallel or combinations thereof.
• the current produced by the photovoltaic cells 12 are communicated via bus bars or other conductive materials or layers to wires or lead lines 15 that exit the solar module 10.
• the lead lines 15 communicate with a junction box 17 in order to distribute the electrical current generated by the solar module 10 to a power circuit.
• the first substrate 14, or front panel is formed from a material operable to allow wavelengths of sunlight to pass therethrough.
• the first substrate 14 is glass or a plastic film such as polyvinylflouride.
• the second substrate 16, or back panel is selected to provide additional strength to the solar module 10.
• the second substrate 16 is a plastic such as fluorinated ethylene-propylene copolymer (FEP), poly(ethylene-co- tetrafluoroethylene) (ETFE), polyvinylidene fluoride (PVDF), polyvinyl fluoride (PVF), poly(tetrafluoroethylene) (PTFE) and combinations of these with other polymeric materials.
• FEP fluorinated ethylene-propylene copolymer
• ETFE poly(ethylene-co- tetrafluoroethylene)
• PVDF polyvinylidene fluoride
• PVDF polyvinyl fluoride
• PTFE poly(tetrafluoroethylene)
• a border or edge seal 18 is located near an edge of the solar module 10 between the first substrate 14 and the second substrate 16.
• the border seal 18 may have various widths.
• a second border seal (not shown) may also be included.
• the second border seal may be comprised of, for example, for example, a silicone, a MS polymer, a Silanated Polyurethane, a butyl, or a polysulfide.
• the border seal 18 is operable to seal the laminate layer 19 and photovoltaic devices 12.
• the border seal 18 must have sufficient weatherability to withstand exposure to outside environments including prolonged ultra-violet radiation exposure, have low moisture vapor transmission (MVT), and have low conductivity.
• the border seal 20 is comprised of a sealant composition having the unique characteristics of high weatherability with low conductivity and MVT, as well as the ability to permanently absorb and react with water during normal operating conditions of the solar module 10.
• Calcium oxide reacts with water to form calcium hydroxide, according to the equation:
• the calcium oxide adsorbs a much greater amount of water vapor at a very low relative humidity than other materials. Calcium oxide is most effective where a low critical relative humidity is necessary, and where there is a high concentration of water vapor present. Calcium oxide removes water from the environment very slowly, often taking days to reach its maximum capacity. In addition, calcium oxide has a low water capacity at room temperature and humidity. As the calcium oxide adsorbs moisture, it swells. Accordingly, the sealant composition must have balanced properties to account for any swelling during use. The properties are balanced by, for example, adjusting the amount of calcium oxide in the composition.
• the density of calcium oxide is 3.25-3.38 g/mL, and the density of calcium hydroxide is 2.24 g/mL, according to the CRC Handbook of Chemistry and Physics, 60 th edition. Therefore, theoretically, there is a limit as to how much calcium oxide may be incorporated into an edge sealant formulation. However, no difficulties have been observed over the incorporation range tested.
• FIGS. 3 and 4 show the break through times associated with use of calcium oxide over molecular sieves. Break through time is the amount of time it takes to reach 5% of the steady state MVTR value after the initial 90 hour predrying phase is complete. As seen by FIG. 3, the breakthrough time for the composition containing calcium oxide is about 9 hours and the break through time for the composition containing the molecular sieve shown in FIG. 4 is about 20 hours.
• Calcium oxide is corrosive and can theoretically react with other components within an edge seal and within a solar module. However, within edge seals in solar modules with the present composition, no corrosive effects manifest. [0046] In addition, calcium oxide can be combined with molecular sieves to further increase the moisture trapping ability of the edge 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.

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• Chemical & Material Sciences (AREA)
• Organic Chemistry (AREA)
• Health & Medical Sciences (AREA)
• Chemical Kinetics & Catalysis (AREA)
• Medicinal Chemistry (AREA)
• Polymers & Plastics (AREA)
• Sealing Material Composition (AREA)
• Photovoltaic Devices (AREA)
• Compositions Of Macromolecular Compounds (AREA)

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• 2010
  • 2010-10-14 KR KR1020127012107A patent/KR20120095902A/ko not_active Withdrawn
  • 2010-10-14 WO PCT/US2010/052726 patent/WO2011068597A1/en not_active Ceased
  • 2010-10-14 EP EP10834903A patent/EP2489070A1/en not_active Withdrawn
  • 2010-10-14 JP JP2012534369A patent/JP2013509453A/ja active Pending
  • 2010-10-14 CN CN2010800568414A patent/CN102742006A/zh active Pending

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