JP5647136B2 - 電子デバイスモジュールのための同時押出された多層ポリオレフィンベースのバックシート - Google Patents
電子デバイスモジュールのための同時押出された多層ポリオレフィンベースのバックシート Download PDFInfo
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- JP5647136B2 JP5647136B2 JP2011534895A JP2011534895A JP5647136B2 JP 5647136 B2 JP5647136 B2 JP 5647136B2 JP 2011534895 A JP2011534895 A JP 2011534895A JP 2011534895 A JP2011534895 A JP 2011534895A JP 5647136 B2 JP5647136 B2 JP 5647136B2
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- polyolefin
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Description
本出願は、2008年11月6日に出願された米国特許出願第61/112011号に基づく優先権を主張するものであり、前記特許出願は参照することによって全体として本明細書に組み込まれる。
本発明は、電子デバイス(ED(electronic device))モジュール、例えば光起電力(PV(photovoltaic))モジュールに関するものである。ひとつの態様において、本発明はそのようなモジュールのバックシートに関するものであり、もうひとつの態様においては、本発明は、同時押出された多層ポリオレフィンを含むそのようなバックシートに関するものである。さらにもうひとつの態様において、本発明は、バックシート及びそのようなバックシートを組み込んだEDモジュールの製造法に関するものである。
本発明の実施に有用なポリオレフィン樹脂に関する特性についての以下の説明は、グラフト化又は他の変性を行う前のポリオレフィンに関するものである。
バックシートの上部層のための使用に特に好適なポリオレフィンのひとつは、電子デバイスや他の構成要素と接着状態で接触するようにされた場合に、電子デバイス及び/又はモジュールの他の構成要素、例えば封入剤、ガラスカバーシートなどと、封止関係を形成するEVAコポリマーである。グラフト又は他の変性を行う以前のコポリマーにおける、エチレン由来の単位の酢酸ビニル由来の単位に対する比は、幅広く変化させることができるが、典型的にはEVAコポリマーは、酢酸ビニル由来の単位を約25重量%未満、好適には約22重量%未満、より好適には約18重量%未満、そしてさらに好適には約15重量%未満含む。EVAコポリマーは、エマルション、溶液及び高圧重合を含むいずれの方法でも製造することができる。
MAH−m−ポリオレフィンにはMAH−g−ポリオレフィン及びMAH共重合体が含まれる。すなわち、MAHの官能性は、ポリマーの主鎖にグラフトすることによって、又は、MAHをオレフィンモノマーと共重合して主鎖に官能性を組み込むことによって、ポリオレフィン中に存在する。
高い温度、例えば多層構造体が40℃以上の温度(例えば80℃)で用いられる場合でありこのような温度は砂漠環境に置かれたPVモジュールであれば経験する可能性がある、で使用されるような応用のために、結合層は、必ずしもいつもではないが、しばしば有用であり望ましい。より低い温度プロフィールでの応用のためには、結合層の存在は通常は任意的であり、他のファクター、例えばコスト、物理的強靭性などによって定まる。
好ましくはないが、本発明の実施において用いられるポリオレフィンは低い密度及びモジュラスを有することから、これらのポリマーは接触の時点で、又は、バックシートなどの多層構造体若しくはモジュールが組み立てられた後に、通常は直後に、硬化又は架橋されることが一般的である。架橋は、多数の異なった既知の方法のいずれによっても行うことができ、例えば次のようなものを用いて行うことができる:過酸化物及びアゾ化合物のような熱活性化開始剤;ベンゾフェノンのような光開始剤;電子ビーム(E−beam)及びX線を含む放射線技術;ビニルトリエトキシシラン又はビニルトリメトキシシランのようなビニルシラン:及び湿気硬化。
多層構造体の個々の層は、さらに1種以上の添加剤を含むことができる。添加剤の例には、UV安定剤、UV吸収剤、及び三価リン化合物のような加工安定剤が含まれる。UV安定剤及びUV吸収剤は、例えば酸化崩壊を減少させ生産物の耐侯性を改善するのに有用であり、Cyasorb UV−2908のようなヒンダードフェノール、Cyasorb UV−1164のようなトリアジン、Cyasorb UV−3529、Cyasorb UV−3346、Cyasorb UV−3583、Hostavin N30、Univil 4050、Univin 5050、Chimassorb UV−119、Chimassorb 944LD、Tinuvin 622LD及び同類物などのヒンダードアミンが含まれる。リン化合物にはホスホニット(PEPQ)及びホスフィット(Weston 399、TNPP、Irgafos 168 及び Doverphos 9228)が含まれる。UV安定剤及びUV吸収剤の量は、層又は副次層を構成するポリマー材料の重量を基準にして、典型的には約0.1〜1.0%であり、好適には0.2〜0.5%である。加工安定剤の量は、層又は副次層を構成するポリマー材料の重量を基準にして、典型的には約0.02〜0.5%であり、好適には0.05〜0.15%である。
本発明のポリマー材料は、多層構造体及び電子デバイスモジュールを構成する上で、例えば米国特許第6586271号、米国特許出願公開第2001/0045229A1、国際公開第99/05206号、国際公開第99/04971号において教示されるような、当技術分野において既知であるものと同じ方法及び同じ使用量で用いられる。これらの材料は、電子デバイスの「スキン」、すなわちデバイスの一方又は両方の表側表面、特にはそのようなデバイスの背面、へ応用するための多層構造体を構成するために使用することができる。多層構造体、例えばバックシートは、好適には同時押出、すなわち多層構造体のすべての層を同時に押し出す処理に付され、これにより、多層構造体はその形成時に電子デバイスの背面上に直接貼り付けられるか、又は、前もって電子デバイス上に貼り付けられた封入剤の上に直接貼り付けられる。多層構造体の上部層の上部表側表面は、デバイスの表側表面、特にデバイスの背面、及び/又はデバイスを封入する材料に対して、良好な付着性を示す。
Claims (8)
- 多層構造体であって、それぞれの層は相互に反対面となる表側表面を有しており、該構造体は、(A)無水マレイン酸で変性された(MAH−m)ポリオレフィン又はポリオレフィンとMAH−m−ポリオレフィンとのブレンド物を含有し、上部表側表面及び底部表側表面を有する上部層、(B)エチレン及び不飽和カルボン酸のグリシジルエステル及び任意的な第3のコモノマーの共重合体を含む接着剤を含有し、上部表側表面及び底部表側表面を有し、その上部表側表面は上部層の底部表側表面と接着状態で接触している第1結合層、及び、(C)プロピレンポリマーとMAH−m−ポリオレフィンのブレンド物であって、125℃を越えるところで少なくとも1つの融解ピークを有するブレンド物を含有し、上部表側表面及び底部表側表面を有し、その上部表側表面は第1結合層の底部表側表面と接着状態で接触している底部層、を含んでいる多層構造体。
- 上部層は2つの副次層を含み、それぞれの副次層は相互に反対面となる表側表面を有し、上部副次層はポリオレフィン又はMAH−m−ポリオレフィンを含み、底部副次層はMAH−m−ポリオレフィン、又はポリオレフィンとMAH−m−ポリオレフィンのブレンド物を含み、底部副次層の上部表側表面は、上部副次層の底部表面と接着状態で接している、請求項1記載の多層構造体。
- 上部層は、上部副次層及び底部副次層を含み、それぞれの副次層は相互に反対面となる上部及び底部表側表面を有しており、ひとつの副次層はポリエステル又はポリアミドを含み、他の副次層はMAH−m−ポリオレフィン、又はポリオレフィンとMAH−m−ポリオレフィンのブレンド物を含み、底部副次層の上部表側表面は上部副次層の底部表面と接着状態で接している、請求項1記載の多層構造体。
- ポリエステルがポリエチレンテレフタレートであり、ポリアミドがナイロンである、請求項3記載の多層構造体。
- 上部表側表面と底部表側表面を有する第2結合層をさらに含み、第2結合層は、第1結合層の接着剤とは異なる接着剤を含んでおり、前記接着剤は、アミン官能化ポリオレフィン、又は、エチレン及びα,β−不飽和酸のグリシジルエステル及び任意的な第3のコモノマーの共重合体を含むものである、請求項1記載の多層構造体。
- 底部層は2つの副次層を含み、それぞれの副次層は相互に反対面となる表側表面を有し、上部副次層は、プロピレンポリマーとMAH−m−ポリオレフィンのブレンド物であって125℃を越えるところで少なくとも1つの融解ピークを有するブレンド物を含んでおり、底部副次層は、125℃を越えるところで少なくとも1つの融解ピークを有するポリオレフィンを含んでおり、上部副次層の上部表側表面は結合層の底部表面と接着状態で接しており、上部副次層の底部表側表面は底部副次層の上部表側表面と接着状態で接している、請求項1記載の多層構造体。
- 請求項1記載の多層構造体を備えた電子デバイス(ED)モジュール。
- 電子デバイスは光起電力電池、液晶パネル、エレクトロルミネセンスデバイス及びプラズマディスプレーユニットのいずれかひとつである、請求項7記載のEDモジュール。
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US7713636B2 (en) | 2006-12-15 | 2010-05-11 | Exxonmobil Chemical Patents Inc. | Multi-layer films comprising propylene-based polymers |
CN101933164B (zh) | 2008-02-02 | 2013-05-01 | 雷诺丽特比利时股份有限公司 | 光电组件及制造方法 |
EP2086019A1 (en) | 2008-02-02 | 2009-08-05 | RENOLIT Belgium N.V. | Profiles for fixing rigid plates |
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KR20110083716A (ko) | 2011-07-20 |
EP2346686A1 (en) | 2011-07-27 |
CN102202885B (zh) | 2013-11-13 |
ES2628754T3 (es) | 2017-08-03 |
KR101620308B1 (ko) | 2016-05-12 |
EP2346686B1 (en) | 2017-04-26 |
US20100108128A1 (en) | 2010-05-06 |
WO2010053936A1 (en) | 2010-05-14 |
WO2010053936A9 (en) | 2011-01-06 |
BRPI0916046A2 (pt) | 2015-11-10 |
US8431235B2 (en) | 2013-04-30 |
CN102202885A (zh) | 2011-09-28 |
JP2012508120A (ja) | 2012-04-05 |
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