US20140174509A1 - Multilayered polyolefin-based films having a layer comprising a crystalline block copolymer composite or a block copolymer composite resin - Google Patents

Multilayered polyolefin-based films having a layer comprising a crystalline block copolymer composite or a block copolymer composite resin Download PDF

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Publication number
US20140174509A1
US20140174509A1 US14/119,588 US201214119588A US2014174509A1 US 20140174509 A1 US20140174509 A1 US 20140174509A1 US 201214119588 A US201214119588 A US 201214119588A US 2014174509 A1 US2014174509 A1 US 2014174509A1
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layer
ethylene
polymer
block
multilayer film
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US14/119,588
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Inventor
Jeffrey E. Bonekamp
Yushan Hu
Nichole E. Nickel
Lih-Long Chu
John A. Naumovitz
Mark G. Hofius
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Dow Global Technologies LLC
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Dow Global Technologies LLC
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Abandoned legal-status Critical Current

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    • H01L31/0487—
    • 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
    • H01L31/048—Encapsulation of modules
    • H01L31/049—Protective back sheets
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C41/00—Shaping by coating a mould, core or other substrate, i.e. by depositing material and stripping-off the shaped article; Apparatus therefor
    • B29C41/003—Shaping by coating a mould, core or other substrate, i.e. by depositing material and stripping-off the shaped article; Apparatus therefor characterised by the choice of material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C41/00—Shaping by coating a mould, core or other substrate, i.e. by depositing material and stripping-off the shaped article; Apparatus therefor
    • B29C41/24—Shaping by coating a mould, core or other substrate, i.e. by depositing material and stripping-off the shaped article; Apparatus therefor for making articles of indefinite length
    • B29C41/26—Shaping by coating a mould, core or other substrate, i.e. by depositing material and stripping-off the shaped article; Apparatus therefor for making articles of indefinite length by depositing flowable material on a rotating drum
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C41/00—Shaping by coating a mould, core or other substrate, i.e. by depositing material and stripping-off the shaped article; Apparatus therefor
    • B29C41/24—Shaping by coating a mould, core or other substrate, i.e. by depositing material and stripping-off the shaped article; Apparatus therefor for making articles of indefinite length
    • B29C41/32—Making multilayered or multicoloured articles
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    • B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B27/08—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
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    • B32B27/30—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers
    • B32B27/302—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers comprising aromatic vinyl (co)polymers, e.g. styrenic (co)polymers
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    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/14—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers
    • B32B37/16—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with all layers existing as coherent layers before laminating
    • B32B37/18—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with all layers existing as coherent layers before laminating involving the assembly of discrete sheets or panels only
    • B32B37/182—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with all layers existing as coherent layers before laminating involving the assembly of discrete sheets or panels only one or more of the layers being plastic
    • B32B37/185—Laminating sheets, panels or inserts between two discrete plastic layers
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L53/00—Compositions of block copolymers containing at least one sequence of a polymer obtained by reactions only involving carbon-to-carbon unsaturated bonds; Compositions of derivatives of such polymers
    • 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
    • H01L31/048—Encapsulation of modules
    • H01L31/0481—Encapsulation of modules characterised by the composition of the encapsulation material
    • 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
    • H01L31/18—Processes or apparatus specially adapted for the manufacture or treatment of these devices or of parts thereof
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2023/00—Use of polyalkenes or derivatives thereof as moulding material
    • B29K2023/04—Polymers of ethylene
    • B29K2023/06—PE, i.e. polyethylene
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2023/00—Use of polyalkenes or derivatives thereof as moulding material
    • B29K2023/04—Polymers of ethylene
    • B29K2023/06—PE, i.e. polyethylene
    • B29K2023/0608—PE, i.e. polyethylene characterised by its density
    • B29K2023/0625—LLDPE, i.e. linear low density polyethylene
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2009/00—Layered products
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    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2270/00—Resin or rubber layer containing a blend of at least two different polymers
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    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/704—Crystalline
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
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    • B32B2323/00—Polyalkenes
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    • B32B2457/00—Electrical equipment
    • B32B2457/12—Photovoltaic modules
    • 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
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    • C08L2205/02—Polymer mixtures characterised by other features containing two or more polymers of the same C08L -group
    • C08L2205/025—Polymer mixtures characterised by other features containing two or more polymers of the same C08L -group containing two or more polymers of the same hierarchy C08L, and differing only in parameters such as density, comonomer content, molecular weight, structure
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
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    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
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    • C08L2205/035—Polymer mixtures characterised by other features containing three or more polymers in a blend containing four or more polymers in a blend
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    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
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    • C08L2205/12—Polymer mixtures characterised by other features containing additives being liquid crystalline or anisotropic in the melt
    • 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

  • 61/503,326 filed the same date herewith and entitled “MULTILAYERED POLYOLEFIN-BASED FILMS HAVING INTEGRATED BACKSHEET AND ENCAPSULATION PERFORMANCE COMPRISING A LAYER COMPRISING CRYSTALLINE BLOCK COPOLYMER COMPOSITE OR BLOCK COPOLYMER COMPOSITE” and claiming priority from provisional U.S. Patent application Ser. No. 61/503,326.
  • This invention relates to films having a layer comprising a Crystalline Block Composite (“CBC”) or a specified Block Composite (“BC”) and having improved combinations of properties; being particularly suited for use as protective layers, for example “backsheets”, in electronic device (ED) modules, e.g., photovoltaic (PV) modules.
  • ED electronic device
  • the invention relates to the backsheet films for use in such modules.
  • the invention relates to co-extruded, multilayered films of this type.
  • the invention relates to the ED module incorporating such a backsheet.
  • Thermoplastic polymeric material films are commonly used as layers in the manufacture of modules or assemblies comprising one or more electronic devices including, but not limited to, solar cells (also known as photovoltaic (PV) cells), batteries, liquid crystal panels, electro-luminescent devices and plasma display units.
  • the modules often comprise an electronic device in combination with one or more substrates, often positioned between two substrates, in which one or both of the substrates comprise, as support(s), glass, metal, plastic, rubber or another material.
  • ED component layers varies somewhat between different writers and different producers but polymeric film materials are typically used as internally located “encapsulant” or “sealant” layers for the device itself or, depending upon the design of the device, as outer “cover” or “skin” layer components of the module.
  • PV modules are well known in the art, and typically comprise the following components that are assembled into the final module structure:
  • the present invention is concerned with improved films or film layers utilizing a crystalline block copolymer composite or a specific block copolymer composite in a layer that in turn provides improved PV modules in terms of cost effectiveness and performance.
  • Backsheet layers as discussed in more detail below, protect the back surface of the cell and may have additional features that enhance the performance of the PV module.
  • TPE-type structures a PVF/PET/EVA laminate
  • Icosolar 2442 a PVF/PET/PVF laminate
  • PPE-type structures PET/PET/EVA structure available from Dunmore.
  • a number of proposed improved and enhanced backsheets are also disclosed including the following.
  • multi-layer films comprising propylene-based polymers having improved peel strength properties and comprising a core layer and a first tie layer made from at least 5 wt % of a grafted propylene-based polymer.
  • WO 2010/053936 discloses backsheet layers for electronic device (ED) modules, e.g., photovoltaic (PV) modules, having at least three layers including a tie layer of a glycidyl methacrylate (GMA) graft resin joining layers that each use a maleic anhydride modified resin (MAH-m resin) in each of the joined layers to provide good interlayer adhesion.
  • ED electronic device
  • PV photovoltaic
  • US 2011/0048512 discloses backsheet layers for electronic device (ED) modules, e.g., photovoltaic (PV) modules, comprising a coextruded multilayer sheet that comprises: i) an inner layer comprising a polyolefin resin; ii) a core layer comprising a polypropylene resin, a blend of a polypropylene resin and a maleic anhydride grafted polypropylene (MAH-g-PP), or a polypropylene resin/MAH-g-PP multilayer structure; iii) an outer layer comprising a maleic anhydride grafted polyvinylidene fluoride (MAH-g-PVDF), a blend of a polyvinylidene fluoride (PVDF) and a MAH-g-PVDF, or a PVDF/MAH-g-PVDF multilayer structure; iv) a first tie layer between the core layer and the outer layer; and v) an optional second tie layer
  • WO/2011/009568 there are disclosed photovoltaic module backsheets on base of preferably high molecular weight, impact resistant, shrinkage and thermal (flow) resistant FPP (Flexible Polypropylene) compositions preferably containing functional particles or being coextruded with a primer adhesive layer to obtain highly reliable adhesion on EVA adhesive layers.
  • the backsheet has a functionalized polyolefin (PO) adhesive layer allowing direct adhesion to cells back-contacts, i.e. without the use of an EVA adhesive layer.
  • the backsheet, with functional PO adhesive layer allows the use of an upper adhesive layer which has s a transparent thermoplastic polyolefin (TPO) film layer.
  • TPO transparent thermoplastic polyolefin
  • a multilayer film structure comprising a layer (Layer B) and a bottom layer (Layer C), each layer having opposing facial surfaces in adhering contact with the other layer, wherein:
  • Layer B comprises a crystalline block copolymer composite (CBC) or a specified block copolymer composite (BC), comprising:
  • an ethylene polymer (EP) comprising at least 80 mol % polymerized ethylene
  • CAOP alpha-olefin-based crystalline polymer
  • a block copolymer comprising (a) an ethylene polymer block comprising at least 80 mol % polymerized ethylene and (b) a crystalline alpha-olefin block (CAOB), or a mixture of said composite(s); and
  • bottom Layer C comprises a polyolefin having at least one melting peak greater than 125° C. and having a top facial layer and a bottom facial surface, the top facial surface of Layer C in adhering contact with the bottom facial surface of Layer B.
  • the i) EP in Layer B comprises at least 80 mol % polymerized ethylene and the balance polymerized propylene and, preferably wherein the block composite resin in Layer B is a crystalline block composite resin; the Layer B block composite resin has a CAOB amount (in part (iii)) in the range of from 30 to 70 weight % of the CAOB, preferably from 40 to 60 weight % of the CAOB; Layer B comprises a CBC having a CBCI of between 0.3 to 1.0 or a specified BC having a BCI of between 0.1 to 1.0; propylene is the alpha-olefin in ii) and iii) in tie Layer B; tie Layer B is a blend comprising greater than 40 weight percent CBC or specified BC, preferably further comprising one or more polyolefin selected from an ethylene octene plastomer, LLDPE and LDPE; and/or the CBC or
  • multilayer film structures as described herein comprising: (A) a seal layer A having a top facial surface and a bottom facial surface, the bottom facial surface in adhering contact with the top facial surface of layer B; preferably such a film in which the top layer A comprises a linear low density polyethylene (LLDPE) and more preferably such a film in which the top layer A comprises a blend formulation of a linear low density polyethylene (LLDPE) comprising a polar ethylene copolymer in an amount of from 10 to 45 weight %.
  • the top layer A comprises a BC or CBC and the layer composition is different from layer B composition.
  • multilayer film structures as described above where the bottom layer C comprises: a propylene-based polymer or optionally a propylene-based polymer having a heat of fusion value of at least 60 Joules per gram (J/g).
  • a further independent embodiment of the present invention is a multilayer structure as described herein wherein Layer A is from 0 to 200 micrometer ( ⁇ m) in thickness; Layer B is from 25 to 100 ⁇ m in thickness; and Layer C is from 150 to 350 ⁇ m in thickness.
  • a further independent embodiment of the present invention is a multilayer film structure as described herein comprising a top seal Layer A comprising a blend formulation of a linear low density polyethylene (LLDPE) comprising a polar ethylene copolymer in an amount of from 10 to 45 weight %, a bottom Layer C comprising a propylene-based polymer and a Layer B between Layer A and Layer C comprising a crystalline block copolymer composite (CBC) comprising i) an ethylene polymer (EP) comprising at least 93 mol % polymerized ethylene; ii) a crystalline propylene polymer and iii) a block copolymer comprising (a) an ethylene polymer block comprising at least 93 mol % polymerized ethylene and (b) a crystalline propylene polymer block.
  • LLDPE linear low density polyethylene
  • CBC crystalline block copolymer composite
  • a further independent embodiment of the present invention is an electronic device (ED) module comprising an electronic device and a multilayer film structure as described above.
  • ED electronic device
  • a light-receiving top sheet layer having an exterior light-receiving facial surface and an interior facial surface
  • a light transmitting thermoplastic polymer encapsulation layer having one facial surface directed toward the top sheet layer and one directed toward a light-reactive surface of a PV cell
  • a PV cell have a light reactive surface
  • a second encapsulating film layer and
  • a backsheet layer comprising a multilayer film structure according to claims 1 ;
  • Step (1.) heating and compressing the layers of Step (1.) at conditions sufficient to create the needed adhesion between the layers and, if needed in some layers or materials, initiation of their crosslinking.
  • FIG. 1 is a cross-sectional view of an exemplary three-layer backsheet in adhering contact with an encapsulant layer on the back surface of an electronic device.
  • a layer that comprises a block composite resin comprising: i) an ethylene-based polymer; ii) an alpha-olefin-based crystalline polymer (which is preferably based on propylene) and iii) a block copolymer comprising an ethylene block and a crystalline alpha-olefin (preferably propylene) block.
  • a block composite resin comprising: i) an ethylene-based polymer; ii) an alpha-olefin-based crystalline polymer (which is preferably based on propylene) and iii) a block copolymer comprising an ethylene block and a crystalline alpha-olefin (preferably propylene) block.
  • compositions and like terms mean a mixture of two or more materials, such as a polymer which is blended with other polymers or which contains additives, fillers, or the like. Included in compositions are pre-reaction, reaction and post-reaction mixtures the latter of which will include reaction products and by-products as well as unreacted components of the reaction mixture and decomposition products, if any, formed from the one or more components of the pre-reaction or reaction mixture.
  • Blend means a composition of two or more polymers. Such a blend may or may not be miscible. Such a blend may or may not be phase separated. Such a blend may or may not contain one or more domain configurations, as determined from transmission electron spectroscopy, light scattering, x-ray scattering, and any other method known in the art. Blends are not laminates, but one or more layers of a laminate may contain a blend.
  • Polymer means a compound prepared by polymerizing monomers, whether of the same or a different type.
  • the generic term polymer thus embraces the term homopolymer, usually employed to refer to polymers prepared from only one type of monomer, and the term interpolymer as defined below. It also embraces all forms of interpolymers, e.g., random, block, etc.
  • the terms “ethylene/ ⁇ -olefin polymer” and “propylene/ ⁇ -olefin polymer” are indicative of interpolymers as described below.
  • Interpolymer means a polymer prepared by the polymerization of at least two different monomers. This generic term includes copolymers, usually employed to refer to polymers prepared from two or more different monomers, and includes polymers prepared from more than two different monomers, e.g., terpolymers, tetrapolymers, etc.
  • Polyolefin “polyolefin polymer”, “polyolefin resin” and like terms mean a polymer produced from a simple olefin (also called an alkene with the general formula C n H 2n ) as a monomer.
  • Polyethylene is produced by polymerizing ethylene with or without one or more comonomers, polypropylene by polymerizing propylene with or without one or more comonomers, etc.
  • polyolefins include interpolymers such as ethylene/ ⁇ -olefin copolymers, propylene/ ⁇ -olefin copolymers, etc.
  • (Meth) indicates that the methyl substituted compound is included in the term.
  • ethylene-glycidyl (meth)acrylate includes ethylene-glycidyl acrylate (E-GA) and ethylene-glycidyl methacrylate (E-GMA), individually and collectively.
  • Melting Point as used here (also referred to a melting peak in reference to the shape of the plotted DSC curve) is typically measured by the DSC (Differential Scanning calorimetry) technique for measuring the melting points or peaks of polyolefins as described in U.S. Pat. No. 5,783,638. It should be noted that many blends comprising two or more polyolefins will have more than one melting point or peak; many individual polyolefins will comprise only one melting point or peak.
  • the polyolefin resins useful in the bottom layer or Layer C of the backsheet have a melting point of at least 125° C., preferably greater than 130 C, preferably greater than 140° C., more preferably greater than 150° C. and even more preferably greater than 160° C.
  • These polyolefin resins are preferably propylene-based polymers, commonly referred to as polypropylenes.
  • These polyolefins are preferably made with multi-site catalysts, e.g., Zeigler-Natta and Phillips catalysts. In general, polyolefin resins with a melting point of at least 125° C. often exhibit desirable toughness properties useful in the protection of the electronic device of the module.
  • the sole monomer is typically selected from ethylene, propene (propylene), 1-butene, 4-methyl-1-pentene, 1-hexene, 1-octene, 1-decene, 1-dodecene, 1-tetradecene, 1-hexadecene, and 1-octadecene and is preferably propylyene for the Layer C polyolefin resin.
  • the comonomer(s) different from the first or primary monomer is/are typically one or more ⁇ -olefins.
  • ethylene is an ⁇ -olefin if propylene or higher olefin is the primary monomer.
  • the co- ⁇ -olefin is then preferably a different C 2-20 linear, branched or cyclic ⁇ -olefin.
  • C 2-20 ⁇ -olefins for use as comonomers include ethylene, propene (propylene), 1-butene, 4-methyl-1-pentene, 1-hexene, 1-octene, 1-decene, 1-dodecene, 1-tetradecene, 1-hexadecene, and 1-octadecene.
  • the ⁇ -olefins for use as comonomers can also contain a cyclic structure such as cyclohexane or cyclopentane, resulting in an ⁇ -olefin such as 3-cyclohexyl-1-propene (allyl cyclohexane) and vinyl cyclohexane.
  • cyclic olefins such as norbornene and related olefins
  • cyclic olefins are ⁇ -olefins and can be used as comonomer in place of some or all of the ⁇ -olefins described above.
  • styrene and its related olefins are ⁇ -olefins for purposes of comonomers according to this invention.
  • Acrylic and methacrylic acid and their respective ionomers, and acrylates and methacrylates are also comonomer ⁇ -olefins for purposes of this invention.
  • Illustrative polyolefin copolymers include but are not limited to ethylene/propylene, ethylene/butene, ethylene/1-hexene, ethylene/1-octene, ethylene/styrene, ethylene/acrylic acid (EAA), ethylene/methacrylic acid (EMA), ethylene/acrylate or methacrylate, EVA and the like.
  • Illustrative terpolymers include ethylene/propylene/1-octene, ethylene/propylene/butene, ethylene/butene/1-octene, and ethylene/butene/styrene.
  • the copolymers can be random or blocky.
  • the high melting point polyolefin resins (having a melting point of at least 125° C.), that are useful in the present invention and preferred for use as all or most of bottom layer Layer C in the practice of this invention include propylene-based polymers, also referred to as propylene polymers or polypropylenes, including e.g., polypropylene or propylene copolymers comprising a majority of units derived from propylene and a minority of units derived from another ⁇ -olefin (including ethylene).
  • propylene-based polymers also referred to as propylene polymers or polypropylenes, including e.g., polypropylene or propylene copolymers comprising a majority of units derived from propylene and a minority of units derived from another ⁇ -olefin (including ethylene).
  • propylene-based polymers include polypropylene homopolymer, copolymers of propylene and one or more other olefin monomers, a blend of two or more homopolymers or two or more copolymers, and a blend of one or more homopolymer with one or more copolymer, as long as it has a melting point of 125° C. or more.
  • the polypropylene-based polymers can vary widely in form and include, for example, substantially isotactic propylene homopolymer, random propylene copolymers, and graft or block propylene copolymers.
  • the propylene copolymers preferably comprise at least 85, more preferably at least 87 and even more preferably at least 90, mole percent units derived from propylene.
  • the remainder of the units in the propylene copolymer is derived from units of at least one ⁇ -olefin having up to 20, preferably up to 12 and more preferably up to 8, carbon atoms.
  • the ⁇ -olefin is preferably a C 3-20 linear, branched or cyclic ⁇ -olefin as described above.
  • preferred propylene polymer resins include hompolymer polypropylenes, preferably high crystallinity polypropylene such as high stiffness and toughness polypropylenes.
  • the propylene polymer MFR (measured in dg/min at 230° C./2.16 kg,) is at least 0.5, preferably at least 1.5, and more preferably at least 2.5 dg/min and less than or equal to 25, preferably less than or equal to 20, and most preferably less than or equal to 18 dg/min.
  • preferred propylene polymer resins for Layer C have heat of fusion values (reflecting the relatively higher crystallinity) as measured by DSC of at least about 60 Joules per gram (J/g), more preferably at least about 90 J/g, still more preferably at least about 110 J/g and most preferably at least about 120 J/g.
  • J/g Joules per gram
  • the DSC is run as generally described below under nitrogen at 10° C./min from 23° C. to 220° C., held isothermal at 220° C. for 3 minutes, dropped to 23° C. at 10° C./min and ramped back to 220° C. at 10° C./min.
  • the second heat data is used to calculate the heat of fusion of the melting transition.
  • propylene polymers that can be used in the backsheets of this invention: a propylene impact copolymer including but not limited to former DOW Polypropylene T702-12N; a propylene homopolymer including but not limited to former DOW Polypropylene H502-25RZ; and a propylene random copolymer including but not limited to former DOW Polypropylene R751-12N.
  • a propylene impact copolymer including but not limited to former DOW Polypropylene T702-12N
  • a propylene homopolymer including but not limited to former DOW Polypropylene H502-25RZ
  • propylene random copolymer including but not limited to former DOW Polypropylene R751-12N.
  • polypropylenes include some of the VERSIFY° polymers available from The Dow Chemical Company, the VISTAMAXX° polymers available from ExxonMobil Chemical Company, and the PRO-FAX polymers available from Lyondell Basell Industries, e.g., PROFAXTM SR-256M, which is a clarified propylene copolymer resin with a density of 0.90 g/cc and a MFR of 2 g/10 min, PROFAXTM 8623, which is an impact propylene copolymer resin with a density of 0.90 g/cc and a MFR of 1.5 g/10 min.
  • PROFAXTM SR-256M which is a clarified propylene copolymer resin with a density of 0.90 g/cc and a MFR of 2 g/10 min
  • PROFAXTM 8623 which is an impact propylene copolymer resin with a density of 0.90 g/cc and a MFR of 1.5 g/10 min.
  • propylene resins include CATALLOYTM in-reactor blends of polypropylene (homo- or copolymer) with one or more of propylene-ethylene or ethylene-propylene copolymer (all available from Basell, Elkton, Md.), Shell's KF 6100 propylene homopolymer; Solvay's KS 4005 propylene copolymer; and Solvay's KS 300 propylene terpolymer.
  • INSPIRETM D114 which is a branched impact copolymer polypropylene with a melt flow rate (MFR) of 0.5 dg/min (230° C./2.16 kg) and a melting point of 164° C.
  • suitable polypropylene would be a suitable polypropylene.
  • suitable high crystallinity polypropylene with high stiffness and toughness include but are not limited to INSPIRETM 404 with an MFR of 3 dg/min, and INSPIRETM D118.01 with a melt flow rate of 8.0 dg/min (230° C./2.16 kg), (both also formerly available from The Dow Chemical Company).
  • Propylene polymer blend resins can also be used where polypropylene resins as described above can be blended or diluted with one or more other polymers, including polyolefins as described below, to the extent that the other polymer is (i) miscible or compatible with the polypropylene, (ii) has little, if any, deleterious impact on the desirable properties of the polypropylene, e.g., toughness and modulus, and (iii) the polypropylene constitutes at least 55, preferably at least 60, more preferably at least 65 and still more preferably at least 70, weight percent of the blend.
  • the propylene polymer can be also be blended with cyclic olefin copolymers such as Topas 6013F-04 cyclic olefin copolymer available from Topas Advanced Polymers, Inc. with preferred amounts when used at least 2, preferably 4, and more preferably 8 weight percent up to and including to 40, preferably 35 and more preferably 30 weight percent.
  • cyclic olefin copolymers such as Topas 6013F-04 cyclic olefin copolymer available from Topas Advanced Polymers, Inc.
  • propylene polymer resins for Layer C can comprise an impact modifier such as ethylene octene plastomers such as AFFINITY PL 1880G, PL8100G, and PL 1850G brand resins or ethylene octene elastomers such as ENGAGE 8842, ENGAGE 8150, and ENGAGE XLT 8677 brand resins commercially available from The Dow Chemical Company, olefin block copolymers such as for example INFUSE 9100 and 9107 brand resins commercially available from The Dow Chemical Company or propylene based elastomers such as VERSIFY 2300 and VERSIFY 3300 brand resins available from The Dow Chemical Company.
  • an impact modifier such as ethylene octene plastomers such as AFFINITY PL 1880G, PL8100G, and PL 1850G brand resins or ethylene octene elastomers such as ENGAGE 8842, ENGAGE 8150, and ENGAGE XLT
  • these are used in amounts at least of 2 weight percent, preferably at least 5 and more preferably at least 8 weight percent and preferably less than 45 weight %, preferably less than 35 weight percent and more preferably less than 30 weight percent.
  • Other candidate impact modification or blend resins are ethylene/propylene rubbers (optionally blended with polypropylene in-reactor) and one or more block composites as described herein. Combinations of impact modifiers of different types may also be used.
  • additives that could be used with the propylene polymer resins are inorganic fillers such as talc (including epoxy coated talc), colorants, flame retardants (halogenated and non-halogenated) and flame retardant synergists such as Sb 2 O 3 .
  • inorganic fillers such as talc (including epoxy coated talc), colorants, flame retardants (halogenated and non-halogenated) and flame retardant synergists such as Sb 2 O 3 .
  • the composition of Layer B in the films according to the present invention is selected to be adhered, either preferably by co-extrusion or alternatively but less preferably by a lamination process (such as extrusion lamination, thermal lamination, or adhesive lamination) to the layers C and optionally A (or optionally another layer) in production of the films according to the invention.
  • Layer B comprises a Crystalline Block Copolymer Composite Resin (“CBC”) and/or certain Block copolymer Composite Resins (“BC's”), CBC's and BC's collectively referred to herein as “Crystalline Block and Block Composite Resins” “Composite Resins” or “(C)BC's”.
  • Layer B can alternatively comprise a blend of one or more CBC and with one or more BC, or a blend of one or both of these resins with one or more other resin.
  • block copolymer or “segmented copolymer” refers to a polymer comprising two or more chemically distinct regions or segments (referred to as “blocks”) joined in a linear manner, that is, a polymer comprising chemically differentiated units which are joined (covalently bonded) end-to-end with respect to polymerized functionality, rather than in pendent or grafted fashion.
  • the blocks differ in the amount or type of comonomer incorporated therein, the density, the amount of crystallinity, the type of crystallinity (e.g.
  • the block copolymers of the invention are characterized by unique distributions of both polymer polydispersity (PDI or Mw/Mn) and block length distribution, due, in a preferred embodiment, to the effect of a shuttling agent(s) in combination with the catalyst(s).
  • block composite or “block copolymer composite” resins are different from “crystalline block composites” or “crystalline block copolymer composite resins” based on the amount of comonomer polymerized with the ethylene polymer and ethylene block in the composite.
  • BC refers generally to polymers comprising (i) a soft ethylene copolymer (EP) having polymerized units in which the comonomer content is greater than 10 mol % and having less than 90 mol % polymerized ethylene, and preferably greater than 20 mol % and less than 80 mol % ethylene, and most preferably greater than 33 mol % and less than 75 mol ethylene %, (ii) a hard or crystalline ⁇ -olefin polymer (CAOP), in which the ⁇ -olefin monomer (preferably propylene) is present in an amount of from greater than 90 up to 100 mol percent, and preferably greater than 93 mol percent, and more preferably greater than 95 mol percent, and most preferably greater than 98 mol percent and (iii) a block copolymer, preferably a diblock, having a soft segment and a hard segment, wherein the hard segment of the block copolymer is essentially the same composition as the hard ⁇ -
  • the block copolymers can be linear or branched. More specifically, when produced in a continuous process, the block composites desirably possess PDI from 1.7 to 15, preferably from 1.8 to 3.5, more preferably from 1.8 to 2.2, and most preferably from 1.8 to 2.1. When produced in a batch or semi-batch process, the block composites desirably possess PDI from 1.0 to 2.9, preferably from 1.3 to 2.5, more preferably from 1.4 to 2.0, and most preferably from 1.4 to 1.8.
  • Such block composites are described in, for example, US Patent Application Publication Nos US2011-0082257, US2011-0082258 and US2011-0082249, all published on Apr. 7, 2011 and incorporated herein by reference with respect to descriptions of the block composites, processes to make them and methods of analyzing them.
  • certain suitable “BC” resins can be employed in Layer B in the films according to the present invention.
  • the specific suitable “BC's” comprise a soft ethylene copolymer (EP) having the comonomer content greater than 80 mol % and up to 90 mol % and preferably greater than 85 mol % and most preferably greater than 87 mol %, but otherwise a BC as generally described herein.
  • EP soft ethylene copolymer
  • crystalline block composite refers to polymers comprising a crystalline ethylene based polymer (CEP), a crystalline alpha-olefin based polymer (CAOP), and a block copolymer having a crystalline ethylene block (CEB) and a crystalline alpha-olefin block (CAOB), wherein the CEB of the block copolymer is essentially the same composition as the CEP in the block composite and the CAOB of the block copolymer is essentially the same composition as the CAOP of the block composite. Additionally, the compositional split between the amount of CEP and CAOP will be essentially the same as that between the corresponding blocks in the block copolymer.
  • the block copolymers can be linear or branched. More specifically, each of the respective block segments can contain long chain branches, but the block copolymer segment is substantially linear as opposed to containing grafted or branched blocks.
  • the crystalline block composites desirably possess PDI from 1.7 to 15, preferably 1.8 to 10, preferably from 1.8 to 5, more preferably from 1.8 to 3.5.
  • Such crystalline block composites are described in, for example, the following filed patent applications: PCT/US11/41189; U.S. Ser. No. 13/165,054; PCT/US11/41191; U.S. Ser. No. 13/165,073; PCT/US11/41194; and U.S. Ser. No. 13/165,096; all filed on 21 Jun. 2011 and incorporated herein by reference with respect to descriptions of the crystalline block composites, processes to make them and methods of analyzing them.
  • CAOB refers to highly crystalline blocks of polymerized alpha olefin units in which the monomer is present in an amount greater than 90 mol %, preferably greater than 93 mol percent, more preferably greater than 95 mol percent, and preferably greater than 96 mol percent.
  • the comonomer content in the CAOBs is less than 10 mol percent, and preferably less than 7 mol percent, and more preferably less than 5 mol percent, and most preferably less than 4 mol %.
  • CAOBs with propylene crystallinity have corresponding melting points that are 80° C. and above, preferably 100° C. and above, more preferably 115° C. and above, and most preferably 120° C. and above.
  • the CAOB comprise all or substantially all propylene units.
  • CEB refers to blocks of polymerized ethylene units in which the comonomer content is 10 mol % or less, preferably between 0 mol % and 10 mol %, more preferably between 0 mol % and 7 mol % and most preferably between 0 mol % and 5 mol %.
  • Such CEB have corresponding melting points that are preferably 75° C. and above, more preferably 90° C., and 100° C. and above.
  • Hard segments refer to highly crystalline blocks of polymerized units in which the monomer is present in an amount greater than 90 mol percent, and preferably greater than 93 mol percent, and more preferably greater than 95 mol percent, and most preferably greater than 98 mol percent.
  • the comonomer content in the hard segments is most preferably less than 2 mol percent, and more preferably less than 5 mol percent, and preferably less than 7 mol percent, and less than 10 mol percent.
  • the hard segments comprise all or substantially all propylene units.
  • Soft segments refer to amorphous, substantially amorphous or elastomeric blocks of polymerized units in which the comonomer content is greater than 10 mol % and less than 90 mol % and preferably greater than 20 mol % and less than 80 mol %, and most preferably greater than 33 mol % and less than 75 mol %.
  • the BC's and/or CBC's are preferably prepared by a process comprising contacting an addition polymerizable monomer or mixture of monomers under addition polymerization conditions with a composition comprising at least one addition polymerization catalyst, a cocatalyst and a chain shuttling agent, said process being characterized by formation of at least some of the growing polymer chains under differentiated process conditions in two or more reactors operating under steady state polymerization conditions or in two or more zones of a reactor operating under plug flow polymerization conditions.
  • the BC's and/or CBC's comprise a fraction of block polymer which possesses a most probable distribution of block lengths.
  • a more preferable approach is to avoid additional unit operations and to utilize the much greater reactivity of ethylene versus higher alpha olefins such that the conversion of ethylene across the CEB reactor approaches 100%.
  • the overall conversion of monomers across the reactors can be controlled by maintaining the alpha olefin conversion at a high level (90 to 95%).
  • Suitable catalysts and catalyst precursors for use in preparing BC's and/or CBC's invention include metal complexes such as disclosed in WO2005/090426, in particular, those disclosed starting on page 20, line 30 through page 53, line 20, which is herein incorporated by reference. Suitable catalysts are also disclosed in US 2006/0199930; US 2007/0167578; US 2008/0311812; U.S. Pat. No. 7,355,089 B2; or WO 2009/012215, which are herein incorporated by reference with respect to catalysts.
  • the BC's and/or CBC's comprise propylene, 1-butene or 4-methyl-1-pentene and one or more comonomers.
  • the block polymers of the BC's and CBC's comprise in polymerized form propylene and ethylene and/or one or more C 4-20 ⁇ -olefin comonomers, and/or one or more additional copolymerizable comonomers or they comprise 4-methyl-1-pentene and ethylene and/or one or more C 4-20 ⁇ -olefin comonomers, or they comprise 1-butene and ethylene, propylene and/or one or more C 5 -C 20 ⁇ -olefin comonomers and/or one or more additional copolymerizable comonomers.
  • Additional suitable comonomers are selected from diolefins, cyclic olefins, and cyclic diolefins, halogenated vinyl compounds, and vinylidene aromatic
  • Comonomer content in the resulting BC's and/or CBC's may be measured using any suitable technique, with techniques based on nuclear magnetic resonance (NMR) spectroscopy preferred. It is highly desirable that some or all of the polymer blocks comprise amorphous or relatively amorphous polymers such as copolymers of propylene, 1-butene or 4-methyl-1-pentene and a comonomer, especially random copolymers of propylene, 1-butene or 4-methyl-1-pentene with ethylene, and any remaining polymer blocks (hard segments), if any, predominantly comprise propylene, 1-butene or 4-methyl-1-pentene in polymerized form. Preferably such segments are highly crystalline or stereospecific polypropylene, polybutene or poly-4-methyl-1-pentene, especially isotactic homopolymers.
  • the block copolymers of the BC's and/or CBC's comprise from 10 to 90 weight percent crystalline or relatively hard segments and 90 to 10 weight percent amorphous or relatively amorphous segments (soft segments), preferably from 20 to 80 weight percent crystalline or relatively hard segments and 80 to 20 weight percent amorphous or relatively amorphous segments (soft segments), most preferably from 30 to 70 weight percent crystalline or relatively hard segments and 70 to 30 weight percent amorphous or relatively amorphous segments (soft segments).
  • the mole percent comonomer may range from 10 to 90 mole percent, preferably from 20 to 80 mole percent, and most preferably from 33 to 75 mol % percent.
  • the comonomer is ethylene
  • it is preferably present in an amount of 10 mol % to 90 mol %, more preferably from 20 mol % to 80 mol %, and most preferably from 33 mol % to 75 mol % percent.
  • the copolymers comprise hard segments that are 90 mol % to 100 mol % propylene.
  • the hard segments can be greater than 90 mol % preferably greater than 93 mol % and more preferably greater than 95 mol % propylene, and most preferably greater than 98 mol % propylene.
  • Such hard segments have corresponding melting points that are 80° C. and above, preferably 100° C. and above, more preferably 115° C. and above, and most preferably 120° C. and above.
  • the block copolymer composites of the invention have a Block Composite Index (BCI), as defined below, that is greater than zero but less than 0.4 or from 0.1 to 0.3. In other embodiments, BCI is greater than 0.4 and up to 1.0. Additionally, the BCI can be in the range of from 0.4 to 0.7, from 0.5 to 0.7, or from 0.6 to 0.9. In some embodiments, BCI is in the range of from 0.3 to 0.9, from 0.3 to 0.8, or from 0.3 to 0.7, from 0.3 to 0.6, from 0.3 to 0.5, or from 0.3 to 0.4. In other embodiments, BCI is in the range of from 0.4 to 1.0, from 0.5 to 1.0, or from 0.6 to 1.0, from 0.7 to 1.0, from 0.8 to 1.0, or from 0.9 to 1.0.
  • BCI Block Composite Index
  • the block composites preferably have a Tm greater than 100° C., preferably greater than 120° C., and more preferably greater than 125° C.
  • the MFR of the block composite is from 0.1 to 1000 dg/min, more preferably from 0.1 to 50 dg/min and more preferably from 0.1 to 30 dg/min.
  • the block composites of this embodiment of the invention have a weight average molecular weight (Mw) from 10,000 to about 2,500,000, preferably from 35000 to about 1,000,000 and more preferably from 50,000 to about 300,000, preferably from 50,000 to about 200,000.
  • Mw weight average molecular weight
  • the block composite polymers of the invention comprise ethylene, propylene, 1-butene or 4-methyl-1-pentene and optionally one or more comonomers in polymerized form.
  • the block copolymers of the crystalline block composites comprise in polymerized form ethylene, propylene, 1-butene, or 4-methyl-1-pentene and optionally one or more C 4-20 ⁇ -olefin comonomers. Additional suitable comonomers are selected from diolefins, cyclic olefins, and cyclic diolefins, halogenated vinyl compounds, and vinylidene aromatic compounds.
  • Comonomer content in the resulting block composite polymers may be measured using any suitable technique, with techniques based on nuclear magnetic resonance (NMR) spectroscopy preferred.
  • NMR nuclear magnetic resonance
  • the crystalline block composite polymers of the invention comprise from 0.5 to 95 wt % CEP, from 0.5 to 95 wt % CAOP and from 5 to 99 wt % block copolymer. More preferably, the crystalline block composite polymers comprise from 0.5 to 79 wt % CEP, from 0.5 to 79 wt % CAOP and from 20 to 99 wt % block copolymer and more preferably from 0.5 to 49 wt % CEP, from 0.5 to 49 wt % CAOP and from 50 to 99 wt % block copolymer. Weight percents are based on total weight of crystalline block composite. The sum of the weight percents of CEP, CAOP and block copolymer equals 100%.
  • the block copolymers of the invention comprise from 5 to 95 weight percent crystalline ethylene blocks (CEB) and 95 to 5 wt percent crystalline alpha-olefin blocks (CAOB). They may comprise 10 wt % to 90 wt % CEB and 90 wt % to 10 wt % CAOB. More preferably, the block copolymers comprise 25 to 75 wt % CEB and 75 to 25 wt % CAOB, and even more preferably they comprise 30 to 70 wt % CEB and 70 to 30 wt % CAOB.
  • CEB crystalline ethylene blocks
  • CAOB crystalline alpha-olefin blocks
  • the block composites of the invention have a Crystalline Block Composite Index (CBCI), as defined below, that is greater than zero but less than 0.4 or from 0.1 to 0.3. In other embodiments, CBCI is greater than 0.4 and up to 1.0. In some embodiments, the CBCI is in the range of from 0.1 to 0.9, from 0.1 to 0.8, from 0.1 to 0.7 or from 0.1 to 0.6. Additionally, the CBCI can be in the range of from 0.4 to 0.7, from 0.5 to 0.7, or from 0.6 to 0.9.
  • CBCI Crystalline Block Composite Index
  • CBCI is in the range of from 0.3 to 0.9, from 0.3 to 0.8, or from 0.3 to 0.7, from 0.3 to 0.6, from 0.3 to 0.5, or from 0.3 to 0.4. In other embodiments, CBCI is in the range of from 0.4 to 1.0, from 0.5 to 1.0, or from 0.6 to 1.0, from 0.7 to 1.0, from 0.8 to 1.0, or from 0.9 to 1.0.
  • the crystalline block composites of this embodiment of the invention have a weight average molecular weight (Mw) of 1,000 to about 2,500,000, preferably of 35000 to about 1,000,000 and more preferably of 50,000 to 500,000, of 50,000 to about 300,000, and preferably from 50,000 to about 200,000.
  • Mw weight average molecular weight
  • each resin is determined as appropriate by DSC, NMR, Gel Permeation Chromatography, Dynamic Mechanical Spectroscopy, and/or Transmission Electron Micrography.
  • Xylene fractionation and high temperature liquid chromatography (“HTLC”) fractionation can be further used to estimate the yield of block copolymer, and in particular the block composite index.
  • the insoluble fractions will contain an appreciable amount of ethylene that would not otherwise be present if the polymer was simply a blend of iPP homopolymer and EP copolymer.
  • a mass balance calculation can be performed to estimate a block composite index from the amount of xylene insoluble and soluble fractions and the weight % ethylene present in each of the fractions.
  • the amount of the soft block (providing the source of the extra ethylene) present in the insoluble fraction is calculated.
  • the weight % C 2 of the insoluble fraction in the left hand side of equation 2 the weight % iPP hard and weight % EP soft can be calculated using equations 3 and 4. Note that the weight % of ethylene in the EP soft is set to be equal to the weight % ethylene in the xylene soluble fraction.
  • the weight % ethylene in the iPP block is set to zero or if otherwise known from its DSC melting point or other composition measurement, the value can be put into its place.
  • w iPPhard wt ⁇ ⁇ % ⁇ ⁇ C 2 overall ⁇ ⁇ or ⁇ ⁇ xyleneinso ⁇ ⁇ lub ⁇ ⁇ le - wt ⁇ ⁇ % ⁇ ⁇ C 2 EPsoft wt ⁇ ⁇ % ⁇ ⁇ C 2 iPPhard - wt ⁇ ⁇ % ⁇ ⁇ C 2 EPsoft Eq . ⁇ 3
  • w EPsoft 1 - w iPPHard Eq . ⁇ 4
  • the EP polymer chain must be connected to an iPP polymer block (or else it would have been extracted into the xylene soluble fraction). Thus, when the iPP block crystallizes, it prevents the EP block from solubilizing.
  • the ratio between the EP soft and iPP hard is used.
  • the ratio of the EP soft polymer and iPP hard polymer can be calculated using Equation 2 from the mass balance of the total ethylene measured in the polymer. Alternatively it could also be estimated from a mass balance of the monomer and comonomer consumption during the polymerization.
  • the weight fraction of iPP hard and weight fraction of EP soft is calculated using Equation 2 and assumes the iPP hard contains no ethylene.
  • the weight % ethylene of the EP soft is the amount of ethylene present in the xylene soluble fraction.
  • an iPP-EP block composite contains an overall ethylene content of 47 wt % C 2 and is made under conditions to produce an EP soft polymer with 67 wt % C 2 and an iPP homopolymer containing zero ethylene
  • the amount of EP soft and iPP hard is 70 wt % and 30 wt %, respectively (as calculated using Equations 3 and 4). If the percent of EP is 70 wt % and the iPP is 30 wt %, the relative ratio of the EP:iPP blocks could be expressed as 2.33:1.
  • Equations 2 thru 4 can be solved to account for this additional ethylene and result in 37.3 wt % EP soft polymer and 62.7 wt % iPP hard polymer present in the insoluble fraction.
  • the insoluble fraction contains 37.3 wt % EP copolymer, it should be attached to an additional 16 wt % of iPP polymer based on the EP:iPP block ratio of 2.33:1. This brings the estimated amount of diblock in the insoluble fraction to be 53.3 wt %.
  • the composition is described as 21.3 wt % iPP-EP Diblock, 18.7 wt % iPP polymer, and 60 wt % EP polymer.
  • the term block composite index (BCI) is herein defined to equal the weight percentage of diblock divided by 100% (i.e. weight fraction).
  • the value of the block composite index can range from 0 to 1, wherein 1 would be equal to 100% diblock and zero would be for a material such as a traditional blend or random copolymer.
  • the block composite index for the block composite is 0.213.
  • the BCI is 0.533, and for the soluble fraction the BCI is assigned a value of zero.
  • Such estimations include the wt % C2 in the iPP hard block as measured from the DSC melting point, NMR analysis, or process conditions; the average wt % C2 in the soft block as estimated from the composition of the xylene solubles, or by NMR, or by DSC melting point of the soft block (if detected).
  • the block composite index calculation reasonably accounts for the unexpected amount of ‘additional’ ethylene present in the insoluble fraction, the only way to have an EP copolymer present in the insoluble fraction, the EP polymer chain must be connected to an iPP polymer block (or else it would have been extracted into the xylene soluble fraction).
  • Crystalline block composites having CAOP and CAOB composed of crystalline polypropylene and a CEP and CEB composed of crystalline polyethylene cannot be fractionated by conventional means.
  • Techniques based on solvent or temperature fractionation for example, using xylene fractionation, solvent/non-solvent separation, temperature rising elution fractionation, or crystallization elution fractionation are not capable of resolving the block copolymer since the CEB and CAOB cocrystallize with the CEP and CAOP, respectively.
  • crystalline polymer species such as polypropylene and polyethylene can be separated from each other and from the block copolymer.
  • the amount of isolated PP is less than if the polymer was a simple blend of iPP homopolymer (in this example the CAOP) and polyethylene (in this case the CEP). Consequently, the polyethylene fraction contains an appreciable amount of propylene that would not otherwise be present if the polymer was simply a blend of iPP and polyethylene.
  • a mass balance calculation can be performed to estimate a crystalline block composite index from the amount of the polypropylene and polyethylene fractions and the weight % propylene present in each of the fractions that are separated by HTLC.
  • the polymers contained within the crystalline block composite include iPP-PE diblock, unbound iPP, and unbound PE where the individual PP or PE components can contain a minor amount of ethylene or propylene respectively.
  • a summation of the weight % propylene from each component in the polymer according to equation 1 results in the overall weight % propylene (of the whole polymer).
  • This mass balance equation can be used to quantify the amount of the iPP and PE present in the diblock copolymer.
  • This mass balance equation can also be used to quantify the amount of iPP and PE in a binary blend or extended to a ternary, or n-component blend.
  • the overall amount of iPP or PE is contained within the blocks present in the diblock and the unbound iPP and PE polymers.
  • w PP weight fraction of PP in the polymer
  • w PE weight fraction of PE in the polymer wt %
  • C3 PP weight percent of propylene in PP component or block
  • wt % C3 PE weight percent of propylene in PE component or block
  • the overall weight % of propylene (C3) is preferably measured from C13 NMR or some other composition measurement that represents the total amount of C3 present in the whole polymer.
  • the weight % propylene in the iPP block (wt % C3 PP ) is set to 100 or if otherwise known from its DSC melting point, NMR measurement, or other composition estimate, that value can be put into its place.
  • the weight % propylene in the PE block (wt % C3 PE ) is set to 100 or if otherwise known from its DSC melting point, NMR measurement, or other composition estimate, that value can be put into its place.
  • the overall weight fraction of PP present in the polymer can be calculated using Equation 2 from the mass balance of the total C3 measured in the polymer. Alternatively, it could also be estimated from a mass balance of the monomer and comonomer consumption during the polymerization. Overall, this represents the amount of PP and PE present in the polymer regardless of whether it is present in the unbound components or in the diblock copolymer.
  • the weight fraction of PP and weight fraction of PE corresponds to the individual amount of PP and PE polymer present.
  • the ratio of the weight fraction of PP to PE also corresponds to the average block ratio between PP and PE present in this statistical block copolymer.
  • w PP wt ⁇ ⁇ % ⁇ ⁇ C ⁇ ⁇ 3 Overall - wt ⁇ ⁇ % ⁇ ⁇ C ⁇ ⁇ 3 PE wt ⁇ ⁇ % ⁇ ⁇ C ⁇ ⁇ 3 PP - wt ⁇ ⁇ % ⁇ ⁇ C ⁇ ⁇ 3 PE Eq . ⁇ 2
  • w PP weight fraction of PP present in the whole polymer
  • wt % C3 PP weight percent of propylene in PP component or block
  • wt % C3 PE weight percent of propylene in PE component or block
  • the amount of the isolated PP that is measured by HTLC analysis is used to determine the amount of polypropylene present in the diblock copolymer.
  • the amount isolated or separated first in the HTLC analysis represents the ‘unbound PP’ and its composition is representative of the PP hard block present in the diblock copolymer.
  • the weight % of C3 in the PE fraction can be calculated using equations 4 and 5.
  • the PE fraction is described as the fraction separated from the unbound PP and contains the diblock and unbound PE.
  • the composition of the isolated PP is assumed to be the same as the weight % propylene in the iPP block as described previously.
  • w PPisolated weight fraction of isolated PP from HTLC
  • PE-fraction weight % of propylene in the PE-fraction that was separated by HTLC wt % C3
  • Overall overall weight % propylene in the whole polymer
  • the amount of wt % C3 in the polyethylene fraction from HTLC represents the amount of propylene present in the block copolymer fraction that is above the amount present in the ‘unbound polyethylene’.
  • the only way to have PP present in this fraction is that the PP polymer chain must be connected to a PE polymer chain (or else it would have been isolated with the PP fraction separated by HTLC). Thus, the PP block remains adsorbed with the PE block until the PE fraction is separated.
  • the amount of PP present in the diblock is calculated using Equation 6.
  • w PP ⁇ - ⁇ diblock wt ⁇ ⁇ % ⁇ ⁇ C ⁇ ⁇ 3 PE ⁇ - ⁇ fraction - wt ⁇ ⁇ % ⁇ ⁇ C ⁇ ⁇ 3 PE wt ⁇ ⁇ % ⁇ ⁇ C ⁇ ⁇ 3 PP - wt ⁇ ⁇ % ⁇ ⁇ C ⁇ ⁇ 3 PE Eq . ⁇ 6
  • wt % C3 PE-fraction weight % of propylene in the PE-fraction that was separated by HTLC (Equation 4)
  • wt % C3 PP weight % of propylene in the PP component or block (defined previously)
  • wt % C3 PE weight % of propylene in the PE component or block (defined previously)
  • w PP-diblock weight fraction of PP in the diblock separated with PE-fraction by HTLC
  • the amount of the diblock present in this PE fraction can be estimated by assuming that the ratio of the PP block to PE block is the same as the overall ratio of PP to PE present in the whole polymer. For example, if the overall ratio of PP to PE is 1:1 in the whole polymer, then it assumed that the ratio of PP to PE in the diblock is also 1:1. Thus the weight fraction of diblock present in the PE fraction would be weight fraction of PP in the diblock (w PP-diblock ) multiplied by two. Another way to calculate this is by dividing the weight fraction of PP in the diblock (w PP-diblock ) by the weight fraction of PP in the whole polymer (equation 2).
  • the estimated amount of diblock in the PE fraction is multiplied by the weight fraction of the PE fraction measured from HTLC.
  • the amount of block copolymer is determined by equation 7.
  • the weight fraction of diblock in the PE fraction calculated using equation 6 is divided by the overall weight fraction of PP (as calculated in equation 2) and then multiplied by the weight fraction of the PE fraction.
  • the value of the CBCI can range from 0 to 1, wherein 1 would be equal to 100% diblock and zero would be for a material such as a traditional blend or random copolymer.
  • w PP-diblock weight fraction of PP in the diblock separated with the PE-fraction by HTLC (Equation 6)
  • w PP weight fraction of PP in the polymer
  • w PE-fraction weight fraction of PE separated from HTLC, containing the diblock and unbound PE (Equation 5)
  • an iPP-PE polymer contains a total of 62.5 wt % C3 and is made under the conditions to produce an PE polymer with 10 wt % C3 and an iPP polymer containing 97.5 wt % C3, the weight fractions of PE and PP are 0.400 and 0.600, respectively (as calculated using Equation 2). Since the percent of PE is 40.0 wt % and the iPP is 60.0 wt %, the relative ratio of the PE:PP blocks is expressed as 1:1.5.
  • the PE fraction contains 0.444 weight fraction of PP, it should be attached to an additional 0.293 weight fraction of PE polymer based on the iPP:PE block ratio of 1.5:1.
  • the weight fraction of diblock present in the PE fraction is 0.741; further calculation of the weight fraction of diblock present in the whole polymer is 0.533.
  • the composition is described as 53.3 wt % iPP-PE diblock, 28 wt % PP polymer, and 18.7 wt % PE polymer.
  • the crystalline block composite index (CBCI) is the estimated weight fraction of diblock present in the whole polymer.
  • the CBCI for the crystalline block composite is 0.533.
  • the Crystalline Block Composite Index provides an estimate of the quantity of block copolymer within the crystalline block composite under the assumption that the ratio of CEB to CAOB within the diblock is the same as the ratio of crystalline ethylene to crystalline alpha-olefin in the overall crystalline block composite. This assumption is valid for these statistical olefin block copolymers based on the understanding of the individual catalyst kinetics and the polymerization mechanism for the formation of the diblocks via chain shuttling catalysis as described in the specification.
  • CBCI The calculation of CBCI is based on the analytical observation that the amount of free CAOP is lower than the total amount of CAOP that was produced in the polymerization. The remainder of the CAOP is bound to CEB to form the diblock copolymer. Because the PE fraction separated by HTLC contains both the CEP and the diblock polymer, the observed amount of propylene for this fraction is above that of the CEP. This difference can be used to calculate the CBCI.
  • the minimum and maximum quantities of block copolymer present in a polymer can be calculated, thus distinguishing a crystalline block composite from a simple copolymer or copolymer blend.
  • w DB Max The upper bound on the amount of block copolymer present within a crystalline block composite, w DB Max , is obtained by subtracting the fraction of unbound PP measured by HTLC from one as in Equation 8. This maximum assumes that the PE fraction from HTLC is entirely diblock and that all crystalline ethylene is bound to crystalline PP with no unbound PE. The only material in the CBC that is not diblock is that portion of PP separated via HTLC.
  • the lower bound on the amount of block copolymer present within a crystalline block composite, w DB Min corresponds to the situation where little to no PE is bound to PP. This lower limit is obtained by subtracting the amount of unbound PP as measured by HTLC from the total amount of PP in the sample as shown in Equation 9.
  • crystalline block composite index will fall between these two values: w DB min ⁇ CBCI ⁇ w DB Max .
  • the CBCI represents the best estimate of the actual fraction of diblock copolymer in the composite.
  • w DB Min can be used to determine if a material is a crystalline block composite.
  • the overall weight fraction of PP should be equal to that of the wt % PP from HTLC and the lower bound on diblock content, Equation 9, is zero. If this analysis is applied to a sample of PP that does not contain PE both the weight fraction of PP and amount of PP obtained from HTLC are 100% and again the lower bound on diblock content, Equation 9, is zero.
  • DSC Differential Scanning calorimetry
  • Differential Scanning calorimetry is used to measure, among other things, the heats of fusion of the crystalline block and block composites and is performed on a TA Instruments 01000 DSC equipped with an RCS cooling accessory and an auto sampler. A nitrogen purge gas flow of 50 ml/min is used. The sample is pressed into a thin film and melted in the press at about 190° C. and then air-cooled to room temperature (25° C.). About 3-10 mg of material is then cut, accurately weighed, and placed in a light aluminum pan (ca 50 mg) which is later crimped shut. The thermal behavior of the sample is investigated with the following temperature profile: the sample is rapidly heated to 190° C. and held isothermal for 3 minutes in order to remove any previous thermal history.
  • the sample is then cooled to ⁇ 90° C. at 10° C./min cooling rate and held at ⁇ 90° C. for 3 minutes.
  • the sample is then heated to 190° C. at 10° C./min heating rate.
  • the cooling and second heating curves are recorded.
  • the baseline for the calculation is drawn from the flat initial section prior to the onset of melting (typically in the range of from about ⁇ 10 to about 20° C. for these types of materials) and extends to the end of melting for the second heating curve.
  • Suitable block composite resins comprise:
  • Crystalline block composite resins comprise:
  • Preferred suitable BC and/or CBC resin(s) for Layer B have a CAOB amount (in part (iii)) in the range of from about 30 to about 70 weight % (based on (iii)), preferably at least about 40 wt %, more preferably at least about 45 wt % and most preferably about 50 wt %, and preferably up to about 60 wt %, and preferably up to about 55 wt % (the balance in each case being ethylene polymer). It has also been found that the BC and/or CBC resin(s) suitable for Layer B have a (crystalline) block composite index of at least about 0.1, preferably at least about 0.3, preferably at least about 0.5 and more preferably at least about 0.7.
  • Another way to characterize the suitable BC and/or CBC resin(s) essential for Layer B is as having a MFR in the range of from about 1 to about 50 dg/min; preferably at least about 2, more preferably at least about 3; and preferably up to about 40, and preferably up to about 30 g/min.
  • BC's that can be used in Layer B according to the present invention will have heat of fusion values (generally related to their ethylene content in the EP and EB) of at least about 75 Joules per gram (J/g), more preferably at least about 80 J/g, still more preferably at least about 85 J/g and most preferably at least about 90 J/g, as measured by DSC.
  • CBC's that can be used in Layer B according to the present invention will have heat of fusion values (reflecting the relatively higher ethylene content in the CEP and CEB) as measured by DSC of at least about 85 Joules per gram (J/g), more preferably at least about 90 J/g.
  • the heat of fusion values for polymers of these types would generally have a maximum in the area of about 125 J/g.
  • the DSC is run as generally described below under nitrogen at 10° C./min from 23° C. to 220° C., held isothermal at 220° C., dropped to 23° C. at 10° C./min and ramped back to 220° C. at 10° C./min.
  • the second heat data is used to calculate the heat of fusion of the melting transition.
  • Blends of these resins can also be used in Layer B where blended or diluted with one or more other polymers, including the polyolefins as described herein.
  • Suitable additional components could be, for example, LDPE, LLDPE, an impact modifier such as ethylene octene copolymer plastomers such as AFFINITY PL 1880G, PL8100G, and PL 1850G or ethylene octene copolymer elastomers such as ENGAGE 8842, ENGAGE 8150, and ENGAGE XLT 8677, or olefin block copolymers such as for example INFUSE 9100 and 9107 brand polymer or propylene based elastomers such as VERSIFY 2300 and VERSIFY 3300 brand resins available from The Dow Chemical Company.
  • the CBC and/or BC polymer resins of Layer B can be blended with other polyolefin resins that are grafted or functionalized with glycidyl methacrylate, maleic anhydride (MAH), amines or silane or they can be blended with polar copolymers of ethylene such as EEA, EVA, EMA, EnBA, EAA and the like.
  • the additional blend polymer needs to be: (i) miscible or highly compatible with the BC and/or CBC, (ii) have little, if any, deleterious impact on the desirable properties of the polyolefin block copolymer composite, e.g., toughness and modulus, and (iii) used in levels such that the BC and/or CBC resin(s) constitute from at least 40 to 99 weight percent of the blend, preferably at least 60, more preferably at least 75, and more preferably at least 80 weight percent of the blend.
  • blend components would be used in the Layer B resins in amounts of at least 2 weight percent, preferably at least 5 and more preferably at least 8 weight percent and preferably less than 30 weight percent, preferably less than 25 weight percent and more preferably less than 20 weight percent. Blending can be used to provide: improve compatibility (adhesion) with C and/or other layers under a range of conditions and lower costs. In particular, blends would desirably be employed where Layer B is employed as surface layer, as discussed below, and this film surface needs properties sufficient for roll-up, handling, packaging, transport and assembly into final laminate structures, such as into electronic device modules.
  • all or part of the BC and/or CBC component in the Layer B are grafted or functionalized with glycidyl methacrylate, maleic anhydride (MAH), amines or silane to provide desired property modifications such as improved adhesion to other films or the surfaces of articles.
  • functionalization or grafting can be done by techniques known to those skilled in this art area. Particularly useful and applicable techniques are taught in copending United States patent applications filed Dec. 14, 2011: (a) Ser. No. 61/570,464 entitled, “FUNCTIONALIZED BLOCK COMPOSITE AND CRYSTALLINE BLOCK COMPOSITE COMPOSITIONS AS COMPATIBILIZERS and (b) Ser. No. 61/570,340 entitled, “FUNCTIONALIZED BLOCK COMPOSITE AND CRYSTALLINE BLOCK COMPOSITE COMPOSITIONS”, which are incorporated herein by reference.
  • Layer B can be designed to have sufficient physical properties and be sufficiently adhesive to other films or articles and the films according to the present invention are two layer structures.
  • Such other films to which adhesion may be desired include, for example, the “encapsulation films” employed in the assembly of electronic devices and discussed in more detail below, eliminating the need to have a further, separate seal layer.
  • Such other articles to which Layer B adhesion may be desired include, for example, the surfaces of photovoltaic cells (eliminating the need to have further seal or encapsulation layers) or metal surfaces such as tin or other metals used in photovoltaic cells, and aluminum or other metals that might be employed in construction of lithium ion batteries.
  • the CBC and/or BC resin formulation employed would comprise: greater than 20 wt % CBC and/or BC resin, preferably greater than 40 wt % CBC and/or BC and more preferably greater than 50 wt % CBC and/or BC and even more preferably greater than 60 wt % CBC and/or BC.
  • the thickness of the Layer B would generally be greater than when used as tie layer with layers A and C in a 3 or more layer film.
  • Layer A is selected to be adhered, either preferably by co-extrusion or alternatively but less preferably by a lamination process (such as extrusion lamination, thermal lamination, or adhesive lamination) to the tie layer (Layer B) in production of the film according to the invention and to adhere the film to other films or articles such as the encapsulation films employed in the assembly of electronic devices (“encapsulation films” being discussed in more detail below).
  • Layer A materials can be selected from a very wide variety of different types of materials assembled in blends and/or layers as described in more detail below. Among other things, the relative thinness of Layer A distinguishes it from a layer that would serve as an “encapsulation” layer.
  • the wide variety of candidate seal layer materials includes generally wide range of thermoplastic ethylene-based polymers, such as high pressure, free-radical low density polyethylene (LDPE), and ethylene-based polymers prepared with Ziegler-Natta catalysts, including high density polyethylene (HDPE) and heterogeneous linear low density polyethylene (LLDPE), ultra low density polyethylene (ULDPE), and very low density polyethylene (VLDPE), as well as multiple-reactor ethylenic polymers (“in reactor” blends of Ziegler-Natta PE and metallocene PE, such as products disclosed in U.S. Pat. No. 6,545,088 (Kolthammer et al.); U.S. Pat. No.
  • linear ethylene-based polymers include ATTANETM Ultra Low Density Linear Polyethylene Copolymer, DOWLEXTM Polyethylene Resins, and FLEXOMERTM Very Low Density Polyethylene, ELITETM brand enhanced polyethylene resin, all available from The Dow Chemical Company.
  • Suitable synthetic polymers include ethylene/diene interpolymers, ethylene acrylic acid (EAA), ethylene-vinyl acetate (EVA), ethylene ethyl acrylate (EEA), ethylene methyl acrylate (EMA), ethylene n-butyl acrylate (EnBA), ethylene methacrylic acid (EMAA), various types of ionomers, and ethylene/vinyl alcohol copolymers.
  • EAA ethylene acrylic acid
  • EAA ethylene-vinyl acetate
  • EAA ethylene ethyl acrylate
  • EMA ethylene methyl acrylate
  • EnBA ethylene n-butyl acrylate
  • EEMAA ethylene methacrylic acid
  • Homogeneous olefin-based polymers such as ethylene-based plastomers or elastomers can also be useful as components in blends or compounds made with the ethylenic polymers of this invention.
  • homogeneous metallocene-catalyzed, ethylene-based plastomers or elastomers include AFFINITYTM polyolefin plastomers and ENGAGETM polyolefin elastomers, both available from The Dow Chemical Company, and commercial examples of homogeneous propylene-based plastomers and elastomers include VERSIFYTM performance polymers, available from The Dow Chemical Company, and VISTAMAXTM polymers available from ExxonMobil Chemical Company.
  • Suitable ethylene-propylene polymers include BC's and CBC's as described above.
  • VLDPE very low density polyethylene
  • FLEXOMER® ethylene/1-hexene polyethylene made by The Dow Chemical Company
  • homogeneously branched, linear ethylene/ ⁇ -olefin copolymers e.g.
  • TAFMER® by Mitsui Petrochemicals Company Limited and EXACT® by Exxon Chemical Company
  • homogeneously branched, substantially linear ethylene/ ⁇ -olefin polymers e.g., AFFINITY® and ENGAGE® polyethylene available from The Dow Chemical Company
  • ethylene multi-block copolymers e.g., INFUSE° olefin block copolymers available from The Dow Chemical Company.
  • the more preferred polyolefin copolymers for use in the top layer of the backsheet are the homogeneously branched linear and substantially linear ethylene copolymers, particularly the substantially linear ethylene copolymers which are more fully described in U.S. Pat. Nos.
  • One preferred polar ethylene copolymer for use in the top layer of the claimed films is an EVA copolymer, including blends comprising EVA copolymers, that will form a sealing relationship with other films or layers, e.g., encapsulant, a glass cover sheet, etc. when brought into adhesive contact with the layer or other component.
  • the ratio of units derived from ethylene to units derived from vinyl acetate in the copolymer, before grafting or other modification, can vary widely, but typically the EVA copolymer contains at least about 1, preferably at least 2, more preferably at least 4 and even more preferably at least 6, wt % units derived from vinyl acetate.
  • the EVA copolymer contains less than about 33 wt % units derived from vinyl acetate, preferably less than 30, preferably less than 25, preferably less than 22, preferably less than 18 and more preferably less than 15 wt % units derived from vinyl acetate.
  • the EVA copolymer can be made by any process including emulsion, solution and high-pressure polymerization.
  • the EVA copolymer before grafting or other modification typically has a density of less than 0.95, preferably less than 0.945, more preferably less than 0.94, g/cc.
  • the same EVA copolymer typically has a density greater than 0.9, preferably greater than 0.92, and more preferably greater than 0.925, g/cc. Density is measured by the procedure of ASTM D-792.
  • EVA copolymers are generally characterized as semi-crystalline, flexible and having good optical properties, e.g., high transmission of visible and UV-light and low haze.
  • ethylene acrylate copolymer such as ethylene ethyl acrylate (EEA) and ethylene methyl acrylate (EMA) copolymers, (including blends comprising either) that can also form a sealing relationship with the adjacent layer, such as an encapsulant layer in an electronic device module, when they are brought into adhesive contact.
  • ESA ethylene ethyl acrylate
  • EMA ethylene methyl acrylate
  • the ratio of units derived from ethylene to units derived from ethyl acrylate or methyl acrylate in the copolymer, before grafting or other modification, can vary widely, but typically the EEA or EMA copolymer contains at least 1, preferably at least 2, more preferably at least 4 and even more preferably at least 6, wt % units derived from the ethyl acrylate or methyl acrylate. Typically, the EEA or EMA copolymer contains less than 28, preferably less than 25, more preferably less than 22, and more preferably less than 19, wt % units derived from ethyl acrylate or methyl acrylateacrylate.
  • polar ethylene copolymers typically have a melt index (MI as measured by the procedure of ASTM D-1238 (190C/2.16 kg) of less than 100, preferably less than 75, more preferably less than 50 and even more preferably less than 30, g/10 min.
  • MI melt index
  • the typical minimum MI is at least 0.3, more preferably 0.7, and more preferably it is at least 1 g/10 min.
  • One preferred top layer of the backsheet is a blend formulation of a linear low density polyethylene (LLDPE) comprising polar ethylene copolymer in an amount of from 10 to 45 weight %, the weight % depending upon the polar ethylene copolymer being used.
  • LLDPE linear low density polyethylene
  • MAH-m-polyolefins are another preferred seal layer material and include MAH-g-polyolefins and MAH interpolymers, i.e., the MAH functionality is present in the polyolefin either by grafting onto the polymer backbone or incorporating the functionality into the backbone through copolymerization of MAH with the olefin monomer.
  • the polyolefin is graft-modified to enhance the interlayer adhesion between the top layer and the bottom layer of the multilayer structure through a reaction of the grafted functionality with the reactive group present in the middle tie layer.
  • Any material that can be grafted to the polyolefin and can react with the reactive group present in the tie layer can be used as the graft material.
  • Any unsaturated organic compound containing at least one ethylenic unsaturation e.g., at least one double bond
  • at least one carbonyl group —C ⁇ O
  • Representative of compounds that contain at least one carbonyl group are the carboxylic acids, anhydrides, esters and their salts, both metallic and nonmetallic.
  • the organic compound contains ethylenic unsaturation conjugated with a carbonyl group.
  • Representative compounds include maleic, fumaric, acrylic, methacrylic, itaconic, crotonic, ⁇ -methyl crotonic, and cinnamic acid and their anhydride, ester and salt derivatives, if any.
  • Maleic anhydride is the preferred unsaturated organic compound containing at least one ethylenic unsaturation and at least one carbonyl group.
  • the unsaturated organic compound content of the graft polyolefin is at least 0.01 wt %, and preferably at least 0.05 wt %, based on the combined weight of the polyolefin and the organic compound.
  • the maximum amount of unsaturated organic compound content can vary to convenience, but typically it does not exceed 10 wt %, preferably it does not exceed 5 wt %, and more preferably it does not exceed 2 wt %.
  • This unsaturated organic content of the graft polyolefin is measured by a titration method, e.g., a grafted polyolefin/xylene solution is titrated with a potassium hydroxide (KOH) solution.
  • KOH potassium hydroxide
  • the MAH functionality can be present in the polyolefin e.g., by grafting, or even by copolymerization with the olefin monomer.
  • a suitable material for Layer A can be provided by a silane grafted polyolefin as described below for use as the encapsulation layer, particularly as provided by silane grafting in the thermoplastic ethylene-based polymers described above, including in an olefinic interpolymer or polar ethylene copolymer described above.
  • the silane grafted polyolefin layer thickness would generally be less than 200 micron ( ⁇ m), and more preferably less than 100 ⁇ m and not sufficient to serve as a typical encapsulation layer that is commonly a film 450 ⁇ m thick. It will, however, in layer A of the present films provide good sealing with such materials used in encapsulation films.
  • Blends comprising these polyolefin resins with others as described above can also be used in Layer A of films according to the invention.
  • Layer A polyolefin polymers can be blended or diluted with one or more other polymers to the extent that the polyolefin is (i) compatible with the other polymer, (ii) the other polymer has little, if any, deleterious impact on the desirable properties of the polyolefin polymer, e.g., toughness and modulus, and (iii) the polyolefin polymer of this invention constitutes at least 55, preferably at least 70, preferably at least 75 and more preferably at least 80, weight percent of the blend.
  • crosslinking would preferably be avoided, due to the low density and modulus of the polyolefin resins used in the practice of this invention, these polymers can be cured or crosslinked at the time of lamination or after, usually shortly after, assembly of the layers into the multilayered article, e.g., PV module.
  • Crosslinking can be initiated and performed by any one of a number of different and known methods, e.g., by the use of thermally activated initiators, e.g., peroxides and azo compounds; photoinitiators, e.g., benzophenone; radiation techniques including Electron-beam and x-ray; vinyl silane, e.g., vinyl tri-ethoxy or vinyl tri-methoxy silane; and moisture cure.
  • thermally activated initiators e.g., peroxides and azo compounds
  • photoinitiators e.g., benzophenone
  • radiation techniques including Electron-beam and x-ray
  • vinyl silane e.
  • the individual layers of the multilayered structure can further comprise one or more additives.
  • exemplary stabilizer additives include UV-stabilizers, UV-absorbers, and antioxidants. These stabilizer additives are useful in, e.g., reducing the oxidative degradation and improving the weatherability of the product.
  • Suitable stabilizers include hindered amines and hindered benzoates such as Cynergy A400, A430, R350 and R350-a4, Cyasorb UV-3529, Cyasorb UV-3346, Cyasorb UV-3583, Hostavin N30, Univil 4050, Univin 5050, Chimassorb UV-119, Chimassorb 944 LD, Tinuvin 622 LD and the like; UV absorbers such as Tinuvin 328 or Cyasorb UV-1164 and the like and; primary and secondary antioxidants such as Cyanox 2777, Irganox 245, 1010, 1076, B215, B225, PEPQ, Weston 399, TNPP, Irgafos 168 and Doverphos 9228.
  • the amounts and combinations of stabilizers needed depend on the type, aging environment and longevity desired and are used in the manner and, as is commonly known in the art, the amounts typically range between greater than 0.01 and less than 3% weight percent based on the polymer weight being stabilize
  • Layer means a single thickness, coating or stratum continuously or discontinuously spread out or covering a surface.
  • Multi-layer means at least two layers.
  • “Facial surface”, “planar surface” and like terms as related to films or layers mean the surfaces of the layers that are in contact with the opposite and adjacent surfaces of the adjoining layers. Facial surfaces are in distinction to edge surfaces.
  • a rectangular film or layer comprises two facial surfaces and four edge surfaces.
  • a circular layer comprises two facial surfaces and one continuous edge surface.
  • “Sealing relationship” and like terms mean that two or more components, e.g., two polymer layers, or a polymer layer and an electronic device, or a polymer layer and a glass cover sheet, etc., join with one another in such a manner, e.g., co-extrusion, lamination, coating, etc., that the interface formed by their joining is separated from their immediate external environment.
  • the multilayer film or sheet structures according to the present invention can be designed to meet certain performance requirements such as in the areas of physical performance properties including toughness, transparency, tensile strength, interlayer adhesion, and heat resistance; electrical properties such as insulation, dielectric breakdown, partial discharge and resistance; reflectance; and appearance.
  • Layer C in the multilayer backsheet structures according to the present invention is prepared from the “Layer C High Melting Point Polyolefin Resins” as discussed above. In one preferred embodiment, it is preferably a highly crystalline homopolymer polypropylene resin.
  • the thickness of Layer C is typically in the range of from 100 ⁇ m to 400 ⁇ m. As for minimum thickness, Layer C is preferably at least 125 ⁇ m, more preferably at least 150 ⁇ m, more preferably at least 160 ⁇ m and most preferably at least 170 ⁇ m thick. As for maximum thickness, the thickness of Layer C can be up to and including 375 ⁇ m; 350 ⁇ m, preferably 300 ⁇ m, more preferably 275 ⁇ m and most preferably 250 ⁇ m.
  • the thickness of the Layer B would generally be at least 10 um, more preferably at least 15 um, even more preferably at least 25 um and preferably less than or equal to 500 um, more preferably less than or equal to 400 um and even more preferably less than or equal to 350 um.
  • Layer B serving as both a surface seal layer it is preferably a blend comprising the CBC and one or more other components such as polymer process aids, colorants, and slip or anti-block additives.
  • Layer B is only as thick as needed to tie the adjacent Layers A and C together and can preferably be at least 2 ⁇ m, preferably at least 3 ⁇ m, preferably at least 4 ⁇ m, more preferably at least 10 ⁇ m, more preferably at least 15 ⁇ m, more preferably at least 20 ⁇ m and most preferably at least 25 ⁇ m thick.
  • the thickness and cost of Layer B are desirably minimized but are preferably up to and including 150 ⁇ m, preferably 100 ⁇ m, more preferably 75 ⁇ m and most preferably up to and including 50 ⁇ m thick.
  • the top or seal Layer A adheres the films according to the present invention to an encapsulating film.
  • the thickness of Layer A is typically in the range of from 15 ⁇ m to 200 ⁇ m.
  • Layer A is only as thick as needed to adhere the backsheet to the encapsulation film layer and should be at least 17 ⁇ m, preferably at least 20 ⁇ m, more preferably at least 23 ⁇ m and most preferably at least 25 ⁇ m thick.
  • the thickness and cost of Layer A are desirably minimized but can be up to and including 175 ⁇ m, preferably 150 ⁇ m, more preferably 130 ⁇ m, and most preferably up to and including 125 ⁇ m.
  • composition of the layers can be selected and optimized along the lines discussed herein depending upon the intended film structure and usage of the film structure.
  • the films can be employed as a 2 layer backsheet or a 3 layer backsheet (comprising both a tie layer and a top seal layer).
  • the films according to the present invention are suitable to be employed as, among other things, backsheet layers for direct use in laminate electronic device structures, such as, for example PV modules.
  • the top facial surface of the multilayered film structure exhibits good adhesion for the facial surfaces of the encapsulation layer material that encapsulates the device.
  • such film structures can be prepared by any of a large number of known film production processes including but not limited to extrusion or co-extrusion methods such as blown-film, modified blown-film, calendaring and casting, as well as sheet extrusion using a roll stack.
  • extrusion or co-extrusion methods such as blown-film, modified blown-film, calendaring and casting, as well as sheet extrusion using a roll stack.
  • Layers A, B and C of the films according to the present invention are selected to be adhered simultaneously together preferably by co-extrusion or alternatively but less preferably by a lamination process (such as extrusion lamination, thermal lamination, or adhesive lamination) into the films according to the invention.
  • a lamination process such as extrusion lamination, thermal lamination, or adhesive lamination
  • a sequential process can be employed to adhere pairs of layers together and to the third and any optional layers.
  • FIG. 1 is a cross-sectional view of an electronic device comprising a three-layer backsheet 14 comprising “A” Layer 14 A, “B” Layer 14 B and “C” Layer 14 C all in adhering contact with each other, further in adhering contact with an encapsulant layer 12 b adhered or laminated to the back surface of an electronic device, e.g., a PV cell.
  • a three-layer backsheet 14 comprising “A” Layer 14 A, “B” Layer 14 B and “C” Layer 14 C all in adhering contact with each other, further in adhering contact with an encapsulant layer 12 b adhered or laminated to the back surface of an electronic device, e.g., a PV cell.
  • PV cells (11) are typically employed in a laminate structure and have at least one light-reactive surface that converts the incident light into electric current.
  • Photovoltaic cells are well known to practitioners in this field and are generally packaged into photovoltaic modules that protect the cell(s) and permit their usage in their various application environments, typically in outdoor applications.
  • PV cells may be flexible or rigid in nature and include the photovoltaic effect materials and any protective coating surface materials that are applied in their production as well as appropriate wiring and electronic driving circuitry (not shown).
  • Photovoltaic modules (“PV Modules”), such as represented by the example structure shown in FIG. 1 , contain at least one photovoltaic cell 11 (in this case having a single light-reactive or effective surface directed or facing upward in the direction of the top of the page) surrounded or encapsulated by a light transmitting protective encapsulating sub-component 12 a on the top or front surface and protective encapsulating sub-component 12 b on the rear or back surface, which is optionally light transmitting.
  • 12 a and 12 b form an encapsulating component 12 , shown here as a combination of two encapsulating layers “sandwiching” the cell.
  • the light transmitting cover sheet 13 has an interior surface in adhering contact with a front facial surface of the encapsulating film layer 12 a , which layer 12 a is, in turn, disposed over and in adhering contact with PV cell 11 .
  • Multilayer backsheet films 14 act as a substrate and supports a rear surface of the PV cell 11 and optional encapsulating film layer 12 b , which, in this case is disposed on a rear surface of PV cell 11 .
  • Back sheet layer 14 (and even encapsulating sub-layer 12 b ) need not be light transmitting if the surface of the PV cell to which it is opposed is not effective, i.e., reactive to sunlight.
  • a flexible PV module as the description “flexible” implies, it would comprise a flexible thin film photovoltaic cell 11 .
  • the top layer or coversheet 13 and the top encapsulating layer 12 a generally need to have good, typically excellent, transparency, meaning transmission rates in excess of 90, preferably in excess of 95 and even more preferably in excess of 97, percent as measured by UV-vis spectroscopy (measuring absorbance in the wavelength range of 250-1200 nanometers.
  • An alternative measure of transparency is the internal haze method of ASTM D-1003-00. If transparency is not a requirement for operation of the electronic device, then the polymeric material can contain opaque filler and/or pigment.
  • the thicknesses of all the electronic device module layers are not critical to this invention and as such, can vary widely depending upon the overall design and purpose of the module.
  • Typical thicknesses for protective or encapsulate layers 12 a and 12 b are in the range of 0.125 to 2 millimeters (mm), and for the cover sheet in the range of 0.125 to 1.25 mm.
  • the thickness of the electronic device can also vary widely.
  • Suitable polymer compositions and films include those used and in the same manner and amounts as the light transmitting layers used in the known PV module laminate structures, e.g., such as those taught in U.S. Pat. No. 6,586,271, US Patent Application Publication US2001/0045229 A1, WO 99/05206 and WO 99/04971. These materials can be used as the light transmitting “skin” for the PV cell, i.e., applied to any faces or surfaces of the device that are light-reactive. Suitable films are known and commercially available including ENLIGHTTM brand polyolefin encapsulant films commercially available from The Dow Chemical Company. Light transmitting Cover Sheet
  • Light transmitting cover sheet layers can be one or more of the known rigid or flexible sheet materials.
  • cover can be one or more of the known rigid or flexible sheet materials.
  • other known materials can be employed for one or more of the layers with which the lamination films according to the present invention are employed.
  • Such materials include, for example, materials such as polycarbonate, acrylic polymers, a polyacrylate, a cyclic polyolefin such as ethylene norbornene, metallocene-catalyzed polystyrene, polyethylene terephthalate, polyethylene naphthalate, fluoropolymers such as ETFE (ethylene-tetrafluoroethlene), PVF (polyvinyl fluoride), FEP (fluoroethylene-propylene), ECTFE (ethylene-chlorotrifluoroethylene), PVDF (polyvinylidene fluoride), and many other types of plastic or polymeric materials, including laminates, mixtures or alloys of two or more of these materials.
  • materials such as polycarbonate, acrylic polymers, a polyacrylate, a cyclic polyolefin such as ethylene norbornene, metallocene-catalyzed polystyrene, polyethylene terephthalate, polyethylene naphthalate, fluoro
  • the location of particular layers and need for light transmission and/or other specific physical properties would determine the specific material selections.
  • the down conversion/light stabilizer formulations discussed above can be employed in the transparent cover sheets. However, the inherent stability of some of these may not require light stabilization according to the present invention.
  • the “glass” used as a light transmitting cover sheet refers to a hard, brittle, light transmitting solid, such as that used for windows, many bottles, or eyewear, including, but not limited to, soda-lime glass, borosilicate glass, sugar glass, isinglass (Muscovy-glass), or aluminum oxynitride.
  • soda-lime glass borosilicate glass
  • sugar glass isinglass (Muscovy-glass), or aluminum oxynitride.
  • isinglass Melcovy-glass
  • aluminum oxynitride aluminum oxynitride.
  • glass is an inorganic product of fusion which has been cooled to a rigid condition without crystallizing.
  • Many glasses contain silica as their main component and glass former.
  • SiO2 glass the same chemical compound as quartz, or, in its polycrystalline form, sand
  • SiO2 glass does not absorb UV light and is used for applications that require transparency in this region.
  • Large natural single crystals of quartz are pure silicon dioxide, and upon crushing are used for high quality specialty glasses.
  • Synthetic amorphous silica an almost 100% pure form of quartz, is the raw material for the most expensive specialty glasses.
  • the glass layer of the laminated structure is typically one of, without limitation, window glass, plate glass, silicate glass, sheet glass, float glass, colored glass, specialty glass which may, for example, include ingredients to control solar heating, glass coated with sputtered metals such as silver, glass coated with antimony tin oxide and/or indium tin oxide, E-glass, and SolexiaTM glass (available from PPG Industries of Pittsburgh, Pa.).
  • the methods of making PV modules known in the art can readily be adapted to use the multilayer backsheet film structures according to present invention.
  • the multilayer backsheet film structures according to present invention can be used in the PV modules and methods of making PV modules such as those taught in U.S. Pat. No. 6,586,271, US Patent Application Publication US2001/0045229 A1, WO 99/05206 and WO 99/04971.
  • the assembly process typically requires a lamination step with heating and compressing at conditions sufficient to create the needed adhesion between the layers and, if needed in some layers or materials, initiation of their crosslinking.
  • the layers may be placed into a vacuum laminator for 10 to 20 minutes at lamination temperatures in order to achieve layer-to-layer adhesion and, if needed, crosslinking of the polymeric material of the encapsulation element.
  • the lamination temperatures need to be at least 130° C., preferably at least 140° C. and, at the upper end, less than or equal to 170° C., preferably less than or equal to 160° C.
  • CBC's crystalline block copolymer composites
  • EP ethylene-based polymer
  • CEP crystalline
  • CPP propylene-based crystalline polymer
  • block copolymer comprising
  • CBC samples are further characterized by the indicated:
  • UV Stabilizer masterbatch formulations All amounts are based on weight percent.
  • Type of UV 1 UV 2 Component additive Supplier (Wt %) (Wt %) LDPE2 Resin Dow Chemical 89.5 PP2 Resin Dow Chemical 87.5 Cyasorb UV stabilizers Cytec Industries, 1.0 UV1164 Inc Cyasorb UV stabilizers Cytec Industries, 4.0 UV3853S Inc Cyasorb UV stabilizers Cytec Industries, 6.0 UV3853PP5 Inc Cyasorb UV stabilizers Cytec Industries, 2.0 UV3346 Inc Cyasorb UV stabilizers Cytec Industries, 2.0 UV3529 Inc Cyasorb UV stabilizers Cytec Industries, 3.0 THT7001 Inc Uvinul 5050H UV stabilizers BASF Corporation 2.0 Tinuvin 770 UV stabilizers BASF Corporation 1.0 Irganox 1010 Antioxidant BASF Corporation 0.75 0.25 Irganox 168 Antioxidant BASF Corporation 0.75
  • the films are prepared using the indicated processing conditions in Table 4 on a pilot scale cast film line using a standard type of feedblock configuration to produce 3 layers and providing the PP side of the film against cast roll.
  • the cast film components and structures are summarized in Table 5 below.
  • the films are tested for their sealing and interlayer strengths.
  • the two A (top) layers are sealed together by heat sealing at 204° C. for 10 seconds at 30 psi (207 kPa, 2.07 bar) pressure.
  • the films are thus sealed as CBA-ABC.
  • the sealed films are then tested by a peel strength test according to ASTM F88/8F88-09 for 180° peel at 23° C. on an INSTRON® tester (model 5500R) at 50 mm gap at a rate of 50 mm/min. Peel strengths are recorded below.
  • the location of the delamination is noted and the sample is tested in the INSTRON tester in a similar manner but by peeling the film layers that are then separating by delamination.
  • This second peel test is the interlayer adhesion strength test done at 23° C. The layers that delaminate are recorded along with their interlayer adhesion strength values.
  • the entire film thickness breaks, tears or greatly elongates as only failure and there is no delamination failure observable.
  • all the interlayer adhesion strength values are clearly excellent but there is no interlayer adhesion strength value measurable or recorded.
  • the experimental films are compared against a commercial backsheet film available from Madico and referred to as a TPE film.
  • the TPE film thickness is 191 microns and has polyvinylfluoride (PVF) in the outside or bottom layer, PET in a core layer and EVA/LDPE blend in the top or seal layer.
  • PVF polyvinylfluoride
  • PET in a core layer
  • EVA/LDPE blend in the top or seal layer.
  • backsheet can be made using crystalline block composite that has better interlayer adhesion and no delamination within the backsheet structure as compared to commercial backsheet.
  • the film examples prepared according to the present invention all exhibit good to excellent interlayer strength.
  • the tie layer for the polypropylene film layer C is a plastomer that is commonly sold and used for this purpose and is considered suitable in many applications. It is noteworthy, therefore, that all the films according to the present invention have higher interlayer strength than comparative Experimental Film 8.
  • Experimental films 9 through 12 are prepared on a mini-scale blown film line and evaluated for their sealing and interlayer strengths. Table 9 summarizes the process conditions. Experimental films 9-12 show, among other things, that films which have more CBC in the tie layer Layer B results in less delamination.
  • annealed samples are prepared by heat sealing samples in the same manner as described above, separating the unsealed tabs with Teflon film to prevent sticking of tabs and heating the samples for 15 minutes in an air oven operating at 150° C., removing the samples and then testing peel strengths as described above at 23° C.
  • the numerical ranges in this disclosure are approximate, and thus may include values outside of the range unless otherwise indicated. Numerical ranges include all values from and including the lower and the upper values, in increments of one unit, provided that there is a separation of at least two units between any lower value and any higher value. As an example, if a compositional, physical or other property or process parameter, such as, for example, molecular weight, viscosity, melt index, temperature, etc., is from 100 to 1,000, it is intended that all individual values, such as 100, 101, 102, etc., and sub ranges, such as 100 to 144, 155 to 170, 197 to 200, etc., are expressly enumerated.
  • a compositional, physical or other property or process parameter such as, for example, molecular weight, viscosity, melt index, temperature, etc.
  • any process or composition claimed through use of the term “comprising” may include any additional steps, equipment, additive, adjuvant, or compound whether polymeric or otherwise, unless stated to the contrary.
  • the term, “consisting essentially of” excludes from the scope of any succeeding recitation any other component, step or procedure, excepting those that are not essential to operability.
  • the term “consisting of” excludes any component, step or procedure not specifically delineated or listed.

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