WO2007079246A2 - Fluoropolymer coated films useful for photovoltaic modules - Google Patents

Fluoropolymer coated films useful for photovoltaic modules Download PDF

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Publication number
WO2007079246A2
WO2007079246A2 PCT/US2006/049624 US2006049624W WO2007079246A2 WO 2007079246 A2 WO2007079246 A2 WO 2007079246A2 US 2006049624 W US2006049624 W US 2006049624W WO 2007079246 A2 WO2007079246 A2 WO 2007079246A2
Authority
WO
WIPO (PCT)
Prior art keywords
fluoropolymer
film
coated film
coating
substrate film
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/US2006/049624
Other languages
English (en)
French (fr)
Other versions
WO2007079246A3 (en
Inventor
Michael Debergalis
Larry Glen Snow
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
EIDP Inc
Original Assignee
EI Du Pont de Nemours and Co
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by EI Du Pont de Nemours and Co filed Critical EI Du Pont de Nemours and Co
Priority to KR1020087018643A priority Critical patent/KR101382008B1/ko
Priority to EP06848366A priority patent/EP1976954A2/en
Priority to CN2006800500097A priority patent/CN101351521B/zh
Priority to CA 2628967 priority patent/CA2628967C/en
Priority to AU2006332650A priority patent/AU2006332650B2/en
Priority to JP2008548775A priority patent/JP5232654B2/ja
Publication of WO2007079246A2 publication Critical patent/WO2007079246A2/en
Publication of WO2007079246A3 publication Critical patent/WO2007079246A3/en
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
    • C09D127/00—Coating compositions based on homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by a halogen; Coating compositions based on derivatives of such polymers
    • C09D127/02—Coating compositions based on homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by a halogen; Coating compositions based on derivatives of such polymers not modified by chemical after-treatment
    • C09D127/12—Coating compositions based on homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by a halogen; Coating compositions based on derivatives of such polymers not modified by chemical after-treatment containing fluorine atoms
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B17/00—Layered products essentially comprising sheet glass, or glass, slag, or like fibres
    • B32B17/06—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material
    • B32B17/10—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin
    • B32B17/10005—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing
    • B32B17/10009—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing characterized by the number, the constitution or treatment of glass sheets
    • B32B17/10018—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing characterized by the number, the constitution or treatment of glass sheets comprising only one glass sheet
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B17/00—Layered products essentially comprising sheet glass, or glass, slag, or like fibres
    • B32B17/06—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material
    • B32B17/10—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin
    • B32B17/10005—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing
    • B32B17/1055—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing characterized by the resin layer, i.e. interlayer
    • B32B17/10788—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing characterized by the resin layer, i.e. interlayer containing ethylene vinylacetate
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J7/00—Chemical treatment or coating of shaped articles made of macromolecular substances
    • C08J7/04—Coating
    • C08J7/0427—Coating with only one layer of a composition containing a polymer binder
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J7/00—Chemical treatment or coating of shaped articles made of macromolecular substances
    • C08J7/04—Coating
    • C08J7/043—Improving the adhesiveness of the coatings per se, e.g. forming primers
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J7/00—Chemical treatment or coating of shaped articles made of macromolecular substances
    • C08J7/04—Coating
    • C08J7/048—Forming gas barrier coatings
    • H—ELECTRICITY
    • H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
    • H10F—INORGANIC SEMICONDUCTOR DEVICES SENSITIVE TO INFRARED RADIATION, LIGHT, ELECTROMAGNETIC RADIATION OF SHORTER WAVELENGTH OR CORPUSCULAR RADIATION
    • H10F19/00—Integrated devices, or assemblies of multiple devices, comprising at least one photovoltaic cell covered by group H10F10/00, e.g. photovoltaic modules
    • H10F19/80—Encapsulations or containers for integrated devices, or assemblies of multiple devices, having photovoltaic cells
    • H10F19/85—Protective back sheets
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2367/00—Polyesters, e.g. PET, i.e. polyethylene terephthalate
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J2367/00—Characterised by the use of polyesters obtained by reactions forming a carboxylic ester link in the main chain; Derivatives of such polymers
    • C08J2367/02—Polyesters derived from dicarboxylic acids and dihydroxy compounds
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J2427/00—Characterised by the use of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by a halogen; Derivatives of such polymers
    • 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
    • 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
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Definitions

  • This invention relates to forming a fluoropolymer coated film which is useful as a backsheet in a photovoltaic module.
  • Photovoltaic cells are used to produce electrical energy from sunlight, offering a green alternative to traditional methods of electricity generation. These solar cells are built from various semiconductor systems which must be protected from environmental effects such as moisture, oxygen, and UV light. The cells are usually jacketed on both sides by encapsulating layers of glass and/or plastic films forming a multilayer structure known as a photovoltaic module. Fluoropolymer films are recognized as an important component in photovoltaic modules due to their excellent strength, weather resistance, UV resistance, and moisture barrier properties. Especially useful in these modules are film composites of fluoropolymer film and polyester film which act as a backing sheet for the module.
  • Such composites have traditionally been produced from preformed films of fluoropolymer, specifically polyvinyl fluoride (PVF), adhered to polyester substrate film, specifically polyethylene terephthalate.
  • fluoropolymer such as PVF
  • PVF polyvinyl fluoride
  • Fluoropolymer backing sheets are frequently employed in the form of laminate with polyethylene terephthalate (PET) films, typically with the PET sandwiched between two fluoropolymer films.
  • PET polyethylene terephthalate
  • laminates of preformed fluoropolymer films on polymeric substrates having a bond which will not delaminate after years of outdoor exposure are difficult to make.
  • Prior art systems such as U.S.
  • Patent 3,133,854 to Simms U.S. Patent 5,139,878 to Kim etal., and US 6,632,518 to Schmidt et a/, describe primers and adhesives for preformed films that will produce durable laminate structures.
  • these processes require the application of at least one adhesive layer, or both a primer and adhesive layer, prior to the actual lamination step.
  • the lamination step then requires the application of heat and pressure to form the laminate. Therefore, prior art laminates using preformed fluoropolymer films are expensive to manufacture and/or require capital intensive equipment. Because preformed fluoropolymer films must have sufficient thickness to provide strength for handling during manufacture and subsequent processing, the resulting laminates may also incorporate thick expensive layers of fluoropolymer, i.e., thicker than are necessary for an effective protective layer.
  • the invention provides a fluoropolymer coated film comprising polymeric substrate film and fluoropolymer coating on the polymeric substrate film.
  • the fluoropolymer coating comprises fluoropolymer selected from homopolymers and copolymers of vinyl fluoride and homopolymers and copolymers of vinylidene fluoride polymer blended with compatible adhesive polymer comprising functional groups selected from carboxylic acid, sulfonic acid, aziridine, anhydride, amine, isocyanate, melamine, epoxy, hydroxy, anhydride and mixtures thereof.
  • the polymeric substrate film comprises functional groups on its surface that interact with the compatible adhesive polymer to promote bonding of the fluoropolymer coating to the substrate film.
  • the invention provides a fluoropolymer coated polymer film with fewer overall processing steps than manufacturing laminates with preformed fluoropolymer films while providing strong adhesion to the substrate and good durability to the fluoropolymer coated substrate.
  • providing the fluoropolymer in the form of a coating enables thinner fluoropolymer layers if desired to save cost.
  • Employing fluoropolymer coatings also enables the incorporation of additives into the fluoropolymer layer tailored to the intended use of the fluoropolymer coated film, e.g., fillers which improve barrier properties.
  • Fluoropolymers useful in the fluoropolymer coated film in accordance with the invention are selected from homopolymers and copolymers of vinyl fluoride (VF) and homopolymers and copolymers of vinylidene fluoride (VF2) polymer.
  • the fluoropolymer is selected from homopolymers and copolymers of vinyl fluoride comprising at least 60 mole % vinyl fluoride and homopolymers and copolymers of vinylidene fluoride comprising at least 60 mole % vinylidene fluoride.
  • the fluoropolymer is selected from homopolymers and copolymers of vinyl fluoride comprising at least 80 mole % vinyl fluoride and homopolymers and copolymers of vinylidene fluoride comprising at least 80 mole % vinylidene fluoride.
  • Blends of the fluoropolymers with nonfluoropolymers, e.g., acrylic polymers, may also be suitable for the practice of the invention.
  • Homopolymer polyvinyl fluoride (PVF) and hornopolymer polyvinylidene fluoride (PVDF) are well suited for the practice of the invention.
  • comonomers can be either fluorinated or nonfluorinated or mixtures thereof.
  • copolymers is meant copolymers of VF or VF2 with any number of additional fluorinated monomer units so as to form dipolymers, terpolymers, tetrapolymers, etc. If nonfluorinated monomers are used, the amount used should be limited so that the copolymer retains the desirable properties of the fluoropolymer, i.e., weather resistance, solvent resistance, barrier properties, etc.
  • fluorinated comonomers are used including fluoroolefins, fluorinated vinyl ethers, or fluorinated dioxoles.
  • fluorinated comonomers include tetrafluoroethylene (TFE), hexafluoropropylene (HFP), chlorotrifluoroethylene (CTFE), trifluoroethylene, hexafluoroisobutylene, perfluorobutyl ethylene, perfluoro (propyl vinyl ether) (PPVE), perfluoro (ethyl vinyl ether) (PEVE) 1 perfluoro (methyl vinyl ether) (PMVE), perfluoro-2,2-dimethyl-1 ,3-dioxole (PDD) and perfluoro-2-methylene-4- methyl-1 ,3-dioxolane (PMD) among many others.
  • TFE tetrafluoroethylene
  • HFP hexafluoropropylene
  • CTFE chlor
  • Homopolymer PVDF coatings can be formed from a high molecular weight PVDF.
  • Blends of PVDF and alkyl (meth)acrytates polymers can be used. Polymethyl methacrylate is particularly desirable. Typically, these blends can comprise 50-70% by weight of PVDF and 30- 50% by weight of alkyl (meth)acrylate polymers, preferably, polymethyl methacrylate.
  • Such blends may contain compatibilizers and other additives to stabilize the blend.
  • Such blends of polyvinylidene fluoride, or vinylidene fluoride copolymer, and acrylic resin as the principal components are described in U.S. patents 3,524,906; 4,931 ,324; and 5,707,697.
  • Homopolymer PVF coatings can be formed from a high molecular weight PVF.
  • Suitable VF copolymers are taught by US Patents 6,242,547 and 6,403,740 to Uschold.
  • the compatible adhesive polymers employed in the fluoropolymer coated film according to the invention comprise functional groups selected from carboxylic acid, sulfonic acid, aziridine, amine, isocyanate, melamine, epoxy, hydroxy, anhydride and mixtures thereof.
  • the compatible adhesive polymer preferably has (1) a backbone composition that is compatible with the fluoropolymer in the composition and (2) pendant functionality capable of reacting with complementary functional groups on a substrate film surface.
  • the compatibility of the adhesive polymer backbone with the fluoropolymer will vary but is sufficiently compatible so that the adhesive polymer can be introduced into the fluoropolymer in the desired amount to secure the fluoropolymer coating to the substrate film.
  • homo and copolymers derived largely from vinyl fluoride and vinylidene fluoride will show compatibility characteristics that will favor acrylic, urethane, aliphatic polyester, polyester urethane,. acrylamide, urea and polycarbonate backbones having the functional groups described above.
  • the free radical addition polymers derived from acrylic and acrylamide monomers are well suited to the introduction of pendant functional groups using the wealth of functional monomers available. Some representatives include glycidyl acrylate and methacrylate for the introduction of epoxy groups. These can then be converted into reactive aminoalcohol groups by reaction of the epoxy functional acrylic with ammonia or primary alkylamines. Carboxylic acid, isocyanate, hydroxy and anhydride functionalities are all available using acrylic / methacrylic acid, isocyanatoethyl methacrylate, hydroxyethyl methacrylate or maleic anhydride respectively. Numerous other functional monomers are available for functional group introduction as is well known in the art.
  • Preferred compatible adhesive polymers are amine functional polymers, more preferably, amine functional acrylic polymers.
  • pigments and fillers can be incorporated into the fluoropolymer coating composition dispersion during manufacture.
  • Pigments preferably are used in amounts of about 1 to about 35 wt% based on fluoropolymer solids.
  • Typical pigments that can be used include both clear pigments, such as inorganic siliceous pigments (silica pigments, for example) and conventional pigments.
  • pigments that can be used include metallic oxides such as titanium dioxide, and iron oxide; metal hydroxides; metal flakes, such as aluminum flake; chromates, such as lead chromate; sulfides; sulfates; carbonates; carbon black; silica; talc; china clay; phthalocyanine blues and greens, organo reds; organo maroons and other organic pigments and dyes.
  • metallic oxides such as titanium dioxide, and iron oxide
  • metal hydroxides such as aluminum flake
  • chromates such as lead chromate
  • sulfides sulfates
  • carbonates carbon black
  • silica talc
  • china clay china clay
  • phthalocyanine blues and greens organo reds
  • Preferred are pigments that are stable at high temperatures during processing. It is also preferable that the type and amount of pigment is selected to prevent any significant adverse affects on the desirable properties of fluoropolymer
  • Pigments can be formulated into a millbase by mixing the pigments with a dispersing resin that may be the same as or compatible with the fluropolymer composition into which the pigment is to be incorporated.
  • Pigment dispersions can be formed by conventional means, such as sand grinding, ball milling, attritor grinding or two-roll milling.
  • Other additives while not generally needed or used, such as fiber glass and mineral fillers, anti-slip agents, plasticizers, nucleating agents, and the like, can be incorporated.
  • the fluoropolymer coating compositions may contain one or more light stabilizers as additives.
  • Light stabilizer additives include compounds that absorb ultraviolet radiation such as hydroxybenzophenones and hydroxybenzotriazoles.
  • Other possible light stabilizer additives include hindered amine light stabilizers (HALS) and antioxidants.
  • Thermal stabilizers can also be used if desired.
  • the fluoropolymer coating composition includes barrier particles.
  • the particles are platelet-shaped particles. Such particles tend to align during application of the coating and, since water, solvent and gases such as oxygen cannot pass readily through the particles themselves, a mechanical barrier is formed in the resulting coating which reduces permeation of water, solvent and gases.
  • the barrier particles substantially increase the moisture barrier properties of the fluoropolymer and enhance the protection provided to the solar cells.
  • barrier particles are preferably present in the amount of about 0.5 to about 10% by weight based on the total dry weight of the fluoropolymer composition in the coating. Examples of typical platelet shaped filler particles include mica, glass flake and stainless steel flake, and aluminum flake.
  • the platelet shaped particles are preferably mica particles, including mica particles coated with an oxide layer such as iron or titanium oxide. These particles have an average particle size of about 10 to 200 ⁇ m, preferably 20 -100 ⁇ m, with no more than 50% of the particles of ftake having average particle size of more than about 300 ⁇ m.
  • the mica particles coated with an oxide layer are described in U. S. Patent Nos. 3,087,827 (Klenke and Stratton); 3,087,828 (Linton); and 3,087,829 (Linton).
  • micas described in these patents are coated with oxides or hydrous oxides of titanium, zirconium, aluminum, zinc, antimony, tin, iron, copper, nickel, cobalt, chromium, or vanadium. Mixtures of coated micas can also be used.
  • the fluoropolymer coating compositions may contain the fluoropolymer either in the form of a solution or dispersion of the fluoropolymer.
  • Typical solutions or dispersions for the fluoropolymer are prepared using solvents which have boiling points high enough to avoid bubble formation during the film forming/drying process.
  • a solvent which aids in coalescence of the fluoropolymer is preferable.
  • the polymer concentration in these solutions or dispersions is adjusted to achieve a workable viscosity of the solution and will vary with the particular polymer, the other components of the composition, and the process equipment and conditions used.
  • the fluoropolymer is present in an amount of about 10 wt% to about 25 wt% based the total weight of the composition.
  • the fluoropolymer is preferably present in an amount of about 25 wt% to about 50 wt% based the total weight of the composition.
  • the form of the polymer in the coating composition is dependent upon the type of fluoropolymer and the solvent used.
  • Homopolymer PVF is normally in dispersion form.
  • Homopolymer PVDF can be in dispersion or solution form dependent upon the solvent selected.
  • homopolymer PVDF can form stable solutions at room temperature in many polar organic solvents such as ketones, esters and some ethers. Suitable examples include acetone, methylethyl ketone (MEK) and tetrahydrofuran (THF).
  • polar organic solvents such as ketones, esters and some ethers. Suitable examples include acetone, methylethyl ketone (MEK) and tetrahydrofuran (THF).
  • copolymers of VF and VF2 may be used either in dispersion or solution form.
  • PVF polyvinyl fluoride
  • the fluoropolymer and the compatible adhesive polymer and, optionally one or more dispersants and/or pigments are generally first milled together in a suitable solvent.
  • the various components are milled or appropriately mixed separately. Components which are soluble in the solvent such as the compatible adhesive polymer do not require milling.
  • the mill employs a dense agitated grinding medium, such as sand, steel shot, glass beads, ceramic shot, Zirconia, or pebbles, as in a ball mill, an ATTRITOR® available from Union Process, Akron, Ohio, or an agitated media mill such as a "Netzsch” mill available from Netzsch, Inc., Exton, Pennsylvania.
  • a dense agitated grinding medium such as sand, steel shot, glass beads, ceramic shot, Zirconia, or pebbles
  • ATTRITOR® available from Union Process, Akron, Ohio
  • an agitated media mill such as a "Netzsch” mill available from Netzsch, Inc., Exton, Pennsylvania.
  • the dispersion is milled for a time sufficient to cause deagglomeration of the PVF.
  • Typical residence time of the dispersion in a Netzsch mill ranges from thirty seconds up to ten minutes.
  • the adhesive polymer is employed in the coating composition at a level sufficient to provide the desired bonding to the polymeric substrate film but below the level at which the desirable properties of the fluoropolymer would be significantly adversely affected.
  • coating composition contains about 1 to about 40 wt % adhesive polymer, more preferably about 1 to about 25 wt% adhesive polymer, and most preferably 1 to about 20 wt% adhesive polymer, based on the weight of the fluoropolymer.
  • Polymeric substrate films used in this invention may be selected from a wide number of polymers, with thermoplastics being preferred.
  • the polymeric substrate film comprises functional groups on its surface that interact with the compatible adhesive polymer to promote bonding of the fluoropolymer coating to the substrate film.
  • the polymeric substrate film is preferably a polyester, and more preferably a polyester selected from the group consisting of polyethylene terephthalate, polyethylene naphthalate and a coextrudate of polyethylene terephthalate/ polyethylene naphthalate.
  • Fillers may also be included in the substrate film, where their presence may improve the physical properties of the substrate, for example, higher modulus and tensile strength. They may also improve adhesion of the fluoropolymer to the substrate film.
  • One exemplary filler is barium sulfate, although others may also be used.
  • the surface of the polymeric substrate film which is to be coated may naturally possess functional groups suitable for bonding as in hydroxy and/or carboxylic acid in a polyester film or amine and/or acid functionality in a polyamide film.
  • Many polymeric substrate films may need or would further benefit from activation however, and this may be achieved by surface treatment. That is, the surface can be made receptive by forming functional groups of carboxylic acid, sulfonic acid, aziridine, amine, isocyanate, melamine, epoxy, hydroxy, anhydride and/or mixtures thereof on the surface.
  • the activation can be achieved by chemical exposure such as to a gaseous Lewis acid such as BF 3 or to sulfuric acid or to hot sodium hydroxide.
  • the surface can be activated by exposing one or both surfaces to an open flame while cooling the opposite surface. Activation can also be achieved by subjecting the film to a high frequency, spark discharge such as corona treatment or atmospheric nitrogen plasma treatment.
  • a primer layer is deposited on the polymer substrate film and provides the functional groups that interact with the compatible adhesive polymer in the fluoropolymer coating composition to promote bonding of the fluoropolymer coating to the substrate film.
  • Suitable primers may include polyamines, polyamides, acrylamide polymers (especially amorphous acrylamides), polyethyleneimines, ethylene copolymers or terpolymers, acid-modified polyolefins (e.g.
  • maleated polyolefins acrylate or methacrylate polymers
  • acrylate or methacrylate polymers e.g., emulsion polymers
  • polyester e.g., dispersions
  • polyurethanes e.g., dispersions
  • epoxy polymers epoxyacrylic oligomers, and mixtures thereof.
  • An example of this is the introduction of amine functionality by the application of a polyethyleneimine primer coating.
  • a second example is coextrusion of an acid or anhydride functional thermoplastic polymer, such as the polymer sold by the DuPont Company under the trademark
  • BYNEL® with the base PET substrate film.
  • the primer can be applied either before or after the substrate film has been stretched.
  • the fluoropolymer compositions for making the fluoropolymer coated film in accordance with the present invention can be applied as a liquid directly to suitable polymeric substrate films by conventional coating means with no need to form a preformed film.
  • Techniques for producing such coatings include conventional methods of casting, dipping, spraying and painting.
  • the fluoropolymer coating contains fluoropolymer in dispersion form, it is typically applied by casting the dispersion onto the substrate film, using conventional means, such as spray, roll, knife, curtain, gravure coaters, or any other method that permits the application of a uniform coating without streaks or other defects. Spray and roller applications are the most convenient application methods.
  • the dry coating thickness of cast dispersion is preferably about 2.5 ⁇ m (0.1 mil) and about 250 ⁇ m (10 mils), preferably between about 13 ⁇ m (0.5 mil) to about 130 ⁇ m (5 mils).
  • the wet solutions or dispersion are dried to remove the solvent and coalesced thermally if necessary to form the fluoropolymer coating on the substrate film.
  • the compositions can be coated onto substrate films and allowed to air dry at ambient temperatures. Although not necessary to produce a coalesced film, heating is generally desirable to dry the coating more quickly. Drying temperature thus preferably in the range of about 25°C (ambient conditions) to about 200 0 C (oven temperature — the film temperature will be lower).
  • the temperature used should also be sufficient to promote the interaction of the functional groups in the adhesive polymer with the functional groups of the polymeric substrate film to provide secure bonding of the fluoropolymer coating to the substrate film.
  • This temperature varies widely with the adhesive polymer employed and the functional groups of substrate film and can range from room temperature to oven temperatures in excess of that required for the coalescence of fluoropolymers in dispersion form as discussed below.
  • the fluoropolymer in the composition is in dispersion form, it is necessary for the solvent to be removed and also for the fluoropolymer to be heated to a sufficiently high temperature that the fluoropolymer particles coalesce into a continuous film.
  • fluoropolymer in the coating is heated to temperature of about 150°C to about 250 0 C.
  • the solvent used preferably aids in coalescence, i.e., enables a lower temperature to be used for coalesce than would be necessary with no solvent present.
  • the conditions used to coalesce polymer will vary with the fluoropolymer used, the thickness of the cast dispersion and the substrate film, and other operating conditions.
  • oven temperatures of about from 340 0 F (171 0 C) to about 480 0 F (249°C) can be used to coalesce the film, and temperatures of about 380 0 F (193°C) to about 450 0 F (232°C) have been found to be particularly satisfactory.
  • the oven air temperatures are not representative of the temperatures reached by the fluoropolymer coating which will be lower.
  • the fluoropolymer coating composition is applied to a substrate film.
  • the substrate film includes a primer layer providing functional groups that interact with said compatible adhesive polymer to promote bonding.
  • the substrate film is polyester such a polyethylene terephthalate, polyethylene napthalate or a coextrudate of polyethylene terephthalate/polyethylene naphthalate.
  • the fluoropolymer coating is applied to both surfaces of the substrate film. This can be performed simultaneously on both sides of the polymeric substrate film or alternately, the coated substrate film can be dried, turned to the uncoated side and resubmitted to the same coating head to apply coating to the opposite side of the film to achieve coating on both sides of the film.
  • Fluoropolymer coated films made in accordance with the invention are especially useful in photovoltaic modules.
  • a typical construction for a photovoltaic module includes a thick layer of glass as a glazing material.
  • the glass protects solar cells comprising crystalline silicon wafers and wires which are embedded in a moisture resisting plastic sealing compound such as cross-linked ethylene vinyl acetate.
  • thin film solar cells can be applied from various semiconductor materials, such as CIGS (copper-indium-gallium-selenide), CTS (cadmium-tellurium-sulfide), a-Si (amorphous silicon) and others on a carrier sheet which is also jacketed on both sides with encapsulant materials. Adhered to the encapsulant is a backsheet.
  • Fluoropolymer coated films made in accordance with the invention are useful for such backsheets.
  • the fluoropolymer coating comprises fluoropolymer selected from homopolymers and copolymers of vinyl fluoride and homopolymers and copolymers of vinylidene fluoride polymer blended with compatible adhesive polymer containing functional groups selected from carboxylic acid, sulfonic acid, aziridine, anhydride, amine, isocyanate, melamine, epoxy, hydroxy, anhydride and mixtures thereof.
  • the polymeric substrate film comprises functional groups on its surface that interact with the compatible adhesive polymer to promote bonding of the fluoropolymer coating to the substrate film.
  • the polymeric substrate film is preferably a polyester, and more preferably a polyester selected from the group consisting of polyethylene terephthalate, polyethylene naphthalate and a coextrudate of polyethylene terephthalate/polyethylene naphthalate. Polyester provides electrical insulation and moisture barrier properties, and is an economical component of the back sheet. Preferably both surfaces of the polymeric substrate film is coated with fluoropolymer creating a sandwich of polyester between two layers of coating of fluoropolymer. Fluoropolymer films provide excellent strength, weather resistance, UV resistance, and moisture barrier properties to the backsheet.
  • WVTR Water Vapor Transmission Rate
  • Examples 1 — 5 illustrate bonding PVF based coatings containing an amine functional acrylic adhesive or an epoxy functional acrylic adhesive being used to coat polyethylene terephthalate (PET) films previously primed with either polyethyleneimine (PEI) or ethylene acrylic acid copolymer (EAA). Results show that in general more adhesive polymer is better. Results indicate that no significant bonding is achieved in the absence of the adhesive polymer.
  • PET polyethylene terephthalate
  • PEI polyethyleneimine
  • EAA ethylene acrylic acid copolymer
  • amine functional acrylic is methyl methacrylate / 2-hydroxy-3- aminopropyl methacrylate 97.8 / 2.2 at 30% solids in 2-propanol / toluene
  • Epoxy functional acrylic is methyl methacrylate / glycidyl methacrylate
  • Procedure 1 Ingredients of Table 1 are combined and agitated 15 minutes on a paint shaker to mix. 2. Draw downs of the mixtures in Table 1 are prepared on each of the 4 mil PET webs in Tables 2 and 3 using a 12 mil draw down knife to produce approximately 1.2 mil dry fluoropolymer coatings.
  • a heavy bead of pure PVF dispersion (42% in propylene carbonate) is applied along 1 edge of the wet draw down to help facilitate peel testing.
  • the coated webs are clamped into metal frames and placed into preheated ovens at either 200 0 C or 220°C for 3 minutes.
  • a scalpel is used to initiate peeling at the PVF bead.
  • Peel strengths are measured using a Model 4201 lnstron at 27min, recording the peak value and averaging 3 samples (ASTM D1876-01 T-Peel Test). If samples easily peeled by hand during the peel initiation step a value of 0 was recorded.
  • Fluoropolymer coated PET substrates are prepared in the same manner as those of examples 1 through 5 with the exception that the edge bead of step 3 was omitted. After removing the samples from the oven and allowing them to cool, the fluoropolymer coating side is corona treated using a hand held lab corona treater. The corona treated sample was then laminated to a glass panel (4"x 8" x1/8") using the following procedure.
  • fluoropolymer coated PET film with fluoropolymer coating face down reactive EVA film glass panel
  • the sandwich is centered and covered with a silicone rubber pad
  • the sandwich + vacuum plate is placed into a room temperature oven and heating begun to a target of 150 0 C. 4. The sample is held at 150 0 C for 20 minutes
  • the resulting laminates are placed into a paint sample rack in a humidity cabinet controlled at 85 0 C / 85% humidity. 7. Samples are exposed to the humidity cabinet for 1000 hours and then examined for adhesion using both peel testing and a cross hatch tape test.
  • Examples 6-9 illustrate PVF coating compositions containing an amine function acrylic adhesive being used to coat PET films primed with polyallylamine primer.
  • Example 6 illustrates the application of a white PVF coating to both sides of unpigmented and pigmented PET film primed with a polyallylamine primer.
  • a white PVF coating formulation is prepared from the formula in the following Table 5.
  • the thermal stabilizer solution listed in Table 5 is prepared from 4.0 wt % Irganox® 1035 (Ciba), 1 wt % Weston® THOP (Crompton) and 95 wt % propylene carbonate.
  • the amine function acrylic polymer solution listed in Table 5 is prepared by post reacting methyl methacrylate/glycidyl methacrylate (98/2) with ammonia to convert the glycidyl groups into 2-hydroxy-3-aminopropyl groups to produce a primary amine functional acrylic polymer in a solvent of toluene and isopropanol.
  • the white PVF coating formulation is coated on a 2 mil unpigmented PET film primed with a polyailylamine primer and on barium sulfate pigmented 3.8 mil wide PET film primed with a polyallylamine primer.
  • the coatings are baked in a preheated oven for 10 min at 200 0 C for 10 minutes.
  • the cooled coated films are then coated on the opposite side with the same PVF formulation and are baked 15 min at 200 0 C.
  • Table 6 shows the range of resultant dry film thicknesses for coatings on pigmented and unpigmented PET films: Table 6 film thickness (mils) sample PET Pigmented? PET 1st PVF Coating 2nd PVF Coating
  • Example 7 illustrates the application of a PVF coating containing pearlescent barrier particles of mica to both sides of unpigmented and pigmented PET film primed with a polyallylamine primer.
  • a pearlescent PVF coating formulation is prepared from the formula in the following Table 7:
  • the pearlescent PVF coating formulation is coated on a 2 mil wide, unpigmented PET film primed with a polyallylamine primer and on a 3.8 mil wide, barium sulfate pigmented PET film primed with a polyallylamine primer. These coatings are baked in a preheated oven for 10 min at 200 0 C for 10 minutes. The cooled coated films are then coated on the opposite side with the same PVF formulation and baked 15 min at 200 0 C.
  • Table 8 shows the range of resultant dry coating thicknesses: Table 8 film thickness (mils) sample PET Pigmented? PET 1st PVF Coating 2nd PVF Coating
  • Example 8 the vapor barrier properties of two side coated PET films of Example 6 (sample 7) and Example 7 (sample 2) having white pigmented and mica pigmented fluoropolymer coatings, respectively, are evaluated by measuring the Water Vapor Transmission Rate (WVTR).
  • WVTR Water Vapor Transmission Rate Table 9 shows the improvement of vapor barrier properties when using barrier particles such as mica, as indicated by a lower WVTR value.
  • Example 9 the shrinkage properties of white two side coated PET samples made according to Example 6 (samplei) are compared with samples of PET films with conventional preformed PVF films laminated to both sides.
  • the former contained a filler (barium sulfate) in the PET substrate, while the latter did not.
  • Table 10 shows the measured shrinkage data at various temperatures.
  • Example 10 illustrates the application of a white pigmented and an unpigmented polyvinylidene (PVDF) coating to one side of an unpigmented and a pigmented PET film primed with a polyallylamine primer.
  • PVDF polyvinylidene
  • the unpigmented PVDF coating formulation is prepared from the following components shown in Table 11 :
  • Methyl methacrylate/glycidyl methacrylate (98/2) post reacted with ammonia to convert the glycidyi groups into 2-hydroxy-3-aminopropyl groups to produce a primary amine functional acrylic polymer in a solvent of toluene and isopropanol.
  • the mixture is dispersed on a paint shaker in the presence of 3 mm glass beads for 10 minutes.
  • the white pigmented coating formulation is prepared from the following components shown in Table 12:
  • both the clear PVDF formulation and the white PVDF formulation are coated on unpigmented 2 mil PET film and pigmented 3.8 mil PET film primed with a polyallylamine primer using a 7-mil doctor blade.
  • a comparison 3.8 mil unprimed PET is similarly coated.
  • the coated films were baked in a preheated 400 0 F convection oven for 5 minutes. After cooling, a scalpel was used to attempt to remove the PVF films from PET films. Both the pigmented and unpigmented films could be peeled from unprimed PET but could not be peeled from primed PET.

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Cited By (13)

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EP2210912A1 (en) * 2009-01-09 2010-07-28 Rohm and Haas Company Acrylic film and acrylic backsheet prepared therefrom
JP2010526886A (ja) * 2007-04-23 2010-08-05 イー・アイ・デュポン・ドウ・ヌムール・アンド・カンパニー フルオロポリマー被膜フィルム、それの形成方法、およびフルオロポリマー液体組成物
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JP5232654B2 (ja) 2013-07-10
CN101351521A (zh) 2009-01-21
KR20080081087A (ko) 2008-09-05
US8062744B2 (en) 2011-11-22
CN101351521B (zh) 2012-06-27
US8197933B2 (en) 2012-06-12
CN102700208A (zh) 2012-10-03
US20090293944A1 (en) 2009-12-03
US20090260677A1 (en) 2009-10-22
CN102700208B (zh) 2016-06-15
WO2007079246A3 (en) 2007-08-23
KR101382008B1 (ko) 2014-04-11
US8048518B2 (en) 2011-11-01
EP1976954A2 (en) 2008-10-08
JP2009522414A (ja) 2009-06-11
US7553540B2 (en) 2009-06-30
AU2006332650B2 (en) 2012-04-05
US20070154704A1 (en) 2007-07-05
US20120240986A1 (en) 2012-09-27
US20120024352A1 (en) 2012-02-02
AU2006332650A1 (en) 2007-07-12
CA2628967A1 (en) 2007-07-12
CA2628967C (en) 2015-03-17

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