Classifications

• • 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
  • H10F19/804—Materials of encapsulations
• • 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
• • 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
  • H10F77/00—Constructional details of devices covered by this subclass
  • H10F77/10—Semiconductor bodies
  • H10F77/12—Active materials
  • H10F77/126—Active materials comprising only Group I-III-VI chalcopyrite materials, e.g. CuInSe2, CuGaSe2 or CuInGaSe2 [CIGS]
• • 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
  • Y02B—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO BUILDINGS, e.g. HOUSING, HOUSE APPLIANCES OR RELATED END-USER APPLICATIONS
  • Y02B10/00—Integration of renewable energy sources in buildings
  • Y02B10/10—Photovoltaic [PV]
• • 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
  • 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
  • Y02E10/541—CuInSe2 material PV cells

Definitions

• Solar devices are used outdoors, and so are exposed to the elements, including wind, water and sunlight. Water penetration into solar panels has been a long-standing problem. Solar panels may also be deleteriously affected by wind and sunlight.
• Any multi-layer film laminate has the potential for delamination, especially at the edges. Reducing delamination at the edges will improve overall performance of the barrier films.
• the present application is directed to an assembly comprising an electronic device, and a multilayer film.
• the multilayer film comprises a barrier stack adjacent the electronic device; and a weatherable sheet adjacent the barrier stack opposite the electronic device.
• the assembly additionally comprises a protective layer in contact with the electronic device and the weatherable sheet.
• Figure 1 illustrates an assembly according to an embodiment of the present disclosure using a schematic cross section view.
• Figure 2 illustrates an assembly according to a second embodiment of the present disclosure using a schematic cross section view.
• Figure 3 illustrates an assembly according to a third embodiment of the present disclosure using a schematic cross section view.
• Figure 4 illustrates an assembly according to a fourth embodiment of the present disclosure using a schematic cross section view.
• Figure 5 illustrates an assembly according to a fifth embodiment of the present disclosure using a schematic cross section view.
• Figure 6 illustrates an assembly according to a sixth embodiment of the present disclosure using a schematic cross section view.
• Figure 7 illustrates an assembly according to a seventh embodiment of the present disclosure using a schematic cross section view.
• Figure 8 is an elevated view of an assembly according to the present disclosure.
• Edge delamination is a concern for multi-layer articles. Slight edge delamination may cause separation of the multiple layers. It has been found that delamination can be controlled by the assessment, control and modification of three inputs.
• the first input that is assessed is the exposure to light at the interface. The light exposure encompasses visible light in addition to ultraviolet light. Water exposure is the second input.
• the third input is the stress on an interface. Modification and control of these three input values will reduce spontaneous delamination, or a peel of less than 20 grams/inch as measured according to ASTM D3330 Method A "Standard Test Method for Peel Adhesion of Pressure-Sensitive Tape.”
• FIG. 1 illustrates an embodiment according to the present application.
• Assembly 10 comprises an electronic device 12.
• a barrier stack 18 is shown adjacent the electronic device 12.
• the barrier stack comprises multiple layers (not shown ) as described herein.
• a weatherable sheet 20 is adjacent the barrier stack opposite the electronic device. Together, the weatherable sheet 20 and the barrier stack 18 form a multilayer film 22.
• Protective layers 21 and 21a are bonded to the electronic device 12 at locations 24 and 26 and to the weatherable sheet 20 at locations 28 and 30. This bond can be formed using any method known in the art, including a pressure sensitive adhesive, including surface treatment on the weatherable sheet to allow it to stick to the edge seal material, a primed surface, or a pressure sensitive adhesive.
• FIG. 2 illustrates a second embodiment according to the present application.
• Assembly 210 comprises an electronic device 212.
• a barrier stack 218 is shown adjacent the electronic device 212.
• a substrate 217 is shown between the barrier stack 218 and the electronic device 212.
• the barrier stack comprises multiple layers (not shown ) as described herein.
• a weatherable sheet 220 is adjacent the barrier stack opposite the electronic device. Together, the weatherable sheet 220, the barrier stack 218 and the substrate 217 form a multilayer film 222.
• Protective layers 221 and 221a is bonded to the electronic device 212 at locations 224 and 226 and to the weatherable sheet 220 at locations 228 and 230.
• FIG. 3 illustrates a third embodiment according to the present application.
• Assembly 310 comprises an electronic device 312.
• a barrier stack 318 is shown adjacent the electronic device 312.
• a substrate 317 is shown between the barrier stack 318 and the electronic device 312.
• the barrier stack comprises multiple layers (not shown ) as described herein.
• a weatherable sheet 320 is adjacent the barrier stack opposite the electronic device. Together, the weatherable sheet 320, the barrier stack 318 and the substrate 317 form a multilayer film 322.
• a pressure sensitive adhesive layer 319 is shown between the barrier stack 318 and the weatherable sheet 320 within the multilayer film 322.
• Protective layers 321 and 321a are bonded to the electronic device 312 at locations 324 and 326 and to the weatherable sheet 320 at locations 328 and 330.
• FIG. 4 illustrates a fourth embodiment according to the present application.
• Assembly 410 comprises an electronic device 412.
• a barrier stack 418 is shown adjacent the electronic device 412.
• the barrier stack comprises multiple layers (not shown ) as described herein.
• a weatherable sheet 420 is adjacent the barrier stack opposite the electronic device. Together, the weatherable sheet 420 and the barrier stack 418 form a multilayer film 422.
• Protective layers 421 and 421a are bonded to the electronic device at locations 424 and 426 and to the weatherable sheet 420 at locations 428 and 430.
• the multilayer film 428 may additionally include all the layers disclosed in Figures 2 and 3.
• FIG. 5 illustrates a fifth embodiment according to the present application.
• Assembly 510 comprises an electronic device 512, barrier stack 518 and weatherable sheet 520.
• the electronic device 512 comprises an edge seal material 514 and 516.
• the protective layers 521 and 521a are bonded to the electronic device 512 at the edge seal material 514 and 516.
• Figure 6 illustrates a sixth embodiment according to the present application. Assembly
• the 610 comprises an electronic device 612, barrier stack 618 and weatherable sheet 620.
• the electronic device 612 comprises an encapsulant 613.
• the protective layers 621 and 621a are bonded to the electronic device 612 at the encapsulant 613.
• FIG 7 illustrates a seventh embodiment according to the present application.
• Assembly 710 comprises an electronic device 712, barrier stack 718 and weatherable sheet 720.
• the electronic device 712 comprises a backsheet 715.
• the protective layers 721 and 721a are bonded to the electronic device 712 at the backsheet 715.
• Assemblies according to the present disclosure include, for example, an electronic device, for example solar devices like a photovoltaic cell. Accordingly, the present disclosure provides an assembly comprising a photovoltaic cell.
• Suitable photovoltaic cells include those that have been developed with a variety of materials each having a unique absorption spectra that converts solar energy into electricity.
• Examples of materials used to make photovoltaic cells and their solar light absorption band-edge wavelengths include: crystalline silicon single junction (about 400 nm to about 1 150 nm), amorphous silicon single junction (about 300 nm to about 720 nm), ribbon silicon (about 350 nm to about 1 150 nm), CIS (Copper Indium Selenide) (about 400 nm to about 1300 nm), CIGS (Copper Indium Gallium di-Selenide) (about 350 nm to about 1 100 nm), CdTe (about 400 nm to about 895 nm), GaAs multi-junction (about 350 nm to about 1750 nm).
• the electronic device is a CIGS cell.
• the solar device (e.g., the photovoltaic cell) to which the assembly is applied comprises a flexible film substrate, resulting in a flexible photovoltaic device.
• the development of methods to prevent separation/delamination of the flexible barrier films in a flexible photovoltaic device are especially valuable to the photovoltaic industry.
• the present application is directed to increasing flexible photovoltaic module lifetime, without interfering with barrier properties of a flexible barrier stack.
• the electronic device comprises an encapsulant.
• An encapsulant is applied over and around the photovoltaic cell and associated circuitry.
• encapsulants are ethylene vinyl acetate (EVA), polyvinyl butraldehyde (PVB), polyolefins, thermoplastic urethanes, clear polyvinylchloride, and ionomers.
• EVA ethylene vinyl acetate
• PVB polyvinyl butraldehyde
• polyolefins polyolefins
• thermoplastic urethanes thermoplastic urethanes
• clear polyvinylchloride and ionomers.
• the encapsulant is applied to the solar device, in some embodiments it may include a crosslinker (e.g. a peroxide for EVA) which can crosslink the encapsulant.
• the encapsulant is then cured in place on the solar device.
• JURASOL TL an encapsulant useful for CIGS photovolt
• the electronic device comprises an edge seal to seal it at the edges.
• an edge seal material is applied over and around the sides of the photovoltaic cell and associated circuitry.
• the encapsulant is sealed at the edges.
• the electronic device e.g. photovoltaic cell
• the electronic device is already covered with an encapsulant material as described above and a back sheet material and the edges of the entire encapsulated device is sealed.
• edge seal materials include dessicated polymers and butyl rubbers such as those sold under the tradenames HELIOSEAL PVS lOl from Adco, Lincolnshire, IL and SOLARGAIN LP02 edge tape commercially available from TruSeal, Solon, Ohio.
• the electronic device comprises a backsheet which fully encapsulates the photovoltaic device from behind as the encapsulant does from the front.
• Backsheets are typically polymeric films, and in many embodiments are multilayer films.
• backsheet films examples include 3MTM ScotchshieldTM Film commercially available from 3M Company, Saint Paul, Minnesota.
• the backsheet may be connected to a building material, such as a roofing membrane (for example, in building integrated photovoltaics (BIPV)).
• a roofing membrane for example, in building integrated photovoltaics (BIPV)
• BIPV building integrated photovoltaics
• the electronic device would comprise such roofing membrane or other part of the roof.
• protective layers include weatherable tapes.
• weatherable tapes include polyvinyl fluoride tapes, such as those commercially available from 3M Company (St.
• protective layers are especially important around the edges of the assembly, or within 5 mm of the edge.
• the protective layers may be placed in a perimeter of the assembly, or forming a frame around the surface of the assembly. Because if the stresses that are focused on the edge, delamination is generally more likely to start there. Once delamination has begun, the edge may advance toward the opposite side of the multi-layer article, eventually resulting in delamination of the entire interface between layers. Stopping the delamination at the edge will allow for the layers in a multilayer article to remain adhered.
• the protective layers limit light to the assembly.
• the light is limited in a portion of the surface area of the assembly, for example less than 5%, for example less than 1% and in specific examples less than 0.5%.
• the light can be blocked continuously or in discontinuous pattern, e.g. dots. It may also be beneficial to block light in a perimeter around the assembly,.
• the protective layer is opaque.
• a layer is opaque if it causes a reduction in transmission of visible light (380 to 750 nm), specifically it reduces transmission between 380 and 450nm, thereby blocking it from reaching the barrier stack.
• a layer is opaque if the addition of the layer creates a maximum of 20% transmission at any wavelength between 380 and 450 nm in the multilayer film.
• the opaque layer creates a maximum transmission of 2% transmission at any wavelength between 380 and 450 nm. In specific embodiments, the opaque layer creates a maximum transmission of 0.2% transmission at any wavelength between 380 and 450 nm
• FIG 8 illustrates an embodiment according to the present application.
• An assembly 810 shows electronic device 812 and a protective layer 821.
• Weatherable sheet 820 can be seen from the elevated view.
• the protective layer 821 is shown surrounding the perimeter of the assembly 810.
• the multi-layer film generally comprises a barrier stack and a weatherable sheet, and in some embodiments a substrate.
• the multilayer film is generally transmissive to visible and infrared light.
• the term "transmissive to visible and infrared light” as used herein can mean having an average transmission over the visible and infrared portion of the spectrum of at least about 75% (in some embodiments at least about 80, 85, 90, 92, 95, 97, or 98%) measured along the normal axis.
• the visible and infrared light-transmissive assembly has an average transmission over a range of 400 nm to 1400 nm of at least about 75% (in some embodiments at least about 80, 85, 90, 92, 95, 97, or 98%).
• Visible and infrared light-transmissive assemblies are those that do not interfere with absorption of visible and infrared light, for example, by photovoltaic cells.
• the visible and infrared light-transmissive assembly has an average transmission over a range wavelengths of light that are useful to a photovoltaic cell of at least about 75% (in some embodiments at least about 80, 85, 90, 92, 95, 97, or 98%).
• the multi-layer film is flexible.
• the term "flexible” as used herein refers to being capable of being formed into a roll. In some embodiments, the term “flexible” refers to being capable of being bent around a roll core with a radius of curvature of up to 7.6 centimeters (cm) (3 inches), in some embodiments up to 6.4 cm (2.5 inches), 5 cm (2 inches), 3.8 cm (1.5 inch), or 2.5 cm (1 inch). In some embodiments, the flexible assembly can be bent around a radius of curvature of at least 0.635 cm (1/4 inch), 1.3 cm (1/2 inch) or 1.9 cm (3/4 inch). Substrate
• Assemblies according to the present disclosure comprise a substrate.
• the substrate is a polymeric film.
• polymeric will be understood to include organic homopolymers and copolymers, as well as polymers or copolymers that may be formed in a miscible blend, for example, by co-extrusion or by reaction, including transesterification.
• polymer and copolymer include both random and block copolymers.
• the substrate may be selected, for example, so that its CTE is about the same (e.g., within about 10 ppm/K) or lower than the CTE of the electronic device (e.g., flexible photovoltaic device). In other words, the substrate may be selected to minimize the CTE mismatch between the substrate and the electronic device.
• the substrate has a CTE that is within 20, 15, 10, or 5 ppm/K of the device to be encapsulated. In some embodiments, it may be desirable to select the substrate that has a low CTE.
• the substrate has a CTE of up to 50 (in some embodiments, up to 45, 40, 35, or 30) ppm/K.
• the CTE of the substrate is in a range from 0.1 to 50, 0.1 to 45, 0.1 to 40, 0.1 to 35, or 0.1 to 30 ppm/K.
• the difference between the CTE of the substrate and the weatherable sheet may be, in some embodiments, at least 40, 50, 60, 70, 80, 90, 100, or 1 10 ppm/K.
• the difference between the CTE of the substrate and the weatherable sheet may be, in some embodiments, up to 150, 140, or 130 ppm/K.
• the range of the CTE mismatch between the substrate and the weatherable sheet may be, for example, 40 to 150 ppm/K, 50 to 140 ppm/K, or 80 to 130 ppm/K.
• the CTE can be determined by thermal mechanical analysis.
• the CTE of many substrates can be found in product data sheets or handbooks.
• the substrate has a modulus (tensile modulus) up to 5 x 10 9 Pa.
• the tensile modulus can be measured, for example, by a tensile testing instrument such as a testing system available from Instron, Norwood, MA, under the trade designation "INSTRON 5900".
• the tensile modulus of the substrate is up to 4.5 x 10 9 Pa, 4 x 10 9 Pa, 3.5 x 10 9 Pa, or 3 x 10 9 Pa.
• the substrate is heat-stabilized (e.g., using heat setting, annealing under tension, or other techniques) to minimize shrinkage up to at least the heat stabilization temperature when the support is not constrained.
• suitable materials for the substrate include polyethylene terephthalate (PET), polyethylene naphthalate (PEN), polyetheretherketone (PEEK), polyaryletherketone (PAEK), polyarylate (PAR), polyetherimide (PEI), polyarylsulfone (PAS), polyethersulfone (PES), polyamideimide (PAI), and polyimide, any of which may optionally be heat-stabilized. These materials are reported to have CTEs of in a range from ⁇ 1 to about 42 ppm/K.. Suitable substrates are commercially available from a variety of sources.
• Polyimides are available, for example, from E.I. Dupont de Nemours & Co., Wilmington, DE, under the trade designation "KAPTON” (e.g, “KAPTON E” or “KAPTON H”); from Kanegafugi Chemical Industry Company under the trade designation “APICAL AV”; from UBE Industries, Ltd., under the trade designation “UPILEX”.
• KAPTON e.g, "KAPTON E” or “KAPTON H”
• APICAL AV e.g, Kanegafugi Chemical Industry Company
• UBE Industries, Ltd. under the trade designation "UPILEX”.
• Polyethersulfones are available, for example, from Sumitomo.
• Polyetherimides are available, for example, from General Electric Company, under the trade designation "ULTEM”. Polyesters such as PET are available, for example, from DuPont Teijin Films, Hopewell, VA.
• the substrate has a thickness from about 0.05 mm to about 1 mm, in some embodiments, from about 0.1 mm to about 0.5 mm or from 0.1 mm to 0.25 mm.
• the substrate has a thickness of at least 0.05, 0.06, 0.07, 0.08, 0.09, 0.1, 0.1 1, 0.12, or 0.13 mm.
• Barrier stack
• the multilayer film comprises a barrier stack.
• Barrier stacks can be selected from a variety of constructions.
• the term "barrier stack” refers to films that provide a barrier to at least one of oxygen or water. Barrier stacks are typically selected such that they have oxygen and water transmission rates at a specified level as required by the application.
• the barrier stack has a water vapor transmission rate (WVTR) less than about 0.005 g/m ⁇ /day at 38° C and 100% relative humidity; in some embodiments, less than about 0.0005 g/m ⁇ /day at 38° C and
• the barrier stack has a WVTR of less than about
• the barrier stack has an oxygen transmission rate of less than about 0.005 g/m ⁇ /day at 23° C and 90% relative humidity; in some embodiments, less than about 0.0005 g/m 2 /day at 23°
• Exemplary useful barrier stacks include inorganic films prepared by atomic layer deposition, thermal evaporation, sputtering, and chemical vapor deposition. Useful barrier stacks are typically flexible and transparent.
• useful barrier films comprise inorganic/organic multilayers.
• Flexible ultra-barrier films comprising inorganic/organic multilayers are described, for example, in U.S. Patent No. 7,018,713 (Padiyath et al.). Such flexible ultra-barrier films may have a first polymer layer disposed on polymeric film that may be overcoated with two or more inorganic barrier layers separated by additional second polymer layers.
• the barrier film comprises one inorganic oxide interposed on a first polymer layer.
• Useful barrier stacks can also be found, for example, in U.S. Patent Nos.
• the barrier stack and the substrate are insulated from the environment.
• the barrier stack and substrate are insulated when they have no interface with the air surrounding the assembly.
• the major surface of the substrate can be treated to improve adhesion to the barrier stack.
• Useful surface treatments include electrical discharge in the presence of a suitable reactive or non- reactive atmosphere (e.g., plasma, glow discharge, corona discharge, dielectric barrier discharge or atmospheric pressure discharge); chemical pretreatment; or flame pretreatment.
• a separate adhesion promotion layer may also be formed between the major surface of the substrate and the barrier stack.
• the adhesion promotion layer can be, for example, a separate polymeric layer or a metal-containing layer such as a layer of metal, metal oxide, metal nitride or metal oxynitride.
• the adhesion promotion layer may have a thickness of a few nanometers (nm) (e.g., 1 or 2 nm) to about 50 nm or more.
• one side (that is, one major surface) of the substrate can be treated to enhance adhesion to the barrier stack, and the other side (that is, major surface) can be treated to enhance adhesion to a device to be covered or an encapsulant (e.g., EVA) that covers such a device.
• EVA encapsulant
• Some useful substrates that are surface treated are commercially available, for example, from Du Pont Teijin. For some of these films, both sides are surface treated (e.g., with the same or different pretreatments), and for others, only one side is surface treated.
• Assemblies according to the present disclosure comprise a weatherable sheet, which can be mono or multi-layer.
• the weatherable sheet is generally flexible and transmissive to visible and infrared light and comprises organic film- forming polymers.
• Useful materials that can form weatherable sheets include polyesters, polycarbonates, polyethers, polyimides, polyolefins, fluoropolymers, and combinations thereof.
• the weatherable sheet In embodiments wherein the electronic device is, for example, asolar device, it is typically desirable for the weatherable sheet to be resistant to degradation by ultraviolet (UV) light and weatherable. Photo-oxidative degradation caused by UV light (e.g., in a range from 280 to 400 nm) may result in color change and deterioration of optical and mechanical properties of polymeric films.
• UV light e.g., in a range from 280 to 400 nm
• the weatherable sheets described herein can provide, for example, a durable, weatherable topcoat for a photovoltaic device.
• the substrates are generally abrasion and impact resistant and can prevent degradation of, for example, photovoltaic devices when they are exposed to outdoor elements.
• a variety of stabilizers may be added to the weatherable sheet to improve its resistance to UV light.
• stabilizers include at least one of ultra violet absorbers (UVA) (e.g., red shifted UV absorbers), hindered amine light stabilizers (HALS), or anti- oxidants.
• UVA ultra violet absorbers
• HALS hindered amine light stabilizers
• anti- oxidants anti-oxidants.
• UVA ultra violet absorbers
• HALS hindered amine light stabilizers
• anti- oxidants anti- oxidants.
• the phrase "resistant to degradation by ultraviolet light” means that the weatherable sheet includes at least one ultraviolet absorber or hindered amine light stabilizer.
• the phrase "resistant to degradation by ultraviolet light” means that the weatherable sheet at least one of reflects or absorbs at least 50 percent of incident ultraviolet light over at least a 30 nanometer range in a wavelength range from at least 300 nanometers to 400 nanometers.
• the weatherable sheet need not include UVA or HALS.
• the UV resistance of the weatherable sheet can be evaluated, for example, using accelerated weathering studies. Accelerated weathering studies are generally performed on films using techniques similar to those described in ASTM G- 155, "Standard practice for exposing non- metallic materials in accelerated test devices that use laboratory light sources". The noted ASTM technique is considered a sound predictor of outdoor durability, that is, ranking materials performance correctly.
• One mechanism for detecting the change in physical characteristics is the use of the weathering cycle described in ASTM G155 and a D65 light source operated in the reflected mode.
• the article should withstand an exposure of at least 18,700 kJ/m 2 at 340 nm before the b* value obtained using the CIE L*a*b* space increases by 5 or less, 4 or less, 3 or less, or 2 or less before the onset of significant cracking, peeling, delamination or haze.
• the weatherable sheet disclosed herein comprises a fluoropolymer.
• Fluoropolymers typically are resistant to UV degradation even in the absence of stabilizers such as UVA, HALS, and anti-oxidants.
• Useful fluoropolymers include ethylene-tetrafluoroethylene copolymers (ETFE), ethylene-chloro-trifluoroethylene copolymers (ECTFE), tetrafluoroethylene- hexafluoropropylene copolymers (FEP), tetrafluoroethylene-perfluorovinylether copolymers (PFA, MFA) tetrafluoroethylene-hexafluoropropylene-vinylidene fluoride copolymers (THV), polyvinylidene fluoride homo and copolymers (PVDF), blends thereof, and blends of these and other fluoropolymers.
• Fluoropolymers typically comprise homo or copolymers of TFE, CTFE,
• VDF, HFP or other fully fluorinated, partially fluorinated or hydrogenated monomers such as vinyl ethers and alpa-olefins or other halogen containing monomers.
• the CTE of fluoropolymer films is typically high relative to films made from hydrocarbon polymers.
• the CTE of a fluoropolymer film may be at least 75, 80, 90, 100, 1 10, 120, or 130 ppm/K.
• the CTE of ETFE may be in a range from 90 to 140 ppm/K.
• the substrates comprising fluoropolymer can also include non- fluorinated materials.
• a blend of polyvinylidene fluoride and polymethyl methacrylate can be used.
• Useful flexible, visible and infrared light-transmissive substrates also include multilayer film substrates.
• Multilayer film substrates may have different fluoropolymers in different layers or may include at least one layer of fluoropolymer and at least one layer of a non- fluorinated polymer.
• Multilayer films can comprise a few layers (e.g., at least 2 or 3 layers) or can comprise at least 100 layers (e.g., in a range from 100 to 2000 total layers or more).
• the different polymers in the different multilayer film substrates can be selected, for example, to reflect a significant portion (e.g., at least 30, 40, or 50%) of UV light in a wavelength range from 300 to 400 nm as described, for example, in U.S. Pat. No. 5,540,978 (Schrenk).
• Such blends and multilayer film substrates may be useful for providing UV resistant substrates that have lower CTEs than the fluoropolymers described above.
• Useful weatherable sheets comprising a fluoropolymer can be commercially obtained, for example, from E.I. duPont De Nemours and Co., Wilmington, DE, under the trade designation "TEFZEL ETFE” and “TEDLAR", and films made from resins available from Dyneon LLC,
• Weatherable sheets containing polycarbonate may have relatively high CTEs in comparison to polyesters, for example.
• polycarbonate may be, for example, about 70 ppm/K.
• the major surface of the weatherable sheet e.g., fluoropolymer
• a suitable reactive or non-reactive atmosphere e.g., plasma, glow discharge, corona discharge, dielectric barrier discharge or atmospheric pressure discharge
• chemical pretreatment e.g., using alkali solution and/or liquid ammonia
• flame pretreatment e.g., using alkali solution and/or liquid ammonia
• electron beam treatment e.g., using alkali solution and/or liquid ammonia
• a separate adhesion promotion layer may also be formed between the major surface of the weatherable sheet and the PSA.
• the weatherable sheet may be a fluoropolymer that has been coated with a PSA and subsequently irradiated with an electron beam to form a chemical bond between the substrate and the pressure sensitive adhesive; (see, e.g., U. S. Pat. No. 6,878,400 (Yamanaka et al.).
• Some useful weatherable sheets that are surface treated are commercially available, for example, from St. Gobain Performance Plastics under the trade designation "NORTON ETFE".
• the weatherable sheet has a thickness from about 0.01 mm to about 1 mm, in some embodiments, from about 0.05 mm to about 0.25 mm or from 0.05 mm to 0.15 mm.
• barrier films are required in the assemblies disclosed herein to reduce the permeation of water vapor to levels that allow its use in long term outdoor applications such as building integrated photovoltaic's (BIPV).
• BIPV building integrated photovoltaic's
• PSA pressure sensitive adhesive
• PSAs are well known to those of ordinary skill in the art to possess properties including the following: (1) aggressive and permanent tack, (2) adherence with no more than finger pressure, (3) sufficient ability to hold onto an adherend, and (4) sufficient cohesive strength to be cleanly removable from the adherend.
• Materials that have been found to function well as PSAs are polymers designed and formulated to exhibit the requisite viscoelastic properties resulting in a desired balance of tack, peel adhesion, and shear holding power.
• This criterion defines a pressure sensitive adhesive as an adhesive having a 1 second creep compliance of greater than 1 x 10 ⁇ 6 cm 2 /dyne as described in "Handbook of Pressure Sensitive Adhesive Technology", Donatas Satas (Ed.), 2 nd Edition, p. 172, Van Nostrand Reinhold, New York, NY, 1989, incorporated herein by reference.
• pressure sensitive adhesives may be defined as adhesives having a storage modulus of less than about 1 x 10 6 dynes/cm 2 .
• PSAs useful for practicing the present disclosure typically do not flow and have sufficient barrier properties to provide slow or minimal infiltration of oxygen and moisture through the adhesive bond line.
• the PSAs disclosed herein are generally transmissive to visible and infrared light such that they do not interfere with absorption of visible light, for example, by photovoltaic cells.
• the PSAs may have an average transmission over the visible portion of the spectrum of at least about 75% (in some embodiments at least about 80, 85, 90, 92, 95, 97, or 98%) measured along the normal axis.
• the PSA has an average transmission over a range of 400 nm to 1400 nm of at least about 75% (in some embodiments at least about 80, 85, 90, 92, 95, 97, or 98%).
• Exemplary PSAs include acrylates, silicones, polyisobutylenes, ureas, and combinations thereof.
• Some useful commercially available PSAs include UV curable PSAs such as those available from Adhesive Research, Inc., Glen Rock, PA, under the trade designations "ARclear 90453" and “ARclear 90537” and acrylic optically clear PSAs available, for example, from 3M Company, St. Paul, MN, under the trade designations "OPTICALLY CLEAR LAMINATING ADHESIVE 8171 ", "OPTICALLY CLEAR
• PSAs useful for practicing the present disclosure have a modulus (tensile modulus) up to 50,000 psi (3.4 x 10 8 Pa).
• the tensile modulus can be measured, for example, by a tensile testing instrument such as a testing system available from Instron, Norwood, MA, under the trade designation "INSTRON 5900".
• the tensile modulus of the PSA is up to 40,000, 30,000, 20,000, or 10,000 psi (2.8 x 10 8 Pa, 2.1 x 10 8 Pa, 1.4 x 10 8 Pa, or 6.9 x 10 8 Pa).
• PSAs useful for practicing the present disclosure are acrylic PSAs.
• the term "acrylic” or “acrylate” includes compounds having at least one of acrylic or methacrylic groups.
• Useful acrylic PSAs can be made, for example, by combining at least two different monomers (first and second monomers).
• first monomers include 2- methylbutyl acrylate, 2-ethylhexyl acrylate, isooctyl acrylate, lauryl acrylate, n-decyl acrylate, 4- methyl-2-pentyl acrylate, isoamyl acrylate, sec-butyl acrylate, and isononyl acrylate.
• Exemplary suitable second monomers include a (meth)acrylic acid (e.g., acrylic acid, methacrylic acid, itaconic acid, maleic acid, and fumaric acid), a (meth)acrylamide (e.g., acrylamide,
• a (meth)acrylate e.g., 2-hydroxyethyl acrylate or methacrylate, cyclohexyl acrylate, t-butyl acrylate, or isobornyl acrylate
• N-vinyl pyrrolidone N-vinyl caprolactam, an alpha-olefin, a vinyl ether, an allyl ether, a styrenic monomer, or a maleate.
• Acrylic PSAs may also be made by including cross-linking agents in the formulation.
• cross-linking agents include copolymerizable polyfunctional ethylenically unsaturated monomers (e.g., 1,6-hexanediol diacrylate, trimethylolpropane triacrylate, pentaerythritol tetraacrylate, and 1,2-ethylene glycol diacrylate); ethylenically unsaturated compounds which in the excited state are capable of abstracting hydrogen (e.g., acrylated benzophenones such as described in U.S. Pat. No.
• nonionic crosslinking agents which are essentially free of olefinic unsaturation and is capable of reacting with carboxylic acid groups, for example, in the second monomer described above (e.g., 1 ,4-bis(ethyleneiminocarbonylamino)benzene; 4,4- bis(ethyleneiminocarbonylamino)diphenylmethane; l,8-bis(ethyleneiminocarbonylamino)octane; 1,4-tolylene diisocyanate; 1 ,6-hexamethylene diisocyanate, N,N'-bis-l,2- propyleneisophthalamide, diepoxides, dianhydrides, bis(amides), and bis(imides)); and nonionic crosslinking agents which are essentially free of olefinic unsaturation, are noncopolymerizable with the first and second monomers, and, in the excited state, are capable of abstracting hydrogen (e.g., 2,4-bis(trichloromethyl)
• the first monomer is used in an amount of 80-100 parts by weight (pbw) based on a total weight of 100 parts of copolymer
• the second monomer is used in an amount of 0-20 pbw based on a total weight of 100 parts of copolymer.
• the crosslmking agent can be used in an amount of 0.005 to 2 weight percent based on the combined weight of the monomers, for example from about 0.01 to about 0.5 percent by weight or from about 0.05 to 0.15 percent by weight.
• the acrylic PSAs useful for practicing the present disclosure can be prepared, for example, by a solvent free, bulk, free-radical polymerization process (e.g., using heat, electron-beam radiation, or ultraviolet radiation). Such polymerizations are typically facilitated by a solvent free, bulk, free-radical polymerization process (e.g., using heat, electron-beam radiation, or ultraviolet radiation). Such polymerizations are typically facilitated by a solvent free, bulk, free-radical polymerization process (e.g., using heat, electron-beam radiation, or ultraviolet radiation). Such polymerizations are typically facilitated by a solvent free, bulk, free-radical polymerization process (e.g., using heat, electron-beam radiation, or ultraviolet radiation). Such polymerizations are typically facilitated by a solvent free, bulk, free-radical polymerization process (e.g., using heat, electron-beam radiation, or ultraviolet radiation). Such polymerizations are typically facilitated by a solvent free, bulk, free-radical polymerization process
• photoinitiators include benzoin ethers such as benzoin methyl ether and benzoin isopropyl ether, substituted benzoin ethers such as anisoin methyl ether, substituted acetophenones such as 2,2- dimethoxy-2-phenylacetophenone, and substituted alpha-ketols such as 2-methyl-2- hydroxypropiophenone.
• examples of commercially available photoinitiators include IRGACURE 651 and DAROCUR 1 173, both available from Ciba-Geigy Corp., Hawthorne, NY, and
• thermal initiators include, but are not limited to, peroxides such as dibenzoyl peroxide, dilauryl peroxide, methyl ethyl ketone peroxide, cumene hydroperoxide, dicyclohexyl peroxydicarbonate, as well as 2,2-azo- bis(isobutryonitrile), and t-butyl perbenzoate.
• thermal initiators include VAZO 64, available from ACROS Organics, Pittsburgh, PA, and LUCIDOL 70, available from Elf Atochem North America, Philadelphia, PA.
• the polymerization initiator is used in an amount effective to facilitate polymerization of the monomers (e.g., 0.1 part to about 5.0 parts or 0.2 part to about 1.0 part by weight, based on 100 parts of the total monomer content).
• the coated adhesive can be exposed to ultraviolet radiation having a wavelength of about 250 nm to about 400 nm.
• the radiant energy in this range of wavelength required to crosslink the adhesive is about 100 millijoules/cm ⁇ to about 1,500 millijoules/cm ⁇ , or more specifically, about 200 millijoules/cm ⁇ to about 800 millijoules/cm ⁇ .
• a mixture of first and second monomers can be polymerized with a portion of a photoinitiator by exposing the mixture to UV radiation in an inert environment for a time sufficient to form a coatable base syrup, and subsequently adding a crosslmking agent and the remainder of the photoinitiator.
• This final syrup containing a crosslmking agent e.g., which may have a Brookfield viscosity of about 100 centipoise to about 6000 centipoise at 23 C, as measured with a No. 4 LTV spindle, at 60 revolutions per minute
• a crosslmking agent e.g., which may have a Brookfield viscosity of about 100 centipoise to about 6000 centipoise at 23 C, as measured with a No. 4 LTV spindle, at 60 revolutions per minute
• the syrup is coated onto the weatherable sheet, further polymerization and crosslinking can be carried out in an inert environment (e.g., nitrogen, carbon dioxide, helium, and argon, which exclude oxygen).
• an inert environment e.g., nitrogen, carbon dioxide, helium, and argon, which exclude oxygen.
• a sufficiently inert atmosphere can be achieved by covering a layer of the photoactive syrup with a polymeric film, such as silicone-treated PET film, that is transparent to UV radiation or e-beam and irradiating through the film in air.
• PSAs useful for practicing the present disclosure comprise polyisobutylene.
• the polyisobutylene may have a polyisobutylene skeleton in the main or a side chain.
• Useful polyisobutylenes can be prepared, for example, by polymerizing isobutylene alone or in combination with n-butene, isoprene, or butadiene in the presence of a Lewis acid catalyst (for example, aluminum chloride or boron trifluoride).
• Useful polyisobutylene materials are commercially available from several manufacturers. Homopolymers are commercially available, for example, under the trade designations
• OPPANOL and "GLISSOPAL” (e.g., OPPANOL B 15, B30, B50, B 100, B150, and B200 and GLISSOPAL 1000, 1300, and 2300) from BASF Corp. (Florham Park, NJ); "SDG", "JHY”, and “EFROLEN” from United Chemical Products (UCP) of St. Russia.
• Polyisobutylene copolymers can be prepared by polymerizing isobutylene in the presence of a small amount (e.g., up to 30, 25, 20, 15, 10, or 5 weight percent) of another monomer such as, for example, styrene, isoprene, butene, or butadiene.
• Exemplary suitable isobutylene/isoprene copolymers are commercially available under the trade designations "EXXON BUTYL” (e.g., EXXON BUTYL 065, 068, and 268) from Exxon Mobil Corp., Irving, TX.; "BK- 1675N” from UCP and
• LANXESS (e.g., LANXESS BUTYL 301, LANXESS BUTYL 101-3, and LANXESS BUTYL 402) from Sarnia, Ontario, Canada.
• exemplary suitable isobutylene/styrene block copolymers are commercially available under the trade designation "SIBSTAR” from Kaneka (Osaka, Japan).
• Other exemplary suitable polyisobutylene resins are commercially available, for example, from Exxon Chemical Co. under the trade designation "VISTANEX”, from Goodrich Corp., Charlotte, NC, under the trade designation "HYCAR", and from Japan Butyl Co., Ltd., Kanto, Japan, under the trade designation "JSR BUTYL”.
• a polyisobutylene useful for practicing the present disclosure may have a wide variety of molecular weights and a wide variety of viscosities. Polyisobutylenes of many different molecular weights and viscosities are commercially available.
• the PSA further comprises a hydrogenated hydrocarbon tackifier (in some embodiments, a poly(cyclic olefin)).
• a hydrogenated hydrocarbon tackifier in some embodiments, a poly(cyclic olefin)
• about 5 to 90 percent by weight the hydrogenated hydrocarbon tackifier in some embodiments, the poly(cyclic olefin)
• Useful polyisobutylene PSAs include adhesive compositions comprising a hydrogenated poly(cyclic olefin) and a
• polyisobutylene resin such as those disclosed in Int. Pat. App. Pub. No. WO 2007/087281 (Fujita et al.).
• the "hydrogenated" hydrocarbon tackifier component may include a partially
• the hydrogenated hydrocarbon tackifier is completely hydrogenated, which may lower the moisture permeability of the PSA and improve the compatibility with the polyisobutylene resin.
• the hydrogenated hydrocarbon tackifiers are often hydrogenated cycloaliphatic resins, hydrogenated aromatic resins, or combinations thereof.
• some tackifying resins are hydrogenated C9-type petroleum resins obtained by copolymerizing a C9 fraction produced by thermal decomposition of petroleum naphtha, hydrogenated C5-type petroleum resins obtained by copolymerizing a C5 fraction produced by thermal decomposition of petroleum naphtha, or hydrogenated C5/C9-type petroleum resins obtained by polymerizing a combination of a C5 fraction and C9 fraction produced by thermal decomposition of petroleum naphtha.
• the C9 fraction can include, for example, indene, vinyl- toluene, alpha-methylstyrene, beta-methylstyrene, or a combination thereof.
• the C5 fraction can include, for example, pentane, isoprene, piperine, 1,3-pentadiene, or a combination thereof.
• the hydrogenated hydrocarbon tackifier is a hydrogenated poly(cyclic olefin) polymer.
• the hydrogenated poly(cyclic olefin) is a hydrogenated poly(dicyclopentadiene), which may provide advantages to the PSA (e.g., low moisture permeability and transparency).
• the tackifying resins are typically amorphous and have a weight average molecular weight no greater than 5000 grams/mole.
• ARKON e.g., ARKON P or ARKON M
• ESCOREZ from Exxon Chemical.
• REGALREZ e.g., REGALREZ 1085, 1094, 1 126, 1 139, 3102, and 6108
• WINGTACK e.g., WINGTACK 95 and RWT-7850 resins from Cray Valley (Exton, PA)
• PICCOTAC e.g., PICCOTAC 6095-E, 8090-E, 8095, 8595, 9095, and 9105
• PSAs useful for practicing the present disclosure comprise at least one of a uv absorber (UVA), a hindered amine light stabilizer, or an antioxidant.
• UVA uv absorber
• a hindered amine light stabilizer or an antioxidant.
• useful UVAs include those described above in conjunction with multilayer film substrates (example.g., those available from Ciba Specialty Chemicals Corporation under the trade designations "TINUVIN 328", "TINUVIN 326",
• UVAs when used, can be present in an amount from about 0.01 to 3 percent by weight based on the total weight of the pressure sensitive adhesive composition.
• useful antioxidants include hindered phenol-based compounds and phosphoric acid ester-based compounds and those described above in conjunction with multilayer film substrates (e.g., those available from Ciba Specialty Chemicals Corporation under the trade designations "IRGANOX 1010”, “IRGANOX 1076”, and “IRGAFOS 126" and butylated hydroxytoluene (BHT)).
• Antioxidants when used, can be present in an amount from about 0.01 to 2 percent by weight based on the total weight of the pressure sensitive adhesive composition.
• useful stabilizers include phenol-based stabilizers, hindered amine -based stabilizers (e.g., including those described above in conjunction with multilayer film substrates and those available from BASF under the trade designation "CHIMASSORB” such as “CHIMASSORB 2020”), imidazole-based stabilizers, dithiocarbamate- based stabilizers, phosphorus-based stabilizers, and sulfur ester-based stabilizers.
• Such compounds when used, can be present in an amount from about 0.01 to 3 percent by weight based on the total weight of the pressure sensitive adhesive composition.
• the PSA layer disclosed herein is at least 0.005 mm (in some embodiments, at least 0.01, 0.02, 0.03, 0.04, or 0.05 mm) in thickness. In some embodiments, the PSA layer has a thickness up to about 0.2 mm (in some embodiments, up to 0.15, 0.1, or 0.075 mm) in thickness. For example, the thickness of the PSA layer may be in a range from 0.005 mm to 0.2 mm, 0.005 mm to 0.1 mm, or 0.01 to 0.1 mm.
• release liner Before being applied to the weatherable sheet, the exposed major surface may be temporarily protected with a release liner before being applied to a barrier film disclosed herein.
• useful release liners include craft paper coated with, for example, silicones; polypropylene film; fluoropolymer film such as those available from E.I. du Pont de Nemours and Co. under the trade designation "TEFLON"; and polyester and other polymer films coated with, for example, silicones or fluorocarbons.
• a variety of stabilizers may be added to the PSa layer to improve its resistance to UV light.
• stabilizers include at least one of ultra violet absorbers (UVA) (e.g., red shifted UV absorbers), hindered amine light stabilizers (HALS), or anti- oxidants.
• UVA ultra violet absorbers
• HALS hindered amine light stabilizers
• anti- oxidants e.g., anti-oxidants.
• UVA ultra violet absorbers
• HALS hindered amine light stabilizers
• the PSA layer in the barrier assembly according to the present disclosure serves to protect the barrier assembly from thermal stresses that may be caused by a high CTE weatherable sheet (e.g., a fluoropolymer).
• the PSA layer serves as a convenient means for attaching the weatherable sheet to the barrier film deposited on the first polymeric film substrate (e.g., having a CTE of up to 50 ppm/K).
• the PSA layer contains at least one of UVA, HALS, or anti-oxidants, it can further provide protection to the barrier film from degradation by UV light.
• assemblies according to the present disclosure can contain desiccant.
• assemblies according to the present disclosure are essentially free of desiccant.
• "Essentially free of desiccant” means that desiccant may be present but in an amount that is insufficient to effectively dry a photovoltaic module.
• Assemblies that are essentially free of desiccant include those in which no desiccant is incorporated into the assembly.
• Various functional layers or coatings can optionally be added to the assemblies disclosed herein to alter or improve their physical or chemical properties.
• Exemplary useful layers or coatings include visible and infrared light-transmissive conductive layers or electrodes (e.g., of indium tin oxide); antistatic coatings or films; flame retardants; abrasion resistant or hardcoat materials; optical coatings; anti-fogging materials; anti-reflection coatings; anti-smudging coatings; polarizing coatings; anti-fouling materials; prismatic films; additional adhesives (e.g., pressure sensitive adhesives or hot melt adhesives); primers to promote adhesion to adjacent layers; additional UV protective layers; and low adhesion backsize materials for use when the barrier assembly is to be used in adhesive roll form.
• These components can be incorporated, for example, into the barrier film or can be applied to the surface of the polymeric film substrate.
• the assembly disclosed herein could be treated with inks or other printed indicia such as those used to display product identification, orientation or alignment information, advertising or brand information, decoration, or other information.
• the inks or printed indicia can be provided using techniques known in the art (e.g., screen printing, inkjet printing, thermal transfer printing, letterpress printing, offset printing, flexographic printing, stipple printing, and laser printing).
• Spacer structures could be included, for example, in the adhesive, to maintain specific bond line thickness. Assemblies according to the present disclosure can conveniently be assembled using a variety of techniques.
• the pressure sensitive adhesive layer may be a transfer PSA on a release liner or between two release liners.
• the transfer adhesive can be used to laminate a weatherable sheet to a barrier film deposited on a weatherable sheet after removal of the release liner(s).
• a PSA can be coated onto the weatherable sheet and/or onto the barrier film deposited on the first polymeric film substrate before laminating the first and weatherable sheets together.
• a solvent- free adhesive formulation for example, can be coated between the weatherable sheet and the barrier film deposited on the first polymeric film substrate. Subsequently, the formulation can be cured by heat or radiation as described above to provide an assembly according to the present disclosure.
• the present application is directed to an assembly comprising an electronic device, and a multilayer film.
• the multilayer film comprises a barrier stack adjacent the electronic device; and a weatherable sheet adjacent the barrier stack opposite the electronic device.
• the assembly additionally comprises a protective layer in contact with the electronic device and the weatherable sheet.
• An example of the inventive assembly with a simulated electronic device, edge seal, multilayer film, weathearable sheet and a protective layer in contact with the edge seal material was constructed in the following manner.
• a sheet of "UBF 9L” barrier film laminate available from 3M Company, StPaul, MN (17 cm (6.5 in) wide x 24 cm (9.5 in) long) was placed with the weatherable surface down to simulate a low water vapor transmission rate (WVTR) backsheet.
• a 12 mm (1 ⁇ 2 in) wide strip of edge seal material 1.0 mm thick commercially available from under the trade designation "HELIOSEAL PVS 101" from Adco, Lincolnshire, IL was placed around the entire perimeter of the "UBF 9L” barrier film laminate opposite the weatherable surface of the"UBF 9L” barrier film laminate.
• PTFE polytetrafluoroethylene coated 140 micron (5.6 mil) aluminum foil
• PTFE polytetrafluoroethylene coated 140 micron (5.6 mil) aluminum foil
• Another sheet of "UBF 9L” barrier film laminate was cut to 15 cm (6.0 in) x 23 cm (9.0 in), orientated with the weatherable surface up and placed to cover the "JURASOL TL" encapsulant plus 6.4 mm (0.25 in) around the entire perimeter of the edge seal material.
• the entire assembly was placed in a Spire 350 Vacuum Laminator (commercially available from Spire Corporation Bedford, MA) and cured at 150°C for 12 min.
• the resulting assembly was visually intact and meant to simulate an electronic device comprising an opaque protective layer in contact with the edge seal material and the weatherable sheet.
• This peel strip construction was laminated at 150 °C for 12 min and 10 5 Pa (1 atm) of pressure. The resulting laminate was then tested in the T-Peel test according to AST D 18776-08.
• the two unbonded ends of the PVF tape were placed in a tension testing machine according to ASTM D 1876-08 "Standard Test Method for Peel Resistance of Adhesives (T-Peel Test)". A grip distance of 12.7 mm was used and a peel speed of 254 mm/min (10 in/min) was used. T-Peel testing was completed according to ASTM D 1876-08 except where otherwise stated.
• the average peel force was measured for five samples of the edge seal bonding material and averaged to produce the following results:
• Example 1 An example of a barrier assembly comprising a protective layer in contact with an edge seal material and the weatherable sheet was prepared as Example 1 , except a black RTV silicone caulk available from CRC Industries, Inc. Warminster, PA was applied in place of the PVF tape after the assembly was cured in the laminator. The caulk was applied first as a bead covering the weatherable sheet and edge seal followed by further spreading using a wood tongue depressor to fully cover the remaining edge seal and about 6 mm (0.25 in) of the weatherable topsheet. The caulk was then allowed to cure at room temperature per the manufacturer's instructions.
• a black RTV silicone caulk available from CRC Industries, Inc. Warminster, PA was applied in place of the PVF tape after the assembly was cured in the laminator.
• the caulk was applied first as a bead covering the weatherable sheet and edge seal followed by further spreading using a wood tongue depressor to fully cover the remaining edge seal and about 6 mm (0.25 in) of the weather
• the resulting assembly was visually intact and meant to simulate an electronic device comprising a curable resin protective layer in contact with the edge seal material and the weatherable sheet.

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• 2012
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