CN104385747A - 多层复合膜及由其制备的制品 - Google Patents
多层复合膜及由其制备的制品 Download PDFInfo
- Publication number
- CN104385747A CN104385747A CN201410662731.2A CN201410662731A CN104385747A CN 104385747 A CN104385747 A CN 104385747A CN 201410662731 A CN201410662731 A CN 201410662731A CN 104385747 A CN104385747 A CN 104385747A
- Authority
- CN
- China
- Prior art keywords
- laminate
- ionomer
- core layer
- acid copolymer
- layer
- 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.)
- Pending
Links
- 239000002131 composite material Substances 0.000 title abstract 2
- 229920000554 ionomer Polymers 0.000 claims abstract description 60
- 239000005001 laminate film Substances 0.000 claims abstract description 7
- 238000004806 packaging method and process Methods 0.000 claims abstract description 4
- 239000010410 layer Substances 0.000 claims description 120
- 239000012792 core layer Substances 0.000 claims description 61
- 239000002253 acid Substances 0.000 claims description 29
- 230000003287 optical effect Effects 0.000 claims description 29
- 238000002834 transmittance Methods 0.000 claims description 27
- 229920000642 polymer Polymers 0.000 claims description 26
- 229920001577 copolymer Polymers 0.000 claims description 24
- 230000007704 transition Effects 0.000 claims description 14
- 239000005038 ethylene vinyl acetate Substances 0.000 claims description 11
- 239000012528 membrane Substances 0.000 claims description 9
- VGGSQFUCUMXWEO-UHFFFAOYSA-N Ethene Chemical compound C=C VGGSQFUCUMXWEO-UHFFFAOYSA-N 0.000 claims description 8
- 239000000203 mixture Substances 0.000 claims description 7
- 239000005977 Ethylene Substances 0.000 claims description 6
- 239000011521 glass Substances 0.000 claims description 5
- 238000004519 manufacturing process Methods 0.000 claims description 4
- 150000001732 carboxylic acid derivatives Chemical class 0.000 claims description 3
- 239000005336 safety glass Substances 0.000 claims description 3
- 238000007334 copolymerization reaction Methods 0.000 claims description 2
- 229920006037 cross link polymer Polymers 0.000 claims description 2
- 229920006228 ethylene acrylate copolymer Polymers 0.000 claims description 2
- 238000001125 extrusion Methods 0.000 claims description 2
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- 241001074085 Scophthalmus aquosus Species 0.000 claims 1
- 125000003178 carboxy group Chemical group [H]OC(*)=O 0.000 claims 1
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- 239000013047 polymeric layer Substances 0.000 claims 1
- 239000008393 encapsulating agent Substances 0.000 description 16
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- 229920001200 poly(ethylene-vinyl acetate) Polymers 0.000 description 9
- DQXBYHZEEUGOBF-UHFFFAOYSA-N but-3-enoic acid;ethene Chemical compound C=C.OC(=O)CC=C DQXBYHZEEUGOBF-UHFFFAOYSA-N 0.000 description 8
- 230000000704 physical effect Effects 0.000 description 6
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 description 5
- 229910052710 silicon Inorganic materials 0.000 description 5
- 239000010703 silicon Substances 0.000 description 5
- 238000004132 cross linking Methods 0.000 description 4
- QTBSBXVTEAMEQO-UHFFFAOYSA-N Acetic acid Chemical compound CC(O)=O QTBSBXVTEAMEQO-UHFFFAOYSA-N 0.000 description 3
- 150000002148 esters Chemical class 0.000 description 3
- 229920006225 ethylene-methyl acrylate Polymers 0.000 description 3
- 239000000565 sealant Substances 0.000 description 3
- 239000002356 single layer Substances 0.000 description 3
- 229920001897 terpolymer Polymers 0.000 description 3
- SMZOUWXMTYCWNB-UHFFFAOYSA-N 2-(2-methoxy-5-methylphenyl)ethanamine Chemical compound COC1=CC=C(C)C=C1CCN SMZOUWXMTYCWNB-UHFFFAOYSA-N 0.000 description 2
- NIXOWILDQLNWCW-UHFFFAOYSA-N 2-Propenoic acid Natural products OC(=O)C=C NIXOWILDQLNWCW-UHFFFAOYSA-N 0.000 description 2
- CERQOIWHTDAKMF-UHFFFAOYSA-N Methacrylic acid Chemical compound CC(=C)C(O)=O CERQOIWHTDAKMF-UHFFFAOYSA-N 0.000 description 2
- HCHKCACWOHOZIP-UHFFFAOYSA-N Zinc Chemical compound [Zn] HCHKCACWOHOZIP-UHFFFAOYSA-N 0.000 description 2
- 238000002835 absorbance Methods 0.000 description 2
- 230000008033 biological extinction Effects 0.000 description 2
- 230000005540 biological transmission Effects 0.000 description 2
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- 229910021419 crystalline silicon Inorganic materials 0.000 description 2
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- DGAQECJNVWCQMB-PUAWFVPOSA-M Ilexoside XXIX Chemical compound C[C@@H]1CC[C@@]2(CC[C@@]3(C(=CC[C@H]4[C@]3(CC[C@@H]5[C@@]4(CC[C@@H](C5(C)C)OS(=O)(=O)[O-])C)C)[C@@H]2[C@]1(C)O)C)C(=O)O[C@H]6[C@@H]([C@H]([C@@H]([C@H](O6)CO)O)O)O.[Na+] DGAQECJNVWCQMB-PUAWFVPOSA-M 0.000 description 1
- WHXSMMKQMYFTQS-UHFFFAOYSA-N Lithium Chemical compound [Li] WHXSMMKQMYFTQS-UHFFFAOYSA-N 0.000 description 1
- FYYHWMGAXLPEAU-UHFFFAOYSA-N Magnesium Chemical compound [Mg] FYYHWMGAXLPEAU-UHFFFAOYSA-N 0.000 description 1
- 229930182556 Polyacetal Natural products 0.000 description 1
- XTXRWKRVRITETP-UHFFFAOYSA-N Vinyl acetate Chemical compound CC(=O)OC=C XTXRWKRVRITETP-UHFFFAOYSA-N 0.000 description 1
- 239000000853 adhesive Substances 0.000 description 1
- 230000001070 adhesive effect Effects 0.000 description 1
- 239000012790 adhesive layer Substances 0.000 description 1
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 1
- 229910052782 aluminium Inorganic materials 0.000 description 1
- 229910052788 barium Inorganic materials 0.000 description 1
- DSAJWYNOEDNPEQ-UHFFFAOYSA-N barium atom Chemical compound [Ba] DSAJWYNOEDNPEQ-UHFFFAOYSA-N 0.000 description 1
- 230000004888 barrier function Effects 0.000 description 1
- 230000008901 benefit Effects 0.000 description 1
- QYMGIIIPAFAFRX-UHFFFAOYSA-N butyl prop-2-enoate;ethene Chemical compound C=C.CCCCOC(=O)C=C QYMGIIIPAFAFRX-UHFFFAOYSA-N 0.000 description 1
- 150000001735 carboxylic acids Chemical class 0.000 description 1
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- 239000003426 co-catalyst Substances 0.000 description 1
- 230000000052 comparative effect Effects 0.000 description 1
- 239000004020 conductor Substances 0.000 description 1
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- LQZZUXJYWNFBMV-UHFFFAOYSA-N dodecan-1-ol Chemical compound CCCCCCCCCCCCO LQZZUXJYWNFBMV-UHFFFAOYSA-N 0.000 description 1
- 230000007613 environmental effect Effects 0.000 description 1
- 229920006242 ethylene acrylic acid copolymer Polymers 0.000 description 1
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- 239000011229 interlayer Substances 0.000 description 1
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- 229910052749 magnesium Inorganic materials 0.000 description 1
- 239000011777 magnesium Substances 0.000 description 1
- 239000000155 melt Substances 0.000 description 1
- 238000002844 melting Methods 0.000 description 1
- 230000008018 melting Effects 0.000 description 1
- 150000007530 organic bases Chemical class 0.000 description 1
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- 229910052708 sodium Inorganic materials 0.000 description 1
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- 238000001228 spectrum Methods 0.000 description 1
- 229920001169 thermoplastic Polymers 0.000 description 1
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- 229920001187 thermosetting polymer Polymers 0.000 description 1
- 239000004634 thermosetting polymer Substances 0.000 description 1
- 239000004416 thermosoftening plastic Substances 0.000 description 1
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Abstract
本发明涉及多层复合膜及由其制备的制品。具体地说,本发明是一种光学透明层压物膜,包括:至少三层膜,其中,至少三层膜的至少两层包括离子交联聚合物膜,且其中,膜可适用于在光电池或包装中使用。
Description
本申请是申请日为2005年12月7日、发明名称同上的PCT/US2005/044601的发明专利申请的分案申请,原申请的中国专利申请号为200580042072.1。
本申请要求2004年12月7日递交的美国申请No.60/634,421的优先权。
技术领域
本发明涉及用于通常包装的层压物膜且特别是作为光电模块中的密封剂。本发明特别涉及包含乙烯酸共聚物离聚物的透明包装膜。
背景技术
在通常的包装材料特别是太阳能电池模块中,好的光学性能是重要的,因为,好的性能要求入射到电池上的光被高效且有效地传送到电压发生层。差的光传送减小了光电发生过程的效率和/或生产率。
例如,常规形式的太阳能电池模块的制备是通过互连单独形成的且分开的太阳能电池(如由结晶硅制成),然后机械支撑并保护电池不受环境降解(通过使电池集成进入层压太阳能电池模块)。层压模块通常包括刚性透明保护性前面板或片,和通常被称为“后皮(backskin)”的后面板或片。在前后片间放置从而形成夹层结构(sandwich)设置的是互连的太阳能电池和密封剂。
密封剂(或者至少其在电池的前侧和透明的前面板之间延伸的一部分)的必要要求是,它对于日光辐射而言是透明的。形成层压模块的典型模式是装配夹层结构,依次包括:透明的面板,例如,由玻璃或透明聚合物制成的前面板,至少一片密封剂的前层,由电导体互连的太阳能电池阵列(电池的前侧面向透明面板),至少一片密封剂的后层,和后皮或后面板,然后,将这些组件用真空型层合机在加热加压下粘合在一起。密封剂的后层可能是透明的或是任何一种其它的颜色,现有技术的模块通过使用由热塑性或热固性聚合物、玻璃或一些其它材料组成的后皮而形成。
密封剂更进一步的要求是其尺寸稳定性。为了避免硅电池上的潜在破坏性应力,密封剂及周围结构对模块最终使用位置处温度的波动应该是稳定的。
大量的材料已被应用,或考虑作为由单个的硅太阳能电池制成的模块中的密封剂使用。乙烯醋酸乙烯酯共聚物(通常称为“EVA”)通常被用作含有结晶硅太阳能电池的模块的密封剂。然而,EVA可能有某些限制和不足,如其褪色趋势。它也可能分解并释放出醋酸。EVA也可能要求交联——例如US6093757中所描述的——以赋予尺寸稳定性。交联是产品中变异性的潜在源泉,可能促进EVA随后的氧化和降解。另外,由于作为EVA中交联助催化剂的过氧化物的存在,EVA在制作模块时必须在真空中层压。作为密封剂材料使用的EVA通常包括33%(重量)的醋酸乙烯酯,因而是非常软和发粘的材料,从而使得在制造环境中处理EVA多少有些麻烦。
US5478402中描述了作为密封剂的离聚物的使用,由此本文将其全文引入作为参考。US5741370也公开了作为密封剂的离聚物的使用。术语“离聚物”和由此标明的树脂类型是本领域已知的,可由Richard W.Rees,“Ionic Bonding InThermoplastic Resins”,DuPont Innovation,1971,2(2),pp.1-4,和RichardW.Rees,“Physical Properties And Structural Features Of IonomerResins”,Polyelectrolytes,1976,C,177-197得到证明。离聚物可通过乙烯-甲基丙烯酸共聚物或乙烯-丙烯酸共聚物与含有选自周期表第I、II或III族的元素,特别是钠、锌、铝、锂、镁和钡,的阳离子的有机碱的部分中和而形成。离聚物已被标明为乙烯和甲基丙烯酸或烯酸的共聚物,其通常具有83-95℃范围内的熔点。
可能理想的是:提供用作光电池中的密封剂材料的材料,其中,对于密封剂材料可接受的尺寸稳定性而言,交联不是必需的。
发明内容
发明概述
本发明人惊奇地发现,当聚合物被夹入作为离聚物层之间的层压物中的核心层时,该聚合物的一个或多个物理性质能被显著地改进。
一方面,本发明是一种层压物,该层压物包括:至少三个聚合物层,其包括
(1)两个离子交联聚合物的外聚合物层,和
(2)至少一个核心层单元;
其中,每个外层与核心层单元的至少一个表面的相对表面直接接触,其中,该至少一个核心层单元是单一的或多层的聚合物膜或片,其包括至少一个非离子交联聚合物层,且其中,通过透光度测量的层压物的光学透明性,和它的尺寸稳定性均分别相对于单个的层压物层所述性质的期望值得到增强。
另一方面,本发明是一种层压物,包括:
(i)包括第一离聚物的第一外层;
(ii)包括至少一个聚合物层的核心层单元,该核心层单元的位置使得核心层单元的第一表面与第一外层的至少一个表面直接接触;
(iii)包括第二离聚物的第二外层,该第二外层的位置使得核心层单元的第二表面与第二外层的至少一个表面直接接触;
其中,至少一个核心层聚合物是非离子交联聚合物,且其中第一离聚物层、第二离聚物层、核心层单元和层压物中的每一个在相同波长下的单独的光学透光度均可被测量,且其中对于该层压物测量的透光度大于从该三个单独的层在其非层压状态的透光度通过它们在该层压物中的厚度加权而计算得到的透光度期望值。
另一方面,本发明是一种包括密封剂的太阳能电池模块,其包括:
(i)包括第一离聚物的第一外层;
(ii)包括至少一个聚合物层的核心层单元,该核心层单元的位置使得核心层单元的第一表面与第一外层的至少一个表面直接接触;
(iii)包括第二离聚物的第二外层,该第二外层的位置使得核心层单元的第二表面与第二外层的至少一个表面直接接触;
其中,至少一个核心层聚合物是非离子交联聚合物,且其中第一离聚物层、第二离聚物层、核心层单元和层压物中的每一个在相同波长下的单独的光学透光度均可被测量,且其中对于该层压物测量的透光度大于从该三个单独的层在其非层压状态的透光度通过它们在该层压物中的厚度加权而计算得到的透光度期望值。
另一方面,本发明是包括密封剂的多个相互连接的太阳能电池,其包括:
(i)包括第一离聚物的第一外层;
(ii)包括至少一个聚合物层的核心层单元,该核心层单元的位置使得核心层单元的第一表面与第一外层的至少一个表面直接接触;
(iii)包括第二离聚物的第二外层,该第二外层的位置使得核心层单元的第二表面与第二外层的至少一个表面直接接触;
其中,至少一个核心层聚合物是非离子交联聚合物,且其中第一离聚物层、第二离聚物层、核心层单元和层压物中的每一个在相同波长下的单独的光学透光度均可被测量,且其中对于该层压物测量的透光度大于从该三个单独的层在其非层压状态的透光度通过它们在该层压物中的厚度加权而计算得到的透光度期望值。
发明详细描述
在一个具体实施方式中,本发明是一个层压物制品,其包含(a)包含离子交联聚合物的外层和(b)设置在外层之间并包含非离子交联聚合物的核心层单元。在本发明的一个层压物中,测量的层压物光学和/或尺寸稳定性可相对于层压物的单独的各层的所述性质任一或二者的期望值得到增强。
性质的“期望值”,指的是考虑加权平均的层厚度,从层压物单独的层计算出的所述层压物性质的预测值。作为例证,其中每层均具有光学消光系数的三层层压物,将被期望具有对单独的消光系数之和的进行层厚度加权的吸光度。相似地,其中每层均具有拉伸模量的三层层压物,将被期望具有对单独的层进行层厚度加权平均的拉伸模量。
层压物,作为本文使用的术语,包括处于彼此面对面关系的多聚合物层,其中,层之间的粘合使得在施加这些应力(该结构物在所述层压物的正常或预期用途期间所受)期间各层保持粘合到一起。粘合可以通过在材料的制造过程中彼此粘合的不同层中使用聚合物来实现,或者通过使用附加的粘合剂或底漆来实现。
本发明的外层为本发明层压物的结构层,这些结构层的位置使得其与核心层单元在所述核心层单元的至少一个表面上直接接触。本发明层压物的外层为本发明的层压物贡献了好的光学性质。本发明层压物的外层包括离子交联聚合物(离聚物)。每个外层可包括与其它外层的离聚物组成相同的或不同的离聚物组成。在本发明实践中有用的离聚物是通过乙烯和烯属不饱和C3-C8羧酸共聚获得的共聚物。优选地,不饱和羧酸为丙烯酸或甲基丙烯酸。酸共聚物优选包括大约8wt%至大约25wt%的酸,基于共聚物的总重量。在本发明实践中适用作光学层的离聚物优选包括大约11wt%至大约25wt%的酸,更优选大约14wt%至大约19wt%的酸,以及最优选大约15wt%至大约19wt%的酸。
本文适用的离聚物可以包含第三共聚单体组分,其为烯属不饱和C3-C8羧酸的酯。酯的羟基取代基可优选衍生自C1至C12的醇,但是,任何一种能够提供本文所述的光学性质的不饱和酯都能用于本发明的实践过程。包含第三共聚单体的常规离聚物是商业可获得的,例如,来自E.I.du Pont de Nemours and Company,且能适用于本发明的实践过程,只要其光学和物理性质适用于本发明的应用。
本发明的核心层单元是本发明层压物中的结构组分,其与至少一个外层在该至少一个外层的至少一个表面直接接触。本发明的核心层单元向层压物提供的性质是不能由单独的外层提供的。例如,核心层能够提供更高或更低的模量、阻隔性能、强度、吸光度、渗透性,或者在包装或其它制品中其它理想的性能。
核心层单元自身可以是单一的聚合物层、或者层压的聚合物结构、或者多个重叠层的膜和/或片。出于本文的目的,在本发明核心层单元内包含或使用的任何层都被认为是核心层。本文适用的核心层可包括任何提供给层压物理想性质的聚合物。例如,核心层可以是聚氨酯、乙烯醋酸乙烯酯(EVA)、聚氯乙烯(PVC)、聚酯、聚缩醛、乙烯酸共聚物(其可包括乙烯酸三元聚合物或更高级的共聚物)、乙烯丙烯酸酯共聚物(其可包括三元聚合物或更高级的共聚物)、或者其它具有合适的物理性质并能被直接地或通过连接或粘合剂层而层压到离聚物以获得多层膜的聚合物层。本发明的层压物可以包括多于一个的核心层单元。
在另一个具体实施方式中,本发明是包括至少三个膜层的光学透明的多层层压物膜结构。所述光学透明,意思是指,在多层膜结构的至少三层的组合上进行的光学测量,对于光谱可见区内的光是至少85%透明的。光学透明性与多层层压物膜的雾值有关。在本发明的实践中,多层层压物结构的雾值不大于6%。
本发明的光学透明的层压物的构造使得外层接触核心层并与该至少一个核心层的相对表面形成分界面。
尽管本发明的层压物结构传送至少大约85%的入射光,和/或具有小于大约6%的雾值时,但层压物的单独组件并不需要具有满足那些标准的光学性质。特别地,本发明的至少一个核心层不需要具有满足层压物最小光学标准的光学性质。事实上,本发明的一个目的就在于,通过组合核心结构层(一个或多个)和本文描述的本发明外层或光学层,克服核心层组分中相对差的光学性质,从而提供具有可接受光学性能的层压物。
在另一个实施方式中,本发明的光学透明多层层压物包括:(1)至少两个独立具有至少约85%的透明度和/或小于大约6%的雾值的离聚物外层,和(2)至少一个提供其它不能由光学层提供的理想性能的核心层,但当单独且不在具有外层的层压物中测量时,其具有小于约85%的透明度和/或大于约6%的雾值。
外层均可独立地传送至少约85%的入射光。优选的是外层传送至少约88%的入射光,更优选的是至少约89%的入射光。最优选地,外层传送至少约90%的入射光。在一个更优选的实施方式中,外层均可独立地传送至少约91%、92%、93%、94%、95%或更多的入射光。外层的雾值优选小于约5%,更优选小于约4%,最优选小于约3%。在本发明一个特别优选的实施方式中,外层的雾值小于约2%,并可低到1%或更小,光的传送可达到至少98%或甚至99%或更多。
在本发明的实践中,多层膜的外层在化学上与该至少一个核心层不同,且彼此在化学上可以不相同。通过例子举证,离聚物中酸组分的百分比、酸组分的中和水平、在至少两个离聚物中存在的反离子个体(identity)、以及第三共聚单体的存在与否都可在该至少两个离聚物层之间变化。这些情况的每一种,以及其它,可以单独地或组合地变化,以使得外层化学区别于核心层和/或彼此区别。优选地,为了成本及减少复杂性的原因,外层彼此之间是相同的。
在本发明的一个优选实施方式中,本发明的层压物具有转变温度,通过DMA(在下面的实施例中描述)在1Hz测量为65℃或更高。更优选地,材料的转变温度大于约65℃,单独的核心层的转变温度在1Hz为40℃或更小。
本发明的透明多层膜可适用于作为中间层在层压玻璃窗系统中使用,如车辆挡风玻璃或侧挡玻璃(sidelite);作为建筑物的安全玻璃;橱柜玻璃;门上的玻璃窗;搁板;在其它传统应用中的层压玻璃窗。
本发明的多层膜令人惊奇地显示出与单独的核心层相比优越的光学性能,外层给多层膜提供其它的物理性能。这个结果是令人惊奇的,因为光学层能提供理想的光学性能,而不管核心层(一个或多个)的光学性质的不足。
本发明的多层层压物具有40.0密耳或更小的总厚度。优选地,层压物具有20.0或更小的总厚度。更优选地,层压物可具有10.0密耳或更小的总厚度,甚至更优选地,具有4.0密耳或更小的厚度。更优选地,层压物可具有约3.0密耳或更小,或2.0密耳或更小的总厚度。多层膜需要的厚度可以是获得例如保护包装内含物所需的结构性能与获得其它的目的如满足透明度光学需求、使用成本有效的材料、和/或最小化生产成本之间的平衡。
本发明的外层可薄于本发明的核心层,但这并不是本发明所有应用中的必要条件。外层(一个或多个)的厚度均可独立地为外层厚度的约50%或更小。本发明层压物的外层均可独立地具有20.0密耳或更小的厚度,优选15密耳或更小,更优选10密耳或更小,条件是任何膜厚度可被改变以平衡理想的光学和其它物理性质,具有生产成本有效膜的实际方面。
本发明的多层层压物膜在各种应用中是有用的并且可适合与玻璃、清洁塑料结合使用,以制作光学上清澈或透明的层压物制品,诸如太阳能电池模块、或层压窗、或其它安全玻璃、或塑料瓶、或可挤压瓶。
在另一个实施方式中,本发明是光电池,其中,光敏硅器件被设置对着包含多层层压物层的离聚物之一(“第一层”),其中,外层包含离聚物且内部、核心层包括非离子交联聚合物。硅器件的光敏部分面对三层层压物。硅器件的另一表面被设置对着第二层,所述第二层可以包括第二个三层层压物,或任何能够对第一层形成密封的聚合物。第二层也可以包括后板层,后板层可与第二层一起被层压或与之分离。
在一个优选的实施方式中,本发明是包括至少一个太阳能电池的太阳能电池模块,其依次包括邻近太阳能电池的至少一个表面放置的透明密封剂材料。密封剂材料包括层压物材料,该层压物材料进一步包括:
(i)包括第一离聚物的第一外层;
(ii)包括至少一个聚合物层的核心层单元,其位置使得核心层单元的第一表面与第一外层的至少一个表面直接接触;
(iii)包括第二离聚物的第二外层,其位置使得核心层单元的第二表面与第二外层的至少一个表面直接接触;
其中,该至少一个核心层聚合物是非离子交联聚合物,并且其中第一离聚物层、第二离聚物层、核心层单元和层压物中的每一个在相同波长下的单独的光学透光度均可被测量,且其中对于该层压物测量的透光度大于从该三个单独的层在其非层压状态的透光度通过它们在该层压物中的厚度加权而计算得到的透光度期望值。
本发明的模块进一步包括邻近密封剂材料前表面放置的由透光材料形成的前支撑层,和邻近密封剂材料后表面放置的后皮层。
太阳能电池模块可进一步包括至少一个依次包括很多互连的太阳能电池的太阳能电池。
在另一个实施方式中,本发明是层压物,其包括依次包含离聚物的外层,和设置于外层之间并包含非离子交联聚合物的核心层,使得层压物的相转变温度相对于仅单独的层压物层的期望值得到加强。对于层压结构而言,在动态机械分析下具有的DMA相转变温度高于用于制备核心材料的材料的相转变温度是可能的。强化的相转变温度产生一种在环境温度下尺寸稳定的物质。任选地,该实施方式的层压物具有光学透光性,然而本发明的实施方式并不限制于透明层压物。
具体实施方式
实施例和比较例仅为说明目的进行介绍,不意味着以任何方式限制本发明的范围。
在以下实施方式中,流延膜在Sano多层挤塑线上被制造。460微米厚度结构的整体结构包括相同的25微米厚的(Du Pont,Wilmington,DE)外层,其限制包含第二树脂的410微米厚的核心层。
在膜样品上测量正割模量(使用ASTM D 882-01的Instru-Met负荷框1122张力检查器)。
在膜样品上测量雾值%(使用ASTM D 1003 00的BYK Gardner haze-gardplus)。
在膜样品上测量透光度%(Varian Cary 5uv/vis/nir,System I.D.Cary5-1081139,从800nm到200nm扫描,在500nm报告)。透光度的期望值被计算为从每层包括的材料的每单位厚度的吸光度计算的层厚度加权值。
为了确定样品的尺寸稳定性,进行了动态机械分析(DMA)。试验在Seiko DMS210上以拉伸模式运行,以1℃/分钟的加热速率从环境温度加热到150℃,频率1Hz,振幅10μm。“DMA转变”指的是在试样长度梯度对温度的绘图剧烈改变方向之处的温度,显示样品的收缩或膨胀,也就是在给定的温度下缺乏尺寸稳定性(尺寸不稳定)。
在以下的实施例中,是乙烯-丙烯酸甲酯共聚物,具有30%的MA和3熔融指数(MI)。是乙烯-丙烯酸甲酯共聚物,具有35%的MA和3MI。是乙烯-丙烯酸丁酯共聚物,具有27%的BA和4MI。是5.5MI,锌中和的乙烯-甲基丙烯酸共聚物,而是4MI,锌中和的乙烯-甲基丙烯酸-丙烯酸-丙烯酸异丁酯的三元聚合物。
DMA数据
对照试样
膜组成 | 观测的DMA转变(℃) |
S1705 | 82 |
S1857 | NM |
E1335 | 33 |
E1330 | 35 |
E3427 | 38 |
NM=未测
层压物样品
膜组成 | 观测的转变 |
S1705/E1330/S1705 | 78 |
S1705/E1335/S1705 | 75 |
S1705/E3427/S1705 | 74 |
在1Hz从0℃到150℃的DMA数据显示在EMA核心(16-密耳)外有薄层压物(1-密耳),在从环境温度升到70多摄氏度,提供了多层结构的尺寸稳定性,结果几乎相当于单一层
光学和拉伸数据
对照试样
膜组成 | 观测的透光度(%) | 观测的MD正割模量(psi) | TD模量(psi) |
S1705 | 90.5 | 29459 | 26930 |
S1857 | 89.4 | NM | NM |
E1335 | 37.3 | 992 | 744 |
E1330 | 34.1 | 1727 | 1458 |
E3427 | 75.7 | 3310 | 3310 |
层压物样品
膜组成 | 期望透光度(%) | 观测的透光度(%) |
S1705/S1875/S1705 | 89.4 | 89.7 |
S1705/E1330/S1705 | 38.0 | 88.1 |
S1705/E1335/S1705 | 41.2 | 85.1 |
S1705/E3427/S1705 | 77.2 | 88.1 |
拉伸数据(正割模量)
三层结构的透明性比单层膜得到改善,然而保留了EMA低模量的优点,而通过DMA转变测量的三层结构的尺寸稳定性也比单层膜显著改善。避免了交联核心层的需要。
本发明用某些实施方式和实施例进行了描述,然而,本领域技术人员能用明显的修改方式改进本发明。本发明用权利要求的范围意图包括所有的这些改进,而不限制于本文描述的实施例和具体实施方式。
Claims (20)
1.一种层压物制品,包括:
(i)包括第一离聚物的第一外层;
(ii)包括至少一个聚合物层的核心层,且其位置使得核心层的第一表面与第一外层的至少一个表面直接接触;
(iii)包括第二离聚物的第二外层,且其位置使得核心层的第二表面与第二外层的至少一个表面直接接触;
其中,所述至少一个核心层聚合物是非离子交联聚合物,且
其中第一离聚物层、第二离聚物层、核心层和层压物中的每一个在相同波长下的单独的光学透光度均可被测量,且其中对于该层压物测量的透光度大于从该三个单独的层在其非层压状态的透光度通过它们在该层压物中的厚度加权而计算得到的透光度期望值;或
其中所述层压物、第一离聚物和第二离聚物和核心层聚合物的特征在于它们在拉伸条件下在1Hz通过DMA测量的转变温度,使得层压物的转变温度值高于核心层聚合物在相同的条件下非层压状态中时测量的转变温度值。
2.权利要求1的层压物制品,其中,第一外层和第二外层包括相同的组成。
3.权利要求1的层压物制品,其在500nm波长的光的光学透光度大于85%。
4.权利要求1的层压物制品,其显示了在1Hz的DMA转变温度大于65℃。
5.权利要求4的层压物制品,其中,核心层聚合物显示了当没有层压到外层时在1Hz的DMA转变温度低于40℃。
6.权利要求1的层压物制品,其中,核心层是层压物。
7.权利要求1的层压物制品,其中核心层聚合物包括选自以下的聚合物:聚氨酯;乙烯醋酸乙烯酯(EVA);聚氯乙烯(PVC);聚酯;聚缩醛;乙烯酸共聚物、乙烯丙烯酸酯共聚物及其掺混物、层压物或组合。
8.权利要求1的层压物制品,其中,第一离聚物和第二离聚物独立地包括由乙烯和烯属不饱和C3-C8羧酸共聚获得的共聚物。
9.权利要求1的层压物制品,其中,第一离聚物和第二离聚物独立地包括酸共聚物,所述酸共聚物包括大约8wt%至大约25wt%的酸,基于酸共聚物的总重量。
10.权利要求9的层压物制品,其中,第一离聚物和第二离聚物独立地包括酸共聚物,所述酸共聚物包括大约11wt%至大约25wt%的酸,基于酸共聚物的总重量。
11.权利要求10的层压物制品,其中,第一离聚物和第二离聚物独立地包括酸共聚物,所述酸共聚物包括大约14wt%至大约19wt%的酸,基于酸共聚物的总重量。
12.权利要求11的层压物制品,其中,第一和第二离聚物独立地包括酸共聚物,所述酸共聚物包括大约15wt%至大约19wt%的酸,基于酸共聚物的总重量。
13.一种光学透明的层压物膜,包括:至少三层膜,其中,(a)所述至少三层膜中的至少两层包括离聚物膜,(b)处于非层压状态的、所述至少三层膜中的至少一层独立地(i)传送少于约85%的入射可见光,或(ii)具有等于或大于约6%的雾值,其在具有约40密耳或更小的厚度的该至少一层上根据ASTM D1003-00测得, 以及(c)所述透明层压物(i)传送至少约85%的入射可见光或(ii)具有根据ASTM D1003-00测量的等于或小于约6%的雾值。
14.一种制品,该制品包括权利要求13所述的光学透明的层压物膜。
15.权利要求14的制品,其中,所述制品是包装或容器。
16.权利要求15的制品,其中,所述制品包括层压到离聚物膜至少之一的一个或多个玻璃层。
17.权利要求1的层压物制品,其中,第一离聚物或第二离聚物独立地包括由乙烯;烯属不饱和C3-C8羧酸;和第二烯属不饱和C3-C8羧酸的烷基酯共聚获得的共聚物。
18.权利要求1的层压物制品,其为通过挤塑制造。
19.权利要求1的层压物制品,其还包括层压到第一外层或第二外层至少之一的一个或多个玻璃层。
20.层压玻璃窗系统,其包括权利要求19的层压物制品,且选自:车辆挡风玻璃或侧挡玻璃;层压窗;建筑物的其它安全玻璃;橱柜玻璃;门上的玻璃窗;搁板;其它层压玻璃窗。
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Also Published As
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EP1824680A2 (en) | 2007-08-29 |
EP1824680B1 (en) | 2019-07-03 |
JP5036551B2 (ja) | 2012-09-26 |
US20090145475A1 (en) | 2009-06-11 |
US8835750B2 (en) | 2014-09-16 |
CN101072677A (zh) | 2007-11-14 |
US8080728B2 (en) | 2011-12-20 |
US20060165929A1 (en) | 2006-07-27 |
WO2006063223A3 (en) | 2007-01-11 |
USRE45163E1 (en) | 2014-09-30 |
WO2006063223A2 (en) | 2006-06-15 |
US20120067420A1 (en) | 2012-03-22 |
CN105216387A (zh) | 2016-01-06 |
JP2008522877A (ja) | 2008-07-03 |
US20140349048A1 (en) | 2014-11-27 |
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