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WO2011109646A1 - Composition adhésive thermofusible thermiquement résistante, ses procédés d'utilisation et ensemble panneau solaire la comprenant - Google Patents

Composition adhésive thermofusible thermiquement résistante, ses procédés d'utilisation et ensemble panneau solaire la comprenant Download PDF

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Publication number
WO2011109646A1
WO2011109646A1 PCT/US2011/027068 US2011027068W WO2011109646A1 WO 2011109646 A1 WO2011109646 A1 WO 2011109646A1 US 2011027068 W US2011027068 W US 2011027068W WO 2011109646 A1 WO2011109646 A1 WO 2011109646A1
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WO
WIPO (PCT)
Prior art keywords
solar panel
adhesive composition
thermoplastic
component
adhesive
Prior art date
Application number
PCT/US2011/027068
Other languages
English (en)
Inventor
Heidi Hoglund
Kevin Reid
Sharf U. Ahmed
Original Assignee
H.B. Fuller Company
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 H.B. Fuller Company filed Critical H.B. Fuller Company
Publication of WO2011109646A1 publication Critical patent/WO2011109646A1/fr

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Classifications

    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
    • C09J177/00—Adhesives based on polyamides obtained by reactions forming a carboxylic amide link in the main chain; Adhesives based on derivatives of such polymers
    • 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
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
    • C08G2170/00—Compositions for adhesives
    • C08G2170/20—Compositions for hot melt adhesives
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K5/00—Use of organic ingredients
    • C08K5/54—Silicon-containing compounds
    • C08K5/544—Silicon-containing compounds containing nitrogen
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L23/00—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers
    • C08L23/02—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers not modified by chemical after-treatment
    • C08L23/04—Homopolymers or copolymers of ethene
    • C08L23/08—Copolymers of ethene
    • C08L23/0846—Copolymers of ethene with unsaturated hydrocarbons containing atoms other than carbon or hydrogen
    • C08L23/0853—Ethene vinyl acetate copolymers
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L2666/00—Composition of polymers characterized by a further compound in the blend, being organic macromolecular compounds, natural resins, waxes or and bituminous materials, non-macromolecular organic substances, inorganic substances or characterized by their function in the composition
    • C08L2666/02—Organic macromolecular compounds, natural resins, waxes or and bituminous materials
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E10/00—Energy generation through renewable energy sources
    • Y02E10/50—Photovoltaic [PV] energy

Definitions

  • the invention is directed to maintaining adhesion between two substrates under challenging environmental conditions.
  • Solar panels and solar panel fields have unique requirements in that they must maintain their integrity under conditions of high humidity, because they are often positioned out doors and exposed to rain, freezing rain, and snow, and under conditions of widely varying temperature extremes because they are often positioned in hot deserts, on hot asphalt rooftops, and in climates that experience extremely high temperatures, extremely low temperatures, and strong winds.
  • any mechanism used to secure and maintain solar panels in a fixed position must function under a difficult set of environmental conditions.
  • the invention features a hot melt adhesive composition that includes a thermoplastic component having a softening point of at least 120°C and selected from the group consisting of thermoplastic elastomers, thermoplastic polymers, and combinations thereof; a silane adhesion promoter having a flash point greater than 100°C at atmospheric pressure and a boiling point greater than 100°C at from 0.5 mmHg (millimeters of mercury) to 15 mmHg; optionally, a thermoplastic tackifying agent having a softening point greater than 80°C; and optionally a thermoplastic component having a softening point of lower than 120°C and selected from the group consisting of thermoplastic elastomers, thermoplastic polymers, and combinations thereof.
  • the adhesive composition includes from about 5 % by weight to about 35 % by weight of the thermoplastic tackifying agent.
  • the adhesive composition exhibits an initial lap shear of at least 1 psi at 23 °C.
  • the adhesive composition further includes a spacer in a form of spheres, cylinders, tubes, strips, ropes, or any other suitable forms.
  • the invention features a solar panel assembly that includes a solar panel, a support, and a hot melt adhesive composition disclosed herein, the support being bonded to the solar panel through the adhesive composition.
  • the solar panel includes a substrate that includes glass, and a superstrate, the adhesive composition being in contact with the glass of the substrate.
  • the solar panel includes a substrate that includes polymer, and the adhesive composition is in contact with the polymer of the substrate.
  • the support is metal.
  • the support remains bonded to the substrate of the solar panel through the adhesive composition after undergoing the at least one of the Simulated Aging Tests set forth in UL 1703 and the tests set forth in IEC 6646.
  • the invention features a method of adhering a component of a solar panel assembly to a solar panel, the method including contacting at least one of a first component and a second component with an adhesive composition disclosed herein, the first component including a component of the solar panel assembly other than the solar panel, and the second component including the solar panel, and allowing the adhesive composition to bond the first component to the second component.
  • the first component includes at least one of a back rail, a frame and a junction box
  • the second component includes a substrate of the solar panel, the substrate including at least one of polymer and glass.
  • the first component includes a metal back rail and the second component includes a substrate of the solar panel, the substrate including at least one of polymer and glass.
  • the adhesive composition exhibits good green strength, an ability to be handled shortly after application (e.g., an assembly that includes the adhesive composition can be handled shortly after application of the adhesive composition thereto), and, when full adhesion is achieved, good durability in a wide range of environmental conditions.
  • the adhesive composition can also be applied using an automated process.
  • FIG. 1 is a plane view a back rail of a solar panel assembly bonded to a substrate of a solar panel through an adhesive composition disclosed herein.
  • FIG. 2 is a plane view of a junction box of a solar panel assembly bonded to a substrate of a solar panel through an adhesive composition disclosed herein.
  • FIG. 3 is a plane view of an end bracket of a solar panel assembly bonded to a solar panel through an adhesive composition disclosed herein.
  • FIG. 4 is a perspective view of a framed solar panel assembly.
  • FIG. 5 is view taken in cross section along line A-A of the framed solar panel assembly of FIG. 4.
  • FIG. 6 is a perspective view of a solar panel.
  • FIG. 7 is an enlarged view of a portion of a framed solar panel assembly with an adhesive/sealant composition configured according to another embodiment.
  • the hot melt adhesive composition includes a thermoplastic component having a softening point of at least 120°C, and a silane adhesion promoter having a flash point greater than 100°C at atmospheric pressure and a boiling point greater than 100°C at from 0.5 mmHg to 15 mmHg.
  • the adhesive composition exhibits a tensile strength of at least 20 psi at 23 °C, or even at least 70 psi at 23 °C, and at least 20 psi at 85°C, or even at least 70 psi at 85°C.
  • the adhesive composition preferably exhibits an initial lap shear strength (i.e., green strength) of at least 1 psi, at least 2 psi, or even at least 4 psi at 23°C, and a final lap shear of at least 1 psi, at least 2 psi, or even at least 4 psi at 85°C.
  • the adhesive composition also exhibits cold temperature flexibility.
  • the adhesive composition is creep resistant and preferably passes the creep resistance test method at 85°C, or even at a higher temperature than 85°C.
  • Solar panel assemblies that include the adhesive composition preferably pass the Simulated Aging Tests set forth in UL 1703, or even the tests of IEC 6646.
  • the adhesive composition preferably maintains a support bonded to a solar panel after undergoing the Simulated Aging Tests set forth in UL 1703, or even the tests of IEC 6646.
  • the thermoplastic component having a softening point of at least 120°C includes a thermoplastic elastomer that has a softening point of at least 120°C, a thermoplastic polymer that has a softening point of at least 120°C, or a combination thereof.
  • the thermoplastic component having a softening point of at least 320°C is present in the adhesive composition in an amount of from about 10 % by weight, or from about 20% by weight, or from about 40% by weight to about 75 % by weight, or to about 70 % by weight, or to about 60 % by weight, based on the weight of the composition.
  • Suitable thermoplastic elastomers having a softening point of at least 120°C include, e.g., polyetheramide block copolymers, polyesters, butadiene-styrene elastomers including, e.g., A-B, A-B-A, A-(B-A)n-B, (A-B)n-Y, and radial block copolymers and grafted versions thereof where the A block(s) is a polyvinyl aromatic block (e.g., styrene), and the B block is a rubbery midblock (e.g., isoprene, butadiene, ethyl ene-butylene, and ethylene-propylene) (e.g., styrene-butadiene-styrene block copolymers, styrene-isoprene-styrene block copolymers, styrene-ethylene-butylene-
  • thermoplastic elastomers having a softening point of at least 120°C include, e.g., thermoplastic elastomers available under the HYTREL 3078, HYTR.EL 4053 and HYTREL 4056 trade designations from E.I.
  • DuPont de Nemours (Worthington, Delaware), styrene-ethylene/butylene-styrene block copolymers available under the KRATON G series of trade designations including, e.g., KRATON G-1652 and G- 1657, from Kraton Polymers (Houston, Texas); styrene-butadiene-styrene and styrene- isoprene-styrene block copolymers available under the KRATON D series of trade designations including, e.g., KRATON D-l 1 11 and D-l 112 from Kraton Polymers; silane tenninated block copolymers available under the KRATON SKFGI OI trade designation from Kraton Polymers; and styrene-butadiene-styrene and styrene-isoprene-styrene block copolymers available under the VECTOR series of trade designations including,
  • thermoplastic elastomer having a softening point of at least 120°C can be present in the adhesive composition in an amount of 0 % by weight, or from about 10 % by weight, or from about 20% by weight to about 75 % by weight, or to about 60% by weight, or to about 40 % by weight, based on the weight of the composition.
  • thermoplastic polymers having a softening point of at least 120°C can be selected from a variety of classes of thermoplastic polymers including, e.g., polyalkylenes (e.g., polyethylene, polypropylene and polybutylene), poly(alpha)olefms including, e.g., homo-, co- and terpolymers of aliphatic mono- 1 -olefins (alpha olefins) (e.g., poly(aIpha)olefms containing from 2 to 10 carbon atoms), homogeneous linear or substantially linear
  • polyalkylenes e.g., polyethylene, polypropylene and polybutylene
  • poly(alpha)olefms including, e.g., homo-, co- and terpolymers of aliphatic mono- 1 -olefins (alpha olefins) (e.g., poly(aIpha)olefms containing from
  • interpolymers of ethylene having at least one C 3 to C?o alphaolefm polyisobutylenes, poly(alkylene oxides), poly(phenylenediamine terephthalamide), polyesters (e.g.,
  • polyethylene terephthalate polyacrylates, polymethacrylates, polyacrylamides,
  • polyacrylonitriles copolymers of acrylonitrile and monomers including, e.g., butadiene, styrene, polymethyl pentene, and polyphenylene sulfide (e.g., styrene-acrylonitrile, acrylonitrile-butadiene-styrene, acrylonitrile-styrene-butadiene rubbers), polyimides, polyamides, copolymers of vinyl alcohol and ethylenically unsaturated monomers, polyvinyl acetate (e.g..).
  • acrylonitriles copolymers of acrylonitrile and monomers including, e.g., butadiene, styrene, polymethyl pentene, and polyphenylene sulfide (e.g., styrene-acrylonitrile, acrylonitrile-butadiene-styrene, acrylonitrile-styren
  • thermoplastic polymers include asphalts, bitumens, crude rubbers, fluorinated rubbers, and cellulosic resins.
  • thermoplastic polymers having a softening point of at least 120°C include, e.g., amoiphous polyalphaolefins available from Evonik under the trade designations VESTOPLAST 308, VESTOPLAST 608, and VESTOPLAST 703, atactic polypropylene polymers available under the REXTAC series of trade designations including, e.g., REXTAC RT 2535 and RT 2585, from REXtac LLC (Odessa, Texas) and the
  • EASTOFLEX series of trade designations including, e.g., EASTOFLEX El 060, from
  • thermoplastic polymer having a softening point of at least 120°C is preferably present in the adhesive composition in an amount of 0 % by weight, or from about 10 % by weight, or from about 20 % by weight to about 75% by weight, or to about 60 % by weight, or to about 40 % by weight, based on the weight of the composition.
  • the adhesive composition also includes a silane adhesion promoter that has a flash point greater than 100°C at atmospheric pressure and a boiling point greater than 100°C at from 0.5 mmHg to 15 mmHg.
  • Silane adhesion promoters are compounds or monomers that have an average molecular weight of from about 300 to about 1000, or from about 300 to about 800, or from about 500 to about 700.
  • Useful silane adhesion promoters include silyl groups such as alkoxysilyls, acryloxysilyls, alkyloxyiminosilyls, oxime silyls, amino silyls. and combinations thereof.
  • alkoxysilyl groups include methoxysilyl, efhoxysilyl, propoxysilyl, butoxysilyl, and acyloxysilyl reactive groups including, e.g., silyl ester of various acids including, e.g., acetic acid, 2-ethylhexanoic acid, palmitic acid, stearic acid, and oleic acid.
  • Suitable silane adhesion promoters include, e.g., methacryloxy propyl triethoxy-silane, M-aminophenyltriethoxy-silane, P-aminophenyltriethoxy-silane, N-(2-aminoethyl)-3- aminopropyl triethoxy-silane, n-butylaminopropyltrimethoxy-silane,
  • Suitable silane adhesion promoters are commercially available under the SILQUEST
  • the silane adhesion promoter is preferably present in the composition in an amount of from about 0.01 % by weight to about 5 % by weight, from about 0.01 % by weight to about 2
  • the adhesive composition may also include other optional ingredients e.g., a thennoplastic component having a soften point of less than 120°C, a thennoplastic tackifying agent having a ring and ball softening point of at least 80°C. and combinations thereof.
  • a thennoplastic component having a soften point of less than 120°C
  • a thennoplastic tackifying agent having a ring and ball softening point of at least 80°C. and combinations thereof.
  • Useful thermoplastic components having a soften point of less than 120°C include such as thennoplastic elastomers having a soften point of less than 120°C, thennoplastic polymers having a soften point of less than 120°C, and combinations thereof.
  • Examples of useful thennoplastic components include all the classes of the thennoplastic components listed above.
  • thermoplastic elastomers having a soften point of less than 120°C include e.g., polyisobutylene, butyl rubber, ethylene/propylene/diene rubber (i.e., EPDM rubber), and combinations thereof.
  • thermoplastic elastomers having a soften point of less than 120°C include e.g., polyisobutylenes available under the OPPANOL series of trade designations including B50, B80, B100, B 150, B200, B246, B12 and B15 trade designation from BASF (Germany); polyisobutylenes available under the VISTANEX series of trade designations from ExxonMobil including ViSTANEX LMMS, MML-80, MML-100, MML-120, and MML 140; isobutylene-isoprene copolymers available the BUTYL Rubber series of trade designations including BUTYL 268 and BUTYL 065 from ExxonMobil Chemical Co. (Houston, Texas); ethylene-propylene copolymers available under the VISTALON series of trade designations including, e.g., VISTALON 404, from ExxonMobil Chemical Co.
  • thermoplastic polymers having a soften point of less than 120°C include e.g., ethylene vinyl acetate copolymers available under the ATEVA series of trade designations from AT Plastics ( Brampton, Ontario, Canada) including ATEVA 403 OMC and ATEVA 1850, the ELVAX series of trade designations from DuPont de Nemours (Wilmington, Delaware) and the ULTRATHENE series of trade designations from Millennium Petrochemicals (Rolling Meadows, Illinois); ethylene n-butyl acrylate copolymers available under the LOTRYL series of trade designations from Elf Atochem North America (Philadelphia, Pennsylvania), the ESCORENE series of trade designations from ExxonMobil Chemical Co. and the ENATHENE series of trade
  • thermoplastic polyurethane polymers available under the PEARLSTICK series of trade designations from Aries Technologies (Deny, New Hampshire a distributor for Merquinsa, Barcelona, Spain); ethylene acrylate copolymers also available under the ELVALOY series of trade designations from DuPont; and acrylic polymers available under the ELVACITE series of trade designations from 1CI Acrylics (St.
  • useful commercially available homogeneous linear or substantially linear interpolymers of ethylene having at least one C 3 to C 2 o alphaolefm and a polydispersity less than about 2.5 include, e.g., EXACT 5008 ethylene- butene copolymer, EXXPOL SLP-0394 ethylene-propylene copolymer, and EXACT 3031 an ethylene-hexene copolymer from ExxonMobil Chemical Co. (Houston, Texas) and ethylene/1 -octene polymers available under the trade designation AFFINITY from Dow Chemical Co. (Midland, Michigan).
  • thermoplastic component having a softening point of less than 120°C is preferably present in the adhesive composition in an amount of from 0 % by weight, to about 20 % by weight, based on the total weight of the composition.
  • thermoplastic tackifying agents have a ring and ball softening point of at least 80°C, or even from about 85°C to about 150°C.
  • suitable tackifying agents include aliphatic, cycloaliphatic, aromatic, aliphatic-aromatic, aromatic modified alicyclic, and alicyclic hydrocarbon resins and modified versions and hydrogenated derivatives thereof; terpenes (polyterpenes), styrenated terpenes, modified teipenes (e.g., phenolic modified terpen e resins), hydrogenated derivatives thereof, and combinations thereof; alpha methyl styrene resins and hydrogenated derivatives thereof; and combinations thereof.
  • Other useful tackifying agents are disclosed in, e.g., U.S. Patent No. 6,355,317, and incorporated herein.
  • tackifying agents include natural and modified rosins such as gum rosin, wood rosin, tall oil rosin, distilled rosin, completely or partially hydrogenated rosin, dimerized rosin and polymerized rosin; rosin esters including, e.g., glycerol and pentaerythritol esters of natural and modified rosins, (e.g., glycerol esters of pale, wood rosin, glycerol esters of hydrogenated rosin, glycerol esters of polymerized rosin, pentaerythritol esters of
  • Suitable commercially available tackifying agents include, e.g., cycloaliphatic hydrocarbon resins and aromatic-modified, cycloaliphatic hydrocarbon resins available under the ESCOREZ 5637 and ESCOREZ 5340 trade designations from Exxon Mobile Chemical Company; partially hydrogenated cycloaliphatic petroleum hydrocarbon resins available under the EASTOTAC series of trade designations (e.g., EASTOTAC H-l 30 and H-142) from Eastman Chemical Co. (Kingsport, Tennessee) available in grades E, R, L and W, which have differing levels of hydrogenation from least hydrogenated (E) to most hydrogenated (W), the ESCOREZ series of trade designations including, e.g., ESCOREZ 5320 and
  • HERCOLITE 2100 trade designation from Eastman Chemical Co. partially hydro genated aromatic modified petroleum hydrocarbon resins available under the ESCOREZ 5600 trade designation from Exxon Chemical Co.; aromatic hydrogenated hydrocarbon resins available under the trade designation REGALREZ 1 126, and alphamethyl styrene resins available under the trade designation KRISTALEX 5140 from Eastman Chemical Co. (Kingsport, Tennessee).
  • the tackifying agent is preferably present in the composition in an amount of from about 0 % by weight, or from about 5 % by weight to about 15 % by weight, or to about 20 % by weight, or to about 35 % by weight, based on the weight of the composition.
  • the adhesive composition may also include other additives including, e.g., fillers, waxes, plasticizers, thermal stabilizers, light stabilizers (e.g., UV light stabilizers and absorbers), optical brighteners, antistats, lubricants, antioxidants, catalysts, rheology modifiers, biocides, coiTosion inhibitors, dehydrators, organic solvents, colorants (e.g., pigments and dyes), surfactants antiblocking agents, nucleating agents, flame retardants and combinations thereof.
  • additives including, e.g., fillers, waxes, plasticizers, thermal stabilizers, light stabilizers (e.g., UV light stabilizers and absorbers), optical brighteners
  • Suitable fillers include, e.g., fumed silica, precipitated silica, talc, calcium carbonates, carbon black, apatinasilicates, clay, zeolites, ceramics, mica, titanium dioxide, and combinations thereof.
  • the composition can include filler in an amount of from 0 % by weight to about 40 % by weight, from about 10 % by weight to about 35 % by weight, or even from about 20 % by weight to about 30 % by weight, based on the weight of the composition.
  • the plasticizer preferably has a boiling point of greater than about 85°C.
  • Preferred plasticizers include paraffmic oils, naphthenic oils, low molecular weight poly-l-butene, low molecular weight polyisobutene, and combinations thereof.
  • Plasticizer can be present in the composition in an amount of from 0 % by weight to about 10 % by weight, based on the weight of the composition.
  • the adhesive composition is useful for bonding a variety of substrates to each other including substrates made from, e.g., glass, polymer (e.g., polymer composites), metal (e.g., stainless steel, aluminum (e.g., anodized aluminum), galvanized steel and cold-rolled steel), and combinations thereof, treated and coated substrates (e.g., substrates treated for corrosion resistance, aluminum and zinc coated substrates, and combinations thereof), painted substrates and combinations thereof.
  • substrates made from, e.g., glass, polymer (e.g., polymer composites), metal (e.g., stainless steel, aluminum (e.g., anodized aluminum), galvanized steel and cold-rolled steel), and combinations thereof, treated and coated substrates (e.g., substrates treated for corrosion resistance, aluminum and zinc coated substrates, and combinations thereof), painted substrates and combinations thereof.
  • substrates made from, e.g., glass, polymer (e.g., polymer composites), metal (e.g., stainless
  • the adhesive composition is useful for bonding the various components of a solar panel assembly to each other including such components as, e.g., solar panel frames (e.g., C- shaped channels), junction boxes (e.g., polymeric junction boxes), back rails for supporting solar panels (e.g., metal back rails), , brackets (e.g., end brackets), solar panels, components of solar panels (e.g., superstrate, substrate and edges), components used in mounting the solar panels, components used in supporting the solar panels, and combinations thereof.
  • Useful solar panel superstrates include a layer of an ultra violet light transparent material (e.g., glass), and useful solar panel substrates include a layer of polymer, polymer composite, and combinations thereof.
  • the aforesaid adhesive composition is particularly used for sealing and mounting frames on a solar panel to form a framed solar panel assembly.
  • Solar panels are often surrounded by a frame and adhered to the frame with a structural adhesive. It is often necessary to include both a structural adhesive and a moisture vapor barrier to achieve a framed solar panel that will maintain its integrity under the rigorous conditions to which it is often exposed including, e.g., high humidity, widely varying temperature extremes, and strong winds.
  • the aforesaid adhesive composition can function as both an adhesive and a moisture vapor barrier, therefore, is referred to as an adhesive/sealant composition.
  • the adhesive/sealant composition exhibits a moisture vapor transmission rate (MVTR) of no greater than 2 g/m /day.
  • the adhesive/sealant composition exhibits a MVTR of no greater than 1 g/m 2 /day.
  • the adhesive/sealant composition exhibits a MVTR of no greater than 0.2 g/m 2 /day.
  • the invention provides a framed solar panel assembly.
  • the solar panel assembly includes a solar panel that includes edges; a peripheral frame including an interior surface; and any one of the aforesaid adhesive/sealant compositions disposed between the interior surface of the frame and the edges of the solar panel, the panel being bonded to the frame through the adhesive/sealant composition.
  • the invention provides a method of framing a solar panel.
  • the method includes contacting at least one of the interior surfaces of a frame and the solar panel with any one of the adhesive/sealant compositions disclosed herein, and affixing the frame to the solar panel.
  • the framed solar panel assemblies exhibit good protection against moisture, which can adversely affect the efficiency of the solar panel.
  • the method provides an efficient framing process and enables the manufacture of a framed solar panel assembly using an adhesive/sealant composition that functions as both an adhesive composition and a sealant composition at the same time, especially as an edge sealant composition.
  • a back rail 10 of a solar panel assembly 5 is bonded to a substrate 8 of a solar panel 12 through an adhesive composition 6.
  • FIG. 2 illustrates a junction box 20 bonded to a substrate 8 of a solar panel 12 through an adhesive composition 6.
  • an end bracket 30 is bonded to an edge 22, substrate 8 and superstate 24 of a solar panel 12 through an adhesive composition 6.
  • FIGS. 4-6 illustrate a framed solar panel assembly 1 1 includes a solar panel 12 and a peripheral frame 14.
  • the solar panel 12 is surrounded by the frame 14 along edges 16, 18, 20, and 22.
  • An adhesive/sealant composition 4 is disposed between the edges 16, 18, 20 and 22 and the interior surface 28 of the frame 14 so as to seal the solar panel 12, which provides a barrier to moisture entering the solar panel 12, and to adhere the frame 14 to the edges 16, 18, 20 and 22 of the solar panel 12.
  • a continuous bead of the adhesive/sealant composition 4 is in continuous contact with the edge of the solar panel 12 to form a vapor barrier.
  • the frame 14 defines a U-shaped channel 32 that receives an edge of the solar panel 12.
  • the channel 32 includes a back wall 34.
  • the adhesive/sealant composition 4 is in contact with at least one component of the channel 32 of the frame 14, e.g., the back wall 34, a top wall 36, and a bottom wall 38 of the frame 14, and at least one component of the solar panel 12, e.g., the edges 16, 18, 20, and 22 of the panel 12, the superstrate 24 (e.g., a glass superstrate) of the solar panel 12, and the substrate 8 (e.g., a polymer substrate or a glass substrate) of the solar panel 12, as shown in FIG. 6.
  • the substrate 8 e.g., a polymer substrate or a glass substrate
  • the adhesive/sealant composition 4 is positioned in a discontinuous manner on the bottom wall 38, back wall 34, and top wall 36 of the channel 32 of the frame 14 that receives the solar panel 12.
  • the adhesive/sealant composition 4 bonds the frame 14 to the solar panel 12 and preferably provides a vapor barrier.
  • the adhesive/sealant composition 4 preferably exhibits a moisture vapor transmission rate (MVTR) of no greater than 2 g/m 2 /day, when in the form of a 60 mil film.
  • MVTR moisture vapor transmission rate
  • solar panel assemblies in which the adhesive composition is particularly useful include those constructions described in, e.g., U.S. 2009/0205703 and U.S. 2010/0018570, which are incorporated herein.
  • Test procedures used in the examples include the following.
  • the tensile strength at break is determined according to ASTM-D638-00 entitled, "Standard Test Method for Tensile Properties of Plastics. " A homogeneous film of the adhesive composition is pressed to a thickness of from 40 mil to 60 mil. The film is conditioned at 23°C and 50 % relative humidity for at least about 24 hours. Specimens are cut from the film and tested for tensile strength at break according to ASTM D638-00. Lap Shear Strength Test Method
  • the lap shear strength is determined according to ASTM C-961-01 entitled. "Standard Test Method for Lap Shear Strength of Hot Applied Sealants, " with the exception that the test specimen is prepared as follows. A 1 in x 1 in film of adhesive composition having a thickness of from 50 mil to 60 mil is placed on a 4 in x 1 in piece of a first substrate (stainless steel). Another 1 in x 4 in piece of a second substrate (stainless steel) is then placed on top of the film and pressed hard against the film using maximum hand pressure. The test specimen is then heated to a temperature of from 120°C-150°C for 10 minutes to achieve good wet out of the adhesive composition.
  • Initial lap shear i.e., green strength
  • Final lap shear is measured at least about 24 hours after preparing the bond sample.
  • Creep resistance is determined as follows. A 1 in x 1 in film of an adhesive composition having a thickness of from 50 mil to 60 mil is placed on a 4 in x 1 in piece of aluminum. A 1 in x 3 in piece of glass is then placed on top of the film and pressed hard against the film using maximum hand pressure. The test specimen is then heated to a temperature of from 120°C to 150°C for 10 minutes to achieve good wet out of the adhesive composition. The test specimen is conditioned at 23°C and 50% relative humidity for at least about 24 hours.
  • a one pound load is then hung from an end of the test specimen and placed in an oven at a specified temperature, e.g., at 85°C or even a higher temperature. The time to failure is recorded. The test specimen is recorded as pass at the test temperature if there is no failure after seven days.
  • Hot melt adhesive compositions of Examples 1 and 2 are prepared by mixing all the ingredients according to Table I at 150°C until uniformly blended.
  • the adhesive is prepared by mixing all the ingredients according to Table I at 150°C until uniformly blended.
  • compositions are then tested according to the test methods disclosed herein, and the results are also listed in Table I.

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  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Organic Chemistry (AREA)
  • Adhesives Or Adhesive Processes (AREA)

Abstract

L'invention concerne une composition adhésive thermofusible et son utilisation pour un ensemble panneau solaire. La composition adhésive comprend un composant thermoplastique ayant un point de ramollissement d'au moins 120 °C et choisi dans le groupe constitué par les élastomères thermoplastiques, les polymères thermoplastiques et leurs combinaisons ; un promoteur d'adhésion silane ayant un point d'éclair supérieur à 100 °C à pression atmosphérique et un point d'ébullition supérieur à 100 °C à une pression de 0,5 mmHg à 15 mmHg ; et éventuellement un agent collant thermoplastique ayant un point de ramollissement supérieur à 80 °C.
PCT/US2011/027068 2010-03-05 2011-03-03 Composition adhésive thermofusible thermiquement résistante, ses procédés d'utilisation et ensemble panneau solaire la comprenant WO2011109646A1 (fr)

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US31090410P 2010-03-05 2010-03-05
US31092810P 2010-03-05 2010-03-05
US31083410P 2010-03-05 2010-03-05
US61/310,834 2010-03-05
US61/310,904 2010-03-05
US61/310,928 2010-03-05

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Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN102610681A (zh) * 2012-03-30 2012-07-25 江苏明昊新材料科技有限公司 太阳能光伏组件的框架

Citations (8)

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Publication number Priority date Publication date Assignee Title
US3792002A (en) * 1971-04-17 1974-02-12 Schering Ag Hot melt pressure sensitive adhesives
EP0845816A1 (fr) * 1995-08-14 1998-06-03 Sunstar Giken Kabushiki Kaisha Module de piles solaires et son procede de fabrication
WO1998058003A1 (fr) * 1997-06-19 1998-12-23 H.B. Fuller Licensing & Financing, Inc. Polyurethannes thermoplastiques durcissant a l'humidite
US20040181007A1 (en) * 2003-03-13 2004-09-16 Margarita Acevedo Moisture curable, radiation curable sealant composition
US20040180155A1 (en) * 2003-03-13 2004-09-16 Nguyen-Misra Mai T. Moisture curable hot melt sealants for glass constructions
US20050222363A1 (en) * 2002-07-31 2005-10-06 Michael Krebs Segmented polyurethane hotmelt adhesives
US20090205703A1 (en) 2008-02-14 2009-08-20 Applied Materials, Inc. Apparatus and method of mounting and supporting a solar panel
US20100018570A1 (en) 2008-05-16 2010-01-28 Cashion Steven A Concentrating photovoltaic solar panel

Patent Citations (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3792002A (en) * 1971-04-17 1974-02-12 Schering Ag Hot melt pressure sensitive adhesives
EP0845816A1 (fr) * 1995-08-14 1998-06-03 Sunstar Giken Kabushiki Kaisha Module de piles solaires et son procede de fabrication
WO1998058003A1 (fr) * 1997-06-19 1998-12-23 H.B. Fuller Licensing & Financing, Inc. Polyurethannes thermoplastiques durcissant a l'humidite
US6355317B1 (en) 1997-06-19 2002-03-12 H. B. Fuller Licensing & Financing, Inc. Thermoplastic moisture cure polyurethanes
US20050222363A1 (en) * 2002-07-31 2005-10-06 Michael Krebs Segmented polyurethane hotmelt adhesives
US20040181007A1 (en) * 2003-03-13 2004-09-16 Margarita Acevedo Moisture curable, radiation curable sealant composition
US20040180155A1 (en) * 2003-03-13 2004-09-16 Nguyen-Misra Mai T. Moisture curable hot melt sealants for glass constructions
US20090205703A1 (en) 2008-02-14 2009-08-20 Applied Materials, Inc. Apparatus and method of mounting and supporting a solar panel
US20100018570A1 (en) 2008-05-16 2010-01-28 Cashion Steven A Concentrating photovoltaic solar panel

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN102610681A (zh) * 2012-03-30 2012-07-25 江苏明昊新材料科技有限公司 太阳能光伏组件的框架

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