WO2006093936A2 - Solar encapsulants with protective additives - Google Patents
Solar encapsulants with protective additives Download PDFInfo
- Publication number
- WO2006093936A2 WO2006093936A2 PCT/US2006/007028 US2006007028W WO2006093936A2 WO 2006093936 A2 WO2006093936 A2 WO 2006093936A2 US 2006007028 W US2006007028 W US 2006007028W WO 2006093936 A2 WO2006093936 A2 WO 2006093936A2
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- WO
- WIPO (PCT)
- Prior art keywords
- encapsulant
- polymer
- composition according
- weight
- encapsulant composition
- Prior art date
Links
- 239000008393 encapsulating agent Substances 0.000 title claims abstract description 109
- 239000000654 additive Substances 0.000 title description 18
- 230000001681 protective effect Effects 0.000 title description 7
- 229920000642 polymer Polymers 0.000 claims abstract description 79
- 239000000203 mixture Substances 0.000 claims abstract description 71
- 239000006096 absorbing agent Substances 0.000 claims abstract description 33
- 229920000554 ionomer Polymers 0.000 claims abstract description 19
- 239000003963 antioxidant agent Substances 0.000 claims abstract description 16
- 230000003078 antioxidant effect Effects 0.000 claims abstract description 16
- 235000006708 antioxidants Nutrition 0.000 claims abstract description 16
- 239000006078 metal deactivator Substances 0.000 claims abstract description 14
- HCILJBJJZALOAL-UHFFFAOYSA-N 3-(3,5-ditert-butyl-4-hydroxyphenyl)-n'-[3-(3,5-ditert-butyl-4-hydroxyphenyl)propanoyl]propanehydrazide Chemical group CC(C)(C)C1=C(O)C(C(C)(C)C)=CC(CCC(=O)NNC(=O)CCC=2C=C(C(O)=C(C=2)C(C)(C)C)C(C)(C)C)=C1 HCILJBJJZALOAL-UHFFFAOYSA-N 0.000 claims description 20
- ZSSVCEUEVMALRD-UHFFFAOYSA-N 2-[4,6-bis(2,4-dimethylphenyl)-1,3,5-triazin-2-yl]-5-(octyloxy)phenol Chemical compound OC1=CC(OCCCCCCCC)=CC=C1C1=NC(C=2C(=CC(C)=CC=2)C)=NC(C=2C(=CC(C)=CC=2)C)=N1 ZSSVCEUEVMALRD-UHFFFAOYSA-N 0.000 claims description 15
- 229920001400 block copolymer Polymers 0.000 claims description 14
- 239000004611 light stabiliser Substances 0.000 claims description 14
- 150000001412 amines Chemical class 0.000 claims description 13
- 239000004020 conductor Substances 0.000 claims description 13
- BGYHLZZASRKEJE-UHFFFAOYSA-N [3-[3-(3,5-ditert-butyl-4-hydroxyphenyl)propanoyloxy]-2,2-bis[3-(3,5-ditert-butyl-4-hydroxyphenyl)propanoyloxymethyl]propyl] 3-(3,5-ditert-butyl-4-hydroxyphenyl)propanoate Chemical group CC(C)(C)C1=C(O)C(C(C)(C)C)=CC(CCC(=O)OCC(COC(=O)CCC=2C=C(C(O)=C(C=2)C(C)(C)C)C(C)(C)C)(COC(=O)CCC=2C=C(C(O)=C(C=2)C(C)(C)C)C(C)(C)C)COC(=O)CCC=2C=C(C(O)=C(C=2)C(C)(C)C)C(C)(C)C)=C1 BGYHLZZASRKEJE-UHFFFAOYSA-N 0.000 claims description 12
- 229920005989 resin Polymers 0.000 claims description 12
- 239000011347 resin Substances 0.000 claims description 12
- 239000011521 glass Substances 0.000 claims description 10
- OWXXKGVQBCBSFJ-UHFFFAOYSA-N 6-n-[3-[[4,6-bis[butyl-(1,2,2,6,6-pentamethylpiperidin-4-yl)amino]-1,3,5-triazin-2-yl]-[2-[[4,6-bis[butyl-(1,2,2,6,6-pentamethylpiperidin-4-yl)amino]-1,3,5-triazin-2-yl]-[3-[[4,6-bis[butyl-(1,2,2,6,6-pentamethylpiperidin-4-yl)amino]-1,3,5-triazin-2-yl]ami Chemical compound N=1C(NCCCN(CCN(CCCNC=2N=C(N=C(N=2)N(CCCC)C2CC(C)(C)N(C)C(C)(C)C2)N(CCCC)C2CC(C)(C)N(C)C(C)(C)C2)C=2N=C(N=C(N=2)N(CCCC)C2CC(C)(C)N(C)C(C)(C)C2)N(CCCC)C2CC(C)(C)N(C)C(C)(C)C2)C=2N=C(N=C(N=2)N(CCCC)C2CC(C)(C)N(C)C(C)(C)C2)N(CCCC)C2CC(C)(C)N(C)C(C)(C)C2)=NC(N(CCCC)C2CC(C)(C)N(C)C(C)(C)C2)=NC=1N(CCCC)C1CC(C)(C)N(C)C(C)(C)C1 OWXXKGVQBCBSFJ-UHFFFAOYSA-N 0.000 claims description 9
- VNQNXQYZMPJLQX-UHFFFAOYSA-N 1,3,5-tris[(3,5-ditert-butyl-4-hydroxyphenyl)methyl]-1,3,5-triazinane-2,4,6-trione Chemical compound CC(C)(C)C1=C(O)C(C(C)(C)C)=CC(CN2C(N(CC=3C=C(C(O)=C(C=3)C(C)(C)C)C(C)(C)C)C(=O)N(CC=3C=C(C(O)=C(C=3)C(C)(C)C)C(C)(C)C)C2=O)=O)=C1 VNQNXQYZMPJLQX-UHFFFAOYSA-N 0.000 claims description 7
- 125000000217 alkyl group Chemical group 0.000 claims description 6
- 150000004945 aromatic hydrocarbons Chemical class 0.000 claims description 6
- 125000004432 carbon atom Chemical group C* 0.000 claims description 6
- 150000001993 dienes Chemical class 0.000 claims description 6
- 230000000379 polymerizing effect Effects 0.000 claims description 6
- 238000005984 hydrogenation reaction Methods 0.000 claims description 3
- 229920006030 multiblock copolymer Polymers 0.000 claims description 3
- 239000002861 polymer material Substances 0.000 claims 1
- 229910000679 solder Inorganic materials 0.000 claims 1
- 239000000463 material Substances 0.000 abstract description 17
- 238000002845 discoloration Methods 0.000 abstract description 14
- 230000015556 catabolic process Effects 0.000 abstract description 13
- 238000006731 degradation reaction Methods 0.000 abstract description 13
- 229910052751 metal Inorganic materials 0.000 abstract description 12
- 239000002184 metal Substances 0.000 abstract description 12
- 230000005855 radiation Effects 0.000 abstract description 8
- 150000002739 metals Chemical class 0.000 abstract description 7
- JYEUMXHLPRZUAT-UHFFFAOYSA-N 1,2,3-triazine Chemical compound C1=CN=NN=C1 JYEUMXHLPRZUAT-UHFFFAOYSA-N 0.000 abstract description 3
- 230000009257 reactivity Effects 0.000 abstract description 2
- 239000005038 ethylene vinyl acetate Substances 0.000 description 22
- 229920001200 poly(ethylene-vinyl acetate) Polymers 0.000 description 22
- 238000009472 formulation Methods 0.000 description 15
- 238000012360 testing method Methods 0.000 description 11
- 239000004433 Thermoplastic polyurethane Substances 0.000 description 9
- 239000000126 substance Substances 0.000 description 9
- 229920002803 thermoplastic polyurethane Polymers 0.000 description 9
- 229920002633 Kraton (polymer) Polymers 0.000 description 7
- 230000006866 deterioration Effects 0.000 description 6
- BQCADISMDOOEFD-UHFFFAOYSA-N Silver Chemical compound [Ag] BQCADISMDOOEFD-UHFFFAOYSA-N 0.000 description 5
- QRUDEWIWKLJBPS-UHFFFAOYSA-N benzotriazole Chemical compound C1=CC=C2N[N][N]C2=C1 QRUDEWIWKLJBPS-UHFFFAOYSA-N 0.000 description 5
- 239000012964 benzotriazole Substances 0.000 description 5
- 238000000034 method Methods 0.000 description 5
- 229910052709 silver Inorganic materials 0.000 description 5
- 239000004332 silver Substances 0.000 description 5
- JLZIIHMTTRXXIN-UHFFFAOYSA-N 2-(2-hydroxy-4-methoxybenzoyl)benzoic acid Chemical compound OC1=CC(OC)=CC=C1C(=O)C1=CC=CC=C1C(O)=O JLZIIHMTTRXXIN-UHFFFAOYSA-N 0.000 description 4
- RWCCWEUUXYIKHB-UHFFFAOYSA-N benzophenone Chemical compound C=1C=CC=CC=1C(=O)C1=CC=CC=C1 RWCCWEUUXYIKHB-UHFFFAOYSA-N 0.000 description 4
- 239000012965 benzophenone Substances 0.000 description 4
- 150000001875 compounds Chemical class 0.000 description 4
- 229920000728 polyester Polymers 0.000 description 4
- 229920002620 polyvinyl fluoride Polymers 0.000 description 4
- LEVFXWNQQSSNAC-UHFFFAOYSA-N 2-(4,6-diphenyl-1,3,5-triazin-2-yl)-5-hexoxyphenol Chemical compound OC1=CC(OCCCCCC)=CC=C1C1=NC(C=2C=CC=CC=2)=NC(C=2C=CC=CC=2)=N1 LEVFXWNQQSSNAC-UHFFFAOYSA-N 0.000 description 3
- QTBSBXVTEAMEQO-UHFFFAOYSA-N Acetic acid Chemical compound CC(O)=O QTBSBXVTEAMEQO-UHFFFAOYSA-N 0.000 description 3
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 3
- -1 Cyasorb UV- 1164 compound Chemical class 0.000 description 3
- 230000000996 additive effect Effects 0.000 description 3
- 230000008901 benefit Effects 0.000 description 3
- 229910052802 copper Inorganic materials 0.000 description 3
- 239000010949 copper Substances 0.000 description 3
- 238000011835 investigation Methods 0.000 description 3
- 238000010030 laminating Methods 0.000 description 3
- 238000004519 manufacturing process Methods 0.000 description 3
- 150000001282 organosilanes Chemical class 0.000 description 3
- 229920003311 DuPont™ Surlyn® 1601 Polymers 0.000 description 2
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 2
- PPBRXRYQALVLMV-UHFFFAOYSA-N Styrene Chemical compound C=CC1=CC=CC=C1 PPBRXRYQALVLMV-UHFFFAOYSA-N 0.000 description 2
- 238000006243 chemical reaction Methods 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 230000007613 environmental effect Effects 0.000 description 2
- VNWKTOKETHGBQD-UHFFFAOYSA-N methane Chemical compound C VNWKTOKETHGBQD-UHFFFAOYSA-N 0.000 description 2
- 238000002156 mixing Methods 0.000 description 2
- 238000012667 polymer degradation Methods 0.000 description 2
- VMRIVYANZGSGRV-UHFFFAOYSA-N 4-phenyl-2h-triazin-5-one Chemical class OC1=CN=NN=C1C1=CC=CC=C1 VMRIVYANZGSGRV-UHFFFAOYSA-N 0.000 description 1
- UWSMKYBKUPAEJQ-UHFFFAOYSA-N 5-Chloro-2-(3,5-di-tert-butyl-2-hydroxyphenyl)-2H-benzotriazole Chemical compound CC(C)(C)C1=CC(C(C)(C)C)=CC(N2N=C3C=C(Cl)C=CC3=N2)=C1O UWSMKYBKUPAEJQ-UHFFFAOYSA-N 0.000 description 1
- VGGSQFUCUMXWEO-UHFFFAOYSA-N Ethene Chemical compound C=C VGGSQFUCUMXWEO-UHFFFAOYSA-N 0.000 description 1
- 239000005977 Ethylene Substances 0.000 description 1
- 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
- 241000907681 Morpho Species 0.000 description 1
- 239000004698 Polyethylene Substances 0.000 description 1
- 239000004793 Polystyrene Substances 0.000 description 1
- BLRPTPMANUNPDV-UHFFFAOYSA-N Silane Chemical compound [SiH4] BLRPTPMANUNPDV-UHFFFAOYSA-N 0.000 description 1
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 description 1
- XTXRWKRVRITETP-UHFFFAOYSA-N Vinyl acetate Chemical compound CC(=O)OC=C XTXRWKRVRITETP-UHFFFAOYSA-N 0.000 description 1
- HCHKCACWOHOZIP-UHFFFAOYSA-N Zinc Chemical compound [Zn] HCHKCACWOHOZIP-UHFFFAOYSA-N 0.000 description 1
- XYLMUPLGERFSHI-UHFFFAOYSA-N alpha-Methylstyrene Chemical class CC(=C)C1=CC=CC=C1 XYLMUPLGERFSHI-UHFFFAOYSA-N 0.000 description 1
- 229910052782 aluminium Inorganic materials 0.000 description 1
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 1
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 1
- 230000005540 biological transmission Effects 0.000 description 1
- 125000000484 butyl group Chemical group [H]C([*])([H])C([H])([H])C([H])([H])C([H])([H])[H] 0.000 description 1
- 239000003795 chemical substances by application Substances 0.000 description 1
- 230000008602 contraction Effects 0.000 description 1
- 230000001351 cycling effect Effects 0.000 description 1
- 238000000354 decomposition reaction Methods 0.000 description 1
- 230000007850 degeneration Effects 0.000 description 1
- 230000008030 elimination Effects 0.000 description 1
- 238000003379 elimination reaction Methods 0.000 description 1
- 238000005538 encapsulation Methods 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- NAQMVNRVTILPCV-UHFFFAOYSA-N hexane-1,6-diamine Chemical compound NCCCCCCN NAQMVNRVTILPCV-UHFFFAOYSA-N 0.000 description 1
- 125000001841 imino group Chemical group [H]N=* 0.000 description 1
- 239000004615 ingredient Substances 0.000 description 1
- 230000007246 mechanism Effects 0.000 description 1
- 238000002844 melting Methods 0.000 description 1
- 230000008018 melting Effects 0.000 description 1
- BQJCRHHNABKAKU-KBQPJGBKSA-N morphine Chemical compound O([C@H]1[C@H](C=C[C@H]23)O)C4=C5[C@@]12CCN(C)[C@@H]3CC5=CC=C4O BQJCRHHNABKAKU-KBQPJGBKSA-N 0.000 description 1
- 229910052760 oxygen Inorganic materials 0.000 description 1
- 239000001301 oxygen Substances 0.000 description 1
- 229920000573 polyethylene Polymers 0.000 description 1
- 229920002223 polystyrene Polymers 0.000 description 1
- 238000004321 preservation Methods 0.000 description 1
- 125000002924 primary amino group Chemical group [H]N([H])* 0.000 description 1
- 230000008569 process Effects 0.000 description 1
- 230000003252 repetitive effect Effects 0.000 description 1
- 230000035945 sensitivity Effects 0.000 description 1
- 229910000077 silane Inorganic materials 0.000 description 1
- 229910052710 silicon Inorganic materials 0.000 description 1
- 239000010703 silicon Substances 0.000 description 1
- 235000012239 silicon dioxide Nutrition 0.000 description 1
- 239000000377 silicon dioxide Substances 0.000 description 1
- 229910052708 sodium Inorganic materials 0.000 description 1
- 239000011734 sodium Substances 0.000 description 1
- 239000007787 solid Substances 0.000 description 1
- 239000000758 substrate Substances 0.000 description 1
- 230000002195 synergetic effect Effects 0.000 description 1
- 239000011885 synergistic combination Substances 0.000 description 1
- 125000000383 tetramethylene group Chemical group [H]C([H])([*:1])C([H])([H])C([H])([H])C([H])([H])[*:2] 0.000 description 1
- 238000005979 thermal decomposition reaction Methods 0.000 description 1
- 229920001169 thermoplastic Polymers 0.000 description 1
- 229920002725 thermoplastic elastomer Polymers 0.000 description 1
- 239000004416 thermosoftening plastic Substances 0.000 description 1
- 238000002834 transmittance Methods 0.000 description 1
- 238000004383 yellowing Methods 0.000 description 1
- 229910052725 zinc Inorganic materials 0.000 description 1
- 239000011701 zinc Substances 0.000 description 1
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B17/00—Layered products essentially comprising sheet glass, or glass, slag, or like fibres
- B32B17/06—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material
- B32B17/10—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin
- B32B17/10005—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing
- B32B17/1055—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing characterized by the resin layer, i.e. interlayer
- B32B17/10788—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing characterized by the resin layer, i.e. interlayer containing ethylene vinylacetate
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B17/00—Layered products essentially comprising sheet glass, or glass, slag, or like fibres
- B32B17/06—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material
- B32B17/10—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin
- B32B17/10005—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing
- B32B17/1055—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing characterized by the resin layer, i.e. interlayer
- B32B17/10678—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing characterized by the resin layer, i.e. interlayer comprising UV absorbers or stabilizers, e.g. antioxidants
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B17/00—Layered products essentially comprising sheet glass, or glass, slag, or like fibres
- B32B17/06—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material
- B32B17/10—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin
- B32B17/10005—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing
- B32B17/1055—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing characterized by the resin layer, i.e. interlayer
- B32B17/10743—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing characterized by the resin layer, i.e. interlayer containing acrylate (co)polymers or salts thereof
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L31/00—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
- H01L31/04—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof adapted as photovoltaic [PV] conversion devices
- H01L31/042—PV modules or arrays of single PV cells
- H01L31/048—Encapsulation of modules
-
- 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
- This invention relates to the manufacture of photovoltaic solar cell modules and more particularly to an improved encapsulant material for encapsulating the solar cells in the modules.
- photovoltaic solar cells e.g., silicon solar cells
- solar cells are relatively small and hence conventional industry practice is to electrically interconnect a row of cells in series to form a string, and to electrically interconnect several strings together in a selected series and/or parallel arrangement so as to form a physically integrated module with a correspondingly greater power output.
- the solar cells typically have a first grid contact on their front side that comprises silver and collects current from across the width of the cells, and a second contact on their back side that typically comprises aluminum and/or silver. Electrical interconnection of the cells is typically accomplished by copper tabbing. Those conductors are commonly arranged to form stress relief loops to compensate for expansion and contractions caused by temperature changes.
- Two or more modules may be connected together in a selected series and/or parallel arrangement to form a larger array with correspondingly greater power output.
- An essential aspect of solar cell modules is the need to mechanically support and protect the cells against environmental degradation.
- the typical module arrangement comprises disposing the cells between a transparent front (top) protective support sheet or superstrate (usually a glass plate) and a back (bottom) support sheet or substrate, with the cells being encapsulated by a transparent or light-transmitting polymeric encapsulant that is bonded to the front and back support sheets.
- the back support sheet may be in the form of glass plate or a flexible polymeric sheet (commonly called the "backskin") such as, but not limited to, Tedlar/Polyester/Tedlar (“TPT”), Tedlar/Polyester/EVA (“TPE”), and Polyester/Silicon Dioxide/Polyester.
- TPT Tedlar/Polyester/Tedlar
- TPE Tedlar/Polyester/EVA
- Polyester/Silicon Dioxide/Polyester polyester/Silicon Dioxide/Polyester.
- the modules may take the form of the modules described and illustrated in U.S. Patents Nos. 4,692,557, 5,733,382, 5,994,641 , and 6,660,930. The disclosures of those patents are incorporated herein by reference.
- the light-transmitting encapsulant serves three functions: it allows sunlight to impinge on the solar cells; it bonds together the front and back support sheets so as to form a laminated structure with the solar cells disposed between those sheets; and it provides protection for the cells against environmental degradation.
- a large number of materials have been considered for use as solar cell encapsulants, including ionomers (as disclosed in U. S. Patents Nos. 5,478,402, 5,476,553, and 6,353,042), ethylene vinyl acetate copolymer, commonly known as "EVA" (as disclosed in U.S. Patents Nos. 6,586,271 and 6,093,757), block polymers (as disclosed in U.S.
- the conventional practice is to incorporate an ultraviolet (UV) absorber and other additives in the encapsulant composition to protect the encapsulant against degradation and/or improve performance of the module.
- UV ultraviolet
- the foregoing encapsulant materials have suffered from the limitation that they still tend to degrade, albeit at different rates, under the influence of UV radiation, with the degradation being evidenced by discoloration of the encapsulant.
- EVA gets progressively darker as it decomposes under sunlight, and its decomposition releases acetic acid, which in turn promotes further degradation, particularly in the presence of heat and/or oxygen.
- the tendency of a given encapsulant to degrade will be evidenced by discoloration occurring within the first year following daily exposure of the solar modules to sunlight.
- the present invention stems from my discovery of a weakness in the additives commonly used for preventing degradation of the encapsulants over the course of the product lifetimes of the solar modules.
- Testing of some encapsulant materials provided by a manufacturer and comprising a thermoplastic polyurethane (TPU) polymer plus a UV absorber and two other additives revealed that rapid yellowing occurred when the encapsulant materials were exposed to accelerated testing conditions of heat, humidity and UV radiation.
- TPU thermoplastic polyurethane
- UV absorber two other additives revealed that rapid yellowing occurred when the encapsulant materials were exposed to accelerated testing conditions of heat, humidity and UV radiation.
- Some of these materials were quite stable when tested between sheets of glass without the presence of any solar cells, but discolored fairly rapidly when solar cells were incorporated in the test samples. Moreover, the discoloration was most pronounced in the regions of the solar cell where silver electrical conductors were present.
- block copolymers described in U.S. Patents 4,749,430 and 4,692,557 offer certain advantages with respect to serving as a solar cell encapsulant.
- Those block polymers are thermoplastic and, in comparison to EVA, they do not expand or contract as much, absorb less moisture, and become softer at lower temperatures. The latter aspect is advantageous with respect to forming a laminated solar module as described above.
- use of block polymer formulations as solar cell encapsulants has not been successful due to discoloration and deterioration occurring after exposure to sunlight for a relatively short period.
- Tinuvin 1577 2 ⁇ (4,6-Diphenyl-1 ,3,5-triazin-2-yl)-5- hexyloxy-phenol, marketed by Ciba Specialty Chemicals Corporation under the tradename Tinuvin 1577, was known to be effective as a UV absorber, relatively easy to incorporate into many polymers and more stable to UV radiation than benzophenone and benzotriazole UV absorbers. It would, therefore, be expected to protect any polymer containing it against UV-induced discoloration and degradation for a longer period than those other absorbers. Subsequently, test samples were constructed using as an encapsulant a block polymer of the type disclosed and claimed in said U.S. Patents Nos.
- triazine UV absorbers tend to have a lesser tendency toward causing encapsulant degradation in the presence of metals. Accordingly there existed the possibility that another triazine UV absorber compound could be found that would not promote or cause accelerated polymer degradation due to the presence of metal conductors in the solar cell module.
- the primary object of this invention is to provide a new solar cell encapsulating material that is characterized by improved photothermal and photochemical stability.
- Another primary object of this invention is to provide a solar cell module characterized by a new solar cell encapsulating material that exhibits improved photothermal and photochemical stability.
- a more specific object of this invention is to provide a new solar cell encapsulant formulation comprising an ionomer, EVA, or a block polymer composition as disclosed and claimed in U.S. Patents Nos. 4,749,430 and 4,692,557 and a UV absorber that provides improved resistance to discoloration and deterioration under the influence of UV radiation.
- Another specific object is to provide a solar cell module with a novel solar cell encapsulant formulation that comprises a polymeric encapsulant from the group consisting of an ionomer, EVA, or a block polymer composition as disclosed and claimed in U.S. Patents Nos. 4,749,430 and 4,692,557 and a UV absorber, and which is characterized by an improved resistance to discoloration and deterioration under the influence of UV radiation.
- Still another object is to provide a UV absorber/additives package for use in improving the resistance to discoloration and deterioration of encapsulant formulations wherein an ionomer, EVA or a block polymer composition as disclosed and claimed in U.S. Patents Nos. 4,749,430 and 4,692,557 serves as the cell- encapsulating polymer.
- a more specific object is to provide a new and improved encapsulant composition that essentially comprises a block polymer of the type disclosed and claimed in U.S. Patents Nos. 4,749,430 and 4,692,557 and is characterized by improved resistance to discoloration and deterioration from exposure to UV radiation.
- Still another specific object of this invention is to provide an encapsulating material comprising a block polymer, a tackifying resin, UV absorber, and hindered amine light stabilizer that exhibits enhanced stability against moisture and thermal decomposition.
- a preferred embodiment of the invention includes addition of metal deactivator and anti-oxidant to maximize resistance to reaction.
- FIGs. 1 and 2 schematically illustrate components of a conventional form of solar cell module which is modified to incorporate the present invention.
- the invention is practiced by adding to those components a UV absorber in the form of Cyasorb UV-1164 or Cyasorb THT-6460, and a hindered amine light stabilizer (HALS).
- a UV absorber in the form of Cyasorb UV-1164 or Cyasorb THT-6460
- HALS hindered amine light stabilizer
- the block polymer-based encapsulant is further modified by the addition of an anti-oxidant.
- a preferred embodiment includes the addition of a metal deactivator and an anti-oxidant.
- block polymer-based encapsulant compositions provided by this invention utilize as the polymer encapsulant a blend of: about 65 to 75 parts by weight of a selectively hydrogenated two-block polymer wherein one polymer block is designated by A and a second polymer block is designated by B such that prior to hydrogenation,
- each A is a polymer block of a monovinyl or alpha alkyl monovinyl arene having a number average molecular weight in the range of from about 5,000 to about 75,000, said A blocks comprising from about 10 to about 40% by weight of the total block copolymer, and
- each B is a polymer block having a number average molecular weight in the range of from about 10,000 to about 150,000 and is formed by polymerizing a conjugated diene having from 4 to 10 carbon atoms per molecule, and said B blocks comprising from about 90 to about 60% by weight of the total block copolymer, and about 25 to about 35 parts by weight of a selectively hydrogenated multiblock copolymer which contains at least two kinds of polymer blocks wherein one polymer block is designated by A and a second polymer block is designated by B such that:
- each A is a polymer endblock of a monovinyl or alpha alkyl monovinyl arene having a number average molecular weight in the range of from about 5,000 to about 75, 000, said A blocks comprising from about 10 to about 90% by weight of the total block copolymer, and
- each B is a polymer midblock having a number average molecular weight in the range of from about 10,000 to about 150,000 and is formed by polymerizing a conjugated diene having from 4 to 10 carbon atoms per molecule, and said B blocks comprising from about 90 to about 10% by weight of the total block copolymer.
- block polymer composition product sold by Kraton Polymers US LLC under the tradename Kraton G 1726.
- the composition of that product is set forth in U.S. Patent No. 4,692,557. It is further characterized by its manufacturer as a clear, linear triblock polymer based on styrene and ethylene/butylene, with a polystyrene content of 30%.
- the tackifying resin is required to assure that the block polymer-based encapsulant material will adhere strongly to the adjacent components of a solar module.
- the tackifying resin is Regalrez 1094, a product of Eastman Chemical Company.
- Regalrez 1094 is a hydrogenated alpha-methyl styrene polymer.
- the Regalrez 1094 may be replaced by some other tackifying resin, e.g., the resin marketed by Arakawa Chemical Company under the trade name Arkon P85. Still other tackifying resins compatible with the block- polymer may be used.
- Cyasorb UV-1164 is the tradename for the following: 2-[4,6-Bis(2,4- dimethylphenyl)-1 ,3,5-triazin-2-yl]-5-(octyloxy)phenol, with a melting point in the range of 88.0 to 91.0 0 C.
- Cyasorb THT-6460 contains the foregoing Cyasorb UV- 1164 compound plus other ingredients, including a hindered amine light stabilizer believed to be 1 ,6-hexanediamine, N, N'-bis(1 ,2,2,6,6-pentamethyl-4-piperidinyl)-, polymers with morpho!ine-2,4,6-trichloro-1 ,3,5-triazine.
- Chimassorb 119 is the trade name for 1 ) 3 ) 5-triazine-2 ) 4,6-triamine ) N,N l "-[1 ,2-ethane-diyl-bis [ [ [4,6-bis-[butyl (1 ,2,2,6,6- pentamethyl-4-piperidinyl)amino] -1 ,3,5-triazine-2-yl] imino]-3,1-propanediyl] ] bis [N',N"- dibutyl-N,N"-bis (1 ,2,2,6,6-pentamethyl-4-piperdinyl)-.
- hindered amine light stabilizers may be used in combination with the Cyasorb UV-1164 light absorber. No hindered amine light stabilizer compound need be added if the light absorber is Cyasorb THT-6460, since that material already includes a HALS.
- a block polymer-type encapsulant material is prepared by blending together a block polymer composition as described above, a tackifying resin, Cyasorb UV- 1164 absorber, and a hindered amine light stabilizer (HALS) in the following proportions by weight: between about 80 to about 90 % block polymer composition, between about 10 to about 20 % tackifying resin, between about 0.2 to about 1.0 % absorber, and between about 0.3 and about 0.6 % HALS.
- the step of adding the hindered amine light stabilizer may be omitted if the Cyasorb UV-1164 is replaced by Cyasorb THT-6460 since the latter contains a HALS.
- the resultant composition may be formed into flat sheets and used as a cell encapsulant in the manufacture of solar modules.
- a solar module comprising an encapsulant material formed by blending together 80 wt. % Kraton G 1726, about 19 wt. % Regalrez 1094, 0.4 wt.% Cyasorb UV-1164 and 0.4 wt.% Chimassorb 119 will exhibit an improved resistance to discoloration and degradation of the encapsulant under intensive exposure to UV radiation notwithstanding the encapsulant being in contact with metal conductors in the modules, such resistance being significantly better than that of prior encapsulants based on the block polymers described above.
- an alternative embodiment of this invention comprises adding the metal deactivator product sold by Ciba Specialty Chemicals under the trade name Irganox MD 1024 to the encapsulant formulation.
- the chemical name for Irganox MD 1024 is 2',3-bis[[3-[3,5-di-tert-butyl-4- hydroxyphenyl] propionyl]] propionohydrazide (also known as 1 ,2-bis(3,5-di-tert- butyl-4-hydroxyhydrocinnamoyl) hydrazine), CAS No. 32687-78-8.
- This deactivator enhances the lifetime of solar modules in that it suppresses degeneration of the absorber-containing encapsulant due to the presence of the conductors that interconnect the solar cells.
- the amount of this additive added to the encapsulant composition is between about 0.1 and about 1.0 % by weight, preferably between about 0.1 and 0.5 %.
- an anti-oxidant may be added to the encapsulant composition, with or without the presence of the Irganox MD 1024.
- the MD 1024 works well in combination with Irganox 1010, a commonly used antioxidant, to prolong polymer lifetime.
- Irganox 1010 has been identified by its manufacturer, Ciba Specialty Chemicals, as tetrakis-[methy!ene- (3,5-di-terbutyl-4-hydrocinnamate] methane (CAS No. 6683-19-8).
- Irganox MD 1024 and Irganox 1010 in the encapsulant composition, with the Irganox MD 1024 serving to significantly prolong the useful lifetime of the encapsulant, both by means of its primary activity in reducing metal reactivity with polymers, and also through the synergistic effect between the Irganox 1010 and Irganox MD 1024 described in the preceding paragraph.
- the Irganox 1010 may be replaced by another antioxidant, e.g. the compound sold by Ciba Specialty Chemicals under the tradename Irganox 3114.
- the MD 1024 is added to the encapsulant composition in an amount ranging from about 0.1 wt.
- the anti-oxidant e.g. Irganox 1010 or Irganox 3114, may be added in an amount ranging from about 0.1 wt. % to about 2.0 wt. %.
- Figs. 1 and 2 schematically illustrate components of a conventional form of solar cell module which is modified to incorporate the present invention.
- the components used to construct the solar cell module comprise a transparent front panel or superstrate 2, a first layer 4 of a light transmitting encapsulant, an array of separately formed crystalline solar cells 6 interconnected by conductors 8 (Fig. 2), a porous scrim sheet 10, a second layer 12 of a transparent encapsulant, and a protective back panel or backskin 14.
- the front panel is usually made of glass while the back panel may be made of glass or some other material, e.g., Tedlar®.
- the glass is subjected to a silane pretreatment, e.g., as set forth in said U.S. Patent No. 4,749,430.
- a silane pretreatment e.g., as set forth in said U.S. Patent No. 4,749,430.
- the individual conductors 8 that connect adjacent solar cells or strings of cells are oversized in length for stress relief and may form individual loops between the cells.
- Each cell has a first electrode or contact (not shown) on its front radiation-receiving surface and a second electrode or contact (also not shown) on its back surface, with the conductors 8 being soldered to those contacts to establish the desired electrical circuit configuration.
- each cell may have contacts as disclosed in U.S. Patent No.
- Each of the layers 4 and 12 may comprise one or more sheets of encapsulant material, depending_upon the thickness in which the encapsulant is commercially available.
- the solar cells are oriented so that their front contacts face the front panel 2, and also the cells are arranged in rows, i.e., strings, with the several strings being connected by other conductors similar to conductors 8 and with the whole array having terminal leads (not shown) that extend out through a side of the assembly of components.
- the foregoing components are assembled in sandwich fashion, starting with the front panel 2 on the bottom.
- the laminating apparatus is essentially a vacuum press having heating means and a flexible wall or bladder member that coacts with a wall member or platen to compress the components together when the press is closed and evacuated.
- the sandwich is positioned within the press and then the closed press is operated so as to heat the sandwich in vacuum to a selected temperature at which the encapsulant will melt enough to flow around the cells, usually a temperature of at least 12O 0 C, with the pressure applied to the components increasing at a selected rate to a maximum level, usually in the range of about 390 to about 410 torr minimum.
- test sample modules were made according to the foregoing procedure wherein each of the encapsulant layers 4 and 12 had the following composition by weight: about 80% Kraton G 1726 block polymer, 18.2% RegalRez tackifying agent, 0.3 Cyasorb UV- 1164, 0.3% Chimassorb, 0.55% Irganox 3114, and 0.3% Irganox MD 1024.
- Those test modules were subjected to accelerated UV testing that involved repetitive temperature and humidity cycling equivalent to 34 year of daily exposure to sunlight. These test results revealed that the encapsulant did not discolor and exhibited substantially no loss in light transmittance.
- the foregoing invention is not limited to the Kraton G 1726 block polymer product but may be practiced with other block polymer encapsulants encompassed by the blend composition described hereinabove.
- the invention also is not limited to block polymers but is also applicable to providing stable EVA-based and ionomer-based encapsulants formulations that are free of benzotriazole and benzophenone UV absorbers, with the amount of each additive being within the range set forth above in relation to the block polymer encapsulants.
- the invention is applicable to any EVA copolymer composition known in the art for use as an encapsulant.
- the EVA copolymer may have a vinyl acetate content between about 25% and 35% by weight.
- the EVA encapsulant formulation may also comprise an organosilane primer to enhance adherence of the encapsulant to the solar cells and adjacent components of the module, e.g., glass front and back panels.
- Suitable primers are set forth in U.S. Patent No. 5,447,576.
- the glass components of the module may be subjected to an organosilane pretreatment as noted above in connection with the description of the method used to manufacture a module as illustrated In Figs. 1 and 2.
- EVA-based encapsulant composition embodying the invention comprises EVA modified by 0.3 wt. % Cyasorb UV-1164 and 0.3 wt. % Chimassorb 119.
- An alternative and preferred EVA encapsulant composition comprises modifying EVA with 0.3 wt. % Cyasorb UV-1164, 0.3 wt. % Chimassorb, 0.5 wt. % Irganox 3114 and 0.3 wt %. Irganox MD 1024.
- the foregoing EVA encapsulant composition provided by this invention may be formed into sheets whereby it may be use to form a solar modules according to the method and structure herein described and illustrated.
- the Chimassorb 119 may be replaced by some other hindered amine light stabilizer.
- the ionomer component may be any ionomer composition known in the art for use as a solar cell encapsulant, e.g., the Surlyn®1601 and 1705 products of DuPont.
- the term "ionomer” includes sodium and zinc-based ionomers and has the meaning attributed to it in U.S. Patents Nos. 5,478,402 and 5,476,553, issued respectively to J. Hanoka and J. Hanoka et al.
- An example of application of the invention to produce sheets of ionomer- based encapsulant is a composition comprising Surlyn®1601 or 1705 ionomer, 0.3 wt. % Cyasorb UV-1164 and 0.3 wt. % Chimassorb 119.
- An alternative and preferred ionomer encapsulant composition comprises modifying the selected ionomer with 0.3 wt. % Cyasorb UV-1164, 0.3 wt. % Chimassorb 119, 0.5 wt. % Irganox 3114 and 0.3 wt %. Irganox MD 1024.
- the foregoing additive-modified ionomer encapsulant composition provided by this invention may be formed into sheets whereby it may be use to form a solar modules according to the method and structure herein described and illustrated.
- the ionomer encapsulant also may include an organosilane primer to enhance adherence of the encapsulant to the solar cells and adjacent components of the solar module, e.g., glass front and back panels.
- the Chimassorb 119 may be replaced by some other hindered amine light stabilizer.
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US66240105P | 2005-03-16 | 2005-03-16 | |
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US60/662,401 | 2005-03-16 |
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WO2011020762A1 (en) | 2009-08-18 | 2011-02-24 | Basf Se | An uv-stabilized photovoltaic module |
US7902301B2 (en) | 2007-07-30 | 2011-03-08 | Brp Manufacturing Company | Encapsulant materials and associated devices |
WO2011042665A1 (fr) | 2009-10-08 | 2011-04-14 | Arkema France | Module photovoltaïque |
EP2380207A1 (en) * | 2009-01-22 | 2011-10-26 | E. I. du Pont de Nemours and Company | Poly(vinyl butyral) encapsulant comprising chelating agents for solar cell modules |
WO2012017046A1 (en) | 2010-08-06 | 2012-02-09 | Eni S.P.A. | Stabilized photoactive composition and use thereof |
DE112010004375T5 (de) | 2009-11-13 | 2012-11-29 | Du Pont-Mitsui Polychemicals Co., Ltd. | Solarzellenmodul aus amorphem Siliziium |
US8465675B2 (en) | 2010-04-14 | 2013-06-18 | Industrial Technology Research Institute | Encapsulation material |
US8592047B2 (en) | 2008-02-13 | 2013-11-26 | Arkema France | Binder based on carboxylic acid vinyl ethylene ester copolymer and polyolefin containing a functional monomer |
WO2014188376A1 (en) | 2013-05-23 | 2014-11-27 | Eni S.P.A. | Stabilized photoactive composition and use thereof |
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US20150187976A1 (en) * | 2014-01-02 | 2015-07-02 | Chin-Zeng Yeh | Composition of an Encapsulation Film for a Solar Cell Module |
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EP2380207A1 (en) * | 2009-01-22 | 2011-10-26 | E. I. du Pont de Nemours and Company | Poly(vinyl butyral) encapsulant comprising chelating agents for solar cell modules |
EP2380207A4 (en) * | 2009-01-22 | 2012-07-11 | Du Pont | POLY (VINYL BUTYRAL) -APPLICATION FUEL WITH CHELATINES FOR SOLAR CELL MODULES |
US8338699B2 (en) | 2009-01-22 | 2012-12-25 | E I Du Pont De Nemours And Company | Poly(vinyl butyral) encapsulant comprising chelating agents for solar cell modules |
WO2011020762A1 (en) | 2009-08-18 | 2011-02-24 | Basf Se | An uv-stabilized photovoltaic module |
CN102484145A (zh) * | 2009-08-18 | 2012-05-30 | 巴斯夫欧洲公司 | Uv稳定的光伏组件 |
JP2013502712A (ja) * | 2009-08-18 | 2013-01-24 | ビーエーエスエフ ソシエタス・ヨーロピア | Uv安定化光電モジュール |
WO2011042665A1 (fr) | 2009-10-08 | 2011-04-14 | Arkema France | Module photovoltaïque |
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US8465675B2 (en) | 2010-04-14 | 2013-06-18 | Industrial Technology Research Institute | Encapsulation material |
CN103080203A (zh) * | 2010-08-06 | 2013-05-01 | 艾尼股份公司 | 稳定的光活性组合物及其用途 |
WO2012017046A1 (en) | 2010-08-06 | 2012-02-09 | Eni S.P.A. | Stabilized photoactive composition and use thereof |
CN103080203B (zh) * | 2010-08-06 | 2015-07-22 | 艾尼股份公司 | 稳定的光活性组合物及其用途 |
EP2623526A4 (en) * | 2010-09-29 | 2015-06-24 | Zeon Corp | HYDROGENATED BLOCK COPOLYMER WITH AN ALKOXYSILYL GROUP AND USE THEREOF |
CN105027303A (zh) * | 2013-03-08 | 2015-11-04 | 希爱化成株式会社 | 太阳能电池用密封件和太阳能电池模块 |
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US20150187976A1 (en) * | 2014-01-02 | 2015-07-02 | Chin-Zeng Yeh | Composition of an Encapsulation Film for a Solar Cell Module |
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