Polyolefin compositions for photovoltaic encapsulant films

Patent metadata

Field	Value
Publication number	US-2024279437-A1
Application number	US-201716627202-A
Country	US
Kind code	A1
Filing date	Oct 31, 2017
Priority date	Jun 29, 2017
Publication date	Aug 22, 2024
Grant date	—

Abstract

The present disclosure relates to an encapsulant film made from a curable composition comprising: (A) a polyolefin polymer; (B) an organic peroxide; (C) a silane coupling agent; and (D) a co-agent comprising a monocyclic organosiloxane of formula (I).

First claim

What is claimed is:

1 . A curable composition for forming an encapsulant film, wherein the composition comprises:
a) a polyolefin polymer; b) an organic peroxide; c) a silane coupling agent; and d) a co-agent comprising a monocyclic organosiloxane of formula (I):

wherein subscript n is an integer greater than or equal to 3; each R 1 is independently a (C 2 -C 4 )alkenyl; and each R 2 is independently H, (C 1 -C 4 )alkyl, phenyl, or Rt.

2 . The composition of claim 1 comprising:
a) 80 wt % to 99.88 wt % of the polyolefin polymer;
b) from 0.1 wt % to 5 wt % of the organic peroxide;
c) from 0.01 wt % to 2 wt % of the silane coupling agent; and
d) from 0.01 wt % to 5 wt % of the co-agent comprising the monocyclic organosiloxane of formula (I).

3 . The composition of claim 1 , wherein the polyolefin polymer is an ethylene/alpha-olefin copolymer comprising a density of from 0.850 g/cc to 0.890 g/cc (ASTM D792) and a melt index of from 1.0 g/10 min to 50.0 g/10 min (ASTM D1238, at 190° C./2.16 kg).

4 . The composition of claim 1 , wherein the monocyclic organosiloxane of formula (I) is further described by any one of limitations (i) to (vi): (i) subscript n is 3; (ii) each R 1 is independently a (C 2 -C 3 )alkenyl; and each R 2 is independently H, (C 1 -C 2 )alkyl, or (C 2 -C 3 )alkenyl; (iii) each R 1 is vinyl; and each R 2 is independently (C 1 -C 2 )alkyl; (iv) each R 1 is vinyl; and each R 2 is methyl; (v) each R 1 is allyl; and each R 2 is independently (C 1 -C 2 )alkyl; (vi) each R 1 is allyl; and each R 2 is methyl.

5 . The composition of claim 1 , wherein the monocyclic organosiloxane of formula (I) is further described by any one of limitations (i) to (vi): (i) subscript n is 4; (ii) each R 1 is independently a (C 2 -C 3 )alkenyl; and each R 2 is independently H, (C 1 -C 2 )alkyl, or (C 2 -C 3 )alkenyl; (iii) each R 1 is vinyl; and each R 2 is independently (C 1 -C 2 )alkyl; (iv) each R 1 is vinyl; and each R 2 is methyl; (v) each R 1 is allyl; and each R 2 is independently (C 1 -C 2 )alkyl; (vi) each R 1 is allyl; and each R 2 is methyl.

6 . The composition of claim 1 , wherein the monocyclic organosiloxane of formula (I) is further described by any one of limitations (i) to (vi): (i) subscript n is 5 or 6; (ii) each R 1 is independently a (C 2 -C 3 )alkenyl; and each R 2 is independently H, (C 1 -C 2 )alkyl, or (C 2 -C 3 )alkenyl; (iii) each R 1 is vinyl; and each R 2 is independently (C 1 -C 2 )alkyl; (iv) each R 1 is vinyl; and each R 2 is methyl; (v) each R 1 is allyl; and each R 2 is independently (C 1 -C 2 )alkyl; (vi) each R 1 is allyl; and each R 2 is methyl.

7 . The composition of claim 1 , wherein the monocyclic organosiloxane of formula (I) is selected from the group consisting of: 1,3,5,7-tetravinyl-1,3,5,7-tetramethylcyclotetrasiloxane; 1,3,5-trivinyl-1,3,5-trimethylcyclotrisiloxane; 1,3,5,7,9-pentavinyl-1,3,5,7,9-pentamethylcyclopentasiloxane; and combinations thereof.

8 . An encapsulant film comprising a crosslinked polymeric composition comprising the reaction product of:
a) a polyolefin polymer; b) an organic peroxide; c) a silane coupling agent; and d) a co-agent comprising a monocyclic organosiloxane of formula (I):

wherein subscript n is an integer greater than or equal to 3; each R 1 is independently a (C 2 -C 4 )alkenyl; and each R 2 is independently H, (C 1 -C 4 )alkyl, phenyl, or R 1 .

9 . The encapsulant film of claim 8 comprising a crosslinked polymeric composition comprising the reaction product of:
a) From 80 wt % to 99.88 wt % of the polyolefin polymer;
b) from 0.1 wt % to 5 wt % of the organic peroxide;
c) from 0.01 wt % to 2 wt % of the silane coupling agent; and
d) from 0.01 wt % to 5 wt % of the co-agent comprising the monocyclic organosiloxane of formula (I).

10 . The encapsulant film of claim 8 , wherein the polyolefin polymer is an ethylene/alpha-olefin copolymer comprising a density of from 0.850 g/cc to 0.890 g/cc (ASTM D792) and a melt index of from 1.0 g/10 min to 50.0 g/10 min (ASTM D1238, at 190° C./2.16 kg).

11 . The encapsulant film of claim 8 , wherein the monocyclic organosiloxane of formula (I) is further described by any one of limitations (i) to (vi): (i) subscript n is 3; (ii) each R 1 is independently a (C 2 -C 3 )alkenyl; and each R 2 is independently H, (C 1 -C 2 )alkyl, or (C 2 -C 3 )alkenyl; (iii) each R 1 is vinyl; and each R 2 is independently (C 1 -C 2 )alkyl; (iv) each R 1 is vinyl; and each R 2 is methyl; (v) each R 1 is allyl; and each R 2 is independently (C 1 -C 2 )alkyl; (vi) each R 1 is allyl; and each R 2 is methyl.

12 . The encapsulant film of claim 8 , wherein the monocyclic organosiloxane of formula (I) is further described by any one of limitations (i) to (vi): (i) subscript n is 4; (ii) each R 1 is independently a (C 2 -C 3 )alkenyl; and each R 2 is independently H, (C 1 -C 2 )alkyl, or (C 2 -C 3 )alkenyl; (iii) each R 1 is vinyl; and each R 2 is independently (C 1 -C 2 )alkyl; (iv) each R 1 is vinyl; and each R 2 is methyl; (v) each R 1 is allyl; and each R 2 is independently (C 1 -C 2 )alkyl; (vi) each R 1 is allyl; and each R 2 is methyl.

13 . The encapsulant film of claim 8 , wherein the monocyclic organosiloxane of formula (I) is further described by any one of limitations (i) to (vi): (i) subscript n is 5 or 6; (ii) each R 1 is independently a (C 2 -C 3 )alkenyl; and each R 2 is independently H, (C 1 -C 2 )alkyl, or (C 2 -C 3 )alkenyl; (iii) each R 1 is vinyl; and each R 2 is independently (C 1 -C 2 )alkyl; (iv) each R 1 is vinyl; and each R 2 is methyl; (v) each R 1 is allyl; and each R 2 is independently (C 1 -C 2 )alkyl; (vi) each R 1 is allyl; and each R 2 is methyl.

14 . The encapsulant film of claim 8 , wherein the monocyclic organosiloxane of formula (I) is selected from the group consisting of: 1,3,5,7-tetravinyl-1,3,5,7-tetramethylcyclotetrasiloxane; 1,3,5-trivinyl-1,3,5-trimethylcyclotrisiloxane; 1,3,5,7,9-pentavinyl-1,3,5,7,9-pentamethylcyclopentasiloxane; and combinations thereof.

15 . The encapsulant film of claim 8 , further comprising a volume resistivity of greater than 1.0*10 14 ohm-cm at room temperature.

16 . The encapsulant film of claim 8 , further comprising a volume resistivity of greater than 1.0*10 14 ohm-cm at 60° C.

17 . The encapsulant film of claim 8 , further comprising an average initial glass adhesion of greater than 60 N/cm.

18 . An electronic device module comprising:
an electronic device, a cover sheet, and the encapsulant film of claim 8 .

Assignees

• Dow Global Technologies Llc

Inventors

• Yang Yunfeng
• He Chao
• Ma Weiming
• Chen Hongyu
• Sun Yabin
• Zhang Kainan
• Cogen Jeffrey M
• Person Timothy J
• Li Yuyan
• Yang Hong

Classifications

• C08J2323/08

  Copolymers of ethene (C08J2323/16 takes precedence) · CPC title

• H10H20/854

  characterised by their material, e.g. epoxy or silicone resins · CPC title

• C08J5/18

  Manufacture of films or sheets · CPC title

• C08L23/0815

  with aliphatic 1-olefins containing one carbon-to-carbon double bond · CPC title

• C08K5/14

  Peroxides · CPC title