Multi-layered sheet and method of preparing same

Patent metadata

Field	Value
Publication number	US-9312415-B2
Application number	US-201113695739-A
Country	US
Kind code	B2
Filing date	Apr 29, 2011
Priority date	May 6, 2010
Publication date	Apr 12, 2016
Grant date	Apr 12, 2016

Abstract

Provided are a multi-layered sheet, a backsheet for a photovoltaic cell, a method of preparing the same and a photovoltaic module. The multi-layered sheet in which a resin layer including a fluorine-based resin has excellent durability and weather resistance, and also exhibits strong interfacial adhesion to a substrate or polymer coating layer is provided. When a drying process is performed at a low temperature in preparation of the multi-layered sheet, production cost can be reduced, producibility can be increased, and degradation in the quality of a product caused by thermal deformation or thermal shock can be prevented. Such a multi-layered sheet may be effectively used as a backsheet for various photovoltaic cells.

First claim

What is claimed is:

1. A multi-layered sheet comprising:
a substrate; and
a fluorine-based resin layer,
wherein the multi-layered sheet further comprises a polymer coating layer that is compatible with a fluorine-based resin between the substrate and the fluorine-based resin layer,
wherein the fluorine-based resin layer includes a fluorine-based resin having an amorphous region and having a crystallinity of 10% to 50%,
wherein the fluorine-based resin is a copolymer including vinylidene fluoride and a comonomer in a polymerized type or a branched polymer,
wherein the comonomer in the copolymer is 10 to 30 wt % based on the total weight of the copolymer, and
wherein the overall crystallinity of the fluorine-based resin layer is 10 to 35%.

2. The multi-layered sheet according to claim 1 , wherein the polymer coating layer is formed on the substrate, a polymer in the polymer coating layer includes a main chain backbone that is compatible with the fluorine-based resin, and the fluorine-based resin layer is formed on the polymer coating layer.

3. The multi-layered sheet according to claim 2 , wherein the main chain backbone includes at least one selected from the group consisting of (meth)acryl-based, urethane-based, ether-sulfone-based, ether imine-based, amide-based, polyester-based, aliphatic polyester-based, polyester urethane-based, (meth)acrylamide-based, urea-based, and polycarbonate-based main chain backbones; backbones of free radical addition polymers induced from monomer mixtures including a (meth)acryl-based monomer, a (meth)acrylamide-based monomer or a vinyl-based monomer as a main component.

4. The multi-layered sheet according to claim 2 , wherein the polymer coating layer further includes a functional group, the functional group including at least one selected from the group consisting of a carboxyl group, a sulfonic acid group an aziridine group, an acid anhydride group, an amine group, an isocyanate group, a cyanuramide group, an epoxy group, a hydroxy group, an ester functional group, a carbamate functional group, an amide group, a urea group, an imide group, a phosphate group, a phosphoric acid group, a cyano group, a cyanate group and an imine group.

5. The multi-layered sheet according to claim 1 , wherein the polymer coating layer includes a functional group having an equivalent weight of 800 to 30000.

6. The multi-layered sheet according to claim 1 , wherein the polymer coating layer has a thickness of 10 to 5000 nm.

7. The multi-layered sheet according to claim 1 , wherein the comonomer in the copolymer is selected from the group consisting of hexafluoropropylene (HFP), chlorotrifluoroethylene (CTFE), tetrafluoroethylene (TFE), trifluoroethylene, hexafluoroisobutylene, perfluorobutylethylene, perfluoromethylvinylether (PMVE), perfluoro-2,2-dimethyl-1,3-dioxol (PDD) and perfluoro-2-methylene-4-methyl-1,3-dioxolane (PMD).

8. The multi-layered sheet according to claim 1 , wherein the fluorine-based resin has a weight average molecular weight of 50,000 to 1,000,000.

9. The multi-layered sheet according to claim 1 , wherein the fluorine-based resin has a fusing point of 80 to 175° C.

10. The multi-layered sheet according to claim 1 , wherein the fluorine-based resin layer further includes an amorphous resin.

11. The multi-layered sheet according to claim 10 , wherein the amorphous resin is a homopolymer or copolymer including a polymerized type of at least one monomer selected from the group consisting of methyl (meth)acrylate, ethyl (meth)acrylate, propyl (meth)acrylate, butyl (meth)acrylate and isobornyl (meth)acrylate.

12. The multi-layered sheet according to claim 1 , wherein the fluorine-based resin layer further includes a pigment, filler, UV stabilizer, thermal stabilizer or barrier particle.

13. The multi-layered sheet according to claim 1 , wherein the fluorine-based resin layer has a thickness of 3 to 50 μm.

14. The multi-layered sheet according to claim 1 , wherein the substrate is aluminum, iron; or a single sheet, stacked sheet or coextrusion product of polyethylene terephthalate (PET), polyethylene naphthalate (PEN) or polybutylene terephthalate (PBT).

15. The multi-layered sheet according to claim 1 , wherein at least one surface of the substrate is subjected to at least one surface treatment selected from plasma treatment, corona treatment, primer treatment, anchor agent treatment, coupling agent treatment and thermal treatment.

16. The multi-layered sheet according to claim 1 , wherein the substrate has a thickness of 50 to 500 μm.

17. A method of preparing a multi-layered sheet of claim 1 , comprising:
preparing a substrate;
forming a polymer coating layer by coating a polymer composition that is compatible with a fluorine-based resin on the substrate; and
coating a coating solution including a fluorine-based resin having a amorphous region and having a crystallinity of 10% to 50% and a solvent having a boiling point of 200° C. or less on the polymer coating layer,
wherein the fluorine-based resin is a copolymer including vinylidene fluoride and comonomer in a polymerized type or a branched polymer, and
wherein the comonomer in the copolymer is 10 to 30 wt % based on the total weight of the copolymer.

18. A backsheet for a photovoltaic cell comprising the multi-layered sheet according to claim 1 .

Assignees

• Kim Hyun Cheol
• Ko Hyun Seong
• Park Hyo Soon
• Kwon Yoon Kyung
• Ahn Do Won
• Lg Chemical Ltd

Inventors

• Kim Hyun Cheol
• Ko Hyun Seong
• Park Hyo Soon
• Kwon Yoon Kyung
• Ahn Do Won

Classifications

• H10F19/804

  Materials of encapsulations · CPC title

• H10F19/85

  Protective back sheets · CPC title

• C08J2427/16

  Homopolymers or copolymers of vinylidene fluoride · CPC title

• Y10T428/31935

  Ester, halide or nitrile of addition polymer · CPC title

• Y10T428/266

  of base or substrate · CPC title