Fluoropolymer coated films useful for photovoltaic modules

• US 20070154704A1
• Filed: 12/20/2006
• Published: 07/05/2007
• Est. Priority Date: 12/30/2005
• Status: Active Grant

• Current Assignee: DuPont Electronics, Inc. (DuPont de Nemours, Inc.)
• Original Assignee: E. I. du Pont de Nemours and Company (Corteva, Inc.)
• Inventors: Debergalis, Michael, Snow, Larry Glen
• Granted Patent: US 7,553,540 B2
• Time in Patent Office: Days
• US Class Current: 428/323
• CPC Class Codes: B32B 17/10018 comprising only one glass sheet
• CPC Class Codes: B32B 17/10788 containing ethylene vinylacetate
• CPC Class Codes: B32B 2367/00 Polyesters, e.g. PET, i.e. polyethylene terephthalate
• CPC Class Codes: C08J 2367/02 Polyesters derived from dicarboxylic acids and dihydroxy compounds; C08J2367/06 takes precedence
• CPC Class Codes: C08J 2427/00 Characterised by the use of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by a halogen; Derivatives of such polymers
• CPC Class Codes: C08J 7/0427 with only one layer of a composition containing a polymer binder with more layers C08J7/042
• CPC Class Codes: C08J 7/043 Improving the adhesiveness of the coatings per se, e.g. forming primers adhesives in the form of films or foils characterised by the primer layers between the polymer carriers and the adhesives C09J7/50
• CPC Class Codes: C08J 7/048 Forming gas barrier coatings
• CPC Class Codes: H01L 31/049 Protective back sheets
• CPC Class Codes: Y02E 10/50 Photovoltaic [PV] energy
• CPC Class Codes: Y10T 428/24942 including components having same physical characteristic in differing degree
• CPC Class Codes: Y10T 428/25 Web or sheet containing structurally defined element or component and including a second component containing structurally defined particles
• CPC Class Codes: Y10T 428/254 Polymeric or resinous material
• CPC Class Codes: Y10T 428/263 Coating layer not in excess of 5 mils thick or equivalent
• CPC Class Codes: Y10T 428/264 Up to 3 mils
• CPC Class Codes: Y10T 428/265 1 mil or less
• CPC Class Codes: Y10T 428/266 of base or substrate
• CPC Class Codes: Y10T 428/269 including synthetic resin or polymer layer or component
• CPC Class Codes: Y10T 428/2843 including a primer layer
• CPC Class Codes: Y10T 428/287 including epoxy group or epoxy polymer
• CPC Class Codes: Y10T 428/2874 : including aldehyde or ketone condensation polymer [e.g., urea formaldehyde polymer, melamine formaldehyde polymer, etc.]
• CPC Class Codes: Y10T 428/2878 : including addition polymer from unsaturated monomer
• CPC Class Codes: Y10T 428/2891 : including addition polymer from alpha-beta unsaturated carboxylic acid [e.g., acrylic acid, methacrylic acid, etc.] Or derivative thereof
• CPC Class Codes: Y10T 428/2896 : including nitrogen containing condensation polymer [e.g., polyurethane, polyisocyanate, etc.]
• CPC Class Codes: Y10T 428/31507 : Of polycarbonate
• CPC Class Codes: Y10T 428/31511 : Of epoxy ether
• CPC Class Codes: Y10T 428/31536 : Including interfacial reaction product of adjacent layers
• CPC Class Codes: Y10T 428/3154 : Of fluorinated addition polymer from unsaturated monomers
• CPC Class Codes: Y10T 428/31544 : Addition polymer is perhalogenated
• CPC Class Codes: Y10T 428/31786 : Of polyester [e.g., alkyd, etc.]
• CPC Class Codes: Y10T 428/31855 : Of addition polymer from unsaturated monomers
• CPC Class Codes: Y10T 428/31935 : Ester, halide or nitrile of addition polymer

Abstract

A fluoropolymer coated film comprising polymeric substrate film and fluoropolymer coating on the polymeric substrate film. The fluoropolymer coating comprises fluoropolymer selected from homopolymers and copolymers of vinyl fluoride and homopolymers and copolymers of vinylidene fluoride polymer blended with compatible adhesive polymer comprising functional groups selected from carboxylic acid, sulfonic acid, aziridine, anhydride, amine, isocyanate, melamine, epoxy, hydroxy, anhydride and mixtures thereof. The polymeric substrate film comprises functional groups on its surface that interact with the compatible adhesive polymer to promote bonding of the fluoropolymer coating to the substrate film.

Claims

1. A fluoropolymer coated film comprising:

a polymeric substrate film; and

a fluoropolymer coating on said polymeric substrate film, said fluoropolymer coating comprising fluoropolymer selected from homopolymers and copolymers of vinyl fluoride and homopolymers and copolymers of vinylidene fluoride polymer blended with compatible adhesive polymer comprising functional groups selected from carboxylic acid, sulfonic acid, aziridine, anhydride, amine, isocyanate, melamine, epoxy, hydroxy, anhydride and mixtures thereof;

said polymeric substrate film comprising functional groups on its surface that interact with said compatible adhesive polymer to promote bonding of said fluoropolymer coating to said substrate film.

2. The fluoropolymer coated film of claim 1 wherein said polymeric substrate film comprises a primer layer on its surface providing said functional groups that interact with said adhesive to promote bonding of said fluoropolymer coating to said substrate film.

3. The fluoropolymer coated film of claim 1 wherein said functional groups on the surface of said polymeric substrate film are selected from carboxylic acid, sulfonic acid, aziridine, amine, isocyanate, melamine, epoxy, hydroxy, anhydride and mixtures thereof.

4. The fluoropolymer coated film of claim 1 wherein said compatible adhesive polymer is a functional acrylic polymer.

5. The fluoropolymer coated film of claim 1 wherein said compatible adhesion-promoting polymer is an amine functional acrylic polymer.

6. The fluoropolymer coated film of claim 1 wherein said fluoropolymer is selected from homopolymers and copolymers of vinyl fluoride comprising at least 60 mole % vinyl fluoride and homopolymers and copolymers of vinylidene fluoride comprising at least 60 mole % vinylidene fluoride.

7. The fluoropolymer coated film of claim 1 wherein said fluoropolymer is selected from homopolymers and copolymers of vinyl fluoride comprising at least 80 mole % vinyl fluoride and homopolymers and copolymers of vinylidene fluoride comprising at least 80 mole % vinylidene fluoride.

8. The fluoropolymer coated film of claim 1 wherein said fluoropolymer coating comprises about 1 to about 40 weight % of said compatible adhesive polymer based on fluoropolymer solids content.

9. The fluoropolymer coated film of claim 1 wherein said fluoropolymer coating further comprises pigment.

10. The fluoropolymer coated film of claim 1 wherein said fluoropolymer coating further comprises about 1 to about 35 weight % of pigment based on fluoropolymer solids content.

11. The fluoropolymer coated film of claim 1 wherein said fluoropolymer coating is on both surfaces of said substrate film.

12. The fluoropolymer coated film of claim 2 wherein said substrate film comprises polyester.

13. The fluoropolymer coated film of claim 9 wherein said primer comprises a polymer selected from polyallylamine/melamine polymer, polyethylene imine polymer, ethylene acrylic acid copolymer, and acid modified polyolefin.

14. The fluoropolymer coated film of claim 1 wherein said fluoropolymer coating has a thickness of about 0.1 to about 2.0 mils.

15. The fluoropolymer coated film of claim 1 wherein said substrate film has a thickness of about 0.5 to about 10 mils.

16. The fluoropolymer coated film of claim 1 wherein said primer layer has a thickness of about 20 to about 100 nm.

17. The fluoropolymer coated film of claim 1 wherein the surface of said substrate film is activated.

18. The fluoropolymer coated film of claim 1 wherein said substrate film comprises filler.

19. A photovoltaic module comprising the fluoropolymer coated film of claim 1 as backsheet.