FLUOROPOLYMER/PARTICULATE FILLED PROTECTIVE SHEET

• US 20100092759A1
• Filed: 10/09/2009
• Published: 04/15/2010
• Est. Priority Date: 10/13/2008
• Status: Abandoned Application

• Current Assignee: Saint-Gobain Performance Plastics Corporation (Compagnie De Saint-Gobain)
• Original Assignee: Saint-Gobain Performance Plastics Corporation (Compagnie De Saint-Gobain)
• Inventors: DiCorleto Gibson, Julia, Sekhon, Gurkirat S., Conley, Karen, Hong, Keith C., Fan, Hua
• Application Number:
  US12/576,724
• Publication Number:
  US 20100092759A1
• Time in Patent Office: Days
• US Class Current: 428/323
• CPC Class Codes: B32B 2250/24 All layers being polymeric
• CPC Class Codes: B32B 2307/204 Di-electric
• CPC Class Codes: B32B 2307/41 Opaque
• CPC Class Codes: B32B 2307/416 Reflective
• CPC Class Codes: B32B 2307/7246 Water vapor barrier
• CPC Class Codes: B32B 2457/12 Photovoltaic modules
• CPC Class Codes: B32B 2553/00 Packaging equipment or accessories not otherwise provided for
• CPC Class Codes: B32B 27/08 of synthetic resin
• CPC Class Codes: B32B 27/16 specially treated, e.g. irradiated
• CPC Class Codes: B32B 27/20 using fillers, pigments, thixotroping agents
• CPC Class Codes: B32B 27/28 comprising synthetic resins not wholly covered by any one of the sub-groups B32B27/30 - B32B27/42
• CPC Class Codes: B32B 27/304 comprising vinyl halide (co)polymers, e.g. PVC, PVDC, PVF, PVDF
• CPC Class Codes: B32B 27/32 comprising polyolefins comprising vinyl (co)polymers or acrylic (co)polymers B32B27/30
• CPC Class Codes: B32B 27/322 comprising halogenated polyolefins, e.g. PTFE
• 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 428/31504 Composite [nonstructural laminate]
• CPC Class Codes: Y10T 428/31507 Of polycarbonate
• CPC Class Codes: Y10T 428/3154 Of fluorinated addition polymer from unsaturated monomers
• CPC Class Codes: Y10T 428/31544 Addition polymer is perhalogenated

Abstract

The invention describes a particulate filled film, useful as a backsheet for a photovoltaic construct.

Claims

1. A film comprising:

a nonfibrillated fluoropolymer matrix material;

a particulate filler material wherein none of the particles of the particulate filler material exhibit a single linear dimension greater than 10 μ

m; and

wherein

the fluoropolymer matrix material and particulate filler material are included in the composition in relative amounts effective to provide a composite film including less than 15 volume percent filler material.

2. The film of claim 1, wherein the fluoropolymer is selected from polytetrafluoroethylene, polyvinylidenefluoride, polychlorotrifluoroethlylene, polyvinylfluoride, tetrafluoroethylene/hexafluoropropylene/ethylene copolymer, chlorotrifluoroethylene/vinylidenefluoride copolymer, chlorotrifluoroethylene/hexafluoropropylene, chlorotrifluoroethylene/ethylene copolymers, ethylene/trifluoroethylene copolymers, ethylene/tetrafluoroethylene copolymers, tetrafluoroethylene/hexafluoropropylene copolymers, tetrafluoroethylene-perfluoro(alkyl vinyl ether) copolymers or mixtures thereof.

3. An optoelectronic device comprising:

an optoelectronic component and the film of claim 2, wherein the optoelectronic component and the film are packaged together.

4. The optoelectronic device of claim 3, wherein the film is a backsheet to the optoelectronic component.

5. A film comprising:

a nonfibrillated fluoropolymer matrix material;

a particulate filler material wherein none of the particles of the particulate filler material exhibit a single linear dimension greater than 10 μ

m; and

wherein

the fluoropolymer matrix material and particulate filler material are included in the composition in relative amounts effective to provide a composite film including greater than 15 volume percent filler material.

6. The film of claim 5, wherein the fluoropolymer is selected from polytetrafluoroethylene, polyvinylidenefluoride, polychlorotrifluoroethlylene, polyvinylfluoride, tetrafluoroethylene/hexafluoropropylene/ethylene copolymer, chlorotrifluoroethylene/vinylidenefluoride copolymer, chlorotrifluoroethylene/hexafluoropropylene, chlorotrifluoroethylene/ethylene copolymers, ethylene/trifluoroethylene copolymers, ethylene/tetrafluoroethylene copolymers, tetrafluoroethylene/hexafluoropropylene copolymers, tetrafluoroethylene-perfluoro(alkyl vinyl ether) copolymers or mixtures thereof.

7. An optoelectronic device comprising:

an optoelectronic component and the film of claim 6, wherein the optoelectronic component and the film are packaged together.

8. The optoelectronic device of claim 7, wherein the layer film is a backsheet to the optoelectronic component.

9. A multilayer film comprising:

a first fluoropolymer film;

a second film comprising a nonfibrillated fluoropolymer matrix material;

a particulate filler material wherein none of the particles of the particulate filler material exhibit a single linear dimension greater than 10 μ

m; and

wherein

the fluoropolymer matrix material and particulate filler material are included in the composition in relative amounts effective to provide a composite film including less than 15 volume percent filler material; and

a third fluoropolymer film disposed on the second film.

10. The multilayer film of claim 9, wherein the fluoropolymer matrix material is selected from polytetrafluoroethylene, polyvinylidenefluoride, polychlorotrifluoroethlylene, polyvinylfluoride, tetrafluoroethylene/hexafluoropropylene/ethylene copolymer, chlorotrifluoroethylene/vinylidenefluoride copolymer, chlorotrifluoroethylene/hexafluoropropylene, chlorotrifluoroethylene/ethylene copolymers, ethylene/trifluoroethylene copolymers, ethylene/tetrafluoroethylene copolymers, tetrafluoroethylene/hexafluoropropylene copolymers, tetrafluoroethylene-perfluoro(alkyl vinyl ether) copolymers or mixtures thereof.

11. The multilayer film of claim 10, wherein the fluoropolymer layers are each independently selected from polytetrafluoroethylene (PTFE), tetrafluoroethylene-perfluoro(alkyl vinyl ether) copolymers (PFA), ethylene/tetrafluoroethylene copolymers (ETFE), fluorinated ethylene propylene copolymers (FEP), polyvinylidenefluoride (PVDF), polychlorotrifluoroethlylene (PCTFE) or mixtures thereof.

12. An optoelectronic device comprising:

an optoelectronic component and the multilayer film of claim 11, wherein the optoelectronic component and the film are packaged together.

13. The optoelectronic device of claim 12, wherein the multilayer film is a backsheet to the optoelectronic component.

14. A multilayer film comprising:

a first fluoropolymer film;

a second film comprising;

a nonfibrillated fluoropolymer matrix material;

a particulate filler material wherein none of the particles of the particulate filler material exhibit a single linear dimension greater than 10 μ

m; and

wherein

the fluoropolymer matrix material and particulate filler material are included in the composition in relative amounts effective to provide a composite film including greater than 15 volume percent filler material; and

a third fluoropolymer film disposed on the second film.

15. The multilayer film of claim 14, wherein the fluoropolymer matrix material is selected from polytetrafluoroethylene, polyvinylidenefluoride, polychlorotrifluoroethlylene, polyvinylfluoride, tetrafluoroethylene/hexafluoropropylene/ethylene copolymer, chlorotrifluoroethylene/vinylidenefluoride copolymer, chlorotrifluoroethylene/hexafluoropropylene, chlorotrifluoroethylene/ethylene copolymers, ethylene/trifluoroethylene copolymers, ethylene/tetrafluoroethylene copolymers, tetrafluoroethylene/hexafluoropropylene copolymers, tetrafluoroethylene-perfluoro(alkyl vinyl ether) copolymers or mixtures thereof.

16. The multilayer film of claim 15, wherein the fluoropolymer layers are each independently selected from polytetrafluoroethylene (PTFE), tetrafluoroethylene-perfluoro(alkyl vinyl ether) copolymers (PFA), ethylene/tetrafluoroethylene copolymers (ETFE), fluorinated ethylene propylene copolymers (FEP), polyvinylidenefluoride (PVDF), polychlorotrifluoroethlylene (PCTFE) or mixtures thereof.

17. An optoelectronic device comprising:

an optoelectronic component and the multilayer film of claim 16, wherein the optoelectronic component and the multilayer film are packaged together.

18. A process to prepare a multilayer film comprising the steps:

coating a casting composition onto a support, the casting composition comprising;

a carrier;

a nonfibrillated fluoropolymer matrix material;

a particulate filler material; and

wherein the fluoropolymer matrix material and particulate filler material are included in the composition in relative amounts effective to provide a composite film;

contacting the composite film with a second casting composition, wherein the second casting composition comprises;

a carrier; and

polymeric matrix material, thereby providing a multilayer film; and

further contacting the multilayer film with a third casting composition, wherein the third casting composition comprises;

a carrier; and

a polymeric matrix material, thereby providing a 3 layer multilayer film wherein the composite layer is in between the first and third layers.

19. The method of claim 18, further comprising a step of coating the composite film with one or more casting compositions comprising

a carrier;

a nonfibrillated fluoropolymer matrix material;

a particulate filler material; and

wherein the polymer matrix material and particulate filler material are included in the composition in relative amounts effective to provide a multilayer composite film layer.

20. The method of claim 19, further comprising contacting the multilayer composite film with a casting composition, wherein the casting composition comprises:

a carrier; and

fluoropolymeric material, thereby providing a multilayer film with a first outer layer.

21. The method of claim 20, further comprising further contacting the multilayer composite film with a casting composition, wherein the casting composition comprises:

a carrier; and

a fluoropolymeric material, thereby providing a multilayer film with a second outer layer wherein the multilayer composite particle layers are in between the two outer layers.

22. The method of claim 21, further comprising the step of:

subjecting an outer layer to a charged particle process.

23. The method of claim 22, wherein the charged particle process is corona discharge or plasma treatment.

24. A multilayer film comprising:

a first layer comprising an aqueous or solvent castable fluoropolymer or mixtures thereof;

a second layer disposed upon the first layer, the second layer comprising an aqueous or solvent castable fluoropolymer or mixtures thereof and a particulate filler material or mixtures thereof, wherein

the particulate filler material is present in the castable fluoropolymer in a range of from about 10% by volume to about 45% by volume; and

a third layer disposed upon the second layer comprising an aqueous or solvent castable fluoropolymer or mixtures thereof.

25. The multilayer film of claim 24, further including a fourth layer comprising an aqueous or solvent castable fluoropolymer or mixtures thereof disposed upon the first layer.

26. The multilayer film of claim 25, further including a fifth layer comprising an aqueous or solvent castable fluoropolymer or mixtures thereof disposed upon the third layer.

27. The multilayer film of claim 26, wherein the fourth and fifth layers are selected from polytetrafluoroethylene (PTFE), tetrafluoroethylene-perfluoro(alkyl vinyl ether) copolymers (PFA), ethylene/tetrafluoroethylene copolymers (ETFE), fluorinated ethylene propylene copolymers (FEP), polyvinylidenefluoride (PVDF), polychlorotrifluoroethlylene (PCTFE) or mixtures thereof.

28. The multilayer film of claim 24, wherein the dielectric break down strength (kV) is greater than 3 kV measured by ASTM method D3755.

29. The multilayer film of claim 24, wherein the solar reflectance is greater than 70% measured by ASTM method E424.

30. The multilayer film of claim 24, wherein the water vapor transmission rate is less than about 20 g/m²/day measured by ASTM method F1249.

31. The multilayer film of claim 24, wherein the light opacity is greater than about 80% measured by ASTM method E424.

32. A multilayer film of claim 24, wherein the solar reflectance within the infrared range is greater than 30%.

33. A multilayer film of claim 24, wherein the solar reflectance within the infrared range is greater than 50%.

34. A multilayer film of claim 24, wherein the solar reflectance within the infrared range is greater than 70%.

35. A multilayer film of claim 25, wherein one side has high reflectivity of greater than 65% and the total opacity of the film is greater than 90%.

36. A multilayer film of claim 25, wherein one side has high reflectivity of greater than 70% and the total opacity of the film is greater than 95%.

37. A multilayer film of claim 25, wherein one side has high reflectivity of greater than 75% and the total opacity of the film is greater than 99%.