Articles comprising high melt flow ionomeric compositions

Abstract

A polymeric film or sheet comprising an ionomeric composition comprising ionomeric copolymer of an alpha olefin and about 1 to about 30 wt % of alpha,beta-ethylenically unsaturated carboxylic acid having 3 to 8 carbons, based on the total weight of the ionomeric copolymer, wherein the carboxylic acid is neutralized to a level of 1 to 100 mol %, with one or more metal ions, based on the total number of moles of carboxylate groups in the ionomeric copolymer, and wherein the ionomeric copolymer has a Melt Index of about 20 to about 300 g/10 min. The ionomeric composition preferably comprises an additive selected from the group consisting of silane coupling agent, organic peroxide, and combinations thereof. In addition, an article comprising an interlayer formed of the polymeric film or sheet and an additional layer selected from the group consisting of glass, other polymeric interlayer sheets, polymeric film layers, and metal films or sheets. Examples of articles include safety windows and solar cells.

1 - 19 . (canceled) 
     
     
         20 . A process of manufacturing an article, wherein the article is a solar cell module, the process comprising:
 (i) providing a solar cell pre-laminate assembly, said solar cell prelaminate assembly comprising a polymeric film or sheet; a solar cell component; and an additional layer;
 wherein said polymeric film or sheet comprises an ionomeric composition comprising an ionomeric copolymer of an alpha olefin and about 1 to about 30 wt % of alpha,beta-ethylenically unsaturated carboxylic acid having 3 to 8 carbons, based on the total weight of the ionomeric copolymer, wherein the carboxylic acid is neutralized to a level of 1 to 100 mol %, with one or more metal ions, based on the total number of moles of carboxylate groups in the ionomeric copolymer, and wherein the ionomeric copolymer has a Melt Index of about 20 to about 300 g/10 min; 
 wherein said solar cell component comprises one or a plurality of solar cells; and 
 wherein said additional layer is selected from the group consisting of glass, other polymeric interlayer sheets, polymeric film layers, and metal films or sheets; and 
   (ii) laminating the pre-laminate assembly to form the solar cell module.   
     
     
         21 . The process of  claim 20 , wherein the step (ii) of lamination is conducted by subjecting the assembly to heat and, optionally, vacuum. 
     
     
         23 - 25 . (canceled) 
     
     
         26 . A process for making a laminate, said process comprising the steps of:
 providing a polymeric film or sheet, said polymeric film or sheet consisting essentially of an ionomeric composition;
 wherein said polymeric film or sheet is formed from a melt of the ionomeric composition, wherein said melt is processed a temperature sufficiently low to prevent premature cross-linking in the ionomeric composition, and 
 wherein said ionomeric composition consists essentially of:
 an ionomeric copolymer consisting essentially of copolymerized repeat units of ethylene; about 10 to about 30 wt %, of copolymerized repeat units of at least one alpha,beta-ethylenically unsaturated carboxylic acid having 3 to 8 carbons; and 0 to about 50 wt % of copolymerized repeat units of one or more other unsaturated comonomers selected from the group consisting of methyl acrylate, methyl methacrylate, ethyl acrylate, ethyl methacrylate, isopropyl acrylate, isopropyl methacrylate, butyl acrylate and butyl methacrylate; wherein the weight percentages are based on the total weight of the ionomeric copolymer; 
 wherein the ionomeric copolymer is neutralized to a level of 1 to 100 mol %, based on the total number of moles of carboxylate groups in the ionomeric copolymer, and further comprises one or more metal ions; 
 and wherein the ionomeric copolymer has a Melt Index of about 20 to about 300 g/10 min, as measured by ASTM D1238 at 190° C. and under a load of 2160 g; 
 about 0.5 to about 3 wt % of at least one organic peroxide, based on the total weight of the ionomeric composition; optionally 
 about 0.01 to about 5 wt % of one or more silane coupling agents, based on the total weight of the ionomeric composition; and optionally 
 one or more additives selected from the group consisting of initiators, inhibitors, plasticizers, processing aides, flow enhancing additives, lubricants, pigments, dyes, flame retardants, impact modifiers, nucleating agents, antiblocking agents, thermal stabilizers, UV absorbers, UV stabilizers, hindered amine light stabilizers, dispersants, surfactants, chelating agents, coupling agents, adhesives, primers, reinforcement additives and fillers; 
 
   laying up the polymeric film or sheet with a solar cell component comprising one or a plurality of solar cells or with at least one additional layer to form a pre-laminate assembly;   subjecting the pre-laminate assembly to heat and optionally vacuum or pressure to form the laminate; and   heating the laminate at a temperature sufficient to cause the peroxide to cross-link and cure the ionomeric composition.   
     
     
         27 . The process of  claim 26 , wherein the melt is processed at a temperature of about 100° C. or less to prevent premature cross-linking in the ionomeric composition. 
     
     
         28 . The process of  claim 26 , wherein the laminate is heated at a temperature of 145° C. or more to cause the peroxide to cross-link and cure the ionomeric composition. 
     
     
         29 . A laminate made by the process of  claim 26 . 
     
     
         30 . The process of  claim 26 , wherein the laminate is a safety glass laminate or a solar cell module. 
     
     
         31 . The process of  claim 26 , wherein the laminate is a safety glass laminate, and the at least one additional layer is a rigid sheet; and further wherein the safety glass laminate optionally comprises one or more other additional layers selected from the group consisting of a second rigid sheet, a film or sheet comprising a material selected from the group consisting of acid copolymers and ionomers derived therefrom, poly(ethylene vinyl acetate)s, poly(vinyl acetal)s, polyurethanes, polyvinylchlorides, polyethylenes, polyolefin block elastomers, ethylene acrylate ester copolymers, silicone elastomers, epoxy resins, metal foils, polyesters, poly(ethylene naphthalate)s, polycarbonates, polyolefins, norbornene polymers, polystyrenes, styrene-acrylate copolymers, acrylonitrile-styrene copolymers, polysulfones, nylons, acrylics, cellulose acetates, cellophanes, and fluoropolymers. 
     
     
         32 . The process of  claim 26 , wherein the laminate is a solar cell module that comprises the solar cell component; and further wherein the solar cell module optionally comprises one or more other additional layers selected from the group consisting of an incident layer, a backing layer, an encapsulant, a barrier layer, a dielectric layer, and a scrim. 
     
     
         33 . The process of  claim 31 , wherein the rigid sheet is a glass sheet and the pre-laminate assembly comprises layers laid up in an order selected from the group consisting of:
 glass/ION;   glass/ION/film;   glass/ION/glass;   glass/ION/film/ION/glass; and   glass/ION/film/ION/film;   wherein the film comprises a material selected from the group consisting of acid copolymers and ionomers derived therefrom, poly(ethylene vinyl acetate)s, poly(vinyl acetal)s, polyurethanes, polyvinylchlorides, polyethylenes, polyolefin block elastomers, ethylene acrylate ester copolymers, silicone elastomers, epoxy resins, metal foils, polyesters, poly(ethylene naphthalate)s, polycarbonates, polyolefins, norbornene polymers, polystyrenes, styrene-acrylate copolymers, acrylonitrile-styrene copolymers, polysulfones, nylons, acrylics, cellulose acetates, cellophanes, and fluoropolymers; and   wherein “ION” represents the polymeric film or sheet.   
     
     
         34 . The process of  claim 32 , wherein the pre-laminate assembly comprises layers laid up in an order selected from the group consisting of:
 glass/ION/solar cell/ION/glass;   glass/ION/solar cell/ION/fluoropolymer film;   fluoropolymer film/ION/solar cell/ION/glass;   fluoropolymer film/ION/solar cell/ION/fluoropolymer film;   glass/ION/solar cell/ION/polyester film;   fluoropolymer film/ION/solar cell/ION/polyester film;   glass/ION/solar cell/ION/barrier coated film/ION/glass;   fluoropolymer film/ION/barrier coated film/ION/solar cell/ION/barrier coated film/ION/fluoropolymer film;   glass/ION/solar cell/ION/aluminum stock;   fluoropolymer film/ION/solar cell/ION/aluminum stock;   glass/ION/solar cell/ION/galvanized steel sheet;   glass/ION/solar cell/ION/polyester film/ION/aluminum stock;   fluoropolymer film/ION/solar cell/ION/polyester film/ION/aluminum stock;   glass/ION/solar cell/ION/polyester film/ION/galvanized steel sheet;   fluoropolymer film/ION/solar cell/ION/polyester film/ION/galvanized steel sheet;   glass/ION/solar cell/acoustic poly(vinyl butyral) encapsulant layer/glass;   glass/ION/solar cell/poly(vinyl butyral) encapsulant layer/fluoropolymer film;   fluoropolymer film/ION/solar cell/acid copolymer encapsulant layer/Tedlar® film;   glass/ION/solar cell/ethylene vinyl acetate encapsulant layer/polyester film;   fluoropolymer film/ION/solar cell/poly(ethylene-co-methyl acrylate) encapsulant layer/polyester film; and   glass/poly(ethylene-co-butyl acrylate) encapsulant layer/solar cell/ION/barrier coated film/poly(ethylene-co-butyl acrylate) encapsulant layer/glass;   wherein “ION” represents the polymeric film or sheet.   
     
     
         35 . The process of  claim 26 , wherein the at least one organic peroxide is selected from the group consisting of 2,5-dimethylhexane-2,5-dihydroperoxide, 2,5-dimethyl-2,5-di(tert-betylperoxy)hexane-3, di-tert-butyl peroxide, tert-butylcumyl peroxide, 2,5-dimethyl-2,5-di(tert-butylperoxy)hexane, dicumyl peroxide, alpha,alpha′-bis(tert-butyl-peroxyisopropyl)benzene, n-butyl-4,4-bis(tert-butylperoxy)valerate, 2,2-bis(tert-butylperoxy)butane, 1,1-bis(tert-butyl-peroxy)cyclohexane, 1,1-bis(tert-butylperoxy)-3,3,5-trimethyl-cyclohexane, tert-butyl peroxybenzoate, and benzoyl peroxide. 
     
     
         36 . The process of  claim 26 , wherein the ionomeric composition comprises the one or more silane coupling agents, said silane coupling agent(s) selected from the group consisting of gamma-chloropropylmethoxysilane, vinyltrimethoxysilane, vinyltriethoxysilane, vinyltris(beta-methoxyethoxy)silane, gamma-vinylbenzylpropyltrimethoxysilane, N-beta-(N-vinylbenzylaminoethyl)-gamma-aminopropyltrimethoxysilane, gamma-methacryloxypropyl trimethoxysilane, vinyltriacetoxysilane, gamma-glycidoxypropyltrimethoxysilane, gamma-glycidoxypropyltriethoxysilane, beta-(3,4-epoxycyclohexyl)ethyltrimethoxysilane, vinyltrichlorosilane, gamma-mercaptopropylmethoxysilane, gamma-aminopropyltriethoxysilane, and N-beta-(aminoethyl)-gamma-aminopropyltrimethoxysilane. 
     
     
         37 . The process of  claim 26 , wherein the ionomeric composition comprises the initiator and the initiator comprises dibutyltin dilaurate, or wherein the ionomeric composition comprises one or more inhibitors selected from the group consisting of hydroquinone, hydroquinone monomethyl ether, p-benzoquinone, and methylhydroquinone. 
     
     
         38 . The process of  claim 26 , wherein the ionomeric copolymer has a Melt Index of about 75 to about 200 g/10 min. 
     
     
         39 . The process of  claim 26 , wherein the at least one alpha,beta-ethylenically unsaturated carboxylic acid is selected from the group consisting of acrylic acid and methacrylic acid; the ionomeric copolymer comprises about 10 to about 25 wt % of the alpha,beta-ethylenically unsaturated carboxylic acid; and the ionomeric copolymer is neutralized to a level of 2 to 40 mol %. 
     
     
         40 . The process of  claim 26 , wherein the ionomeric composition consists essentially of the ionomeric copolymer; and about 1.5 to about 3 wt % of the organic peroxide; wherein the ionomeric copolymer consists essentially of the copolymerized repeat units of ethylene and about 15 to about 23 wt % of copolymerized repeat units of acrylic acid, methacrylic acid, or acrylic acid and methacrylic acid; and wherein the ionomeric copolymer has a Melt Index of about 30 to about 200 g/10 min. 
     
     
         41 . The process of  claim 26 , wherein the at least one alpha,beta-ethylenically unsaturated carboxylic acid is selected from the group consisting of acrylic acid and methacrylic acid; the ionomeric copolymer comprises about 15 to about 23 wt % of the copolymerized repeat units of the at least one alpha,beta-ethylenically unsaturated carboxylic acid; and the ionomeric copolymer is neutralized to a level of 2 to 40 mol %. 
     
     
         42 . The process of  claim 26 , wherein; the alpha,beta-ethylenically unsaturated carboxylic acid is selected from the group consisting of acrylic acid and methacrylic acid; the ionomeric copolymer comprises about 18 to about 23 wt % of the copolymerized repeat units of the at least one alpha,beta-ethylenically unsaturated carboxylic acid; the ionomeric copolymer is neutralized to a level of 2 to 20 mol %; and the at least one organic peroxide is selected from the group consisting of 2,5-dimethylhexane-2,5-dihydroperoxide, 2,5-dimethyl-2,5-di(tert-betylperoxy)hexane-3, di-tert-butyl peroxide, tert-butylcumyl peroxide, 2,5-dimethyl-2,5-di(tert-butylperoxy)hexane, dicumyl peroxide, alpha,alpha′-bis(tert-butyl-peroxyisopropyl)benzene, n-butyl-4,4-bis(tert-butylperoxy)valerate, 2,2-bis(tert-butylperoxy)butane, 1,1-bis(tert-butyl-peroxy)cyclohexane, 1,1-bis(tert-butylperoxy)-3,3,5-trimethyl-cyclohexane, tert-butyl peroxybenzoate, and benzoyl peroxide. 
     
     
         43 . The process of  claim 26 , wherein the one or more additives are selected from the group consisting of:
 about 0.01 to about 0.05 wt % of the initiator dibutyltin dilaurate;   up to about 5 wt % of one or more inhibitors, said inhibitor(s) selected from the group consisting of hydroquinone, hydroquinone monomethyl ether, p-benzoquinone, and methylhydroquinone;   about 0.05 wt % up to about 5 wt % of the thermal stabilizer;   about 0.05 wt % to about 5 wt % of the UV absorber; and   about 0.05 wt % to about 5 wt % of the hindered amine light stabilizer;   wherein the weight percentages are based on the total weight of the ionomeric composition.