Solar cell modules with improved backsheet

Abstract

Disclosed is a polyamide-ionomer composition suitable for use in a backsheet in a photovoltaic module comprising a polymer component a polyamide and an anhydride ionomer comprising a copolymer of ethylene, an alpha, beta-unsaturated C 3 -C 8 carboxylic acid and an ethylenically unsaturated dicarboxylic acid or derivative thereof selected from the group consisting of maleic acid, fumaric acid, itaconic acid, maleic anhydride, and a C 1 -C 1 alkyl half ester of maleic acid, wherein the carboxylic acid functionalities present are at least partially neutralized to carboxylate salts of one or more alkali metal, transition metal, or alkaline earth metal cations; 0 to 20 weight % of pigment; and 0 to 40 weight % of filler; preferably wherein the combination of pigment and filler comprises 10 to 50 weight % of the composition; and 0 to 5 weight % of weatherability additives.

1 . A polyamide-ionomer blend composition comprising
 (i) A polymer component comprising   1) 53 to 64 weight %, based on the combination of (1) and (2), of a polyamide component;   2) 36 to 47 weight %, based on the combination of (1) and (2), of an anhydride ionomer component comprising a copolymer of
 (a) ethylene; 
 (b) from 5 weight % to 15 weight % of an alpha, beta-unsaturated C3-C 8  carboxylic acid; 
 (c) from 0.5 weight % to 12 weight % of at least one comonomer that is an ethylenically unsaturated dicarboxylic acid or derivative thereof selected from maleic acid, fumaric acid, itaconic acid, maleic anhydride, or a C 1 -C 4  alkyl half ester of maleic acid; and 
 (d) from 0 weight % to 30 weight % of monomers selected from alkyl acrylate or alkyl methacrylate, wherein the alkyl groups have from one to twelve carbon atoms; wherein the carboxylic acid functionalities present are at least partially neutralized to carboxylate salts comprising one or more alkali metal, transition metal, or alkaline earth metal cations; 
   (ii) 0 to 20 weight % of pigment; and   (iii) 0 to 40 weight % of filler; and   (iv) 0 to 5 weight % of weathering additives selected from oxidation inhibitors, UV stabilizers and hindered amine light stabilizers.   
     
     
         2 . The composition of  claim 1  wherein the combination of (ii) and (iii) comprises 8 to 50 weight % of the combination of (i), (ii), (iii) and (iv). 
     
     
         3 . The composition of  claim 1  wherein the polyamide component comprises nylon 6, nylon 12, nylon 610, nylon 612, nylon 610/6T, nylon 612/6T, or combinations thereof. 
     
     
         4 . The composition of  claim 1  wherein the polyamide component comprises nylon 6. 
     
     
         5 . The composition of  claim 1  wherein the comonomer of (c) is a C 1 -C 4  alkyl half ester of maleic acid. 
     
     
         6 . The composition of  claim 1  wherein the carboxylic acid functionalities present are at least partially neutralized to carboxylate salts comprising zinc or sodium. 
     
     
         7 . The composition of  claim 5  wherein the carboxylic acid functionalities present are at least partially neutralized to carboxylate salts comprising zinc. 
     
     
         8 . The composition of  claim 1  comprising 8 to 20 weight % of pigment and 0 weight % filler. 
     
     
         9 . The composition  claim 1  comprising 8 to 40 weight % of filler and 0 weight % of pigment. 
     
     
         10 . The composition of  claim 1  comprising 10 to 40 weight % of filler and 8 to 15 weight % of pigment. 
     
     
         11 . The composition of  claim 1  comprising 8 to 12 weight % of pigment and 12 to 18 weight % of filler. 
     
     
         12 . The composition of  claim 1  wherein the pigment comprises titanium dioxide, zinc oxide, or antimony oxide. 
     
     
         13 . The composition of  claim 1  wherein the filler comprises an inorganic oxide, carbonate, sulfate, silica, alkali and alkaline earth metal silicate, or baryte of a metal of Groups IA, IIA, IIIA, IIB, VIB or VIII of the periodic table of the elements. 
     
     
         14 . The composition of  claim 13  wherein the filler comprises calcium carbonate, barium sulfate, wollastonite or talc. 
     
     
         15 . The composition of  claim 14  wherein the filler comprises talc. 
     
     
         16 . The composition of  claim 1  comprising 10 to 40 weight % of talc and 8 to 15 weight % of titanium dioxide. 
     
     
         17 . A backsheet for a photovoltaic module comprising the composition of  claim 1 . 
     
     
         18 . The backsheet of  claim 17  wherein the polyamide component comprises nylon 6. 
     
     
         19 . The backsheet of  claim 17  wherein the pigment comprises titanium dioxide, zinc oxide, or antimony oxide. 
     
     
         20 . The backsheet of  claim 17  wherein the filler comprises calcium carbonate, barium sulfate, wollastonite or talc. 
     
     
         21 . The backsheet of  claim 20  wherein the filler comprises talc. 
     
     
         22 . The backsheet of  claim 17  wherein the polyamide-ionomer blend composition comprises 10 to 40 weight % of talc and 8 to 15 weight % of titanium dioxide. 
     
     
         23 . A laminated solar cell module comprising a front support layer formed of a light transmitting material and having first and second surfaces; a plurality of interconnected solar cells having a first surface facing the front support layer and a second surface facing away from the front support layer; a transparent encapsulant surrounding and encapsulating the interconnected solar cells, the transparent encapsulant being bonded to the second surface of the front support layer; and a backsheet of  claim 17  wherein one surface of the backsheet is bonded to the second surface of the transparent encapsulant. 
     
     
         24 . An assembly for conversion under heat and pressure into a laminated solar cell module, the assembly comprising a front support layer formed of a light transmitting material and having front and back surfaces; a first transparent thermoplastic encapsulant layer adjacent to the back surface of the front support layer; a plurality of interconnected solar cells having first and second surfaces adjacent to the first transparent encapsulant layer; a second transparent thermoplastic encapsulant layer disposed adjacent to the solar cells in parallel relation to the first transparent encapsulant layer; and a thermoplastic backsheet of  claim 17 . 
     
     
         25 . A method of manufacturing a solar cell module comprising providing a front support layer formed of a light transmitting material and having front and back surfaces; placing a first transparent thermoplastic encapsulant layer adjacent to the back surface of the front support layer; positioning a plurality of interconnected solar cells having first and second surfaces so that the first surfaces thereof are adjacent to the first transparent encapsulant layer; placing a second transparent thermoplastic encapsulant layer adjacent to the second surfaces of the solar cells; placing a backsheet of  claim 17  adjacent to the second transparent thermoplastic encapsulant layer to thereby form an assembly; subjecting the assembly to heat and pressure so as to melt the encapsulant layers and cause the encapsulant to surround the solar cells, and cooling the assembly so as to cause the encapsulant to solidify and bond to the front support layer, the solar cells and the backsheet, thereby laminating the layers and the solar cells together to form an integrated solar cell module.