CONSTRUCTION ELEMENT FOR LIGHT TRANSPARENT SOLUTIONS

Abstract

A construction element A comprises a) at least one pane of glass B; and b) a frame C made of a non-coated thermoset polymeric composite material with a polymer matrix which is based on at least 50 wt.-% of an aliphatic polyisocyanate; and c) optionally at least one sealant D that connects the pane of glass B with frame C. It is characterized by an excellent long term weathering resistance, high durability and low maintenance efforts.

Claims

1.-10. (canceled)

11. Construction element A comprising a) at least one pane of glass B; and b) a frame C made of a non-coated thermoset polymeric composite material with a polymer matrix which is based on at least 50 wt.-% of an aliphatic polyisocyanate; and c) optionally at least one sealant D that connects the pane of glass B with frame C; wherein (i) the difference of the coefficient of linear thermal expansion of the pane of glass B and of the frame C (measured in axial direction) is less than 600% at 20 C.; and (ii) at least 25% of the circumference of the pane of glass B is embedded into the frame C; and (iii) at least some areas of the construction element A including partly its glass B, its frame C and optionally its sealant D are exposed to the outdoor weather conditions.

12. The construction element of claim 11, wherein the pane of glass B has a circumference between 2.0 m and 25.0 m.

13. The construction element of claim 11, wherein at least 20% of frame C are non-coated.

14. The construction element of claim 11, wherein the thermoset polymeric composite material is manufactured from a reaction mixture having a mass ratio of aliphatic polyisocyanates and isocyanate reactive compounds other than the short chain polyols of more than 5:1.

15. The construction element of claim 11, wherein the aliphatic polyisocyanate comprises at least one aliphatic polyisocyanate selected from the group consisting of 1,6-diisocyanatohexane, 1,5-diisocyanatopentane and isophorone diisocyanate.

16. The construction element of claim 11, wherein the thermoset polymeric composite material is manufactured from a reaction mixture comprising short chain polyols.

17. The construction element of claim 16, wherein the reaction mixture contains at least one short chain polyol selected from the group consisting of glycerol, 1,1,1-trimethylolpropane, 1,1,1-trimethylolethane, pentaerythritol, 1,2,10-decanetriol, 1,2,8-octanetriol and sugar alcohols.

18. The construction element of claim 11, wherein the thermoset polymeric composite material is manufactured from a reaction mixture having a molar ratio of isocyanate groups to all groups reactive with isocyanate groups of at least 2:1.

19. The use of the construction element according to claim 11 in an application wherein said use is characterized by exposure of at least a part of the construction to outdoor conditions for more than 5 years in total.

20. The use of the construction element according to claim 11 in an application wherein said use is characterized by exposure of at least a 10% of the surface area of the construction element to outdoor conditions for more than 5 years in total.

Description

EXAMPLES

[0072] Desmodur N 3600 is an HDI trimer (NCO functionality >3) with an NCO content of 23.0% by weight from Covestro AG. The viscosity is about 1200 mPas at 23 C. (DIN EN ISO 3219/A.3).

[0073] Glycerol (1,2,3-Propantriol) with a purity of 99.0% was sourced from Calbiochem bezogen.

[0074] Baydur PUL 20PL05 is a mixture of polyols and auxiliaries from Covestro AG and is used for production of glass fibre-containing profiles composed of polyurethane in the pultrusion process. The viscosity is about 1600 mPas at 20 C. (DIN 53019).

[0075] Desmodur PUL 10PL01 is a mixture of diphenylmethane 4,4-diisocyanate (MDI) with isomers and higher-functionality homologs having an NCO content of about 31% by weight from Covestro AG and is used for production of glass fibre-containing profiles composed of polyurethane in the pultrusion process. The viscosity is 160-240 mPas at 25 C. (2011-0248603-94).

[0076] Dibutyltin dilaurate (DBTL) was sourced with a purity of >99% by weight from ACROS under the Tinstab BL277 name.

[0077] Polyethylene glycol 400 was sourced with a purity of >99% by weight from ACROS.

[0078] Potassium acetate was sourced with a purity of >99% by weight from ACROS.

[0079] The INT-1940 separating agent was acquired from Axel Plastics Research Laboratories, INC. and, according to the datasheet, is a mixture of organic fatty acids and esters.

[0080] The zinc stearate were acquired from SysKem Chemie GmbH.

[0081] The glass fiber was glass fiber bundles with standard size for UP, VE and epoxy resins with the product name Advantex 399 with 4800 tex from 3B-fibreglass. According to the datasheet, the glass fibers have a diameter of 24 micrometres, are boron-free and consist of E-CR glass. The tensile modulus is 81-83 GPa, the tensile strength 2200-2400 MPa and the density 2.62 g/cm.sup.3.

[0082] The solar glass pane was purchased from Flat Glass Group, type low iron pattern glass, 3.2 mm thickness.

[0083] The solar backsheet was purchased from Jolywood, type TPT-3501.

[0084] The encapsulant material was EVA purchased from First Applied Materials, type F406.

[0085] The sealant was a silicone sealant from Tonsan, type Tonsan 1527.

[0086] Preparation of the Trimerization Catalyst

[0087] Potassium acetate (50.0 g) was stirred in the PEG 400 (950.0 g) at room temperature until all of it had dissolved. In this way, a 5% by weight solution of potassium acetate in PEG 400 was obtained and was used as catalyst without further treatment.

[0088] Preparation of the Resin Mixture

[0089] The isocyanate was initially charged in an open vessel at room temperature and stirred by means of a Dispermat and dissolver disc at 100 revolutions per minute (rpm). Subsequently, first the separating agent and then the catalyst were added, the stirrer speed was increased to 300 rpm and the whole mixture was stirred for a further 10 min, so as to form a homogeneous mixture. This mixture was used without further treatment for the pultrusion.

Production of Frame C

Example 1

[0090] Aliphatic Polyurethane-Based Frame (Frame C for Inventive Example)

[0091] A profile for a frame was pultruded using Desmodur N 3600 (8.56 kg), glycerine (1.38 kg), release agent INT-1940 (0.30 kg), DBTL (0.008 kg) and glass fiber rovings (126 rovings). The rovings were pulled into an injection box in which the resin mixture was pumped, and impregnated. Afterwards, the wetted fibers were passed through a heated dye (temperature 200 C.). The pulling speed was 0.3 m/min. The resulting profile was used without further treatment.

[0092] The samples after performing the weathering test according to SAE J 2527 (10000 h) and the UV tests (A and B); 5000 h) did not show in any change on the surface quality (visual inspection) after 10000 hours. The glass fiber content of the profile was 80.8 wt.-% (DIN EN ISO 1172/A). The coefficient of linear thermal expansion in axial direction was 8.9e-6/K.

Example 2

[0093] Aliphatic Polyisocyanurate-Based Frame (Frame C for Inventive Example)

[0094] A profile for a frame was pultruded using Desmodur N 3600 (9.45 kg), release agent INT-1940 (0.30 kg), trimerisation catalyst 100 (0.2 kg), zinc stearate (0.05 kg) and glass fiber rovings (126 rovings). The rovings were pulled into an injection box in which the resin mixture was pumped, and impregnated. Afterwards, the wetted fibers were passed through a heated dye (temperature 200 C.). The pulling speed was 0.3 m/min. The resulting profile was used without further treatment.

[0095] The samples after performing the weathering test according to SAE J 2527 (10000 h) and the UV tests (A and B); 5000 h) did not show any change on the surface quality or (visual inspection) after 10000 hours. The glass fiber content of the profile was 80.8 wt.-% (DIN EN ISO 1172/A). The coefficient of linear thermal expansion in axial direction was 8.9e-6/K.

[0096] Example for Construction Element A (Inventive Example 3)

[0097] A pane of glass (solar glass, 3.2 mm, 1.60 m1.00 m) was rimmed using over the whole circumference the frame C of example 1 using a silicone sealant. The finished construction element A was put outdoors (Shanghai) for more than 12 months without any change of appearance.

[0098] Example for Construction Element A (Inventive Example 4)

[0099] A pane of glass (solar glass, 3.2 mm, 1.60 m1.00 m) was rimmed using over the whole circumference the frame C of example 2, and using a silicone sealant. The finished construction element A was put outdoor (Shanghai) for more than 12 months without any change of appearance.

[0100] Example for Construction Element A Used in a Solar Module (Inventive Example 5)

[0101] A sandwich stack consisting of a pane of glass (solar glass, 3.2 mm, 1.60 m1.00 m), EVA-sheet, wired solar cells, EVA-sheet and a backsheet was assembled by vacuum lamination process as well known in the industry. The whole circumference of the stack was enclosed by the frame C of example 2 and using a silicone sealant. The finished solar module assembly was subjected to the tests according to standard IEC 61215:2005 and passed these.

[0102] Aromatic PU Frame (Non-Inventive Example for Frame)

[0103] A profile for a frame was pultruded using Baydur PUL 20PL05, Desmodur PUL 10PL01 and release agent 4 wt.-% and glass fiber rovings (126 rovings). The rovings were pulled into an injection box in which the resin mixture was pumped, and impregnated. Afterwards, the wetted fibers were passed through a heated dye (temperature 160 C.). The pulling speed was 0.6 m/min. The resulting profile was used without further treatment.

[0104] The samples after performing the weathering test showed strong surface changes such as pristine glass fibers on the surface and discoloration. The test according to SAE J 2527 was already stopped after 1000 h due to sample degradation. The profile could not be used for making a construction element A.