MONO-BACKSHEET FOR SOLAR CELL MODULES

Abstract

The current invention relates to a solar-cell module backing monolayer obtained by melt-extruding a polymer composition comprising (a) a polyamide, (b) an elastomer and (c) an elastomer that contains groups that bond chemically and/or interact physically with the polyamide, and wherein the elastomer constitutes the continuous phase of the polymer composition and the polyamide constitutes the dispersed phase of the polymer composition, characterized in that the polymer composition comprises from 10 to 50 wt. % of the polyamide (a) and from 50 to 90 wt. % of the elastomer (b) and (c) (of the total weight of polyamide (a) and elastomer (b) and (c) present in the polymer composition).

Claims

1. A solar-cell module backing monolayer obtained by melt-extruding a polymer composition comprising (a) a polyamide, (b) an elastomer and (c) an elastomer that contains groups that bond chemically and/or interact physically with the polyamide, and wherein the elastomer constitutes the continuous phase of the polymer composition and the polyamide constitutes the dispersed phase of the polymer composition, wherein the polymer composition comprises from 10 to 50 wt. % of the polyamide (a) and from 50 to 90 wt. % of the elastomer (b) and (c) (of the total weight of polyamide (a) and elastomer (b) and (c) present in the polymer composition).

2. A backing monolayer according to claim 1, wherein the amount of groups that bond chemically or interact physically with the polyamide is from 0.025 to 2 wt. % (of the total weight of the polymer composition), preferably from 0.05 to 2 wt. %.

3. A backing monolayer according to claim 1, wherein the polyamide is selected from the group consisting of polyamide-6,6, polyamide-4,6 and polyamide-6 and any mixture thereof.

4. A backing monolayer according to claim 1, wherein the elastomer (b) is a copolymer of ethylene and C3-C12--olefin with a density of from 0.85 to 0.93 g/cm.sup.3 and a Melt Flow Index (ASTM D1238, 190 C., 2.16 kg) of from 0.5 to 30 g/10 min.

5. A backing monolayer according to claim 4, wherein the copolymer of ethylene and a-olefin is an ethylene-octene copolymer.

6. A backing monolayer according to claim 5, wherein the ethylene-octene copolymer is obtained by polymerization in the presence of a metallocene catalyst.

7. A backing monolayer according to claim 1, wherein the polymer composition comprises functionalized elastomer (c) that contains groups that bond chemically with the polyamide.

8. A backing monolayer according to claim 7, wherein the groups that bond chemically with the polyamide are chosen from the group consisting of anhydrides, acids, epoxides, silanes, isocyanates, oxazolines, thiols and/or (meth)acrylates.

9. A backing monolayer according to claim 7, wherein the groups that bond chemically with the polyamide are chosen from the group consisting of unsaturated dicarboxylic acid anhydrides, unsaturated dicarboxylic acids and unsaturated dicarboxylic acid esters and mixtures of the two or more thereof

10. A backing monolayer according to claim 7, wherein the groups that bond chemically with the polyamide are chosen from the group consisting of unsaturated dicarboxylic acid anhydrides.

11. A backing monolayer according to claim 7, wherein the functionalized elastomer (c) is obtained by graft polymerizing elastomer with maleic acid, maleic anhydride and/or fumaric acid.

12. A backing monolayer according to claim 1, wherein the composition further comprise at least one additive selected from UV stabilizers, UV absorbers, anti-oxidants, heat stabilizers and/or hydrolysis stabilisers.

13. Polymer composition comprising (a) a polyamide, (b) an elastomer and (c) an elastomer that contains groups that bond chemically and/or interact physically with the polyamide, and wherein the elastomer constitutes the continuous phase of the polymer composition and the polyamide constitutes the dispersed phase of the polymer composition, whereby the polymer composition comprises from 10 to 50 wt. % of the polyamide (a) and from 50 to 90 wt. % of the elastomer (b) and (c) (of the total weight of polyamide (a) and elastomer (b) and (c) present in the polymer composition, and whereby the elastomer (b) is a copolymer of ethylene and C3-C12-a-olefin with a density from 0.85 to 0.93 g/cm.sup.3 and a Melt Flow Index (ASTM D1238, density from 0.85 to 0.93 g/cm.sup.3 and a Melt Flow Index (ASTM D1238, 190 C., 2.16 kg) of from 0.5 to 30 g/10 min.

14. Polymer composition according to claim 13, wherein the copolymer of ethylene and C3-C12--olefin is an ethylene-octene copolymer.

15. Polymer composition according to claim 14, wherein the ethylene-octene copolymer is obtained by polymerization in the presence of a metallocene catalyst.

16. Polymer composition according to claim 13, wherein the polymer composition comprises functionalized elastomer (c) that contains groups that bond chemically with the polyamide.

17. Polymer composition according to claim 16, wherein the groups that bond chemically with the polyamide are chosen from the group consisting of anhydrides, acids, epoxides, silanes, isocyanates, oxazolines, thiols and/or (meth)acrylates.

18. Polymer composition according to claim 16, wherein the groups that bond chemically with the polyamide are chosen from the group consisting of unsaturated dicarboxylic acid anhydrides, unsaturated dicarboxylic acids and unsaturated dicarboxylic acid esters and mixtures of the two or more thereof

19. Polymer composition according to claim 16, wherein the groups that bond chemically with the polyamide are chosen from the group consisting of unsaturated dicarboxylic acid anhydrides.

20. Polymer composition according to claim 16, wherein the functionalized elastomer (c) is obtained by graft polymerizing elastomer with maleic acid, maleic anhydride and/or fumaric acid, preferably with maleic anhydride.

21. A solar-cell module containing essentially, in order of position from the front-sun facing side to the back non-sun-facing side, a transparent pane, a front encapsulant layer, a solar cell layer comprised of one or more electrically interconnected solar cells, and a backing layer, wherein the backing layer is connected to the lower sides of the solar cells, wherein the backing layer is a monolayer obtained by melt-extruding a polymer composition as claimed in claim 13.

22. A solar-cell module according to claim 21, wherein the solar cells in the solar cell layer are wafer-based solar cells.

23. Use of the melt extruded layer according to claim 1 as backing layer for a solar cell module, wherein the backing layer is the rear layer of the solar-cell module and the backing layer is connected to the lower sides of the solar cells.

Description

EXAMPLE 1

[0038] The following compound was made on a ZSK25 extruder: 25 wt % Akulon K122, 61.85 wt % Queo 8201, 10 wt % Fusabond N 525, 0.15 wt % Cupper Iodide, and 3 wt % Irganox 1098. From the compound a 500 micrometer film was made via film-extrusion.

[0039] A laminate was made by making the following stack: 1)film of above compound, 2) one standard multi-crystalline solar cell, 3) APOLHYA Solar R333A and 4) glass plate of 20 by 30 cm. Lamination was done at 157 C. during 12 minutes.

[0040] Samples were aged in a climate chamber at 85 C. and 85% relative humidity. Samples were exposed to the damp heat test.

[0041] It was visually assessed that the sample showed no delamination during 3000 hours of ageing. Flash testing did not show any significant decrease of the power output after 3000 hours of ageing.

EXAMPLE 2

[0042] The following compound was made on a ZSK25 extruder: 10 wt % Akulon K122, 76.85 wt % Queo 8201, 10 wt % Fusabond N 525, 0.15 wt % Cupper Iodide, and 3 wt % Irganox 1098. From the compound a 500 micrometer film was made via film-extrusion.

[0043] A laminate was made by making the following stack: 1)film of above compound, 2) one standard multi-crystalline solar cell, 3) APOLHYA Solar R333A, 4) glass plate of 20 by 30 cm. Lamination was done at 157 C. during 12 minutes.

[0044] Samples were aged in a climate chamber at 85 C. and 85% relative humidity. Samples were exposed to the damp heat test.

[0045] It was visually assessed that the sample showed no delamination during 3000 hours of ageing. Flash testing did not show any significant decrease of the power output after 3000 hours of ageing.