E.i. Dupont De Nemours and Company

Performance Materials Na, Inc.

Steven C Pesek

Richard Allen Hayes

Charles Anthony Smith

W Alexander Shaffer

Sam Louis Samuels

Stephen John Bennison

Karlheinz Hausmann

Geraldine Marie Lenges

Jerrel Charles Anderson

John W Paul

C Anthony Smith

George Wyatt Prejean

Rebecca L Smith

Jacques Roulin

Kristof Proost

Robert J Cadwallader

Shannon D Meerscheidt

Anthony C Smith

Provided are novel ethylene acid copolymers, their ionomers and their use in various articles, including packaging films and injection molded articles. The ethylene acid copolymers comprise copolymerized units of ethylene, about 10 to about 30 wt % of copolymerized units of a first &#x3b1;,&#x3b2;-unsaturated carboxylic acid having 3 to 10 carbon atoms; and about 5 to about 15 wt % of copolymerized units of a derivative of a second &#x3b1;,&#x3b2;-unsaturated carboxylic acid having 3 to 10 carbon atoms. Preferred derivatives include esters, and in particular alkyl esters. These ethylene acid copolymers and ionomers have improved optical properties when compared to conventional ethylene acrylic or methacrylic acid copolymers and their ionomers.

Ethylene acid copolymers, their ionomers, and their use in packaging films and injection molded articles

Provided herein are glass laminates, preferably safety glass laminates, that comprise a polymeric interlayer sheet formed of an acid copolymer composition. The acid copolymer composition comprises an ethylene acid copolymer which, in turn, comprises copolymerized units of ethylene, about 5 to about 90 wt % of copolymerized units of a first &#x3b1;,&#x3b2;-unsaturated carboxylic acid having 3 to 10 carbon atoms; and optionally about 2 to about 40 wt % of copolymerized units of a derivative of a second &#x3b1;,&#x3b2;-unsaturated carboxylic acid having 3 to 10 carbon atoms. Optionally, a portion of the carboxylic acid groups of the copolymerized units of the ethylene acid copolymer are neutralized to form carboxylate salts. The acid copolymer composition also includes a hydroxyl-containing crosslinking agent and may also include an adjuvant. The glass laminates have superior resistance to creeping due to the properties of the acid copolymer composition, which may optionally be cross-linked.

Cross-linkable acid copolymer composition and its use in glass laminates

The present invention provides a solar cell module comprising at least one encapsulant layer which has 1) a total thickness of from about 0.1 to about 20 mils and 2) at least one surface layer made of ionomers containing a finite amount of polymerized residues of &#x3b1;-olefins and from about 18 to about 25 wt % of polymerized residues of &#x3b1;,&#x3b2;-ethylenically unsaturated carboxylic acids. The present invention also provides a process of manufacturing the solar cell module.

Solar cell encapsulant layers with enhanced stability and adhesion

A solar cell module comprising a solar cell layer and a sheet comprising at least one layer of a sodium ionomer composition, wherein the sodium ionomer composition consists essentially of a sodium ionomer that is an ionic, neutralized derivative of a precursor &#x3b1;-olefin carboxylic acid copolymer, wherein about 10% to about 35% of the total content of the carboxylic acid groups present in the precursor &#x3b1;-olefin carboxylic acid copolymer have been neutralized with sodium ions, and wherein the precursor &#x3b1;-olefin carboxylic acid copolymer comprises (i) copolymerized units of an &#x3b1;-olefin having 2 to 10 carbons and (ii) about 20 to about 25 wt %, based on the total weight of the &#x3b1;-olefin carboxylic acid copolymer, of copolymerized units of an &#x3b1;,&#x3b2;-ethylenically unsaturated carboxylic acid having 3 to 8.

Solar cell module having a low haze encapsulant layer

A safety laminate comprises an interlayer that comprises an ionomer that is the neutralized product of a precursor acid copolymer. The precursor acid copolymer comprises copolymerized units of a first &#x3b1;-olefin having 2 to 10 carbon atoms and about 20 to about 30 wt % of copolymerized units of a first &#x3b1;,&#x3b2;-ethylenically unsaturated carboxylic acid having 3 to 8 carbon atoms; and has a melt flow rate of about 10 to about 4000 g/10 min. When neutralized to a level of about 40% to about 90% and when comprising counterions that consist essentially of sodium cations, the precursor acid copolymer produces a sodium ionomer that has a melt flow rate of about 0.7 to about 25 g/10 min and a freeze enthalpy that is not detectable or that is less than about 3.0 j/g. The ionomer composition may further comprise a second ionomer that has a melt flow rate of about 10 g/10 min or less.

High clarity laminated articles comprising an ionomer interlayer

An ionomer blend composition comprises a blend of a first ionomer and a second ionomer that is different from the first ionomer. The first ionomer is derived from a first precursor acid copolymer that has a melt flow rate of about 10 to about 4000 g/10 min and that comprises copolymerized units of an &#x3b1;-olefin and about 20 to about 30 wt % of copolymerized units of an &#x3b1;,&#x3b2;-ethylenically unsaturated carboxylic acid. Moreover, the first precursor acid can be neutralized to a level of about 40% to about 90% to form a sodium ionomer that has a MFR of about 0.7 to about 25 g/10 min and a freeze enthalpy that is less than about 3.0 j/g or that is not detectable, when determined by differential scanning calorimetry (DSC). A variety of articles may comprise or be produced from the ionomer blend composition, for example by injection molding.

High-clarity blended ionomer compositions and articles comprising the same

An ionomer composition comprises an ionomer that is the neutralized product of a precursor acid copolymer. The precursor acid copolymer comprises copolymerized units of an &#x3b1;-olefin having 2 to 10 carbon atoms and about 20 to about 30 wt %, based on the total weight of the precursor acid copolymer, of copolymerized units of an &#x3b1;,&#x3b2;-ethylenically unsaturated carboxylic acid having 3 to 8 carbon atoms; a melt flow rate of about 10 to about 4000 g/10 min; and, when neutralized to a level of about 40% to about 90% and when comprising counterions that consist essentially of sodium cations, the precursor acid copolymer produces a sodium ionomer that has a melt flow rate of about 0.7 to about 25 g/10 min and a freeze enthalpy that is not detectable or that is less than about 3.0 j/g. Further provided are articles comprising the ionomer composition.

High-clarity ionomer compositions and articles comprising the same

A laminate comprises an ionomeric interlayer sheet which, in turn, comprises or is prepared from a sodium/zinc mixed ionomer that comprises carboxylate groups and a combination of counterions that consists essentially of sodium cations and zinc cations. The sodium/zinc mixed ionomer is the neutralization product of a precursor acid copolymer. The precursor acid copolymer comprises copolymerized units of an &#x3b1;-olefin and an &#x3b1;,&#x3b2;-ethylenically unsaturated carboxylic acid, and it has a melt flow rate of about 70 to about 1000 g/10 min. In addition, the precursor acid copolymer, when neutralized to a level of about 40% to about 90%, and when comprising counterions that consist essentially of sodium ions, produces a sodium ionomer that has a freeze enthalpy that is not detectable or that is less than about 3.0 j/g, when determined by differential scanning calorimetry.

Laminates comprising ionomer interlayers with low haze and high moisture resistance

A solar cell module comprising a solar cell layer and an ionomer sheet comprising a sodium/zinc mixed ionomer that is the neutralization product of a precursor acid copolymer; wherein the precursor acid copolymer comprises copolymerized units of an &#x3b1;-olefin having 2 to 10 carbon atoms and about 20 to about 30 wt % of copolymerized units of an &#x3b1;,&#x3b2;-ethylenically unsaturated carboxylic acid having 3 to 8 carbon atoms based on the total weight of the precursor acid copolymer; wherein the precursor acid copolymer has a melt flow rate of about 70 to about 1000 g/10 min, as determined in accordance with ASTM D1238 at 190&#xb0; C. and 2.16 kg; and wherein when about 40% to about 90% of the total content of the carboxylic acid groups present in the precursor acid copolymer are neutralized to carboxylate groups to comprise carboxylate groups and counterions that consist essentially of sodium ions, the resulting sodium ionomer has a freeze enthalpy that is not detectable or that is less than about 3.0 j/g, when determined by differential scanning calorimetry in accordance with ASTM D3418.

Solar cell modules comprising encapsulant sheets with low haze and high moisture resistance

A solar cell module comprises a solar cell layer and an ionomer sheet. The ionomer sheet comprises a first ionomer that is the neutralized product of a first precursor acid copolymer, which, in turn, comprises copolymerized units of ethylene and about 20 to about 30 wt % of copolymerized acrylic or methacrylic acid. The first precursor acid copolymer has a melt flow rate of about 70 to about 1000 g/10 min. When neutralized to a level of about 40% to about 90% and when comprising counterions that consist essentially of sodium cations, the first precursor acid copolymer produces a sodium ionomer that has a melt flow rate of about 0.7 to about 25 g/10 min and a freeze enthalpy that is not detectable or that is less than about 3.0 j/g. The ionomer sheet may further comprise a second ionomer that is different from the first ionomer.

Solar cells modules comprising low haze encapsulants

A sodium/zinc mixed ionomer comprises carboxylate groups and a combination of counterions that consists essentially of sodium cations and zinc cations. The sodium/zinc mixed ionomer is the neutralization product of a precursor acid copolymer. The precursor acid copolymer comprises copolymerized units of an &#x3b1;-olefin and an &#x3b1;,&#x3b2;-ethylenically unsaturated carboxylic acid, and it has a melt flow rate of about 10 to about 4000 g/10 min. In addition, the precursor acid copolymer, when neutralized to a level of about 40% to about 90%, and when comprising counterions that consist essentially of sodium ions, produces a sodium ionomer that has a freeze enthalpy that is not detectable or that is less than about 3.0 j/g, when determined by differential scanning calorimetry. Further provided are articles comprising or prepared from the sodium/zinc mixed ionomer.

Ionomer compositions with low haze and high moisture resistance and articles comprising the same

The present invention provides a pre-formed bi-layer thermoplastic film or sheet comprising a first surface layer made of acid copolymers, or ionomers, or combinations thereof and a second surface layer made of ethylene acrylate ester copolymers, a solar cell pre-laminate assembly comprising the same, and a simplified process for manufacturing a solar cell module derived therefrom.

Low modulus solar cell encapsulant sheets with enhanced stability and adhesion

The invention describes a polymeric sheet that has at least one layer that comprises an ionomer or ionomer blend that incorporates a partially neutralized alpha, beta-ethylenically unsaturated carboxylic acid component and is useful in glass laminate applications. The ionomer or ionomer blend contains one or more monovalent metal ions in an amount ranging from about 1 to about 60%, preferably about 10 to about 55%, and more preferably about 15 to about 50%, and one or more polyvalent metal ions in an amount ranging from about 40 to about 99%, preferably about 45 to about 90%, and more preferably about 50 to about 85%. This ratio range of monovalent and polyvalent metal neutralization ions provides synergistically greater adhesion to glass than found for either the monovalent or the polyvalent metal neutralization ions alone.

Mixed ion ionomeric sheets and high strength laminates produced therefrom

The present invention is an improved polymeric resin composition comprising or consisting essentially of from about 70 wt % to about 79 wt % units derived from ethylene and from about 21 wt % to about 30 wt % units derived from an &#x3b1;,&#x3b2;-unsaturated carboxylic acid having from 3 to 8 carbons. Resins of the present invention are particularly suitable for preparing transparent laminates useful as glazing elements that provide a greater measure of safety than non-laminated glazing elements. Laminates of the present invention have 3% haze or less without the addition of amines.

Thermoplastic resin compositions suitable for use in transparent laminates

The present invention provides a thermoplastic film or sheet comprising two surface layers made of acid copolymers, or ionomers, or combinations thereof and at least one inner layer made of ethylene acrylate ester copolymers, a solar cell module comprising at least one encapsulant layer derived therefrom, and a process of manufacturing the solar cell module.

Growing community of inventors

Orange, TX, United States of America

Steven C Pesek