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WO2025136781A1 - Dispositifs photovoltaïques revêtus - Google Patents

Dispositifs photovoltaïques revêtus Download PDF

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Publication number
WO2025136781A1
WO2025136781A1 PCT/US2024/059736 US2024059736W WO2025136781A1 WO 2025136781 A1 WO2025136781 A1 WO 2025136781A1 US 2024059736 W US2024059736 W US 2024059736W WO 2025136781 A1 WO2025136781 A1 WO 2025136781A1
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WO
WIPO (PCT)
Prior art keywords
composition
weight percent
coating
photovoltaic device
silanol
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
PCT/US2024/059736
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English (en)
Inventor
Stephen BUSSJAEGER
Maria Elisa CANTU-BROWNING
Donald P. BROWNING
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Phazebreak Coatings Inc
Original Assignee
Phazebreak Coatings Inc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Phazebreak Coatings Inc filed Critical Phazebreak Coatings Inc
Publication of WO2025136781A1 publication Critical patent/WO2025136781A1/fr
Pending legal-status Critical Current
Anticipated expiration legal-status Critical

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Classifications

    • H—ELECTRICITY
    • H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
    • H10F—INORGANIC SEMICONDUCTOR DEVICES SENSITIVE TO INFRARED RADIATION, LIGHT, ELECTROMAGNETIC RADIATION OF SHORTER WAVELENGTH OR CORPUSCULAR RADIATION
    • H10F19/00—Integrated devices, or assemblies of multiple devices, comprising at least one photovoltaic cell covered by group H10F10/00, e.g. photovoltaic modules
    • H10F19/80—Encapsulations or containers for integrated devices, or assemblies of multiple devices, having photovoltaic cells
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
    • C08G77/00—Macromolecular compounds obtained by reactions forming a linkage containing silicon with or without sulfur, nitrogen, oxygen or carbon in the main chain of the macromolecule
    • C08G77/04—Polysiloxanes
    • C08G77/14—Polysiloxanes containing silicon bound to oxygen-containing groups
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
    • C08G77/00—Macromolecular compounds obtained by reactions forming a linkage containing silicon with or without sulfur, nitrogen, oxygen or carbon in the main chain of the macromolecule
    • C08G77/04—Polysiloxanes
    • C08G77/14—Polysiloxanes containing silicon bound to oxygen-containing groups
    • C08G77/16—Polysiloxanes containing silicon bound to oxygen-containing groups to hydroxyl groups
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
    • C09D183/00—Coating compositions based on macromolecular compounds obtained by reactions forming in the main chain of the macromolecule a linkage containing silicon, with or without sulfur, nitrogen, oxygen, or carbon only; Coating compositions based on derivatives of such polymers
    • C09D183/04—Polysiloxanes
    • G—PHYSICS
    • G02—OPTICS
    • G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B1/00—Optical elements characterised by the material of which they are made; Optical coatings for optical elements
    • G02B1/10—Optical coatings produced by application to, or surface treatment of, optical elements
    • G02B1/14—Protective coatings, e.g. hard coatings

Definitions

  • This disclosure relates to coatings and coated photovoltaic devices such as solar panels and systems.
  • Solar panels/systems are often used under various weather conditions.
  • a coating can be applied.
  • a coated photovoltaic device includes a photovoltaic device having a first surface for receiving incoming light and an opposing second surface, and a coating disposed on at least the first surface, the second surface, or both the first and second surfaces of the photovoltaic device, wherein the coating is a cured product of a coating composition including: (i) an epoxy-silicone; (ii) an aminosilane; (iii) a silanol-functional silicone; and (iv) a fluorinated silane, a plasticizer, or a combination thereof.
  • a method of protecting a photovoltaic device includes applying a coating composition on a first surface, an opposing second surface, or both the first surface and the second surface of the photovoltaic device; and curing the coating composition to form a coating on the first surface, the second surface, or both the first surface and the second surface of the photovoltaic device, wherein the coating composition comprises: (i) an epoxysilicone; (ii) an aminosilane; (iii) a silanol-functional silicone; and (iv) a fluorinated silane, a plasticizer, or a combination thereof.
  • a coating composition includes, based on a total weight of the coating composition: about 35 to about 65 weight percent, or about 40 to about 65 weight percent, about 50 to about 65 weight percent, or about 45 to about 55 weight percent of an epoxysilicone; about 1 to about 25 weight percent, or about 1 to about 20 weight percent, about 10 to about 20 weight percent, or about 5 to about 15 weight percent of an aminosilane; about 0.5 to about 25 weight percent, or about 1 to about 20 weight percent, or about 5 to about 15 weight percent of a silanol-functional silicone; and about 5 to about 45 weight percent, about 8 to about 40 weight percent, about 8 to about 20 weight percent, or about 25 to about 25 weight percent of a plasticizer.
  • the Figure is a schematic cross-sectional view of a coated photovoltaic device according to one or more embodiments.
  • the present disclosure relates to coatings and coated articles such as coated photovoltaic devices.
  • the coatings can enhance the weather resistance of the coated photovoltaic devices.
  • the coatings may repel water, delay ice formation, reduce ice adhesion, or facilitate the removal of ice, snow, or frozen contaminants from the coated article.
  • the coatings do not interfere with light penetration or power generation of the coated photovoltaic devices.
  • the coatings can even provide improved optical gain.
  • a coated photovoltaic device includes a photovoltaic device having a first surface for receiving an incoming light, and an opposing second surface; and a coating disposed on the first surface, the second surface, or both the first and second surfaces of the photovoltaic device, wherein the coating comprises a cured product of a coating composition comprising: (i) an epoxy-silicone; (ii) an aminosilane; (iii) a silanol-functional silicone; and (iv) a fluorinated silane, a plasticizer, or a combination thereof.
  • a coated photovoltaic device 100 may comprise a photovoltaic device 101 with a first surface 101a and a second surface 101b.
  • a coating may be disposed on the first surface 101a (coating 102a), the second surface 101b (coating 102b), or both the first surface 101a and the second surface 101b.
  • the first surface 101a is oriented at the top of the photovoltaic device facing the incoming light (hv).
  • the coating 102a comprises a cured product of a coating composition comprising: (i) an epoxy-silicone; (ii) an aminosilane; (iii) a silanol-functional silicone; and (iv) a fluorinated silane, a plasticizer, or a combination thereof.
  • the epoxy-silicone (i) in the coating composition can be a polysiloxane having epoxide functional groups.
  • the epoxy equivalent weight of the epoxy-silicone can be at least about 200 grams, about 200 to about 700 grams, about 300 to about 700 grams, or about 400 to about 600 grams.
  • the epoxide or epoxy equivalent weight (EEW) refers to the mass in grams which one mole of epoxy groups contains. EEW can be determined by ASTM D1652.
  • the epoxy-silicone can have a polysiloxane framework.
  • the polysiloxane framework or a side chain of the polysiloxane framework has OH groups and/or alkoxy groups.
  • the epoxy-silicone used is preferably a liquid at 0 to 40 °C. Otherwise, the addition of solvents may be needed. It is preferable that the addition of solvents is to be kept as low as possible.
  • the aminosilane (ii) in the coating composition can have a structure represented by Formula I or Formula II
  • R is hydrogen, alkyl, cycloalkyl, aryl, or aralkyl; each occurrence of R' is independently hydrogen, alkyl, or cycloalkyl; each occurrence of R" is independently alkyl, cycloalkyl, aryl, or aralkyl; each occurrence of X and X' is independently alkylene, cycloalkylene, or -R2-NH-R 3 -, wherein R2 and R3 are independently alkylene, or cycloalkylene; x is 0 to 2, y is 0 to 2, n is 0 to 2, m is 0 to 2, and m+n is 2.
  • each of R, R2, R 3 , R', R", X, and X' can each independently have 1 to 20, 1 to 10, or 1 to 6 carbon atoms.
  • the aminosilane can comprise at least one of a primary aminoalkylalkoxysilane of Formula I when R is H, and R' is an alkyl group; a secondary aminoalkylalkoxysilane of Formula I when R is an alkyl group, and R' is an alkyl group; a bisalkoxysilylamine of Formula III; or a diaminosilane of Formula I when X is -R2-NH-R 3 -.
  • Examples of the primary aminoalkylalkoxysilane include 2- aminoethyltrimethoxysilane, 2-aminoethyltriethoxysilane, 3-aminopropyltrimethoxysilane, 3- aminopropyltriethoxysilane, 4-aminobutyltrimethoxysilane, or 4-aminobutyltriethoxysilane.
  • Preferred primary aminoalkylalkoxysilane is 3-aminopropyltrimethoxysilane or 3- aminopropyltriethoxysilane.
  • Examples of the secondary aminoalkylalkoxysilane include N-(2- (trimethoxysilyl)ethyl)alkylamines, N-(3-(trimethoxysilyl)propyl)alkylamines, N-(4- (trimethoxysilyl)butyl)alkylamines, N-(2-(triethoxysilyl)ethyl)alkylamines, N-(3- (triethoxysilyl)propyl)alkylamines, or N-(4-(triethoxysilyl)butyl)alkylamines.
  • Preferred secondary aminoalkylalkoxysilane is N-(3-(triethoxysilyl)propyl)butylamine or N-(3- (trimethoxysilyl)propyl)butylamine .
  • Examples of the bisalkoxysilylamine include bis(2- ethyltrimethoxysilyl)amine , bis(3 -propyltrimethoxysil-yl)amine, bis(4- butyltrimethoxysilyl)amine, bis(2-ethyltriethoxysilyl)amine, bis(3-propyltriethoxy- silyl)amine, or bis(4-butyltriethoxysilyl)amine.
  • diaminosilane examples include H2N-(CH2)2NH(CH2)2Si(OCH3)3, or H2N(CH2)2NH(CH2)3Si(OCH3)2CH3.
  • Diaminosilanes are commercially available, for example, under the trade name SILQUEST Al 120, SILQUEST Al 120J, or SILQUEST 2120, from Momentive.
  • the silanol-functional silicone (iii) can have a structure represented by Formula III
  • each occurrence of R'" is independently alkyl, cycloalkyl, aryl, or aralkyl, and n is 2 to 20 or 3 to 10.
  • R'" can be halogenated.
  • each R'" is independently a Ci-io or Ci-6 alkyl, or phenyl. More preferably each occurrence of R'" is methyl or phenyl. More preferably each occurrence of R"' is independently methyl, phenyl, or trifluoropropyl.
  • the silanol-functional silicone can have a functional group equivalent weight of about 500 g/mol to about 2,500 g/mol, preferably about 500 g/mol to about 2,000 g/mol, and more preferably about 1,000 g/mol to about 2,000 g/mol.
  • a viscosity of the silanol- functional silicone can range from about 30 centistokes (cSt) to about 4,000 cSt, preferably about 30 cSt to about 1,500 cSt, about 30 cSt to about 500 cSt, or about 30 cSt or about 100 cSt, each measured at 25°C.
  • the silanol-functional silicone can comprise at least one of a silanol- terminated polydimethylsiloxane, a silanol-terminated polydiphenylsiloxane, a silanol- terminated diphenylsiloxane-dimethylsiloxane copolymer, or a silanol-terminated polytrifluoropropylmethylsiloxane.
  • a silanol-terminated polydimethylsiloxane is preferred.
  • the silanol-terminated polydimethylsiloxane can have a viscosity of about 35 cSt to about 100 cSt, or about 45 to about 85 cSt measured at room temperature (23 °C).
  • the fluorinated silane (vi)(l) can have a structure represented by Formula IV Ri-Si(OR')3 Formula IV wherein Ri is a fluorinated alkyl, and each occurrence of R' is independently hydrogen, alkyl, or cycloalkyl.
  • Ri is a fluorinated C1-20 alkyl or a fluorinated C1-10 alkyl
  • R' is a C1-10 alkyl, C1-5 alkyl, or C1-3 alkyl.
  • a specific example of the fluorinated silane is (tridecafluofo-l,l,2,2-tetrahydrooctyl)trimethoxysilane.
  • the fluorinated silane can react with the silanol-functional silicone during curing to form a phase change material that imparts anti-icing characteristics to the coating surface.
  • the phase change material may have a structure of the Formula V
  • the plasticizer (vi)(2) may be any of the plasticizers commonly used in compositions based on silane-functional polymers. These include, for example, carboxylic esters such as phthalates, for example di(2-propylheptyl) phthalate, diisodecyl phthalate, dioctyl phthalate, dioctylterephthalate, diisononyl phthalate, and diisodecyl phthalate; trimellitates, such as tris(2-ethylhexyl) trimellitate; diesters of cyclohexane-dicarboxylic acid, such as diisononyl 1 ,2-cyclohexanedicarboxylate; adipates, such as dioctyl adipate, bis(2- ethylhexyl) adipate; azelates, such as bis(2-ethylhexyl) azelate; sebacates, such as
  • the coating composition further comprise an alkoxysilane.
  • the alkoxysilane can have a structure represented by Formula VI
  • R' is independently hydrogen, alkyl, or cycloalkyl.
  • R' is a C1-10 alkyl, C1-5 alkyl, CM alkyl, or C2-4 alkyl.
  • the coating composition can optionally further comprise an alkyl phosphonate, for example C2-C25 alkyl phosphonate, C5-C25 alkyl phosphonate, or C8-C20 alkyl phosphonate.
  • an alkyl phosphonate for example C2-C25 alkyl phosphonate, C5-C25 alkyl phosphonate, or C8-C20 alkyl phosphonate.
  • the coating composition can also comprise at least one of a curing catalyst, a surface-active agent, a heat stabilizer, an ultraviolet-light absorber, or a colorant.
  • the curing catalyst can be present in an amount of about 0.5 to about 5 weight percent, about 0.05 to about 1 weight percent, about 1 to about 5 weight percent, or about 0.5 to about 4 weight percent, or about 0.8 to about 3 weight percent, based on a total weight of the coating composition.
  • the curing catalyst if present, can comprise at least one of an organotin compound, an organozinc compound, an organotitanium compound, an organozirconium compound, or an organic acid.
  • organotin compound examples include dibutyltin dicarboxylates, such as dibutyltin dilaurate and dibutyltin bis(alkyl maleate); dioctyltin dicarboxylates such as dioctyltin dilaurate, dialkyltin alkoxide derivatives such as dibutyltin dimethoxide and dibutyltin diphenoxide; intramolecular coordination derivatives of dialkyltins, such as dibutyltin diacetylacetonate and dibutyltin acetoacetate; reaction mixtures of dibutyltin oxide with ester compounds; reaction mixtures of dibutyltin oxide with silicate compounds, or tetravalent dialkyltin oxide derivatives such as oxy derivatives of said dialkyltin oxide derivatives as described in U.S.
  • dibutyltin dicarboxylates such as dibutyltin dilaurate
  • Patent 6,642,309 the content of which is incorporated herein by reference in its entirety.
  • Two or more of the curing catalyst can be used.
  • the coating composition can be free of tin or tin-containing compounds yet still providing the beneficial effects as described herein.
  • a surface-active agent can modify the interaction of a coating composition with the substrate, in particular, the agent can modify the ability of the composition to wet a substrate.
  • Surface active agents may also include leveling, defoaming, or flow agents, and the like. If used, the surface active agent can be present in an amount of about 0.1 to about 5 weight percent, based on the total weight of the coating composition.
  • Surface-active agent is known and can include polysiloxane defoamers such as a methylalkylpolysiloxane commercially available under the trade name BYK-077 or BYK- 500 from Byk Chemie, polymeric defoamers such as that commercially available under the trade name BYK 051, or other surface-active agent such as BYK-053, BYK-055, BYK-057, BYK-020, BYK-065, BYK-066N, BYK-067A, BYK-070, BYK-080A, BYK-088, BYK- 141, BYK-019, BYK-021, BYK-022, BYK-023, BYK-024, BYK-025, BYK-028, BYK-011, BYK-031, BYK-032, BYK-033, BYK-034, BYK-035, BYK-036,
  • the light stabilizer can include a hindered amine light stabilizer (HALS).
  • HALS is commercially available, for example, under the trade name BLS 292 from Mayzo, TINUVIN 123 or UVINUL 4092 from BASF Corp., OMNISTAB LS292 from ICG Specialty Chemicals, OMNISTAB LS944 from ICG Specialty Chemicals, SABOSTAB 119 or SABOSTAB 94 from Sabo S.p.A., or LOWILITE from Addivant.
  • Other commercially available HALS can also be used.
  • the light stabilizer can be used in an amount of about 0.01 to about 1 weight percent based on a total weight of the coating composition.
  • the coating composition can comprise more than one light stabilizer, if desired.
  • the ultraviolet-light (UV) absorber that can be useful with the coating composition include avobenzone, 2,5-bis(5-tert-butyl-benzoxazol-2-yl)thiophene (Benetex OB+), disodium 4,4'-bis(2-sulfonatostyryl)biphenyl (Benetex OB-M1), benzenepropanoic acid (BLS 99-2), 2,3,6,7-tetrahydro-9-methyl-lH,5H-quinolizino(9,l-gh)coumarin (Coumarin 102), Martius Yellow, morin hydrate, nitrofurazone, 2-nitrophenyl phenyl sulfide (NPS), 5,12-naphthacenequinone (NTAQ), octocrylene, phenazine, l,4-bis-(2-(5- phenyloxazolyl))-benzene (POPOP), Quinoline Yellow,
  • the coating composition can comprise (i) about 60 to about 80 weight percent, or about 65 to about 75 weight percent of the epoxy-silicone; (ii) about 10 to about 25 weight percent, or about 15 to about 20 weight percent of the aminosilane; (iii) about 1 to about 20 weight percent, or about 5 to about 15 weight percent of the silanol-functional silicone; (iv) about 0.5 to about 10 weight percent, or about 1 to about 5 weight percent of the fluorinated silane; about 0.05 to about 1 weight percent of the curing catalyst; optionally about 0.1 to about 5 weight percent of the surface active agent, optionally about 0.05 to about 1 weight percent of an UV absorber, and optionally about 0.1 to about 1 weight percent of a light stabilizer, each based on a total weight of the coating composition.
  • the coating composition can comprise (i) about 35 to about 65 weight percent, about 40 to about 65 weight percent, about 50 to about 65 weight percent, or about 45 to 55 weight percent of the epoxy-silicone; (ii) about 1 to about 25 weight percent, about 5 to about 20 weight percent, about 10 to about 20 weight percent, or about 5 to 15 weight percent of the aminosilane; (iii) about 0.5 to about 25 weight percent, about 1 to about 20 weight percent, or about 5 to about 15 weight percent of the silanol- functional silicone; (iv) about 5 to about 45 weight percent, about 8 to about 40 weight percent, about 8 to about 20 weight percent, or about 25 to about 35 weight percent of the plasticizer; optionally about 0.05 to about 1 weight percent of the curing catalyst; optionally about 0.1 to about 10 weight percent or about 1 to about 10 weight percent of the surface active agent, optionally about 0.05 to about 1 weight percent of an UV absorber, optionally about 0.1 to about 1 weight percent of a light stabilizer, each based on
  • the coating composition is free of tin, tin-containing compounds, or per- or polyfluoroalkyl substances (PFAS). More preferably, the coating composition is free of tin, tin-containing compounds, PFAS, or both while still providing the benefits as described herein.
  • PFAS per- or polyfluoroalkyl substances
  • the solids content of the coating composition can be greater than 90 volume percent (vol%), greater than 92 vol%, or greater than 95 vol%.
  • the solids content of the coating composition can be less than 99.5 vol% or less than 99 vol%.
  • the coating components can be separately packaged in three parts as part A, part B, and part C compositions (3K system).
  • the part A composition may be packaged in a container A
  • the part B composition may be packaged in a container B
  • the part C composition may be packaged in a container C.
  • a coating formed from the separately packaged three part compositions can have improved properties as compared to coatings formed from a two-component system (2K system) which includes a first package containing both the same part A composition and the same part C composition, and a second package containing the same part B composition.
  • 2K system two-component system
  • the curing time for a 2K system can be longer than desired. Further, under certain circumstances, the coating formed from the 2K system may not be hard enough after cure.
  • a coating formed from the separately packaged part A, part B, and part C compositions can have consistent thickness and desired hardness without oily residues, even when the part A, part B, and part C compositions are stored at room temperature for more than 3 months before use.
  • the coating formed from the 3K system can also be cured in a short period of time (e.g., curing times of 1 minute to 1 hour, 5 minutes to 24 hours, 10 minutes to 30 minutes, or the like).
  • the part A composition can include the epoxysilicone; the part B composition can include the aminosilane and fluorinated silane, and the part C composition can include the silanol- functional silicone, wherein the part A composition, the part B composition, the part C composition, or a combination thereof each independently further comprises at least one of the curing catalyst, the surface-active agent, the heat stabilizer, or the ultraviolet-light absorber.
  • the part A composition can include the epoxy- silicone and the plasticizer;
  • the part B composition can include the aminosilane, and optionally the alkoxysilane, and the part C composition can include the silanol- functional silicone, wherein the part A composition, the part B composition, the part C composition, or a combination thereof each independently further comprises at least one of the curing catalyst, the surface-active agent, the heat stabilizer, or the ultraviolet-light absorber.
  • the part A composition further comprises at least one of a surface-active agent, a heat stabilizer, or an ultraviolet-light absorber.
  • the part B composition optionally further comprise a curing catalyst.
  • the part A composition can comprise about 80 weight percent to about 100 weight percent, about 85 weight percent to about 99 weight percent, or about 88 weight percent to about 98 weight percent of the epoxy-silicone, each based on a total weight of the part A composition.
  • the part B composition can comprise about 75 to about 90 weight percent or about 75 to about 85 weight percent of the aminosilane, about 5 to about 20 weight percent or about 10 to about 20 weight percent of the fluorinated silane, and about 0.5 to about 5 weight percent, or about 1 to about 5 weight percent of the curing catalyst, each based on a total weight of the part B composition.
  • the part C composition can comprise about 90 to about 100 weight percent or about 95 to about 100 weight percent of the silanol- functional silicone, each based on a total weight of the part C composition.
  • the part A composition can comprise about 70 to about 90 weight percent of the epoxy-silicone and about 10 to about 20 weight percent of the plasticizer, each based on a total weight of the part A composition.
  • the part B composition can comprise about 90 to about 100 weight percent of the aminosilane based on a total weight of the part B composition.
  • the part C composition can comprise about 90 to about 100 weight percent or about 95 to about 100 weight percent of the silanol- functional silicone, each based on a total weight of the part C composition.
  • the coating composition can be formed by combining the components of the coating composition.
  • the coating composition can be made by combining the part A composition with the part B composition and the part C composition.
  • combining includes mixing.
  • the part A, part B, and part C compositions can be mixed shortly before the coating composition is applied to a substrate.
  • the part C composition can be mixed with the part B composition to form an intermediate composition; and the intermediate composition can be mixed with the part A composition to form the coating composition.
  • the coating composition can be applied by any of the suitable application methods, such as spraying, knife coating, spreading, pouring, dipping, impregnating, trickling, or rolling, for example.
  • the substrate to be coated may itself be at rest, with the application equipment or unit being moved.
  • the substrate to be coated may be moved, with the application unit being at rest relative to the substrate or being moved appropriately.
  • the coating composition can be applied to various substrates such as metallic substrates, polymeric substrates, composite substrates, and the like.
  • the coating composition can be applied to the first surface, the second surface, or both the first and second surfaces of the photovoltaic device.
  • the first and second surfaces can be provided by a glass layer or a polymer layer.
  • the first surface is a top surface of a glass layer and the second surface is a bottom surface of a polymer layer or a second glass layer.
  • the coating composition is applied to the first surface of the photovoltaic device. It is unexpected that the coating formed from the coating composition does not interfere with light penetration or power generation of the coated photovoltaic devices.
  • the coating can even provide an improved energy production for the coated optical gain for the coated photovoltaic device.
  • a photovoltaic device includes a photovoltaic cell, module, panel, array, and system.
  • the photovoltaic device includes a photovoltaic cell layer including at least one photovoltaic cell between an upper layer (e.g. a glass layer or a polymer layer) and a lower layer (a polymer backsheet or a glass layer).
  • the photovoltaic cell layer can include a plurality of photovoltaic cells, metallic fingers, and busbars such as flat ribbon busbars and/or thin wire (MBB) busbars.
  • the upper layer, the photovoltaic cell layer, and the lower layer can be supported within a frame.
  • the photovoltaic device can also include one or more encapsulation layers such as ethylene vinyl acetate films between the upper layer and the solar photovoltaic cell layer, between the lower layer and the photovoltaic cell layer, or a combination thereof.
  • the photovoltaic device can also include an anti-reflective layer disposed on the photovoltaic cell layer.
  • the photovoltaic device also includes an electrical component such as a junction box including connectors and/or bypass diodes. Other suitable electrical components can be present if needed.
  • the applied coating composition can be cured after a certain cure time.
  • the cure time may be tuned by adjusting the cure temperature and/or humidity, provided that this does not entail any damage or alteration to the coating, such as premature complete crosslinking, for instance.
  • a thermal cure can be conducted at a temperature of about 30 to about 200° C., more preferably about 30 to about 150° C, and in particular about 30 to about 100° C for a time of about 1 minute (min) up to about 70 hours (h), more preferably about 1 h up to about 60 h, and in particular about 5 h to about 50 h.
  • the ready-to-use composition can achieve 95% hardness in 48 hours when cured at 77°F and 50% relative humidity.
  • a coating formed by curing the coating composition can consistently have a thickness of about 5 micrometers to about 5 millimeters (mm), about 10 micrometers to about 2 mm, or about 50 micrometers to about 1 mm.
  • the coating composition can form a coating that enhances weather resistance of the photovoltaic device.
  • weather resistance properties such as anti-icing characteristics, and the coating can maintain structural integrity with minimized cracking or peeling off with a long service life when used outdoor in low temperature environments.
  • the hardness of the cured coating may be greater than H, greater than 2H, or 2H to 5H, as measured in accordance with ASTM D3363.
  • the coating may provide no field rusting after 500 hours as tested in accordance with ASTM Bl 17.
  • the weathering resistance of the coating may provide 95% or greater gloss retention after 1000 hours as tested in accordance with ASTM G154.
  • Adhesion of the coating may provide a 4B or a 5B adhesion rating as measured in accordance with ASTM D3359.
  • the adhesion pull off strength of the coating on a coated substrate may be greater than 350 pounds per square inch (psi) as measured in accordance with ASTM D4541.
  • the coating can be transparent and does not interfere with light transmission or power generation for the photovoltaic device.
  • the coated photovoltaic device can be used in a power generation system.
  • Solar modules 1 and 2 are sharp NU- Q2354F4 photovoltaic modules without any additional coating.
  • Solar module 3 is a sharp NU-Q2354F4 photovoltaic module coated with a cured product (coating 1) of a coating composition including an epoxy-silicone, an aminosilane, a silanol-functional silicone, a fluorinated silane, a curing catalyst, a light stabilizer and/or an ultraviolet-light absorber, and a surface-activate agent.
  • a coating composition including an epoxy-silicone, an aminosilane, a silanol-functional silicone, a fluorinated silane, a curing catalyst, a light stabilizer and/or an ultraviolet-light absorber, and a surface-activate agent.
  • Solar module 4 is a sharp NU-Q2354F4 photovoltaic module coated with a cured product (coating 2) of a coating composition containing an epoxy-silicone, an aminosilane, a silanol-functional silicone, a plasticizer, an alkoxylsilane, a curing catalyst, a light stabilizer and/or an ultraviolet-light absorber, and a surface-activate agent.
  • a coating composition containing an epoxy-silicone, an aminosilane, a silanol-functional silicone, a plasticizer, an alkoxylsilane, a curing catalyst, a light stabilizer and/or an ultraviolet-light absorber, and a surface-activate agent.
  • Isc open circuit current
  • Voc voltage at open circuit
  • Imp current at maximum power
  • Vmp voltage at maximum power point
  • Pmp fill factor
  • Eff. efficiency
  • Rsh series resistance
  • Rs series resistance
  • Electroluminescence (EL) images at low (0.1/sc) and high (//sc) current bias were obtained.
  • Uncoated NU-Q2354F4 photovoltaic modules were subjected to real-world conditions and irradiance and subsequent produced amperes (amps) were recorded.
  • the NU- Q2354F4 photovoltaic modules were then coated with a cured product (coating 3) of a coating composition containing an epoxy-silicone, an aminosilane, a silanol-functional silicone, a plasticizer, a light stabilizer and/or an ultraviolet-light absorber, and a surface- activate agent.
  • the coating composition is free of tin and PFAS.
  • the coated photovoltaic modules were then subjected to real- world conditions under similar conditions to the uncoated photovoltaic modules. Side by side comparison data for the uncoated versus coated photovoltaic modules are provided in Table 3.
  • the coated photovoltaic modules produced increased amps in comparison to the uncoated photovoltaic modules with an average increase of 11.63%, corrected for the irradiance differences for each test point pair.
  • Test panels coated with coating 3 as described in Example 2 were struck by a 45 (mm) lab manufactured ice ball at terminal velocity (30 meters per second) in 11 different locations at a 0°C angle as per the IEC 61215 hail test procedure. Testing results revealed no cracking of the coating. The results indicate that the coating as described herein can have excellent impact resistance.
  • a coated photovoltaic device comprising a photovoltaic device having a first surface for receiving incoming light and an opposing second surface, and a coating disposed on at least the first surface, the second surface, or both the first and second surfaces of the photovoltaic device, wherein the coating is a cured product of a coating composition comprising: (i) an epoxy-silicone; (ii) an aminosilane; (iii) a silanol-functional silicone; and (iv) a fluorinated silane, a plasticizer, or a combination thereof.
  • Aspect 2 The coated photovoltaic device of Aspect 1, wherein the coating composition comprises, based on a total weight of the coating composition: about 60 to about 80 weight percent, or about 65 to about 75 weight percent of the epoxy-silicone; about 10 to about 25 weight percent, or about 15 to about 20 weight percent of the aminosilane; about 1 to about 20 weight percent, or about 5 to about 15 weight percent of the silanol-functional silicone; and about 0.5 to about 10 weight percent, or about 1 to about 5 weight percent of the fluorinated silane.
  • Aspect 3 The coated photovoltaic device of Aspect 1, wherein the coating composition comprises, based on a total weight of the coating composition: about 35 to about 65 weight percent, about 50 to about 65 weight percent, about 40 to about 60, or about 45 to about 55 weight percent of the epoxy-silicone; about 1 to about 25 weight percent, or about 1 to about 20 weight percent, about 10 to about 20 weight percent, or about 5 to about 15 weight percent of the aminosilane; about 0.5 to about 25 weight percent, or about 1 to about 20 weight percent, or about 5 to about 15 weight percent of the silanol-functional silicone; and about 5 to about 45 weight percent, or about 8 to about 40 weight percent, about 8 to about 20 weight percent, or about 25 to about 35 weight percent of the plasticizer.
  • Aspect 4 The coated photovoltaic device of any one of Aspects 1 to 3, wherein the epoxy-silicone has an epoxy equivalent weight of about 200 to about 700 grams, about 300 to about 700 grams, or about 400 to about 600 grams.
  • Aspect 5 The coated photovoltaic device of any one of Aspects 1 to 4, wherein the aminosilane has a structure represented by Formula I or Formula II: HRN-X-SiR" x (OR') 3 -x Formula I
  • R is hydrogen, alkyl, cycloalkyl, aryl, or aralkyl; each occurrence of R' is independently hydrogen, alkyl, or cycloalkyl; each occurrence of R" is independently alkyl, cycloalkyl, aryl, or aralkyl; each occurrence of X and X' is independently an alkylene, cycloalkylene, or -R2-NH-R 3 -, wherein R2 and R 3 are independently alkylene, or cycloalkylene; x is 0 to 2, y is 0 to 2, n is 0 to 2, m is 0 to 2, and m+n is 2.
  • Aspect 6 The coated photovoltaic device of any one of Aspects 1 to 5, wherein the silano-fiinctional silicone has a structure represented by Formula III HO-(SiR'"2O)n-SiR'" 2 -OH Formula III wherein each occurrence of R'" is independently alkyl, cycloalkyl, aryl or aralkyl, and n is 2 to 20.
  • Aspect 9 The coated photovoltaic device of any one of Aspects 1 to 8, wherein the plasticizer comprises at least one of a phthalate, a trimellitate, a diester of a cyclohexane-dicarboxylic acid, an adipate, an azelate, a sebacate, a glycol ethers a glycol ester, an organic phosphoric or sulfonic ester, a polybutene, or a fatty acid methyl or ethyl ester derived from a natural fat or oil.
  • the plasticizer comprises at least one of a phthalate, a trimellitate, a diester of a cyclohexane-dicarboxylic acid, an adipate, an azelate, a sebacate, a glycol ethers a glycol ester, an organic phosphoric or sulfonic ester, a polybutene, or a fatty acid methyl or ethyl
  • Aspect 11 The coated photovoltaic device of any one of Aspects 1 to 10, wherein the first surface is a top surface of a glass layer, and the second surface is a bottom surface of a polymer sheet or a glass layer.
  • Aspect 12 The coated photovoltaic device of any one of Aspects 1 to 11, wherein the photovoltaic device is a photovoltaic cell, module, panel, array, or system.
  • Aspect 14 A power generation system comprising the coated photovoltaic device of any one of Aspects 1 to 13.
  • Aspect 16 The method of Aspect 15, further comprising providing in a part A composition in a container A, a part B composition in a container B, and a part C composition in a container C, and combining the part A composition with the part B composition and the part C composition to form the coating composition, wherein the part A composition comprises the epoxy-silicone; the part B composition comprises the aminosilane; and the part C composition comprises the silanol-functional silicone.
  • the method of Aspect 15, further comprising providing in separate containers a part A composition, a part B composition, and a part C composition, and combining the part A composition with the part B composition and the part C composition to form the coating composition, wherein the part A composition comprises the epoxy-silicone and the plasticizer; the part B composition comprises the aminosilane; and the part C composition comprises the silanol-functional silicone.
  • a coating composition comprising, based on a total weight of the coating composition: about 35 to about 65 weight percent, or about 40 to about 65 weight percent, about 50 to about 65 weight percent, or about 45 to about 55 weight percent of an epoxy-silicone; about 1 to about 25 weight percent, or about 1 to about 20 weight percent, about 10 to about 20 weight percent, or about 5 to about 15 weight percent of an aminosilane; about 0.5 to about 25 weight percent, or about 1 to about 20 weight percent, or about 5 to about 15 weight percent of a silanol- functional silicone; and about 5 to about 45 weight percent, about 8 to about 40 weight percent, about 8 to about 20 weight percent, or about 25 to about 35 weight percent of a plasticizer.
  • Aspect 19 The coating composition of Aspect 18, further comprising an alkoxysilane.
  • Aspect 20 A three-component coating kit to provide the coating composition of Aspect 18 or Aspect 19, comprising in separate containers a part A composition, a part B composition, and a part C composition, wherein the part A composition comprises the epoxysilicone and the plasticizer; the part B composition comprises the aminosilane; and the part C composition comprises the silanol-functional silicone, and the part A composition, the part B composition, and the part C composition are packaged separately.
  • Aspect 21 The three-component coating kid of Aspect 20, wherein the part A composition, the part B composition, the part C composition, or a combination thereof further comprises at least one of a curing catalyst, a surface-active agent, a heat stabilizer, an ultraviolet-light absorber, a colorant, or an alkoxysilane.
  • Aspect 22 The three-component coating kit of Aspect 20 or Aspect 21, wherein the part A composition comprises about 40 to about 90 weight percent, about 70 to about 90 weight percent, or about 50 to about 70 weight percent of the epoxy-silicone, and about 10 to about 60 weight percent, about 10 to about 20 weight percent, or about 30 to about 50 weight percent of the plasticizer, each based on a total weight percent of the part A composition; the part B composition comprises about 60 to about 100 weight percent, about 90 to about 100 weight percent, or about 65 to about 90 weight percent of the aminosilane, each based on a total weight of the part B composition; and the part C composition comprises about 90 to about 100 weight percent of the silanol-functional silicone, based on a total weight of the part C composition.
  • a coated article comprising: a substrate; and a coating disposed on a surface of the substrate, wherein the coating comprises a cured product of a coating composition of Aspect 18 or Aspect 19.
  • compositions, methods, and articles can alternatively comprise, consist of, or consist essentially of, any appropriate components or steps herein disclosed.
  • the compositions, methods, and articles can additionally, or alternatively, be formulated so as to be devoid, or substantially free, of any steps, components, materials, ingredients, adjuvants, or species that are otherwise not necessary to the achievement of the function or objectives of the compositions, methods, and articles.
  • hydrocarbyl and “hydrocarbon” refers broadly to a substituent comprising carbon and hydrogen, optionally with 1 to 3 heteroatoms, for example, oxygen, nitrogen, halogen, silicon, sulfur, or a combination thereof; “alkyl” refers to a straight or branched chain, saturated monovalent hydrocarbon group; “alkylene” refers to a straight or branched chain, saturated, divalent hydrocarbon group; “cycloalkyl” refers to a non-aromatic monovalent monocyclic or multicylic hydrocarbon group having at least three carbon atoms; “aryl” refers to an aromatic monovalent group containing only carbon in the aromatic ring or rings; “arylene” refers to an aromatic divalent group containing only carbon in the aromatic ring or rings; and “arylalkyl” refers to an alkyl group that has been substituted with an aryl group as defined above, with benzyl being an exemplary arylalkyl group.
  • each of the foregoing groups can be unsubstituted or substituted, provided that the substitution does not significantly adversely affect synthesis, stability, or use of the compound.
  • substituted as used herein means that at least one hydrogen on the designated atom or group is replaced with another group, provided that the designated atom’s normal valence is not exceeded.
  • any reference to standards, regulations, testing methods and the like refers to the standard, regulation, guidance or method that is in force at the time of filing of the present application.

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Abstract

Un dispositif photovoltaïque revêtu comprend un dispositif photovoltaïque ayant une première surface configurée pour recevoir une lumière entrante et une seconde surface opposée, et un revêtement disposé sur au moins la première surface, la seconde surface, ou à la fois les première et seconde surfaces du dispositif photovoltaïque, le revêtement étant un produit durci d'une composition de revêtement comprenant : (i) une époxy-silicone ; (ii) un aminosilane; (iii) une silicone à fonction silanol ; et (iv) un silane fluoré, un plastifiant ou une combinaison de ceux-ci.
PCT/US2024/059736 2023-12-18 2024-12-12 Dispositifs photovoltaïques revêtus Pending WO2025136781A1 (fr)

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US63/611,306 2023-12-18

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Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US8211264B2 (en) * 2010-06-07 2012-07-03 E I Du Pont De Nemours And Company Method for preparing transparent multilayer film structures having a perfluorinated copolymer resin layer
US20160083622A1 (en) * 2013-02-15 2016-03-24 Momentative Performance Materials, Inc. Antifouling system comprising silicone hydrogel
US20220267654A1 (en) * 2021-02-25 2022-08-25 Bmic Llc Roofing putty, methods and systems utilizing the same
WO2024015316A1 (fr) * 2022-07-15 2024-01-18 Phazebreak Coatings, Inc. Articles flexibles revêtus ayant une surface anti-givrage

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US8211264B2 (en) * 2010-06-07 2012-07-03 E I Du Pont De Nemours And Company Method for preparing transparent multilayer film structures having a perfluorinated copolymer resin layer
US20160083622A1 (en) * 2013-02-15 2016-03-24 Momentative Performance Materials, Inc. Antifouling system comprising silicone hydrogel
US20220267654A1 (en) * 2021-02-25 2022-08-25 Bmic Llc Roofing putty, methods and systems utilizing the same
WO2024015316A1 (fr) * 2022-07-15 2024-01-18 Phazebreak Coatings, Inc. Articles flexibles revêtus ayant une surface anti-givrage

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