Structural bonding compositions and attachment brackets, and their use in photovoltaic solar modules

{
  "publication_number": "US9941441B2",
  "country": "US",
  "kind": "B2",
  "title": "Structural bonding compositions and attachment brackets, and their use in photovoltaic solar modules",
  "abstract": "The present disclosure relates to structural bonding compositions and attachment brackets, and their use in photovoltaic solar modules. Another aspect of the present disclosure relates to methods of affixing an attachment bracket to a solar module during the lamination step used to manufacture the module.",
  "claims": [
    "1. A method of affixing an attachment bracket to a solar module comprising: providing a pre-lamination solar module comprising: one or more photovoltaic cells each comprising a first major surface and a second major surface, a glazing pane adjacent one of the major surfaces of the one or more photovoltaic cells, providing an attachment bracket, providing a thermosettable adhesive composition, forming a solar module assembly by positioning the thermosettable adhesive composition between the glazing pane of the pre-lamination solar module and the attachment bracket, and heating the solar module assembly, thereby forming a bond between the glazing pane and the attachment bracket via the thermosettable adhesive composition.",
    "2. The method according to claim 1, wherein the thermosettable adhesive composition comprises an intermediate bonding composition, wherein the intermediate bonding composition comprises: a thermosettable epoxy composition comprising one or more epoxy resins, and an acrylic composition comprising the polymerization reaction product of a mixture comprising: an acrylic ester, and a polymerizable monomer.",
    "3. The method according to claim 2, wherein the thermosettable epoxy composition comprises one or more epoxy resins each comprising di(glycidyl ether) of bisphenol A.",
    "4. The method according to claim 2, wherein the acrylic ester in the acrylic composition is chosen from n-butyl acrylate, hexyl acrylate, 2-ethylhexyl acrylate, octyl acrylate, dodecyl acrylate, lauryl acrylate, octadecyl acrylate, and mixtures thereof.",
    "5. The method according to claim 2, wherein the polymerizable monomer in the acrylic composition is chosen from isobornyl acrylate, N-vinyl pyrrolidone, N-vinyl caprolactam, N-vinyl piperidine, N,N-dimethylacrylamide, acrylonitrile, and mixtures thereof.",
    "6. The method according to claim 2, wherein the intermediate bonding composition further comprises one or more additives chosen from adhesion promoters, photoinitiators, acrylate crosslinking agent, hardeners, pigments, curative agents, curing accelerators, and fillers.",
    "7. The method according to claim 2, wherein the intermediate bonding composition comprises from 10% to 40% of the thermosettable epoxy composition by weight with respect to the total weight of the intermediate bonding composition.",
    "8. The method according to claim 1, wherein the thermosettable adhesive composition is a structural bonding tape.",
    "9. The method according to claim 1, wherein the thermosettable adhesive composition is a pressure sensitive adhesive.",
    "10. The method according to claim 1, wherein the thermosettable adhesive composition further comprises one or more support materials chosen from glass beads, glass bubbles, fibers, wires, non-woven scrims, and meshes.",
    "11. The method according to claim 1, wherein the solar module assembly shows bowing after 7 days in the glass panel bowing test from 0 mm to 2.5 mm.",
    "12. The method according to claim 1, wherein the thermosettable adhesive composition is a structural bonding tape and the structural bonding tape has a stress at 100% strain in the overlap shear stress strain test from 0 N/cm 2 to 150 N/cm 2.",
    "13. The method according to claim 1, wherein the thermosettable adhesive composition is a structural bonding tape and the structural bonding tape has a pluck adhesion in the pluck adhesion test from 35 N/cm 2 to 350 N/cm 2.",
    "14. The method according to claim 1, wherein the thermosettable adhesive composition is a structural bonding tape and the structural bonding tape has a storage modulus at 25° C. from 0.5 MPa to 30 MPa.",
    "15. The method according to claim 1, wherein the heating occurs at temperatures form 100° C. to 200° C."
  ],
  "description_excerpt": "There are currently various methods of installing photovoltaic (PV) solar modules in the field. The applicability of each method depends on field conditions and the type of solar module being installed, among other factors. The two most common rigid solar modules are glass/backsheet modules and glass/glass modules.\n\nGlass/backsheet rigid modules are commonly used for crystalline silicon PV modules. The dominant mounting method for glass/backsheet modules uses metal frames that surround the entire perimeter of the module. These frames typically have a U-channel, where the panel edges are inserted and secured by either a liquid adhesive or a pressure-sensitive adhesive tape.\n\nGlass/glass rigid modules are the dominant type of module in the thin film PV industry. Clips are more common with glass/glass modules than glass/backsheet modules. Clips contact small areas around the edge of the module, and are subjected to the stress of full wind or snow loads. Clip use is sensitive to the specific clip design as module failure can occur in these areas if the clipped area is unable to withstand the applied loads. Multiple clips around the edge can be used to minimize the forces at each clip area. Thicker glass can also help reduce the potential for failure, but may be cost prohibitive.\n\nA third option for mounting solar modules is to use adhesive bonded rails on the back side of the module. The adhesive can be a pressure-sensitive adhesive tape, a liquid, or combination of the two. Rail attachment could be a cost-effective and attractive option for glass/glass modules.",
  "cpc": [
    "C09J 5/06",
    "C09J 2203/322",
    "C09J 2301/304",
    "C09J 2433/00",
    "C09J 2463/00",
    "H01L 31/04",
    "H01L 31/18",
    "H02S 20/00",
    "H10F 10/00",
    "H10F 19/807",
    "H10F 71/00",
    "Y02E 10/50"
  ],
  "ipc": [
    "C09J 5/06",
    "H01L 31/04",
    "H01L 31/18"
  ],
  "assignees": [
    "3M Innovative Properties Co"
  ],
  "inventors": [
    "Cyrus A. Anderson",
    "Christopher J. Duda",
    "Scott R. Meyer"
  ],
  "filing_date": "2015-09-23",
  "publication_date": "2018-04-10",
  "grant_date": "2018-04-10",
  "priority_date": "2014-09-23",
  "application_number": "US-201515512942-A",
  "family_id": "54261101",
  "cited_by_count": 1,
  "citations": [
    "JPH06151935A",
    "US6348118B1",
    "JP2011054743A",
    "JP2011113988A",
    "US20120211056A1",
    "US20150047695A1"
  ]
}