Photovoltaic devices with encapsulating barrier film

Abstract

Encapsulated device including a photovoltaic cell and a composite film overlaying at least a portion of the photovoltaic cell, the composite film further including a substrate, a base (co)polymer layer on a major surface of the substrate, an oxide layer on the base (co)polymer layer, and a protective (co)polymer layer derived from a silane precursor compound on the oxide layer

1 . An encapsulated device comprising:
 a photovoltaic cell; and   a composite film overlaying at least a portion of the photovoltaic cell, the composite film further comprising:   a substrate;   a base (co)polymer layer on a major surface of the substrate;   an oxide layer on the base (co)polymer layer; and   a protective (co)polymer layer on the oxide layer, wherein the protective (co)polymer layer comprises the reaction product of at least one urea (multi)-(meth)acrylate (multi)-silane precursor compound of the formula: R S —N(R 5 )—C(O)—N(H)—R A , wherein:   R S  is a silane containing group of the formula: —R 1 —[Si(Y p )(R 2 ) 3-p ] q , wherein:   R 1  is a multivalent alkylene, arylene, alkarylene, or aralkylene group, said alkylene, arylene, alkarylene, or aralkylene groups optionally containing one or more catenary oxygen atoms,   each Y is a hydrolysable group,   R 2  is a monovalent alkyl or aryl group;   p is 1, 2, or 3, and   q is 1-5;   R A  is a (meth)acryl group containing group of the formula: R 11 —(A) n , wherein:   R 11  is a polyvalent alkylene, arylene, alkarylene, or aralkylene group, said alkylene, arylene, alkarylene, or aralkylene groups optionally containing one or more catenary oxygen atoms,   A is a (meth)acryl group comprising the formula: X 2 —C(O)—C(R 3 )═CH 2 , further wherein:   X 2  is —O, —S, or —NR 3 ,   R 3  is H, or C 1  -C 4 , and   n=1 to 5; and   R 5  is H, C 1  to C 6  alkyl or cycloalkyl, or R S , with the proviso that at least one of the following conditions applies:   n is 2 to 5, R 5  is R S , or q is 2 to 5.   
     
     
         2 . An encapsulated device comprising:
 a photovoltaic cell; and   a composite film overlaying at least a portion of the photovoltaic cell, the composite film further comprising:   a substrate;   a base (co)polymer layer on a major surface of the substrate;   an oxide layer on the base (co)polymer layer; and   a protective (co)polymer layer on the oxide layer, wherein the protective (co)polymer layer comprises the reaction product of at least one urea (multi)-(meth)acrylate (multi)-silane precursor compound of the formula: R S1 —N(R 4 )—C(O)—(H)-R A1 , wherein:   R S1  is a silane containing group of the formula: —R 1d —Si(Y p )(R 2 ) 3-p , further wherein:   R 1d  is a divalent alkylene, arylene, alkarylene, or aralkylene group, said alkylene, arylene, alkarylene, or aralkylene groups optionally containing one or more catenary oxygen atoms,   each Y is a hydrolysable group,   R 2  is a monovalent alkyl or aryl group, and   p is 1, 2, or 3;   R 4  is H, C 1  to C 6  alkyl or C 1  to C 6  cycloalkyl; and   R A1  is a (meth)acryl containing group of the formula: R 11d —(A), wherein:   R 11d  is a divalent alkylene, arylene, alkarylene, or aralkylene group, said alkylene, arylene, alkarylene, or aralkylene groups optionally containing one or more catenary oxygen atoms, and   A is a (meth)acryl group comprising the formula: X 2 —C(O)—C(R 3 )═CH 2 , further wherein:   X 2  is —O, —S, or —NR 3 , and   R 3  is H, or C 1 -C 4 .   
     
     
         3 . An encapsulated device comprising:
 a photovoltaic cell; and   a composite film overlaying at least a portion of the photovoltaic cell, the composite film further comprising:   a substrate;   a base (co)polymer layer on a major surface of the substrate;   an oxide layer on the base (co)polymer layer; and   a protective (co)polymer layer on the oxide layer, wherein the protective (co)polymer layer comprises the reaction product of at least one urethane (multi)-(meth)acrylate (multi)-silane precursor compound of the formula: R S —N(H)—C(O)—O—R A  or R S —O—C(O)—N(H)—R A , wherein:   R S  is a silane containing group of the formula —R 1 —[Si(Y p )(R 2 ) 3-p ] q , further wherein:   R 1  is a multivalent alkylene, arylene, alkarylene, or aralkylene group, said alkylene, arylene, alkarylene, or aralkylene groups optionally containing one or more catenary oxygen atoms,   each Y is a hydrolysable group,   R 2  is a monovalent alkyl or aryl group;   p is 1, 2, or 3, and   q is 1-5; and   R A  is a (meth)acryl group containing group of the formula R 11 —(A) n , wherein:   R 11  is a polyvalent alkylene, arylene, alkarylene, or aralkylene group, said alkylene, arylene, alkarylene, or aralkylene groups optionally containing one or more catenary oxygen atoms,   A is a (meth)acryl group comprising the formula X 2 —C(O)—C(R 3 )═CH 2 , further wherein:   X 2  is —O, —S, or —NR 3 ,   R 3  is H, or C 1 -C 4 , and   n=1 to 5.   
     
     
         4 . An encapsulated device comprising:
 a photovoltaic cell; and   a composite film overlaying at least a portion of the photovoltaic cell, the composite film further comprising:   a substrate;   a base (co)polymer layer on a major surface of the substrate;   an oxide layer on the base (co)polymer layer; and   a protective (co)polymer layer on the oxide layer, wherein the protective (co)polymer layer comprises the reaction product of at least one urea (multi)-urethane (meth)acrylate-silane precursor compound of the formula: R A —NH—C(O)—N(R 4 )—R 11 —[O—C(O)NH—R S ] n , wherein:   R A  is a (meth)acryl containing group of the formula R 11 —(A) n , further wherein   R 11  is a polyvalent alkylene, arylene, alkarylene, or aralkylene group, said alkylene, arylene, alkarylene, or aralkylene groups optionally containing one or more catenary oxygen atom,   A is a (meth)acryl group comprising the formula X 2 —C(O)—C(R 3 )═CH 2 , additionally wherein:   X 2  is —O, —S, or —NR 3 ,   R 3  is independently H, or C 1 -C 4 , and   n=1 to 5;   R 4  is H, C 1  to C 6  alkyl, or C 1  to C 6  cycloalkyl;   R S  is a silane containing group of the formula —R 1 —Si(Y p )(R 2 ) 3-p , wherein:   R 1  is a polyvalent alkylene, arylene, alkarylene, or aralkylene group, said alkylene, arylene, alkarylene, or aralkylene groups optionally containing one or more catenary oxygen atoms,   Y is a hydrolysable group,   R 2  is a monovalent alkyl or aryl group, and   p is 1, 2, or 3.   
     
     
         5 . An encapsulated device comprising:
 a photovoltaic cell; and   a composite film overlaying at least a portion of the photovoltaic cell, the composite film further comprising:   a composite film, comprising:   a substrate;   a base (co)polymer layer on a major surface of the substrate;   an oxide layer on the base (co)polymer layer; and   a protective (co)polymer layer on the oxide layer, wherein the protective (co)polymer layer comprises the reaction product of at least one urea (multi)-urethane (meth)acrylate-silane precursor compound of the formula: R S —NH—C(O)—N(R 4 )—R 11— [O—C(O)NH—R A ] n , wherein:   R S  is a silane containing group of the formula —R 1 —Si(Y p )(R 2 ) 3-p , wherein:   R 1  is a polyvalent alkylene, arylene, alkarylene, or aralkylene group, said alkylene, arylene, alkarylene, or aralkylene groups optionally containing one or more catenary oxygen atoms,   Y is a hydrolysable group,   R 2  is a monovalent alkyl or aryl group, and   p is 1, 2, or 3;   R 4  is H, C 1  to C 6  alkyl, or C 1  to C 6  cycloalkyl;   R A  is a (meth)acryl group containing group of the formula R 11 —(A) n , further wherein:   R 11  is a polyvalent alkylene, arylene, alkarylene, or aralkylene group, said alkylene, arylene, alkarylene, or aralkylene group optionally containing one or more catenary oxygen atom,   A is a (meth)acryl containing group of the formula X 2 —C(O)—C(R 3 )═CH 2 , additionally wherein:   X 2  is —O, —S, or —NR 3 ,   R 3  is independently H, or C 1 -C 4 ; and   n=1 to 5.   
     
     
         6 . An encapsulated device comprising:
 a photovoltaic cell; and   a composite film overlaying at least a portion of the photovoltaic cell, the composite film further comprising:   a substrate;   a base (co)polymer layer on a major surface of the substrate;   an oxide layer on the base (co)polymer layer; and   a protective (co)polymer layer on the oxide layer, wherein the protective (co)polymer layer comprises the reaction product of at least one urethane (multi)-(meth)acrylate (multi)-silane precursor compound of the formula: R S —N(H)—C(O)—O—R A  or R S —O—C(O)—N(H)—R A , wherein:   R S  is a silane containing group of the formula —R 1 —[Si(Y p )(R 2 ) 3-p ] q , further wherein:   R 1  is a multivalent alkylene, arylene, alkarylene, or aralkylene group, said alkylene, arylene, alkarylene, or aralkylene groups optionally containing one or more catenary oxygen atoms,   each Y is a hydrolysable group,   R 2  is a monovalent alkyl or aryl group;   p is 1, 2, or 3, and   q is 1-5; and   R A  is a (meth)acryl group containing group of the formula R 11 —(A) n , wherein:   R 11  is a polyvalent alkylene, arylene, alkarylene, or aralkylene group, said alkylene, arylene, alkarylene, or aralkylene groups optionally containing one or more catenary oxygen atoms,   A is a (meth)acryl group comprising the formula X 2 —C(O)—C(R 3 )═CH 2 , further wherein:   X 2  is —O, —S, or —NR 3 ,   R 3  is H, or C 1 -C 4 , and   n=1 to 5.   
     
     
         7 . The encapsulated device of  claim 1 , wherein each hydrolysable group Y is independently selected from an alkoxy group, an acetate group, an aryloxy group, and a halogen. 
     
     
         8 . The encapsulated device of  claim 7 , wherein at least some of the hydrolysable groups Y are alkoxy groups. 
     
     
         9 . The encapsulated device of  claim 7 , wherein at least some of the hydrolysable groups Y are chlorine. 
     
     
         10 . The encapsulated device of  claim 1 , further comprising a plurality of alternating layers of the oxide layer and the protective (co)polymer layer on the base (co)polymer layer. 
     
     
         11 . The encapsulated device of  claim 1 , wherein the substrate comprises a flexible transparent (co)polymeric film, optionally wherein the substrate comprises polyethylene terephthalate (PET), polyethylene napthalate (PEN), heat stabilized PET, heat stabilized PEN, polyoxymethylene, polyvinylnaphthalene, polyetheretherketone, fluoro(co)polymer, polycarbonate, polymethylmethacrylate, poly a-methyl styrene, polysulfone, polyphenylene oxide, polyetherimide, polyethersulfone, polyamideimide, polyimide, polyphthalamide, or combinations thereof. 
     
     
         12 . The encapsulated device of  1 , wherein the base (co)polymer layer comprises a (meth)acrylate smoothing layer. 
     
     
         13 . The encapsulated device of  claim 1 , wherein the oxide layer comprises oxides, nitrides, carbides or borides of atomic elements from Groups IIA, IIIA, IVA, VA, VIA, VIIA, IB, or IIB, metals of Groups IIIB, IVB, or VB, rare-earth metals, or combinations thereof. 
     
     
         14 . The encapsulated device of  claim 1 , further comprising an oxide layer applied to the protective (co)polymer layer, optionally wherein the oxide layer comprises silicon aluminum oxide.