US 11,884,044 B2
Process for producing a multilayer laminate
Stefan Hellstrom, Stenungsund (SE); Francis Costa, Linz (AT); Jeroen Oderkerk, Stenungsund (SE); and Bert Broeders, Beringen (BE)
Assigned to BOREALIS AG, Vienna (AT)
Appl. No. 17/042,992
Filed by BOREALIS AG, Vienna (AT)
PCT Filed Apr. 8, 2019, PCT No. PCT/EP2019/058810
§ 371(c)(1), (2) Date Sep. 29, 2020,
PCT Pub. No. WO2019/201646, PCT Pub. Date Oct. 24, 2019.
Claims priority of application No. 201820538314.0 (CN), filed on Apr. 16, 2018; and application No. 18167590 (EP), filed on Apr. 16, 2018.
Prior Publication US 2021/0023831 A1, Jan. 28, 2021
Int. Cl. B32B 27/32 (2006.01); B32B 27/30 (2006.01); B32B 27/18 (2006.01); B32B 17/10 (2006.01); B32B 3/10 (2006.01); H01L 31/048 (2014.01); H01L 31/049 (2014.01); B32B 37/10 (2006.01)
CPC B32B 27/32 (2013.01) [B32B 17/10036 (2013.01); B32B 27/18 (2013.01); B32B 27/308 (2013.01); B32B 37/1054 (2013.01); H01L 31/049 (2014.12); H01L 31/0488 (2013.01); B32B 2250/03 (2013.01); B32B 2250/05 (2013.01); B32B 2250/40 (2013.01); B32B 2309/02 (2013.01); B32B 2309/105 (2013.01); B32B 2309/12 (2013.01); B32B 2315/08 (2013.01); B32B 2323/04 (2013.01); B32B 2333/08 (2013.01); B32B 2457/12 (2013.01)] 16 Claims
OG exemplary drawing
 
1. A process for producing a multilayer laminate being a photovoltaic (PV) module comprising, in the given order, a protective front layer element, a front encapsulation layer element, a photovoltaic element, a rear encapsulation layer element, and a protective back layer element,
wherein any one or more of the front encapsulation layer element or rear encapsulation layer element is/are a polymeric layer element(s) (LE);
the protective front layer element is a first substrate element being a glass element; and
the protective back layer element is a second substrate element being a glass element;
wherein the polymeric layer element (LE) comprises a polymer composition comprising:
(a) a polymer;
and wherein the process comprises the steps of:
(i) assembling step to arrange the at least one substrate element and the at least one polymeric layer element (LE) in form of a multilayer assembly;
(ii) heating step to heat up the multilayer assembly;
(iii) pressure build up step, where the pressure on the multilayer assembly is gradually increased in a single or multiple steps;
(iv) pressure holding step, where the pressure is kept on the multilayer assembly at the heated conditions attained at the end of step (ii); and
(v) recovering step to cool and remove the obtained multilayer laminate for later use;
wherein the pressure during pressure holding step (iv) is kept at 790 mbar or below; and
wherein average thickness variation of the resultant multilayer laminate is 60% or less, wherein the average thickness variation (%) is the average of the thickness variation of two opposite edges of the multilayer laminate compared to the middle of the multilayer laminate.