Patents by Inventor Richard Allen Hayes
Richard Allen Hayes has filed for patents to protect the following inventions. This listing includes patent applications that are pending as well as patents that have already been granted by the United States Patent and Trademark Office (USPTO).
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Patent number: 8772624Abstract: 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 ?-olefins and from about 18 to about 25 wt % of polymerized residues of ?,?-ethylenically unsaturated carboxylic acids. The present invention also provides a process of manufacturing the solar cell module.Type: GrantFiled: July 28, 2006Date of Patent: July 8, 2014Assignee: E I du Pont de Nemours and CompanyInventors: Richard Allen Hayes, Geraldine M. Lenges, Steven C. Pesek, Sam Louis Samuels, Charles Anthony Smith
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Publication number: 20140182664Abstract: A polymeric film or sheet comprising an ionomeric composition comprising ionomeric copolymer of an alpha olefin and about 1 to about 30 wt % of alpha,beta-ethylenically unsaturated carboxylic acid having 3 to 8 carbons, based on the total weight of the ionomeric copolymer, wherein the carboxylic acid is neutralized to a level of 1 to 100 mol %, with one or more metal ions, based on the total number of moles of carboxylate groups in the ionomeric copolymer, and wherein the ionomeric copolymer has a Melt Index of about 20 to about 300 g/10 min. The ionomeric composition preferably comprises an additive selected from the group consisting of silane coupling agent, organic peroxide, and combinations thereof. In addition, an article comprising an interlayer formed of the polymeric film or sheet and an additional layer selected from the group consisting of glass, other polymeric interlayer sheets, polymeric film layers, and metal films or sheets. Examples of articles include safety windows and solar cells.Type: ApplicationFiled: March 5, 2014Publication date: July 3, 2014Applicant: E. I. DU Pont DE Nemours And CompanyInventors: RICHARD ALLEN HAYES, SAM LOUIS SAMUELS, MATTHEW SCOTT HALL
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Patent number: 8753472Abstract: A pipe or tube article comprising an innermost layer made from a grafted polyolefin composition is disclosed which can provide long lifetime, highly abrasion-resistant pipes for mining and other transportation uses. Methods for preparing the article and transporting abrasive materials through the article are also described.Type: GrantFiled: April 5, 2013Date of Patent: June 17, 2014Assignee: E I du Pont de Nemours and CompanyInventors: Richard Allen Hayes, Qin Lin
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Patent number: 8728600Abstract: A pipe- or tube-shaped article comprising an innermost layer made from a grafted polyolefin composition is disclosed which can provide long lifetime, highly abrasion-resistant pipes for mining and other transportation uses. Methods for preparing the article and transporting abrasive materials through the article are also described.Type: GrantFiled: June 27, 2012Date of Patent: May 20, 2014Assignee: E I du Pont de Nemours and CompanyInventor: Richard Allen Hayes
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Publication number: 20140134442Abstract: A polymeric film or sheet comprising an acid copolymer composition comprising acid copolymer of an alpha olefin and about 1 to about 30 wt % of alpha,beta-ethylenically unsaturated carboxylic acid having 3 to 8 carbons, based on the total weight of the acid copolymer composition, wherein the acid copolymer has a Melt Index of about 75 to about 600 g/10 min. The acid copolymer composition preferably comprises an additive selected from the group consisting of silane coupling agent, organic peroxide, and combinations thereof. In addition, an article comprising an interlayer formed of the polymeric film or sheet and an additional layer selected from the group consisting of glass, other polymeric interlayer sheets, polymeric film layers, and metal films or sheets. Examples of articles include safety windows and solar cells.Type: ApplicationFiled: January 21, 2014Publication date: May 15, 2014Applicant: E I DU PONT DE NEMOURS AND COMPANYInventors: RICHARD ALLEN HAYES, SAM LOUIS SAMUELS, MATTHEW SCOTT HALL
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Patent number: 8691372Abstract: A polymeric film or sheet comprising an ionomeric composition comprising ionomeric copolymer of an alpha olefin and about 1 to about 30 wt % of alpha,beta-ethylenically unsaturated carboxylic acid having 3 to 8 carbons, based on the total weight of the ionomeric copolymer, wherein the carboxylic acid is neutralized to a level of 1 to 100 mol %, with one or more metal ions, based on the total number of moles of carboxylate groups in the ionomeric copolymer, and wherein the ionomeric copolymer has a Melt Index of about 20 to about 300 g/10 min. The ionomeric composition preferably comprises an additive selected from the group consisting of silane coupling agent, organic peroxide, and combinations thereof. In addition, an article comprising an interlayer formed of the polymeric film or sheet and an additional layer selected from the group consisting of glass, other polymeric interlayer sheets, polymeric film layers, and metal films or sheets. Examples of articles include safety windows and solar cells.Type: GrantFiled: February 6, 2008Date of Patent: April 8, 2014Assignee: E I du Pont de Nemours and CompanyInventors: Richard Allen Hayes, Sam Louis Samuels, Matthew Scott Hall
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Publication number: 20140069565Abstract: Disclosed are methods to form coatings on a substrate, the coatings comprising a blend of a poly(vinyl alcohol) composition comprising a poly(vinyl alcohol) characterized by a hydrolysis level of from about 85 to about 93 mole % and a 4 weight % aqueous viscosity at 20° C. of about 16 to about 75 centipoise; and an ionomer comprising a parent acid copolymer that comprises ethylene and about 18 to about 30 weight % of acrylic acid or methacrylic acid, the acid copolymer having a melt flow rate from about 200 to about 1000 g/10 min., wherein about 50% to about 70% of the carboxylic acid groups of the copolymer are neutralized to carboxylic acid salts comprising potassium cations, sodium cations or combinations thereof. Multilayer structures comprising the blend composition on a substrate are also disclosed.Type: ApplicationFiled: November 12, 2013Publication date: March 13, 2014Applicant: E I DU PONT DE NEMOURS AND COMPANYInventors: ELLIOTT ECHT, Richard Allen Hayes
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Patent number: 8657993Abstract: A process of manufacturing a solar cell module, the process comprising: (i) providing a solar cell pre-laminate assembly comprising a solar cell component comprising one or a plurality of solar cells and an encapsulant film or sheet consisting essentially of a non-neutralized acid copolymer composition prepared from (a) non-neutralized acid copolymer of an alpha olefin and about 15 to about 23 wt % of alpha,beta-ethylenically unsaturated carboxylic acid having 3 to 8 carbons, based on the total weight of the acid copolymer, wherein the acid copolymer has a Melt Index of greater than 100 to about 600 g/10 min, and (b) about 0.01 to about 10 wt %, based upon the total weight of the acid copolymer composition, of organic peroxide; and (ii) laminating the pre-laminate assembly to form the solar cell module by subjecting the assembly to heat and, optionally, vacuum.Type: GrantFiled: December 13, 2011Date of Patent: February 25, 2014Assignee: E I du Pont de Nemours and CompanyInventors: Richard Allen Hayes, Sam Louis Samuels, Matthew Scott Hall
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Patent number: 8637150Abstract: The present invention provides an acid terpolymer comprising multilayer film or sheet and safety laminates and solar cell pre-lamination assemblies comprising the same.Type: GrantFiled: October 1, 2007Date of Patent: January 28, 2014Assignee: E I du Pont de Nemours and CompanyInventors: Richard Allen Hayes, Jane Kapur, Sam Louis Samuels
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Publication number: 20130225750Abstract: Disclosed is a blend composition comprising a combination of (a) about 99 to about 1 weight %, based on the combination of (a) and (b), of a poly(vinyl alcohol) characterized by a hydrolysis level of from about 85 to about 93 mol % and a 4 weight % aqueous viscosity of 16 to about 75 centipoise; and (b) about 1 to about 99 weight % of an ionomer comprising a parent acid copolymer that comprises ethylene and about 18 to about 30 weight % of acrylic acid or methacrylic acid, the acid copolymer having a melt flow rate from about 200 to about 1000 g/10 min., wherein about 50% to about 70% of the carboxylic acid groups of the copolymer are neutralized to carboxylic acid salts comprising potassium and/or sodium cations. Also disclosed are aqueous dispersions, methods to prepare the aqueous dispersions and articles comprising the blend composition.Type: ApplicationFiled: February 29, 2012Publication date: August 29, 2013Applicant: E. I. DU PONT DE NEMOURS AND COMPANYInventors: Elliott Echt, Richard Allen Hayes
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Publication number: 20130225021Abstract: Disclosed are methods to form coatings on a substrate, the coatings comprising a blend of a poly(vinyl alcohol) composition comprising a poly(vinyl alcohol) characterized by a hydrolysis level of from about 85 to about 93 mole % and a 4 weight % aqueous viscosity at 20° C. of about 16 to about 75 centipoise; and an ionomer comprising a parent acid copolymer that comprises ethylene and about 18 to about 30 weight % of acrylic acid or methacrylic acid, the acid copolymer having a melt flow rate from about 200 to about 1000 g/10 min., wherein about 50% to about 70% of the carboxylic acid groups of the copolymer are neutralized to carboxylic acid salts comprising potassium cations, sodium cations or combinations thereof. Multilayer structures comprising the blend composition on a substrate are also disclosed.Type: ApplicationFiled: February 29, 2012Publication date: August 29, 2013Applicant: E.I. DU PONT DE NEMOURS AND COMPANYInventors: Elliott Echt, Richard Allen Hayes
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Publication number: 20130224505Abstract: Disclosed are methods to form coatings on a substrate, the coatings comprising a blend of a poly(vinyl alcohol) composition comprising a poly(vinyl alcohol) characterized by (i) a hydrolysis level of from about 85 to about 93 mol % and a 4 weight % aqueous viscosity of 15 centipoise (cp) or less; or (ii) a hydrolysis level of about 95 mol % to 100%; and an ionomer comprising a parent acid copolymer that comprises ethylene and about 18 to about 30 weight % of acrylic acid or methacrylic acid, the acid copolymer having a melt flow rate from about 200 to about 1000 g/10 min., wherein about 50% to about 70% of the carboxylic acid groups of the copolymer are neutralized to carboxylic acid salts comprising potassium cations, sodium cations or combinations thereof. Multilayer structures comprising the blend composition on a substrate are also disclosed.Type: ApplicationFiled: February 29, 2012Publication date: August 29, 2013Applicant: E.I. DU PONT DE NEMOURS AND COMPANYInventors: Elliott Echt, Richard Allen Hayes
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Publication number: 20130225749Abstract: Disclosed is a composition comprising (a) a poly(vinyl alcohol) characterized by (i) a hydrolysis level of from about 85 to about 93 mole % and a 4 weight % aqueous viscosity at 20° C. of 15 centipoise or less; or (ii) a hydrolysis level of about 95 mole % or greater; and (b) an ionomer comprising a parent acid copolymer comprising copolymerized units of ethylene and acrylic acid or methacrylic acid with melt flow rate from about 200 to about 1000 g/10 min., wherein about 50% to about 70% of the carboxylic acid groups of the copolymer are neutralized to carboxylic acid salts.Type: ApplicationFiled: February 29, 2012Publication date: August 29, 2013Applicant: E.I. DU PONT DE NEMOURS AND COMPANYInventors: Elliott Echt, Richard Allen Hayes
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Patent number: 8497005Abstract: A pipe or tube article comprising an innermost comprising a grafted polyolefin composition made from a grafted polyolefin composition is disclosed which can provide long lifetime, highly abrasion-resistant pipes for mining and other transportation uses. Methods for preparing the article and transporting abrasive materials through the article are also described.Type: GrantFiled: June 27, 2012Date of Patent: July 30, 2013Assignee: E I du Pont de Nemours and CompanyInventors: Richard Allen Hayes, Qin Lin
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Patent number: 8445776Abstract: 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 ?-olefin carboxylic acid copolymer, wherein about 10% to about 35% of the total content of the carboxylic acid groups present in the precursor ?-olefin carboxylic acid copolymer have been neutralized with sodium ions, and wherein the precursor ?-olefin carboxylic acid copolymer comprises (i) copolymerized units of an ?-olefin having 2 to 10 carbons and (ii) about 20 to about 25 wt %, based on the total weight of the ?-olefin carboxylic acid copolymer, of copolymerized units of an ?,?-ethylenically unsaturated carboxylic acid having 3 to 8.Type: GrantFiled: June 1, 2009Date of Patent: May 21, 2013Assignee: E I du Pont de Nemours and CompanyInventors: Richard Allen Hayes, Rebecca L. Smith, Kristof Proost, Steven C. Pesek, Charles Anthony Smith
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Publication number: 20130116373Abstract: Disclosed is a method to form an aqueous dispersion comprising a blend composition comprising or consisting essentially of about 75 to about 99.9 weight of an ionomer composition and about 0.1 to about 25 weight % of an ethylene acrylate ester copolymer composition, a grafted polyolefin composition or a combination thereof, the method comprising mixing the solid blend composition with water heated to a temperature from about 80 to about 100° C.Type: ApplicationFiled: November 7, 2011Publication date: May 9, 2013Applicant: E. I. DU PONT DE NEMOURS AND COMPANYInventor: RICHARD ALLEN HAYES
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Patent number: 8399081Abstract: 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 ?-olefin having 2 to 10 carbon atoms and about 20 to about 30 wt % of copolymerized units of an ?,?-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° 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.Type: GrantFiled: November 2, 2009Date of Patent: March 19, 2013Assignee: E I du Pont de Nemours and CompanyInventors: Richard Allen Hayes, Steven C. Pesek, W Alexander Shaffer, Charles Anthony Smith, George Wyatt Prejean
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Patent number: 8399095Abstract: 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.Type: GrantFiled: November 2, 2009Date of Patent: March 19, 2013Assignee: E I du Pont de Nemours and CompanyInventors: Steven C. Pesek, Charles Anthony Smith, W Alexander Shaffer, Richard Allen Hayes
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Patent number: 8399098Abstract: 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 ?-olefin and an ?,?-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.Type: GrantFiled: November 2, 2009Date of Patent: March 19, 2013Assignee: E I du Pont de Nemours and CompanyInventors: Stephen J. Bennison, Richard Allen Hayes, Steven C. Pesek, W Alexander Shaffer, Charles Anthony Smith
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Patent number: 8399082Abstract: 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 ?-olefin and about 20 to about 30 wt % of copolymerized units of an ?,?-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.Type: GrantFiled: June 1, 2012Date of Patent: March 19, 2013Assignee: E I du Pont de Nemours and CompanyInventors: Karlheinz Hausmann, Richard Allen Hayes, Steven C Pesek, W Alexander Shaffer, Charles Anthony Smith