Evaluation of the Effect of Backsheet Properties on PV Encapsulant Degradation under Ultraviolet-Damp-Heat Conditions

The reliability of photovoltaic (PV) modules is highly determined by the durability of the polymeric components (backsheet and encapsulant). The power degradation and failure of PV modules can be caused by changes in the physical, chemical, and mechanical properties of these polymeric components during the module lifetime. In this thesis, different experimental techniques to investigate changes in PV modules polymeric components were deployed. Apart from the known techniques available in the literature, new advanced methods (e.g. Nanoindentation and Scanning Acoustic Microscopy (SAM)) were also applied and benchmarked with already established methods. PV encapsulation processes were also investigated with the aim to optimize the lamination conditions that can help to improve the reliability of PV modules.To demonstrate the effects of backsheet permeation properties on encapsulant degradation, one type of EVA was aged in glass/EVA/backsheet laminates in accelerated aging tests (up to 4000 h for Damp-Heat (DH) and up to 480 kWh/m² for Ultraviolet (UV) and UV-DH combined). Firstly, by using samples with different backsheets, the effects of different material combinations on the EVA degradation mechanisms (chemical changes) were investigated. Fourier transforminfrared spectroscopy with attenuated total reflectance (FTIR-ATR) studies identified two different EVA degradation processes. A thermal oxidation was taking place in the glass/EVA/Polyamide (PA)-based backsheet configuration after 500 h DH tests. However other EVA degradation products were observed in the glass/EVA/PET-based backsheet after 1500 h DH tests. Secondly, it has been perceived that a different material combination leads to different EVA degradation rates, by analyzing the EVA thermal and mechanical changes using Differential Scanning Calorimetry (DSC) and Nanoindentation respectively. As a consequence of these findings, the changes in the melting enthalpy and the viscoelastic properties at the EVA surface was more pronounced when PA-based backsheet was used then when PET-based backsheet was used under combined UV-DH aging tests. The comparison of three accelerated aging stress factors revealed that EVA suffers the strongest chemical and optical degradation when high UV, high temperature and high relative humidity are combined simultaneously.Additionally, in current PV module technology research, there exists a missing link between the PV material degradation and the PV performance degradation after accelerated lifetime tests. Therefore, in this research, a contribution towards this missing link was added by investigating the correlation of material degradation to power degradation. To do this, several PV modules were built and subjected to artificial aging tests. The influence of different micro-climates was investigated and changes in material properties were related to the PV performance degradation. Furthermore, a good correlation between the changes in PV performance parameters and PV module optical evolution of themodules with different material combinations was reached. Moreover, the power output and the series resistance degradation of the PV module was much more severe and stronger under this combined UV-DH aging test than the addition of both factors individually. Under these combined aging conditions, several degradation modes were observed under the visual inspection of the PV modules, including corrosion, backsheet cracking and EVA discoloration.

Ultra-light photovoltaic composite sandwich structures

Julien Rion

The ultra-light photovoltaic sandwich structure is a new multifunctional structure concept enabling weight and thus energy to be saved in high-tech solutions such as solar cars, solar planes or satellites. The novelty of this approach is to use solar cells as a load carrying element in the structure. The aim of this work was to investigate the failure mechanisms of such ultra-light sandwich structure and their correlation with microstructure, processing pressure, and strength in order to obtain optimal design and processing. To this end, composite sandwich structures were extensively studied with weights in the range of 650 – 850 g/m2, and comprising one 140 µm thick skin made of 0/90° carbon fiber-reinforced plastic (CFRP), one skin made of 130 µm thick mono-crystalline silicon solar cells, and a 29 kg/m3 honeycomb core. As a first step, core-to-skin bonding in a symmetric (CFRP / core / CFRP) sandwich, for which a design criterion was lacking, was especially studied. An adhesive deposition technique was developed enabling the adhesive weight used for core-to-skin bonding to be tailored. Based on adhesive contact angles, the formation of the adhesive fillets between honeycomb cell walls and skin was modeled. Core / skin debonding energy was measured and compared to core tearing energy measured with a new video-based method, and the failure mechanisms during skin peeling were investigated. It was thus ascertained that, to provide the highest debonding energy-to-weight ratio, the optimal adhesive weight was 35-40 g/m2. Furthermore, in contrast with classic sandwich structures with thicker skins, it was observed that the bending strength of the ultra-light sandwich panels increased with adhesive weight. This was due to the formation of adhesive fillets, which significantly increased the bending stiffness of the thin CFRP skin, and thus increased the compressive load causing local instability of the skin. Models taking into account the increased skin stiffness showed that the best adhesive quantity required to increase the strength-to-weight ratio was ∼40 g/m2. In a second step, the influence of processing pressure on the morphology and strength of symmetric (CFRP / core / CFRP) ultralight sandwich structures was investigated by using one-shot vacuum bag processing. This showed that higher processing pressures caused the formation of larger adhesive fillets and an increased waviness of the CFRP skin on vacuum bag side. These two effects had conflicting impacts on the strength of the structure. Waviness of the skin favored local instabilities, whereas adhesive menisci stabilized the skin. Modeling of the local instability of the skin by taking into account the waviness of the skin and the size of the menisci as a function of processing pressure enabled an optimal processing pressure of 0.7 bar to be identified, giving the highest strength-to-weight ratio. The third step of the study was devoted to the mechanical analysis of the mono-crystalline silicon solar cells. The brittle behavior of the cells was confirmed, and the Weibull failure probability curve was established with the mean tensile strength at 221 MPa. It was demonstrated by experimental testing and finite element modeling (FEM) that the low strength of the cells compared to the intrinsic strength of silicon (∼6.9 GPa) was not due to surface texturation of the cells used for increased efficiency, but to more severe surface or edge defects. FEM also showed that no significant reinforcing effect of the cells could be obtained with polymer encapsulation. In addition, thermo-mechanical stresses due to a mismatch of the coefficient of thermal expansion (CTE) between the Si cells and the polymer encapsulation were found to be negligible. In order to protect the cells against the environment, encapsulation of the cells was successfully carried out, using highly transparent fluoropolymer films treated with SiO2 plasma sputtering for improved adhesion, together with silicone adhesive. Finally, the integration of solar cells as a photovoltaic skin of an ultra-light sandwich structure was achieved using thin stress transfer ribbons to ensure load transfer between adjacent cells. It was observed that the cells were not damaged by sandwich panel processing, even in curved panels, thus showing that the processing windows of the different constituents were compatible. The asymmetric (Si / core / CFRP) photovoltaic sandwich structure with a weight equal to 800 g/m2 and a specific power density equal to ∼250 W/kg (i.e. 20 times more than standard commercial photovoltaic panels) demonstrated an equilibrated mechanical behavior, i.e. the CFRP skin, reinforcing ribbons, and solar cells had similar failure loads.

EPFL2008

Air cooling powered by façade integrated coloured opaque solar thermal panels

Stefan Mertin, Andreas Schueler

For building integration of solar-powered energy systems, aesthetic aspects play an importantrole. Covering a standard solar collector with a coloured glazing, opaque to the human eye but highly transparent to solar energy, permits a perfect architectural integration of solar thermal panels into glazed building façades. The thermal energy produced can be used for both solar heating and cooling, as well as for domestic hot water. The principle of the coloured appearance is based on interference in the thin-film coating on the reverse side of the cover glass. Different interference filters based on nano-composite materials deposited by the solgel method were presented at CISBAT 2007 [1]. Currently, we are developing new plasma-deposition processes, which are more suitable for industrial large-scale production. A new state-of-the-art ultra-high vacuum (UHV) system for magnetron sputtering deposition of novel nano-composite solar coatings has recently been designed, constructed, and installed at the Solar Energy and Building Physics Laboratory (LESO-PB). Up to five different magnetron sources can be used simultaneously, in reactive and non-reactive mode. The geometric configuration of the chamber has been optimised for best film homogeneity and allows the deposition on substrates up to 100 mm in diameter. The optical and electronic properties of thin films are closely interrelated and highly relevant for solar coatings. Photoelectron spectroscopy provides information on the coating structure, the deposited material and its chemical state inside the coating, as well as the nature of the interface between different layers. A system for ESCA analysis (Electron Spectroscopy for Chemical Analysis) has recently been installed and put into operation at LESO-PB. By ellipsometry and spectrophotometry, we can determine exactly the different optical properties of the coating, such as layer thickness, refractive index, or absorption coefficient. This provides best conditions for highly efficient research and development on new materials for further optimisation of the coloured interference filters.First results have been obtained with our new experimental infrastructure and will be presented in this contribution.

EPFL2011

Coloured coatings for glazing of active solar thermal façades by reactive magnetron sputtering

Martin Joly, Stefan Mertin, Jean-Louis Scartezzini, Andreas Schueler

For building integration of solar-powered energy systems, aesthetic aspects play an important role. Covering a standard solar collector with a coloured glazing, opaque to the human eye but highly transparent to solar energy, permits a perfect architectural integration of solar thermal panels into glazed building façades. The thermal energy produced can be used for both solar heating and cooling, as well as for domestic hot water. The principle of the coloured appearance is based on interference in the thin-film coating on the reverse side of the cover glass. Different interference filters based on nano-composite materials deposited by the solgel method were presented at CISBAT 2007 [1]. Currently, we are developing new plasma-deposition processes, which are more suitable for industrial large-scale production. A new state-of-the-art ultra-high vacuum (UHV) system for magnetron sputtering deposition of novel nano-composite solar coatings has recently been designed, constructed, and installed at the Solar Energy and Building Physics Laboratory (LESO-PB). Up to five different magnetron sources can be used simultaneously, in reactive and non-reactive mode. The geometric configuration of the chamber has been optimised for best film homogeneity and allows the deposition on substrates up to 100 mm in diameter. The optical and electronic properties of thin films are closely interrelated and highly relevant for solar coatings. Photoelectron spectroscopy provides information on the coating structure, the deposited material and its chemical state inside the coating, as well as the nature of the interface between different layers. A system for ESCA analysis (Electron Spectroscopy for Chemical Analysis) has recently been installed and put into operation at LESO-PB. By ellipsometry and spectrophotometry, we can determine exactly the different optical properties of the coating, such as layer thickness, refractive index, or absorption coefficient. This provides best conditions for highly efficient research and development on new materials for further optimisation of the coloured interference filters. First results have been obtained with our new experimental infrastructure and will be presented in this contribution.

EPFL2011

Ultra-light photovoltaic composite sandwich structures

Julien Rion

EPFL2008

Coloured coatings for glazing of active solar thermal façades by reactive magnetron sputtering

Martin Joly, Stefan Mertin, Jean-Louis Scartezzini, Andreas Schueler

For building integration of solar-powered energy systems, aesthetic aspects play an important role. Covering a standard solar collector with a coloured glazing, opaque to the human eye but highly transparent to solar energy, permits a perfect architectural integration of solar thermal panels into glazed building façades. The thermal energy produced can be used for both solar heating and cooling, as well as for domestic hot water. The principle of the coloured appearance is based on interference in the thin-film coating on the reverse side of the cover glass. Different interference filters based on nano-composite materials deposited by the solgel method were presented at CISBAT 2007 [1]. Currently, we are developing new plasma-deposition processes, which are more suitable for industrial large-scale production. A new state-of-the-art ultra-high vacuum (UHV) system for magnetron sputtering deposition of novel nano-composite solar coatings has recently been designed, constructed, and installed at the Solar Energy and Building Physics Laboratory (LESO-PB). Up to five different magnetron sources can be used simultaneously, in reactive and non-reactive mode. The geometric configuration of the chamber has been optimised for best film homogeneity and allows the deposition on substrates up to 100 mm in diameter. The optical and electronic properties of thin films are closely interrelated and highly relevant for solar coatings. Photoelectron spectroscopy provides information on the coating structure, the deposited material and its chemical state inside the coating, as well as the nature of the interface between different layers. A system for ESCA analysis (Electron Spectroscopy for Chemical Analysis) has recently been installed and put into operation at LESO-PB. By ellipsometry and spectrophotometry, we can determine exactly the different optical properties of the coating, such as layer thickness, refractive index, or absorption coefficient. This provides best conditions for highly efficient research and development on new materials for further optimisation of the coloured interference filters. First results have been obtained with our new experimental infrastructure and will be presented in this contribution.

EPFL2011

Air cooling powered by façade integrated coloured opaque solar thermal panels

Stefan Mertin, Andreas Schueler

EPFL2011