Photovoltaic Module Backsheets Research Articles

Field retrieved photovoltaic backsheet survey from diverse climate zones: Analysis of degradation patterns and phenomena

Understanding the impact of climate stressors on photovoltaic (PV) backsheet degradation in real-use conditions is critical to improve the accelerated testing exposures, extend the backsheet lifetime, and increase the confidence in PV reliability. In this work, a total of 33 PV module backsheets were retrieved from six climatic zones worldwide with 2 - 28 years of exposure. These modules included five types of backsheet air-side materials (or outer layer): poly(vinylidene fluoride) (PVDF), poly(tetrafluoroethylene-co-hexafluoropropylene-co-vinylidene fluoride) (THV), poly(vinyl fluoride) (PVF), poly(ethylene terephthalate) (PET), and polyamide (PA). Attenuated total reflection Fourier-transform infrared spectroscopy (ATR-FTIR) was used to identify air-side materials. The degradation induced color change, gloss loss, and chemical material changes analyzed using optical microscopy, differential scanning calorimetry (DSC), scanning electron microscopy (SEM), colorimetry (yellowness index (YI)), and gloss measurements. PVDF, THV, and PVF air-side layer backsheets, in particular PVF, had minimal degradation in the air-side layer appearance and chemical structures after exposure in different climatic zones. The PET air-side backsheets exhibited obvious color increase (22.55 YI units after about 9 years exposure) and the PA/PA/PA backsheets showed large gloss loss (up to 76.4 %) relative to the unexposed backsheets. Severe cracks between cells that penetrated through the entire thickness of backsheets are observed on PA/PA/PA backsheets after 4-6 years of exposure in 6 climatic zones. The current indoor exposure standards were not sufficient to identify this degradation type. However, fluoropolymer based PV backsheets showed lower levels of degradation predictors and increased climatic resistance. Specific samples (PVF) showed little change from baseline after 28 years of outdoor exposure.

Drivers for the cracking of multilayer polyamide‐based backsheets in field photovoltaic modules: In‐depth degradation mapping analysis

AbstractThere is a lack of understanding on the root cause of cracking of photovoltaic (PV) backsheets due to the challenge of multilayer characterization and the complicated failure modes at the submodule level. In this work, the in‐depth degradation mapping of field‐exposed polyamide‐based (PA‐based) PV module backsheets was studied, with the major focus on the identification of underlying drivers for the through cracking (in between the solar cells). PV modules were retrieved from five different locations, comprising a variety of climates, including humid subtropical, hot‐summer Mediterranean, tropical savanna climate, and hot arid. A suite of microscale cross‐sectional characterizations, including chemical changes, fluorescence intensity, and modulus as a function of distance from the air surface of the backsheet, was performed. Results showed more advanced signs of degradation of the inner layer than the outer layer in the cracking region. Increases in the modulus were identified as the major indicator for the cracking. Moreover, a rudimentary test by immersion in acetic acid, which forms during photodegradation of the ethylene‐vinyl acetate copolymer (EVA) encapsulant, showed the first‐time direct evidence that acetic acid can largely accelerate the chemical degradation and facilitate the cracking of PA inner layer. This study suggests that the field cracking of PA‐based backsheet can be attributed to the combined effects of chemical degradation and physical reorganization (chemi‐crystallization) under cyclic thermomechanical stresses. Therefore, it is important to consider effects of local microclimates and interlayer infection to understand the heterogeneous nature of backsheet failures.

Degradation Mechanism Detection in Photovoltaic Backsheets by Fully Convolutional Neural Network

Materials and devices age with time. Material aging and degradation has important implications for lifetime performance of materials and systems. While consensus exists that materials should be studied and designed for degradation, materials inspection during operation is typically performed manually by technicians. The manual inspection makes studies prone to errors and uncertainties due to human subjectivity. In this work, we focus on automating the process of degradation mechanism detection through the use of a fully convolutional deep neural network architecture (F-CNN). We demonstrate that F-CNN architecture allows for automated inspection of cracks in polymer backsheets from photovoltaic (PV) modules. The developed F-CNN architecture enabled an end-to-end semantic inspection of the PV module backsheets by applying a contracting path of convolutional blocks (encoders) followed by an expansive path of decoding blocks (decoders). First, the hierarchy of contextual features is learned from the input images by encoders. Next, these features are reconstructed to the pixel-level prediction of the input by decoders. The structure of the encoder and the decoder networks are thoroughly investigated for the multi-class pixel-level degradation type prediction for PV module backsheets. The developed F-CNN framework is validated by reporting degradation type prediction accuracy for the pixel level prediction at the level of 92.8%.

Generalized Spatio-Temporal Model of Backsheet Degradation From Field Surveys of Photovoltaic Modules

Photovoltaic (PV) module backsheets degrade at different rates because of the specific polymeric materials and the local exposure environments of the installations. Studies of real-world backsheet degradation provide valuable information to understand backsheet degradation and failure. Field surveys of PV module backsheets were conducted on 1310 modules in four commercial PV power plant sites with different exposure times. The backsheet's local exposure environment is determined by its location along the rack length and depth, the modules’ elevation above the ground, and the ground cover albedo. Backsheets that are installed at the ends of the module rack length exhibit larger degradation rates (with yellowness index difference of 1.14 $\pm$ 0.45 and 7.80 $\pm$ 1.3 for backsheets of poly (ethylene terephthalate) and poly (ethylene naphthalate) as the air-side layer, respectively) than backsheets in the center section of the rack. A generalized spatio-temporal model was developed to predict the large-scale backsheet degradation of different backsheet polymers across time/age and location in the PV power plant rack. The model utilizes a cubic-spline relationship between backsheet degradation and rack length, and a quadratic relationship between backsheet discoloration and rack depth. This generalized spatio-temporal model predicts the outdoor backsheet degradation with an adjusted- $R^2$ range between 0.31 to 0.89. The similarity between this model and the spatial variation of the rear-side irradiance, indicates that the irradiance plays a significant role in outdoor backsheet degradation. The generalized spatio-temporal model can be used to evaluate large scale PV backsheet performance, as well as a guidance for PV site designers and operations and maintenance crews.

Lightweight and Durable PVDF-SSPF Composites for Photovoltaics Backsheet Applications: Thermal, Optical and Technical Properties.

Photovoltaic module backsheets are characterized according to their thermal, optical, mechanical, and technical properties. This work introduces new fabricated backsheets for PV modules using polyvinylidene fluoride (PVDF) reinforced with short sugar palm fiber (SSPF) composites. The preparation of composites undergoes multiple phases of fabrication. Thermal, optical, and technical investigations of their properties were conducted. Fourier transform infrared spectroscopy (FTIR), Raman spectroscopy, in-situ scanning probe microscopy (SPM), dynamic mechanical analysis (DMA), thermal mechanical analysis (TMA), thermogravimetric analysis (TGA), differential scanning calorimetry (DSC), and prolonged technical testing were accomplished to expansively understand the complex behavior of composites under various conditions. The optical properties of PV backsheets are critical components in determining the reflectance, absorbance, and transmittance of light. The PVDF–SSPF composites exhibited exceptional compatibility and thermal stability, further revealing a homogenous composite structure with enhanced interfacial bonding between the short fiber and polymer matrix.

Tearing and reliability of photovoltaic module backsheets

AbstractThe backsheet in photovoltaic modules belongs to an important class of layered materials where the tearing behavior of the individual layers does not necessarily represent the tearing behavior of the entire backsheet. Such characteristic arises from the interaction between the individual layers during the tearing process, where one layer of the backsheet is mechanically constrained by its neighboring layers and the layers may debond from each other. The mechanical constraint and debonding change the amount of energy dissipated during tearing and affect the overall tearing energy. In this work, we exposed a wide selection of backsheets with polymers including ethylene‐vinyl acetate (EVA), polyethylene terephthalate (PET), polyvinylidene fluoride (PVDF), and ethylene tetrafluoroethylene (ETFE) to damp heat (85°C/85%RH) for up to 2000 hours. We report on the effect of damp heat on the tearing energy as a function of damp heat exposure. We developed a model that describes the tearing energy of a layered structure by accounting for the tearing of the individual layers in the backsheet, the effect of mechanical constraint, and the adhesive debonding between the layers. Additionally, we explore the relationship between the microstructural change in the polymers which resulted from the damp heat exposure and the mechanical properties using modulated differential scanning calorimetry (MDSC), small and wide angle X‐ray scattering (SAXS and WAXS), and tensile testing.

Characterizing the weathering induced degradation of Poly(ethylene-terephthalate) using PARAFAC modeling of fluorescence spectra

Poly(ethylene-terephthalate) (PET) film is widely used in photovoltaic module backsheets, for its dielectric breakdown strength, and in applications requiring high optical clarity. PET degrades under exposure to ultraviolet (UV) irradiance, heat, and moisture, which leads to loss of optical clarity and performance properties. To study the weathering driven degradation of PET films, three grades of PET, including unstabilized and stabilized grades, were exposed to three types of accelerated weathering exposure. Fluorescence excitation-emission matrix (EEM) spectra were collected after predetermined exposure intervals. Parallel factor analysis (PARAFAC) was applied to the resulting spectra to decompose the fluorescence data into individual fluorophore components and monitor their relative concentrations over time. EEM-PARAFAC was used to identify and distinguish between the formation of monohydroxy-terephthalate and dihydroxy-terephthalate units in PET over time under the UV-light bearing accelerated exposures. The relative concentrations of these fluorophores were found to increase, while the relative concentration of the PARAFAC component assigned to PET was found to generally decrease. ATR-FTIR was used to support findings from EEM-PARAFAC. Results were also used to assess the impact of additives (UV stabilizer and TiO2) on degradation.

Multivariate multiple regression models of poly(ethylene-terephthalate) film degradation under outdoor and multi-stressor accelerated weathering exposures.

Developing materials for use in photovoltaic (PV) systems requires knowledge of their performance over the warranted lifetime of the PV system. Poly(ethylene-terephthalate) (PET) is a critical component of PV module backsheets due to its dielectric properties and low cost. However, PET is susceptible to environmental stressors and degrades over time. Changes in the physical properties of nine PET grades were modeled after outdoor and accelerated weathering exposures to characterize the degradation process of PET and assess the influence of stabilizing additives and weathering factors. Multivariate multiple regression (MMR) models were developed to quantify changes in color, gloss, and haze of the materials. Natural splines were used to capture the non-linear relationship between predictors and responses. Model performance was evaluated via adjusted-R2 and root mean squared error values from leave-one-out cross validation analysis. All models described over 85% of the variation in the data with low relative error. Model coefficients were used to assess the influence of weathering stressors and material additives on the property changes of films. Photodose was found to be the primary degradation stressor and moisture was found to increase the degradation rate of PET. Direct moisture contact was found to impose more stress on the material than airbone moisture (humidity). Increasing the concentration of TiO2 was found to generally decrease the degradation rate of PET and mitigate hydrolytic degradation. MMR models were compared to physics-based models and agreement was found between the two modeling approaches. Cross-correlation of accelerated exposures to outdoor exposures was achieved via determination of cross-correlation scale factors. Cross-correlation revealed that direct moisture contact is a key factor for reliable accelerated weathering testing and provided a quantitative method to determine when accelerated exposure results can be made more aggressive to better approximate outdoor exposure conditions.

Structure and basic properties of photovoltaic module backsheet films

In this paper commercially relevant backsheets are characterized as to their material and laminate structure and basic optical and mechanical properties. Various multilayer backsheet materials were selected and analysed by optical microscopy, Raman spectroscopy, infrared spectroscopy (FTIR-ATR), thermal gravimetric analysis (TGA), differential scanning calorimetry (DSC), ultra violet visible near infrared spectroscopy (UV/VIS/NIR) and monotonic tensile testing. By Raman and infrared spectroscopy and DSC the polymeric materials of the various layers were identified. Furthermore it was shown for the thermoplastic ethylene vinylacetate copolymer (EVA) layers that three different vinylacetate (VA) contents were used. By TGA a content of inorganic fillers and pigments from about 6%m to approximately 20%m was detected. The hemispherical solar reflectance of the white pigmented backsheets was ranging from 0.695 to 0.838. The highest Young׳s modulus was found in polyvinylfluoride based multilayers while the lowest values were detected for polyamide based structures.

Fire Behaviour and Performance of Photovoltaic Module Backsheets

Given that photovoltaic (PV) power plant can cause and/or contribute to fires in buildings, the fire risk resulting from a PV power plant installation on a building roof or facade should be assessed in order to meet building fire-safety requirements. In fact, PV plant installed on a roof or a facade could fail and cause a fire and/or promote or facilitate its spread. Accident analyses have shown that PV systems are often installed without due consideration of fire propagation and fire spread caused by the presence of modules, cables and electrical boards on the roof. This paper shows a proposal for a method to evaluate the reaction-to-fire characteristics of a PV module and provides experimental results that compare the behaviours and performances of four kinds of PV module backsheet. Some of the commonest type of backsheet materials available on the market have been selected in order to evaluate and compare the reaction-to-fire performances of these products: Backsheet no.1 has three layers (PET/PET/Primer), Backsheet no.2 is composed of four layers (PET/Aluminium/PET/Primer), Backsheet no.3 is a Fluoro-Coating/PET/EVA three-layer sheet and Backsheet no. 4 comprises an outside coating, a PET layer and an inside Coating. Test results show that the choice of a single layer for Backsheet no.4 represents the best solution among the ones tested. Even though Backsheet no.2 shows the same reaction-to-fire rating as that of Backsheet no.4, the PV module production process could be critical as regards the electrical behaviour of the module itself, since aluminium foil is a material that conducts electricity. Moreover, since the fire-performance assessment of PV panels in Europe is left at a national level, the approach reported in this paper could represent a useful reference to be used as a baseline for developing a European standard or, better still, an International standard.