Thomas C. Felder

Weathering and durability of PV backsheets and impact on PV module performance

Polymeric backsheets form the outer protective layer of most crystalline and multi-crystalline silicon cell photovoltaic panels. The mechanical, electrical, optical and chemical properties and durability of these backsheets are critical to the long term reliability, durability and safety of the photovoltaic modules. The stability of these backsheet properties is typically determined based on accelerated testing using individual stresses. However, the impact of multiple stresses applied sequentially or simultaneously can lead to changes in materials properties that are more predictive of performance in the field. An important consideration in the development of accelerated test protocols is the level and duration of the stress, including temperature variation, light intensity and spectral power distribution, humidity, rainfall and powered module current. In this paper, we discuss observations of the aging and degradation of solar panel from the field. Then how these changes correlate to accelerated testing results, and how accelerated tests can be modified to better match observations in the field.

Enhanced reflective liquid crystal displays using DuPont holographic recording films

Holographic reflectors with high brightness and excellent environmental stability have been produced using DuPont holographic films. The center wavelength, color bandwidth and viewing cone are defined for the optimal viewing performance. Measurement methods used to quantify holographically enhanced reflective LCD performance are presented. The test results show that holographic reflectors based on the DuPont OmniDex film experienced less than 1 percent brightness degradation under 70 degrees and 95 percent relative humidity for 200 hours, with no measurable color shift. Two examples of how this technology can be extended to enhance color LCDs are also presented.

Environmental performance of photopolymer holographic optical elements

A variety of environmental exposure tests were conducted on holographic optical elements. Previous reports from our lab have largely been confined to studies on simple mirror holograms in unconverted format. This study was expanded to include slant-fringe diffuse reflectors as well as normal- incidence simple mirrors converted into commercially practical formats with adhesives and different types of support substrates. Holograms were characterized using reflectance as well as transmission spectroscopy. Films were subjected to 30 cycles of 80 degree(s)C to -30 degree(s)C air-to- air temperature cycling, 14 day 70 degree(s)C/95% RH hold, 14 day 100 degree(s)C dry heat hold, 540 hour continuous ultraviolet exposure, and 14 day cycled fluorescent roomlight exposure. Playback wavelength and diffraction efficiency was stable under all conditions. As reported earlier, exposure to intense ultraviolet light increases yellowness of the photopolymer holograms, but this can be prevented by laminating a UV-absorbing layer atop the film.

Sequential accelerated tests: Improving the correlation of accelerated tests to module performance in the field

DuPont has been working steadily to develop accelerated backsheet tests that correlate with solar panels observations in the field. This report updates efforts in sequential testing. Single exposure tests are more commonly used and can be completed more quickly, and certain tests provide helpful predictions of certain backsheet failure modes. DuPont recommendations for single exposure tests are based on 25-year exposure levels for UV and humidity/temperature, and form a good basis for sequential test development. We recommend a sequential exposure of damp heat followed by UV then repetitions of thermal cycling and UVA. This sequence preserves 25-year exposure levels for humidity/temperature and UV, and correlates well with a large body of field observations. Measurements can be taken at intervals in the test, although the full test runs 10 months. A second, shorter sequential test based on damp heat and thermal cycling tests mechanical durability and correlates with loss of mechanical properties seen in the field. Ongoing work is directed toward shorter sequential tests that preserve good correlation to field data.

Multi-stress durability testing to better predict outdoor performance of PV modules

Photovoltaic modules in the outdoor environment are subjected to a wide range of stresses which can operate simultaneously and sequentially and can vary based on climate and installation. These stresses can include temperature, temperature variation, localized heating, humidity, moisture (rain, snow, humidity, condensation), weathering, mechanical stress, abrasion and internal electric fields. These multiple stress make prediction of service lifetime challenging. Frequently resistance to an extended single stress is improperly used to assess durability. We have used sequential and simultaneous multistress exposure of materials and modules to better predict the synergistic effects of these stresses on module performance. We have also assessed the change in component materials properties to better understand performance changes. Finally, we compare these results to inspection of modules from the field to validate the test methods proposed.

Development of backsheet tests and measurements to improve correlation of accelerated exposures to fielded modules

Matching accelerated test results to field observations is an important objective in the photovoltaic industry. We continue to develop test methods to strengthen correlations. We have previously reported good correlation of FTIR spectra between accelerated tests and field measurements. The availability of portable FTIR spectrometers has made measurement in the field convenient and reliable. Recently, nano-indentation has shown promise to correlate changes in backsheet mechanical properties. A precisely shaped stylus is pressed into a sample, load vs displacement recorded and mechanical properties of interest calculated in a nondestructive test. This test can be done on full size modules, allowing area variations in mechanical properties to be recorded. Finally, we will discuss optical profilometry. In this technique a white light interferogram of a surface is Fourier transformed to produce a three-dimensional image. Height differences from 1 nm to 5 mm can be detected over an area of a few cm. This technique can be used on minimodules, and is useful to determine crack and defect dimensions. Results will be presented correlating accelerated tests with fielded modules covering spectroscopic, mechanical, and morphological changes.

Optical properties of PV backsheets: key indicators of module performance and durability

Polymeric backsheets are an important component affecting the performance and durability of photovoltaic modules. The optical properties of the backsheet should be considered in the design and performance of a photovoltaic module and the stability and durability of optical properties have an impact on power, safety and appearance. Changes in optical properties in fielded modules and accelerated durability testing are compared. IR analysis was conducted on various backsheet materials in accelerated durability testing and compared to outdoor performance to better understand the relevant chemical changes and associated degradation mechanisms. The connection between optical properties and chemical changes is discussed.

Display applications for holographic optical elements

In the last several years, holographic elements have been introduced into a wide array of display applications. Holographic Reflectors are incorporated with liquid crystal displays to shift optimum viewing angle away form specular glare and raise brightness by concentrating light at a convenient viewing angle. Reflectors can be produced in blue, green, gold, red, or white colors. Denso GlassVision projection screens incorporate transmission holograms to efficiently direct projected light to the viewer in a screen that reverts to clear glass When the projection image is turned off. JVC has introduce da large-screen HDTV that uses a holographic color filter to separate blue, green, and red light from the illumination beam, and direct the sorted colors to the appropriate color pixel, raising brightness with a passive component. Most recently, HOE prototypes have been produced to improve the efficiency of portable liquid crystal color display. Front diffuser are affixed to the face of reflective color LCDs and direct output light from the LCD to the viewer at a convenient viewing angle in a concentrated view cone. Reflective Colors Filters are pixelated diffuse reflectors internal to the LCD structure and aligned to the LCD matrix. These reflective filters provide higher brightness, larger color gamut, and better color saturation including a holographic grating are under development to provide wider view angle in direct-view LCDs.

Analysis of glass-glass modules

Glass-Glass modules are gaining popularity for bifacial application and have believed advantages over PV modules with polymeric backsheets. Frameless glass-glass modules are promoted as PID-free, resistant to solvents, fire, and load stress, and capable of higher system voltages. We have found glass-glass modules run at higher operating temperature than Glass-Flex modules, and this reduces power output. Field power output results will be presented. Impermeable glass traps chemical byproducts, and faster power degradation from corrosion has been documented. Delamination has been observed in the field with glass-glass modules. A new accelerated test replicates this delamination. PID testing results will be presented comparing Glass-Glass and Glass-Flex modules.

Comparison of higher irradiance and black panel temperature UV backsheet exposures to field performance

The need for faster PV qualification tests that more accurately match field observations is leading to tests with higher acceleration levels, and validating the new tests through comparison to field data is an important step. We have tested and compared a wide panel of backsheets according to a proposed new backsheet UV exposure qualification standard from the International Electrotechnical Commission (IEC). Weathering Technical Standard IEC 62788-7-2 specifies higher irradiance and higher black panel temperature UV Xenon exposures. We tested PVF, PVDF, PET, PA and FEVEbased backsheets in glass laminates and simple backsheet coupons in UV exposure condition A3 (0.8W/sqmnm@340nm and 90° C BPT) We find mild yellowing with no mechanical loss in the original lower intensity ASTM G155 0.55 W/sqm-nm 70C BPT exposure condition. The new A3 exposures creates mechanical loss in sensitive backsheets, with no effect on known durable backsheets. Results from the new exposure are closer to field mechanical loss data.