The influence of the type of backsheet on the electrical performance of test modules was evaluated before and after increasing time of accelerated ageing (damp heat [DH] exposure). Besides the measurement of the electrical power of the modules and the performance of the cells by electroluminescence, the ageing-induced changes within the polymeric encapsulate and backsheets were investigated by means of vibrational spectroscopy and by thermo analytical methods. In addition, the permeability of the backsheets in the original and aged state was determined. This wide set of test parameters and methods allowed for the detection of correlations between (i) physical and chemical properties as well as their ageing-induced changes of the materials and (ii) the module performance. A clear dependence of the relative loss in power output upon exposure under DH conditions for 2000 h could be observed for a set of identical test modules varied in composition only in the type of back cover used. While the modules containing gas-tight backsheets and glass experienced only little loss in the relative power output, some modules with permeable backsheets showed a significant relative decrease in the power output and fill factor in dependence of the backsheet type used. Cell degradation could be visualised by recording electroluminescence images before and after the accelerated ageing test. The permeation properties of the backsheet used and their ageing-induced changes seem to have an influence on the module performance. However, the absolute values neither of the water vapour transmission rate (WVTR) nor of the oxygen transmission rate (OTR) are directly linked to the loss in power output upon accelerated ageing under DH conditions. It could be shown that the ageing-induced changes (relative transmission rates) between WVTR and OTR can be correlated with the module performance. These ageing-induced changes in the permeation behaviour of the backsheets can be explained by (i) physical changes (e.g. post-crystallisation, changes in the crystal structure or the crystalline microstructure) and (ii) chemical ageing effects such as a decrease in the molecular mass of the polyester (PET) polymer chains because of hydrolytic polymer degradation leading to a change in the crystallisation behaviour of PET. Hydrolytic degradation (= chemical ageing) of the PET core layer was observed (with varying extent) for all PET-based backsheets and can, thus, not be directly correlated with the loss in performance of the corresponding test modules. The physical ageing effects, however, were detected only for those backsheets showing (i) strong deviating changes in the relative permeation rates for oxygen and water vapour upon accelerated ageing and (ii) a clear loss in electrical performance.

In reliability testing of components for PV modules an always remaining question is about material (in)compatibilities and synergistic effects and thus, how results of singly tested materials correlate with materials aged within PV modules. Testing of single materials would simplify sample preparation, reduce costs and offer more testing options. Therefore the main objective of this study was to compare the aging behavior of single backsheets with that of backsheets incorporated within PV modules. Four different types of backsheets were chosen, all of them comprising of polyethylene terephthalate (PET) core layers, but differing outer protection layers. Test modules using identical components, varying only in the type of backsheet used were produced and damp heat aged (85 C/85% RH 2000 h). The results revealed no influence of the PV module lamination on the thermal characteristics of the polymeric backsheets. Even after DH aging, differences between single and module laminated backsheets were negligible. Degradation effects of PET could be detected for all aged sheets by thermal analysis and were confirmed by tensile tests and rheological measurements. Thus, it can be stated that testing of single PET based backsheets under DH aging conditions is a practicable way to investigate the applicability of a new backsheet.

The electrical ageing of photovoltaic modules during extended damp-heat tests at different stress levels is investigated for three types of crystalline silicon photovoltaic modules with different backsheets, encapsulants and cell types. Deploying different stress levels allows determination of an equivalent stress dose function, which is a first step towards a lifetime prediction of devices. The derived humidity dose is used to characterise the degradation of power as well as that of the solar cell's equivalent circuit parameters calculated from measured current-voltage characteristics. An application of this to the samples demonstrates different modes in the degradation and thus enables better understanding of the module's underlying ageing mechanisms. The analysis of changes in the solar cell equivalent circuit parameters identified the primary contributors to the power degradation and distinguished the potential ageing mechanism for each types of module investigated in this paper.

As the PV market shows enormous potential with huge growth rates especially in climatic‐sensible regions, specific artificial ageing test procedures are a key point for an efficient and fast product development of new PV modules/materials optimized for the use in specific climatic regions. Based on the definition of four climate profiles (dry and hot—arid, moderate, humid, and hot—tropical and high irradiation—alpine), a program was worked out with 14 climate specific test conditions for accelerated ageing tests. The big challenge in this respect was the adaption/advancement of existing standard procedures for PV modules/components testing in a way that reliable testing for certain climatic conditions optimized PV modules is possible. The time‐dependent repeated application of combined climatic and environmental stresses (temperature, temperature cycles, humidity, irradiation, mechanical load, salt mist) was used to induce performance losses, material degradation, and failures in test modules which resemble those effects occurring in real‐life PV installations under comparable climatic and environmental conditions. For this demanding task, a large number of identical test modules with respect to composition and module design was manufactured. A detailed nondestructive analysis/characterization of all modules was performed: (1) before; (2) during (six intermediate stages); and (3) after the accelerated ageing test. The nondestructive characterization methods used to follow the module's ageing processes throughout the whole accelerated ageing procedure were current‐voltage characteristics measurements and electroluminiscence images for the electrical performance evaluation and ultraviolet fluorescence (spectroscopic and imaging) measurements, Fourier transform infrared spectroscopy as well as colour measurements of the backsheets outer layer for recording of chemical changes of the encapsulant and backsheet. The electrical and material characterization data were incorporated in an optimized database. As stated above, a set of three identical modules was exposed together in the respective climate specific ageing tests and subsequently characterized in order to increase statistical reliability of the measuring results. The analysis of the data and first approaches of advanced data treatment have already clearly shown that the electrical and material degradation of the test modules is dependent on (1) the type and combination, (2) duration, and (3) mode (sequential versus constant) of the stresses applied. On the one hand, the simulation of environmental stresses like heavy snow and wind load and enhanced frequency of temperature cycling resulting in cell cracks and cell connector breakage could be demonstrated. Additional treatment in salty atmosphere, on the other hand, did not show an accelerating effect on degradation on the electrical or material side. The accelerating effect of enhanced temperature, humidity, or additional irradiation on the degradation of power and materials could be shown very well. D...

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In the last decade and longer, photovoltaic module manufacturers have experienced a rapidly growing market along with a dramatic decrease in module prices. Such cost pressures have resulted in a drive to develop and implement new module designs, which either increase performance and/or lifetime of the modules or decrease the cost to produce them. In this paper, the main motivations and benefits but also challenges for material innovations will be discussed. Many of these innovations include the use of new and novel materials in place of more conventional materials or designs. As a result, modules are being produced and sold without a long-term understanding about the performance and reliability of these new materials. This has lead to unexpected new failure mechanisms occuring few years after deployment, such as Potential Induced Degradation or backsheet cracking. None of these failure modes have been detected after the back then common single stress tests. New accelerated test approaches are based on a combination or sequence of multiple stressors that better reflect outdoor conditions. That allows for identification of new degradation modes linked to new module materials or module designs.