Cracking in Silicon solar cells is an important factor for the electrical power-loss of photovoltaic modules. Simple geometrical criteria identifying the amount of inactive cell areas depending on the position of cracks with respect to the main electric conductors have been proposed in the literature to predict worst case scenarios. Here we present an experimental study based on the electroluminescence (EL) technique showing that crack propagation in monocrystalline Silicon cells embedded in photovoltaic (PV) modules is a much more complex phenomenon. In spite of the very brittle nature of Silicon, due to the action of the encapsulating polymer and residual thermo-elastic stresses, cracked regions can recover the electric conductivity during mechanical unloading due to crack closure. During cyclic bending, fatigue degradation is reported. This pinpoints the importance of reducing cyclic stresses caused by vibrations due to transportation and use, in order to limit the effect of cracking in Silicon cells.
A multi-physics and multi-scale computational approach is proposed in the present work to study the evolution of microcracking in polycrystalline Silicon (Si) solar cells composing photovoltaic (PV) modules. Coupling between the elastic and the electric fields is provided according to an equivalent circuit model for the PV module where the electrically inactive area is determined from the analysis of the microcrack pattern. The structural scale of the PV laminate (the macro-model) is coupled to the scale of the polycrystals (the micro-model) using a multiscale nonlinear finite element approach where the macro-scale displacements of the Si cell borders are used as boundary conditions for the micro-model. Intergranular cracking in the Si cell is simulated using a nonlinear fracture mechanics cohesive zone model (CZM). A case-study shows the potentiality of the method, in particular as regards the analysis of the microcrack orientation and distribution, as well as of the effect of cracking on the electric characteristics of the PV module.
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