Development and testing of light-weight PV modules based on glass-fibre reinforcement

Abstract

In this paper we report on our approach on integrating c-Si PV into lightweight structures, in particular towards vehicle integration. To this end we want to get rid of the (bulk weight of the) glass but seek a suitable replacement in terms of mechanical stability. First we elaborate on the most basic standards and norms that VIPV products should relate to in terms of (thermo-)mechanical testing. Then, for the experimental part, 2 concepts are investigated. In a first approach, we reinforced the encapsulant with glass fibre material, while in a second one we applied a dedicated glass-fibre-reinforced sheet as a replacement of the backsheet. In both cases we stay as close as possible to using commercially available material. For each approach we elaborate the testing that has been carried out: thermal cycling, vibrations, mechanical shock and hail impact. On a final note, we point out some initial damp heat testing results, that are a particular challenge for light-weight modules without glass.

Overview of key results achieved in H2020 HighLite project helping to raise the EU PV industries' competitiveness

“…While this is a promising result, it is not the final solution. As work in progress, the next steps are to look into either plastically deforming the frontsheet material, or using preformed frontsheets, potentially combined with stretchable materials 57 …”

“…As work in progress, the next steps are to look into either plastically deforming the frontsheet material, or using preformed frontsheets, potentially combined with stretchable materials. 57 After manufacturing all VIPV modules were I-V (and EL) measured VIPV modules reached fill factors between 78.3-79.7%, independent of the module layout. Vibration testing of those demo VIPV modules equivalent to 1000 km of driving has now been started and results will be reported elsewhere.…”

Water vapor permeability of polymeric packaging materials for novel glass‐free photovoltaic applications

“…Internal reinforcement can be achieved through the inclusion of glass fiber mats within the module laminate, typically in the encapsulant behind the PV cells to avoid cell shading, as well as in the backsheet. 15,16 External reinforcement often relies on 3-dimensional polymeric composite structures, such as honeycomb sandwiches, to which the semiflexible PV modules are glued after lamination. Alternatively, the backsheet may be replaced directly by the top skin layer of the reinforcing composite.…”

Interconnection and lamination technologies towards ubiquitous integration of photovoltaics

“…Apart from the sunroof's PV integration, where anyway glass-glass was required as a boundary condition, many VIPV applications require minimal weight. In other publications, [23][24][25] we have elaborated our approach towards fibre reinforced encapsulants (GFRE)…”

“…Apart from the sunroof's PV integration, where anyway glass–glass was required as a boundary condition, many VIPV applications require minimal weight. In other publications, 23–25 we have elaborated our approach towards fibre reinforced encapsulants (GFRE) and glass fibre reinforced back cover (GFRB), including results on reliability testing as TC, DH and HF as well as UV exposure and hail impact testing. Figure 20 indicates the minimal additional weight of integrating PV on top of the existing metal (steel) pieces.…”