Progress in Photovoltaics: Research and Applications
Hartley, James Y.; Miller, David C.; Ulicna, Sona; Bosco, Nick; Hacke, Peter
Low-temperature soldered wire interconnection (LTSWI) is a technology utilizing many interconnect wires carried on a polymer foil to form electrical connections against cell gridlines without a separate soldering process. In this work, LTSWI module samples were characterized for material properties and assembly dimensions and subjected to accelerated aging experiments to induce degradation. A finite element analysis model was developed based on characterization results, to analyze internal stressors during environmental exposures. The polymer foil contains polyethylene terephthalate and low-density polyethylene layers, and solder composition was tin bismuth, which notably was not metallurgically bonded to cell gridlines. High temperature accelerated exposures created power loss up to 9% in minimodule samples, with fill factor losses implicating contact degradation. Posttest characterization identified solder-gridline cracking and wire-cell separation as contributing mechanisms. Finite element modeling demonstrated that wire-to-cell contact is maintained by polymer contraction post lamination but is reversible, resulting in contact loss and wire separation during high temperature exposure. Simulations also detected in-plane wire-to-cell displacements, driven by surrounding polymer motion in response to high temperatures and mechanical load. We hypothesize that the propensity for wire movement during environmental exposure damages the not-metallurgically bonded wire-gridline interface and contributes to LTSWI contact degradation. Because distinct from thermal expansion mismatches which damage traditionally soldered modules, current test protocols are likely not applying the intended acceleration factors to LTSWI modules. This work highlights how construction-specific accelerated testing may be needed for nontraditional module designs and provides a starting point for accurate LTSWI life assessment.
A finite element model of a 60-cell monocrystalline silicon glass-polymer photovoltaic module was simulated with ±1.0 kPa and ±2.4 kPa loads applied to the glass to calculate the deformation under load. Cell-to-cell displacements were used to approximate interconnect strain and stress. A mathematical fatigue cycle life relation was fitted to data for the interconnect material (copper), to generate a life prediction at each interconnect location based on the local stress means, reversal extents, and amplitudes. Interconnect stress was found to be significantly asymmetric about zero despite symmetric positive and negative module loads due to laminate thickness offsets about the neutral plane and the effects of module framing. Cycle life results indicated that interconnect fatigue failure was unlikely to occur over a 30-year lifetime of conservative wind and snow load cycles since the typical cell design feature of leaving some unconstrained length between the cell edge and first solder pad increases the effective gauge length and decreases the stress levels below the material endurance limit. Follow-up analyses found that 3.6 mm and 6.4 mm were the minimum unconstrained lengths required to survive the assumed lifetime of wind and snow cycles, respectively, confirming that typical industrial module constructions with 8–15 mm unconstrained lengths should survive conservatively. Notably, large magnitude, low-cycle snow loading was consistently the limiting factor requiring a longer unconstrained interconnect length. Finally, insights and workflows from this study inform module interconnection design limits for survival against mechanical fatigue in deployment environments.
Stereo high-speed video of photovoltaic modules undergoing laboratory hail tests was processed using digital image correlation to determine module surface deformation during and immediately following impact. The purpose of this work was to demonstrate a methodology for characterizing module impact response differences as a function of construction and incident hail parameters. Video capture and digital image analysis were able to capture out-of-plane module deformation to a resolution of ±0.1 mm at 11 kHz on an in-plane grid of 10 × 10 mm over the area of a 1 × 2 m commercial photovoltaic module. With lighting and optical adjustments, the technique was adaptable to arbitrary module designs, including size, backsheet color, and cell interconnection. Impacts were observed to produce an initially localized dimple in the glass surface, with peak deflection proportional to the square root of incident energy. Subsequent deformation propagation and dissipation were also captured, along with behavior for instances when the module glass fractured. Natural frequencies of the module were identifiable by analyzing module oscillations postimpact. Limitations of the measurement technique were that the impacting ice ball obscured the data field immediately surrounding the point of contact, and both ice and glass fracture events occurred within 100 μs, which was not resolvable at the chosen frame rate. Increasing the frame rate and visualizing the back surface of the impact could be applied to avoid these issues. Applications for these data include validating computational models for hail impacts, identifying the natural frequencies of a module, and identifying damage initiation mechanisms.
Hail poses a significant threat to photovoltaic (PV) systems due to the potential for both cell and glass cracking. This work experimentally investigates hail-related failures in Glass/Backsheet and Glass/Glass PV modules with varying ice ball diameters and velocities. Post-impact Electroluminescence (EL) imaging revealed the damage extent and location, while high-speed Digital Image Correlation (DIC) measured the out-of-plane module displacements. The findings indicate that impacts of 20 J or less result in negligible damage to the modules tested. The thinner glass in Glass/Glass modules cracked at lower impact energies (-25 J) than Glass/Backsheet modules (-40 J). Furthermore, both module types showed cell and glass cracking at lower energies when impacted at the module's edges compared to central impacts. At the time of presentation, we will use DIC to determine if out-of-plane displacements are responsible for the impact location discrepancy and provide more insights into the mechanical response of hail impacted modules. This study provides essential insights into the correlation between impact energy, impact location, displacements, and resulting damage. The findings may inform critical decisions regarding module type, site selection, and module design to contribute to more reliable PV systems.
Photovoltaic modules undergoing laboratory hail tests were observed using high speed video to analyze the key characteristics of impact-induced glass fracture, including crack onset time, initiation location relative to the impact site, and propagation trends. Fifteen commercially representative glass-glass thin-film modules were recorded at 300,000 frames per second during hail impacts which happened to cause glass fracture. Images were processed to identify the time between impact and first plausible glass crack appearance (average 126 μs, standard deviation 59 μs) along with the time to a confirmed crack (average 158 μs, standard deviation 77μs), during the ice ball impacts which had a median kinetic energy of 47 J delivered by 55 mm diameter balls. Limiting factors for identifying glass crack timings were ice ball fragmentation obscuring the impact site and indistinct initial crack appearance, which were inherent to the images and not improved with processing. Computational simulations corresponding to each impact event showed that glass stresses were still localized to the impact site during times with definitively identifiable fracture, and even impacts which did not induce failure created local stress magnitudes exceeding stress levels associated with static glass fracture. These observations confirm that impact-induced glass failure is a time-and rate-dependent phenomena. Results from this study provide baseline metrics for developing a glass fracture criterion to predict module damage during hail impact events, which in turn allows for analysis of design features that may affect damage susceptibility.
Hail poses a significant threat to photovoltaic (PV) systems due to the potential for both cell and glass cracking. This work experimentally investigates hail-related failures in Glass/Backsheet and Glass/Glass PV modules with varying ice ball diameters and velocities. Post-impact Electroluminescence (EL) imaging revealed the damage extent and location, while high-speed Digital Image Correlation (DIC) measured the out-of-plane module displacements. The findings indicate that impacts of 20 J or less result in negligible damage to the modules tested. The thinner glass in Glass/Glass modules cracked at lower impact energies (-25 J) than Glass/Backsheet modules (-40 J). Furthermore, both module types showed cell and glass cracking at lower energies when impacted at the module's edges compared to central impacts. At the time of presentation, we will use DIC to determine if out-of-plane displacements are responsible for the impact location discrepancy and provide more insights into the mechanical response of hail impacted modules. This study provides essential insights into the correlation between impact energy, impact location, displacements, and resulting damage. The findings may inform critical decisions regarding module type, site selection, and module design to contribute to more reliable PV systems.
Photovoltaic modules undergoing laboratory hail tests were observed using high speed video to analyze the key characteristics of impact-induced glass fracture, including crack onset time, initiation location relative to the impact site, and propagation trends. Fifteen commercially representative glass-glass thin-film modules were recorded at 300,000 frames per second during hail impacts which happened to cause glass fracture. Images were processed to identify the time between impact and first plausible glass crack appearance (average 126 μs, standard deviation 59 μs) along with the time to a confirmed crack (average 158 μs, standard deviation 77μs), during the ice ball impacts which had a median kinetic energy of 47 J delivered by 55 mm diameter balls. Limiting factors for identifying glass crack timings were ice ball fragmentation obscuring the impact site and indistinct initial crack appearance, which were inherent to the images and not improved with processing. Computational simulations corresponding to each impact event showed that glass stresses were still localized to the impact site during times with definitively identifiable fracture, and even impacts which did not induce failure created local stress magnitudes exceeding stress levels associated with static glass fracture. These observations confirm that impact-induced glass failure is a time-and rate-dependent phenomena. Results from this study provide baseline metrics for developing a glass fracture criterion to predict module damage during hail impact events, which in turn allows for analysis of design features that may affect damage susceptibility.
Deflection and stress calculated from an experimentally validated, high-fidelity finite element model (FEM) of a photovoltaic module experiencing mechanical load was compared to results from a simplified FEM treating the module laminate as a homogenized composite using a rule of mixtures approach, and further compared to analytical calculations treating the module as a Kirchoff-Love flat plate. The goal of this study was to determine the error incurred by analyzing module mechanics with varying levels of simplification, since resolving the aspect ratios of a module is computationally expensive. Homogenized FEMs were found to underpredict peak deflection under a 1.0 kPa load by between 13 and 19% for lower and upper bound application of the rule of mixtures. However, module shape was captured, implying that a useful replication of a resolved model could be achieved with a reduced, calibrated material stiffness. Homogenized stress results captured glass layer tensile stress components to within 46 to 52% at a sample location of interest, though agreement was poor through the remainder of the laminate due to the lack of material resolution. For plate theory, deflection was overpredicted by 45 to 67% for upper and lower bound homogenizations, and frame-adjacent module shapes were not adequately replicated. Stress results mirrored FEM trends but magnitudes were not well correlated to resolved model values. These results support the use of homogenized laminate models for module shape derivation, though resolved models remain necessary for stress analyses. The accuracy of plate theory was found to be inadequate for most applications.
Photovoltaic modules are subjected to various mechanical stressors in their deployment environments, ranging from installation handling to wind and snow loads. Damage incurred during these mechanical events has the potential to initiate subsequent degradation mechanisms, reducing useful module lifespan. Thus, characterizing the mechanical state of photovoltaic modules is pertinent to the development of reliable packaging designs. In this work, photovoltaic modules with strain gauges directly incorporated into the module laminate were fabricated and subjected to mechanical loading to characterize internal strains within the module when under load. These experimental measurements were then compared against results obtained by high-fidelity finite-element simulations. The simulation results showed reasonable agreement in the strain values over time; however, there were large discrepancies in the magnitudes of these strains. Both the instrumentation technique and the finite-element simulations have areas where they can improve. These areas of improvement have been documented. Despite the observed discrepancies between the experimental and simulated results, the module instrumentation proved to be a useful gauge in monitoring and characterizing the mechanical state. With some process improvements, this method could potentially be applied to other environments that a photovoltaic module will encounter in its lifetime that are known to cause damage and degrade performance.
