Electricity from photovoltaic solar cells: Flat-Plate Solar Array Project final report. Volume VII: Module encapsulation

The Flat-Plate Solar Array (FSA) Project, funded by the U.S. Government and managed by the Jet Propulsion Laboratory, was formed in 1975 to develop the module/array technology needed to attain widespread terrestrial use of photovoltaics by 1985. To accomplish this, the FSA Project established and managed an Industry, University, and Federal Government Team to perform the needed research and development. The objective of the Encapsulation Task was to develop, demonstrate, and qualify photovoltaic (PV) module encapsulation systems that would provide 20-year (later increased to 30-year) life expectancies in terrestrial environments, and which would be compatible with the cost and performance goals of the FSA Project. The scope of the Encapsulation Task included the identification, development, and evaluation of material systems and configurations required to support and protect the optically and electrically active solar cell circuit components in the PV module operating environment. Encapsulation material technologies summarized in this report include the development of low-cost ultraviolet protection techniques, stable low-cost pottants, soiling resistant coatings, electrical isolation criteria, processes for optimum interface bonding, and analytical and experimental tools for evaluating the long-term durability and structural adequacy of encapsulated modules. Field testing, accelerated stress testing, and design studies have demonstrated that encapsulation materials, processes, and configurations are available that will meet the FSA cost and performance goals. Thirty-year module life expectancies are anticipated based on accelerated stress testing results and on extrapolation of real-time field exposures in excess of 9 years

Accelerated UV Testing and Characterization of PV Modules with UV-cut and UV-pass EVA Encapsulants

abstract: Encapsulant is a key packaging component of photovoltaic (PV) modules, which protects the solar cell from physical, environmental and electrical damages. Ethylene-vinyl acetate (EVA) is one of the major encapsulant materials used in the PV industry. This work focuses on indoor accelerated ultraviolet (UV) stress testing and characterization to investigate the EVA discoloration and delamination in PV modules by using various non-destructive characterization techniques, including current-voltage (IV) measurements, UV fluorescence (UVf) and colorimetry measurements. Mini-modules with glass/EVA/cell/EVA/backsheet construction were fabricated in the laboratory with two types of EVA, UV-cut EVA (UVC) and UV-pass EVA (UVP). The accelerated UV testing was performed in a UV chamber equipped with UV lights at an ambient temperature of 50°C, little or no humidity and total UV dosage of 400 kWh/m2. The mini-modules were maintained at three different temperatures through UV light heating by placing different thickness of thermal insulation sheets over the backsheet. Also, prior to thermal insulation sheet placement, the backsheet and laminate edges were fully covered with aluminum tape to prevent oxygen diffusion into the module and hence the photobleaching reaction. The characterization results showed that mini-modules with UV-cut EVA suffered from discoloration while the modules with UV-pass EVA suffered from delamination. UVf imaging technique has the capability to identify the discoloration region in the UVC modules in the very early stage when the discoloration is not visible to the naked eyes, whereas Isc measurement is unable to measure the performance loss until the color becomes visibly darker. YI also provides the direct evidence of yellowing in the encapsulant. As expected, the extent of degradation due to discoloration increases with the increase in module temperature. The Isc loss is dictated by both the regions – discolored area at the center and non-discolored area at the cell edges, whereas the YI is only determined at the discolored region due to low probe area. This led to the limited correlation between Isc and YI in UVC modules. In case of UVP modules, UV radiation has caused an adverse impact on the interfacial adhesion between the EVA and solar cell, which was detected from UVf images and severe Isc loss. No change in YI confirms that the reason for Isc loss is not due to yellowing but the delamination. Further, the activation energy of encapsulant discoloration was estimated by using Arrhenius model on two types of data, %Isc drop and ΔYI. The Ea determined from the change in YI data for the EVA encapsulant discoloration reaction without the influence of oxygen and humidity is 0.61 eV. Based on the activation energy determined in this work and hourly weather data of any site, the degradation rate for the encaspulant browning mode can be estimated.Dissertation/ThesisMasters Thesis Chemical Engineering 201

Effect of aging on discoloration of two composite surface sealants

Objectives Composite surface sealants were introduced aiming to prevent or decrease the discoloration and microleakage of composite restorations. This study sought to assess the effect of aging on discoloration of two composite surface sealants.Methods In this experimental study, 24 samples were fabricated of Fortify Plus and BisCover LV composite surface sealants (10 mm in diameter and 1 mm in thickness) and their baseline color coordinates were measured using the CIE L* a* b* system by a reflection spectrophotometer. The samples made of each material (n = 12) were randomly divided into 4 groups of 3 and aged in xenon chamber, tea, distilled water and dry ambient environment (control). Color change (ΔE*) was calculated in the reflectance mode. The data were analyzed using two-way ANOVA and t-test (P < 0.05).Results The minimum ∆E* value was 0.95 ± 0.6 belonging to Fortify Plus stored in the dry ambient environment while the maximum ∆E* value was 21.85 ± 4 belonging to BisCover LV aged in tea. Two-way ANOVA showed significant differences in ∆E* among the aging protocols (P < 0.001); the effect of two materials (P < 0.001) and the interaction effect of the type of material and aging were also significant (P = 0.001). Conclusions It can be concluded that aging affects the discoloration of composite surface sealants. Tea caused the greatest discoloration. There were no significant differences in the color change of the two materials after accelerated aging with xenon

In vitro evaluation of the color stability and surface roughness of a new composite flow

The aim of this study was to evaluate the color stability and the surface roughness of a bulk-fill composite flow (SDR® Plus) by comparison to an ORMOCER-based composite (Ceram.x® Universal SphereTEC?) in order to confirm the validity of using SDR® Plus

Accelerated Aging: Photochemical and Thermal Aspects

Surveys accelerated-aging tests and the underlying causes of the deterioration of organic coatings, based on research conducted at the Carnegie Mellon Research Institute

On the Use of Gallic Acid as a Potential Natural Antioxidant and Ultraviolet Light Stabilizer in Cast-Extruded Bio-Based High-Density Polyethylene Films

This study originally explores the use of gallic acid (GA) as a natural additive in bio-based high-density polyethylene (bio-HDPE) formulations. Thus, bio-HDPE was first melt-compounded with two different loadings of GA, namely 0.3 and 0.8 parts per hundred resin (phr) of biopolymer, by twin-screw extrusion and thereafter shaped into films using a cast-roll machine. The resultant bio-HDPE films containing GA were characterized in terms of their mechanical, morphological, and thermal performance as well as ultraviolet (UV) light stability to evaluate their potential application in food packaging. The incorporation of 0.3 and 0.8 phr of GA reduced the mechanical ductility and crystallinity of bio-HDPE, but it positively contributed to delaying the onset oxidation temperature (OOT) by 36.5 °C and nearly 44 °C, respectively. Moreover, the oxidation induction time (OIT) of bio-HDPE, measured at 210 °C, was delayed for up to approximately 56 and 240 min, respectively. Furthermore, the UV light stability of the bio-HDPE films was remarkably improved, remaining stable for an exposure time of 10 h even at the lowest GA content. The addition of the natural antioxidant slightly induced a yellow color in the bio-HDPE films and it also reduced their transparency, although a high contact transparency level was maintained. This property can be desirable in some packaging materials for light protection, especially UV radiation, which causes lipid oxidation in food products. Therefore, GA can successfully improve the thermal resistance and UV light stability of green polyolefins and will potentially promote the use of natural additives for sustainable food packaging applications

Ultra-Violet Degradation Behavior of Polymeric Backsheets of Photovoltaic Modules

This study is designed to understand the ultra-violet (UV) degradation of polymeric backsheets used in PV modules. Commercial photovoltaic backsheets from four suppliers were UV-aged for up to 3000 hours. The aged samples were tested using optical microscopy, scanning electron microscopy (SEM), shrinkage rate test, color measurements, UV-Vis-NIR, Fourier transform infrared spectroscopy (FTIR), and dielectrical tests to study the microstructural, color, chemical and electrical properties. Yellowness Index (YI) and Delta E were used to quantify the color changes which were found in strong correlation with FTIR results. The characters of the surface cracks generated were found to be affected by degree of UV degradation and polymer chain alignment of the backsheets. Electrical properties were not significantly affected by UV irradiation. The results suggest insufficient UV aging time designated in current PV module test standard. A longer aging time is recommended for quality assurance

RELIABILITY TESTING & BAYESIAN MODELING OF HIGH POWER LEDS FOR USE IN A MEDICAL DIAGNOSTIC APPLICATION

While use of LEDs in fiber optics and lighting applications is common, their use in medical diagnostic applications is rare. Since the precise value of light intensity is used to interpret patient results, understanding failure modes is very important. The contributions of this thesis is that it represents the first measurements of reliability of AlGaInP LEDs for the medical environment of short pulse bursts and hence the uncovering of unique failure mechanisms. Through accelerated life tests (ALT), the reliability degradation model has been developed and other LED failure modes have been compared through a failure modes and effects criticality analysis (FMECA). Appropriate ALTs and accelerated degradation tests (ADT) were designed and carried out for commercially available AlGaInP LEDs. The bias conditions were current pulse magnitude and duration, current density and temperature. The data was fitted to both an Inverse Power Law model with current density J as the accelerating agent and also to an Arrhenius model with T as the accelerating agent. The optical degradation during ALT/ADT was found to be logarithmic with time at each test temperature. Further, the LED bandgap temporarily shifts towards the longer wavelength at high current and high junction temperature. Empirical coefficients for Varshini's equation were determined, and are now available for future reliability tests of LEDs for medical applications. In order to incorporate prior knowledge, the Bayesian analysis was carried out for LEDs. This consisted of identifying pertinent prior data and combining the experimental ALT results into a Weibull probability model for time to failure determination. The Weibull based Bayesian likelihood function was derived. For the 1st Bayesian updating, a uniform distribution function was used as the Prior for Weibull á-â parameters. Prior published data was used as evidence to get the 1st posterior joint á-â distribution. For the 2nd Bayesian updating, ALT data was used as evidence to obtain the 2nd posterior joint á-â distribution. The predictive posterior failure distribution was estimated by averaging over the range of á-â values. This research provides a unique contribution in reliability degradation model development based on physics of failure by modeling the LED output characterization (logarithmic degradation, TTF â<1), temperature dependence and a degree of Relevance parameter `R' in the Bayesian analysis

The fate of colors in the 20th - 21st centuries: preserving the organic colorants in plastic artifacts

Objectos modernos e contemporâneos feitos de plástico são amplamente encontrados no património cultural. Presentemente, a sua preservação levanta questões críticas aos conservadores e cientistas uma vez que estes objectos podem facilmente sofrer degradação num curto espaço de tempo. Um dos fenómenos que pode alterar significativamente a aparência de objectos em plástico é a alteração de cor (descoloração). De um modo geral, a descoloração é habitualmente associada à degradação dos polímeros, contudo, os pigmentos, que são parte integrante das formulações do plástico, também podem desvanecer devido à exposição à luz. A identificação de objetos de plástico com pigmentos sensíveis à luz é um exercício bastante exigente devido à sensibilidade dos mesmos a alterações na cor. A caracterização dos corantes nos plásticos é normalmente realizada através de amostragem, métodos de extração e testagem destrutiva. Como alternativa, esta tese apresenta uma abordagem inovadora e multi- analítica baseada em espectroscopias que foi desenvolvida para a identificação in situ dos pigmentos em plásticos históricos. Esta metodologia compreendeu a utilização de microscopia ótica (MO), microespectrometria por fluorescência de raios X dispersiva de energias (μ-EDXRF), espectroscopia UV-Vis-NIR de reflectância, fotoluminescência (PL) e micro-espectroscopia de Raman (μ-Raman) na análise de obras de arte, objetos industriais e de uso diário, datados de 1950-2000s e pertencentes a coleções Portuguesas. Deste estudo resultou a identificação dos pigmentos comumente presentes na paleta de cor dos coloristas da indústria dos plásticos portuguesa: óxido de ferro (PR 101, α-Fe2O3), molibdato de cromato de chumbo (PR 104, Pb(Cr,Mo,S)O4), vermelho de cádmio (PR 108, Cd(S,Se); PR 113, (Cd,Hg)S), amarelo de cádmio (PY 37, CdS; PY 35; (Cd,Zn)S), branco de titânio (PW 6, TiO2 ambos rutilo e anátase), oxicloreto de bismuto (PW 14, BiOCl) e lacas do pigmento orgânico β-naftol (PR 48, PR 49, PR 53). Adicionalmente, foi também identificado um pigmento fora do comum, o pigmento perlascente plumbonacrite Pb5(CO3)3O(OH)2. Para todos os casos de estudo, μ-Raman foi a ferramenta chave para a caracterização dos pigmentos nos objetos de plástico, aportando dados conclusivos para a identificação dos mesmos. A impressão digital vibracional dos pigmentos orgânicos e inorgânicos foi adquirida com sucesso recorrendo à focagem do laser na superfície das partículas. A aquisição de dados espectrais de pigmentos com concentrações muito baixas (0.1 % a 5%, aproximadamente) à escala micro foi possível através de microscopia confocal, que faz parte do sistema do equipamento de μ-Raman. Adicionalmente, foi também possível obter informação sobre o polímero base (principalmente termoplásticos) e cargas. Os métodos analíticos desenvolvidos neste estudo deverão, em trabalhos futuros, facilitar a obtenção de informação complementar sobre estes objetos de plástico e permitir uma melhor identificação e avaliação do seu estado de conservação. Esta tese foca particularmente objectos de plástico vermelhos visto que estes foram identificados como os mais severamente afetados por alterações de cor. O estado avançado de desvanecimento identificado no pigmento β-naftol PR 53 mostrou a sua fraca estabilidade à luz em formulações de plástico. Esta situação, junto com as alterações de cor descritas em literatura para o pigmento PR 48 em objetos de plástico, sugere uma sensibilidade dos pigmentos vermelhos da família dos β-naftol ao desvanecimento. O PR 53 e os pigmentos vermelhos da família dos β-naftóis são pigmentos históricos facilmente encontrados em objetos do património cultural. No entanto, o conhecimento acerca da sua estabilidade a longo prazo e resistência à foto-degradação é limitado, especialmente para os casos onde os mesmos se encontram em polímeros, sendo que este conhecimento é essencial para a sua preservação. Neste estudo, a quantificação da foto-estabilidade para uma série de pigmentos vermelhos da família dos β-naftol foi realizada pela primeira vez, através do cálculo do rendimento quântico de fotodegradação (ΦR). Os valores obtidos variaram entre 3x10-6 e 4x10-5, indicativo de uma estabilidade relativamente boa à luz por parte das moléculas. Tendo em consideração que a estabilidade dos pigmentos não se limita exclusivamente ao pigmento em si, mas também à sua interação com o meio envolvente, foram realizados ensaios de envelhecimento por exposição à luz (λ>300 nm) do pigmento em solução, em pó e incorporado em polímeros de modo a avaliar o papel do meio na estabilidade à luz dos pigmentos e as vias pelas quais estes se degradam. Verificou-se que o ligante tem um impacto significativo na estabilidade do pigmento uma vez que se foi detetada uma maior sensibilidade à luz dos pigmentos PR 48 e PR 53 quando incorporados nos plásticos, comparativamente ao ensaio do pigmento em pó. Este novo conhecimento irá contribuir para o desenvolvimento de novas estratégias na conservação dos plásticos com estes pigmentos vermelhos fotossensíveis através da previsão do desvanecimento. Espectrometrias de massa (MS) por cromatografia em fase líquida e gasosa foram utilizadas na caracterização dos principais subprodutos da degradação. Observou-se uma fotodegradação significativa e a formação de compostos ftálicos e ftalatos nos pigmentos em solução e em pó.Modern and contemporary objects made of plastics are widely found in cultural heritage. Today, their preser- vation poses critical issues to conservators and scientists, as they can suffer from extensive degradation in a short time period. Color change (discoloration) is one of the alteration phenomena that can significantly affect their appearance. Discoloration is commonly associated with the degradation of polymers. However, pigments within plastics can also fade due to exposure to light. The identification of objects that contain light-sensitive pigments is demanding because of the sensitivity of plastics to color change. Normally sampling, extraction methods and destructive testing are required for the characterization of colorants in plastics. In this work, an innovative multi-analytical spectroscopic approach for the in situ identification of pigments in historical plastics was developed. Optical microscopy (MO), micro-energy dispersive X-ray fluo- rescence (μ-EDXRF), UV-Vis-NIR reflectance, photoluminescence (PL) and Raman microscopy (μ-Raman), were used for the analysis of artworks, industrial and daily objects dated from 1950s-2000s from Portuguese collections. A common colorists’ palette within the Portuguese plastics industry was identified: iron oxide (PR 101, α-Fe2O3), lead chromate molybdate (PR 104, Pb(Cr,Mo,S)O4), cadmium red (PR 108, Cd(S,Se); PR 113, (Cd,Hg)S) and cadmium yellow (PY 37, CdS; PY 35; (Cd,Zn)S) pigments, titanium whites (PW 6, TiO2 both rutile and anatase), bismuth oxychloride (PW 14, BiOCl) and organic β-naphthol lakes (PR 48, PR 49, PR 53). An exceptional pigment found was the pearlescent plumbonacrite pigment Pb5(CO3)3O(OH)2. In all the case studies, μ-Raman was the key analytical tool for pigment characterization in the plastic objects, providing conclusive data for their identification. The vibrational fingerprint of both inorganic and organic pigments was successfully recorded by focusing the laser beam on particle surfaces. The confocal microscopy system used in μ-Raman enabled the collection of spectral data from low concentrations of pigments (ap- proximately 0.1%-5%) on the micro-scale. In addition to pigments, information on the base polymer (mainly thermoplastics) and fillers was obtained. The analytical methods developed will facilitate the acquisition of complementary data from plastics allowing material identification and condition assessment in the future. This thesis focused on red pigmented plastic artifacts, as they were found to be severely faded among the studied objects. The identification of β-naphthol pigment lake PR 53 as a faded pigment highlighted its poor fastness in plastics, that together with the color change of PR 48 in plastic objects, reported in literature, suggests the particular susceptibility of β-naphthol red lakes to fading. PR 53, and the other β-naphthol reds, are historical pigments widely found in cultural heritage. However, little is known about their photodegradation and stability, especially when they are found in polymer media, and this knowledge is essential for their long- term preservation. For the first time, photodegradation quantum yields (ΦR) were calculated for a series of red pigments based on β-naphthol in order to quantify their photo-stability. ΦR values ranging from 3x10-6 to 4x10-5 were obtained, indicating relatively light-stable molecules. Bearing in mind that pigment fastness is not only related to the pigment itself, but also to its interaction with the confined environment, light-aging experiments (λ>300 nm) were conducted in solution, on powders, and in polymers to assess the role of the medium on the lightfastness of the pigments and their degradation pathways. A significant impact of the binder on their stability was found. Indeed, a higher sensitivity to light of PR 48 and PR 53 pigments, when incorporated in plastics than in powder, was observed. This new knowledge will contribute to the prediction of plastic fading and inform effective preventive conservation strategies for objects containing light- sensitive β-naphthol red pigments. Liquid- and gas-chromatography mass spectrometry (MS) were used for the characterization of the main degradation products. Extensive photodegradation was observed with the formation of phthalic compounds and phthalates in both solution and powder phases

Delamination-and electromigration-related failures in solar panels—a review

The reliability of photovoltaic (PV) modules operating under various weather conditions attracts the manufacturer’s concern since several studies reveal a degradation rate higher than 0.8% per year for the silicon-based technology and reached up to 2.76% per year in a harsh climate. The lifetime of the PV modules is decreased because of numerous degradation modes. Electromigration and delamination are two failure modes that play a significant role in PV modules’ output power losses. The correlations of these two phenomena are not sufficiently explained and understood like other failures such as corrosion and potential-induced degradation. Therefore, in this review, we attempt to elaborate on the correlation and the influence of delamination and electromigration on PV module components such as metallization and organic materials to ensure the reliability of the PV modules. Moreover, the effects, causes, and the sites that tend to face these failures, particularly the silicon solar cells, are explained in detail. Elsewhere, the factors of aging vary as the temperature and humidity change from one country to another. Hence, accelerated tests and the standards used to perform the aging test for PV modules have been covered in this review