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• Completed accelerated testing program (thermal cycling, damp heat, and surface cuts) for a group of advanced prototype crystalline silicon modules and provided results and conclusions to the manufacturer. • An intensive effort was continued in support of NREL’s thin-film module hot and humid, long-term outdoor reliability testing program. NREL and SNL provided detailed baseline characterizations of over 180 modules from 4 manufacturers prior to field deployment at the hot and humid test sites (Florida and Texas). • An advanced indoor module light-soaking apparatus was completed and used to collect and publish data on a-Si and c-Si modules. Capabilities will be used, in collaboration with industry partners, to improve characterization of module light-soaking behavior. • A large number (more than 20) of module backsheet and encapsulant materials were evaluated for their moisture barrier and adhesion properties. Several promising packaging material and design candidates were identified, and results were published in a report to industry. • A new mathematical model was developed to project the time-phased ingress of water vapor (moisture) into module backsheet and encapsulant materials, based on laboratory measurements of material diffusivity and solubility. This model can now be used to estimate how long a given module-packaging design will prevent moisture from reaching the PV material/absorber. • Using outdoor PV module performance data dating back to 1991, annual module performance degradation rates were calculated and published for both thin-film and c-Si modules. A major conclusion was that a 0.5%/year module performance degradation rate is a reasonable goal for all module manufacturers. The following milestones were completed: • Provided initial baseline (pre-aging) report for group of First Solar CdTe modules (12/1/03). • Investigated performance loss in Uni-Solar Ovonic a-Si modules in Arizona Public Service system (12/5/03). • Provided ultrasonic analysis of resistance- welded ribbons for Shell Solar (12/30/03) • Performed second baseline testing for 12 Uni- Solar Ovonic a-Si modules after 6-year exposure at FSEC and SWTDI (1/30/04). • Investigated recently discovered field failure mechanism in First Solar CdTe modules (2/1/04). • Investigated and confirmed solder bond failures in Kyocera modules from 200 NTUA systems in Arizona (3/1/04). • Conducted SNL/NREL rheometric analysis of multiple polymer materials for edge seal and encapsulation (4/1/04). • Completed testing agreement with First Solar on CdTe modules delivered in FY 2003 (6/1/04). • Conducted workshop on the physical properties of PV packaging materials and industry requirements (6/24/04). • Completed extensive technical report covering water vapor transmission rates, peel strengths, and stress testing of existing and new PV module packaging materials (9/17/04). • Established archive baseline and subcontractor-delivered data for the thin-film hot and humid experiment (9/29/04). 4. Planned FY 2005 Activities This project will consist of the following tasks: • Exploratory Reliability & Performance R&D (NREL) • Module Packaging Research & Reliability (NREL) • Module Reliability Characterization (SNL). The major expected results include the following: • A technical report/publication addressing the influence of cell edges on cell performance and projected results for module scribe lines • An overview publication documenting the degradation characteristics of commercial PV modules, using 5 to 15 years of outdoor exposure data for 10 module types. • Water-resistant formulations and procedures for enhanced adhesion of a production- compatible self-priming PV encapsulation materialPDF Image | FY 2004 ANNUAL REPORT DOE Solar
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