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.