DuPont Expert View

A COMPARATIVE ANALYSIS OF PHOTOVOLTAIC

BACKSHEET MATERIAL PERFORMANCE

Long-term reliability of photovoltaic (PV) backsheet materials is critical to

ensure that photovoltaic modules will maintain their power output and keep
their physical integrity for more than 25 years.

After all, when module manufacturers guarantee their modules for 25 or more years,
they need to be confident that the materials they’ve chosen won’t fail or lead to a
decline in module performance over time.

As the leading global supplier of materials to the photovoltaic industry, DuPont

knows how much materials matter. That’s why we are completing extensive testing
to determine how material performance relates to and can ultimately benefit module
performance.

Dr. Michael DeBergalis, Technology Fellow – DuPont Photovoltaic Solutions, is a key

Dr. Michael DeBergalis
Technology Fellow, DuPont Photovoltaic Solutions technical expert who puts PV backsheet materials to the test every day. A 32-year
veteran of DuPont, he has been leading Tedlar polyvinyl fluoride (PVF) film innovation
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for over 20 years and has focused on high performing backsheets for the PV industry
for the past nine years and has shared his insights through published articles and
presentations delivered at conferences around the world.

Results from recent materials testing will be presented at the European PV Solar
Energy Conference and Exhibition to be held in Valencia, Spain, in September 2010.
In the meantime, Dr. DeBergalis has agreed to answer some questions to give us a
preview of the study.

What types of backsheet constructions were tested?

DuPont tested the broadest range of commercially available PV backsheets,
including several Tedlar backsheet constructions, and multiple competitive material
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constructions. Most backsheets are multilayer composites which enhance the

performance of PV modules in many ways. They provide protection from the
environment, electrical insulation, and contribute to aesthetics. Backsheets must
provide these properties throughout the life of modules, which today can exceed
25 years. Tedlar PVF film exhibits the properties needed in high performing backsheets
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which is why TPT (Tedlar /Polyester/Tedlar ) is one of the most popular backsheets
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used today. In this backsheet construction, Tedlar film provides a dual role.
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The outside layer protects the module from the environment and the inside layer
provides protection and excellent long term adhesion to the encapsulant layer of
the module.
Why select backsheets containing Tedlar Film?
The primary reasons are performance and design. When today’s
popular “glass/backsheet” module was designed in the 1970’s,
many materials were considered for the polymeric backsheet.
Tedlar film was adopted as the best choice because of its
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combination of durability, adhesion, color and cost vs. other
available materials. Those properties still make sense today.
When you add those properties to the 25 year performance
track record, Tedlar remains a compelling choice and continues
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to be the standard used to compare other materials.
What material properties did you examine—and why?
We tested a range of critical backsheet properties, performed
a series of exposure tests and conducted a visual inspection
of various backsheet materials, using the same structure and
same conditions for a true side-by-side comparison. The physical
properties we tested included:
• peel strength to EVA—determines adhesion of the
backsheet to the encapsulant.
• tensile properties—determines physical integrity,
mechanical strength and resistance to cracking
• dielectric breakdown voltage—important from a safety and
performance standpoint
• coefficient of thermal expansion—determines the impact
of exposure to wide temperature ranges
• color/color stability—color change during exposure can
indicate degradation of materials and potential loss
of performance
• water vapor permeability—determines the potential for the
module to absorb water in humid environments
• cut susceptibility—determines whether the backsheet may
be damaged during handling
• reflectance—can contribute to improved module
performance by capturing light between cells and
reflecting it back into the cell
• dimensional stability—important to ensure that the
backsheet materials are compatible with the manufacturing
process of the modules
What tests were performed to measure these properties?
For all tests, we used typical IEC, UL and ASTM test conditions;
however, accelerated exposure tests were run for more cycles
than standards require in order to better approximate long term
exposure.
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What were the findings?
Full details of the findings will be presented at the European PV
Solar Energy Conference and Exhibition in Valencia, Spain, in
September 2010, three key findings are:
First, when testing backsheet adhesion to encapsulant after
damp heat, we saw a loss of adhesion or mechanical failure
for some PET-based and fluoropolymer-based backsheets at
1,000 hours. In sharp contrast, the TPT constructions showed
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improved adhesion after exposure.
Second, when testing backsheet elongation after damp heat,
we saw embrittlement of a PVDF-based backsheet tested at
500 hours that worsened at 1,000 hours. The TPT constructions
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continued to provide superior performance after exposure.
Third, when evaluating color change, we saw a significant
change after 1190h xenon exposure and 2380h xenon exposure
for both the all-polyester-based backsheet and the PFAVE-based
backsheet. On the other hand, the TPT backsheet exhibited
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only a slight color change.
What are the key findings from this study?
We understand that a broad range of properties must be
considered when designing a PV module and selecting the
appropriate backsheet materials. Testing backsheet materials
for the stability of properties under accelerated conditions is
important for predicting long-term reliability. The challenge is in
understanding the connection between the performance of the
materials and the performance of the module. Findings from
studies like this can help guide materials choices to ensure
long term module performance. They also help our new product
development teams, enabling them to continue to provide the
best solutions for this ever-changing industry.
What’s next for testing?
In conjunction with materials testing, we are conducting module
testing and accelerated aging testing. We are also looking
beyond the lab, testing modules that have been in the field.
Many PV modules with TPT backsheets have been operating
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reliably for more than 25 years. Tedlar is the only backsheet
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material that has delivered proven performance in modules
for more than 25 years, and will continue to enable long-term,
reliable power output and module performance for many years
to come.
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