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Minimizing module heating is an effective way to increase the lifetime energy output of photovoltaic systems. Maximizing the reflection of light that is unusable for energy conversion is one of the most promising ways to reduce the operating temperature of fielded modules. We derive a model based on a steady-state energy balance to quantify the temperature benefit of cell or module optical modifications aimed at improving reflection of light with photon energies below the photovoltaic cell bandgap energy. This more detailed model is then simplified so that, from outdoor measured data, temperature differences arising from reflectance can be isolated from those arising from irradiance, wind speed, and module standard-test-condition efficiency.

In this article, we explore the influence of module size on the rate of interconnecting solder bond thermomechanical fatigue (TMF) damage. Structural mechanics models of crystalline silicon PV models are created to solve with the finite-element method. Results conclusively demonstrate that the rate of solder bond TMF damage is independent of module size, interconnect location across the cell and cell location across the module.

Large-scale deployment of photovoltaic (PV) modules has considerably increased in recent decades. Given an estimated lifetime of 30 years, the challenge of how to handle large volumes of end-of-life PV modules is starting to emerge. In this Perspective, we assess the global status of practice and knowledge for end-of-life management for crystalline silicon PV modules. We focus in particular on module recycling, a key aspect in the circular economy of photovoltaic panels. We recommend research and development to reduce recycling costs and environmental impacts compared to disposal while maximizing material recovery. We suggest that the recovery of high-value silicon is more advantageous than the recovery of intact silicon wafers. This approach requires the identification of contaminants and the design of purification processes for recovered silicon. The environmental and economic impacts of recycling practices should be explored with techno–economic analyses and life-cycle assessments to optimize solutions and minimize trade-offs. As photovoltaic technology advances rapidly, it is important for the recycling industry to plan adaptable recycling infrastructure. The increasing deployment of photovoltaic modules poses the challenge of waste management. Heath et al. review the status of end-of of-life management of silicon solar modules and recommend research and development priorities to facilitate material recovery and recycling of solar modules.

We present a detailed case study of degradation in monocrystalline silicon photovoltaic modules operating in a utility-scale power plant over the course of approximately three years. We present the results of degradation analysis on arrays within the site, and find that five of the six arrays degraded faster than the best performing array, even though the arrays consist of modules of the same manufacturer and model. We also describe the results of extensive laboratory characterization of modules returned from the field, including module- and cell-level current–voltage characterization, luminescence imaging, and accelerated testing. The laboratory test results and the field performance are consistent with light and elevated temperature induced degradation (LeTID). Notably, we observe differences in back contact technology between affected and unaffected modules. This article also demonstrates a method to identify possible LeTID degradation in the field and confirm the result with laboratory testing of a small number of modules.

Heat mitigation for large-scale solar photovoltaic (PV) arrays is crucial to extend lifetime and energy harvesting capacity. PV module temperature is dependent on site-specific farm geometry, yet common predictions consider panel-scale and environmental factors only. Here, we characterize convective cooling in diverse PV array designs, capturing combined effects of spatial and atmospheric variation on panel temperature and production. Parameters, including row spacing, panel inclination, module height, and wind velocity, are explored through wind tunnel experiments, high-resolution numerical simulations, and operating field data. A length scale based on fractal lacunarity encapsulates all aspects of arrangement (angle, height, etc.) in a single value. When applied to the Reynolds number Re within the canonical Nusselt number heat transfer correlation, lacunarity reveals a relationship between convection and farm-specific geometry. This correlation can be applied to existing and forthcoming array designs to optimize convective cooling, ultimately increasing production and PV cell life.

When the temperature of solar photovoltaic modules rises, efficiency drops and module degradation accelerates. The spatial arrangement of solar modules can affect convective cooling and, consequently, module temperatures. However, the impact of row spacing on convective cooling in realistic solar farms has not yet been studied. Here, we develop six solar farm arrangements consisting of a fixed number of rows with varying streamwise row spacing. We model the flow and heat transfer of each solar farm using high-resolution large-eddy simulations. Results indicate that increasing row spacing can enhance convective cooling by 14.8%, which reduces module temperature by 6.6 °C and increases power output by 4.0% on average.

In this case study, we investigate a degradation mode occurring at the cell level in fielded multi-Si modules. Affected cells in the module show a progressive, series-resistance-related power degradation observed in module- and cell-level IV curves along with EL and PL imaging at the module, cell, and cell core sample scale. SEM and elemental analysis via EDS reveal a difference in the oxides in the silver paste used in screen printing of the finger contacts. This suggests that the cells were screen printed with different silver paste compositions and possibly firing conditions. One of these combinations leads to degradation of the contact at the interface between the cell and contact finger, causing severe series resistance across the cell that continues to progress over time.

When cells in a crystalline silicon photovoltaic module crack, packaging materials hold the fragments together. Changes in module temperature cause cell fragments to move, allowing cracked metallization to lose and regain contact. We intentionally cracked cells in commercial PV modules and characterized the modules’ temperature-dependent electroluminescence (EL) response. Here we show that (1) metallization makes contact across cracks in a way that is temperature dependent and (2) this contact is not a function of temperature, but is hysteretic. We expect that any electro-optical characterization made at a single temperature will be misleading as to the effects of cracked cells at different temperatures. And we expect that a single temperature sweep cannot fully characterize the temperature dependence of electro-optical performance of modules with cracked cells.

In this work, we explore the influence of module size on the rate of interconnect solder bond thermomechanical fatigue (TMF) damage and the probability of cell fracture. For the solder bond TMF damage evaluation, structural mechanics models of crystalline silicon PV models are created to solve with the Finite Element Method. For the probability of cell fracture evaluation, Weibull analysis and weakest link theory are employed to resolve the probability of crystalline silicon PV cell fracture when measured as bare cells and when stressed in reduced- and full-sized modules. Results conclusively demonstrate that the rate of solder bond TMF damage is independent of module size, interconnect location across the cell and cell location across the module and that smaller, representative, modules must be loaded to a much higher level than their parent full-sized modules to achieve an equivalent driving force for cell fracture.

Bifacial photovoltaics are predicted to become the dominant device architecture over the next couple of years, but their thermal performance is not yet well understood. In this study, we model the thermal effects of different backside lamination materials on the performance of bifacial PERC cells. Glass-glass laminated cells were found to operate hotter than equivalent glass-polymer backsheet packed cells. This was solely due to the increased absorption of rear side incident light.

Many existing commercially manufactured photovoltaic modules include a cover layer of glass, commonly coated with a single layer antireflection coating (ARC) to reduce reflection losses. As many common photovoltaic cells, including c-Si, CdTe, and CIGS, decrease in efficiency with increasing temperature, a more effective coating would increase reflection of sub-bandgap light while still acting as an antireflection coating for higher energy photons. The sub-bandgap reflection would reduce parasitic sub-bandgap absorption and therefore reduce operating temperature. This reduction under realistic outdoor conditions would lead to an increase in annual energy yield of a photovoltaic module beyond what is achieved by a single layer ARC. However, calculating the actual increase in energy yield provided by this approach is difficult without using time-consuming simulation. Here, we present a time-independent matrix model which can quickly determine the percentage change in annual energy yield of a module with a s...

The thermal emissivity of solar cell cover glasses with differences in glass composition or manufacture and surface texture are evaluated using specular and specular+diffuse infrared reflectance at different angles of incidences. Non-textured and textured glasses all exhibit similar emissivity at all angles of incidence regardless of composition and patterning. Both diffuse and specular reflectance must be included for textured glass at any angle of incidence and may be needed for planar glass at a high angle of incidences to properly determine emissivity.

Parasitic absorption in photovoltaic modules is a major source of waste heat, which drives operating temperatures 20-30K above ambient. Spectrally-selective sub-bandgap reflection can reduce parasitic absorption, thereby improving module efficiency and power output. Here, we investigate the performance of 1-D spectrally-selective mirrors in monofacial Al BSF and PERC modules, and bifacial PERC modules. In monofacial modules, these mirrors offer >1.2% increase in energy yield compared to single-layer anti-reflection coatings, while cooling by over 1K on average. Mirrors reduced bifacial module parasitic absorption by up to 34 W/m2 out of 1240 W/m2 incident.

We present a model for a yield analysis of tandem devices consisting of Si bottom cells with III-V top cells. It accounts for the spectral properties of the subcells as well as their reduced operating temperature due to increased efficiency and luminescent coupling. Inputs are the experimental I–V and QE data of the subcells (e.g., available from laboratory prototypes) and the irradiance-dependent module temperature of the bottom cell. We apply the model to compare two types of tandem cells, GaInP and GaAs top cells on Si bottom cells. The impact of the temperature model, compared to a constant temperature, shows a relative change in energy yield of up to 2.7%rel. Including luminescent coupling for GaAs/Si devices with two terminals, increases the energy yield by 34.0%rel. This is still 34.2%rel less energy yielded than for GaInP/Si two-terminal devices. The performance of the GaInP/Si devices can be improved by 5.8%rel using three-terminal devices with back-contacted bottom cells instead of a two-terminal configuration under the assumption of a cell string with voltage matching of one top cell with two bottom cells. For GaInP/Si, the three-terminal device performs similarly to the four-terminal device, enabling the integration of monolithic tandem cells into modules at comparably high efficiencies.

Waste heat generated during daytime operation of a solar module will raise its temperature and reduce cell efficiency. In addition to thermalization and carrier recombination, one major source of excess heat in modules is the parasitic absorption of light with sub-bandgap energy. Parasitic absorption can be prevented if sub-bandgap radiation is reflected away from the module. We report on the design considerations and projected changes to module energy yield for photonic reflectors capable of reflecting a portion of sub-bandgap radiation while maintaining or improving transmission of light with energy greater than the semiconductor bandgap. Using a previously developed, self-consistent opto-electro-thermal finite-element simulation, we calculate the total additional energy generated by a module, including various photonic reflectors, and decompose these benefits into thermal and optical effects. We show that the greatest total energy yield improvement comes from photonic mirrors designed for the outside o...

Reducing the operating temperature of photovoltaic modules increases their efficiency and lifetime. This can be achieved by reducing the production of waste heat or by improving the rejection of waste heat. We tested, using a combination of simulation and experiment, several thermal modifications in each category. To predict operating temperature and energy yield changes in response to changes to the module, we implemented a physics-based transient simulation framework based almost entirely on measured properties. The most effective thermal modifications reduced the production of waste heat by reflecting unusable light from the cell or the module. Consistent with previous results and verified in this work through year-long simulations, the ideal reflector resulted in an annual irradiance-weighted temperature reduction of 3.8 K for crystalline silicon (c-Si). Our results illustrate that more realistic reflector concepts must balance detrimental optical effects with the intended thermal effects to realize the optimal energy production advantage. Methods improving thermal conductivity or back-side emissivity showed only modest improvements of less than 1 K. We also studied a GaAs module, which uses high-efficiency and high-subbandgap reflectivity to operate at an annual irradiance-weighted temperature 12 K cooler than that of a c-Si module under the same conditions.

In this study, CuInxGa(1-x)Se2 (CIGS) mini-modules are stressed under reverse bias, resembling partial shading conditions, to predict and characterize where failures occur. Partial shading can cause permanent damage in the form of ‘wormlike’ defects on thin-film modules due to thermal runaway. This results in module-scale power losses. We have used dark lock-in thermography (DLIT) to spatially observe localized heating when reverse-bias breakdown occurs on various CIGS mini-modules. For better understanding of how and where these defects originated and propagated, we have developed techniques where the current is limited during reverse-bias stressing. This allows for DLIT-based detection and detailed studying of the region where breakdown is initiated before thermal runaway leads to permanent damage. Statistics of breakdown sites using current-limited conditions has allowed for reasonable identification of the as-grown defects where permanent breakdown will likely originate. Scanning electron microscope results and wormlike defect analysis show that breakdown originates in defects such as small pits, craters, or cracks in the CIGS layer, and the wormlike defects propagate near the top CIGS interface.

For commercial one-sun solar modules, up to 80% of the incoming sunlight may be dissipated as heat, potentially raising the temperature 20 C - 30 C higher than the ambient. In the long term, extreme self-heating erodes efficiency and shortens lifetime, thereby dramatically reducing the total energy output. Therefore, it is critically important to develop effective and practical (and preferably passive) cooling methods to reduce operating temperature of PV modules. In this paper, we explore two fundamental (but often overlooked) origins of PV self-heating, namely, sub-bandgap absorption and imperfect thermal radiation. The analysis suggests that we redesign the optical properties of the solar module to eliminate parasitic absorption (selective-spectral cooling) and enhance thermal emission (radiative cooling). Our Comprehensive opto-electro-thermal simulation shows that the proposed techniques would cool the one-sun and low-concentrated terrestrial solar modules up to 10 C and 20 C, respectively. This self-cooling would substantially extend the lifetime for solar modules, with The corresponding increase in energy yields and reduced LCOE., Discussion of low concentration PV is added

The extensive photovoltaic field reliability literature was analyzed and reviewed. Future work is prioritized based upon information assembled from recent installations, and inconsistencies in degradation mode identification are discussed to help guide future publication on this subject. Reported failure rates of photovoltaic modules fall mostly in the range of other consumer products; however, the long expected useful life of modules may not allow for direct comparison. In general, degradation percentages are reported to decrease appreciably in newer installations that are deployed after the year 2000. However, these trends may be convoluted with varying manufacturing and installation quality world-wide. Modules in hot and humid climates show considerably higher degradation modes than those in desert and moderate climates, which warrants further investigation. Delamination and diode/j-box issues are also more frequent in hot and humid climates than in other climates. The highest concerns of systems installed in the last 10 years appear to be hot spots followed by internal circuitry discoloration. Encapsulant discoloration was the most common degradation mode, particularly in older systems. In newer systems, encapsulant discoloration appears in hotter climates, but to a lesser degree. Thin-film degradation modes are dominated by glass breakage and absorber corrosion, although the breadth of information for thin-film modules is much smaller than for x-Si. Copyright © 2017 John Wiley & Sons, Ltd.

Several studies have found indications that PV degradation may increase in hotter climates. We show in this paper that degradation does correlate to higher module temperatures, but that these temperatures are significantly affected by the module mounting and. The mechanisms of degradation vary with module technology and quality. Using data from different HIT module installations we were able to extract an activation energy that is consistent with hydrogen passivation layer degradation. In addition, we show that low degradation in hot climates can be achieved for Al-BSF technology if properly installed to reduce heat transfer in order to thermally decouple the modules from the roof. We also found that monofacial and bifacial PERC module degradation is in line with historical degradation rates of Al-BSF.

Cracks in crystalline silicon solar cells can lead to substantial power loss. While the cells’ metal contacts can initially bridge these cracks and maintain electrical connections, the bridges are damaged by mechanical loads, including those due to temperature changes. We investigated the metallization bridges that form over cracks in encapsulated silicon solar cells. Microscopic characterization showed that the crack in the silicon can immediately propagate through the metal grid, but the grid can maintain electrical contact once the load is removed. We also quantified the movement of the cell fragments separated by a crack as a function of temperature. Cell fragments are free to move diagonally and to rotate, so the change in gap across the crack during a temperature change varies along the length of the crack. In one sample, we showed that a 10 ◦C temperature change, causing a 2 µm increase in the separation of cell fragments, was sufficient to cause a reversible electrical disconnection of metallization bridging a crack.

The efficiency of a c-Si cell drops with increasing cell temperature. A typical photovoltaic module with a c-Si cell will operate 20-30K above ambient temperature. Spectrally-selective photonic mirrors which reflect sub-bandgap light can reduce waste heat generated by parasitic absorption in the module and reduce module operating temperature. Here, a spectrally selective 4-layer and 12-layer mirror are designed and fabricated on module cover glass. When integrated into modules, these mirrors reduce the operating temperature of the module by 0.16K and 1.5K, respectively when compared to a module with bare outer glass.

One of the ways to reduce the cost of solar electricity to 3¢/kWh, thus reaching parity with fossil-fuel-based generation, is to reduce the degradation rate of solar modules and extend their lifetime well beyond 30 years. The extended module lifetime in turn can positively influence the financial model and the bankability of utility-scale PV projects. Today, the highest-riskpriority solar module degradation mechanism is what is known as hot spots, often induced by cell cracks. In order to address this degradation mechanism, we make use of low-cost, multi-walled carbon nanotubes embedded in commercial screen-printable silver pastes. When the carbon nanotubes are properly functionalized and appropriately incorporated into commercial silver pastes, the resulting metal contacts on solar cells, after screen-printing and firing, show exceptional fracture toughness. These composite metal contacts possess increased ductility, electrical gap-bridging capability up to 50 µm, and "self-healing" to regain electrical continuity even after cycles of complete electrical failure under extreme strain.

One of the simplest and most effective ways to reduce the operating temperature of photovoltaic systems in the field is to reflect unusable, "sub-bandgap" light with energies below the cell absorber’s bandgap energy. In this work, low-refractive index SiO2 nanoparticle films inserted between c-Si wafers and metal electrodes significantly increase the reflectance of sub-bandgap light in fabricated test structures. These films are then integrated into the standard PERC fabrication sequence, revealing that the reflection benefits remains after some processing steps but are lost in certain conditions. The SiO2 nanoparticle films are easily ablated during laser contact opening, but are undesirably etched during post-laser cleaning. After Al metallization, the fully fabricated devices show enhanced sub-bandgap reflection when annealed at moderate temperatures, but energy-dispersive x-ray spectroscopy shows that high-temperature firing causes unwanted Al penetration into the SiO2 nanoparticle film, compromising reflection.

Summary Elevated operating temperatures of solar cells encapsulated in modules lead to reduced efficiency and module lifetime. Here, we provide a comprehensive overview of the challenges and opportunities for passive optical thermal management of PV modules based on the rejection of sub-band-gap light by idealized reflectors and scatterers applied at different interfaces within crystalline Si modules and discuss the limitations to performance at each interface. We find that the annual power-weighted average operating temperature is most readily reduced via sub-band-gap reflection from the module glass, by 3.3 K for Al-BSF modules and 2.9 K for PERC modules with 100% sub-band-gap reflection. Sub-band-gap reflection at the cell interface offers up to 2.2 K (1.8 K) temperature reduction for Al-BSF (PERC) modules, increased cell rear reflection offers up to 1.2 K temperature reduction, and directional scattering offers up to 1.5 K reduction.

Finite element model (FEM) simulations have been performed to elucidate the effect of flat plate photovoltaic (PV) module materials and design on PbSn eutectic solder joint thermal fatigue durability. The statistical method of Latin Hypercube sampling was employed to investigate the sensitivity of simulated damage to each input variable. Variables of laminate material properties and their thicknesses were investigated. Using analysis of variance, we determined that the rate of solder fatigue was most sensitive to solder layer thickness, with copper ribbon and silicon thickness being the next two most sensitive variables. By simulating both accelerated thermal cycles (ATCs) and PV cell temperature histories through two characteristic days of service, we determined that the acceleration factor between the ATC and outdoor service was independent of the variables sampled in this study. This result implies that an ATC test will represent a similar time of outdoor exposure for a wide range of module designs. This is an encouraging result for the standard ATC that must be universally applied across all modules.

Photovoltaic (PV) reliability and durability have seen increased interest in recent years. Historically, and as a preliminarily reasonable approximation, linear degradation rates have been used to quantify long-term module and system performance. The underlying assumption of linearity can be violated at the beginning of the life, as has been well documented, especially for thin-film technology. Additionally, non-linearities in the wear-out phase can have significant economic impact and appear to be linked to different failure modes. In addition, associating specific degradation and failure modes with specific time series behavior will aid in duplicating these degradation modes in accelerated tests and, eventually, in service life prediction. In this paper, we discuss different degradation modes and how some of these may cause approximately linear degradation within the measurement uncertainty (e.g., modules that were mainly affected by encapsulant discoloration) while other degradation modes lead to distinctly non-linear degradation (e.g., hot spots caused by cracked cells or solder bond failures and corrosion). The various behaviors are summarized with the goal of aiding in predictions of what may be seen in other systems. Published 2016. This article is a U.S. Government work and is in the public domain in the USA.

In this paper, we present a physics-based analytical model for copper indium gallium diselenide (CIGS) solar cells that describes the illumination- and temperature-dependent current–voltage ( I–V ) characteristics and accounts for the statistical shunt variation of each cell. The model is derived by solving the drift-diffusion transport equation so that its parameters are physical and, therefore, can be obtained from independent characterization experiments. The model is validated against CIGS I–V characteristics as a function of temperature and illumination intensity. This physics-based model can be integrated into a large-scale simulation framework to optimize the performance of solar modules, as well as predict the long-term output yields of photovoltaic farms under different environmental conditions.

The typical configuration of monolithic thin-film photovoltaic modules makes it possible for partial shade to place one or more cells in such a module in reverse bias. Reverse bias operation leads to high voltage, current density, and power density conditions, which can act as driving forces for failure. We showed that a brief outdoor shadow event can cause a 7% permanent loss in power. We applied an indoor partial shade durability test that moves beyond the standard hot spot endurance test by using more realistic mask and bias conditions and by carefully quantifying the permanent change in performance due to the stress. With the addition of a pass criterion based on change in maximum power, this procedure will soon be proposed as a part of the module-type qualification test. All six commercial copper indium gallium diselenide and cadmium telluride modules we tested experienced permanent damage due to the indoor partial shade test, ranging from 4% to 14% loss in maximum power. We conclude by summarizing ways to mitigate partial shade stress at the cell, module, and system levels.

FEM simulations of PbSn solder fatigue damage are used to evaluate seven cities that represent a variety of climatic zones. It is shown that the rate of solder fatigue damage is not ranked with the cities' climate designations. For an accurate ranking, the mean maximum daily temperature, daily temperature change and a characteristic of clouding events are all required. A physics-based empirical equation is presented that accurately calculates solder fatigue damage according to these three factors. An FEM comparison of solder damage accumulated through service and thermal cycling demonstrates the number of cycles required for an equivalent exposure. For an equivalent 25-year exposure, the number of thermal cycles (− 40 °C to 85 °C) required ranged from roughly 100 to 630 for the cities examined. It is demonstrated that increasing the maximum cycle temperature may significantly reduce the number of thermal cycles required for an equivalent exposure.

Optical modeling of aluminum back surface field (Al-BSF) and passivated emitter and rear contact (PERC) silicon wafer solar cells are extended into the infrared wavelength range (300–2500 nm). The model incorporates ray tracing to account for pyramidal texture of the front silicon surface, free carrier absorption in the front emitter; bulk silicon wafer, BSF; and Lambertian scattering at the silicon back contact. Total reflectance of pyramidal textured cells with different contact geometries with and without encapsulation are simulated. Simulated reflectance and short circuit current density match well with experimental values. These physics-based optical models serve as input for evaluating optical and thermal management strategies for silicon wafer solar cells.

Operation at elevated temperatures is detrimental to the performance of crystalline Si solar modules. One method of reducing module operating temperature is selective reflection of sub-bandgap photons, which can otherwise only be absorbed parasitically. We numerically optimize the design of a series of multilayer photonic mirrors based on real materials using a previously developed optimization routine. Combined ray tracing and finite element simulations reveal the ability of each mirror to increase energy yield and decrease operating temperature. The best design outperforms a conventional glass antireflection coating, contains only nine layers, and maintains performance regardless of geographic location.