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IEA INTERNATIONAL ENERGY AGENCY PHOTOVOLTAIC POWER SYSTEMS PROGRAMME

Crack statistic of crystalline silicon photovoltaic modules


S. Kajari-Schrder, I. Kunze, F. Haase, M. Kntges

Institute for Solar Energy Research Hamelin

IEA INTERNATIONAL ENERGY AGENCY PHOTOVOLTAIC POWER SYSTEMS PROGRAMME

Why analyze cracking of cells?

Cell cracks in PV modules can lead to electrically separated cell area fractions after artificial aging

200 Humidityfreeze cycles

For 230W module with 60 cells: separated cell area fraction of 8% or more leads to significant reduction of module power

Inactive cell area


M. Kntges, I. Kunze, S. Kajari-Schrder, X. Breitenmoser, B. Bjrneklett, Sol. Energy Mater. Sol. Cells (2011), doi:10.1016/j.solmat.2010.10.034

IEA INTERNATIONAL ENERGY AGENCY PHOTOVOLTAIC POWER SYSTEMS PROGRAMME

Crack classification
no crack dendritic several directions +45 -45 parallel to busbar perpend. to busbar

IEA INTERNATIONAL ENERGY AGENCY PHOTOVOLTAIC POWER SYSTEMS PROGRAMME

Crack statistics Different load histories


Transport

IEA INTERNATIONAL ENERGY AGENCY PHOTOVOLTAIC POWER SYSTEMS PROGRAMME

Experimental as delivered
103 PV modules 60 cells (15.6 cm), multicrystalline From various manufacturers Max. 5 PV modules/package
Production
Transport

Inflict cracks to cells in PV module only by production or transport


Determine local crack distribution in EL image

EL

Exemplary image, not analyzed transport M. Kntges, S. Kajari-Schrder, I. Kunze, U. Jahn, Proc. 26th EUPVSEC (WIP, Hamburg, Germany, 2011) 4EO.3.6

IEA INTERNATIONAL ENERGY AGENCY PHOTOVOLTAIC POWER SYSTEMS PROGRAMME

Lateral crack distribution


As delivered

High breakage rate in center Moderate breakage rate near frame Low breakage rate in corners Symmetry to increase statistical significance

IEA INTERNATIONAL ENERGY AGENCY PHOTOVOLTAIC POWER SYSTEMS PROGRAMME

Lateral crack distribution


As delivered

High breakage rate in center Moderate breakage rate near frame Low breakage rate in corners Symmetry to increase statistical significance

IEA INTERNATIONAL ENERGY AGENCY PHOTOVOLTAIC POWER SYSTEMS PROGRAMME

Lateral crack distribution


Noise reduction utilizing symmetries
Dendritic

PV modules show non-homogeneous crack distribution Distribution correlates with strain distribution of 1st eigenmode 45crack in corners does not correlate Tensile strain promotes crack growth

IEA INTERNATIONAL ENERGY AGENCY PHOTOVOLTAIC POWER SYSTEMS PROGRAMME

Crack statistics Different load histories


Field

IEA INTERNATIONAL ENERGY AGENCY PHOTOVOLTAIC POWER SYSTEMS PROGRAMME

Measurement in the field


574 PV modules (multi cryst.) with FL method
Exemplary image, not the analyzed field

Exemplary image, not analyzed field M. Kntges, S. Kajari-Schrder, I. Kunze, SOPHIA Workshop PV Module Reliability, May 4-3 2012, Lago di Lugano (Switzerland)

4CO.11.4

IEA INTERNATIONAL ENERGY AGENCY PHOTOVOLTAIC POWER SYSTEMS PROGRAMME

Lateral crack distribution


Noise reduction utilizing symmetries
Dendritic

PV modules show non-homogeneous crack distribution Distribution correlates with strain distribution of 1st eigenmode Tensile strain promotes crack growth Parallel to busbar more often than tensile strain suggests

IEA INTERNATIONAL ENERGY AGENCY PHOTOVOLTAIC POWER SYSTEMS PROGRAMME

Crack statistics Different load histories


Uniform mechanical load

IEA INTERNATIONAL ENERGY AGENCY PHOTOVOLTAIC POWER SYSTEMS PROGRAMME

Uniform mechanical load


Flash/EL

27 PV modules 60 cells (15.6 cm)


Multi & mono crystalline cells From various manufacturers Inflict cracks to cells in PV module by mechanical load test 5400 Pa Determine crack distribution in EL image analysis

Mechanical load test 5400 Pa

Flash/EL

S. Kajari-Schrder, I. Kunze, U. Eitner, M. Kntges, Sol. Energy Mater. Sol. Cells (2011),doi: 10.1016/j.solmat.2011.06.032

IEA INTERNATIONAL ENERGY AGENCY PHOTOVOLTAIC POWER SYSTEMS PROGRAMME

Lateral crack distribution


Noise reduction utilizing symmetries
Cracked cells [%]
R/C

Dentritic cracks [%] Dendritic 3 44 53 40 4 38 46 35 5 36 46 43


R/C

Serveral directions [%] 4 2 6 6 5 3 10 10


R/C

1 59 27 31

2 37 52 31

1 5 9 11

2 1 9 4

3 2 6 8

1 6 5 8

2 2 9 6

3 3 10 14

4 3 4 6

5 1 1 11

Cells per module: Number of modules:

60 27

1 2 3

1 2 3

1 2 3

Cracked cells per module[ %]: 41,2 Cracked cells per module[#]: 24,7

Parallel to Busbar [%]


R/C

Perpendicular to Busbar [%] 4 32 33 22 5 32 33 21


R/C

45 cracks [%] 5 0 0 0
R/C

Simulation pressure 5400 Pa 3 4 6 11 4 0 3 1 5 0 1 0


R/C

1 0 1 4

2 19 18 12

3 35 30 15

1 0 1 6

2 0 0 0

3 0 0 0

4 0 0 0

1 48 10 1

2 15 16 5

1 2 3

1 2 3

1 2 3

1 2 3

PV modules show non homogenous crack distribution Distribution correlates with strain distribution of load simulation 45 crack in corners is higher than expected Tensile strain promotes crack growth

IEA INTERNATIONAL ENERGY AGENCY PHOTOVOLTAIC POWER SYSTEMS PROGRAMME

Crack statistics Different load histories


Comparison

IEA INTERNATIONAL ENERGY AGENCY PHOTOVOLTAIC POWER SYSTEMS PROGRAMME

Different load histories compared


Relative amount of cracked cells:
Busbars in: long direction short direction long direction

Transport: 5.74 %
Field: 4.15 % Uniform: 41.2 % Cracks are ubiquitous

Dendritic cracks more dominant in artificial crack initiation


Cracks perpendicular to busbars are rare
Transport
Dendritic

Field

Uniform mec. load

IEA INTERNATIONAL ENERGY AGENCY PHOTOVOLTAIC POWER SYSTEMS PROGRAMME

Risk of cell part separation in artificial aging

IEA INTERNATIONAL ENERGY AGENCY PHOTOVOLTAIC POWER SYSTEMS PROGRAMME

Separated cell area


Definition of the potentially separated cell area: Area that is limited by a crack or the border of the cell and that has no functional metal finger to the busbar

Crack

Different crack orientations have different worst case separated cell areas different potential impact on module power output

IEA INTERNATIONAL ENERGY AGENCY PHOTOVOLTAIC POWER SYSTEMS PROGRAMME

Experimental
Power Measurement Electroluminescence Mechanical load test (5400 Pa) Power Measurement Electroluminescence 200 humidity freeze cycles Power Measurement Electroluminescence PV modules with 60 15.6x15.6 cm mono & multi crystalline cells

Initiation of cracks into the cells in the PV


modules with mechanical load test (IEC 61215)

Stressing of the cells by 200 humidity


freeze cycles (similar to IEC 61215)

IEA INTERNATIONAL ENERGY AGENCY PHOTOVOLTAIC POWER SYSTEMS PROGRAMME

Potentially separated cell area all crack orientations

30 % of the cracked cells


show less than 8 % potentially separated cell area Low risk for power losses 11 % of the cracked cells show more than 25 % potentially separated cell area High risk for power losses

IEA INTERNATIONAL ENERGY AGENCY PHOTOVOLTAIC POWER SYSTEMS PROGRAMME

Crack orientation dependence

IEA INTERNATIONAL ENERGY AGENCY PHOTOVOLTAIC POWER SYSTEMS PROGRAMME

Crack orientation dependence

Cracks parallel to the busbars


shows peak between 16 24 % potentially separated cell area Diagonally cracked cells mostly have lower potentially separated cell areas

IEA INTERNATIONAL ENERGY AGENCY PHOTOVOLTAIC POWER SYSTEMS PROGRAMME

Experimental
Power Measurement Electroluminescence Mechanical load test (5400 Pa) Power Measurement Electroluminescence 200 humidity freeze cycles Power Measurement Electroluminescence PV modules with 60 15.6x15.6 cm mono & multi crystalline cells

Initiation of cracks into the cells in the PV


modules with mechanical load test (IEC 61215)

Stressing of the cells by 200 humidity


freeze cycles (similar to IEC 61215)

IEA INTERNATIONAL ENERGY AGENCY PHOTOVOLTAIC POWER SYSTEMS PROGRAMME

Crack type definition


EL Image @ Isc EL Image @ 1/10 Isc

A No resistance across crack B Degraded, still connected, but increased resistance C Isolated, inactive cell area

IEA INTERNATIONAL ENERGY AGENCY PHOTOVOLTAIC POWER SYSTEMS PROGRAMME

Isolated cell area after artificial aging


C

Correlation of potentially separated cell area due to crack orientation and electrically isolated cell area after aging 7 % of the cracked cells develop isolated cell parts Isolated cell area of up to 17 %

isolated

IEA INTERNATIONAL ENERGY AGENCY PHOTOVOLTAIC POWER SYSTEMS PROGRAMME

Degraded cell area after artificial aging


B

Correlation of potentially separated cell area due to crack orientation and electrically degraded cell area after aging 29 % of the cracked cells degrade in artificial aging Degraded cell areas of up to 34 %

IEA INTERNATIONAL ENERGY AGENCY PHOTOVOLTAIC POWER SYSTEMS PROGRAMME

Degraded cell area after artificial aging


Cracks partially not detected before aging

Correlation of potentially separated cell area due to crack orientation and electrically degraded cell area after aging 29 % of the cracked cells degrade in artificial aging Degraded cell areas of up to 34 %

IEA INTERNATIONAL ENERGY AGENCY PHOTOVOLTAIC POWER SYSTEMS PROGRAMME

Isolation and degradation of different crack orientations

Relative probability for electrically isolated cell area independent of crack orientation Cells with several crack orientations and cracks parallel to the busbars degrade most often

IEA INTERNATIONAL ENERGY AGENCY PHOTOVOLTAIC POWER SYSTEMS PROGRAMME

Summary
Cracks are ubiquitous Cracks distribution depends on load history Cracks parallel to the busbars are most frequent and can separate large cell areas 29 % of cracked cells degrade in aging
Funding was provided by the State of Lower Saxony and BMU under contract number 0325194C TASK13

IEA INTERNATIONAL ENERGY AGENCY PHOTOVOLTAIC POWER SYSTEMS PROGRAMME

Advanced technologies and materials for crystalline Si solar cells and modules

March 25 - 27, 2013 Hamelin, Germany

Scientific topics:

Junction formation Surface morphology and passivation Cleaning and etching Structuring and contact formation Silicon material Wafering and kerfless technologies Advanced characterization and simulation Process integration Module integration Reliability

Hosted by:

Sponsors:

www.siliconpv.com

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