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Cell cracks in PV modules can lead to electrically separated cell area fractions after artificial aging
For 230W module with 60 cells: separated cell area fraction of 8% or more leads to significant reduction of module power
Crack classification
no crack dendritic several directions +45 -45 parallel to busbar perpend. to busbar
Experimental as delivered
103 PV modules 60 cells (15.6 cm), multicrystalline From various manufacturers Max. 5 PV modules/package
Production
Transport
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
High breakage rate in center Moderate breakage rate near frame Low breakage rate in corners Symmetry to increase statistical significance
High breakage rate in center Moderate breakage rate near frame Low breakage rate in corners Symmetry to increase statistical significance
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
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
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
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
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
60 27
1 2 3
1 2 3
1 2 3
Cracked cells per module[ %]: 41,2 Cracked cells per module[#]: 24,7
45 cracks [%] 5 0 0 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
Transport: 5.74 %
Field: 4.15 % Uniform: 41.2 % Cracks are ubiquitous
Field
Crack
Different crack orientations have different worst case separated cell areas different potential impact on module power output
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
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
A No resistance across crack B Degraded, still connected, but increased resistance C Isolated, inactive cell area
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
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 %
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 %
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
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
Advanced technologies and materials for crystalline Si solar cells and modules
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
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