Fast quality testing of high barrier films with inorganic barrier layer

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1 Fast quality testing of high barrier films with inorganic barrier layer Dr. Stefan-H. Schulze, Christian Ehrich, Matthias Pander, Dr. Sven Henning Fraunhofer Center for Silicon Photovoltaics CSP Otto-Eissfeldt Str Halle (Saale), Germany Phone: Mail:

2 Fraunhofer Center for Silicon Photovoltaics founded in 2007 as a joint venture of Fraunhofer ISE and Fraunhofer IWM Halle Heads of Center Prof. Dr. Jörg Bagdahn Prof. Dr. Peter Dold Institute Building 68 researchers + students and guests Budget 2014: 7 Mio. Fraunhofer CSP sites: Weinberg Campus Halle Module Technology Center (Dow ValuePark, Schkopau) Module Technology Center Schkopau

3 Fraunhofer Center for Silicon Photovoltaics Dr. Christian Hagendorf Dr. Roland Kunert Prof. Dr. Peter Dold

4 Solar Module Technologies Brief Overview Crystalline silicon photovoltaics (flexible) thin film photovoltaics

5 Encapsulation Materials for PV-Applications Overview Source: Market study: The global market for polymers in photovoltaics; AMI consulting (October 2012)

6 Encapsulation Materials for PV-Applications Overview Source: Market study: The global market for polymers in photovoltaics; AMI consulting (October 2012)

7 Encapsulation Materials for PV-Applications Overview Source: Market study: The global market for polymers in photovoltaics; AMI consulting (October 2012)

8 High Barrier Films for Flexible Photovoltaics Problem Requirements to front encapsulaion materials in flexible thin film PV: WVTR <10-5 g/m²/d High light transmittance Ageing resistance Solution: inorganic interlayer as barrier (SiO x, AlO x ) Problems: Brittleness of these layers and need for fast and reliable quality control (foil processing in roll-to-roll process) Classical tests (WVTR) are too slow and not sensitive enough as a fast method for quality control issues Which maximum elongations may be applied to such a foil or the module itself before the brittle barrier layer fails?

9 High Barrier Films for Flexible Photovoltaics Problem

10 High Barrier Films for Flexible Photovoltaics Mechanical Loading

11 elongation [%] High Barrier Films for Flexible Photovoltaics Mechanical Loading when Barrier Foil is Winded roll diameter [mm] Local elongation increases with decreasing roll diameter

12 elongation [%] High Barrier Films for Flexible Photovoltaics Mechanical Loading when Module is Winded roll diameter [mm] Black: elastic deformation front barrier foil Red: plastic deformation back sheet

13 High Barrier Front Films for Flexible Photovoltaics Materials and Methods SEM picture of high barrier film cross section Design of high barrier film 1 ETFE front side 2 brittle SiO x layer 3 PET inner layer Loading regime of foil samples Sample size 200x200 mm Tensile loading in machine direction and perpendicular Elongation 1/2/4/6 % Permeation measurements Permeation measurement with He and H 2 O vapor Measurements at 23 C

14 High Barrier Front Films for Flexible Photovoltaics Anisotropic Behaviour of Polymer Films undrawn drawn Foil extrusion and casting on a slit-die Re-organization of semicrystalline and amorphous phases during drawing process

15 High Barrier Front Films for Flexible Photovoltaics Tensile Test s e s e direction Youngs- Modulus Yield strain Yield stress Strain at rupture [MPa] [%] [MPa] [%] machine 2987 ± ± 11 across 2600 ± ± 7

16 High Barrier Front Films for Flexible Photovoltaics Permeation Measurement

17 High Barrier Front Films for Flexible Photovoltaics Permeation Measurement Equipment Parameters Temperature range climate chamber Sample surface Detection limits C 78,5 cm² < 1 ppm Quadrupol-mass spectrometer Helium flow ml/min N 2 flow 1 50 ml/min Stainless steel measuring cell

18 High Barrier Front Films for Flexible Photovoltaics Phases of Permeation Course of permeation: Van der Waals-forces, temperature

19 High Barrier Front Films for Flexible Photovoltaics Phases of Permeation Course of permeation: Henry s law solubility, partial pressure Van der Waals-Kräfte, Temperatur

20 High Barrier Front Films for Flexible Photovoltaics Phases of Permeation Course of permeation: Henry s law solubility, partial pressure Van der Waals-forces, temperature Fick s diffusion, concentration gradient

21 High Barrier Front Films for Flexible Photovoltaics Phases of Permeation Course of permeation: Henry s law solubility, partial pressure Van der Waals-forces, temperature Van der Waals-forces, temperature Fick s diffusion, concentration gradient

22 High Barrier Front Films for Flexible Photovoltaics He-Permeation Measurement on Strained ETFE-Film

23 High Barrier Front Films for Flexible Photovoltaics He-Permeation Measurement on Strained ETFE-Film adsorption, absorption, diffusion

24 High Barrier Front Films for Flexible Photovoltaics He-Permeation Measurement on Strained High-Barrier Film machine direction machine direction

25 High Barrier Front Films for Flexible Photovoltaics He-Permeation Measurement on Strained High-Barrier Film elongation (%) transmission perpendicular (ml/m²/d) transmission machine direction (ml/m²/d)

26 water transmission [g/m 2 /d] High Barrier Front Films for Flexible Photovoltaics WVTR Measurement on Strained High-Barrier Film MD TD MD TD MD-machine direction TD-transverse direction time [h]

27 High Barrier Front Films for Flexible Photovoltaics Influence of Film Deterioration on Module Performance Specific damage of front barrier films Lamination of mini-modules with thin film cells Application of 2000 h dampheat test ab 85 % rel. hum and 85 C

28 High Barrier Front Films for Flexible Photovoltaics Influence of Film Deterioration on Module Performance

29 Conclusion Elongation larger 2% is critical for maintaining high barrier effect when brittle high barrier film is applied He-permeation is appropriate as a fast and reliable method to characterize barrier deterioration H 2 O permeation measurements exhibit long measuring times Good correlation between foil deterioration and module performance under simulated weathering procedure

30 Acknowledgements grand no.: 03SF0389B

31 Thank you for your attention!

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