Channel cracking fragmentation testing and attenuated total reflectance Fourier transform infrared (ATR-FTIR) spectroscopy were utilized to study mechanical and chemical degradation of a multilayered backsheet after outdoor and accelerated laboratory aging. A model sample of commercial PPE backsheet, namely polyethylene terephthalate/polyethylene terephthalate/ethylene vinyl acetate (PET/PET/EVA) was investigated. Outdoor aging was performed in Gaithersburg, Maryland, USA for up to 510 days, and complementary accelerated laboratory aging was conducted on the NIST (National Institute of Standards and Technology) SPHERE (Simulated Photodegradation via High Energy Radiant Exposure). Fracture energy, mode I stress intensity factor and film strength were analyzed using an analytical model based on channel cracking fragmentation testing results. The correlation between mechanical and chemical degradation was discussed for both outdoor and accelerated laboratory aging. The results of this work provide preliminary understanding on failure mechanism of backsheets after weathering, laying the groundwork for linking outdoor and indoor accelerated laboratory testing for multilayer photovoltaic backsheets.
Polymeric multilayer backsheets protect the photovoltaic modules from damage of moisture and ultraviolet (UV) while providing electrical insulation. Due to the multilayer structures, the properties of the inner layers of the backsheets, including their interfaces, during weathering are not well known. In this study, a commercial type of PPE (polyethylene terephthalate (PET)/PET/ethylene vinyl acetate (EVA)) backsheet films was selected as a model system for a depth profiling study of mechanical properties of a backsheet film during UV exposure. The NIST SPHERE (Simulated Photodegradation via High Energy Radiant Exposure) was used for the accelerated laboratory exposure of the materials with UV at 85°C and two relative humidities (RH) of 5 % (dry) and 60 % (humid). Cryomicrotomy was used to obtain cross-sectional PPE samples. Mechanical depth profiling of the cross-sections of aged and unaged samples was conducted by nanoindentation, and a peak-force based quantitative nanomechanical atomic force microscopy (QNM-AFM) mapping techniquewas used to investigate the microstructure and adhesion properties of the adhesive tie layers. The nanoindentation results show the stiffening of the elastic modulus in the PET outer and pigmented EVA layers. From QNM-AFM, the microstructures and adhesion properties of the adhesive layers between PET outer and core layers and between PET core and EVA inner layers are revealed and found to degrade significantly after aging under humidity environment. The results from mechanical depth profiling of the PPE backsheet are further related to the previous chemical depth profiling of the same material, providing new insights into the effects of accelerated UV and humidity on the degradation of multilayer backsheet.
The channel crack and delamination phenomena that occurred during tensile tests were utilized to study surface cracking
and delamination properties of a multilayered backsheet. A model sample of commercial PPE (polyethylene
terephthalate (PET)/PET/ethylene vinyl acetate (EVA)) backsheet was studied. Fragmentation testing was performed
after accelerated aging with and without ultraviolet (UV) irradiation in two relative humidity (RH) levels (5 % RH and
60 % RH) at elevated temperature (85 °C) conditions for 11 days and 22 days. Results suggest that the embrittled surface
layer resulting from the UV photo-degradation is responsible for surface cracking when the strain applied on the sample
is far below the yielding strain (2.2 %) of the PPE sample. There was no surface cracking observed on the un-aged
sample and samples aged without UV irradiation. According to the fragmentation testing results, the calculated fracture
toughness (KIC) values of the embrittled surface layer are as low as 0.027 MPa·m1/2 to 0.104 MPa·m1/2, depending on the
humidity levels and aging times. Surface analysis using attenuated total reflectance Fourier transform infrared and
atomic force microscopy shows the degradation mechanism of the embrittled surface layer is a combination of the photodegradation
within a certain degradation depth and the moisture erosion effect depending on the moisture levels.
Specifically, UV irradiation provides a chemical degradation effect while moisture plays a synergistic effect on surface
erosion, which influences surface roughness after aging. Finally, there was no delamination observed during tensile
testing in this study, suggesting the surface cracking problem is more significant than the delamination for the PPE
backsheet material and conditions tested here.
Polymeric multilayer backsheets provide protection for the backside of photovoltaic (PV) module from the damage of moisture and ultraviolet (UV). Due to the nature of multilayer films, certain material property characterization of a backsheet could only be studied by examining its cross-section parallel to the thickness direction of the film. In this study, commercial PPE (polyethylene terephthalate (PET)/PET/ethylene vinyl acetate (EVA)) backsheet films were aged on the NIST (National Institute of Standards and Technology) SPHERE (Simulated Photodegradation via High Energy Radiant Exposure) with UV irradiance at 170 W/m2 (300 nm to 400 nm) under accelerated weathering conditions of 85°C and two relative humidity (R.H.) levels of 5% (low) and 60% (high). Cryo-microtomy was used to obtain cross-sectional PPE samples with a flat surface parallel to the thickness direction, and chemical depth profiling of multilayers was conducted by Raman microscopic mapping. Atomic force microscopy with peak force tapping mode was used complementarily for cross-sectional imaging. The results revealed that the PPE backsheet films were comprised of five main layers, including pigmented-PET, core PET, inner EVA, pigmented-EVA and outer EVA, along with their interfacial regions and two adhesive layers. UV and moisture degradation on the outer pigmented PET layer was clearly observed; while the damage on the core PET layer was less significance, indicating that the outer pigmented PET layer effectively reduced the damage from UV. In high R.H. exposure, both adhesive layers were severely deteriorated. It was found that the EVA layers were susceptible to moisture at elevated temperature, especially for the pigmented-EVA. Based on the results of accelerated weathering, this depth profiling study brings new understanding to the mechanisms of failure observed in polymeric multilayer backsheets during field exposure.
Linking accelerated laboratory test to field performance for predicting the service life of polymeric materials are being investigated at NIST using the reliability-based methodology. Based on this methodology, a successful linkage between the laboratory and field exposure data for a model polymeric material has been made. Recently, this methodology, for the first time, was introduced to the lifetime assessment of PV polymeric materials. In this paper, a mechanistic study of the degradation of three unstabilized model ethylene vinyl acetate (EVA) systems---uncured EVA, cured EVA and laminated EVA---was carried out under accelerated laboratory exposure and outdoor exposure. The NIST SPHERE (Simulated Photodegradation via High Energy Radiant Exposure) was used for the accelerated laboratory tests, and the outdoor exposure was conducted in Gaithersburg, Maryland. Simultaneous multiple stresses, including temperature, relative humidity and UV radiation, were applied individually or in combination during SPHERE exposure. The effects of the environmental factors on the main degradation mechanisms of different EVA systems were investigated. The results showed that the UV radiation was the most important factor for the degradation of EVA and a synergistic effect occurred between UV radiation and relative humidity. A slower degradation rate was observed for the laminated system as a result of limited diffusion of O2 and H2O into EVA. It was also found that the substantial chemical changes of the uncured EVA system did not yield yellowing, which was dramatically different from the peroxide cured EVA system. Additionally, the chemical degradation modes of the three EVA systems exposed outdoors appeared to be similar to those exposed to the SPHERE. The implication of this work to the current test standards was discussed.
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