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The lifetime of industrial polymer products is in many cases limited by aging. Therefore, it is necessary to develop a fast and sensitive method to detect polymer aging at an early stage. A commercially available 50-µm-thick and transparent polyethylene terephtalate (PET) film was aged under different artificial conditions, and the evolution of mechanical properties with increasing aging time was investigated via nanoindentation (NI) and tensile testing. Chemical aging was studied with gel permeation chromatography (GPC), and physical aging was monitored by the first heating of differential scanning calorimetry. NI data evaluated with the method of Oliver and Pharr was compared to tensile test data with good agreement between the results on the macro- and nanoscales. Furthermore, a correlation between NI creep data and GPC data was obtained, which indicates that the aging of the PET films primarily originated from chemical aging. This study states that NI is an appropriate method to determine degradation of PET at an early stage.

A comprehensive understanding of failure modes of solar photovoltaic (PV) modules is key to extending their operational lifetime in the field. In this review, first, specific failure modes associated with mature PV technologies, such as crystalline silicon (c-Si), copper indium gallium selenide (CIGS) and cadmium telluride (CdTe), are framed by sources of specific failure modes, their development from the early-developmental stages onwards and their impact upon long term performance of PV modules. These failure modes are sorted by both PV technology and location of occurrence in PV modules, such as substrate, encapsulant, front and rear electrode, absorber and interlayers. The second part of the review is focused on emerging PV technologies, such as perovskites solar cells, dye sensitised and organic PVs, where due to their low to medium technology readiness levels, specific long-term degradation mechanisms have not fully emerged, and most mechanisms are only partially understood. However, an in-depth summary of the known stability challenges associated with each emerging PV technology is presented. Finally, in this paper, lessons learned from mature PV technologies are reviewed, and considerations are given in to how these might be applied to the further development of emerging technologies. Namely, any emerging PV technology must eventually pass industry-standard qualification tests, while warranties for the lifetime of modern c-Si-based modules might be extended beyond the existing warranted life of 25 years.

This work covers a lifecycle assessment of monolayer and multilayer films to quantify the environmental impacts of changing the management of plastic film waste. This lifecycle assessment offers the possibility of quantifying the environmental impacts of processes along the lifecycle of monolayer and multilayer films and mapping deviating impacts due to changed process parameters. Based on the status quo, the changes in global warming potential and abiotic fossil resource depletion were calculated in different scenarios. The changes included collecting, sorting, and recycling mono- and multilayer films. The “Functional Unit” under consideration comprised 1000 kg of plastic film waste, generated as post-consumer waste in Austria and captured in the lightweight packaging collection system. The results showed the reduction of environmental impacts over product lifecycles by improving waste management and creating a circular economy. Recycling all plastic film reduced global warming potential by 90% and abiotic fossil resource consumption by 93%. The necessary optimisation steps to meet the politically required recycling rates by 2025 and 2030 could be estimated, and the caused environmental impacts are presented. This work shows the need for increased collection, recycling, and significant improvement in the sorting of films to minimise global warming potential and resource consumption.

Delamination is one of the most critical failure modes of a PV module during service lifetime. Delamination within a backsheet primarily imposes a safety risk, but may also accelerate various other PV module degradation modes. The main aim of this paper is to present a peel test set-up, which is more practical in sample preparation and execution than the width-tapered cantilever beam test and overcomes some issues of standard peel tests like the influence of sample geometry and energy dissipation through deformation on the peel test results. The best results with respect to accuracy and effort were achieved by using a 180° peel geometry where an additional adhesive tape is applied to the peel arm in order to avoid plastic deformation or breakage. The additional support of the adhesive tape leads to comparable peel strength values without any influence of the plastic deformation behavior of the peel arms with different thickness.

A better understanding of moisture ingress in photovoltaic modules is crucial for better predictions of their long-term behavior in the field. Current calculations and simulations of moisture uptake in photovoltaic modules are based on the Fickian diffusion model in a homogeneous material. In this article, in situ humidity measurements in four different encapsulants exposed to transient humidity conditions are compared with Fickian simulations. It is found that the model cannot accurately describe the measured moisture ingress and egress curves. Thus, a new model for finite-element simulations based on two transport mechanisms is applied. The mesh is split into two regions, where channels with a high diffusion coefficient lead through a bulk with a low diffusion coefficient. The diffusion in both regions as well as the flow between them is simulated as Fickian. The new model is able to predict the measured ingress and egress curves more accurately than the Fickian model in all four encapsulants. The same simulation parameters can accurately describe ingress for various relative humidity values between 20% and 80%, as well as egress from 40% to 20%. This allows further prediction of moisture ingress after the measurement of a single ingress curve and a corresponding parameter optimization. However, a nonlinearity of the diffusion during egress at higher moisture values in the encapsulants is found.

During their outdoor service, photovoltaic (PV) modules are exposed to different set of external stresses that can affect their efficiency and lifetime such as UV irradiation, temperature and humidity cycles, rain, snow and wind loads, hail, sand and/or salt. Moreover, internal stresses such as choice of materials and design (additives, morphology and compatibility of materials) can drive degradation of PV modules as well. The failure data collection started already in 1980s and is still ongoing. Most of these studies are focused mainly on power data or categorizing PV failure modes concerning solely climate, EVA or cell-technology. However, relationship between climate, degradation of polymeric materials and degradation of PV modules has not been reported so far. Hence, within this study a lot of effort was put into finding the appropriate data and publications with as many as possible data on PV, climate and materials degradation. As a result, a great overview of climate and polymeric materials induced PV failure modes is given. Based on the reported data, the topic of new, climate-based design of PV modules is discussed. This paper provides numerous number of selected references that can be beneficial in further studies on degradation of PV modules, design of PV modules and choice of materials.

The main focus of this work is to investigate the degradation behavior of two newly developed encapsulants for photovoltaic applications (thermoplastic polyolefin (TPO) and polyolefin elastomer (POE)), compared to the most widely used Ethylene Vinyl Acetate (EVA) upon exposure to two different artificial ageing tests (with and without ultraviolet (UV) irradiation). Additive composition, optical and thermal properties and chemical structure (investigated by means of Thermal Desorption Gas Chromatography coupled to Mass Spectrometry, UV-Visible-Near Infrared spectroscopy, Differential Scanning Calorimetry, Thermogravimetric Analysis and Fourier Transform-Infrared spectroscopy, respectively) of the analyzed polymers were monitored throughout the exposure to artificial ageing tests. Relevant signs of photo-oxidation were detectable for TPO after the UV test, as well as a depletion of material&rsquo, s stabilizers. Signs of degradation for EVA and POE were detected when the UV dose applied was equal to 200 kW h m&minus, 2. A novel approach is presented to derive information of oxidation induction time/dose from thermogravimetric measurements that correlate well with results obtained by using oxidation indices.

Instrumented nanoindentation (NI) was used to examine the viscoelastic properties of poly(methyl methacrylate) (PMMA) as an amorphous polymer model. An evaluation combining adhesive contact and empiric spring–dashpot models has been applied to obtain the instantaneous elastic modulus E 0 and the infinitely elastic modulus E ∞ from nanoindentation creep curves. The value of E 0 has been compared to moduli obtained with atomic force microscopy-based nanoindentation (AFM-NI) and compression tests. Furthermore, the elastic modulus has been evaluated by the method introduced by Oliver and Pharr ( O & P ) for the NI and AFM-NI results. Comparison of the elastic modulus E 0 from the creep measurements of NI and AFM-NI to compression tests reveals good agreement of the results. However, only the O & P based AFM-NI results yield to lower values.

This paper describes the production of a high-performance composite with a bio-based carbon content of 100 %. The material is based on epoxidized linseed oil (cured by crystalline citric acid) and flax fiber reinforcement and manufactured via hand layup followed by vacuum bagging. Specific focus is on evaluating the effect of fiber moisture on the thermoset's chemical structure and the overall composite's morphology and mechanical characteristics. Pre-drying of the fibers is shown to be essential in order to maximize the composite's performance. The inherent fiber moisture content (∼8 wt.%) adversely affects the resin's curing reaction and moreover causes a significant porosity within the composite (resulting from water vaporization and hindered consistent impregnation).

To contribute to the targeted 10 million tons per year of recycled plastic in Europe by 2025 and to improve the mechanical sorting degree of polyethylene (PE) products, density prediction models were developed from Fourier transform infrared-attenuated total reflectance (FTIR-ATR) and Raman spectroscopic data. State-of-the-art sorting in mechanical recycling provides separated polymer classes, however an improved classification with specific chemical and physical features such as density or melt flow rate has not been developed yet. Applying multivariate data analysis (MVDA) on the spectral datasets of 10 different PE materials, one FTIR-ATR and two Raman spectra based partial least square (PLS) density models were developed. However, whereas all three models are applicable to predict PE density accurately, the Raman models have shown some advantages. Firstly, less principle components (PC) are needed and secondly the density can be assessed with higher accuracy, due to the more robust cross-validated PLS model. Moreover, the obtained PC-s indicate that in the FTIR-ATR model the CH3/CH2 ratio, while in the Raman model the CH2, CH and the crystalline C–C bands can be correlated with the PE density. The most accurate PLS model was obtained from the 1500-1000 cm−1 Raman shift region. The developed models could improve the density based mechanical separation of PE and consequently increase the quality of recycled and reprocessed PE products.

Acetic acid, which is formed during degradation of the most frequently used photovoltaic (PV) encapsulant ethylene vinyl acetate (EVA), is linked to several PV module failure mechanisms like corrosion of interconnectors, cells or potential induced degradation (PID). An evaluation of a new measurement technique and data analysis for acetic acid permeation through photovoltaic backsheet films is described. The influence of the layer composition of the multilayer backsheets on the acetic acid permeation rates (AATR) was determined by investigating the permeation properties of the individual layers as well as the whole polymeric multilayer composites. Various polymeric backsheet types based on PET-core layers showing a very high barrier for acetic acid permeation were compared to fully polyamide material stacks which allow for a much higher transmission of acetic acid through the backsheet out of the module. Incorporated Al-layers were found to not affect the AATRs of PET based backsheets.

Due to the general price pressure PV modules experienced in the last decade, a variety of alternative polymer materials and new backsheet designs were developed and introduced into the market, amongst others also extruded backsheets based on polypropylene (PP). The production of co-extruded films represents a backward integration of backsheet manufacturers, allowing for easy material and design modifications regarding additive formulation, fillers and geometry. The main objective of this paper was to describe the influence of the special properties of PP-based backsheets on the performance and reliability of PV modules. The higher reflectance of the PP backsheet compared to a reference polyester (PET) based laminate led to an increase in power output between 1.5 and 2.5%. Test modules using PP and PET backsheets were exposed to 3000 h of damp heat testing. No changes in power output for either of the test modules was observed. However, the selective permeation properties of PP backsheets prevent humidity from entering the module (similarly to PET based backsheets) but allow for significantly higher diffusion of acetic acid out of the PV module. Therefore, in contrast to test modules using Ethylene Vinyl Acetate (EVA) encapsulants and PET backsheets, no silver grid corrosion was observed for modules using PP backsheets. Co-extruded backsheets based on PP show great potential to be a valid replacement of standard PET based backsheets in PV modules. On the one hand, the PP backsheet so far proved excellent stability, exhibiting no severe material degradation after extended exposure to temperature, humidity and irradiation. On the other hand, its improved functional properties (optical properties; selective permeability) lead to increased performance and improved long-term stability of the tested PV modules.

The influence of the ethylene-vinyl acetate (EVA) film quality on potential induced degradation was studied on in-house developed mini modules with p -type monocrystalline silicon solar cells. The modules were assembled with EVA films of equivalent qualities, but different ages and exposed to an accelerated test (relative humidity = 85%, T = 60 °C, Vbias = +1000 V). The age of the EVA film was determined from the time we received the EVA film, and opened the sealed enclosure and the time of lamination. After the EVA film was removed from the sealed enclosure, it was kept in a dark place at room temperature. The storage times of the “fresh,” “aged,” and “expired” films were: less than 14 d, around 5 mo, and more than 5 years, respectively. While modules with a “fresh” EVA film exhibit almost no degradation, the modules with the “aged” EVA film degrade very rapidly and severely. Their degradation rate was around 0.2%/d during the 2000 h of damp heat test. We also observed a strong silver line corrosion, which occurs because of the peroxide leftovers in the “aged” EVA films.

The object of this paper is to determine the thermal expansion behavior of nine different encapsulants in order to identify possible deficiencies in production processes and allow for the optimization of the process parameters. High dimensional stability of the encapsulant is of great importance in photovoltaic (PV) module production to avoid problems during lamination and/or in application. For this purpose, the samples were heated twice in a thermo-mechanical analyzer (TMA) in tensile mode, and the coefficient of thermal expansion (CTE) over temperature was evaluated. To get additional information about transition temperatures of the encapsulants, differential scanning calorimetry (DSC) measurements were made. The TMA results for most samples showed anisotropic behavior which was eliminated after the first heating run. Three samples showed shrinkage with subsequent increased thermal expansion as well as anisotropic behavior. It could be shown that knowing the thermal expansion behavior of the solar cell encapsulants is highly relevant for the PV module lamination process, and Thermo-Mechanical Analysis proved to be a suitable method to evaluate and also for quality control of solar cell encapsulation films.

In order to characterize the damping behavior of thin passively constrained layer damping (CLD) loudspeaker membranes, usually the whole loudspeaker has to be built. Therefore, a method was established to characterize the damping performance of these membranes with thicknesses below 50 μm at the film level using dynamic mechanical analysis (DMA). Since in the CLD design damping is provided via shear deformation of the middle damping layer, a test was set up to determine the mechanical loss factor tan δ (f,T) in DMA shear mode. Subsequently, results from 1-200 Hz were extrapolated to application-relevant frequencies of up to 1000 Hz via time-temperature superposition. Finally, the damping behavior was rated by the frequency dependent integrated average of the mechanical loss factor t A ¯ . Furthermore, in experiments with different constraining and damping layers, it was found that the damping performance was maintained as long as the adhesion between them was sufficiently strong.

An 80-membered library of gels composed of monofunctional 2-ethyl-2-oxazoline and 2-nonyl-2-oxazoline and one of four selected difunctional 2-oxazolines (containing either ether or ester bonds) were synthesized by microwave-assisted ring-opening polymerizations. The difunctional 2-oxazolines were prepared from the thiol-ene reaction of glycol dimercaptoacetate or 2,2′-(ethylenedioxy)diethanethiol and 2-but-3′-enyl-2-oxazoline or 2-dec-9′-enyl-2-oxazoline. 53 of the gels exhibited glass-transition temperatures, which ranged from −5.9 to 45.3 °C. 13 Derivatives exhibited glass-transition temperatures in the range from 20 to 30 °C, which renders them stiff at room temperature and flexible at body temperature. The gels that did not contain any 2-ethyl-2-oxazoline acted as lipogels, whereas the gels that did not contain any 2-nonyl-2-oxazoline acted as hydrogels; all other gels may be classified as amphigels. The swelling degrees were measured by gravimetry and maximum swelling degrees of 6 (in water) were observed for the gels with the lowest degrees of crosslinking. In a second approach, the synthesis of crosslinked networks had been achieved by performing the polymeranalogous thiol-ene reaction of copoly(2-oxazoline)s containing olefinic side-chains and glycol dimercaptoacetate. This soft strategy enabled the straightforward loading of such gels with active pharmaceutical ingredients without altering them. This method delivered gels with selected composition exhibiting a targeted disc-shape and loaded with active pharmaceutical ingredients from one-step syntheses. The maximum swelling degrees of these specimens were found to be in accordance with the ones from the first route investigated. Preliminary degradation studies were performed at 25 °C; these types of gels were found to be degraded in alkaline media as well as by esterases.

The weathering stability of polymeric backsheets is very important for the reliability of photovoltaic (PV) modules. In addition to reliability, cost reduction and sustainability are upcoming challenges the PV backsheet industry is facing with. The most commonly used material for PV backsheets is poly(ethylene-terephthalate)-PET. However, PET is in general very sensitive to hydrolysis, which leads to chain scission and causes embrittlement, cracking, delamination, and dimensional instability of the backsheet. Compared to that newly developed modified polyolefin backsheets have favorable selective permeation properties and high mechanical flexibility, which could be key properties for backsheets in terms of higher PV module reliability. In this work, the weathering stability of PET/fluoropolymer backsheet and an alternative coextruded polyolefin-backsheet was investigated in terms of thermal and mechanical stability. Both materials were artificially aged and the changes caused by aging were investigated. The polyester-based backsheet showed embrittlement and reduced elongation at break for 70%. The polyolefin-based backsheet retained its mechanical flexibility even after 2000 h of aging under damp-heat conditions, with no significant physical or chemical aging processes occurring. The comparison of the results of both backsheets suggests that the polyolefin backsheet is a promising candidate for the reduction of cracks and delamination in the field

A total of 16 analytical methods, spanning from classical solvent extraction over different thermo-analytic and mechanical approaches to acoustic and optical spectroscopy, have been evaluated as to their ability to determine the crosslinking state of ethylene vinyl acetate (EVA), the prevailing encapsulant for photovoltaics applications. The key objective of this work was to create a systematic and comprehensive comparison, using a unified set of traceable test samples covering the full range of realistically occurring degrees of EVA crosslinking. A majority number of these tested methods proved fundamentally suitable for detecting changes in the polymer properties during crosslinking based on the effect e.g. its mechanical properties or its crystallinity. Interestingly, when investigated in detail, most of the methods showed mutually different dependencies on the lamination time, indicating a complex range of effects of the chemical crosslinking on the properties and behaviour of the material. Furthermore, Raman spectroscopy could be identified as a potential new method for measuring the degree of crosslinking in-line in the PV module manufacturing process, thus providing an interesting approach for improving process control in PV module processing.

In the project ‘NEW-MINE’ the use of sensor-based sorting machinery in the field of ‘landfill mining’ is investigated. Defilements pose a particular challenge in the treatment and sorting of plastics contained in landfills. For this reason, the effects of various pollutants caused by the interactions in the landfill body or the mechanical treatment steps in landfill mining are examined. In the following elaboration, the focus is on the influences of surface moisture and surface roughness of plastics on sensor-based sorting by means of near-infrared technology. Near-infrared radiation (NIR) in a wavelength range of 990 nm to 1500 nm has been used for the detection and classification of plastic particles. The experiments demonstrate that increased surface roughness reduces signal noise and thereby improves the classification of both spectrally similar and transparent plastics, but reduces the yield of low-softening plastics because their sliding speed on a sensor-based chute sorter varies as a result of the heating of the chute. Surface moisture causes the absorption of radiation from 1115 nm (high density polyethylene [HDPE], linear low density polyethylene [LLDPE], polyethylen terephthalate [PET] and polyvinylchloride [PVC]) or from 1230 nm (low density polyethylene [LDPE], polypropylene [PP] and thermoplastic polyurethane [TPU]) up to at least 1680 nm, which causes amplification or attenuation of various extremes in the derivative. However, the influence of surface moisture on the yield of plastics is usually very low and depends on the spectral differences between the different plastics.

The power degradation and failure of photovoltaic (PV) modules can be caused by changes in the mechanical properties of the polymeric components during the module lifetime. This paper introduces instrumented nanoindentation as a method to investigate the mechanical properties of module materials such as polymeric encapsulants. To this end, nanoindentation tests were carried out on ethylene vinyl acetate (EVA) surfaces, which have been separated from the glass panel. Two types of time-dependent indentation cycle modes, the time domain (creep mode) and frequency domain (dynamic mode) were performed to determine the viscoelastic behavior. For each mode, a corresponding model was applied to calculate the main mechanical properties. The general capability of nanoindentation as cross-linking determination method is investigated with the methodological advantages over bulk mechanical characterization methods. A large number of Glass/EVA/Backsheet laminates were built using different lamination conditions resulting in different degrees of curing. Both indentation modes indicate good modulus sensitivity for following the EVA crosslinking in its early stages but could not reliably differentiate between samples with higher EVA branching. Additional dynamic mechanical analysis (DMA) characterization was used as an established method to validate the indentation measurements. Both nanoindentation and DMA tensile mode produce similar quantitative viscoelastic responses, in the form of the damping factor parameter, demonstrated for three different frequencies at room temperature. A statistical study of the data reveals the advantages for the investigation of multilayer PV laminates by using nanoindenation as a surface method while also being applicable to field aged modules.