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DuPont Photovoltaic Solutions DuPont

Latest developments in thin-

film encapsulant technology

August 18, 2011

J. I. Kim

Regional Technical Services Leader


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Materials Cost Impact on PV Cells & Modules

Crystalline Silicon Thin Film

SiliconMetal(51%)

Bill of Materials

MetallizationPastes (12%)

Backsheet Film (8%)

Front Glass (6%)Encap Film (6%)

Junction Box (5%)

Other Matls (12%)

TCO FrontGlass (29%)

Module Frame (25%)

Glass or Backsheet (13%)

Gases & Targets (11%)

Encapsulant Film (7%)

Junction Box (6%)

Reflector Paint (4%)

Conductive Ribbon (1%)

Other Materials (4%)

With encapsulants at only 6-7% of module cost, the largest cost impact comes from choosingthe optimal encapsulant to enable overall system cost reductions


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Examples of Required Encapsulant Attributes

Durability

25 years no delamination

Cell efficiency over life of module

Meets operating temperature requirements

Low System Cost

Compatibility with Top Coat Material

Low Moisture Permeability

Protect the Cell from Corrosion

High Resistivity = Low Current Leakage

Safety requirement

Important in maintaining cell efficiency overlifetime

Ease of Processing with High Thru-put

Autoclave

Vacuum laminator

No Lamination Defects

No bubblesEase of Handling

Encapsulant Requirements for Thin Film Glass/ Glass Modules


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PVB

Encapsulant Materials*

PolyolefinProperty

Resistivity

Moisture Ingress

UV Durability

High Modulus

Low Modulus

Thermoplastic

Transmittance

Flow Properties

Impact

Electrical Insulation

Cell degradation

Yellowing/Degradation

Laminate strength

Internal Stress Relief

Yield, rework

Module Energy Output

Works with multiplelamination technologies

EVA Ionomer

Relative Performance of Encapsulantsin Thin Film, Glass/Glass Modules

*Colors based on published data or DuPont Internal Testing Poor Best

Performance Spectrum


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BOS

Back End

Front End

DPVS Technology Roadmap - Thin Film Rigid

2009 2010 2011 2012

PV 5200 Encapsulant Optimized PVB based films for glass-glass modules.

PV 5300 Encapsulant High strength/low permeability films for reduced system costs.

Functionalized Encapsulants Higher reflectivity PVB & ionomer systems for efficiency gains.

Up to$0.20/W

Module Installation

Integrated material solutions for total installed system cost reduction.

> $0.8/W cost reduction target

Up to

$0.45/W

Up to$0.20/W

Savings

Advanced TCO Layers New oxide systems with better cost-performance.

Front Glass Enhancements Materials and processes to improve light trapping, self cleaning.

Back End Process improvement Optimized encapsulant & lamination processes.


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Enabling Materials Reduced LCOE via:Innovation

Materials Innovations Contribute to Lower Costs

Reflective

EncapsulantFilms

ModuleCostEncapsulants

Thin high reflective encapsulant

DuPont PV5223 0250100encapsulant films introducedto market in April 2010

50% higher reflectivity

Paint elimination lowercost, process simplification

40% encapsulant thicknessreduction

0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

0.9

1

350 450 550 650 750 850 950 1050

Wavelength, nm

Reflectance

PV5223 - 0250100

White paint


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Wider Lamination processing window & lower material

consumption

White reflective DuPont PV5223 -0250100 encapsulant sheet is textured foreasy de-airing in Oerlikon Solar's multi-stack

laminating process.

At 0.45-mm thickness, new DuPontPV5223 0250100 white PVBencapsulant sheet is more than 40%

lighter-weight than traditional 0.76-mmclear PVB.


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ThermoplasticIonomer Films


Lower moisture ingress

DuPont Ionomer film wasintroduced to market in 2009

Unique properties are idealfor glass-glass PV modules

Cost savings of $3/panel byelimination of edge sealing

PV modules moisture ingress after 2000hr DH

0.00

0.05

0.10

0.15

0.20

0.25

0.30

0.35

0.40

0.45

0 2 4 6 8 10 12 14 16 18 20

Distance from Edge (cm)

%M

oisture

EVA

Ionomer



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Ionomers have Excellent Solar Transmission

Total Solar Transmission

80.0

82.0

84.0

86.0

88.0

90.0

92.0

94.0

300 400 500 600 700 800 900 1000 1100 1200

Wavelength (nm)

%T

33% VA EVA

28% VA EVA

Ionomer A

Ionomer B


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Ionomer FilmsBOSCost

Encapsulants,Thin Glass

Stronger laminates

Reduced weight can reduceBOS costs

Impermeable barrier formoisture sensitivetechnologies

Laminate life well

demonstrated in PV andarchitectural use

DuPont PV5300 Ionomertougher (5x) and stiffer(100x) vs. PVB

Thin float glass0.3mm to 1.1mm

Glass-like durabilityWith polymer-like

weight



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Bending Data clearly shows the strength of

Ionomer/Glass laminates

The bending test showed the high strength of ionomer-glass laminates

0000

50505050

10 010 010 010 0

15 015 015 015 0

20 020 020 020 0

25 025 025 025 0

-2 0-2 0-2 0-20 -10-1 0-1 0-10 0000 10101010 20202020 30303030 40404040 5050505 0 60606060

Glass/Ionomer/Glass Glass/EVA/Glass Glass/PVB/Glass

EVA

PVB

Temperature (deg.C)

BreakageLoad(N)

Fig. Shimadzu Autograph (AG-X)1kN load cell, 3 point bending, Sample : 15*90*t3.0mm

142N

65N

51N

Test resultsTest results Bending testBending test

(PV5300)

The bending test showed the high strength of ionomer-glass laminates

0000

50505050

10 010 010 010 0

15 015 015 015 0

20 020 020 020 0

25 025 025 025 0

-2 0-2 0-2 0-20 -10-1 0-1 0-10 0000 10101010 20202020 30303030 40404040 5050505 0 60606060

Glass/Ionomer/Glass Glass/EVA/Glass Glass/PVB/Glass

EVA

PVB

Temperature (deg.C)

BreakageLoad(N)

Fig. Shimadzu Autograph (AG-X)1kN load cell, 3 point bending, Sample : 15*90*t3.0mm

142N

65N

51N

Test resultsTest results Bending testBending test

(PV5300)


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ModifiedIonomer Films


Faster lamination cycle DuPont PV8600* modified

ionomer will be availableoutside Japan in 2011

Designed for modules withbacksheet construction

Laminates faster than EVA

Brings capital cost savings in

laminators and/or curing ovens


*available in Japan as DuPont PV8600 Himilan ES Encapsulant Series

Standard cure type

EVA

Fast cure type

EVA

PV8600

125 x 5min150 x 16min150 x 6minLamination

Used mainlyoutside Japan

Standard processNon cure processShorter Laminationtime

Remarks

150 x 60minCure process

Standard cure type

EVA

Fast cure type

EVA

PV8600

125 x 5min150 x 16min150 x 6minLamination

Used mainlyoutside Japan

Standard processNon cure processShorter Laminationtime

Remarks

150 x 60minCure process

We are recommending 150 3min 5min as a lamination

condition to our customers.

DuPont PV8600 Lamination Performance


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Other benefits include improved moisture resistance

and excellent corrosion resistance

Data above is measured with no

backsheet.Damp Heat testing of DuPont

PV8600 in contact with silver couponsshows no change after 1000hrs

DuPont PV8600 - Moisture barrier @ high temp.

0000

50505050

100100100100

150150150150

200200200200

250250250250

300300300300

350350350350

Moisuture

Permeability

Moisuture

Permeability

Moisuture

Permeability

Moisuture

Permeability

(

(

((gggg////mmmm2222mmmmmmmmday

day

day

day))))

40*90%RH40*90%RH40*90%RH40*90%RH 60*90%RH60*90%RH60*90%RH60*90%RH 85*90%RH85*90%RH85*90%RH85*90%RH

PV8600PV8600PV8600PV8600 EVAEVAEVAEVA

No changeInter connector

No changeAg Plate

No changeMo substrate

PV8600

No changeInter connector

No changeAg Plate

No changeMo substrate

PV8600

Test condition 85*90%RH*1000h

Metal plate

Structure: Glass/ PV8600/Metal plates/PV8600/Glas

DuPont PV8600 - Corrosion


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High VA EVA EfficiencyEncapsulants

More transparent encapsulant

Measurable increase in poweroutput with higher VA%

DuPont Elvax resins have

demonstrated performanceover 30 years

Individual sheet performance

can vary with formulation usedby sheet producer



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Power Gain variation with VA%*

*Constant formulation other than VA%

33% VA EVA demonstrates 0.6% additional power output


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DuPontTM PV5200 series (PVB sheet) based on Butacite

DuPontTM PV5300 series (Ionomer sheet) based on SentryGlas

DuPont PV8600 series (Modified Ionomer sheet)

DuPontTM Elvax PV1000 series (EVA Resin)- sold into PV market for 30 years

Pipeline of new innovative encapsulants

DuPont currently offers four Encapsulant solutions

Developed bythe leader inthe glassindustry withover 60 yearsof innovation

Developedby MDP JV


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PVB

Encapsulant Materials

PolyolefinProperty

Resistivity

Moisture Ingress

UV Durability

High Modulus

Low Modulus

Thermoplastic

Transmittance

Flow Properties

Impact

Electrical Insulation

Cell degradation

Yellowing/Degradation

Laminate strength

Internal Stress Relief

Yield, rework

Module Energy Output

Works with multiplelamination technologies

EVA Ionomer

Relative Performance of Encapsulantsin Thin Film, Glass/Glass Modules

Colors based on ublished data or DuPont Internal Testin

Encapsulant choice can enable or optimize manyaspects of module design and performance.

There is no single encapsulant solution thatmeets all needs

Module design, the manufacturing process andend-use applications may require very differentencapsulant properties


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Copyright 2011 DuPont. All rights reserved. The

DuPont Oval Logo, DuPont, The miracles of science,

energy for a thriving world, and all products denoted

with or are registered trademarks or trademarks ofE.I. du Pont de Nemours and Company or its affiliates.

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