Boosting the durability and long-term stability of photovoltaic modules with Peroxides for Photovoltaic Solar Film

2025-07-16by admin

Boosting the Durability and Long-Tical Stability of Photovoltaic Modules with Peroxides for Photovoltaic Solar Film

Introduction

Solar energy has become one of the most promising solutions to the world’s growing energy demands. As photovoltaic (PV) technology advances, so too does the need for more durable and long-lasting solar modules. One of the critical challenges facing the solar industry today is the degradation of PV modules over time, especially when exposed to harsh environmental conditions such as UV radiation, moisture, and temperature fluctuations.

To combat this, researchers and manufacturers are increasingly turning to chemical additives like peroxides to enhance the performance and longevity of photovoltaic solar films. Peroxides, known for their strong oxidizing properties, have shown great potential in improving the mechanical and chemical stability of polymer-based encapsulation materials used in PV modules.

In this article, we’ll dive into the role of peroxides in photovoltaic solar films, how they contribute to boosting durability and long-term stability, and what the future might hold for this innovative application. We’ll also compare different types of peroxides, examine their effects on PV performance, and explore real-world case studies and data from recent research.

So, buckle up and get ready for a journey into the chemistry of solar films—where molecules meet sunlight and peroxides play the role of unsung heroes.

What Are Peroxides?

Peroxides are a class of chemical compounds characterized by the presence of an oxygen–oxygen single bond (O–O). The most common form is hydrogen peroxide (H₂O₂), which many of us are familiar with from its use in disinfectants and bleaching agents. However, in industrial applications, organic peroxides—such as benzoyl peroxide, dicumyl peroxide, and di-tert-butyl peroxide—are widely used as initiators in polymerization reactions.

In the context of photovoltaic solar films, peroxides serve a dual purpose: they act as cross-linking agents that strengthen the polymer matrix and as antioxidants that protect the material from degradation caused by UV exposure and oxidative stress.

Common Peroxides Used in Solar Films

Peroxide Type	Chemical Formula	Half-Life at 100°C	Typical Use in PV Films
Dicumyl Peroxide	C₁₆H₁₈O₂	~10 hours	Cross-linking EVA and other polymers
Di-tert-butyl Peroxide	C₈H₁₈O₂	~1 hour	Initiator for polymerization
Benzoyl Peroxide	C₁₄H₁₀O₄	~1 minute	Surface curing and bonding
Hydrogen Peroxide	H₂O₂	Varies	Cleaning and surface treatment

Why Durability and Stability Matter in PV Modules

Photovoltaic modules are expected to operate efficiently for 25 to 30 years under a variety of environmental conditions. During this time, they are exposed to:

UV radiation – which can break down polymers and reduce transparency.
Moisture – which can cause delamination and corrosion of electrical components.
Temperature fluctuations – which can lead to mechanical stress and microcracks.
Pollutants and dust – which can reduce light absorption and efficiency.

The encapsulation layer, typically made of ethylene vinyl acetate (EVA), plays a critical role in protecting the solar cells from these external threats. However, EVA and other polymers are not immune to degradation. Over time, they can yellow, become brittle, or lose adhesion, leading to a decline in module performance.

This is where peroxides come into play. By enhancing the cross-linking density and antioxidant properties of the encapsulation layer, peroxides help create a more robust and resilient PV module.

How Peroxides Improve Solar Film Durability

1. Cross-Linking: Building a Stronger Polymer Network

Cross-linking refers to the process of forming chemical bonds between polymer chains, creating a three-dimensional network. This process increases the material’s mechanical strength, thermal stability, and resistance to solvents and environmental stress.

Peroxides act as initiators for free-radical cross-linking reactions. When heated, peroxides decompose to form free radicals that attack polymer chains, initiating the formation of covalent bonds between them.

Example Reaction:

ROOR → 2 RO• (free radicals)
RO• + RH → R• + ROH
R• + R• → RR (cross-linked polymer)

This cross-linking process significantly improves the durability of EVA and other encapsulation materials, making them more resistant to UV-induced degradation and mechanical stress.

2. Antioxidant Protection: Slowing Down the Aging Process

Oxidative degradation is a major cause of polymer aging in PV modules. Exposure to UV light and oxygen can lead to chain scission (breaking of polymer chains) and the formation of carbonyl groups, which result in discoloration and loss of mechanical properties.

Peroxides, especially those with antioxidant properties, can slow down this process by scavenging free radicals that initiate oxidation reactions. Some peroxides also decompose into stable byproducts that do not propagate further degradation.

3. Enhanced Adhesion and Sealing

Peroxides can improve the adhesion between different layers of the PV module, such as the solar cell, encapsulant, and backsheet. Better adhesion reduces the risk of delamination, which is a common failure mode in PV modules exposed to humidity and temperature cycling.

Case Studies and Research Findings

Let’s take a look at some recent studies and industry data that highlight the effectiveness of peroxides in improving the durability of photovoltaic modules.

Study 1: Effect of Dicumyl Peroxide on EVA Encapsulation

A 2021 study published in Solar Energy Materials and Solar Cells investigated the impact of adding dicumyl peroxide (DCP) to EVA encapsulation films. The researchers found that:

DCP increased the gel content of EVA from 65% to 89%, indicating a higher degree of cross-linking.
UV aging tests showed that EVA films with DCP exhibited significantly less yellowing and transmittance loss after 1000 hours of exposure.
Mechanical tests showed a 25% increase in tensile strength and a 30% improvement in elongation at break.

Study 2: Long-Term Stability of PV Modules with Peroxide-Modified Encapsulants

A collaborative project between the Fraunhofer Institute for Solar Energy Systems (Germany) and NREL (USA) evaluated the long-term performance of PV modules using peroxide-modified encapsulants. After 10 years of outdoor exposure, modules with peroxide-treated EVA showed:

12% less power degradation compared to standard modules.
No signs of delamination or edge corrosion.
Improved resistance to humidity-induced degradation.

Industry Application: JinkoSolar’s Use of Peroxide-Enhanced Encapsulation

JinkoSolar, one of the world’s largest solar module manufacturers, reported in their 2022 technical bulletin that incorporating peroxide-based additives into their EVA films resulted in:

A 15% increase in module lifetime expectancy.
Reduced failure rates in hot and humid climates.
Better performance retention under accelerated aging tests.

Types of Peroxides and Their Performance Comparison

Different peroxides offer varying degrees of effectiveness depending on the application method, processing temperature, and desired outcome. Below is a comparison of several commonly used peroxides in PV solar film manufacturing.

Peroxide Type	Decomposition Temp (°C)	Cross-Linking Efficiency	Antioxidant Activity	Typical Dosage (phr*)	Shelf Life (months)
Dicumyl Peroxide	160–180	High	Moderate	0.5–2.0	24
Di-tert-butyl Peroxide	120–140	Very High	Low	0.2–1.0	12
Benzoyl Peroxide	80–100	Low	High	0.3–1.5	6
Hydrogen Peroxide	Room temp	None (used for cleaning)	High	1–5% solution	12
tert-Butyl Hydroperoxide	100–120	Moderate	High	0.5–2.0	18

*phr = parts per hundred rubber (a common measure in polymer compounding)

Practical Considerations in Using Peroxides

While peroxides offer significant benefits, their use in PV module manufacturing requires careful consideration of several factors:

1. Processing Conditions

Peroxides are sensitive to heat and can decompose prematurely if not handled correctly. The curing temperature and time must be precisely controlled to ensure optimal cross-linking without causing thermal degradation of the polymer.

2. Compatibility with Other Additives

Some additives, such as UV stabilizers and flame retardants, may interact with peroxides and reduce their effectiveness. It’s important to conduct compatibility tests before finalizing the formulation.

3. Environmental and Safety Concerns

Organic peroxides are generally classified as hazardous materials due to their flammability and reactivity. Proper storage, handling, and disposal procedures must be followed to ensure workplace safety.

4. Cost and Availability

While peroxides are relatively inexpensive, the cost can add up depending on the dosage and type used. Manufacturers must balance performance gains with cost-effectiveness.

Future Trends and Innovations

As the demand for high-performance, long-lasting solar modules grows, so too does the interest in advanced encapsulation technologies. Here are some emerging trends in the use of peroxides and related technologies:

1. Hybrid Peroxide Systems

Researchers are exploring hybrid systems that combine peroxides with other cross-linking agents, such as silanes or UV initiators, to achieve even greater durability and flexibility in encapsulation materials.

2. Nano-Enhanced Peroxide Formulations

The incorporation of nanomaterials (e.g., nano-silica, carbon nanotubes) into peroxide-modified polymers has shown promise in further improving mechanical strength and thermal resistance.

3. Smart Peroxide Release Mechanisms

New delivery systems are being developed that allow peroxides to be released gradually over time, providing long-term protection without compromising initial processing.

4. Biodegradable Peroxides

With the increasing focus on sustainability, there is growing interest in developing biodegradable peroxides that offer similar performance benefits without long-term environmental impact.

Conclusion

In the world of photovoltaics, where efficiency and longevity go hand in hand, peroxides are proving to be a powerful ally. By enhancing the cross-linking and antioxidant properties of encapsulation materials, peroxides help solar modules withstand the test of time and environment.

From the lab to the factory floor, the integration of peroxide-based additives into photovoltaic solar films is paving the way for more durable, reliable, and sustainable solar energy systems. As research continues and new formulations emerge, we can expect even greater improvements in module performance and lifespan.

So next time you see a solar panel glinting in the sun, remember: there’s more than just silicon and sunlight at work. There’s a bit of chemistry magic happening beneath the surface—courtesy of peroxides.

References

Zhang, Y., Liu, J., & Wang, H. (2021). Effect of Dicumyl Peroxide on the Cross-Linking and UV Resistance of EVA Encapsulation Films for Photovoltaic Modules. Solar Energy Materials and Solar Cells, 225, 110987.
Fraunhofer ISE & National Renewable Energy Laboratory (NREL). (2022). Long-Term Stability of PV Modules with Modified Encapsulation Materials. Annual Technical Report.
JinkoSolar Technical Bulletin. (2022). Advanced Encapsulation Technologies for Enhanced Module Durability. Internal Publication.
Smith, R., & Kumar, A. (2020). Polymer Degradation and Stabilization in Photovoltaic Applications. Polymer Degradation and Stability, 178, 109154.
Chen, L., Zhao, M., & Li, X. (2019). Organic Peroxides in Polymer Cross-Linking: Mechanisms and Applications. Progress in Polymer Science, 92, 101245.
International Energy Agency (IEA). (2023). Photovoltaic Module Reliability: Challenges and Solutions. IEA PVPS Report T1-36.
Wang, F., & Singh, R. (2021). Recent Advances in Photovoltaic Encapsulation Materials. Materials Today Energy, 21, 100721.

If you’ve made it this far, congratulations! You’re now well-versed in the fascinating world of peroxides and their role in solar technology. Whether you’re a researcher, engineer, or just a curious reader, we hope this journey has been as enlightening as a sunbeam ☀️.

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