Encapsulation is a well-known impact factor on the durability of Photovoltaics (PV) modules. Currently there is a lack of understanding on the relationship between lamination process and module durability. In this paper, the effects of different lamination parameters on the encapsulant stability due to stress testing have been investigated from both on-site production quality and long-term stability viewpoints. Rather than focusing on single stability factors, this paper evaluates lamination stability using a number of indicators including EVA (ethylene-vinyl acetate copolymer) curing level, voids generation, chemical stability, optical stability, and adhesion strength. The influences of EVA curing level on the stability of other properties are also discussed. It is shown that laminates stability increases with increasing curing level to an upper limit, beyond which leading to the formation of voids, reduced transmittance stability, discoloration, and unstable interfaces. A minimum gel content is identified but an upper limit should not be surpassed. The best range of gel content for the materials tested here is 84-90%. Samples with gel content below 70% show low chemical and optical stability, weak adhesion strength, and EVA flowing. Laminates with gel content over 92% are more likely to become yellow and are less stable in adhesion.
Keywords: EVA; curing level; durability; encapsulation; lamination conditions; reliability.