Cited by 7Electronic Packaging and Soldering TechnologiesSilicon and Solar Cell TechnologiesSolar Thermal and Photovoltaic Systems

Effect of viscoelasticity of ethylene vinyl acetate encapsulants on photovoltaic module solder joint degradation due to thermomechanical fatigue

Open access
Zhu, Jiang, Owen-Bellini, Michael, Montiel-Chicharro, Daniel, Betts, Thomas R., Gottschalg, Ralph·2018·Japanese Journal of Applied Physics

Abstract

Abstract The solder joint degradation due to thermomechanical fatigue is investigated in this paper for photovoltaic (PV) mini-modules with ethylene vinyl acetate (EVA) of different viscoelastic properties. The mini-modules were laminated at different curing temperatures in order to obtain EVA encapsulation with different viscoelastic properties. The influence of viscoelasticity of EVA on the thermomechanical fatigue generated on solder joint is analyzed based on a two-dimensional (2D) finite-element model. Based on simulation of thermomechanical stresses accumulation, mini-modules with EVA cured at lower temperatures accumulated approximately 40% more stresses during the thermal cycle testing than mini-modules with optimal cured EVA. The tested mini-modules with EVA cured at lower temperature showed greater power degradation than the optimal cured mini-modules. An apparent increase in equivalent series resistance is the primary factor the power loss. A good correlation between the accumulated thermomechanical fatigue and the increase in equivalent series resistance is demonstrated with the tested samples.

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Registry

Crossref · 10.7567/jjap.57.08rg03

Cites

27 of 27 references verified0 citation errors · 0 not checkable

Statistics

Nothing to recompute.

Claims the paper makes

0 of 9 cited sources checked · 0 supported · 0 flagged

  • Findingown data

    A good correlation exists between accumulated thermomechanical fatigue and increase in equivalent series resistance in the tested samples.

    “A good correlation between the accumulated thermomechanical fatigue and the increase in equivalent series resistance is demonstrated with the tested samples.”
    • Also stated in: § 3.2 Correlation of thermomechanical fatigue accumulation and series resistance degradation Simulations of thermomechanical fatigue accumulation on solder bonds are carried out for L125, L135, L145 and L150 samples.Figure 4 shows both the accumulated damage and cycling temperature for L125 samples.It can be identified that the thermomechanical fatigue accumulated largely during ramping periods.This is characteristic of the behavior of the solder that is explained by the hyperbolic sine term in Anand's model.The damage accumulation is faster when temperature ramps up from 50 to 85°C, as 1) the solder resistance to deformation is smaller at higher temperature; 32) and 2) the loss factor tanδ increases with the increasing temperature, which leads to higher energy dissipation and increased displacement.The loss factor decreases, when temperature ramps down.As temperature ramps down below 0°C and approaches the lower dwell temperature at -40°C, EVA material passes through the glass transition and the loss factor becomes higher again and therefore increasing the strain imposed on solder bonds.This simulation can be applied to all samples including L125, L135, L145 and L150.With EVA of different viscoelastic properties as indicated by the loss factor shown in Fig. 2, according to simulations, the L125 samples see about 40% more accumulated damage than the L150 samples do.correlation between the equivalent series resistance and the estimated fatiguing can be established.Changes in slopes of I-V curves are evident from the I-V measurements as plotted in Fig. 5 for L125 and L150 samples, respectively.Clear changes in slopes at V OC can be observed for the L125 sample, but no changes for the L150 sample.With the comparison analysis of extracted diode model parameters presented in Ref. 3), the equivalent series resistances for all mini-modules over TC test are evaluated.The averaged values and standard deviations of the equivalent series resistance for L125, L135, L145 and L150 samples are plotted in Fig. 6 against TC testing cycles.The L125 samples saw early increases in equivalent R S , which is followed by the L135 and L145 samples.The equivalent R S of L150 samples remained stable after 1400 cycles.The degradation of equivalent R S for L125, L135 and L145 samples tend to stabilize after a fast increase.This could be due to the ageing of EVA and other components of the module and their properties, therefore, can change over the course of ageing. The increase of equivalent R S is observed over time as a result of solder bond degradation and a correlation between the changes in R S and the thermomechanical fatigue is established and plotted in Fig. 7 for the L125, L135, L145 and L150 samples, respectively.Considering the nonlinear behaviour of solder joints degradation and change of equivalent R S , which are basically determined by material properties, the damage of thermomechanical stresses on solder joints is estimated by a Coffin-Manson type equation, 34) as , with S the generated thermomechanical stress, A and m are the constants found through least square regression represent the nonlinear degradation behaviours.Three stages of the degradation can be identified: 1) Initial thermomechanical fatigue accumulation before the increase in R S .This means there is an induction or initiation phase before rapid degradation takes place on solder bonds.This can be the initiation of crack on solder bonds.2) Thermomechanical fatigue led deformation of solder joints results in fast increase in R S .This can be the crack growth.3) Stabilization of R S .The stabilization of R S is not clearly understood and further investigation is required.But it could be explained by the fact that material's resistance to deformation increases with deformation.32) Another factor may be the PV material ages during the test, which minimizes the influences of thermomechanical fatigue on solder joints as well.V (V) 0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 I (A) 0 0.5 1 1.5 2 2.5 3 3.5 4 4.5 5 L125 V (V) 0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 I (A) 0 0.5 1 1.5 2 2.5 3 3.5 4 4.5 5 L150 · plain
      “a correlation between the changes in R S and the thermomechanical fatigue is established and plotted in Fig. 7 for the L125, L135, L145 and L150 samples, respectively.”
    • Also stated in: § 4. Conclusions · boosted
      “the correlation between the accumulation of thermomechanical fatigue and the increase in the equivalent series resistance shows good agreement.”
    Quote in the paperSubstantial claim
  • Findingreasoning

    Displacement of cells and interconnect ribbons can introduce significantly different stresses on module solder joints, as observed in this work.

    “These cause displacement of cells and interconnect ribbons, which can introduce significantly different stresses on module solder joints as observed in this work.”
    Quote in the paperSubstantial claim
  • Findingown data

    Mini-modules with EVA cured at lower temperatures accumulated approximately 40% more thermomechanical stresses/damage during thermal cycle testing than mini-modules with optimally cured EVA.

    “Based on simulation of thermomechanical stresses accumulation, mini-modules with EVA cured at lower temperatures accumulated approximately 40% more stresses during the thermal cycle testing than mini-modules with optimal cured EVA.”
    • Also stated in: § 3.2 Correlation of thermomechanical fatigue accumulation and series resistance degradation Simulations of thermomechanical fatigue accumulation on solder bonds are carried out for L125, L135, L145 and L150 samples.Figure 4 shows both the accumulated damage and cycling temperature for L125 samples.It can be identified that the thermomechanical fatigue accumulated largely during ramping periods.This is characteristic of the behavior of the solder that is explained by the hyperbolic sine term in Anand's model.The damage accumulation is faster when temperature ramps up from 50 to 85°C, as 1) the solder resistance to deformation is smaller at higher temperature; 32) and 2) the loss factor tanδ increases with the increasing temperature, which leads to higher energy dissipation and increased displacement.The loss factor decreases, when temperature ramps down.As temperature ramps down below 0°C and approaches the lower dwell temperature at -40°C, EVA material passes through the glass transition and the loss factor becomes higher again and therefore increasing the strain imposed on solder bonds.This simulation can be applied to all samples including L125, L135, L145 and L150.With EVA of different viscoelastic properties as indicated by the loss factor shown in Fig. 2, according to simulations, the L125 samples see about 40% more accumulated damage than the L150 samples do.correlation between the equivalent series resistance and the estimated fatiguing can be established.Changes in slopes of I-V curves are evident from the I-V measurements as plotted in Fig. 5 for L125 and L150 samples, respectively.Clear changes in slopes at V OC can be observed for the L125 sample, but no changes for the L150 sample.With the comparison analysis of extracted diode model parameters presented in Ref. 3), the equivalent series resistances for all mini-modules over TC test are evaluated.The averaged values and standard deviations of the equivalent series resistance for L125, L135, L145 and L150 samples are plotted in Fig. 6 against TC testing cycles.The L125 samples saw early increases in equivalent R S , which is followed by the L135 and L145 samples.The equivalent R S of L150 samples remained stable after 1400 cycles.The degradation of equivalent R S for L125, L135 and L145 samples tend to stabilize after a fast increase.This could be due to the ageing of EVA and other components of the module and their properties, therefore, can change over the course of ageing. The increase of equivalent R S is observed over time as a result of solder bond degradation and a correlation between the changes in R S and the thermomechanical fatigue is established and plotted in Fig. 7 for the L125, L135, L145 and L150 samples, respectively.Considering the nonlinear behaviour of solder joints degradation and change of equivalent R S , which are basically determined by material properties, the damage of thermomechanical stresses on solder joints is estimated by a Coffin-Manson type equation, 34) as , with S the generated thermomechanical stress, A and m are the constants found through least square regression represent the nonlinear degradation behaviours.Three stages of the degradation can be identified: 1) Initial thermomechanical fatigue accumulation before the increase in R S .This means there is an induction or initiation phase before rapid degradation takes place on solder bonds.This can be the initiation of crack on solder bonds.2) Thermomechanical fatigue led deformation of solder joints results in fast increase in R S .This can be the crack growth.3) Stabilization of R S .The stabilization of R S is not clearly understood and further investigation is required.But it could be explained by the fact that material's resistance to deformation increases with deformation.32) Another factor may be the PV material ages during the test, which minimizes the influences of thermomechanical fatigue on solder joints as well.V (V) 0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 I (A) 0 0.5 1 1.5 2 2.5 3 3.5 4 4.5 5 L125 V (V) 0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 I (A) 0 0.5 1 1.5 2 2.5 3 3.5 4 4.5 5 L150 · hedged
      “according to simulations, the L125 samples see about 40% more accumulated damage than the L150 samples do.”
    Quote in the paperSubstantial claim
  • Findingown data

    Tested mini-modules with EVA cured at lower temperature showed greater power degradation than optimally cured mini-modules.

    “The tested mini-modules with EVA cured at lower temperature showed greater power degradation than the optimal cured mini-modules.”
    • Also stated in: § 3.1 Degradation of performance parameters · plain
      “The mini-modules with EVA of high tanδ values, which would exhibit more significant displacement during TC test, showed greater degradation.”
    Quote in the paperSubstantial claim
  • Findingnone given

    Different curing temperatures result in different viscoelastic behaviour of EVA.

    “Different curing temperatures result in different viscoelastic behaviour of EVA.”
    Quote in the paperSubstantial claim
  • Borderline: one of the tests for a substantial claim is unclear. 1
  • May combine two claims. 9
  • Classified as probably not a substantial claim. 5
  • Borderline on S1 (asserted), S3 (load-bearing), S4 (based): unclear from the text.

    Findingnone given

    Thermomechanical fatigue accumulated largely during ramping periods.

    “It can be identified that the thermomechanical fatigue accumulated largely during ramping periods.”
    Quote in the paperNot a substantial claim
  • May combine two claims.

    Findingown data

    Clear changes in slopes at VOC can be observed for the L125 sample, but no changes for the L150 sample.

    “Clear changes in slopes at V OC can be observed for the L125 sample, but no changes for the L150 sample.”
    Quote in the paperSubstantial claim
  • May combine two claims.

    Findingown data

    The L145 and L150 samples experienced less than 3% degradation after 400 cycles and degraded 13% and 6%, respectively, after 1400 cycles.

    “The L145 and L150 samples showed good performance and experienced less than 3% degradation after 400 cycles and degraded 13% and 6%, respectively, after 1400 cycles.”
    Quote in the paperSubstantial claim
  • May combine two claims.

    Findingown data

    The L135 samples experienced around 8% degradation after 400 cycles and about 30% power loss after 1400 cycles.

    “This is followed by the L135 samples, which experienced around 8% degradation after 400 cycles and then degraded faster afterwards and saw power losses about 30% after 1400 cycles.”
    Quote in the paperSubstantial claim
  • May combine two claims.

    Findingown data

    The L125 samples saw the largest PMPP degradation of more than 20% after 400 cycles and about 30% after 1400 cycles.

    “The mini-modules with EVA cured at 125°C (referred to in the following as L125 samples, the same as for L135, L145 and L150 samples) saw the largest P MPP degradation of more than 20% after 400 cycles and about 30% after 1400 cycles.”
    Quote in the paperSubstantial claim
  • Classified as probably not a substantial claim.

    Premisecitation

    The rate of solder fatiguing in different environments is not fully understood because it depends on factors such as thermomechanical properties of materials, stress levels, and material response.

    “The rate of solder fatiguing in different environments is not fully understood as it depends on a variety of factors, such as thermomechanical properties of the various materials in a PV module as well as the detailed stress levels and the material response to these particular stress levels.[25][26][27][28]”
    Quote in the paperSubstantial claim0 of 3 sources checked
    • cites [25] Osterwald

      Couldn’t be matched to a paper in Crossref, so it can’t be checked.

    • cites [26] Wohlgemuth source
    • cites [27] Herrmann, 2010, Proc. SPIE source
  • Classified as probably not a substantial claim.

    Premisecitation

    A study on the influence of different types of encapsulants on PV module solder joints demonstrates distinct difference in thermomechanical behavior for different encapsulants.

    “However, a study on the influence of different types of encapsulants on PV module solder joints is carried out in Ref. 30), which demonstrates distinct difference in thermomechanical behavior for different encapsulants.”
    Quote in the paperSubstantial claim0 of 1 sources checked
    • cites [30] Owen-Bellini, 2018, IEEE J. Photovoltaics source
  • Classified as probably not a substantial claim. May combine two claims.

    Premisecitation

    The encapsulant's role in thermomechanical fatigue generation is not clear, and its contribution to damage on solder bonds is rarely reported.

    “It is, however, not clear its role in thermomechanical fatigue generation.Its contribution to damage on the solder bonds is rarely reported as its influence is not as critical as other components'.29)”
    Quote in the paperSubstantial claim0 of 1 sources checked
    • cites [29] Bosco, 2016, IEEE J. Photovoltaics source
  • Probably not a substantial claim: may not pass S3 (load-bearing).

    Premisecitation

    PV module solder joint failure is a common failure mechanism widely observed in the field.

    “PV module solder joint failure is a common failure mechanism that is widely observed in the field.[18][19][20][21][22][23][24]”
    Quote in the paperNot a substantial claim0 of 3 sources checked
    • cites [18] Suzuki, 2018, Jpn. J. Appl. Phys. source
    • cites [19] Jordan, 2017, Prog. Photovoltaics source
    • cites [20] Jordan source
  • Probably not a substantial claim: may not pass S3 (load-bearing).

    Premisecitation

    The material parameters for 60Sn40Pb solder alloy are well-defined in the literature.

    “These material parameters for 60Sn40Pb solder alloy are well-defined in the literature 33) and are given in Table I below.”
    Quote in the paperNot a substantial claim0 of 1 sources checked
    • cites [33] Cheng, 2000, Soldering Surf. Mount Technol. source
  • May combine two claims.

    Interpretationown data

    The degradation of power of different mini-modules appears to be due to FF losses, and shows similar curved pattern as the increase in series resistance.

    “The degradation of power of different mini-modules appears to be due to FF losses, and shows similar curved pattern as the increase in series resistance.”
    Quote in the paperSubstantial claim
  • May combine two claims.

    Interpretationreasoning

    The loss factor tanδ increases with increasing temperature, leading to higher energy dissipation and increased displacement.

    “the loss factor tanδ increases with the increasing temperature, which leads to higher energy dissipation and increased displacement.”
    Quote in the paperSubstantial claim
  • May combine two claims.

    Interpretationreasoning

    As temperature ramps down below 0°C and approaches -40°C, EVA passes through the glass transition and the loss factor becomes higher again, increasing the strain imposed on solder bonds.

    “As temperature ramps down below 0°C and approaches the lower dwell temperature at -40°C, EVA material passes through the glass transition and the loss factor becomes higher again and therefore increasing the strain imposed on solder bonds.”
    Quote in the paperSubstantial claim
  • May combine two claims.

    Interpretationreasoning

    Samples cured at 125°C exhibit more significant displacement within the module assembly than the other samples, i.e. they are more elastic.

    “This indicates that samples cured at 125°C exhibit more significant displacement within the module assembly than the other samples, i.e. they are more elastic.”
    Quote in the paperSubstantial claim
14 of 14
  • The authors state this as an assumption.

    Thermomechanical fatigue generated during thermal cycle testing leads to ageing of solder bonds, which increases the equivalent series resistance.

    “The thermomechanical fatigue generated during TC test leads to ageing of solder bonds, which increases the equivalent series resistance (R S ).Based on this assumption, a”
    “Based on this assumption of thermomechanical fatiguing leading to series resistance degradation, the correlation between the accumulation of thermomechanical fatigue and the increase in the equivalent series resistance shows good agreement.”
1 of 1

Cites

Flagged first, then by citations

Research works printed but not linked: 1

  1. Coffin, 1954, Trans. ASME, 76, 931

Cited by

Sorted by citations

Authors
Zhu, J., Owen-Bellini, M., Montiel-Chicharro, D., Betts, T. R., & Gottschalg, R.
Affiliations
Loughborough University (GB)
Corresponding author
Zhu, Jiang
Venue
Japanese Journal of Applied Physics
Published
2018-07-03
Volume
57
Issue
8S3
Pages
08RG03
ISSN
  • 0021-4922 (ISSN-L)
  • 1347-4065
OpenAlex
W2810021027
Cited by
7
References
27
Citations by year
2024: 2 · 2023: 1 · 2022: 2 · 2021: 1 · 2020: 1
FWCI
0.19
Type
journal article
Language
en
Open access
Locations
  • Japanese Journal of Applied Physics (publishedVersion)
  • Loughborough University Institutional Repository (Loughborough University) (submittedVersion, cc-by-nc-nd)
Topics
  • Physical Sciences › Engineering › Electrical and Electronic Engineering › Electronic Packaging and Soldering Technologies
  • Physical Sciences › Engineering › Electrical and Electronic Engineering › Silicon and Solar Cell Technologies
  • Physical Sciences › Energy › Renewable Energy, Sustainability and the Environment › Solar Thermal and Photovoltaic Systems
Keywords
ethylene vinyl acetate, EVA encapsulation, solder joint degradation, thermomechanical fatigue, viscoelasticity, curing temperature, equivalent series resistance, power degradation, finite element analysis

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