28.09.

2011

Gel content & Peel test

Benjamin Lippke, Romain Pnidon
PI Photovoltaik-Institut Berlin AG
Photovoltaic module technology
Testing | Consulting | Research
 Overview
EVA gel content
Chemical and technical basics
Problems in the production
Testing of the gel-content and curing of
the EVA
Some results of the PI gel-content testing

Peel test
Problems with the adhesion
Testing procedure
Results

Summary
Motivation

The right curing is necessary to ensure the optical and mechanical

properties which are stated in the datasheets.
Excess curing chemicals might damage the module
The right curing ensures an optimal adhesion between the different layers
A lack of curing might result in delamination of the module
The right curing also provides barrier properties for different diffusion
processes.

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 EVA Chemical basics

EVA or ethylene vinyl-acetate is a simple and common

polymer

The producer of the films buys the bulk material and adds a
number of chemicals e.g.:
Curing system (peroxides)
Ethylene Vinyl-Acetat
UV- absorber
Antioxidants
The film producer forms the film and might modify the
surface chemically and/or physically

Under the heat of the laminator the peroxides decompose

and the EVA forms new links between the polymers.

The process is called curing. The gel-content or curing level

describes the amount of linked polymers. During the
extraction the non linked polymers are solved and removed
from the linked polymers
Arkema, mechanism of crosslinking
A 100% cured sample would be one big polymer
 Lamination process

In the Laminator the EVA film melts and

the curing system starts reacting.

The thermoplast becomes an

elastomere. The EVA is now cured.

Gelcontent over Curingtime

1
0,9
0,8
0,7
Gel-Content [ ]

0,6
0,5
Gelcontent
0,4
0,3
0,2
0,1
0
5 10 15 20 25 30 35 40
Curing Time [min]

For the curing, a combination of peak temperature, time and curing

agents mainly determines the result

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 Quality problems with the EVA and lamination
process
Evaporation of the curing agent before curing

Due to wrong storage or mistakes on

producer-side there is not enough curing
agent left for the curing process.

In order to achieve process optimization and

increase the production, insufficient curing
time or / and too low temperature might be
selected.

Not uniformly cured, deviation of curing level

at different points of the module

Bad EVA delivered by the supplier

Not evenly distributed process chemicals in

the EVA film

Bad heat flow due to warping of the module in

the laminator
 Gel-content testing

Sampling of the EVA

The module is cut open and EVA samples are taken

out of the module. The PI Berlin takes at least two
samples at different positions: corner and middle.

Extraction

The sample are cut into pieces and are extracted in a

solvent

The solvent is heated and a rises in the extractor.

After a certain time the apparatus is cooled and the
solvent drips back into the reservoir. This cycle gets
repeated

The solvent solves the uncured EVA and leaves the

rest in the filter.
Some results from the PI gel-content testing

1. 65% of the samples have gel-

content greater than 67%

2. 20% of the samples have a

gelcontent greater than 50% and
less than 67%

3. 13% of the samples have a gel-

content greater than 20% and less
than 50%

4. 2% of the samples have a gel-

content less than 20%
 Peel test different layers

The backsheet protects the PV- module, from moisture ingression and other
environmental factors
The backsheet provides the necessary electrical insulation
The backsheet itself has 2 to 4 layers of different polymers which have to stick together
The EVA seals the whole module, protects the cell and provides mechanical load
balance
The glass provides the mechanical stability.

1: Glas
3 2: EVA
2
3: Cell with paste
1 4: backsheet
 Problems with the adhesion

Reasons for bad adhesion e.g.

Remaining dirt/process chemicals on the

surfaces

Wrong Primer for the surface

Storage problems, e.g. too warm too long

Wrong washing or not enough washing of

the glass

Incompatible materials e.g. backsheet and Strong glass adhesion, bad

EVA
cell adhesion
Problems in the lamination process

Wrong process parameters

 Peel test

Top: peel in Progress, right top: stripes,

right middle: details; Right bottom: peeling
 Measurements - Results

In the studies and testing made by the PI Berlin internal

guidelines were set:
EVA - cell ca. 4N/cm
EVA - glass ca. 50N/cm
EVA - busbar ca. 40N/cm
EVA - backsheet ca. 15N/cm
For different suppliers and components the values might
Top: very good
deviate
adhesion to the cell

Left: Sample graph

produced by the peel
test
 Summary and notes

Gel-content and peel test are an addition to the IEC testing.

The module is a complex system with many surfaces which need the proper
adhesion. Failure of one bond might reduce the lifetime of the whole module.

Peel test and gel-content test are complementary. It is possible to have good
adhesion and no gel-content and vice versa.

The tests can give an insight in the quality of the module production and give hints
for possible lifetime reduction.

During the test preparation sometimes quality issues can be seen which are
normally invisible: e.g. falling apart of the backsheet or strong local deviation of the
results.

Due to a vast number of different products and lack of standards it is complicated to

give a strict set of rules. The PI Berlin determined a set of values which it considers
minimum for acceptance. In certain cases the values can deviate form that set of
rules.
 Questions and comments
Thank you for your attention
If you have questions or comments feel free to ask them:
lippke@pi-berlin.com
penidon@pi-berlin.com
hanusch@pi-berlin.com

Upon request we can sent you an info sheet describing the tests in more detail, for
further reading please also have a look at our publications (www.pi-berlin.com).

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