Forecasting Glass Resilience of Large-Format PV Modules

DuraMAT will assess the implications of large-format photovoltaic (PV) module designs on module resilience by establishing the necessary framework and tools to predict the probability of low-energy glass fracture and avoid glass breakage in future PV module designs.

The increasing size of large-format PV modules and their use of thinner glass have introduced challenges in module durability, particularly a rise in glass breakage incidents. Modern modules, 40%–60% larger than previous generations, often feature 2-mm heat-strengthened glass instead of fully tempered 3.2-mm glass, smaller frames, and, therefore, reduced structural rigidity. These design changes, coupled with nonideal mounting configurations and reductions in testing loads, have led to higher susceptibility to module glass breakage under operational conditions.

To address these issues, this study employs probabilistic fracture mechanics and experimental characterization of full-size modules. Static and dynamic mechanical load testing frameworks have been designed to evaluate the impacts of glass thickness, heat treatment, and module architecture on fracture risk. High-speed imaging is used to identify strength-limiting flaws and crack propagation dynamics. Additionally, dynamic mechanical testing is used to simulate real-world loading conditions, investigating the role of edge defects caused by frame/glass interactions. The findings aim to establish relationships between module design parameters and glass breakage probability, offering insights to improve module durability. This research highlights the need for better process control, quality assurance, and comprehensive testing to ensure the structural resilience of next-generation PV modules.