CASE STUDY ON THE INCIDENCE AND PATTERNS OF GLASS CRACKS IN LARGE-AREA BIFACIAL SILICON GLASS-GLASS PHOTOVOLTAIC MODULES

Abstract

This case study details a phenomenon of spontaneous cracks, the origin of which remains unknown, manifesting in bifacial monocrystalline silicon modules during a Research and Development project at the Photovoltaic Laboratory– UFSC, located in Florianópolis/SC – Brazil. The modules in question, with a power output of 645 Wp and dimensions of 2400 x 1300 x 33 mm, weight of 38 kg, and an area of 3 m², feature both sides coated with 2 mm semi-tempered glass. The project was conceived as a 100 kWp photovoltaic plant composed of 158 modules, aiming to analyze the performance of next-generation bifacial and thin-film modules under various albedo conditions and extreme temperature, irradiance, and soiling conditions. The objective was to evaluate the performance of these systems and seek to maximize photovoltaic generation. However, during the project, it became necessary to establish a specific research focus to analyze the cracks that emerged in the modules, seeking to comprehend the phenomenon, its relevance to the broader technology context, and its impacts on the safety and performance of photovoltaic systems. The subsequent study covered the crack occurrence rate, patterns of formats, number of branches, incidence on constructional aspects, and other relevant criteria. Although inconclusive, the results propose considerations regarding the tests currently employed for certifications, as well as reflections on the quality tests of inputs used in module manufacturing and the rapid implementation of innovative technologies, emphasizing the necessary caution in the face of technological innovations.