Jan 20 2010
As solar module manufacturers strive to realize cost structures meeting grid parity, Saflex®, a unit of Solutia Inc. (NYSE: SOA), recently announced the commercial availability of a new thin gauge polyvinyl butyral (PVB) based encapsulant designed specifically for photovoltaic applications. The new product, Saflex PA41, significantly reduces encapsulant usage while maintaining module durability and processing performance. The global launch of Saflex PA41 comes shortly after successful completion of IEC 61646 certification testing on thin film photovoltaic modules manufactured with the Saflex encapsulant.
"We developed a robust PVB-based encapsulant that passed a rigorous reliability and durability test program including tests that went beyond standard industry testing. Module manufacturers can continue producing high quality photovoltaic modules with significantly reduced encapsulation usage," reports Matt Rose, Saflex Market Development Manager. "For over 80 years, Saflex has driven PVB-based product and process advancements in the automotive and architectural markets. We're now leveraging that expertise to develop innovative solutions for photovoltaic applications," continues Rose.
Saflex's PA41 is a second generation photovoltaic product designed specifically to reduce encapsulant thickness by 33% (from 1.14mm to 0.76mm). To accomplish this, properties of the Saflex PA41 formulation were optimized to improve encapsulating flow around bus bars and other critical components. "A primary objective throughout the development process was to ensure that a thin gauge encapsulant could provide the same performance and long term durability of thicker gauge encapsulants while maintaining high encapsulation yields," comments Francois Koran, Saflex Photovoltaic Development Manager.
In addition to the successful IEC and UL testing, Saflex developed a rigorous testing regimen which included a series of natural and accelerated weathering tests that go beyond photovoltaic industry standards. Saflex also partnered with module manufacturers to confirm that handling, processing and throughput of Saflex PA41 met or exceeded expectations compared to thicker gauge PVB encapsulations. To that end, Saflex provided on-site education and trial processing guidance to fine-tune the encapsulation process and ensure that high yields were realized. "With eight decades of experience in manufacturing PVB products for glazing applications, we understand that testing, education, and technical support are as critical as producing a high quality product," said Matt Rose.