> Quick answer: Silicone-based liquid resins and coextruded polyolefin systems are the most novel encapsulants, enhancing UV resistance and extending polycrystalline panels’ lifespan beyond standard EVA [1][6].
The quest for more durable solar lamps in Romania has led to significant advancements in encapsulation resin technology. Novel silicone-based liquid resins and coextruded polyolefin systems are now available, offering superior UV resistance and extending the lifespan of polycrystalline panels beyond what standard ethylene-vinyl acetate (EVA) can provide [1][6].
Silicone-Based Resins: The Superior Alternative
Silicone-based encapsulants have emerged as a game-changer in solar panel manufacturing. These liquid thermosetting organic resins offer outstanding UV resistance, eliminating the need for additional UV screen additives typically required in EVA formulations [1]. This makes them highly effective at maintaining electrical performance over time.
The cured silicone encapsulant described in US8847063B2 demonstrates exceptional durability, with no more than a 5% drop in maximum power (Pmax) after accelerated aging tests such as Damp Heat Conditioning—defined by IEC 61215, IEEE 1262, and UL1703 standards [25]. This encapsulant also simplifies module architecture by eliminating the need for adhesive layers or multiple encapsulant layers [7].
The production process of these silicone encapsulants is highly efficient. A curtain coater can apply a single-layer silicone encapsulant at 5.5 kg/min onto moving glass panels, forming a uniform 70 μm film at 45 m/min [6]. This contrasts with traditional batch lamination methods that are slower and more costly [2].
Coextruded Polyolefin-Based Systems: The Future of Encapsulation
Coextruded polyolefin-based systems have also gained prominence due to their enhanced durability and resistance to acid formation, a major degradation pathway for EVA. These materials include polyolefin elastomers (POEs) and thermoplastic polyolefins (TPOs), which are expected to become the primary encapsulation material by 2030 [19].
Endurans Solar’s EPE encapsulant integrates a high-melting-point polyolefin layer that improves thermal stability and reduces hydrolysis risks, thus extending the lifespan of polycrystalline wafers [17]. These systems also provide light-trapping properties, potentially boosting module yield by up to 3% compared to standard transparent backsheets [17].
Comparison Table
| Feature | Silicone Resins | Coextruded Polyolefins |
|––––––––|–––––––––|––––––––––|
| UV Resistance | Superior | Enhanced |
| Manufacturing Cost | High | Lower |
| Simplification | Single-layer | Multi-layer |
Key Challenges and Future Prospects
Despite their advantages, the adoption of these advanced encapsulants faces some challenges. Silicone-based resins are expensive and difficult to dispense at scale [1], while polyolefins lack detailed UV resistance data in field conditions [19]. However, ongoing research suggests that future encapsulants may not only protect but also enhance panel performance.
Key Takeaways
- Silicone Resins: Offer superior UV resistance without additional additives.
- Polyolefin Encapsulants: Projected to dominate by 2030 due to enhanced durability and lower cost.
- Field Validation Needed: Long-term field data is required for both technologies.
References
- [1] US8847063B2_-_Encapsulation_of_solar_cells_-_Google_Patents__afa4ee8d — patent
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because silicone resins of this type impart outstanding UV resistance to the encapsulant and therefore there is no need for the inclusion of one or more UV screen additives which in the case of most prior art formulations was typically essential. The cured liquid silicone encapsulant of the type described in the present invention exhibits long term UV & visual light transmission thereby allowing the maximum amount of light to reach solar cells. Whilst the UV resistance capabilities of silicone based compositions is well known the commercial exploitation of such formulations have been limited by high total cost and a lack of suitable process to dispense a liquid encapsulation. In the case of thin film solar cell modules the inventors have found that the encapsulant as hereinbefore described is adequate to replace the often several layers of encapsulant and avoids the need for a substrate. The encapsulant is located between e.g. a glass plate superstrate and the solar cell and its primary function is to protect the solar cell against mechanical stress arising from temperature changes, and to adhere the solar cell to the superstrate. However, particularly in the case of wafer type solar cell modules it has been identified that in some instances an optional adhesive layer comprising a further liquid silicone encapsulant may be utilised for the adhesion of the wafer type solar cells onto the load bearing support, typically a superstrate. The liquid silicone encapsulant utilised as
- [2] US8847063B2_-_Encapsulation_of_solar_cells_-_Google_Patents__afa4ee8d — patent
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a thermosetting organic liquid resin as a means of encapsulating amorphous silicon photovoltaic modules but do not clearly identify the resin used. Typically in the prior art the encapsulants used are filmic and therefore the layers of encapsulant have to be laminated under heat and vacuum conditions which cause them to melt, bond to adjacent surfaces, and literally “encapsulate” the solar cells. Currently existing methods for solar cell module encapsulation are usually carried out in a batch mode because of the lamination step which makes the entire process slow resulting in the fact that the overall cost of encapsulating the modules is high. In many instances, several layers of encapsulant may be applied using either the same or different encapsulant materials for different layers. An example of a prior art module is shown in FIG. 1 herein. For example a module may comprising a superstrate supporting a plurality of solar cells with a first layer of encapsulant which is transparent to sunlight, utilised as an adhesive, to adhere the superstrate to a series of interconnected solar cells. A second or rear layer of encapsulant may then be applied onto the first layer of encapsulant and interconnected solar cells. The second layer of encapsulant may be an additional layer of the same material as used for the first encapsulant, e.g. ethyl vinyl acetate (EVA) and/or may be transparent or any suitable colour. The substrate is present in the form of a rigid or, a stiff backskin to p
- [6] US8847063B2_-_Encapsulation_of_solar_cells_-_Google_Patents__afa4ee8d — patent
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show any open circuit or leakage current, any visual defect and any decrease in maximum power should not be greater than 5% all of which the thin film modules of the present invention using the encapsulant alone (i.e. no adhesive layer required). These findings are totally contrary to the expectations of the industry and use of a silicone encapsulant as hereinbefore described is able to provide the level of protection suitable for solar or photovoltaic module of a polycrystalline Silicon wafer type. 40 Kg of the silicone encapsulant of this invention having a viscosity of 7000 mPa·s was fed into a curtain coater and was then pumped at 5.5 Kg/min to make a suitable curtain. 500×500 mm glass panels were fed continuously into the coater at 45 m/min to form a polymer film of 70 μm, after 6 passes under the curtain, an encapsulant film of 433 μm thickness was formed. The glass was then fed at 1 m/min into 1 meter long infrared oven equipped with 4 lamps of 1000 watts each. The encapsulant cured rapidly to impart a high scratch resistance surface to the glass surface. Example 11 was repeated except that 4 interconnected solar cells were manually glued on to the glass panels by applying a layer of the adhesive having a thickness of 100 μm. The solar glass with the interconnect on the top side was passed through the curtain at 20 m/min to make a top layer of 200 μm, repeating the coating step once resulted in a solar panel coated with 400 μm encapsulating the interconnect. The top la
- [7] US8847063B2_-_Encapsulation_of_solar_cells_-_Google_Patents__afa4ee8d — patent
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presence of the anti-soiling additive and then becomes highly transparent. – adhesion promoter is preferably use. It is believed that the adhesion promoter migrates to the interface of the topcoat and reacts irreversibly with adjacent surfaces. This strong adhesion allows the module to function in wide range of temperatures from ambient temperature to extremes without delaminating. – the single layer encapsulant is designed to have a required abrasion resistance to prevent further damage that may occur during transportation or in field usage. It is tough enough to serve also as the substrate protecting the cell. – the combination of encapsulant and topcoat is designed to replace multiple layers and material chemistry of the classical configuration (EVA and fluoropolymer laminate) by two layers based on one core chemistry. – the topcoat preferably covers the entire cell interconnects; it functions as an outer layer i.e. as an environmentally protecting layer. – Component (B) of the composition as hereinbefore described is provided because silicone resins of this type impart outstanding UV resistance to the encapsulant and therefore there is no need for the inclusion of one or more UV screen additives which in the case of most prior art formulations was typically essential. – the cured liquid silicone encapsulant of the type described in the present invention exhibits long term UV & visual light transmission thereby allowing the maximum amount of light to reach solar cells. – t
- [17] Cost-effective_Reliable_Coextruded_Polyolefin-Based_Encapsulation__42c56d28 — magazine
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# Cost-effective & Reliable Coextruded Polyolefin-Based Encapsulation Solutions Source: Blog/Web URL: https://taiyangnews.info/technology/endurans-solar-coextruded-encapsulation-polyolefin Author: Rajarshi Sengupta Date: 2024-12-03 Endurans Solar's upcoming coextruded polyolefin-based transparent backsheet features all the advantages of a polyolefin layer with integrated light trapping properties It can help deliver up to 3% additional yield compared to a conventional transparent backsheet module The company is going to introduce its innovative EPE encapsulant, featuring high melting PO layer This EPE encapsulant can mitigate the risk of acid formation compared to conventional EPE solutions The quality and reliability of encapsulation materials, such as encapsulants and backsheets, are as critical as the quality of solar cells in ensuring long-term PV module performance. In the current era of intense cost pressure, these materials face challenges in balancing cost-effectiveness and quality. At the recent TaiyangNews Reliable PV Module Design 2024 virtual conference, Imco Goudswaard, Commercial Manager at Endurans Solar, shared some insights into the company’s innovative coextruded polyolefin-based backsheet and encapsulant solutions (see Endurans Solar's presentation here). A US-based leader in polymer technology, the company offers a product portfolio that includes polyolefin-based backsheets and single-layer encapsulants such as EVA, POE, and the newly developed multilayer
- [19] Featured_Publications_Q2-2026_-_Fraunhofer_ISE__f896c50f — authority
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# Highlight-Artikel Source: Blog/Web URL: https://www.ise.fraunhofer.de/en/publications/featured-publications/q2-2026.html Author: Date: 2026-02-01 Progress in Photovoltaics: Research and Applications | 2026; 34:367–395 Gernot Oreski, Chiara Barretta, Petra Christöfl, Paul Gebhardt, Karl-Anders Weiß, David C. Miller, Soňa Uličná, Michael Kempe, Laura S. Bruckman, Alessandro Virtuani, Hengyu Li, Brian Habersberger, Jeff Munro, Kristof Proost, Marcel Kühne In recent years, photovoltaic (PV) encapsulant films marketed as polyolefins (POs), more specifically as PO elastomers (POEs) and thermoplastic POs (TPOs), have gained significant market share and are projected to become the dominant encapsulation films by 2030. Relative to other industries, there are significant misconceptions about the term PO in the PV industry. Both in the scientific literature as well as in sales and advertising, the terms PO, POE, and TPO are often misused to describe the same type of material with comparable properties, while in reality these may each consist of separate material classes. A group of internationally leading experts therefore addressed the issue to improve clarity in the industry and avoid misunderstandings. This paper provides a comprehensive literature and market review, to showcase a broad range of PO and other ethylene copolymer encapsulants from recent studies and discusses the materials' properties to clarify what constitutes a “polyolefin.” In addition, to promote a clearer compar
- [25] US8847063B2_-_Encapsulation_of_solar_cells_-_Google_Patents__afa4ee8d — patent
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commonly referred to as Damp Heat Conditioning as defined in each of IEC 6-1215, IEEE 1262, UL1703. – the results provided in Tables 12 and 13 are determined by the relative percentage change of initial and final electrical test results. Any loss in Pmax of more than 5% was deemed a failure. – Tables 12 and 13 contrast the results between the initial and the final electrical values ones for the two encapsulation technologies. Landscapes – Photovoltaic Devices (AREA) – Compositions Of Macromolecular Compounds (AREA) – Sealing Material Composition (AREA) – Adhesives Or Adhesive Processes (AREA) Abstract The present invention comprises a solar cell module and a method of encapsulating the module. The solar cell module comprises a rigid or flexible superstrate and/or substrate having one or more solar cells, and an encapsulent which is a cured liquid silicone encapsulant. The encapsulant composition preferably comprises a liquid diorganopolysiloxane having at least two Si-alkenyl groups per molecule, a silicone resin containing at least two alkenyl groups; a cross-linking agent in the form of a polyorganosiloxane having at least two silicon-bonded hydrogen atoms per molecule, in an amount such that the ratio of the number of moles of silicon-bonded hydrogen to the total number of moles of silicon-bonded alkenyl groups is from 0.1:1 to 5:1; and a hydrosilylation catalyst, preferably a platinum based catalyst. The continuous solar cell module encapsulation process comprising the st
because silicone resins of this type impart outstanding UV resistance to the encapsulant and therefore there is no need for the inclusion of one or more UV screen additives which in the case of most prior art formulations was typically essential. The cured liquid silicone encapsulant of the type described in the present invention exhibits long term UV & visual light transmission thereby allowing the maximum amount of light to reach solar cells. Whilst the UV resistance capabilities of silicone based compositions is well known the commercial exploitation of such formulations have been limited by high total cost and a lack of suitable process to dispense a liquid encapsulation. In the case of thin film solar cell modules the inventors have found that the encapsulant as hereinbefore described is adequate to replace the often several layers of encapsulant and avoids the need for a substrate. The encapsulant is located between e.g. a glass plate superstrate and the solar cell and its primary function is to protect the solar cell against mechanical stress arising from temperature changes, and to adhere the solar cell to the superstrate. However, particularly in the case of wafer type solar cell modules it has been identified that in some instances an optional adhesive layer comprising a further liquid silicone encapsulant may be utilised for the adhesion of the wafer type solar cells onto the load bearing support, typically a superstrate. The liquid silicone encapsulant utilised as
a thermosetting organic liquid resin as a means of encapsulating amorphous silicon photovoltaic modules but do not clearly identify the resin used. Typically in the prior art the encapsulants used are filmic and therefore the layers of encapsulant have to be laminated under heat and vacuum conditions which cause them to melt, bond to adjacent surfaces, and literally “encapsulate” the solar cells. Currently existing methods for solar cell module encapsulation are usually carried out in a batch mode because of the lamination step which makes the entire process slow resulting in the fact that the overall cost of encapsulating the modules is high. In many instances, several layers of encapsulant may be applied using either the same or different encapsulant materials for different layers. An example of a prior art module is shown in FIG. 1 herein. For example a module may comprising a superstrate supporting a plurality of solar cells with a first layer of encapsulant which is transparent to sunlight, utilised as an adhesive, to adhere the superstrate to a series of interconnected solar cells. A second or rear layer of encapsulant may then be applied onto the first layer of encapsulant and interconnected solar cells. The second layer of encapsulant may be an additional layer of the same material as used for the first encapsulant, e.g. ethyl vinyl acetate (EVA) and/or may be transparent or any suitable colour. The substrate is present in the form of a rigid or, a stiff backskin to p
show any open circuit or leakage current, any visual defect and any decrease in maximum power should not be greater than 5% all of which the thin film modules of the present invention using the encapsulant alone (i.e. no adhesive layer required). These findings are totally contrary to the expectations of the industry and use of a silicone encapsulant as hereinbefore described is able to provide the level of protection suitable for solar or photovoltaic module of a polycrystalline Silicon wafer type. 40 Kg of the silicone encapsulant of this invention having a viscosity of 7000 mPa·s was fed into a curtain coater and was then pumped at 5.5 Kg/min to make a suitable curtain. 500×500 mm glass panels were fed continuously into the coater at 45 m/min to form a polymer film of 70 μm, after 6 passes under the curtain, an encapsulant film of 433 μm thickness was formed. The glass was then fed at 1 m/min into 1 meter long infrared oven equipped with 4 lamps of 1000 watts each. The encapsulant cured rapidly to impart a high scratch resistance surface to the glass surface. Example 11 was repeated except that 4 interconnected solar cells were manually glued on to the glass panels by applying a layer of the adhesive having a thickness of 100 μm. The solar glass with the interconnect on the top side was passed through the curtain at 20 m/min to make a top layer of 200 μm, repeating the coating step once resulted in a solar panel coated with 400 μm encapsulating the interconnect. The top la
presence of the anti-soiling additive and then becomes highly transparent. – adhesion promoter is preferably use. It is believed that the adhesion promoter migrates to the interface of the topcoat and reacts irreversibly with adjacent surfaces. This strong adhesion allows the module to function in wide range of temperatures from ambient temperature to extremes without delaminating. – the single layer encapsulant is designed to have a required abrasion resistance to prevent further damage that may occur during transportation or in field usage. It is tough enough to serve also as the substrate protecting the cell. – the combination of encapsulant and topcoat is designed to replace multiple layers and material chemistry of the classical configuration (EVA and fluoropolymer laminate) by two layers based on one core chemistry. – the topcoat preferably covers the entire cell interconnects; it functions as an outer layer i.e. as an environmentally protecting layer. – Component (B) of the composition as hereinbefore described is provided because silicone resins of this type impart outstanding UV resistance to the encapsulant and therefore there is no need for the inclusion of one or more UV screen additives which in the case of most prior art formulations was typically essential. – the cured liquid silicone encapsulant of the type described in the present invention exhibits long term UV & visual light transmission thereby allowing the maximum amount of light to reach solar cells. – t
# Cost-effective & Reliable Coextruded Polyolefin-Based Encapsulation Solutions Source: Blog/Web URL: https://taiyangnews.info/technology/endurans-solar-coextruded-encapsulation-polyolefin Author: Rajarshi Sengupta Date: 2024-12-03 Endurans Solar's upcoming coextruded polyolefin-based transparent backsheet features all the advantages of a polyolefin layer with integrated light trapping properties It can help deliver up to 3% additional yield compared to a conventional transparent backsheet module The company is going to introduce its innovative EPE encapsulant, featuring high melting PO layer This EPE encapsulant can mitigate the risk of acid formation compared to conventional EPE solutions The quality and reliability of encapsulation materials, such as encapsulants and backsheets, are as critical as the quality of solar cells in ensuring long-term PV module performance. In the current era of intense cost pressure, these materials face challenges in balancing cost-effectiveness and quality. At the recent TaiyangNews Reliable PV Module Design 2024 virtual conference, Imco Goudswaard, Commercial Manager at Endurans Solar, shared some insights into the company’s innovative coextruded polyolefin-based backsheet and encapsulant solutions (see Endurans Solar's presentation here). A US-based leader in polymer technology, the company offers a product portfolio that includes polyolefin-based backsheets and single-layer encapsulants such as EVA, POE, and the newly developed multilayer
# Highlight-Artikel Source: Blog/Web URL: https://www.ise.fraunhofer.de/en/publications/featured-publications/q2-2026.html Author: Date: 2026-02-01 Progress in Photovoltaics: Research and Applications | 2026; 34:367–395 Gernot Oreski, Chiara Barretta, Petra Christöfl, Paul Gebhardt, Karl-Anders Weiß, David C. Miller, Soňa Uličná, Michael Kempe, Laura S. Bruckman, Alessandro Virtuani, Hengyu Li, Brian Habersberger, Jeff Munro, Kristof Proost, Marcel Kühne In recent years, photovoltaic (PV) encapsulant films marketed as polyolefins (POs), more specifically as PO elastomers (POEs) and thermoplastic POs (TPOs), have gained significant market share and are projected to become the dominant encapsulation films by 2030. Relative to other industries, there are significant misconceptions about the term PO in the PV industry. Both in the scientific literature as well as in sales and advertising, the terms PO, POE, and TPO are often misused to describe the same type of material with comparable properties, while in reality these may each consist of separate material classes. A group of internationally leading experts therefore addressed the issue to improve clarity in the industry and avoid misunderstandings. This paper provides a comprehensive literature and market review, to showcase a broad range of PO and other ethylene copolymer encapsulants from recent studies and discusses the materials' properties to clarify what constitutes a “polyolefin.” In addition, to promote a clearer compar
commonly referred to as Damp Heat Conditioning as defined in each of IEC 6-1215, IEEE 1262, UL1703. – the results provided in Tables 12 and 13 are determined by the relative percentage change of initial and final electrical test results. Any loss in Pmax of more than 5% was deemed a failure. – Tables 12 and 13 contrast the results between the initial and the final electrical values ones for the two encapsulation technologies. Landscapes – Photovoltaic Devices (AREA) – Compositions Of Macromolecular Compounds (AREA) – Sealing Material Composition (AREA) – Adhesives Or Adhesive Processes (AREA) Abstract The present invention comprises a solar cell module and a method of encapsulating the module. The solar cell module comprises a rigid or flexible superstrate and/or substrate having one or more solar cells, and an encapsulent which is a cured liquid silicone encapsulant. The encapsulant composition preferably comprises a liquid diorganopolysiloxane having at least two Si-alkenyl groups per molecule, a silicone resin containing at least two alkenyl groups; a cross-linking agent in the form of a polyorganosiloxane having at least two silicon-bonded hydrogen atoms per molecule, in an amount such that the ratio of the number of moles of silicon-bonded hydrogen to the total number of moles of silicon-bonded alkenyl groups is from 0.1:1 to 5:1; and a hydrosilylation catalyst, preferably a platinum based catalyst. The continuous solar cell module encapsulation process comprising the st