The glass breakages observed occur in modules with a surface area of more than 2.5 square meters. The largest modules on the market today cover more than 3 square meters. The size of the modules is one cause of glass breakage. The Fraunhofer Institute for Solar Energy Systems (ISE) has tested in the laboratory what other correlations there are.
The latter broke under a significantly lower load than the other module types. While the first glass-glass modules with thinner glass and the first glass-foil modules only showed cracks at more than 5,400 pascals, this was the case for the modules with 2-millimeter glass between 3,500 and 4,700 pascals.
Studies have found that contact between glass and frames is linked to spontaneous breakage in some PV modules. A recommended solution is using rubbery silicone spacers which maintain separation between the glass and the frame. Many modules already use silicone gaskets, but some designs leave gaps where the glass directly touches the metal frame.
Double-glass PV modules undergo a lamination process, where two sheets of glass encase the solar cells. During this step, heat and pressure bond the materials together. If the process is not precisely controlled, edge pinch can occur—where the glass edges become compressed unevenly, creating built-in stress. Edge pinch and resultant stress.
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