Advancements in PV Backsheet Technology: Innovations, Trends, and Market Dynamics

Solar power has become the main renewable energy source worldwide, and solar PV accounted for three-quarters of renewable capacity additions worldwide in 2023. The benefits such as longevity, durability, and comparatively easy installation have been a major point of attraction of the technology. However, solar panels are exposed to various weathering agents around the year throughout their lifespan of about 25-30 years. Thanks to the photovoltaic backsheet, a crucial component of solar panels system, achieving this longevity by keeping the solar durable and efficient for longer periods is possible.

A PV backsheet serves as the outermost layer on the backside of the panel, protecting the photovoltaic cells and other internal components from various environmental factors such as moisture, heat, and UV radiation. The backsheet is typically made of polymer materials, such as polyester or fluoropolymer, laminated with other materials to enhance durability and weather resistance. It acts as an insulating layer, electrically insulating the solar cells and providing mechanical support to the panel. The quality and durability of the PV backsheet are crucial for the long-term performance and reliability of the solar panel.

Being a key component of solar panels, the demand for backsheets is directly linked to the growth of the solar power industry. As the need to improve solar technology became imminent, to boost their adoption, the components of solar also evolved. This study highlights the trends and innovations in solar PV backsheets which are facilitating PV penetration further.

Trends and Innovations Driving the Growth

The Solar PV backsheet market is divided into two primary categories: Fluoropolymer and Non-Fluoropolymer. Fluoropolymer backsheets utilise materials such as polyvinyl fluoride, known for their exceptional resistance to UV radiation, moisture, and temperature fluctuations. Conversely, Non-Fluoropolymer backsheets are crafted from materials like polyethylene terephthalate or polyamide, offering commendable electrical insulation properties but potentially lacking the same level of protection against harsh weather conditions. Both types are essential for safeguarding PV modules from external elements and ensuring their prolonged durability.

Technological advancements and innovations in backsheet materials are revolutionising the efficiency and dependability of solar panels. Manufacturers are rolling out backsheet products with superior UV resistance, fire resistance, and durability against extreme weather conditions. These advancements are expected to appeal to a broader consumer base and fuel the expansion of the Solar PV backsheet market.

Transparent Backsheets & Bifacial Solar Trending

Numerous emerging trends are propelling these advancements. One notable trend gaining traction is the rising preference for transparent backsheet materials, allowing for visually pleasing installations without compromising efficiency. The adoption of transparent backsheets in bifacial PV, a rapidly expanding segment of PV technology, is increasingly popular. For example, solar panel manufacturer Maysun Solar emphasises that their solar modules, featuring transparent backsheets alongside high-efficiency mono-passivated emitter rear contact (PERC) bifacial cells and POE film for backsheets, can generate electricity from the front while achieving up to a 20 percent energy gain from the back.

Tackling Backsheet Demerits

Degradation and failures of backsheets pose significant concerns for solar enthusiasts. Backsheets are intended to serve as insulators, meaning that any defects or malfunctions can severely impact the performance of PV modules. The most prevalent consequence of backsheet failure is ground faults stemming from diminished insulation resistance. This frequently results in the shutdown of inverters, leading to substantial power loss. Besides performance degradation, ground faults can also pose safety risks and fire hazards to the entire system. Other potential failures encompass cracking of the inner or outer layers, delamination, and yellowing.

Research and development efforts aimed at enhancing the durability of components and devising mechanisms to detect failures or faults have gained momentum in recent years. For example, scientists in Austria are conducting research to comprehend the degradation of polymers utilised in PV backsheets. Their objective is to create models that quantify degradation rates, enabling manufacturers to select superior, longer-lasting materials.

Keeping it Lightweight, Durable, and Smart

There is also a noticeable trend towards favouring lightweight and durable backsheet materials, such as glass and polyvinyl fluoride, aimed at improving overall module performance and lifespan. Additionally, manufacturers are progressively integrating smart functionalities into backsheet designs, including self-cleaning and self-healing capabilities, to enhance module reliability and minimise maintenance expenses. The market is also witnessing a surge in the adoption of double-glass modules, further driving the demand for specialised backsheets.

Moreover, the industry is undergoing a significant yet inconspicuous transition from PVDF-based to CPC backsheets. In the past year, the market share of CPC backsheets has surged to nearly 50 percent from a mere 12-13 percent initially. This shift is attributable not only to the volatile pricing of PVDF but also to the technological advantages offered by CPC structures.

Solar Backsheet Market Trends

Fluoropolymer is projected to emerge as a substantial segment compared to non-fluoropolymer. With the solar market expanding due to heightened adoption, the production cost, a drawback of fluoropolymer compared to its counterpart, is anticipated to decrease owing to economies of scale in mass production.

Naturally, the Asia-Pacific region is poised to lead the market, propelled by China's vigorous promotion of renewables and India's rapid transition to solar energy in recent years. The significant projects in the pipeline in the region are expected to further stimulate growth in the backsheet market. 

Major Market Players

The solar backsheet market is expected to register a CAGR of over 15.5 percent during 2022-2027. Several manufacturers are pushing in the sector. 

Some prominent players in India manufacturing Solar PV Backsheet include RenewSys, manufacturer of Solar PV Modules and its key components, which include Encapsulants, Backsheets, and Solar PV Cells. At present, RenewSys boasts a PV module capacity of 1.85 GW, encompassing 1 GW of mono PERC, 600 MW of TOPCon, and 250 MW of mono modules. Additionally, it possesses capacities of 5 GW for encapsulants and 4 GW for backsheets. The manufacturer has indicated its intention to introduce mono DCR cells soon.

Vishakha Renewables also offers a range of solar backsheets, including PET, PVDF, and PVF materials. The Gujarat-based manufacturer provides solar aluminium frames, solar encapsulants, solar backsheets, and solar glass. The firm boasts significant manufacturing capacities of 3 GW for PET, PVDF, and PVF-based Back Sheets. In addition, the firm has capacities of 3 GW for Fast Cure Encapsulants, 2.4 GW for Aluminum Frames, and 4 GW for Solar Glass.

Some of the key global players in the competitive solar PV backsheet market include the likes of Coveme, an Italian company that has been operating since 1965, and Dunmore, a US-based company with over 45 years of experience in producing high-performance engineered films. Toray, a Japanese multinational corporation, is also amongst the major players in the market.