Silicone gel encapsulation offers a range of advantages over traditional EVA (ethylene-vinyl acetate) encapsulants. Its superior physical, chemical, and optical properties make it the ideal choice for next-generation PV modules.
1. Inert Material
EVA limitation: EVA can decompose under high temperatures (~80°C) or prolonged ultraviolet (UV) exposure, producing acetic acid that damages solar cells.
Silicone gel advantage: Chemically inert and stable at temperatures up to 250°C, making it compatible with advanced high-efficiency solar cells that are highly sensitive to acetic acid.
2. High Transparency
Silicone gel offers greater transparency for solar radiation compared to EVA.
Performance impact:
Initial efficiency gain: ~1.5% higher conversion efficiency at the beginning of module life.
Long-term gain: ~15% higher energy yield over 20 years due to no yellowing or browning.
3. Gel Flexibility vs. Solid-State Encapsulant
Unlike EVA, which is a solid film, silicone gel is flexible.
This flexibility allows for mechanical stress relaxation during daily thermal cycling (day–night temperature fluctuations), preventing micro-cracks and damage in PV cells.
4. Extended Lifetime of PV Panels
Due to chemical stability, higher transparency, and stress relaxation, silicone gel extends PV panel lifetimes to 30+ years.
Results in ~15% more total energy generation over the module’s lifetime compared to EVA-based panels.
5. Easier Recycling
At end-of-life, PV modules laminated with silicone gel are easier to recycle, allowing straightforward solar cell extraction, unlike EVA-based panels which are more difficult to process.
6. Shape Flexibility
EVA is limited to flat or simple forms.
Silicone gel enables lamination of complex geometries such as cylindrical, spherical, or custom designs, expanding applications in architectural and specialty solar products.
7. Low Energy Consumption in Manufacturing
Silicone gel lamination consumes ~10 times less energy than EVA lamination, making the manufacturing process more sustainable and cost-efficient.
8. Competitive Pricing
Despite its superior properties, silicone gel encapsulation has negligible cost difference compared to EVA, making it commercially viable.
9. Environmentally Friendly
Manufactured with eco-friendly materials, silicone gel contributes to greener PV technologies.
10. Room Temperature Lamination
Silicone gel lamination can be performed at room temperature (~20°C).
This makes it compatible with temperature-sensitive technologies, where EVA-based processes (high-temperature lamination) would cause material damage.
