DESERT STAR – High-Temperature Solar PV Panels (TRAXLE Technology)

Specific PV applications

  • PV Panel Recycling
  • PV Panel Renovation Technology
  • High-Temperature Solar PV Panels
  • Polar Star
  • Hybrid Photovoltaic
  • Solar Concentrators
  • Bifacial Solar Panels
  • Solar Street Lamp
  • TRAXLE Solar Pumping Systems
  • Photovoltaic Systems

DESERT STAR – High-Temperature Solar PV Panels (TRAXLE Technology)

Background: The Problem with EVA Encapsulation

Most photovoltaic (PV) modules worldwide have traditionally been laminated with EVA (Ethylene-Vinyl Acetate) film, mainly because of its accessibility, cost-effectiveness, and ease of use in mass production. However, real-world performance—especially in high-temperature environments—has revealed critical drawbacks:

  • EVA darkening (also known as yellowing/browning): Over time, EVA encapsulant tends to darken when exposed to heat and UV radiation, reducing light transmission.

     

  • High power loss in hot climates: In field studies, such as those conducted in Carrisa Plains (California, USA), modules encapsulated with EVA lost over 45% power output within 5 years due to discoloration and electrical degradation.

     

  • Thermal limitations: EVA encapsulated panels typically operate reliably only up to +85°C. Beyond this, material decomposition accelerates, releasing acetic acid which damages solar cells.

 

This creates a huge challenge in desert and tropical regions, where panel surface temperatures often exceed +90°C under strong solar radiation.

The Solution: Silicone Gel Encapsulation Technology

To overcome EVA-related degradation, VIESH Institute (Moscow, Russia) in collaboration with Poulek Solar Company developed a silicone gel-based lamination technology, now applied in the TRAXLE line of Desert Star PV panels.

Key Advantages of Silicone Gel Encapsulation
  1. High Thermal Resistance:

    • Operating temperature up to +110°C (vs. EVA’s +85°C).

    • Long-term durability even in desert climates where panels reach +95°C.

  2. Superior UV & Chemical Stability:

    • Unlike EVA, silicone gel does not decompose into acetic acid.

    • Ensures long-term chemical stability and protects solar cells.

  3. Higher Transparency & Efficiency:

    • Silicone gel allows 90–93% light transmission across critical solar wavelengths (360–1000 nm).

    • EVA, in comparison, transmits significantly less (as low as 8% at UV 360 nm).

    • This results in ~1.5% higher efficiency at installation, and up to 15% lifetime energy gain (no yellowing).

  4. Stress Relief During Thermal Cycling:

    • EVA is a solid polymer, which causes microcracks during temperature fluctuations.

    • Silicone gel is soft and flexible, absorbing stress and protecting cells.

  5. Lower Energy Consumption in Production:

    • EVA lamination consumes ~49 kWh per panel.

    • Silicone gel lamination consumes only ~4.5 kWh per panel.

  6. Extended Lifetime:

    • EVA: ~25 years.

    • Silicone gel: 40+ years.

Performance Specifications (Desert Star – TRAXLE 540W Panel)
ParameterValue
TypeTSM-540DS
Peak Power (Pm)540W
Open Circuit Voltage (Voc)63.78V
Short Circuit Current (Isc)10.44A
Max Power Voltage (Vmp)55.05V
Max Power Current (Imp)

9.76A
Temp. Coefficient of Current+0.05% / °C
Temp. Coefficient of Voltage-0.30% / °C
Temp. Coefficient of Power-0.40% / °C
Max System Voltage1500V
Linear Degradation Rate-0.24% per year (50 years)
Working Temperature-55°C to +115°C
Panel Dimensions1998 × 1312 × 40 mm
Cell TypeMonocrystalline (96 pcs, 158.7 × 158.7 mm)
EncapsulantPolysiloxane (Silicone Gel)
Front GlassTempered, 3.2 mm
Back GlassTempered, 2.0 mm
Junction Box & CablesTyco
Mounting HolesD1: 1548 mm, D2: 974 mm, Hole Ø 9 mm
Weight31.5 kg
Comparison: EVA vs Silicone Gel Encapsulation
PropertyEVASilicone Gel
Long-term Operating Temp.-40°C to +80°C-60°C to +250°C
UV ResistanceLowHigh
Operating Lifetime25 years40+ years
Energy Consumption per Panel49 kWh4.5 kWh
Transparency (360 nm)8%90%
Transparency (400 nm)62%92%
Transparency (600–1000 nm)91%93%
Chemical StabilityLow (decomposes to acetic acid)High (inert)
Summary

The DESERT STAR – TRAXLE PV Panels are designed specifically for extreme desert and tropical climates, where conventional EVA-based PV panels degrade rapidly. Thanks to silicone gel encapsulation, these panels offer:

  • Higher efficiency (immediate +1.5%, lifetime +15%)

  • Extended operational lifetime (40+ years vs 25 years)

  • Superior heat resistance (up to +110°C)

  • Lower production cost and energy consumption

  • Environmentally sustainable technology

Poulek Solar Company holds the exclusive worldwide license for this technology and offers complete silicone gel lamination lines for multi-MW PV panel manufacturing.