Trial-Run of a Junction-Box Attachment Test for Use in Photovoltaic Module Qualification: Preprint

Research output: Contribution to conferencePaper


Engineering robust adhesion of the junction box (j-box) is a hurdle typically encountered by photovoltaic module manufacturers during product development and manufacturing process control. There are historical incidences of adverse effects (e.g., fires) caused when the j-box/adhesive/module system has failed in the field. The addition of a weight to the j-box during the 'damp-heat,''thermal-cycle,' or 'creep' tests within the IEC qualification protocol is proposed to verify the basic robustness of the adhesion system. The details of the proposed test are described, in addition to a trial-run of the test procedure. The described experiments examine four moisture-cured silicones, four foam tapes, and a hot-melt adhesive used in conjunction with glass, KPE, THV, and TPE substrates. For the purpose of validating the experiment, j-boxes were adhered to a substrate, loaded with a prescribed weight, and then subjected to aging. The replicate mock-modules were aged in an environmental chamber (at 85 degrees C/85% relative humidity for 1000 hours; then 100 degrees C/<10% relative humidity for 200 hours) or fielded in Golden (CO), Miami (FL), and Phoenix (AZ) for one year. Attachment strength tests, including pluck and shear test geometries, were also performed on smaller component specimens.
Original languageAmerican English
Number of pages8
StatePublished - 2014
Event40th IEEE Photovoltaic Specialists Conference (PVSC) - Denver, Colorado
Duration: 8 Jun 201413 Jun 2014


Conference40th IEEE Photovoltaic Specialists Conference (PVSC)
CityDenver, Colorado

NREL Publication Number

  • NREL/CP-5200-61102


  • adhesion strength
  • durability
  • photovoltaic module qualification
  • PV module
  • reliability


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