New findings push UNSW to rethink solar module testing
Researchers at the University of New South Wales (UNSW) are urging the solar industry to overhaul UV exposure testing for TOPCon solar cells. The call comes after identifying critical gaps in current testing protocols that may fail to capture real-world degradation patterns. In particular, recent analyses suggest that up to one-fifth of PV modules could degrade at a rate 1.5 times faster than industry averages under UV-related stress, a finding with wide-ranging implications for reliability, warranties, and long-term power output.
TOPCon, short for tunnel oxide passivated contact, has gained traction as a high-efficiency technology for solar modules. While the efficiency gains are well-documented, the durability of TOPCon under ultraviolet (UV) irradiation, thermal cycling, and humidity remains less understood. The UNSW research urges a closer look at how UV exposure is simulated in accelerated aging tests and how such tests align with field performance.
Why UV testing matters for TOPCon reliability
UV radiation is a persistent stressor in outdoor environments. For TOPCon cells, UV exposure can influence passivation layers, interconnections, and the semiconductor-metal interfaces that define performance. If current test protocols underrepresent UV-driven degradation, modules might meet certification on paper yet underperform in real-world conditions. The potential consequence is not only reduced energy yield but also more frequent warranty claims and higher lifecycle costs for developers, operators, and homeowners.
The UNSW findings emphasize that reliability is not a single-number metric but a spectrum of behaviors that can diverge based on materials, encapsulation, and packaging. In practice, this means a stricter, more nuanced approach to UV aging tests—one that captures both the immediate and cumulative effects of sunlight exposure on TOPCon structures.
What the calls for enhanced UV testing involve
Experts propose several concrete changes to testing protocols. First, UV aging protocols could be revised to include higher intensity and broader spectral ranges that better mimic real sun exposure over time. Second, the duration and sequencing of UV, thermal, and humidity cycles may need rebalancing to reflect field conditions more accurately. Third, there is a push for large-scale data collection from deployed TOPCon modules, enabling a data-driven calibration of accelerated tests against observed field degradation rates.
Beyond the lab, the research advocates updating international standards—such as IEC 61215 and IEC 61730—to incorporate TOPCon-specific test regimes. Stakeholders argue that consistent standards help ensure fair competition while protecting asset owners from premature failure and unexpected maintenance costs.
Industry implications and how stakeholders can respond
Manufacturers of TOPCon-based modules should anticipate more rigorous UV test requirements and prepare by validating materials, coatings, and interconnects against enhanced aging protocols. A robust testing regime can also reduce supply-chain risk, safeguarding investor confidence in large-scale solar deployments. For installers and operators, a clearer understanding of UV-related degradation pathways enables better decision-making around warranties, service plans, and performance monitoring.
Policy-makers and regulatory bodies may also benefit from the UNSW insights, which underscore the importance of aligning certification processes with real-world performance. In an industry where tiny efficiency differences translate into significant financial and environmental outcomes, rigorous UV testing stands out as a practical lever to improve reliability and long-term power generation.
Looking ahead: balancing innovation with reliability
The push for enhanced UV testing does not aim to curb innovation in TOPCon tech. Instead, it seeks to pair rapid advancement with rigorous validation, ensuring that gains in efficiency do not come at the expense of durability. As the solar sector scales up, materials science, accelerated aging, and real-world field data will converge to shape the next generation of test standards. For researchers and industry players, the message is clear: robust UV testing is an essential part of delivering reliable, long-lasting solar energy.
