DREAM-PV
The project aims to develop and validate advanced photovoltaic module designs and materials tailored for next-generation solar cell technologies such as TOPCon and IBC. By optimizing module packaging, materials, and manufacturing processes, the project seeks to improve reliability, durability, and long-term performance while reducing environmental impact and ensuring cost-competitive and sustainable PV technologies.
Project partners
- Polymer Competence Center Leoben GmbH (A) - Coordinator
- Gebze Technical University (TR)
- International Solar Energy Research Center Konstanz (ISC) (DE)
- SONNENKRAFT Errichtungs-GmbH (AT)
- KALYON PV Solar Technologies Factory
- EMIL OTTO Flux- und Oberflächentechnik GmbH (DE)
- Lenzing Plastics GmbH & Co KG (AT)
Motivation und Ziele
The global transition towards a low-carbon energy system requires a rapid expansion of renewable energy technologies. Among these, photovoltaic (PV) power generation has become one of the most important and scalable solutions for producing clean electricity. Over the past decade, the installed PV capacity worldwide has grown significantly, driven by improvements in module efficiency and reductions in manufacturing costs. As a result, solar energy plays a key role in strategies aimed at achieving climate neutrality and reducing dependence on fossil fuels.
At the same time, the photovoltaic sector is characterized by a very rapid pace of technological innovation. New solar cell architectures and materials are continuously being introduced to improve efficiency and reduce costs. In recent years, next-generation silicon solar cell technologies such as Tunnel Oxide Passivated Contact (TOPCon) and Interdigitated Back Contact (IBC) cells have gained increasing attention due to their high conversion efficiencies and strong potential for large-scale industrial deployment. These technologies are expected to play an important role in the future PV market.
However, the introduction of new cell technologies also brings new challenges related to module reliability and long-term stability. Compared to more established technologies, advanced solar cells can be more sensitive to environmental stressors such as humidity, temperature variations, and ultraviolet radiation. In addition, the interaction between solar cells and surrounding module materials—including encapsulants, backsheets, interconnection materials, and fluxes—can strongly influence degradation processes and ultimately determine the long-term performance of PV modules.
Ensuring that photovoltaic modules remain reliable and stable over lifetimes of more than 25–30 years is therefore a key challenge for the PV industry. Without a deeper understanding of degradation mechanisms and material interactions, the rapid introduction of new technologies may lead to unforeseen failures or performance losses during operation.
Addressing these challenges requires systematic research on module materials, packaging concepts, and manufacturing processes.
The project therefore aims to develop and evaluate optimized module designs tailored for emerging solar cell technologies. By investigating advanced encapsulation materials, improved interconnection strategies, and optimized module integration processes, the project seeks to enhance the durability, reliability, and performance of PV modules. Accelerated aging tests and outdoor exposure experiments will be used to analyse degradation behaviour and identify potential failure mechanisms under realistic environmental conditions.
In addition, the project will assess the environmental and economic implications of the proposed innovations through life-cycle and cost analyses. By improving module durability and reliability while reducing environmental impact, the project contributes to the development of photovoltaic technologies that are both sustainable and economically competitive, supporting the large-scale deployment of solar energy in the future.
Main Goals
- Develop optimized PV module designs tailored for emerging solar cell technologies such as TOPCon and IBC.
- Improve module reliability and durability by understanding material interactions and degradation mechanisms.
- Investigate advanced encapsulation materials and module packaging concepts to enhance long-term stability.
- Validate module performance through accelerated aging tests and outdoor exposure under different climatic conditions.
- Evaluate environmental and economic impacts through life-cycle and cost analyses to support sustainable PV technologies.
Objectives and Approach
DREAM-PV aims to develop reliable and durable photovoltaic modules based on emerging solar cell technologies by optimizing materials, module design, and integration processes.
- Develop optimized module designs and bill-of-materials tailored for next-generation solar cells such as TOPCon and IBC.
- Investigate encapsulation materials and packaging concepts to minimize moisture ingress and improve long-term module stability.
- Analyse degradation mechanisms through accelerated aging tests, outdoor exposure, and advanced material characterization.
- Evaluate environmental and economic impacts through life-cycle assessment and cost analysis to support sustainable PV technologies.
„DREAM-PV develops reliable and durable photovoltaic modules for next-generation solar cell technologies by optimizing materials, module design, and manufacturing processes.“
