Energy generation from alternative feedstock is gaining significance. One of these gaining swift popularity is the photovoltaic system - a system which uses solar cells to convert light into electricity. The system consists of multiple components, including cells, mechanical and electrical connections and mountings and means of regulating and/or modifying the electrical output. Because the individual solar cell has low voltage (typically ca. 0.5V), several cells are wired in series in the manufacture of a laminate. The laminate is assembled into a protective weatherproof enclosure, thus making a photovoltaic module. Modules may then be strung together into an array. The electricity generated can be either stored, used directly (island/standalone plant) or fed into a large electricity grid powered by central generation plants (grid-connected/grid-tied plant) or combined with one or many domestic electricity generators to feed into a small grid (hybrid plant). Depending on the type of application, the rest of the system consists of different components. Systems are generally designed in order to ensure the highest energy yield for a given investment. Considerable research and development work is being conducted on photovoltaic systems across the globe. Plastic products are also being developed to replace traditional materials in the photovoltaic system. New developments in plastic have the potential to save overall cost of photovoltaic system. Some of the replacement parts are Aluminum framing system of solar panels on rooftop, Glass used on top of modules, Flexible device based on organic photovoltaic, Lens or reflector used in concentrated photovoltaic equipment. Because solar cells must be protected from the environment, the panels are often contained by a metal or plastic frame, and may have a glass covering. The aluminum in the framing system can be replaced by injection molded plastic at a lower cost due to light weight, which also reduces the installation cost. Polymeric material for this application requires high heat resistance. With the new COLO-FAST® polyurethane casting system, BASF Polyurethanes offers quick and economical framing of photovoltaic panels and solar modules. The UV-stable PU system is able to replace the aluminum frames normally used in the past and opens up a variety of frame design opportunities for customers. Production is by way of the process known as reaction injection molding (RIM process). Here, the solar cells and solar panels together with electric cables or other appliances are placed into a closed mold and Colo-Fast® is injected through a mixing head. After a reaction time of just 30 seconds, the framed panel can be removed and used immediately. Consequently, very flexible shapes can be cast, different shades of color achieved and - according to the customer’s particular requirements – light, thinner or thicker frames produced. DuPontTM Rynite® polyethylene terephthalate (PET) is an alternative to powder-coated aluminium, with associated benefits including corrosion resistance, design flexibility and lower processing cost and material costs. Through the integration of additional functions in the housing, the number of manufacturing steps has also come down. Exposed to around-the-clock outdoor weather conditions, the material was required to provide excellent heat (temperatures of up to 85 °C) and UV resistance, as well as the structural support required for the entire CPV module to withstand high winds. SABIC Innovative Plastics offers unique materials meeting stringent IEC and UL requirements for c-Si as well as thin film PV systems components. Noryl and Lexan EXL resins are two in particular that are fast becoming the premier solutions in the world of PV materials- Noryl Resin: provides low density, dimensional stability over a wide temperature range (from -40°C to 140°C), low warpage, excellent long-term weathering, damp heat performance with exceptional stability of up to 2,000 hours, and outstanding electrical and thermal performance. These properties make it suitable for use in PV junction boxes. Noryl resin also meets the industry’s critical need for a long-lasting, outdoor-resistant material. Internal tests show that glass-filled and unfilled Noryl resins can already withstand 12,000 hours of UV exposure (which translates to approximately 10 years of outdoor weathering in Florida) with virtually no change in properties. Lexan EXL Resin: A polycarbonate copolymer resin that demonstrates excellent low-temperature ductility (-60 °C to 140 °C) combined with long-term weathering and thermal performance, making it an outstanding choice for use in PV connectors. Multi layer films providing moisture vapour resistance and top layer incorporated with light stabilizer like HALS and UV absorber to provide more than 30 years exposure to solar radiation. The Dow Chemical Company (Dow) has introduced ENLIGHTTM Polyolefin Encapsulant Films, which can enhance efficiencies in photovoltaic (PV) module production and lead to lower conversion costs. The films also can provide greater module stability and improved electrical performance versus traditional encapsulants, such as EVA-based products, which improves the reliability and extends the service life of PV modules. Modules made with these Polyolefin Encapsulant Films can retain efficiency levels after more than 10,000 hours of damp heat exposure. The new encapsulant films are suitable for C-Si and thin-film modules. Based on fully integrated polyolefin technology, these encapsulant films: • Can be formulated to address specific module design needs; • Provide Water Vapor Transmission Rates (WVTR) that can range from 10-20 times lower than EVA materials; • Allow excellent adhesion to glass under various lamination conditions; • Show no creep in use; • Offer a better matched refractive index to glass compared to EVA; and • Are listed with Underwriters Laboratories (UL) as “Recognized Components.” Thin-film solar cells are developing into a rapidly growing market segment. If their commercial potential is to be fully exploited, the solar modules must be produced in a roll-to-roll manufacturing process. Evonik Industries has now developed the "missing link" necessary for continuous production: a highly transparent and also weathering-resistant barrier film based on polymethylmethacrylate (PMMA) that can replace glass plates as a front cover. Most of the solar modules to be found nowadays contain crystalline solar cells, for which the light sensitive semiconductor layers are produced from silicon wafers, and at the front a glass plate shields the cells in the modules from environmental effects. They are produced in a batch process and weigh about 20 kilograms. If the barrier film protecting the solar cells from environmental effects is of plastic rather than glass, lightweight, flexible and therefore cost efficient thin-film solar cells can be realized with a number of semiconductor materials. They can be produced in a continuous roll-to-roll manufacturing process. The covering film should have the same properties as glass as far as possible. That means, it has to act as a barrier to water vapor and oxygen, allow high light transmission, adhere well to solar cells, and be electrically insulating, flexible, and cost efficient. It should also have high weathering and UV resistance. PMMA has many of the required properties such as high transparency, weathering resistance, and UV stability. To meet the other requirements, Evonik has been developing a multilayer film consisting of several functional and bonding layers and an outer PMMA layer. The ROHAGLAS® protects the underlying layers of the film very efficiently against the effects of weathering, thus ensuring the necessary longevity. In the spectral range relevant to photovoltaics, Evonik's new film achieves transmission rates of 88 and 90% in the short-wave and long-wave regions; these figures are comparable to those for glass plates. The film is currently being put through tests for compliance with the IEC 61646 standard for thin-film solar cells. The tests expose the laminated film to strong temperature fluctuations, UV radiation, high humidity, and mechanical loads such as arise from hail, snow, and wind. It is already clear that the multilayer film will more than satisfy the standard in regard to the damp heat test and UV resistance. Its water vapor barrier is 10-3 g/(m2d). The first customers are already testing the film of 1200 mm width for use in their flexible thin-film solar modules. The ZenithSolar optical dish is based on a patented design, utilizing multiple simple flat mirrors mounted on a plastic surface. The molded plastic surface, divided into four quadrants, is fixed onto a rigid, high precision metal frame assembled onto an azimuth and elevation solar tracking system. It is spread over 11 square meters and 1,200 mirrors. The ZenithSolar’s ‘Optics in Plastic’ is the key to manufacturing efficiency and superior product quality achievement. A 2800 ton injection molding press uses advanced custom thermoplastic composition developed by the company’s scientists for reliable, stable and long life operation. The solar dish is injection molded with multiple gate and radius heated runners to ensure even material flow to minimize warpage with a rapid mold fill. Molding is completed in a world-class facility with full material and environmental controls, material sampling and testing of each resin batch. Each dish is subjected to final product check on weighted custom jig fixtures and 3D product scans to ensure product accuracy. Cytec possesses a broad range of technologies and application expertise in the construction and fabrication of photovoltaic materials. The products offered enhance the performance and extend service lifetimes and durability of photovoltaics. In addition, Cytec has ongoing development efforts within these technology areas to address existing and emerging needs in the photovoltaic market. The product line includes adhesives, coatings, and additives. • GELVA (GMS) and GMR grades can be used to improve the adhesion and durability of laminated films that are utilized as photovoltaic back sheets. • EBECRYL® resins, which cure instantaneously with no VOC emissions, find application in protective hard coats, barrier layers, high RI (refractive index) applications, dielectric coatings and inks. • UVEKOL® glass laminating systems are used to reinforce glass, allowing for potential application in protecting solar cell glass layers. • CYANOX® antioxidants and CYASORB® UV light stabilizers represent technologies for increasing the performance lifetimes of EVA and PET films in photovoltaic cell systems. • AEROSOL® surfactants find application as emulsifiers, wetting agents and dispersants. • CYLINK® crosslinking monomers are utilized to manufacture photovoltaic EVA based encapsulants to enhance the hardness and temperature stability of the film. PolyOne Corporation, a global leader in specialty compounds, offers a broad spectrum of materials for a range of applications in the solar market. Photovoltaic cables: used for the interconnection of solar panel, need to meet demanding requirements such as weathering resistance up to 20 years, good flexibility and flex crack resistance is also specified. These cables should also havezero halogen, flame-retardant insulation and sheathing layers. Connectors: PolyOne’s EdgetekTM portfolio covers a broad range of standard and custom formulated high-performance materials including halogen-free flame retardant PBT compounds used for solar connectors. Back sheet Laminates: OnColorTM color and OnCapTM additive concentrates to enhance the performance of photovoltaic polymer back sheet laminates. The white color concentrates gives excellent dispersion, and provides opacity and reflectance enhancing the PV module efficiency. The UV stabilizers offer long term module shelf-life. Solar Energy Lights: GeonTM high flow vinyl molding compound can be used for solar light housing for outdoor use. The SelurisTM range of products offers BASF's customers an all-round solution for cutting, etching, texturing and doping mono- and polycrystalline solar cells. The special feature of Seluris™ is that, the chemicals are specifically geared to the solar cell manufacturing process. Thus, for example, the purity levels are tailored for use in solar cell production. Within the solar cell manufacturing process, BASF cutting fluids are used as cooling and lubricating agents when the wafers are sawn from the high-purity silicon blocks. Special etching and texturing chemicals eliminate the saw damage and the "patterning" created on the wafer surfaces. High-purity phosphorus oxychloride (POCl3) from a new production plant is used for subsequent doping of the wafers.