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DuPont Encapsulant Materials Enable Production, Performance and Cost Advantages for Thin-Film Solar Modules

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Wilmington, Del., Feb. 21, 2011 – DuPont Photovoltaic Solutions announced the introduction of DuPont™ PV5400 series thin ionomer-based encapsulant sheets designed to protect sensitive thin film solar modules, while offering manufacturers new ways to cut costs, speed throughput and deliver more power over the life of each unit.  This is the latest of several recent additions to the company’s already broad and growing portfolio of photovoltaic (PV) solutions developed in line with the company’s aim to help reduce the world’s dependence on fossil fuels.

 PV5400 ionomer-based encapsulant
DuPont™ PV5400 Series ionomer-based encapsulants are available in convenient roll form for easy handling and fast laminating. ( high resolution image ) 
“PV industry innovation moves at a rapid pace, and material innovation is particularly critical to increase the lifetime and efficiency of solar modules and reduce total system costs,” said Steve Cluff, global business manager – DuPont Encapsulants.  “A key challenge is how to protect thin film PV modules from air and water vapor long term, and how to continue to lower manufacturing costs.  Choosing the right encapsulant material such as DuPont™ PV5400 not only increases module durability and production efficiency, but can significantly enhance long-term power generating efficiency.”

Because the new DuPont™ 5400 series ionomer-based encapsulants are fundamentally resistant to moisture intrusion, it is possible to achieve strong, lasting edge integrity without needing caulking or additional edge sealing, saving costs in manufacturing.  The added moisture resistance of assembled modules is expected to result in longer service life, or greater clean energy production, from each thin-film module installation, accompanying the potential for lower manufacturing costs.  Compared with traditional photovoltaic encapsulants such as ethylene-vinyl acetate (EVA) and polyvinyl butyral (PVB), new DuPont™ PV5400 series encapsulants have up to 100 times more electrical resistivity.  This offers modules improved electrical insulation, which minimizes current leakage.

Users of DuPont™ PV5400 series encapsulants also may be able to cut module lamination times by as much as 50 percent for significant productivity gains on suitable thin film manufacturing lines.  The DuPont™ PV5400 series encapsulant is DuPont's first ionomer sheet to be available in convenient roll form, easing storage and handling for large-volume, high-speed manufacturing. Available sheet thicknesses include 400 and 500 microns (0.4 and 0.5 mm), similar to incumbent encapsulant sheet materials.

DuPont offers the solar industry’s widest range of encapsulants for traditional and thin film photovoltaic module design.  DuPont™ PV5400 series ionomer-based encapsulants are the latest in a broad and growing portfolio of products represented by DuPont Photovoltaic Solutions, which connects science and technology from across the company on a global scale to help support the dramatic growth in the photovoltaic industry.  To learn more, please visit

DuPont ( is a science-based products and services company.  Founded in 1802, DuPont puts science to work by creating sustainable solutions essential to a better, safer, healthier life for people everywhere.  Operating in more than 90 countries, DuPont offers a wide range of innovative products and services for markets including agriculture and food; building and construction; communications; and transportation.

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