Does CCA PV ribbon affect the lifespan and reliability of solar modules?
1. Electrical performance and degradation
Conductivity: CCA ribbon has slightly lower conductivity than pure copper (depending on copper ratio, typically 60–80% IACS vs ~100% for Cu). This means a little higher series resistance. If not properly designed (e.g., wider cross-section to compensate), it can slightly affect module efficiency.
2. Mechanical reliability
Thermal cycling stress: Aluminum core has a higher thermal expansion coefficient than copper. During repeated heating/cooling cycles in field conditions, mismatch stresses can form at solder joints. If the copper layer is uniform and well bonded, this risk is controlled, but in lower-grade CCA products solder fatigue or ribbon cracking can reduce lifespan.
Flexibility: CCA is slightly less ductile than copper, which may affect stringing process reliability if not carefully managed in lamination.
3. Corrosion and oxidation
The copper cladding layer protects the aluminum core from direct exposure. If manufacturing quality is good and edges are sealed, corrosion risk is minimal.
But if the copper layer is too thin or cracks expose aluminum, galvanic corrosion could occur, especially in humid or coastal environments, which would reduce reliability.
4. Module lifespan impact
Well-manufactured CCA ribbon (with adequate copper thickness, uniform cladding, and sealed edges) shows comparable lifespan to pure copper ribbon in standard IEC reliability tests (thermal cycling, damp heat, humidity freeze).
Low-quality CCA ribbon may fail earlier due to joint fatigue or corrosion, which directly affects module power retention and warranty life.
Conclusion:
CCA PV ribbon does not inherently reduce the lifespan or reliability of solar modules if it meets strict quality and design requirements (proper copper thickness, good adhesion, sealed surfaces, and tested under IEC conditions). In fact, many tier-2 and tier-3 solar module makers adopt CCA to cut cost and reduce weight. However, poor-quality CCA with thin copper layers or uneven cladding can compromise module durability.