A PV Module with Embedded Humidity Sensors to Detect Moisture Ingress

Moisture ingress in photovoltaic (PV) modules reduces power output, accelerates material degradation, and poses safety risks, including electric shock, arcing, and fire hazards, by exposing high-voltage components. PV modules commonly experience challenges with moisture ingress, as many of the encapsulation materials used are not impermeable to air and water vapor. To address these challenges, research has focused on improving encapsulation materials and sealing techniques, alongside developing early-detection of moisture increase to prevent failures. This paper presents the design and fabrication of a PV module with embedded humidity sensors. While other papers have proposed similar ideas, this paper provides complete design details, including lessons learned from the experimental work, and experimental data to validate the technique. The proposed PV module facilitates early moisture ingress detection, supports R&D efforts to enhance durability, verify efficacy of moisture detection techniques, enables moisture trend analysis, and provides manufacturers with reliable moisture exposure data for warranty assessments.