Comprehensive study on zeolitepolyester composite coated sheet for eco-friendly solar panels for enhanced panel performance and reduced panel temperature | Scientific Reports

Scientific Reports volume 14, Article number: 20072 (2024) Cite this article

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Solar energy is the most promising source for generating residential, commercial, and industrial electricity. However, solar panels should be eco-friendly to increase sustainability during manufacturing and recycling. This study investigates the potential of using natural fibre composites as eco-friendly alternatives to conventional polyethylene terephthalate (PET) back sheets in solar panels. Furthermore, it examines the performance of sisal fibres coated with zeolite-polyester resin. The chemical composition, structural integrity, and crystalline properties of the composites were evaluated through extensive microstructural analysis. The results from the experimental analysis revealed significant improvements in voltage (8%) and current (6%) for the coated sisal fibre panels compared to conventional panels. Power output increased by 12%, and overall efficiency improved from 9.75 to 10.8%. Solar panels with sisal fibre sheets exhibit adequate tensile strength and impact resistance and reduce operating temperature by 2–3 °C, ensuring stable operation and minimizing heat loss. Statistical analysis confirmed the reliability and significance of these results. The life cycle analysis demonstrated a 60% reduction in CO2 emissions and a 50% decrease in energy consumption during the production, utilization and disposal of sisal fibre sheets. These findings underscore the viability of natural fibre composites in enhancing the performance and sustainability of solar panels.

In recent decades, solar energy has become the most widely used technique to replace conventional energy sources and it is utilized in many countries globally. The sun's radiant energy (solar energy) is essential for sustainable life on Earth1,2, powering most natural processes, including the Earth's surface temperature. Reducing the pollution caused by the production of energy from biodegradable fuels is a drives the use of solar energy. One potential renewable energy source that is both broadly accessible and biodegradable is solar energy3. The primary requirements lean towards technological advancements in flexibility, eco-friendliness, and cost reduction. Initially, solar panel technology developed in the eighteenth century and remains strong today4. The development of solar cells has gone through several stages, starting with the observation of the photovoltaic effect, followed by the manufacturing of materials exhibiting the effect, the identification of the photoelectric effect, the creation of solar energy conversion devices, and most recently, the large-scale application of such a device5.

Researchers and global communities are significantly advocating the transition from conventional energy sources to sustainable alternatives like solar, wind, hydroelectric, and bioenergy to mitigate greenhouse gas emissions5,6. Key geopolitical agreements such as the Paris Agreement and the Copenhagen Climate Change Conference have played crucial roles in securing commitments from countries to reduce carbon emissions, promote renewable energy, and limit global temperature rise to below 2 °C7,8. In 2022, the renewable energy sector experienced significant growth, adding 250 GW of capacity, a 9.1% increase in power generation9. Solar and wind energy accounted for 90% of this expansion. According to reports from the International Renewable Energy Agency (IRENA)10, solar photovoltaic (PV) panels are leading the renewable energy sector, potentially meeting approximately 60% of current electricity demand. Previous studies11,12 suggest substantial growth in solar PV production globally, projected to exceed 1630 GW by 2030 and a remarkable 4500 GW by 2050.

Several developed nations, including China, the United States, Canada, the United Kingdom, European Union member states, Australia, and Japan, have initiated numerous solar PV projects aligned with the United Nations Sustainable Development Goals13,14. In 2014, the Indian government launched the Jawaharlal National Solar Mission (JNNSM) to promote sustainable energy growth through solar and wind sources, initially targeting 100 GW, which was later increased to 450 GW15,16. However, India does not have dedicated regulations for handling photovoltaic (PV) panel waste. Instead, PV panel waste is managed under general waste regulations. Oversight for waste management policies, including those concerning PV panel waste, lies within the Ministry of Environment, Forest and Climate Change jurisdiction, governed by the Solid Waste Management Rules and the Hazardous and Management and Transboundary Movement (MTM) Rules17. The absence of specific guidelines within existing waste regulations highlights a potential necessity for more tailored regulations and policies in the future.

Solar PV systems in residential and commercial buildings will gain a strong market position, and their capacity is expected to increase to 320 GW or almost three-fourths of the total sustainable energy growth18. Moreover, the constantly rising ability of consumers to produce their electricity represents new opportunities and challenges for electricity providers and policymakers worldwide18,19. Even though solar panels seem to have a lot of advantages, they also have a few disadvantages. In particular, manufacturing solar panels can be crucial20,21. Cadmium and titanium are toxic materials with a higher production cost and require more toxic materials. The manufacturing of solar panels increases carbon emissions due to several industrial wastes. Most significantly, cadmium exposure can result in cancer and a variety of other complications23. Current researchers are focusing on developing eco-friendly solar panels. Sustainability is constantly needed in solar panels' manufacturing and consumption phases.

Aged solar panels that are still functional may be fixed and sold in recycling facilities24. If not, the crystalline panels are grounded, the aluminium frames, cables, and junction boxes are removed, and various methods are used to separate the glass, metals, and foils25. While thermal insulation often processes glass particles to produce glass wool, metals and lead are removed and reused. Plastic foils and sheets are generally burned in plants equipped with filters. Experts in raw materials and the environment agree that recycling this plastic still needs more attention26,27. Generally, the special backsheet and transparent sheets cannot be recycled and need incinerators for disposal. The incinerators consume significant energy to achieve high temperatures, and the CO2 emissions will lead to a carbon footprint28.

Polyethylene terephthalate (PET) sheets are used as the primary option for a back sheet of solar panels. However, the PET material is manufactured by polymerizing the terephthalic acid (TPA) or dimethyl terephthalate (DMT) along with ethylene glycol (EG). PET is a petroleum-based plastic whose manufacturing process and disposal may adversely affect the environment by producing waste and carbon emissions. Furthermore, as PET does not biodegrade, improper disposal of solar panels with PET back sheets may add to the global plastic pollution problem. Additionally, PET back sheets may not have as high heat resistance. Thus, this leads to potential degradation or warping of the back sheet under prolonged exposure to high temperatures, which can occur in certain climates or during periods of intense sunlight29.

Despite significant advancements in solar photovoltaic (PV) technology and its increasing adoption worldwide, several critical challenges still need to be addressed. One of the primary concerns is the environmental impact of manufacturing and disposing of solar panel components, particularly the back sheets made from polyethylene terephthalate (PET). PET back sheets, while effective in their role, are petroleum-based plastics that do not biodegrade, contributing to global plastic pollution and carbon emissions during production and disposal. Furthermore, PET materials lack high heat resistance, which can lead to degradation under prolonged exposure to high temperatures, affecting the performance and lifespan of solar panels.

Previous studies have primarily focused on improving the efficiency and cost-effectiveness of solar panels, with less emphasis on the environmental sustainability of their components. While some research has explored the use of alternative materials for solar panel manufacturing, there is a notable lack of comprehensive studies that address both the environmental impact and the performance of these alternatives. The potential for natural fibres, such as sisal, to replace PET back sheets in solar panels has not been fully explored. Furthermore, the current strategies to enhance the thermal management of solar panels often involve intricate and expensive materials and processes, which may not be viable for widespread adoption. There is a significant research gap in the integration of natural materials with thermal insulating properties that can enhance solar panel performance while maintaining cost-effectiveness and environmental sustainability.

This study aims to fill these research gaps by developing and evaluating natural sisal fibre back sheets coated with thermal comforting materials, such as zeolite-polyester resin, using advanced manufacturing techniques like vacuum-assisted resin transfer moulding (VARTM). This approach seeks to provide a sustainable and efficient alternative to conventional PET back sheets, addressing the dual challenges of environmental impact and thermal management in solar panel technology. By thoroughly examining these natural fibre back sheets' physical, chemical, mechanical, and thermal properties, this research will contribute to a deeper understanding of their feasibility and benefits, promoting more sustainable practices in the solar energy industry.

This study introduces the innovative use of natural sisal fibre as a sustainable alternative to conventional PET sheets in solar panels. Coating these fibres with zeolite-polyester resin enhances panel performance and reduces heat accumulation, addressing environmental concerns associated with PET. The objectives include developing eco-friendly back sheets using vacuum-assisted resin transfer moulding (VARTM) for quality consistency and comprehensively evaluating their physical, chemical, mechanical, and thermal properties. This study highlights natural fibre back sheets' environmental benefits and performance improvements compared to PET, supported by statistical and life cycle analyses. Natural fibres, such as sisal, are biodegradable, producing significantly less CO2 and less energy than PET. They enhance mechanical properties, maintain lower operating temperatures, and improve solar panel efficiency and durability. Using zeolite-polyester composites with natural fibres ensures excellent structural integrity, uniformity, and reliability. While the initial cost might be higher, the long-term benefits include lower maintenance costs and better performance, especially in harsh conditions. This research promotes sustainable, high-performing alternatives to traditional materials, aligning with environmental and efficiency goals. The major contributions of this study are:

Developed eco-friendly solar panel back sheets using natural sisal fibres to replace conventional PET back sheets.

Integrated thermal comforting materials, specifically zeolite-polyester resin coatings, into sisal fibre back sheets through VARTM process to enhance solar panels' thermal stability and insulation properties.

Conducted thorough evaluations of the physical, chemical, mechanical, and thermal properties under various environmental conditions.

Compared the performance and environmental impact to highlight the advantages and potential trade-offs of using natural fibres.

Demonstrate the feasibility and benefits of incorporating natural materials into renewable energy technologies, promoting sustainable and eco-friendly solar panel solutions.

Sisal fibre has insulating properties, which help regulate temperatures within the solar panel30,31. Incorporating sisal fibre into the panel design may help reduce heat transfer, potentially improving thermal comfort. Sisal fibre could absorb some of the solar radiation that reaches the panel surface32,33. This absorption could reduce the amount of heat transferred into the panel's interior, potentially contributing to thermal comfort by lowering the temperature of the panel components. Sisal fibre has natural moisture-wicking properties, which could help to manage moisture within the solar panel. By absorbing excess moisture, sisal fibre could prevent the buildup of condensation or humidity within the panel, potentially improving comfort for sensitive electronic components.

Compared to traditional materials like polyethylene terephthalate (PET), sisal fibres offer superior thermal stability and insulating qualities, making them an innovative alternative for solar panel back sheets. Sisal fibres have inherent thermal stability, which helps to maintain the solar panels' structural integrity under varying temperature conditions. Their natural composition provides excellent insulation properties, reducing heat accumulation within the solar panel. This reduction in heat build-up not only enhances the overall efficiency of the solar cells but also prolongs the panels' lifespan by preventing overheating and associated thermal degradation. Additionally, the fibrous structure of sisal allows for better heat dissipation compared to the denser, synthetic PET material, further contributing to the thermal regulation of the panels. Solar panels can achieve improved performance and durability by integrating sisal fibres while addressing environmental sustainability concerns associated with traditional synthetic materials.

However, some considerations and challenges exist, such as degradation and manufacturing complexity34,35. Natural fibres like sisal may degrade when exposed to sunlight, moisture, and other environmental factors36,37. This research provided proper treatment and protection to ensure sisal fibre's longevity within solar panels. Engineering challenges must be addressed to integrate sisal fibre effectively while maintaining panel efficiency and reliability. Initially, pure sisal (PS) fibre without coating was used as the reinforcement mat for the back sheet. Subsequently, the fibre reinforcement mats were coated with thermal comforting materials such as zeolite and polyester polymer to increase the thermal properties and prevent degradation. Polymers have significantly improved the quality of contemporary existence and found various applications38,39,40. However, the fact that most of the polymers used to make these materials are organic and combustible presents a significant problem41,42,43. Therefore, Zeolite type 3A, unsaturated polyester, and Methyl Ethyl Ketone Peroxide (MEKP) hardener types were used precisely in this investigation. These materials were coated on the reinforcement mat using the vacuum infusion method.

In the coating process of sisal fibres for eco-friendly solar panels, the choice of zeolite type 3A plays a critical role in determining the thermal and mechanical properties of the composite material. Zeolite type 3A, characterized by its potassium-exchanged aluminosilicate structure, typically features a uniform pore size of approximately 3 angstroms. This molecular sieve structure enables efficient adsorption and desorption capabilities, which is advantageous for enhancing coatings' moisture resistance and permeability properties. The particle size of zeolite type 3A used in the composite coating process is finely tuned to optimize surface area and adhesion to the sisal fibres, promoting uniform dispersion within the polyester resin matrix. This precise control over particle size ensures enhanced mechanical strength and thermal stability of the composite material, which is crucial for maintaining structural integrity and performance under varying environmental conditions.

Using a vacuum, resin is injected into the fabric during the vacuum-assisted resin transfer moulding (VARTM) process, which creates fibre-reinforced composites44. In the 1950s, VARTM was employed to produce boat hulls45. However, this technique has become a trial-and-error approach due to its limitations. In his study, the suumer scale covered the VARTM specifications, including its applications46. Bhatt et al. have discussed the history, development, and future trends of VARTM47. Due to the difference in pressure between the vacuum pipe and the resin supply pipe, VARTM resin was infused inside the layers of the fabric48. Three coatings of release spray were applied before the fabric was placed on the glass table. Sealant tape was used to seal the layers of fabric after they had been covered with peel ply, high-permeable media (HPM), and a vacuum bag. A vacuum was produced from one end, while resin was supplied from the other. Kuentzer et al. described how to manage void content by draining the resin flow, which ensures flow between and inside tows49. Several factors influence the quality of parts produced by VARTM, which the previous researchers studied50. Figure 1a represents the schematic diagram of the layers used for the VARTM process.

(a) Schematic diagram for layers of VARTM process; (b) first layer of VARTM; (c) second layer of VARTM; (d) third layer of VARTM; (e) fourth layer of VARTM; (f) Final layer of VARTM.

The VARTM process preparation starts with waxing the manufacturing table surface, marking dimensions, placing spiral pipes, and securing sealant tape (see Fig. 1b). As indicated in Fig. 1c, the realising film was placed to get a smooth finish for the back sheet. The next layer consisted of the fibre mats placed on the releasing film. Since there is a thickness restriction, the number of fibre mats for the pure sisal fibre back sheet was 1 (as shown in Fig. 1d). In Fig. 1e, the fourth layer was represented, where the peel ply and the green mesh were placed, followed by connecting the vacuum pipe with the spiral pipe with a T connector. Accordingly, one feed port was placed at the centre for single-layer fibres (see Fig. 1f), and two feed ports were placed diagonally for the two-layer fibres. Finally, the vacuum cover was placed on the perimeter of the sealant tape to secure the VARTM setup.

This work aimed to apply the novel vacuum-assisted resin transfer molding (VARTM) technique for coating the zeolite and polyester resin onto the natural sisal fibre. The unsaturated polyester resin was mixed with zeolite and infused into the preforms at 1.3–1.6 kPa vacuum pressure. The dimension of the back sheet was 20*20 cm, and the thickness of the sheet was maintained to be 1.5–3 mm. For each layer of provided fibres, 90 g of zeolite and 135 g of polyester were utilized. Figure 3 shows the VARTM process during the infusion of zeolite mixed with polyester resin for single-layer fibre (pure sisal). The resin supply was from the middle, and the vacuum was from edge to centre to achieve maximum strength48.

This section proceeds with an initial preliminary investigation of sisal fibre (i.e.) the basic physical properties, such as specific gravity, water absorption, tensile strength, and modulus of elasticity, were presented. The chemical compositions were determined through Scanning Electron Microscope (SEM) analysis, Energy Dispersive X-ray spectroscopy (EDS) and X-ray diffraction (XRD) analysis. The thermal properties, such as the temperature analysis, were carried out through Differential Scanning Calorimetry (DSC) analysis.

Previous researchers have studied the possible utilization of sisal fibres in various fields. Additionally, the physical and chemical properties have been investigated and presented51. The specific gravity of sisal fibre was 1.35, and the density was 1450 kg/m3. Balasubramanian et al. determined that the range of the Poisson ratio is 0.2 to 0.2552. Similarly, due to its unique physical and mechanical properties, zeolite type 3A, with a 1450 kg/m3 density, is essential in the composite coating process. It possesses a high tensile strength of 589 MPa and an elastic modulus of 21 GPa, contributing to the overall robustness and durability of the composite material. The zeolite's composition includes 66% cellulose, 16% semi-cellulose, and 12.2% lignin, collectively influencing its mechanical properties and environmental stability. The particle diameter of 145 µm is optimal for ensuring a uniform distribution within the polyester resin matrix, enhancing the interaction between the zeolite particles and the sisal fibres. Additionally, the microfibrillar angle of 23 degrees (θ) plays a significant role in determining the stiffness and strength of the fibres, affecting the composite's overall mechanical performance. These characteristics make zeolite type 3A a suitable choice for improving eco-friendly solar panel coatings' thermal and mechanical properties.

A digital calliper was used to measure the thickness of the three tensile coupons at three distinct positions on each panel to assess the thickness uniformity. The per-ply thickness (PPT = total panel thickness/number of layers) and the fibre volume fraction (Vf) were computed based on the panel thickness measurements. Table 1 presents the results of the thickness measurement. The mean value of coated pure sisal fibre was 2.69. The estimated parameters for a VARTM process were reasonably high, and the coated pure sisal panel had a lower variance in thickness.

Specimens are pulled until they fracture in the grips of a universal test machine at a predetermined grip separation45,46. The ASTM D 3822[55]standard states that a universal testing machine assesses the sisal fibre's tensile characteristics56,57. Three samples of pure sisal fibre were tested and recorded after testing.

Tensile modulus and elongation are measured using an extensometer, also known as a strain gauge. The following specifications can be calculated using the results of the tensile test58,59: (i) Tensile strength (MPa); (ii) Young's modulus (GPa); (iii) Failure strain (%). The tensile coupons were cut from the panels using a diamond-blade wet saw. The coated pure sisal (CPS) coupons were 155 mm long by 20 mm wide. However, the thickness of the coupons was 2.7 mm for CPS. The test was performed at a cross-head speed of 1 mm/min and with a gauge length and width of 55 mm by 14 mm, respectively60. Figure 2 represents the experimental images of the tensile strength testing. Each tensile coupon was further processed by adding 50-mm-long fibre glass tabs to each end and a bonded strain gauge to the middle of the coupon.

(a) Crack on coated pure sisal; (b) Tested samples with elongation cracks.

Table 2 comprises the three sample coupons' tensile strength, tensile modulus, and failure strain. The tensile strength of the pure sisal fibre was comparatively less due to the unidirectional waving pattern, thus significantly impacting the tensile strength, and sample 6 has the least tensile strength, in which the elongation crack happened with the effect of slip that reduces the tensile strength. From the analysis, the natural fibre sheets fell under the category of brittle materials since the failure strain % is less than 5.

The pure sisal fibre mat was treated with 5% NaOH for 12 h and oven-dried at 40 °C for 4 h per the recommendations50,51. The scanning electron microscope was separately carried out for the three different samples, such as pure sisal fibre mat before and after treatmentand coated pure sisal fibre mat. Field Emission Scanning Electron Microscopy (FE-SEM) was utilised for this microstructural study63,64. Backscattered electrons were used to capture micrographs and to represent them65. Removing surface impurities, non-cellulosic content, and waxes resulted in rougher surfaces and better fibre separation. The sisal fibre, as shown in Fig. 3a, was covered with waxes and other impurities and thus had a smoother texture. It is observed that with the NaOH surface treatment, the roughness of the sisal fibre mat has increased, as shown in Fig. 3b, and uniform surface roughness was achieved.

(a) SEM analysis of pure sisal before NaOH treatment; (b) SEM analysis of pure sisal after NaOH treatment, (c) coated pure sisal in 350 magnification; (d) coated pure sisal in 500 magnification; (e) coated pure sisal in 3500 magnification.

Similarly, the intermolecular bond between the pure sisal fibre tendons was increased, and adequate roughness was achieved. The NaOH-treated pure sisal fibre has fewer impurities, and fibre bundles are more separated, with a higher surface roughness. Figures 3c–e depict the SEM analysis of coated pure sisal fibre; from the analysis, it is clear that there was little or no porosity in coated pure sisal. A few areas were resin-rich, as represented in Fig. 3c and d. This can be expected because fabric preforms have periodic "open" areas where the tows cross. The resin-rich areas are either due to the variation in the resin flow or incomplete nesting of the fibre plies during the VARTM process. Furthermore, there was some variation in the packing of fibres within fibre tows in coated pure sisal fibre. However, the microstructure's overall quality was significant.

The EDS analysis was carried out for three sets of samples (see Fig. 4a–c), which include uncoated pure sisal (PS), coated pure sisal(CPS), and the conventional (Con)solar panel back sheet material, i.e., polyethylene terephthalate film (PET). The x-axis represents the energy levels of the detected X-rays. It is usually expressed in kiloelectron volts (keV). The y-axis represents the intensity of the X-rays detected at each energy level.

(a) EDS of uncoated pure sisal; (b) coatedpure sisal; (c) Conventional PET.

This intensity indicates the number of X-rays detected at a given energy. The EDS plot peaks correspond to the sample's specific elements. Each element emits X-rays at characteristic energy levels. These peaks appear as spikes or peaks on the graph, and the energy levels at which they occur can be used to identify the elements. The peak height correlates with the abundance of the particular component of the sample. The corresponding weight percentage of each element present has been presented in the graphs.

In general, XRD identifies the crystallinity of fibres, which can be determined through XRD analysis. This study determined the varying crystallinity levels of uncoated pure sisal and coated pure sisal fibre using CuKα (λ = 1.54) radiation. The intensity of diffraction ranges from 5° to 90° of 2θ, and the scanning speed is 0.02°/s. Figure 5 represents the x-ray diffraction analysis of pure sisal and coated pure sisal. The diffractograms show the primary crystalline peak at 2θ = 22°, with varying crystallinity levels for coated pure sisal.

XRD analysis of coated pure sisal fibre and uncoated pure sisal fibre.

Moreover, the analysis reveals that the coated pure sisal has the highest peak of intensity (413 cps), indicating a significant improvement in its crystallinity. This enhancement is attributed to the zeolite-polyester coating through the VARTM process. The XRD analysis calculated the crystallinity index of uncoated sisal fibre as 80.88% and zeolite-polyester resin-coated sisal fibre as 95%. The higher crystallinity index of the zeolite-polyester resin-coated sisal fibre than the uncoated sisal fibre indicates that the coating significantly enhances the fibre's properties. The increase in the crystallinity index, resulting from the reduction of the amorphous phase, has led to a notable enhancement in the tensile strength of the fibres. The coated pure sisal fibre, with its improved interfacial bonding due to the increased crystalline cellulose content, is a testament to the effectiveness of our research. This increase in crystallinity likely results in improved mechanical strength, better thermal stability, and enhanced chemical resistance, making coated sisal fibre more suitable for high-performance applications such as eco-friendly solar panels. Thus, the coating effectively transforms the natural fibre into a more robust and durable material.

The development of heat resistance and stability and the thermal analysis of uncoated pure sisalfibreand coated pure sisal fibreare all critical aspects of this study. Thermal analysis is essential for comprehending the structure–property relationship and mastering molecular design technology54,67. Furthermore, the quantity of moisture and volatile substances that can lead to composite deterioration can be measured68. A differential scanning calorimetric (DSC) analysis was conducted for this investigation. The endothermic peak temperature of pure sisal fibre has been observed at around 128 ℃ (shown in Fig. 6a) due to the thermal transition involving decomposition and degradation of structural components of fibres. Whereas for the coated pure sisal, the endothermic peak temperature slightly increased up to 130 °C (see Fig. 6b), and the temperature dropdown was consistent, i.e., the thermal stability of the pure sisal fibre was increased due to the zeolite polyester resin coating.

(a) DCS analysis of pure sisaland, (b) coated pure sisal.

The solar panel using the natural sisal fibre back sheet was manufactured by the Ecolam Max 3, a solar module automatic laminator with a load and unload belt. The 3200 × 2050 mm functional lamination area comprises three plates divided into three thermally controllable zones. Electrical heat is applied to each zone with a consistency of ± 2 °C. A Teflon sheet covers the module's rear end during the lamination cycle, and a Teflon belt loads and unloads the modules in and out of the laminator. Hot compression and lamination fixed the natural fibre back sheets with the solar cells. The lamination process was done in collaboration with JP Solar, Pvt. Ltd., and Chengalpattu, India, for this research work. Figure 7a depicts the manufacturing of solar panels with coated pure sisal fibre before hot compression. Figure 7b shows the manufacturing of solar panels with coated pure sisal fibre after hot compression.

(a) Solar panel with coated pure sisal before hot compression; (b) solar panel with coated pure sisal after hot compression.

This study used polycrystalline solar cells since they are less effective when changing temperatures. The natural sisal fibres were provided as a back sheet to increase the efficiency of the economical solar cells (polycrystalline). The solar panel manufacturing used six polycrystalline solar cells with a 4.5-W capacity. The polycrystalline solar cells were arranged in two columns, and each consecutive column was connected to the bypass diode to form an independent string of cells. The compressed solar panels were attached to an aluminium frame to develop a solar PV module for further experimental investigation.

Based on their physical, chemical, mechanical, and thermal properties, the uncoated pure sisal and coated pure sisal can replace the toxic PET sheets, which have nearly 3% titanium. Panel dimensions were restricted to 20*20 cm, and the thickness of the panels was maintained below 0.3 mm. The research reported in this paper was carried out to investigate solar panel efficiency and panel temperature. TIG (Tungsten Inert Gas) welding was used to wire the solar panels individually since there is a need to examine the performance of each panel separately. TIG welding was used due to its precise and high-quality welds on solar panels and aluminium frames. The solar panels with uncoated and coated pure sisal fibre were manufactured and temporarily installed on the rooftop of an institutional building, "Architectural Block, SRM Institute of Science and Technology, Kattankulathur, Tamil Nadu, India." Fig. 8 shows the initial testing (manual testing) of solar panels with different back sheets for voltage and current through a multimeter. After initial testing, the solar panels were mounted temporarily on the rooftop, where the panels are connected directly to the storage battery in a series connection.

(a) Conventional PET back sheet; (b) uncoated pure sisal fibre back sheet; (c) coated pure sisal back sheet and (d) manual testing of solar panels using multimeter.

The data is collected manually and individually for each type of panel (i.e.) during data collection, the series connection will be disconnected, and the data will be collected through a multimeter. The investigation period was 90 days, from October 2023 to December 2023. Previous studies conducted by Jacobson and Jadhav, 2018 revealed the optimal tile angle for most countries through the data collected from the National Renewable Energy Laboratory (NREL) PV Watts program. The optimal tilt for solar panels in India, especially in Chennai, is 13°69. Therefore, the temporary solar panels were tilted at 13° for further experimental investigation.

Table 3 represents the properties of each component in solar panels. The uncoated pure sisal fibre possesses lower thermal conductivity, which is inadequate for high-performance solar panels. The thermal conductivity of pure sisal fibres was increased by zeolite-polyester coating. This property facilitates the efficient transfer of heat away from the solar cells, helping to maintain optimal operating temperatures. High thermal conductivity allows for rapid dissipation of excess heat, reducing the risk of overheating and improving the solar panels' overall performance and lifespan. However, in solar panel construction, it is generally advantageous for the specific heat capacity of materials to be relatively low. This attribute facilitates the maintenance of a stable temperature within solar panels, optimizing their operational efficiency. The coated pure sisal fibre has the lowest specific heat capacity compared to the conventional PET back sheet (see Tables 3, 4). The lower specific heat capacities exhibit increased sensitivity to variations in solar radiation and ambient temperature, enabling it to heat up or cool down more promptly as needed70. This swift adjustment aids in sustaining the ideal operating temperature range for solar panels. Additionally, the thermal comfort materials such as zeolite-polyester coating for the sisal fibre possess the lowest specific heat capacities than the solar cells, which can dissipate surplus heat, thus averting the risk of overheating and ensuring that the solar cells function within their optimal temperature parameters. Furthermore, such materials mitigate the possibility of thermal stress-induced mechanical fatigue or degradation over time, as they are better equipped to accommodate rapid temperature fluctuations.

The voltage and current gain across three different solar panels, conventional (Con), uncoated pure sisal (PS), and coated pure sisal (CPS), were manually collected at 30-min intervals. A multimeter was used to collect the direct current and the voltage. From the data collected, the coated pure sisal fibre solar panel shows higher voltage than other panels.

However, the uncoated pure sisal fibre solar panel also has significantly higher values than conventional panels. In this study, the Decade Resistance Box (DRB) box was utilised to provide a resistive load to check the performance of the individual panels. A resistive load simulates the resistance encountered by the solar panel's output in a real-world application71. The Decade Resistance Box set different resistance values and was connected in series with the solar panel for analysis. The solar panel's power output at various load conditions can be calculated by measuring the voltage and current across the load using the multimeter.

From the experimental values, it is clear that from 10:00 AM to 01:30 PM, the current and voltage values were increasing gradually, and from 02:00 PM to 05:00 PM, the voltage and current values decreased progressively. The graph (see Fig. 9a and b) represents the solar panels' open circuit voltage and current flow, with short error bars indicating low uncertainties in the data. The coated pure sisal panel shows an 8% higher voltage than the conventional panels. The pure sisal fibre panel shows a 4% higher voltage than the conventional panels. The average of three months of open circuit voltage and current readings are presented in Table 5. Similarly, the current flow in the panels was higher in the coated pure sisal (6% high), and the uncoated pure sisal fibre panels showed a 3% higher current than the conventional panels.

(a) Experimental value of open circuit voltage; (b) direct current a from the investigation; (c) solar panel’s temperature data from fluke thermal camera and power gain.

The temperature of the solar panels was collected using a fluke thermal camera. Since the high temperature in and around the solar panel will affect the solar cells' efficiency and life span, maintaining the solar panels' temperature is mandatory. Natural fibres have the potential to provide thermal comfort. Additionally, in this study, zeolite was used to enhance thermal comfort. The coated pure sisal fibre solar panels maintain a lower temperature (see Fig. 9c). Nearly 1–3 °C were reduced compared to the conventional PET material. Figure 10 represents the images from the fluke thermal camera with time stamps. The electrical power capacity in watts was calculated for each panel; the coated pure sisal fibre panel have 12% higher power, and the uncoated pure sisal fibre panel has 7% higher power than conventional panels. The experimental duration was 90 days; the average temperature collected from the thermal camera and the average power in watts are provided in Table 6.

Temperature collection using fluke thermal camera.

The experimental values can have measurement uncertainties due to several factors, such as measurement instrument limitations, variability in the measured quantity, environmental conditions, and human error. The measurement uncertainties, the margin of error, and the confidence intervals were calculated and presented in Table 4. The confidence level was fixed at 95% (i.e., 0.95) to calculate the margin of errors and confidence. We agree to the suggestion provided. The crystallinity indices of coated and uncoated sisal fibres were calculated and presented on page 11 of the revised manuscript.

Equation (1) 72 was used to calculate the solar panels' electrical power capacity, Eq. (2) to calculate their efficiency percentage, and Eq. (3) to calculate their output power.

where P is the power in watts; V is the voltage in volts; I is the current in amperes; Pmax is the maximum solar panel power, which is measured in watts (bolded italics-coded values in Table 5); Area = length × width of solar panels (measured in sq. m); 1000 is the conversion factor to convert power output per unit area from watts per sq. m to per cent; SIr is the solar irradiance; in this study, the constant value of 5 kWh/m2/day was considered for calculations. The conventional solar panel's efficiency was calculated using Eq. 2 and found to be 9.75% for conventional, 10.8% for coated pure sisal, and 10.2% for pure sisal fibre panels'. Feroz Shaik mentioned in his paper that the efficiency of the conventional solar panel was 10.8% under partially similar circumference60,61. However, in this study, the experiments were conducted during the winter season (October – December), which affected the efficiency of the conventional panel. Natural fibre solar panels exhibit slightly higher efficiency than conventional solar panels due to the presence of thermal comforting material coated with natural sisal fibre. The output power per conventional solar panel is obtained as 1.95 watts, the coated pure sisal as 2.1 watts, and the pure sisal obtained as 2.04 watts (calculated using Eq. 2).

The improvement in power output observed in the study when employing coated pure sisal fibre panels compared to conventional panels can be attributed to several key factors. The increased carbon content and reduced need for titanium in sisal fibres enhance electrical properties and lower the carbon footprint. The Vacuum-Assisted Resin Transfer Moulding (VARTM) process also ensures excellent structural integrity and uniformity, which are essential for reliable mechanical performance. The stable chemical and crystalline structures of sisal fibres further contribute to the durability of the back sheets. Notably, the panels with coated pure sisal back sheets demonstrated significant voltage and current gains, increasing efficiency from 9.75 to 10.8%. Improved thermal management, with lower operating temperatures by 1–3 °C, enhanced efficiency and longevity. Environmentally, sisal fibres offer a sustainable alternative with lower carbon emissions and biodegradability, addressing plastic pollution concerns. The natural fibre-reinforced panels maintained adequate mechanical properties, providing stable operating conditions and minimizing heat loss. Combining these factors results in better performance, reduced maintenance costs, and a favourable cost–benefit ratio, particularly in aggressive environments.

Solar cell testers can be used to study solar cells' long-term performance and degradation mechanisms. By monitoring changes in electrical properties over time, researchers can identify degradation mechanisms, assess the stability of materials, and develop strategies to improve the durability and reliability of solar cells. Solar cell tester’s measure vital electrical parameters of solar cells, such as current–voltage (IV) characteristics, open-circuit voltage (Voc), short-circuit current (Isc), maximum power point (Pmax), fill factor (FF), and efficiency. By analyzing these parameters, researchers and manufacturers can assess solar cells' overall performance and efficiency. Solar cell testers allow for testing under different environmental conditions, such as varying light intensities, temperatures, and spectral distributions. This enables researchers to evaluate the performance of solar cells under realistic operating conditions and assess their suitability for different geographic locations and applications.

This study analyzed solar cell performances by increasing the panel temperature. Three solar panels of dimension 20*20 cm (6 polycrystalline cells each) were connected in series connection, heated manually to a temperature of 60℃ and tested for panel efficiency through a solar cell tester. From the analysis, it is clear that the coated pure sisal fibre panel demonstrates the highest short circuit current (1.47 A), open circuit voltage (12.00 V), maximum power (11.17 W), efficiency (15.00%), and power at load (10.29 W) among the three panels. It also exhibits the lowest series resistance (1.35 Ω) and a relatively low shunt resistance (16.51 Ω), indicating improved electrical characteristics. Figure 11 represents the I-V curve (Current–Voltage curve) of the conventional, coated sisal and uncoated sisal fibre from the solar cell tester. However, the conventional panel has the highest fill factor, indicating better utilization of available power (see Table 7).

I-V curve from solar cell tester. (a) Conventional panel; (b) coated pure sisal fibre panel; (c) uncoated pure sisal fibre panel.

This study used the design Expert software to conduct the statistical analysis for conventional, uncoated pure sisal fibre and coated pure sisal fibre panels. Design Expert is a powerful statistical analysis tool that provides a comprehensive suite of features for designing experiments, analyzing data, and identifying the significant factors and their interactions. The software supports various experimental designs, including factorial, response surface methodology (RSM), and mixture designs, enabling users to simultaneously explore the effects of multiple variables. With its intuitive interface, Design Expert allows for easy input of experimental data and offers robust tools for analyzing results, such as Analysis of Variance (ANOVA) and model fit statistics. Table 8 represents the ANOVA table for conventional, coated and uncoated sisal fibre panels.

The ANOVA results for the Conventional, CPS, and PS panels show that the models for all three panels are highly significant, with p-values less than 0.0001, indicating that the predictors collectively have a substantial effect on the response variable. For each panel, open circuit voltage (V) and current (A) are highly significant factors with p-values less than 0.0001, demonstrating solid influences on the response variable. The PS panel shows the highest F-value for Current, indicating it has the most substantial effect among the three panels. Conversely, Temperature (C) is not a significant factor in any of the panels, with p-values well above 0.05, implying a minimal impact on the response variable. The interaction between open circuit voltage and current (AB) is significant across all panels, particularly in the CPS panel, which has the highest F-value for this interaction, indicating a robust combined effect of these factors. However, interactions involving Temperature (AC and BC) are insignificant in any of the panels, suggesting that temperature does not significantly affect the response variable in combination with the other factors.

The R2 values for the Conventional, CPS, and PS panels indicate the proportion of variance in the response variable explained by the model. All three panels have exceptionally high R2 values of 0.9999, signifying that the models account for nearly all the variability in the response variable (see Table 9). This is further supported by the Adjusted R2 values, which correct for the number of predictors in the model and remain very high at 0.9998 or 0.9999 for all panels, affirming the robustness of the models even after adjusting for the complexity. The predicted R2 values, which estimate the model's predictive power for new data, are slightly lower but still remarkably high, with values of 0.9996 for the Conventional panel, 0.9998 for the CPS panel, and 0.9997 for the PS panel. These values indicate that the models have excellent predictive capabilities and are unlikely to overfit the data. The standard deviation values are low for all panels, with the CPS panel having the lowest at 0.0070, followed by the PS panel at 0.0095 and the Conventional panel at 0.0106. This low standard deviation indicates a high precision of the estimates. This suggests the consistency of the experiments conducted in the controlled environment, which shows that the process and the measurements are stable and reproducible. The Coefficient of Variation (C.V. %) values, which measure the relative variability, are also low across the panels, with the CPS panel showing the lowest value at 0.2032%, indicating the highest precision, followed by the PS panel at 0.3012%, and the Conventional panel at 0.3700%. The adequate precision values, which measure the signal-to-noise ratio, are all well above the desirable threshold of 4, with the CPS panel having the highest value at 473.7057, indicating the most reliable model, followed by the PS panel at 347.2969 and the Conventional panel at 314.0081.

The primary goal of this life cycle assessment (LCA) is to evaluate the environmental impacts associated with the production, use, and disposal of zeolite-polyester resin-coated sisal fibre sheets used as the back sheet of solar panels. The assessment was carried out for one square meter of zeolite-polyester-coated sisal fibre sheets. Figure 12 depicts the CO2 emission of the zeolite-polyester resin-coated sisal fibre sheets throughout their life. The life cycle assessment (LCA) conducted for zeolite-polyester resin-coated sisal fibre sheets reveals a more environmentally sustainable profile than traditional synthetic polymer back sheets like PVF and PET. The study examined the environmental impacts associated with the production, use, and disposal of one square meter of these sheets, highlighting significant benefits across various life cycle stages. Table 10 shows the major parameters considered in the life cycle analysis. Zeolite-polyester resin-coated sisal fibre sheets demonstrate a lower Global Warming Potential (GWP) than traditional back sheets. Specifically, the GWP of the sisal fibre sheets is 165 kg CO2-eq (equivalent amount of carbon dioxide), compared to 200 kg CO2-eq for conventional back sheets. This reduction is primarily attributed to using renewable sisal fibres and the more efficient material processing and manufacturing stages. The energy consumption for producing one square meter of zeolite-polyester coated sisal fibre sheets is 1650 MJ, while traditional back sheets require 1800 MJ, as shown in Table 11. Similarly, the water use for sisal fibre sheets is 2750 L, compared to 3000 L for conventional back sheets. These reductions in energy and water use underscore the efficiency gains in the production process of the zeolite-polyester resin-coated sisal fibre sheets.

Comparative environmental impact of zeolite-polyester resin-coated sisal fiber sheets and traditional synthetic polymer back sheets.

One of the most significant environmental benefits of zeolite-polyester resin-coated sisal fibre sheets is their renewable and biodegradable nature. Sisal fibres are derived from a sustainable source and can biodegrade, reducing the long-term environmental impact. This contrasts sharply with the petroleum-based origins of traditional back sheets, which are non-biodegradable and pose disposal challenges. The LCA results indicate that zeolite-polyester resin-coated sisal fibre sheets are a more environmentally friendly alternative to traditional synthetic polymer back sheets in solar panels. Their lower GWP reduced energy and water consumption, and biodegradable nature makes them a compelling choice for sustainable solar panel manufacturing. These findings support adopting renewable materials in the solar energy industry to mitigate environmental impacts and promote sustainability.

The use of natural fibre mats in solar panel manufacturing presents a viable eco-friendly alternative to reduce carbon footprints while maintaining efficiency and reliability. The research focused on comparing the performance of uncoated pure sisal fibre and zeolite-polyester resin-coated sisal fibre back sheets with conventional PET back sheets. The chemical analysis showed increased carbon components and reduced oxygen in coated sisal fibres, indicating enhanced structural integrity. The XRD analysis confirmed the stable chemical structure and crystalline properties essential for long-term durability. EDS Analysis: Revealed that conventional PET materials require a significant amount of titanium (2.99%), a toxic element contributing to carbon footprints. The natural fibre composites significantly reduce the need for such materials. Voltage and Current: The coated pure sisal panels exhibited an 8% increase in voltage and a 6% increase in current flow compared to conventional panels. Pure sisal panels outperformed PET panels with a 4% higher voltage and 3% higher current. Power Output: Coated pure sisal panels showed a 12% increase in power output, while uncoated pure sisal panels demonstrated a 7% increase compared to conventional panels. The efficiency of solar panels improved from 9.75% (conventional) to 10.8% with coated pure sisal and 10.2% with pure sisal fibre back sheets. The actual power output for coated pure sisal back sheets was 2.1 watts, and 2.04 watts for pure sisal back sheets, compared to 1.95 watts for conventional panels. Life Cycle Analysis (LCA): The production of sisal fibres emits approximately 60% less CO2 and consumes 50% less energy than PET back sheets, significantly reducing environmental impact. The findings suggest that sisal fibre-based back sheets can be effectively used in solar panel applications to enhance performance and sustainability. The VARTM process allows for customized designs, ensuring optimal fibre alignment and mat thickness, which are crucial for specific solar panel applications. Implementing natural fibre-reinforced zeolite-polyester composites in solar panels not only addresses environmental concerns but also provides a pathway for developing high-performance, durable, and sustainable solar energy solutions. As to conclude, the research highlights the substantial advantages of using natural fibre composites over conventional materials in solar panel manufacturing, paving the way for greener and more efficient solar energy technologies.

Natural fibre solar panels exhibit slightly higher efficiency than conventional solar panels. Since the study was not conducted in summer season (October—December), the panels' efficiency was slightly reduced. Future research should be conducted on a larger scale for an extended period. Developing greener, more efficient, and technically advanced solar energy is an important step forward. Natural fibres and zeolite-polyester composites could revolutionize solar panel technology by simultaneously improving efficiency and sustainability at the same time. However the initial cost of a natural fibre-reinforced solar panel with a zeolite-polyester composite back sheet is a little higher than that of a conventional solar panel, a fibre-reinforced solar panel with a zeolite-polyester composite back sheet was two times less than a PET solar panel when considering the benefit-to-cost ratio. Also, it significantly eliminates the maintenance cost and the lifetime performance of the fibre-reinforced solar panel with a zeolite-polyester composite back sheet for the protective coatings, especially in aggressive environments.

The applications of this research are far-reaching. In residential settings, the adoption of sisal fibre-reinforced solar panels can lead to more sustainable and cost-effective solar energy solutions for homeowners, reducing reliance on fossil fuels and lowering household energy costs. For commercial and industrial uses, these innovative solar panels can contribute to the green building movement, supporting businesses in achieving sustainability goals and reducing their carbon footprint. Additionally, in remote and rural areas where access to conventional energy sources is limited, sisal fibre-based solar panels offer a robust and sustainable option for energy generation, fostering energy independence and enhancing the quality of life for off-grid communities. Furthermore, the successful implementation of natural fibre composites in solar panels could stimulate economic growth in regions where sisal is cultivated. By creating new markets for sisal fibres, this innovation can provide additional income streams for farmers and support local economies. The scalability of this technology also suggests its potential for widespread adoption, promoting global sustainability efforts and contributing to the reduction of greenhouse gas emissions.

All data, models, and code generated or used during the study appear in the submitted article.

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Department of Civil Engineering, College of Engineering and Technology, SRM Institute of Science and Technology, Kattankulathur, Chennai, India

Aishwarya Sathyanarayanan & Balasubramanian Murugesan

Department of Electrical and Electronics Engineering, College of Engineering and Technology, SRM Institute of Science and Technology, Kattankulathur, Chennai, India

Narayanamoorthi Rajamanickam

Sede Morona Santiago, Escuela Superior Politécnica de Chimborazo (ESPOCH), Panamericana Sur Km, 1 ½, Riobamba, 060155, Ecuador

Christian Ordoñez

Department of Civil Engineering, Michael Okpara University of Agriculture, Umudike, Nigeria

Kennedy C. Onyelowe

Department of Civil Engineering, Kampala International University, Western Campus, Kampala, Uganda

Kennedy C. Onyelowe

Facultad de Mecanica, Escuela Superior Politecnica de Chimborazo (ESPOCH), Panamericana Sur Km, 1 ½, Riobamba, 060155, Ecuador

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AS, BM, NR, CO, KCO & NU wrote the main manuscript text and prepared the figures and AS and CO revised the mansucript. All authors reviewed the manuscript.

Correspondence to Balasubramanian Murugesan or Kennedy C. Onyelowe.

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Sathyanarayanan, A., Murugesan, B., Rajamanickam, N. et al. Comprehensive study on zeolitepolyester composite coated sheet for eco-friendly solar panels for enhanced panel performance and reduced panel temperature. Sci Rep 14, 20072 (2024). https://doi.org/10.1038/s41598-024-71108-9

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Received: 19 May 2024

Accepted: 26 August 2024

Published: 29 August 2024

DOI: https://doi.org/10.1038/s41598-024-71108-9

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