Flex Panel Delamination, Bubbling & Yellowing: Causes & Remedies

Flexible solar panels are popular for caravans, boats, and 4WD setups thanks to their lightweight design and ease of installation. But sometimes users notice bubbling, peeling, yellowing, or delamination (the top protective layer separating from the cells).

If left unchecked, these issues can reduce performance or even make the panel unsafe. The good news? With the right knowledge, you can understand what’s happening, when it’s normal wear, and when it’s time to act.

What Is Delamination in Flexible Solar Panels?

Delamination happens when the layers of the solar panel begin to separate. Flexible panels are made of multiple bonded layers: protective polymer film, encapsulant, solar cells, and backing sheet. If the bond weakens, you may see:

• Bubbles or blisters on the surface

• Cloudy or hazy patches

• Edges lifting or peeling away

? These issues often go hand-in-hand with yellowing (discoloration of the top layer) and can reduce light reaching the solar cells.

Common Causes of Bubbling, Peeling & Yellowing

1. Excessive Heat

   • Flexible panels often run hotter than rigid glass panels because they sit flush on surfaces with little airflow.

   • Heat accelerates material breakdown and can cause bubbles or discoloration.

2. UV Exposure

   • Long-term sunlight degrades plastics, causing yellowing and brittleness.

   • Higher UV environments (e.g. Australia, coastal areas) make this more common.

3. Moisture Ingress

   • Water or humidity can seep into poorly sealed edges.

   • This causes fogging, bubbles, and eventual corrosion of the solar cells.

4. Mechanical Stress

   • Excessive bending, walking on the panel, or mounting on uneven surfaces can crack layers, leading to separation.

5. Manufacturing or Material Defects

   • In rare cases, poor lamination or low-quality materials accelerate delamination.

   • Panels from reputable brands typically have stricter quality control.

How Delamination & Yellowing Affect Performance

• Reduced Efficiency: Cloudy or bubbled surfaces block sunlight.

• Hot Spots: Areas with bubbles heat up faster, stressing the cells.

• Accelerated Aging: Once delamination starts, moisture and dirt get in, speeding further damage.

• Electrical Safety Risks: In severe cases, moisture can corrode connections and cause shorts.

Remedies & What You Can Do

✅ Immediate Actions

• Clean the panel gently with mild soapy water and a soft cloth to remove dirt that worsens yellowing.

• Inspect the extent of delamination. Small bubbles or light yellowing may not cause significant power loss.

⚠️ What Not to Do

• Don’t attempt to inject glue or resin into bubbles — it rarely works and can void warranty.

• Don’t ignore large or growing delamination — it usually worsens quickly.

?️ Long-Term Solutions

• Monitor performance: Use a multimeter to check voltage (Voc) and current (Isc). Compare against the panel’s specs.

• Improve mounting: If possible, create an air gap underneath to reduce heat buildup.

• Protect from harsh UV/salt: Where practical, store panels when not in use or use UV-resistant covers.

• Warranty claim: If your panel is within warranty and shows significant bubbling, peeling, or yellowing, it may be covered.

? Take clear photos of the defects and performance readings. Then contact our support team at customersupport@starpoweradvancesolartechnology.com, or use our Live Chat for faster assistance.

When to Replace the Panel

Replace your flexible panel if:

• Output is more than 30% lower than rated despite good sunlight,

• Bubbles or peeling cover large areas or spread quickly,

• The panel shows burn marks, melted spots, or exposed wiring,

• Moisture ingress has reached the electrical junction box.

Preventing Future Delamination & Yellowing

• Always install flexible panels on smooth, clean, and non-abrasive surfaces.

• Avoid bending beyond the manufacturer’s rated curve.

• Allow for airflow under the panel when possible.

• Regularly clean salt, dust, and grime to reduce UV and heat buildup.

• Use protective covers when storing or transporting your panel.

Key Takeaways

• Bubbling, yellowing, or peeling is usually caused by heat, UV, or moisture.

• Small imperfections may be harmless, but growing or widespread delamination reduces efficiency and may be unsafe.

• Proper testing, cleaning, and installation can extend panel life.

• Warranty support is available if your panel fails within its coverage period.