Aluminium fins and discarded plastic bags improve solar panel output by 11.6% in laboratory test

Solar panels could benefit from a simple cooling arrangement made from aluminium fins and discarded plastic bags, according to a laboratory study that explored ways to limit heat-related power losses without consuming additional electricity. The combination increased a panel’s output power by 11.6 per cent under simulated sunlight, only marginally higher than the 11.5% gain recorded with aluminium fins alone.

The findings point to a potential use for waste plastic in solar panel cooling, although outdoor testing is still needed to establish whether the approach can deliver similar results under changing weather conditions.

Aluminium fins offer a simple way to manage solar panel heat

Photovoltaic panels can lose electrical performance as their temperature rises under strong sunlight. To address this problem, researchers have investigated passive cooling methods that remove excess heat without relying on electrically powered equipment.

A 2019 study by Ammar Alkhalidi, Mohamad K. Khawaja and Abdel Ghaffar Al Kelany, titled Investigation of Repurposed Material Utilization for Environmental Protection and Reduction of Overheat Power Losses in PV Panels, examined whether repurposed plastic materials could work alongside aluminium heat-extraction fins to reduce overheating and associated power losses. The research was published in the International Journal of Photoenergy.

The researchers first tested the solar panel under a halogen-lamp simulator before adding heat-extraction fins and incorporating repurposed high-density polyethylene (HDPE) and plastic bags. The perforated aluminium fins were fitted to the rear of the panel, increasing the surface area available for heat exchange while allowing air to pass through the openings.

The perforated design was selected because it offered lower weight and better airflow. The arrangement relied entirely on passive cooling, without fans or pumps.

To know the aluminium casting demand forecast in the construction sector, explore our report "Global Aluminium Casting Market 2026-2032: Plant Economics, Alloy Segmentation, Pricing Intelligence, Supply Chain Analysis & Strategic Recommendations"

Folded plastic bags deliver only a marginal additional gain

The researchers recorded the highest output increase when aluminium fins were combined with folded plastic bags. At a simulated irradiance of 1,000 watts per square metre, the arrangement raised output power by 11.6 per cent compared with an unmodified panel and reduced the panel’s temperature by 22.7 per cent.

However, the improvement over aluminium fins alone was small. The fins increased output power by 11.5 per cent, meaning that adding folded plastic bags contributed just another 0.1 per cent point to the reported gain.

The study also examined a configuration combining the fins with ground HDPE, but the folded plastic bags produced the highest output among the tested arrangements.

These results suggest that the aluminium fins accounted for most of the measured improvement, while the addition of discarded plastic bags delivered a comparatively modest further increase.

Why temperature control matters for photovoltaic performance

The experiment addresses a familiar challenge in solar energy generation: panels need sunlight to produce electricity, but the heat associated with strong irradiance can reduce their voltage and peak power.

The 2009 review by E. Skoplaki and J. A. Palyvos, On the temperature dependence of photovoltaic module electrical performance: A review of efficiency/power correlations, published in Solar Energy, examined the relationship between photovoltaic module temperature, electrical efficiency and power output.

Focused on commercial silicon modules operating under one-sun conditions, the review considered how temperature affects key electrical characteristics, particularly efficiency and maximum power. It also discussed the standard test conditions of 25°C and 1,000 W/m² and the negative temperature coefficient associated with photovoltaic performance.

Against this background, removing excess heat could help solar panels generate more electricity from the same amount of sunlight. The aluminium-fin arrangement offers one possible approach because it seeks to improve heat dissipation without requiring additional electricity to operate cooling equipment.

Outdoor trials needed before wider application

Although the laboratory results demonstrate the potential of combining aluminium fins with repurposed plastic, they do not establish how well the system would perform in actual solar installations.

Outdoor conditions introduce variables that were not fully represented by the simulator test. Changes in sunlight, wind, humidity and dust could influence heat removal and, in turn, the performance of the cooling arrangement.

The system’s durability, maintenance requirements and installation costs also need further investigation before its practical feasibility can be determined.

For now, the experiment demonstrates that passive cooling using aluminium fins and folded plastic bags can improve solar panel output under controlled laboratory conditions. Whether the approach can deliver comparable benefits in outdoor installations remains to be established through further testing.

Explore AL Circle’s B2B Marketplace to discover aluminium electrical and power products, including conductors, busbars, cables and wires, and connect with suppliers across the industry.