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The quality of the packaging process directly determines the quality of the component, including its service life, the ability to resist critical strikes, and especially the attenuation rate. Dust, water, and drop resistance. Generally, the dust and water resistance of components on the market can reach the IP65 level. IP is the abbreviation of Ingress Protection. The IP level is the protection level of the electrical equipment enclosure against the intrusion of foreign objects. The 6 in IP68 represents the dustproof level. The highest level, which means that it can completely prevent the entry of dust. 5 in IP65 is the waterproof level of 5. It is worth noting that the level of 5 is not the highest level of waterproof ability. The level is 8.
1. Solar glass panel structure
1-1. The frame can be made of an aluminum frame, plastic frame, etc. According to the color, it can also be made into different colors such as black, silver, red, etc., usually silver aluminum frame is used.
1-2. The glass panel, usually special glass for photovoltaics, has a concave and convex surface.
1-3. The encapsulant is usually EVA
1-4. The designed number of solar cells are connected in series and parallel with copper strips to form a cell array to achieve the voltage and power required by the design
1-5. TPT is usually used as the solar backplane.
1-6. The junction box can effectively protect the connection between the copper tape and the external line, and can also be used as the confluence of the internal solar cell string and the installation of diode protection and other functions.
2.Flow chart
3. Introduction to Solar Cell Assembly Process
3-1.Solar Cell single welding process
It is to weld the busbar to the busbar on the front side (negative electrode) of the battery. The busbar is a tinned copper tape, and the length of the welding tape is about twice the length of the side of the battery. The extra ribbon is connected to the back electrode of the following cell during back welding.
3-2.Welding of solar cells in series
Back welding is to connect N pieces of batteries in series to form a module string. The positioning of the batteries is mainly based on a membrane plate. On the back electrode (positive pole) of the rear battery", the N pieces are connected in series, and the leads are welded to the positive and negative poles of the module string.
3-3.cascade
After the back is connected in series and passed the inspection, the component strings, glass, cut EVA, and backboard is laid according to a certain level and ready for lamination. When laying, ensure the relative position of the battery string and glass and other materials, adjust the distance between the batteries, and lay the foundation for lamination. (Laying level: from bottom to top: glass, EVA, battery, EVA, backplane).
3-4.Component Lamination
Put the laid battery into the laminator, pump out the air in the module by vacuuming, then heat to melt the EVA to bond the battery, glass, and backplane together; finally, cool down and take out the module. The lamination process is a key step in the production of components, and the lamination temperature and lamination time are determined according to the properties of EVA.
3-5. Cut off the burrs
During lamination, the EVA is melted and then extended and solidified to form burrs due to pressure, so it should be cut off after lamination.
3-6.Install the frame
Similar to installing a mirror frame on the glass; install an aluminum frame on the glass component to increase the strength of the component, further seal the battery component, and prolong the service life of the battery. The gap between the frame and the glass assembly is filled with silicone resin. The frames are connected with corner keys.
3-7.Install the junction box
Glue a box to the leads on the back of the module to facilitate the connection of the battery to other devices or batteries
3-8.Component testing
The purpose of the test is to calibrate the output power of the battery, test its output characteristics, and determine the quality level of the components.
3-9.High-pressure test
A high-voltage test refers to applying a certain voltage between the component frame and the electrode leads to testing the withstand voltage and dielectric strength of the component to ensure that the component is not damaged under harsh natural conditions (lightning strikes, etc.).
4. How to make your own solar panels:
4-1. Design the cell size according to the glass size. Generally, each side of the cell is 5 mm away from the edge of the glass. With the main battery line as the center, by using a cutting machine to cut the solar cell into several pieces, the number of solar cells is the same as the number of glass;
4-2. Using a ruler and a wallpaper knife, cut the EVA and the backboard into small pieces slightly larger than the glass, and the number of EVA should be twice the number of glass.
4-3. Use scissors to cut the welding tape into several small sections with a length slightly longer than the glass length, and the number is twice the number of glass;
4-4. After completing the preparation of the above materials, start to use an electric soldering iron to weld the main grid lines on the front and back of the battery chip with welding strips. The force should not be too large to avoid crushing the battery chip;
4-5. According to the order of glass, EVA, battery sheet, EVA, and backplane, place the materials from bottom to top. After all are laid, put them into the laminator for lamination. In order to prevent dislocation, they can be fixed with tape;
4-6. Take out the laminated small solar panels. After the temperature drops to room temperature, use a wallpaper knife to remove the excess material around the glass. Finally, use an electric soldering iron to connect the independent small solar panels in series, and then they can be used.
