Solar Panel Lamination Acceptability Guidelines

IPC SOLAR SUBCOMMITTEE

A t bilit G id li f S l P l L i ti Acceptability Guidelines for Solar Panel Lamination

IPC Solar Subcommittee Lamination Revision 210/24/2009 1

ACCEPTABILITY GUIDELINES FOR SOLAR PANEL LAMINATION

Title: Acceptability Guidelines for Solar Panel Lamination

This subcommittee will develop Acceptance Standards for the Lamination of Glass-Backside-Foil Solar Modules with crystalline solar cells using encapsulation sheets as an adhesive material.cells using encapsulation sheets as an adhesive material.

The Standard will include visual and other performance criteria for encapsulation sheets, glass, photovoltaic cells, ribbons, bus bars and p , g , p , ,backside foil as they relate to creating the basic laminated assembly.

The post laminated assembly would need to have specific visual criteria for uniformity of lamination, cell position within the fabrication and evidence of structural sealing. Criteria will also be established for the photovoltaic cell visual quality after undergoing the stresses of the lamination process.


lamination process.

LAY-UP OF A SOLAR MODULELAY UP OF A SOLAR MODULE

Backside foil or Protective sheet

Encapsulation Foil (e.g. EVA foil)(e.g. EVA foil)

Strings with Strings with crystalline

cells

Graphic: Robert Brkle GmbH

Encapsulation Foil (e.g. EVA foil)


Toughened Safety Glass Panel

QUALITY CRITERIA OF A SOLAR MODULEQUALITY CRITERIA OF A SOLAR MODULE

Efficiency or or

Power Rating

Mechanical Stability

Optical Appearance

Module Q litQuality

Electrical Stability

Performance over the Lifetime

SafetyLifetime


QUALITY TESTING OF A SOLAR MODULEQUALITY TESTING OF A SOLAR MODULE

Testing, Compliance and Certification according to: UL 1703

(UL Standard for Safety Flat-Plate Photovoltaic Modules and Panels)

IEC 61215 IEC 61215 (Crystalline silicon terrestrial photovoltaic (PV) modules Design qualification and type approval.

IEC 61730((Photovoltaic (PV) module safety qualification Part 2: Requirements for testing)

Safety Class II (Insulation testing over lifetime - based on EN 50178 1998-04)

UL, CSA and CE Mark(granted by TV, UL or CSA)



UL 1703 includes: U 03 c udes Design / Material Tests

Lab Performance Tests

Production Line Tests



Design / Material Testses g / ate a ests Test of individual materials used in the solar panel

Wire ways and connection meansy

Spacing

Fire resistance test

Corrosion resistance test



Lab Performance Tests Mechanical stability tests

(strain relief test, push test, cut test, impact test, bonding path resistance test, loading test, terminal torque test)

Electrical stability safety and performance tests Electrical stability, safety and performance tests(voltage-current-power measurements, leakage current test, dielectric voltage-withstand test, wet insulation-resistance test, reverse current overload test, arcing test, wiring compartment securement test, hot-spot endurance test)endurance test)

Temperature tests / temperature cycling tests

Humidity test / water spray test

Humidity freeze test to evaluate lamination integrity

Accelerated aging test

Fire test


Fire test

Corrosive atmosphere test


Production Line Testsoduct o e ests Voltage, Current, Power Measurements Test (Flash-Test)

Dielectric Voltage-Withstand Test (High-Pot Test)g ( g )

Grounding Test (High-Pot Test)

Optical Inspectionp p


ELEMENTS OF THE LAMINATION PROCESSELEMENTS OF THE LAMINATION PROCESS

Tempera-e pe ature

Lamination Process Vacuum

Lamination Time ProcessTime

Pressure



Temperature Temperature Process temperature depending on encapsulation

foil type.foil type. Temperature accuracy of 2C over the entire

lamination area.Less stress.Same cross-linking level / gel-content over the entire

module area.



Vacuum Vacuum < 1 mbar. Evacuation time long enough Evacuation time long enough. Typical 3 8 minutes.Modules lifted off the heating platen during Modules lifted off the heating platen during

evacuation to avoid trapped air (air bubbles).



Pressure PressureMaximum 1 bar (atmospheric pressure). Pressure not too high to avoid breaking of the solar Pressure not too high to avoid breaking of the solar

cells. Pressure build-up (not too fast) Pressure build up (not too fast).Required Pressure depending on the encapsulation

foil and module design.foil and module design.



Lamination Time Lamination Time Lamination Time depending on encapsulation foil. Encapsulation foil defines how long the module has Encapsulation foil defines how long the module has

to be processed at the specified temperature .



Optional: Cooling Optional: Cooling Active cooling of the modules under pressure

Less internal StressLess internal StressLess Warpage of the modules


ENCAPSULATION MATERIALSENCAPSULATION MATERIALS

Encapsulation Foils used for solar modulesEncapsulation Foils used for solar modulesEVA Foils (Ethylene Vinyl Acetate)

Standard Cure Fast Cure Ultra Fast Cure Standard Cure, Fast Cure, Ultra Fast Cure

PVB Foils (Polyvinyl Butyral)

TPU Foils (Thermoplastic Polyurethane)

Ionomer Foils Ionomer Foils

Geniomer Foils


OPTICAL INSPECTION BEFORE LAMINATIONOPTICAL INSPECTION BEFORE LAMINATION

String Alignment / Camber / Straightness String Alignment / Camber / Straightness Solder Joints Bus Bars Alignment Bus Bars Alignment Ribbon Alignment on the cell

S l C ll Solar Cells Breakage, Chips, Dents Deformation, Shape Coloring

C i t


Consistency

17


Glass Scratches Cleanness Breakage (edges or corners) Breakage (edges or corners)

Encapsulation Foil Alignment to Glass Backside Foil Alignment to Glass Backside Foil Alignment to Glass Foreign Objects or Contamination Hair Fingerprints Solder Splash Stains


Stains


Identification Identification Serial number / part number

Clarity of Marking Clarity of Marking Position, Condition, Cleanness


PERFORMANCE TESTS BEFORE LAMINATIONPERFORMANCE TESTS BEFORE LAMINATION

Power Output Strings Power Output Strings Continuity Resistance Test / Current Flow Test


OPTICAL INSPECTION AFTER LAMINATIONOPTICAL INSPECTION AFTER LAMINATION

Trapped Air or Volatiles (Bubbles) Trapped Air or Volatiles (Bubbles) SizeQuantityQuantity Locations (Center, Edges, )

String Alignment / Camber / Straightness String Alignment / Camber / Straightness Solder Joints Ribbon Alignment on the cell Bus Bars Alignment and Insulation


us a s g e t a d su at o


Solar Cells Solar CellsBreakage, Chips, DentsDeformation ShapeDeformation, Shape Consistency

Spacing Strings / Solar Cells Spacing Strings / Solar Cells Glass Scratches Cleanness


Breakage


Thickness Tolerances Thickness Tolerances Edges / Center

Warpage of the moduleWarpage of the module Excess encapsulation material on the edges of

th l d lthe solar module Contamination of front side glass Trimming of the edges of the module after

lamination required



Backside bus bars exit Backside bus bars exit Encapsulation material flow sufficient Excess encapsulation material Excess encapsulation material

Foreign Objects or Contamination H iHair

Fingerprints Solder Splash Stains



Identification Identification Serial number / part number

Clarity of Marking Clarity of Marking Position, Condition, Cleanness


PERFORMANCE TESTS AFTER LAMINATIONPERFORMANCE TESTS AFTER LAMINATION

Flash-Test Flash Test High-Pot Test Hot Spot Test (IR Heat detection camera) Hot-Spot Test (IR Heat-detection camera) Adhesion Tests, Peel Tests

B k id F il t EVA F il EVA F il t C ll d GlBackside Foil to EVA Foil, EVA Foil to Cells and Glass

EVA: Cross-Linking Test


NEXT STEPSNEXT STEPS

Which other performance tests exist to determine Which other performance tests exist to determine the Quality of a Solar Module?

How many Quality Categories will be required? How many Quality Categories will be required? Illustrations / Pictures are required for the Target

Conditions and Acceptability Conditions of a Conditions and Acceptability Conditions of a Laminated Solar Module


Solar Panel Lamination Acceptability Guidelines

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