Lamination process in solar panels

31 Aug 2021

Solar panel lamination is crucial to ensure the longevity of the solar cells of a module. As solar panels are exposed and subject to various climatic impact factors, the encapsulation of the solar cells through lamination is a crucial step in traditional solar PV module manufacturing.

How is a Solar panel laminated:

PV lamination is a proven concept and works as following:

In order to laminate a solar panel, two layers of ethylene-vinyl acetate (EVA) are used in following sequence: glass / EVA / solar cell strings / EVA / tedlar polyester tedlar (TPT). During the lamination process, the prepared 5-layer module is placed in the lamination machine and heated to max. 135°C for a period of approx. 22 minutes.

The laminate that comes out is completely sealed, and when produced well, will protect the solar cells for at least 25 years.

The module laminators follow this three step process for proper melting and curing of the encapsulate (EVA) and achieving a good quality lamination, it includes a) heating of the module lay-up to required temperatures to perform the EVA cross-linking step. b) Create vacuum t to remove the air and avoid bubble formation. The time of applying a vacuum as well as the rate of evacuation can be varied to optimize the process and hence the end-result. Reducing the pressure too early or at a high rate will result in significant outgassing of the additives in the EVA like adhesion promoters and/or stabilisers, and hence result in a decreased quality of the PV modules, whereas applying the vacuum too late will lead to air inclusion and hence unwanted bubble formation. c) Application of pressure to ensure a good surface contact and adhesion between the different layers of the PV module.

Solar encapsulation are materials to laminate the photovoltaic solar cells to enhance its efficiency and durability. The solar cell circuits are floated in between the materials such as ethylene vinyl acetate (EVA) and non-ethylene vinyl acetates to soften the effects of any external mechanical shocks and vibrations. EVA solar encapsulation has gained major demand in the recent years for its excellent protection against corrosion and delaminating. The EVA solar encapsulation materials are expected to grow at a CAGR of 23.0% during the forecast period. In addition, encapsulated solar cells help improve the efficiency of solar modules owing to their excellent barrier protection against humidity and UV radiations. With the growth in need for alternative sources of energy such as solar energy, the market for solar encapsulation is expected to create potential growth opportunities with increase in applications in photovoltaic solar modules

With the improper lamination of the solar module, it's not possible to withstand harsh environment and give flawless performance till 25 years. EverExceed Solar Panels always follow the advanced lamination technology and use best product or material for production to provide unparalleled efficiency along with greater performance warranty to the solar modules.

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