This is an interesting question if you know how fragile the silicon cells are. The silicon cells are normally squared pieces of 16 x 16 cm2 with thickness between 180 or 200 microns that need to be handled very carefully. Otherwise they are easily broken down. If you ever had the possibility to had one cell in your hands, you probably would have suffer the moment you slightly bended it and listened the “little click”. A few seconds later, after opening your eyes again, you realized that the cell was not as it had been a few seconds before, in one piece. Counting the spilled n-pieces on the ground you probably asked yourself: How that happened? at the same time you advice yourself to extreme its manipulation care next time. They are really very, very fragile.
Could you imagine how to handle 60 cells on rows to manufacture a 250 W glass-glass module or more? If it is not easy to manufacture a normal size PV panel (1.680 x 900 mm) between glasses, much more difficult, if not almost impossible, should be to manufacture much larger sizes PV building elements like facades, roof laminates, and so. Considering the production of special glass-glass silicon cell laminates, all of us would agree that if it is difficult to handle the cells and their connections if you don not have a photovoltaic manufacturing line in your factory, even more difficulty is added when processing these modules under pressure inside an autoclave.
If your question is then: Can I do it in my glass factory without having a photovoltaics line on it? We can answer you saying yes, it is possible. You can do it. It is not a straightforward thing to do, but yes it is possible. Our Development Engineers teams together with our Technical and Optical films manufacturing capacity, have been working on the development of special encapsulant films to be able to laminate cells between glass in autoclave. Our work was not just focused on special films also was extended to the study of the best lamination conditions of them inside autoclaves.
Well, once more, like it happens in the traditional construction of photovoltaic modules, the encapsulant is the most import element of the glass-glass module during the lamination process. When using pressure the encapsulant has to be capable to support and “manage” the applied pressure to avoid the breakage of the cells. Moreover during this process it has to construct the mechanical and optical properties required to be converted into an “power” architectural wall or roof of buildings. This is one of the challenges that Building Integration Photovoltaics (BIPV) technology is facing today.
We have been working on all these challenges considering this particular manufacturing situation. We can provide you the right materials to make this happen, facilitating the manipulation of the cells avoiding their breakage. Moreover we have develop some procedures that should work for you to overcome your autoclaves pressures working conditions. If you are interested on that, just send us your contact references and we will get in touch with you to help you make these type of products on your factory.
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