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A new lab is inventing alternative methods for packaging and installing solar cells, reducing costs and increasing efficiency.
Theresa Christian, a scientist at the Fraunhofer Center in Germany, tests the output power of solar cells, and the basic devices in solar panels absorb light and convert it into electricity. The lab does not design solar cells, but preparing solar panels requires knowing how their performance is because the output power of one panel depends on the worst performing cell.
Once the battery cells are categorized based on power output, another researcher Adam Stokes will string them together and use a tool to weld flat metal bars called busbars. Soldered to the electrical contacts on the front and back of the battery. The lab can test different ways to connect these batteries, change the number and type of buses, and then measure the resulting performance to determine if any additional costs are worth it.
The researchers sandwiched a small section of solar cells between the glass and the protective film. This process was designed to keep the batteries dry. This panel is small enough to fit into a dedicated device that the lab uses to test new materials that are being considered by the solar industry.
This is a large laminating machine. The operator is Dan Doble, who is the head of the Fraunhofer PV Modules Group. The battery is sealed inside the protective package. In order to earn back costs, solar panels must be used well for decades, and often under extreme conditions. Even a small amount of water vapor entering the panel can corrode the contact components and degrade their performance.
This packaged device allows the solar panel to withstand a wide range of temperature and humidity levels. It includes a device invented by the German Fraunhofer laboratory, which uses an inflatable rubber ball to press the surface of the panel to simulate the pressure of a whole lot of snow. Solar power may be associated with a warm, sunny climate, but some of the biggest markets are in snowy places such as Germany.
Researchers Dan Dow and Carola Vlker are lowering the solar panel and putting it into the tank to test how well the internal circuit seals. At least 500 volts of current flow into the circuit, and an electrical wire extends into the water to detect any leakage. This test helps to determine if the panel can withstand exposure to extreme temperatures and mechanical stress. The researchers also studied micrographs to find out if there were any damage.
In most solar panels, a hole is cut in the protective package that encloses the solar cell to connect an external circuit. To speed up manufacturing and avoid water leakage, the lab is developing a device (right) that can be installed before the battery is packaged. The yellow piece can be inserted between a sealing material and the battery and sealed in place using standard laminating steps. The cables that come out of the device are connected to similar cables on adjacent solar panels on the roof and then connected to the frequency converter and the grid. In the current design, this is done by hand, but in the future design, these devices will be integrated together, so that the installation of the battery board is fast and affordable.
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