solar panel manufacturer – Custom Solar Panel

What is the Assembly Process of a Custom Solar Panel?

The assembly process of a small, custom solar panel involves preparing the materials, electrically connecting the solar cells, encapsulating them for protection, framing the unit, and performing final testing.

Materials Needed

Solar cells: The core components that convert light into electricity. Monocrystalline or polycrystalline, typically 0.5V each. The number determines the voltage (e.g., 36 cells for an ~18V panel).
Encapsulant (EVA film): Ethylene Vinyl Acetate, a clear material that bonds and protects the cells. They become clear when heated.
Cover (Tempered glass or clear plastic): Protects the front from weather and impact.
Backsheet: A durable polymer layer on the back for insulation and moisture protection.
Frame (Aluminum or wood): Provides structural integrity and a mounting point.
Tabbing and bus wire: Flat, coated copper wires for electrical connections.
Junction box: Houses the electrical connections and bypass diodes.
Sealant (Silicone/Epoxy): Used for sealing edges and the junction box to prevent water intrusion.
Soldering iron and solder: For making the electrical connections.

Assembly Steps

Preparation and Template Creation: A template is created to ensure the correct and even placement of the solar cells on a backing board.
Cell Stringing (Connecting Cells): Individual solar cells are connected in series (positive to negative) using tabbing wire and a soldering iron to achieve the desired voltage. The size of the cell determines the amperage, while the number of cells in series determines the voltage.
Laying Up the Panel: The stack of materials is layered in the following order: glass, a layer of EVA film, the interconnected solar cells, a second layer of EVA film, and finally the backsheet.
Bussing Soldering: The strings of cells are connected to each other using a thicker bus wire to form the complete electrical circuit.
Lamination: The layered panel assembly is placed in a laminator (or sealed manually with even pressure and a clear cover) under vacuum and high temperature. This melts the EVA, encapsulating the cells and bonding all the layers together for durability and weather resistance.
Trimming and Framing: Any excess encapsulant material around the edges is trimmed off. The laminated unit is then fitted into a protective aluminum or wooden frame.
Junction Box Installation: A junction box is attached to the back of the panel and the main positive and negative output wires are connected to it. A blocking diode may be included here to prevent current backflow. The box and edges are sealed with silicone or epoxy.
Testing and Quality Control: The finished panel undergoes electrical tests, such as a sun simulator test and an electroluminescence (EL) test, to measure its performance and check for any micro-cracks or defects.
Final Steps: The panel is cleaned, labeled with its specifications, and packaged for use.

Posted by Carrie Wong / WSL Solar
WSL Solar has been a quality and professional manufacturer of custom solar panels, solar mini panels, IoT solar panels and solar solution provider in China since 2006.
https://www.wsl-solar.com

Manufacturer of Custom Solar Panels – WSL Solar

WSL Solar has been a quality and professional manufacturer of custom solar panels and solar solution provider in China since 2006.

With our in-house R&D team and management team for over 20 years’ experience in solar industry, we can design and develop a customized solar panel in a variety of sizes, shapes and outputs to meet our client’s specific requirement, and provide solution support start from initial product development stage.

Our product categories include tempered glass solar panels, ETFE solar panels, and amorphous solar panels.

Welcome to contact us for high quality custom solar panels.

Email: info@wsl-solar.com

https://www.wsl-solar.com

What Is the Photovoltaic Conversion Efficiency of Solar Panels?

The photovoltaic conversion efficiency of solar panels refers to the effective ratio of solar panels to convert received sunlight energy into electrical energy, usually expressed as a percentage (%). It is one of the key indicators for measuring the performance of solar panels.

Calculation formula:

Photovoltaic conversion efficiency = output power \ incident solar power x 100%

– Output power: The maximum power (such as peak power Pmax) generated by the solar panel under standard test conditions (STC).

– Incident solar power: Usually based on the solar irradiance \(1000 W/m 2) under standard test conditions (i.e. “1 sun” intensity).

Key point analysis:

1. Efficiency range:

– Commercial solar panels: The efficiency of mainstream crystalline silicon cells (monocrystalline silicon/polycrystalline silicon) is 15%~24%, and the efficiency of thin-film cells (such as cadmium telluride and copper indium gallium selenide) is about 10%~15%.

– Laboratory technology: For example, the efficiency of perovskite cells and multi-junction stacked cells can exceed 30%, but they have not yet been commercialized on a large scale.

2. Influencing factors:

– Material properties: Different semiconductor materials (such as silicon and gallium arsenide) have different abilities to absorb photons and excite electrons.

– Temperature: Rising temperature will lead to a decrease in efficiency (crystalline silicon cells have an efficiency decrease of 0.3%~0.5% for every 1°C increase in temperature).

– Spectral response: The ability of solar panels to utilize light of different wavelengths (such as ultraviolet light, visible light, and infrared light).

– Optical loss: Surface reflection, glass cover transmittance, etc.

– Electrical losses: resistance losses, shadowing, series/parallel mismatch, etc.

3. Standard Test Conditions (STC):

– Irradiance 1000 W/m2, spectrum AM1.5, temperature 25℃, used to fairly compare the efficiency of different products.

Why is efficiency important?

– Higher efficiency means more power can be generated in the same area, reducing installation costs (such as when roof space is limited).

– But there is a trade-off between efficiency and cost: high-efficiency technologies (such as N-type TOPCon, HJT cells) are usually more expensive, and the cost-effectiveness needs to be considered comprehensively.

Future trends:

– Technology breakthroughs: Perovskite-silicon stacked cells, quantum dot cells, etc. are expected to push efficiency to 30%~40%.

– Cost reduction and efficiency improvement: Optimize existing technologies through processes such as passivated emitter (PERC) and back contact (IBC).

10V 7.5W Custom Solar Panel

Key Features:

– Utilize high efficiency mono PERC solar cell,
up to 24% efficiency
– Laminated by tempered glass, rigid, durable
and long lasting
– Waterproof, scratch resistant, and UV resistant
– Customized solar panels for industrial use

Description:
10V 7.5W Solar Panel

This 7.5W solar panel utilizes high efficiency mono PERC solar cells with efficiency up to 24%, to ensure its high output. It is laminated by tempered glass to protect the solar cells inside, making it rigid, durable and long lasting. This custom solar panel is waterproof, scratch resistant, and UV resistant, specially designed for long term outdoor use in any challenging condition.

Applications:
Tempered glass solar panels are widely used in IoT applications, marine buoys, wireless sensors, traffic warning devise, GPS devices, asset tracking, electric fence chargers, outdoor lighting systems, weather monitoring systems etc.

Solar Panel Specification

Item No.	WSL-C041
Solar Panel Size	260x183x15mm
Peak Power (Pmax)	7.5W
Voltage at Pmax (Vmp)	10V
Current at Pmax (Imp)	0.75A
Open Circuit Voltage (Voc)	12V
Short Circuit Current (Isc)	0.82A
Solar Cell Type	Mono PERC Solar Cell
Power Tolerance	±5%
Encapsulation method	3.2mm Tempered glass
Back sheet	TPT
Product Warranty	5 Years
Lead time	25 Days
Storage temperature	-40°C ~ 85°C
Working temperature	-40°C ~ 85°C
Standard Test Conditions (STC)	1000W/m2, 1.5AM, 25°C Cell temperature

Click here to watch the video of this type of custom solar panels.

View More Custom Solar Panels

5V Solar Panels | 6V Solar Panels | 9V Solar Panels

WSL Solar has been a quality and professional manufacturer of custom solar panels and solar solution provider in China since 2006.

18V 25W Solar Panel

Key Features:

– Utilize high efficiency mono PERC solar cell, up to 24% efficiency
– Laminated by tempered glass, rigid, durable and long lasting
– Waterproof, scratch resistant, and UV resistant
– Customized solar panels for industrial use

Description:
18V 25W Solar Panel

WSL Solar’s 25W solar panel utilizes high efficiency mono PERC solar cells with efficiency up to 24%, to ensure its high output. It is laminated by tempered glass to protect the solar cells inside, making it rigid, durable and long lasting. This custom solar panel is waterproof, scratch resistant, and UV resistant, specially designed for long term outdoor use in any challenging condition.

Applications:
Tempered glass solar panels are widely used in IoT applications, marine buoys, wireless sensors, traffic warning devise, GPS devices, asset tracking, electric fence chargers, outdoor lighting systems, weather monitoring systems etc.

Solar Panel Specification

Item No.	WSL-C040
Solar Panel Size	350x450x25mm
Peak Power (Pmax)	27W
Voltage at Pmax (Vmp)	13.4V
Current at Pmax (Imp)	2.01A
Open Circuit Voltage (Voc)	16V
Short Circuit Current (Isc)	2.13A
Solar Cell Type	Mono PERC Solar Cell
Power Tolerance	±5%
Encapsulation method	3.2mm Tempered glass
Back sheet	TPT
Product Warranty	5 Years
Lead time	25 Days
Storage temperature	-40°C ~ 85°C
Working temperature	-40°C ~ 85°C
Standard Test Conditions (STC)	1000W/m2, 1.5AM, 25°C Cell temperature

WSL Solar has been a quality and professional manufacturer of custom solar panels, solar mini panels, IoT solar panels and solar solution provider in China since 2006.

https://www.wsl-solar.com

What is the Assembly Process of a Crystalline Silicon Solar Panel?

The assembly process of a crystalline silicon solar panel involves several precise steps to transform individual solar cells into a fully functional solar panel. Here’s a detailed breakdown of the process:

1. Cell Testing and Sorting
– Each solar cell is tested for electrical performance (efficiency, current, and voltage).
– Cells are sorted into groups with similar electrical characteristics to ensure uniformity in the final panel.

2. Stringing and Tabbing
– Tabbing: Thin metal strips (usually made of copper coated with solder, called tabbing ribbons) are soldered onto the front and back contacts of each solar cell.
– Stringing: The tabbed cells are connected in series by soldering the tabbing ribbons of one cell to the back of the next cell. This forms a “string” of cells.

3. Layering the Solar Panel
   – Glass Layer: A sheet of tempered glass (with high transparency and durability) is placed on the bottom. This will be the front side of the panel, facing the sun.
   – Encapsulant Layer: A layer of ethylene-vinyl acetate (EVA) is placed on top of the glass. EVA is a transparent, adhesive material that protects the cells and ensures proper light transmission.
   – Cell Strings: The interconnected strings of solar cells are carefully placed on top of the EVA layer.
   – Backsheet: Another layer of EVA is added, followed by a backsheet (usually made of a polymer like Tedlar). The backsheet provides electrical insulation and protects the panel from environmental factors.

4. Lamination
   – The layered assembly (glass, EVA, cell strings, EVA, backsheet) is placed in a laminator.
   – The laminator applies heat (around 140-150°C) and vacuum pressure to bond the layers together, ensuring there are no air gaps or moisture trapped inside.
   – This process takes about 10-15 minutes and creates a durable, weatherproof panel.

5. Framing
   – The laminated panel is framed with aluminum for structural support and durability.
   – The frame protects the edges of the panel and makes it easier to mount on rooftops or other structures.
   – Silicone sealant is applied to the edges to ensure a watertight seal.

6. Junction Box Installation
   – A junction box is attached to the back of the panel.
   – The junction box contains diodes that allow current to flow in one direction and prevent reverse current flow (which can reduce efficiency).
   – The tabbing ribbons from the solar cells are connected to the junction box, which provides the electrical output terminals.

7. Cleaning and Inspection
– The panel is cleaned to remove any dust, fingerprints, or residues.
– It undergoes a visual inspection to check for defects, such as cracks, misaligned cells, or poor soldering.

8. Electrical Testing
   – The panel is tested for electrical performance under standard test conditions (STC):
     – Open-circuit voltage (Voc): Voltage when no load is connected.
     – Short-circuit current (Isc): Current when the terminals are shorted.
     – Maximum power (Pmax): The panel’s peak power output.
   – These tests ensure the panel meets its specified power rating.

9. Quality Assurance and Certification
   – The panel undergoes additional quality checks, including:
     – Durability testing: Exposure to extreme temperatures, humidity, and mechanical stress.
     – Safety certifications: Compliance with international standards (e.g., UL, IEC, TUV).
   – Panels that pass these tests are certified for use.

10. Packaging and Shipping
– The finished solar panels are packed in protective materials to prevent damage during transportation.
– They are then shipped to distributors, installers, or end-users.

Summary of Key Components in a Solar Panel:
1. Solar Cells: The core component that converts sunlight into electricity.
2. Tempered Glass: Protects the cells and allows sunlight to pass through.
3. EVA Encapsulant: Bonds the layers and protects the cells.
4. Backsheet: Provides insulation and environmental protection.
5. Aluminum Frame: Adds structural strength and ease of mounting.
6. Junction Box: Manages electrical connections and output.

This assembly process ensures that crystalline silicon solar panels are efficient, durable, and ready to generate electricity for 25-30 years or more.

Posted by Carrie Wong / WSL Solar

WSL Solar has been a quality and professional manufacturer of custom solar panels, solar mini panels, IoT solar panels and solar solution provider in China since 2006.

https://www.wsl-solar.com

What is an Amorphous Solar Panel?

An amorphous solar panel is a type of thin-film solar panel made from amorphous silicon (a-Si), a non-crystalline form of silicon. Unlike traditional crystalline silicon solar panels (monocrystalline or polycrystalline), which have a structured, lattice-like arrangement of silicon atoms, amorphous silicon lacks this ordered structure. This gives it unique properties and applications.

Key Features of Amorphous Solar Panels:

1. Flexibility and Thinness:

– Amorphous solar panels are extremely thin and lightweight, making them flexible and adaptable to various surfaces.

– They can be applied to curved or irregular surfaces, unlike rigid crystalline panels.

2. Manufacturing Process:

– Amorphous silicon is deposited in thin layers onto substrates like glass, plastic, or metal using a process called chemical vapor deposition (CVD).

– This process is less energy-intensive and cheaper compared to producing crystalline silicon.

3. Efficiency:

– Amorphous solar panels typically have lower efficiency (around 6-10%) compared to crystalline panels (15-25%).

– However, they perform better in low-light conditions (e.g., cloudy days or indirect sunlight) and high temperatures.

4. Cost:

– They are generally cheaper to produce due to the lower amount of silicon required and simpler manufacturing processes.

5. Durability:

– Amorphous panels are less prone to cracking or damage because of their flexible nature.

– However, they may degrade faster over time compared to crystalline panels (a phenomenon called the **Staebler-Wronski effect**).

6. Applications:

– Used in small-scale applications like solar-powered calculators, watches, and portable chargers.

– Ideal for building-integrated photovoltaics (BIPV), such as solar windows or roofing materials.

– Suitable for large-scale installations where lightweight and flexible panels are needed.

Advantages:

– Better performance in low-light and high-temperature conditions.

– Lightweight and flexible, enabling unique applications.

– Lower production costs.

Disadvantages:

– Lower efficiency compared to crystalline panels.

– Shorter lifespan and potential degradation over time.

– Requires more space to generate the same amount of power as crystalline panels.

In summary, amorphous solar panels are a versatile and cost-effective option for specific applications, particularly where flexibility, lightweight design, or performance in challenging conditions is needed. However, they are less efficient and durable than traditional crystalline silicon panels.

Posted by Carrie Wong / WSL Solar

WSL Solar has been a quality and professional manufacturer of custom solar panels, solar mini panels, IoT solar panels and solar solution provider in China since 2006.

https://www.wsl-solar.com

What is the Difference Between Crystalline Silicon Solar Panel and Amorphous Silicon Solar Panel?

Crystalline silicon solar panels and amorphous silicon solar panels are two distinct types of photovoltaic technologies, differing in their structure, efficiency, cost, and applications.

Crystalline Silicon Solar Panel

Amorphous Silicon Solar Panel

Here’s a breakdown of the key differences:

1. Structure and Composition

– Crystalline Silicon Solar Panels:

– Made from silicon atoms arranged in a highly ordered, crystalline structure.

– Two main types:

– Monocrystalline Silicon**: Made from a single crystal structure, giving it a uniform appearance and high efficiency.

– Polycrystalline Silicon**: Made from multiple silicon crystals, resulting in a less uniform appearance and slightly lower efficiency.

– Amorphous Silicon Solar Panels:

– Made from non-crystalline (amorphous) silicon, where atoms are arranged in a disordered, random structure.

– Typically deposited as a thin film on substrates like glass, metal, or plastic.

2. Efficiency

– Crystalline Silicon:

– Higher efficiency due to the ordered structure, which allows for better electron movement.

– Monocrystalline panels: ~20-23% efficiency.

– Polycrystalline panels: ~18-20% efficiency.

– Amorphous Silicon:

– Lower efficiency due to the disordered structure, which hinders electron movement.

– Typically ~6-10% efficiency.

3. Cost

– Crystalline Silicon:

– Generally more expensive to produce due to the energy-intensive manufacturing process and high-purity silicon requirements.

– Amorphous Silicon:

– Cheaper to produce because it uses less silicon and can be manufactured using simpler processes like thin-film deposition.

4. Flexibility and Applications

– Crystalline Silicon:

– Rigid and heavy, making them suitable for traditional rooftop installations and large-scale solar farms.

– Amorphous Silicon:

– Lightweight and flexible, enabling use in unconventional applications like curved surfaces, portable devices, and building-integrated photovoltaics (BIPV).

5. Performance in Low Light and High Temperatures

– Crystalline Silicon:

– Performs better under standard test conditions but can lose efficiency in high temperatures.

– Amorphous Silicon:

– Performs better in low-light conditions (e.g., cloudy weather) and is less affected by high temperatures.

6. Lifespan and Durability

– Crystalline Silicon:

– Longer lifespan (25-30 years or more) and higher durability.

– Amorphous Silicon:

– Shorter lifespan and may degrade faster over time (e.g., due to light-induced degradation).

7. Aesthetic Appeal

– Crystalline Silicon:

– Monocrystalline panels have a sleek, black appearance, while polycrystalline panels have a blue, speckled look.

– Amorphous Silicon:

– Thin-film panels have a uniform, dark appearance and can be integrated into building materials for a more aesthetic look.

Summary Table:

Feature	Crystalline Silicon	Amorphous Silicon
Structure	Ordered crystal structure	Disordered, random structure
Efficiency	18-23%	6-10%
Cost	Higher	Lower
Flexibility	Rigid	Flexible
Applications	Rooftops, solar farms	BIPV, portable devices
Low-Light Performance	Moderate	Better
Lifespan	25-30+ years	Shorter
Aesthetic	Sleek black(mono) or blue speckled (poly)	Uniform, dark appearance

In summary, crystalline silicon panels are more efficient and durable but costlier, while amorphous silicon panels are cheaper, flexible, and better suited for specific applications like BIPV or portable devices. The choice depends on the specific needs and constraints of the project.

Posted by Carrie Wong / WSL Solar

WSL Solar has been a quality and professional manufacturer of custom solar panels, solar mini panels, IoT solar panels and solar solution provider in China since 2006.

https://www.wsl-solar.com

What is the Difference between Mono Solar Panel and Poly Solar Panel?

Monocrystalline and polycrystalline solar panels are two predominant types of solar technology, each with unique characteristics that affect their efficiency, cost, appearance, and suitable applications.

Composition and Manufacturing Process
Monocrystalline solar panels are composed of a single crystal structure of silicon, which is created by placing a seed crystal in molten silicon to grow a single ingot. This process gives rise to uniform, dark-colored panels that are recognized for their purity and efficiency. On the other hand, polycrystalline solar panels are made from multiple silicon crystals that are melted together and poured into molds, leading to a less uniform appearance characterized by a bluish hue. The manufacturing process for polycrystalline panels is simpler and less expensive, which typically makes them more affordable than their monocrystalline counterparts.

Efficiency Ratings
In terms of efficiency, monocrystalline solar panels generally outperform polycrystalline panels. Monocrystalline panels achieve efficiencies ranging from 20% to over 24%, while polycrystalline panels usually have efficiencies between 18% and 20%. This difference is primarily due to the structure of the solar cells; the single crystal composition of monocrystalline panels allows electrons more freedom to move and generate electricity efficiently.

Performance in Heat
When exposed to high temperatures, monocrystalline panels tend to perform better than polycrystalline panels. They have a lower temperature coefficient, which means their efficiency decreases less drastically as temperature rises. Conversely, polycrystalline panels exhibit a higher temperature coefficient, resulting in a more significant decrease in efficiency in hot conditions.

Cost Considerations
Cost is a crucial factor for many consumers deciding between the two options. Generally, monocrystalline panels come at a higher price due to the complex manufacturing process, with costs typically ranging from $1 to $1.50 per watt before installation. In contrast, polycrystalline panels are priced more affordably, generally around $0.90 to $1 per watt. Despite the initial cost savings with polycrystalline panels, monocrystalline panels may provide better long-term savings through higher efficiency, especially in space-limited installations.

Aesthetic Differences
The visual appeal of solar panels can also influence choice. Monocrystalline panels are usually sleek and all-black, which many find more aesthetically pleasing. Conversely, polycrystalline panels have a blue hue and may appear more variegated due to their composition, which some consumers might not prefer visually.

In summary, while both monocrystalline and polycrystalline solar panels have their benefits and drawbacks, the choice often hinges on efficiency needs, budget constraints, aesthetic preferences, and roof space considerations. Monocrystalline panels are typically favored for their greater efficiency and sleek appearance, making them suitable for residential applications where space is limited. Polycrystalline panels are a more cost-effective option but may require more panels to achieve the same energy output due to their lower efficiency.

WSL Solar has been a quality and professional manufacturer of custom solar panels, solar mini panels, IoT solar panels and solar solution provider in China since 2006.

https://www.wsl-solar.com

What is a Solar Panel？

A solar panel is a device designed to convert sunlight into electricity using photovoltaic (PV) cells. These cells are typically made of semiconductor materials like silicon, which produce an electric current when exposed to sunlight.

Functionality of Solar Panels

Solar panels operate by absorbing sunlight and converting it into electricity through the photovoltaic effect. This process includes several key components: the solar cells within the panel generate direct current (DC) electricity, which can then be converted into alternating current (AC) electricity suitable for household use using an inverter. An average solar panel consists of multiple solar cells that work in unison to produce a higher voltage and current, creating a more substantial power output.

Types of Solar Panels

There are primarily two types of solar panels: monocrystalline and polycrystalline. Monocrystalline panels, made from a single crystal structure, are known for their high efficiency and performance in low-light conditions. In contrast, polycrystalline panels, formed from multiple crystal structures, tend to be less expensive but also have slightly lower efficiency rates. Thin-film solar panels are another category that utilizes layers of photovoltaic material deposited onto a substrate, which allows for a flexible form factor but often at reduced efficiency compared to crystalline panels.

Applications of Solar Panels

Solar panels have a broad range of applications. They are commonly used in residential and commercial settings to power homes and businesses. Additionally, solar panels are employed in standalone systems for remote areas, satellite systems, and even automotive applications. The versatility of solar panels makes them a suitable solution for a wide array of energy needs, including off-grid living and providing power to essential services in remote locations.

Benefits of Using Solar Panels

Utilizing solar panels offers numerous advantages, including reduced electricity costs, minimal environmental impact, and energy independence. Solar energy is renewable and does not produce greenhouse gases during operation, making it a cleaner alternative to fossil fuels. Furthermore, many government incentives, such as tax credits, encourage the adoption of solar technology by offsetting initial installation costs.

Conclusion

In summary, solar panels are essential components of modern renewable energy systems, allowing for the efficient conversion of sunlight into usable electricity. Their growing popularity is driven by advancements in technology and increasing awareness of sustainable energy practices. As solar technology continues to evolve, it is expected that the efficiency and affordability of solar panels will improve further, expanding their applications and benefits.

WSL Solar has been a quality and professional manufacturer of custom solar panels, solar mini panels, IoT solar panels and solar solution provider in China since 2006.

https://www.wsl-solar.com