Tech Insight : Behind the scenes of solar panel manufacturing!

Discover the fascinating behind-the-scenes of a solar panel factory in this exclusive video! 🌞

Join us for a complete guided tour of the manufacturing chain at CAPSolar in Montreal, where you'll learn how solar panels are designed and built, from the early stages of production to the innovative technologies used in their creation.

Whether you're a solar energy enthusiast, a DIY solar fan, or a photovoltaic professional, this video will answer your questions and inspire you. Learn more about the solar panel manufacturing processes, their efficiency, and their crucial role in the energy transition and the promotion of renewable energy.

👉 Subscribe for more content on solar systems, photovoltaic installations, and green energy solutions.

You can also find the interview of the founder of CAPsolar here

Happy listening, Solar Warriors! 🎧

FAQ

How is a solar panel made?

At CAPSolar, a Montreal manufacturer of custom flexible solar panels, the cells are first soldered together with connectors to form strings, which are then joined with busbars. The panel's layers (backsheet, encapsulants, interlayer, cells, frontsheet) are stacked and laminated under heat and pressure, at around 120 to 150 °C for about fifteen minutes.

What is a back-contact cell?

It is a cell with all its electrical contacts on the back: the front has no solder or silver lines. Developed by SunPower, now Maxeon, this technology offers high efficiency, around 24.4% for the cells CAPSolar uses, and cells flexible enough to follow curved surfaces without cracking.

How are panel defects detected?

With electroluminescence: current is injected into the panel in reverse, and the panel then emits light that a camera captures. Cracks, invisible to the naked eye, and short circuits show up as dark areas or lines. A solar simulator test (flash test) then measures the actual performance loss; before lamination, a cracked cell can still be desoldered and replaced.

Why use different types of encapsulant?

The encapsulant is the polymer that melts during lamination and protects the cells. EVA is the most common in rigid panels, while POE (polyolefin) stays more flexible, so it is preferred for flexible panels. The choice depends on how the panel will be used.

What happens to defective panels?

CAPSolar stores them until it finds a recycling partner. Panel recycling is only just developing, because the first panels installed in large numbers 20 or 30 years ago are only now reaching the end of their life.