2.3.

4 Thin-film encapsulation
In a thin-film module, although the series connection of thin-film cells for
a module is a part the cell fabrication, this only produces a “raw module”
that still requires encapsulation. Lamination with EVA film is the standard
encapsulation method, as for crystalline modules. The back can be fin-
ished with Tedlar or a metal film.
Raw thin-film modules for amorphous silicon and CdTe are coated onto
a superstrate which forms the front glass where light enters. It is not
possible to use tempered glass for these superstrate sheets as the high
temperature used for the semiconductor coating would destroy the glass
strengthening. If the finished thin-film module is to fulfil demands for
toughness, for instance in a façade, it must be laminated with a sheet of
toughened safety glass. Amorphous silicon and CdTe are fabricated onto
a superstrate, so any kind of glass can be used for the back.
CIS and amorphous silicon coated onto a substrate need a front glass. This
needs to be low-iron “white” glass for high transparency. Fig. 2.16 A range of standard PV modules in mono-
crystalline silicon, polycrystalline silicon and thin film
Photo courtesy: M.Art

2.3.5 Cable outlets and junction

boxes
From the cell strings embedded inside a module to the electrical contact
points on the outside, either a rear glass panel with holes is used or the
rear film is penetrated. In these cases, a junction box is fixed to the entry
point. The module junction boxes must have minimum protection to IP 54
and Protection Class II.
Many modules are supplied complete with connecting leads and reverse
polarity-proof, touch-proof plugs to make installation easy. The modules
can then simply be plugged together without opening the module junction
boxes.
Another possibility for the cable outlet is to turn the cables out along the
glass edges. This option is used in custom-made modules where a junction
box on the back would have a visually undesirable effect, such as in the
vision panel of a façade.

2.3.6 Standard complete modules

Standard modules are designed to achieve the maximum energy yields at
lowest cost. They are mostly glass-film laminates, with or without alumin-
ium frames (Fig. 2.16). A frame improves the strength and rigidity of the
module and helps mounting. Frameless modules are mounted into special
profile systems.
Typical crystalline cells are square (often with chamfered corners) so they
fit within the module with a minimum of gaps and thus of wasted space.
Typical cell sizes are of length 100–150mm. The cells are arranged in a
variety of patterns to make a module. A typical standard module consists
of 36 to 216 cells and has a peak power specification of 100WP to 300WP.
The cells are arranged in 4 to 8 rows resulting in rectangular forms. Strings
of 36 or 72 cells are connected in series. Larger modules use parallel con-
nections of 2 or 3 of these strings.
These factors limit the available dimensions to several pre-established
options.

2. PV BASICS 25