Production of solar batteries in Russia: technology, equipment, start-up capital. How are solar panels made? Manufacture of solar panels

The use of solar energy is gaining more and more popularity, which invariably entails an increase in demand for equipment that converts solar radiation into electricity. The most common method of obtaining such is considered photovoltaics. Of course, one of the reasons is that the production of solar cells is based on the use of silicon. This chemical element is the second most abundant in the world.

Now huge global companies operate in the solar battery market, which have multi-million dollar turnover and many years of experience. The technologies underlying the production are being improved from year to year. You can easily find the solar panel you need. Whether it's a device for a car, a calculator or home lighting. If you purchase a single photocell, you will notice that they have very little power. Therefore, more often they are connected to a solar module. Let's figure out how.

Manufacturing technology of solar panels.

It is divided into stages, we will analyze each of them:

Of course, the first thing with which absolutely any production begins, and not only solar panels, is the preparation of raw materials (material). As mentioned earlier, the panels are mainly made of silicon, or to be more precise, from quartz sand of a certain breed. The material preparation technology includes two processes:

1. high temperature melting.
2. Synthesis with the addition of various chemical elements.

After passing through these processes, silicon purification up to 99.99% can be achieved.

Most often, polycrystalline or monocrystalline silicon is taken for the production of solar panels. And although their production technology is different, nevertheless, the production of polycrystalline silicon is considered more economical. Therefore, I choose a solar battery from such raw materials, you will pay less for it.

After cleaning the silicon, it is cut into thin wafers, which are then tested. It is produced by measuring electrical parameters using a very high power xenon lamp flash light. At the end of the testing of the plates, they are sent to the next stage.

• At the second stage, the plates are soldered in sections, after which blocks are formed from them on the glass. Vacuum holders are used to transfer these sections to the glass. With their help, mechanical impact on the finished solar cell is excluded. Usually sections consist of 10 elements, and blocks of 4 sections, less often of 6.
• The blocks obtained in the second stage are laminated with an ethylene vinyl acetate film and a special protective coating. Computer control allows you to monitor the temperature, pressure and vacuum level, as well as program the conditions for lamination.
• This is the last step in the production of solar panels. It consists in mounting an aluminum frame and a junction box. A special adhesive-sealant ensures a secure connection between the module and the box. The solar arrays are then tested by measuring the short circuit current, the maximum power point voltage, and the open circuit voltage.

Equipment for the production of solar panels.

Only the best equipment is used in the production of solar panels. Due to the high quality of the equipment, the minimum error in testing and measuring indicators is achieved. It also guarantees a longer service life, which in turn reduces the cost of purchasing new equipment. Poor quality entails violations in production technology.

The main equipment used in the manufacture of solar panels:

• Cell cutting tool. The cells are cut with a fiber laser. Dimensions can be set using various programs.
• Laminator. The name speaks for itself. Solar cells are laminated with it. It has special controllers to support the selected parameters. Laminators work in two modes: manual and automated.
• Table for moving. It is very difficult to do without this item. It is on it that such operations as trimming the edges, laying the junction box and many others are performed. The tabletop has fixed balls, with which you can open and move the module without fear of damaging it.
• Glass cleaning machine. It is used in the cleaning of glass substrates. The glass is first cleaned with detergent, then rinsed twice with deionized water. After the substrate is dried with cold and hot air.

Manufacturers of solar panels.

The manufacture of solar panels from silicon is quite a promising and profitable business. The demand for solar panels is growing every year. Accordingly, sales volumes are growing.

Of course, the first place in the production of solar panels is occupied by the Chinese. Their main trump card is a very low cost. Naturally, many companies around the world cannot withstand the pressure and competition of Chinese companies. This was the result of the closure of, for example, four German brands in the last couple of years. These are such giants as Solon, Solarhybrid, Q-Cells and SolarMillennium. Following them, the American company FirstSolar closed its branch in Germany, followed by Siemens and Bosch. And this is not surprising. Chinese solar panels are half the price of their foreign counterparts.

Top solar panel manufacturing companies:

• YingliGreenEnergy. YGE has installed more than 2 GW of solar panels during its existence.
• FirstSolar. Despite the fact that the company had to close its plant in Germany, it has not lost its position in the top. Its profile is thin-film panels, which they produced more than 4 GW.
• SuntechPower Co. The manufacturer has put on the market about 13 million batteries.

Russian popular battery manufacturers:

• Plant "Solar wind".
• Plant "Hevel".
• Plant "Telecom-STV".
• "Ryazan plant of ceramic-metal devices".
• "Thermotron-plant".

The CIS countries also do not graze the back. For example, a plant producing solar cells from silicon was also launched in Astana. For Kazakhstan, this is a pioneer in this industry. It is planned to use silicon, which is located in Kazakhstan, as materials there. The equipment purchased for production meets all standards and is of high quality.

The high pace of plant construction indicates a high demand for solar panels. Therefore, in the near future we can expect the widespread use of solar modules. And this will definitely have a positive effect on our atmosphere, saving it from pollution and depletion of fuel reserves.

Mankind is striving to switch to alternative sources of electrical supply that will help keep the environment clean and reduce the cost of energy generation. The production is a modern industrial method. includes solar receivers, batteries, controllers, inverters, and other devices designed for specific functions.

The solar battery is the main element from which the accumulation of rays begins. In the modern world, there are many pitfalls for the consumer when choosing a panel, as the industry offers a large number of products combined under one name.

silicon solar panels

These products are popular with modern consumers. Silicon is the basis for their manufacture. Its reserves in the depths are widespread, and production is relatively inexpensive. Silicon cells compare favorably in terms of performance with other solar cells.

Element types

Silicon production is carried out in the following types:

• monocrystalline;
• polycrystalline;
• amorphous.

The above forms of devices differ in how silicon atoms are arranged in a crystal. The main difference between the elements is the different indicator of light energy conversion, which in the first two types is approximately at the same level and exceeds the values ​​for devices made of amorphous silicon.

Today's industry offers several models of solar light catchers. Their difference lies in the equipment used for the production of solar panels. The manufacturing technology and the type of starting material play a role.

Single crystal type

These elements consist of silicone cells fastened together. According to the method of the scientist Czochralski, absolutely pure silicon is produced, from which single crystals are made. The next process is cutting the frozen and hardened semi-finished product into plates with a thickness of 250 to 300 microns. Thin layers are saturated with a metal grid of electrodes. Despite the high cost of production, such elements are used quite widely due to the high conversion rate (17-22%).

Manufacturing of polycrystalline elements

Solar panels made of polycrystals is that the molten silicon mass is gradually cooled. The production does not require expensive equipment, therefore, the cost of obtaining silicon is reduced. Polycrystalline solar storages have a lower efficiency factor (11-18%), unlike monocrystalline ones. This is explained by the fact that during the cooling process, the mass of silicon is saturated with the smallest granular bubbles, which leads to additional refraction of the rays.

Amorphous silicon elements

Products are classified as a special type, since their belonging to the silicon type comes from the name of the material used, and the production of solar cells is carried out using film device technology. The crystal in the manufacturing process gives way to silicon hydrogen or silon, a thin layer of which covers the substrate. Batteries have the lowest efficiency value, only up to 6%. Elements, despite a significant drawback, have a number of undeniable advantages that give them the right to stand in line with the above types:

• the absorption value of optics is two dozen times higher than that of single-crystal and polycrystalline drives;
• has a minimum layer thickness of only 1 micron;
• cloudy weather does not affect the work of converting light, unlike other types;
• due to its high bending strength, it can be used without problems in difficult places.

The three types of solar converters described above are complemented by hybrid products made from materials with dual properties. Such characteristics are achieved if microelements or nanoparticles are included in amorphous silicon. The resulting material is similar to polycrystalline silicon, but compares favorably with new technical indicators.

Raw materials for the production of CdTe film-type solar cells

The choice of material is dictated by the need to reduce the cost of manufacture and improve performance in operation. The most commonly used light-absorbing cadmium telluride. In the 70s of the last century, CdTe was considered the main contender for space use; in modern industry, it has found wide application in solar energy.

This material belongs to the category of cumulative poisons, so the debate on the issue of its harmfulness does not subside. Research scientists have established the fact that the level of harmful substances entering the atmosphere is acceptable and does not harm the environment. The efficiency level is only 11%, but the cost of converted electricity from such elements is 20-30% lower than from silicon-type devices.

Beam accumulators made of selenium, copper and indium

The semiconductors in the device are copper, selenium and indium, sometimes it is allowed to replace the latter with gallium. This is due to the high demand for indium for the production of flat-type monitors. Therefore, this substitution option was chosen, since the materials have similar properties. But for the efficiency indicator, replacement plays a significant role, the production of a solar battery without gallium increases the efficiency of the device by 14%.

Polymer based solar collectors

These elements are classified as young technologies, as they have recently appeared on the market. Organic semiconductors absorb light to convert it into electrical energy. For production, fullerenes of the carbon group, polyphenylene, copper phthalocyanine, etc. are used. As a result, thin (100 nm) and flexible films are obtained, which in work give an efficiency coefficient of 5-7%. The value is small, but the production of flexible solar panels has several positive aspects:

• large funds are not spent for manufacturing;
• the ability to install flexible batteries in places of bends, where elasticity is of paramount importance;
• comparative ease and availability of installation;
• flexible batteries do not have a harmful effect on the environment.

Chemical etching during production

The most expensive in a solar cell is a multicrystalline or monocrystalline silicon wafer. For the most rational, pseudo-square figures are cut, the same shape allows you to tightly lay the plates in the future module. After the cutting process, microscopic layers of damaged surface remain on the surface, which are removed by etching and texturing to improve the reception of incident rays.

The surface processed in this way is a randomly located micropyramids, reflected from the face of which, the light falls on the side surfaces of other protrusions. The loosening procedure reduces the reflectivity of the material by approximately 25%. In the etching process, a series of acid and alkali treatments are used, but it is unacceptable to greatly reduce the layer thickness, since the plate cannot withstand the following treatments.

Semiconductors in solar cells

The technology for the production of solar cells suggests that the main concept of solid electronics is the p-n junction. If the electronic conductivity of the n-type and the hole conductivity of the p-type are combined in one plate, then a p-n junction occurs at the point of contact between them. The main physical property of this definition is the ability to serve as a barrier and pass electricity in one direction. It is this effect that allows you to establish the full operation of solar cells.

As a result of phosphorus diffusion, an n-type layer is formed at the ends of the plate, which is based near the surface of the element at a depth of only 0.5 μm. The production of a solar battery provides for a shallow penetration of carriers of opposite signs, which arise under the action of light. Their path to the zone of influence of the p-n-junction must be short, otherwise they can extinguish each other when they meet, without generating any amount of electricity.

The use of plasma-chemical etching

The design of the solar battery provides for the front surface with an installed grating for current capture and the back side, which is a solid contact. During the diffusion phenomenon, an electrical short occurs between the two planes and is transmitted to the end.

To remove the short circuit, solar battery equipment is used, which allows this to be done using plasma-chemical, chemical etching or mechanically, by laser. The method of plasma-chemical influence is often used. Etching is performed simultaneously for a stack of silicon wafers stacked together. The outcome of the process depends on the duration of treatment, the composition of the agent, the size of the squares of the material, the direction of the ion flow jets, and other factors.

Application of an anti-reflective coating

By applying a texture to the surface of the element, reflection is reduced to 11%. This means that a tenth of the rays are simply reflected from the surface and do not take part in the formation of electricity. In order to reduce such losses, a coating with a deep penetration of light pulses is applied to the front side of the element, which does not reflect them back. Scientists, taking into account the laws of optics, determine the composition and thickness of the layer, so the production and installation of solar panels with such a coating reduce reflection to 2%.

Contact plating on the front side

The surface of the element is designed to absorb the greatest amount of radiation, it is this requirement that determines the dimensional and technical characteristics of the applied metal mesh. By choosing the design of the front side, engineers solve two opposing problems. The decrease in optical losses occurs with thinner lines and their location at a large distance from one another. The production of a solar battery with an increased grid size leads to the fact that some of the charges do not have time to reach contact and are lost.

Therefore, scientists have standardized the value of the distance and line thickness for each metal. Too thin strips open space on the surface of the element to absorb rays, but do not conduct a strong current. Modern methods of applying metallization consist of screen printing. As a material, silver-containing paste most justifies itself. Due to its use, the efficiency of the element rises by 15-17%.

Metallization on the back of the device

The application of metal to the back of the device occurs in two ways, each of which performs its own work. A continuous thin layer over the entire surface, except for individual holes, is sprayed with aluminum, and the holes are filled with silver-containing paste, which plays a contact role. The solid aluminum layer serves as a kind of mirror device on the back side for free charges that can be lost in the dangling crystal bonds of the lattice. With such a coating, solar panels work 2% more in power. Consumer reviews say that such elements are more durable and do not depend so much on cloudy weather.

Making solar panels with your own hands

Not everyone can order and install solar power sources at home, since their cost today is quite high. Therefore, many craftsmen and craftsmen are mastering the production of solar panels at home.

You can buy kits of photocells for self-assembly on the Internet at various sites. Their cost depends on the number of plates used and power. For example, low power kits, from 63 to 76 W with 36 plates, cost 2350-2560 rubles. respectively. Here they also purchase work items rejected from production lines for any reason.

When choosing the type of photovoltaic converter, one takes into account the fact that polycrystalline cells are more resistant to cloudy weather and work more efficiently than single-crystal ones, but have a shorter service life. Monocrystalline have a higher efficiency in sunny weather, and they will last much longer.

To organize the production of solar panels at home, you need to calculate the total load of all devices that will be powered by the future converter, and determine the power of the device. From this follows the number of photocells, while taking into account the angle of the panel. Some craftsmen provide for the possibility of changing the position of the accumulation plane depending on the height of the solstice, and in winter - on the thickness of the snow that has fallen.

Various materials are used to make the case. Most often they put aluminum or stainless corners, use plywood, chipboard, etc. The transparent part is made of organic or ordinary glass. On sale there are photocells with already soldered conductors, it is preferable to buy such ones, since the assembly task is simplified. The plates are not stacked one on top of the other - the lower ones can give microcracks. Solder and flux are pre-applied. It is more convenient to solder the elements by placing them immediately on the working side. At the end, the extreme plates are welded to the tires (wider conductors), after which the "minus" and "plus" are output.

After the work done, the panel is tested and sealed. Foreign craftsmen use compounds for this, but for our craftsmen they are quite expensive. Home-made transducers are sealed with silicone, and the back side is coated with acrylic-based varnish.

In conclusion, it should be said that the reviews of the masters who did it are always positive. Once having spent money on the manufacture and installation of the converter, the family quickly pays for them and begins to save money using free energy.

What does solar cell technology look like?

The world is experiencing a constant increase in electricity consumption, and the stocks of traditional energy sources are declining. Therefore, the demand for equipment that generates electricity using non-traditional sources of raw materials is gradually growing. One of the most common ways to generate electricity is solar panels powered by solar energy. They are composed of photovoltaic cells, the properties of which make it possible to convert solar radiation into electric current. For their manufacture, one of the most common chemical elements on Earth is used - silicon. In this article, we will talk about how silicon is converted into photovoltaic cells. Simply put, we will look at what solar cell production is and what equipment is required for this.

In the field of solar panels production, a fairly large market has already formed, in which large companies are present. Millions of dollars are already spinning here and there are brands that have earned a reputation for producing quality products. This refers to both the world market and the Russian one. The technologies underlying the production of solar panels are being improved as scientific research in this direction develops. Now solar panels are produced in various sizes and purposes. There are very small ones used in calculators and. And there are large panels used in solar systems and. One photocell has a small power and produces a very small current. Therefore, they are combined into . Now let's look at how photovoltaic cells are made.

The production of solar panels can be divided into the following main stages:

• Testing. At this stage, the electrical characteristics are measured. For this, flashes of powerful xenon lamps are used. Based on the test results, the photocells are sorted and sent to the next stage of production;
• At the second stage of production, the soldering of the elements in the section is performed. Sections are formed from them on a glass substrate. The assembled sections are transferred to the glass using vacuum grippers. This is a mandatory requirement to exclude mechanical or other effects on the surface of the plates. Blocks usually include 4─6 sections. Sections, in turn, consist of 9-10 photovoltaic panels;
• The next stage of production is lamination. The blocks of photocells connected by soldering are laminated with an ethylene vinyl acetate film. A special protective coating is also applied. All this is done on CNC equipment. The computer monitors such characteristics as pressure, temperature, etc. Depending on the material used, the lamination parameters can be changed;
• And the final stage is the manufacture of an aluminum profile frame and a special junction box. To ensure the reliability of the connection, glue-sealant is used. At the same stage of production, testing of solar panels is carried out. In this case, short-circuit currents, output voltage (working and no-load), current strength are measured.

If you pay attention to the roofs of many private houses or small companies, you can see solar panels there. The rise in the price of energy carriers leads to the fact that people begin to look for alternative sources. Under these conditions, the demand for solar panels is growing day by day.

Potential Opportunities

In the context of the growing popularity of alternative energy sources, it is advisable to occupy a niche in the market in time. To do this, you first need to purchase equipment for the production of solar panels. It can be bought both in Europe, the USA and the CIS, and in China.

Depending on the demand for these products in your region or in the places where you can supply the manufactured goods, you need to decide what your production will be focused on. Currently on the market you can find panels designed for various areas of use.

These can be as light portable options that you take with you on camping trips, stationary modules suitable for installation on the roofs of buildings and residential buildings, or powerful panels that are used as small power plants.

Working lines

If you have a manufacturing facility, then you can think about buying equipment for the production of solar panels. Also, do not forget that when making them, you should always have the necessary consumables in sufficient quantities.

So, the list of necessary equipment includes machines that laser cut the material for panels into squares, sort them, laminate them, insert them into frames and join them together. In addition, production requires machines that knead special glue, cut the film under the panel and their edges. In the manufacture of tables, on which it will be necessary to correct the angles, insert wires into the panels and form them, and trolleys designed to move and press them, one cannot do without tables.

Each solar cell production machine is an indispensable component of the solar cell production line. Therefore, before you start ordering materials for production, calculate the total cost of equipment and analyze whether you can afford such expenses. True, it is worth considering that if there are distribution channels, they quickly pay off.

Manufacturing process

If you have seen solar panels before only in pictures and have a poor idea of ​​​​how their creation is going on, then it is better to find a person who knows the technology for the production of solar panels. If we talk about it in general terms, then you need to know that it consists of a number of stages.

Production begins with the verification and preparation for work of the materials received by the workshop. After cutting and sorting photovoltaic converters (PVCs), they go to the equipment, where the process of soldering special tinned copper bars to the contacts of the panels takes place. Only after this, the process of connecting all solar cells into chains of the required length begins.

The next step is the creation of a sandwich, which consists of transducers assembled into a matrix, glass, two layers of sealing film and the back side of the panel. It is at this stage that the equipment for the production of solar panels forms the circuit of the module, and its operating voltage is immediately determined.

The assembled structure is checked and sent for lamination - sealing, which takes place under pressure at high temperature. Only after that, a frame is attached to the prepared semi-finished product and a special junction box is mounted.

Product testing

It is almost impossible to meet a marriage among similar products on the market, because after assembly each panel goes to a special testing workshop.

It is there that they are checked for the possibility of voltage breakdown. After that, they are sorted, packed and sent for sale; in stores you can find both small portable options and solar panels for the home.

The production of these species is practically no different.

Of course, only a large manufacturer with large production volumes and a sufficient number of employees can afford to strictly observe all the stages. It is difficult for new small manufacturers to compete with the giants, because the one-time creation of large batches makes it possible to reduce the cost of production.

"Green" energy has been developing quite rapidly in recent years. In China last year (5 times the size of Manhattan). Solar energy is also growing well in Russia.

But counting that our future will consist entirely of solar power plants, we must not forget the following ...

The production of solar panels is an energy intensive process. Currently, most of the energy used to create solar panels comes from fossil fuels, so even the production of these environmentally friendly products can contribute to pollution and global warming. Approximately 600 kWh of energy is used to produce each square meter of solar panels, which is enough for lighting 1000 60W bulbs for ten hours. The average power system uses about two or three panels, each with an area of ​​about 2 m2. When installed in a favorable location, a solar panel can produce up to 200 kWh per square meter of electricity per year.

Therefore, the energy used in the panel production process is compensated only after a few years of operation.

The starting material for the manufacture of solar cells is trichlorosilane, a poisonous and explosive product. When it is distilled and reduced with hydrogen, pure silicon is obtained. A by-product, at this stage of production, is hydrochloric acid. Further, silicon is melted and ingots are obtained, from which solar cells are made. The production of solar panels requires the use of many hazardous chemicals. Poisons such as arsenic, chromium and mercury are also by-products of the manufacturing process. These chemicals can cause serious damage to the environment if not properly disposed of.

If technologies for capturing and cleaning toxic gases and liquids are observed, production will not be harmful, but often, especially in developing countries, such equipment is not installed at enterprises, which leads to environmental pollution. The energy used in the production of solar panels is not the only energy cost. The energy used to transport them must also be considered, especially if the panels are imported from another part of the world. Recycling solar panels is a big problem. Many of the materials used to make them are difficult to recycle, and the recycling process itself requires a lot of energy.

Disadvantages of using solar energy:
1.- Uneven distribution of solar energy over the surface of the planet. Some areas are sunnier than others;
2. - On cloudy days and at night, solar energy is not available;
3. - The need to use large areas for solar energy sources;
4. - The content of toxic substances in photocells;
5. - Low efficiency of solar panels, the average value of efficiency does not exceed 20%;
6. - High cost of solar photocells;
7. - The surface of solar panels and mirrors (for hot air ES) must be cleaned from ingress of contaminants;
8. - When solar cells are heated, the efficiency of their work drops significantly;
9. - Difficult disposal of solar panels.