Preface
Solar power is the cleanest, easiest to get and unpolluted green energy of the world. It can be designed from simple, sand-alone style onto more complicated control to create power. Thailand is a sunshine country and the population mostly concentrates in bigger cities such as Bangkok that causes the electric power equipment and construction only gather in urban areas, but rural areas or isolated islands can’t get the power adequately due to connection difficulty. The stand-alone Photovoltaic system, therefore, will become the best solution to satisfy those people in the special areas of Thailand.
Meanwhile, the industry of automotive assembly is one of the most important categories supporting from Thai government that has attracted several global automotive companies such as GM, Toyota…to establish the assembly lines in Thailand. This has benefited Thailand from promoting its clusters in auto-industry all over the world. Since LED lights have been commonly developed into automotive such as tail lights & HMSL, there will be a couple of opportunities in LED applications for local market.
Strengths & Opportunities
1. To gain the updated high-tech and process of solar module lamination transferred from NCT
2. Technical support and design consultant from NCT
3. Supply resource promised for the Key materials e.g. cells, LED
4. Plenty of labor manpower in Thailand
5. Cheaper and easier to get the land and factory
6. Convenience in logistics support
7. OEM/ODM chance from NCT
8. Available capital for investment
9. Larger markets in ASEAN
10. To Enjoy preferential tariff & tax-saving of ASEA and the related countries of the world
Benefits
1. The photovoltaic power system can benefit those people in the areas such as insufficient electric areas, remote islands and isolate areas of Thailand.
2. New investment can stimulate local economy and lead to prosperity.
3. To utilize local manpower and increase employment opportunity.
4. Bring the high technology & knowledge in photonics to the country.
5. Higher turnover rate to equipment & capital
6. Not only for domestic market, but also can export to overseas markets.
Modules Description & Production
The photovoltaic module is an assembly of electrically interconnected solar cells enclosed in a weatherproof package to protect it from the effects of the environment. Modules up to 137 cm x 200 cm can be manufactured by the production line.
The module circuit design specifies the number of cells connected in series, the number of cells connected in parallel, and the frequency of parallel interconnects. The number of cells in series determines the module operating voltage. The cell area and the number of cells in parallel are proportional to the module current output. Any practical series/parallel configuration can be made.
Many different module types can be manufactured by production line. The actual design used can include technically qualified materials locally available in the country of manufacture. Following is a description of a module whose components have successfully passed accelerated environmental testing. This design is provided by Spire and is used for the initial line demonstration.
The module consists of interconnected and encapsulated solar cells in a durable and environmentally protected package. A cut-away view is shown in the figure below. The encapsulation system incorporates the latest developments proven by the U.S. Department of Energy program. Tempered low-iron glass is normally used for the front cover (or superstrate) to provide permanently transparent protection for the optical surface of the module. However, other types of glass, such as window glass, may be used. The remainder of the laminate consists of clear ethylene vinyl acetate (EVA) encapsulant, the cell circuit, a second layer of EVA, a fiberglass sheet, and a back cover film.
EVA, which is supplied in sheet form, is both a transparent soft encapsulant and an adhesive for bonding the layers together. The Spire lamination process, using the laminayor, is designed to thoroughly remove air from between all layers. The fiberglass mat protects the back cover film from damage which can be caused by the back side of the cell circuit during the module's lifetime. When the EVA encapsulant is heated for lamination, it melts and impregnates the fiberglass. This provides a strong bond extending from the cell backs, through the fiberglass, to the back cover.
The module edges, where the back cover film meets the glass, are protected by a gasket. This edge gasket cushions the glass panel in the module frame to prevent degradation of the edge by daily thermal cycling.
Electrical output leads are brought through the encapsulant and back cover. The leads go to a junction box mounted on the back of the module. Weather-tight wire connections are made at the junction box
Manufacturing Process
The process for fabricating photovoltaic modules consists of the following steps:
· Sorting solar cells into performance groups (current groups at load voltage) with the solar test
· Assembling and soldering strings of cells interconnected with metal ribbons or "tabs" using the manual or assembler
· Completing the module circuit by soldering bus ribbons to connect the strings together and provide output leads
· Visually inspecting and electrically testing the module circuit by measuring its dark I-V characteristics
· Washing, rinsing, and drying the glass superstrate
· Cutting the EVA, fiberglass, and back cover to length and assembling them with the glass and module circuit, in preparation for encapsulation.
· Laminating the module assembly and curing the EVA with the laminator.
· Proceeding through final assembly, including edge trimming, installing an edge gasket and frame, and attaching a junction box
· Performing a high voltage isolation test to guarantee voltage isolation between the cell circuit and the module frame
· Electrically testing the module performance by measuring a current-voltage curve under simulated sunlight with the simulator.
· Visually inspecting the completed module for quality of materials and workmanship
This process uses solar cells and module materials as input and produces functional PV modules, ready for use. The process sequence is schematically illustrated in the figure below. The product line provides the necessary equipment and training for implementing these process steps.
Major Equipment & technology transfer Cost
PROCESS |
EQUIPMENT |
PRICE (USD) |
1. Cell Testing |
Cell Tester |
150,000 |
2. Module Lamination |
Laminator |
185,000 |
3. Performance Test |
Module Simulator |
200,000 |
4. Others |
|
150,000 |
5. Cell cutting (Option) |
Dicing-saw |
100,000 |
6. Technology transfer fee (testing materials excluded) |
|
780,000 |
7. Training fee – 2 men x 2 months |
|
40,000 |
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