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SES develops new process to speed PV module assembly

A patented new process by Société d'Energie Solaire (SES) of Geneva, Switzerland, allows simple, fast and reliable electrical connections between PV strings and junction boxes. To be shown for the first time at Intersolar (21-23 June 2007, Freiburg/Breisgau), the development offers numerous advantages through material savings, enables automated manufacture and offers high efficiencies to panel manufacturers and installers. In the SES process the strings, instead of being soldered to the peripheral endribbon, are folded over the back of the cells, where they are soldered with a simple machine onto a flexible circuit. The circuit substrate is a DuPont Tedlar PVF film laminated with DuPont Teijin Films Mylar PET polyester film; the circuit has special contacts for attachment to the junction box and also serves to insulate the strings from the cells. After lamination, a special junction box, made by Huber & Suhner, is simply placed over the circuit and the connections are soldered.

SES has also developed a patented process, also based on a flexible circuit, to string back-contact cells. The process allows high-speed non-contact soldering with a simple soldering machine to make a string with electrical connections integrated as above. The mechanical strength provided by the flexible circuit allows thin cells to be used without breakage. The process uses lead-free RoHS solder.

SES plans to licence both processes, as well as use them in its own manufacturing facilities for standard modules and the Swisstile PV integrated roof-slate.



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