Hermetic edge sealing of photovoltaic modules. Final technical report

Technical Report · Fri Jul 01 04:00:00 EDT 1983

DOI:https://doi.org/10.2172/5796526· OSTI ID:5796526

Nowlan, M. J.

The program objective was to investigate the feasibility of using an electrostatic bonding (ESB) and ultrasonic welding process to produce hermetic edge seals on terrestrial solar cell modules. The fabrication sequence is to attach an aluminum foil gasket to the perimeter of a glass sheet. A cell circuit is next encapsulated inside the gasket, and its aluminum foil back cover is seam welded ultrasonically to the gasket. An ESB process for sealing aluminum to glass was developed in an ambient air atmosphere, which eliminates the requirement for a vacuum or pressure vessel. An ultrasonic seam welding process was also developed which did not degrade the quality of the ESB seal. Good quality welds with minimal deformation were produced. The effectiveness of the above described sealing techniques was tested by constructing 20 x 20 cm/sup 2/ (8 x 8 in./sup 2/) sample modules, and then subjecting them to nondestructive fine and gross leak tests. The gross leak tests identified several different causes of leaks which were then eliminated by modifying the assembly process. This program has been successful in demonstrating the technical feasibility of producing hermetically sealed edges on photovoltaic modules using a combination of ESB and ultrasonic welding.

• Research Organization: Spire Corp., Bedford, MA (USA)
• DOE Contract Number: NAS-7-100-956352
• OSTI ID: 5796526
• Report Number(s): DOE/JPL/956352-2; ON: DE83016910
• Country of Publication: United States
• Language: English

Related Subjects

14 SOLAR ENERGY
140501* -- Solar Energy Conversion-- Photovoltaic Conversion
BONDING
DIRECT ENERGY CONVERTERS
ENCAPSULATION
EQUIPMENT
FABRICATION
GASKETS
JOINING
LEAK TESTING
PHOTOELECTRIC CELLS
PHOTOVOLTAIC CELLS
SEALS
SOLAR CELLS
SOLAR EQUIPMENT
TESTING