The production process for bifacial, dual-glass solar panels primarily involves cell preparation, module soldering, lamination and encapsulation, testing, and final processing. While the manufacturing process is fundamentally similar to that of traditional photovoltaic modules, the use of a bifacial power generation structure and dual-glass encapsulation imposes stricter requirements regarding material selection, encapsulation techniques, and quality control to ensure optimal power generation performance and long-term reliability.
In the initial stage of module manufacturing, bifacial solar cells undergo inspection and sorting to ensure consistency in their electrical performance parameters. Subsequently, multiple cells are connected in series or parallel-according to design specifications-via a soldering process to form cell strings. To minimize current transmission losses and enhance module output, modern bifacial dual-glass modules often employ technologies such as multi-busbar (MBB) designs and half-cut cells. Once the cells are interconnected, the cell strings are arranged between layers of encapsulation material to form the module's internal structure.
Encapsulation is a critical step in the production of bifacial dual-glass solar panels. The module is typically assembled by stacking a front layer of tempered glass, an encapsulation film, the cell array, another encapsulation film, and a rear layer of tempered glass. This assembly then undergoes high-temperature, high-pressure treatment in a laminator, causing the encapsulation film to melt and bond securely with the various material layers. Following lamination, the module undergoes edge sealing, the installation of an aluminum alloy frame, and the attachment of a junction box. The junction box typically houses bypass diodes to mitigate the risk of hot spots caused by partial shading and to enhance operational safety.