Double-Glass Bifacial Module Manufacturing Process A Comprehensive Guide

In the rapidly evolving solar energy sector, double-glass bifacial modules have emerged as a game-changer. These advanced photovoltaic panels capture sunlight on both sides, boosting energy output by up to 30% compared to traditional monofacial designs. This article dives deep into the manufacturing process, industry trends, and why these modules are reshaping solar projects worldwide.

What Makes Double-Glass Bifacial Modules Unique?

Imagine solar panels that work like a double-sided tape – absorbing sunlight from the front and reflecting light from the rear. That's exactly how bifacial technology operates. The double-glass construction replaces conventional polymer backsheets with tempered glass, offering:

• Enhanced durability against harsh weather
• 30+ year lifespan with <1% annual degradation
• Improved fire resistance

"Bifacial modules could capture 10-20% more energy annually in optimal installations." – International Renewable Energy Agency (2023)

Key Manufacturing Steps Explained

1. Glass Preparation & Texturing

Workers begin by cleaning 3.2mm tempered glass sheets. A chemical etching process creates micro-pyramids on the surface – think of it as creating microscopic speed bumps to trap more sunlight.

2. Cell Stringing & Layering

High-precision robots arrange 144 half-cut PERC cells (typically 182mm or 210mm size) into strings. These get sandwiched between:

• Front glass with anti-reflective coating
• Encapsulant layer (EVA or POE)
• Rear glass with light-scattering texture

Component	Specification
Glass Thickness	3.2mm ±0.2mm
Cell Efficiency	22.8%-23.5%
Power Output	550W-670W

3. Lamination & Curing

The layered "solar sandwich" undergoes vacuum lamination at 150°C for 12-15 minutes. This critical phase removes air bubbles – picture slowly pressing a panini to perfection without any burnt edges.

Why Manufacturers Are Switching to Bifacial Designs?

Global bifacial module production capacity is projected to reach 120GW by 2025, according to Clean Energy Associates. Three driving factors:

1. Lower LCOE: 5-10% reduction in levelized energy costs
2. Durability: Withstands 5400Pa snow loads and 2400Pa wind pressure
3. Eco-Friendly: Fully recyclable glass-glass structure

Real-World Application: EK SOLAR's 500MW Solar Farm

EK SOLAR, a leading module manufacturer, recently deployed bifacial panels in Morocco's Noor Midelt complex. Early data shows:

• 17% higher yield vs. monofacial counterparts
• 0.21% monthly degradation rate
• ROI achieved in 6.8 years

Conclusion

The double-glass bifacial manufacturing process combines precision engineering with material science breakthroughs. As solar farms increasingly adopt this technology, understanding these production nuances becomes crucial for developers and EPC contractors alike.

FAQ Section

Do bifacial modules require special mounting?

Yes, elevated mounting (≥1m) with reflective surfaces below maximizes rear-side gains.