Solar Array
Prepared by
Toan Nguyen
Implementation Date
8/30/2020
Revision #
1
Page #
1 of 2
Revision by
Owner
Solar Gators
Last Reviewed/Update
Date
Standard Operating Procedure (SOP): Encapsulation
1. Purpose
This SOP outlines the steps taken to handle and encapsulate a solar array module.
2. Scope
This SOP is for the solar array subsystem when manufacturing the solar array or anyone else who is
involved in manufacturing the solar array.
3. Safety/ Hazards
•
The materials must be kept as clean as possible
•
Solar modules are very fragile, handle with care
•
Materials get very hot (~140 ⁰C)
•
Gloves
•
Safety glasses
•
Close toed shoes
4. Control
1. At least 2 people are needed
5. Procedure
1. Place several layers of felt on table surface.
2. Place the heating pads on top of the felt.
3. Place the aluminum plate over the heat pads.
4. Clean the aluminum plate very well with acetone.
5. Roll the tacky tape out around the perimeter of the aluminum plate, leaving the paper on.
6. Cut and place a piece of FEP on the aluminum plate. Perform this step immediately before the
next layers are ready to go on so the FEP doesn’t collect dust. Roll the FEP from under the roll so
the part of the film that faces outward on the roll touches the aluminum.
7. Place the first sheet of TPO on top of the FEP with the smooth side of the TPO facing the cells.
8. Place the solar cells face down on the TPO.
9. Place the second sheet of TPO on top of the cells, aligning it with the first sheet. The smooth side
of the TPO faces the cells.
10. Place the backsheet on top of the TPO, oriented with the shiny side facing the aluminum plate.
11. Place the blue release film over the backsheet.
12. Place the breather over the release film. The breather should cover the aluminum plate to the
tacky tape or else the vacuum bag will get wrinkles that trap the air and prevent the pressure from
getting as low as it should.
13. Place vacuum port over breather in an area where it will not be on top of the backsheet or else
the module will get an indent in the back.
14. Cover the aluminum plate with the vacuum bagging.
15. Remove the paper from the tacky tape and stick the vacuum bagging to the tacky tape. Make
sure there are no holes.
16. Cut a small slit where the port hole is and connect it to the vacuum hose.
17. Turn on the vacuum and listen for holes.