2025.08.22
Common quality issues during the production of solar panel modules are also the main cause of power degradation during module power generation.
Common quality issues include:
1. Failure to properly clean silicone and EVA residue on the light-exposed surface of the module allows outdoor dust to adhere, resulting in hot spots and damage to the module.
2. Improper use of flux
Overuse of flux. Excessive flux residue on the cell surface, if not treated before encapsulation, can still corrode after encapsulation, potentially causing greening of the solder ribbon, increasing module resistance and reducing module power. Furthermore, residual flux with a low pH value can react with the EVA, causing yellowing and resulting in a decrease in module power.
Improper use of flux during cell soldering can cause the EVA to react with the flux, forming numerous white spots on the cell surface and significantly reducing module power.
3. Air bubbles
Significant air bubbles within the module can, over time, increase in size and even form continuous air channels, leading to a decrease in module power and ultimately failure.
4. Cold Solder Joints
The soldering area within the module circuit is too small. Under harsh climate conditions and the effects of alternating high and low temperatures, connection failure is likely to occur, ultimately leading to a significant drop in module power.
5. Cell Binning
Inconsistent cell power and current binning within the module results in a significant discrepancy between the actual module output power and the theoretical module power. Inconsistent binning can cause abnormalities in the module electrical performance test curve, leading to hot spot effects, which can significantly reduce module power over long periods of use.
6. Improper Lamination
Excessive lamination temperatures and prolonged lamination times increase the yellowing aging coefficient of the EVA after the module is exposed to high temperatures. Prolonged outdoor use can cause yellowing of the EVA and auxiliary materials such as the backsheet, ultimately leading to a significant drop in module power.
7. Internal Defects or Contamination in Selected Cells
Cell defects can become apparent over time, significantly reducing module power. Selecting the right cell manufacturer is crucial. Module manufacturers should also equip themselves with relevant testing equipment, such as EL sorters and EL testers, to reduce the number of defective cells entering the production process.
8. Hidden Cracked Cells
Cells with hidden cracks in a module have a slightly lower power output than normal modules of the same specification. Over long-term use, these cracks intensify and extend, reducing the area of the module circuit. This can also cause hot spot effects, which can lead to module burnout.
Destructive effects from external environmental factors can cause module power degradation or even damage. During the later stages of use, photovoltaic power plants are often installed outdoors, subject to a variety of weather and environmental conditions. The hot spot effect is the most common factor that can cause module power degradation.
The hot spot effect caused by external factors primarily occurs when a solar cell module is partially blocked by sunlight, such as clouds or leaves. This causes the covered portion of the module to heat up much more than the uncovered portion, resulting in excessively high temperatures and dark spots that appear as burnt-out spots.
Hot spots can damage the entire module, even causing the entire power plant to shut down and cause losses. Therefore, it is necessary to carefully study the internal and external causes of hot spots to minimize their occurrence.
Keywords：
Sun Earth Solar, Ningbo Sun Earth, Sun-Earth, Sun Earth, solar panels
