PowerFilm Solar Inc

Design Options

PowerFilm can customize many mechanical aspects of a solar panel including size, shape, PV technology, flexibility, charge controller integration, substrate, mounting mechanism, wiring, connectors, contacts, electronic housing, weatherproofing, surface finish, aesthetics, testing, and more.

 

Connections and Mounting

Small amorphous silicon thin film solar panel with wire connectionsSmall amorphous silicon thin film solar panel with backside contactsSmall amorphous silicon thin film solar panel with extended bus tapesolar panel connected to a pcb using backside contacts

 

A solar panel has to integrate electrically and mechanically with the rest of a system. This will look much different for a smaller panel powering an IoT sensor than for a large panel installed on a truck.

 

PowerFilm provides many options for connecting and mounting panels to fit the diverse needs of the industries we serve. 

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Encapsulation

Water splashing on an electronic component solar panel

Protective laminates and other encapsulants are needed to protect the bare solar material, which is prone to scratching and corrosion. Laminate encapsulation can also provide excellent water and weatherproofing to a solar panel. 

 

PowerFilm offers a wide variety of lamination and encapsulation options to meet the diverse needs of the industries we serve. 

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Panel Shape

EB325 custom thin film flexible amorphous silicon solar panelbackside of EB325 custom thin film flexible amorphous silicon solar panel

PowerFilm can manufacture solar panels that are very small, less than a square inch, and large arrays that power base stations. Although the active solar area is typically rectangular, the substrate and material around the panel can be cut into irregular shapes, including fold-over tabs and notches. 

 

Use the Custom Solar Panel Design Tool to see the different sizing options for Electronic Component Panels, which can also be combined to form larger arrays.

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Substrates

thin film amorphous silicon solar material on a fabric substrate   mono crystalline solar cells on a fiberglass substrate   thin film amorphous silicon solar material on a metal substrate thin film amorphous silicon solar material on a plastic substrate

PowerFilm can adhere solar material to many different surfaces, including plastic, fiberglass, metal, fabric, vinyl, and glass. 

Some reasons to use a substrate include increasing rigidity, adding mounting hardware, or combining component panels into an array.  

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