A PV module consists of a number of interconnected solar cells encapsulated into a single, long-lasting, stable unit. The key purpose of encapsulating a set of electrically connected solar cells is to protect them and their interconnecting wires from the typically harsh environment in which they are used. For example, solar cells, since they are relatively thin, are prone to mechanical damage unless protected. In addition, the metal grid on the top surface of the solar cell and the wires interconnecting the individual solar cells may be corroded by water or water vapor. The two key functions of encapsulation are to prevent mechanical damage to the solar cells and to prevent water or water vapor from corroding the electrical contacts.
Many different types of PV modules exist and the module structure is often different for different types of solar cells or for different applications. For example, amorphous silicon solar cells are often encapsulated into a flexible array, while bulk silicon solar cells for remote power applications are usually rigid with glass front surfaces.
The most common modules have either 60 cells or 72 cells with three bypass diodes. 60 cell modules were originally designed for ease of handling in residential applications and heavier 72 cell modules for large utility installations where cranes and hydraulic lift are available. However, it is quite possible to use 72 cell modules in residential installations so long as the rest of the system is designed to handle the large size.
Module lifetimes and warranties on bulk silicon PV modules are over 20 years, indicating the robustness of an encapsulated PV module. A typical warranty will guarantee that the module produces 90% of its rated output for the first 10 years and 80% of its rated output up to 25 years. A third party reinsurance company ensures these warranties are valid in the event the manufacturer goes bankrupt.
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