The fine differences
High quality aleo modules are made from individual solar cells in five central manufacturing steps. Only the most modern technologies and materials are used in our production facilities. To make sure that only masterpieces leave our factory gates, the highly automated production process is also accompanied by strict quality control.
Step 1: The solar cell ribbon (string)
The production begins with the heart of every module: the solar cell.
It begins by linking up to ten solar cells together into what we call a solar cell ribbon (string) and connect them. This process is performed in our factories by what are known as string machines, which solder all of the cells with specially coated copper ribbons in a fully automated procedure. Measuring instruments ensure that only cells with the same properties are connected within one string. By doing this, we ensure a uniformly high performance and quality in each and every module.
Step 2: String alignment
Adding the solar glass is the second step. It protects the strings from outside influences such as wind and weather. At aleo solar, the 3.2mm-thick solar glass is washed before a transparent plastic film (known as EVA film) is laid onto the glass. The individual strings are then placed on this film: properly poled, they are arranged precisely side-by-side by our lay-up station before being soldered and connected in series.
A second EVA film is then laid onto the strings in the same step, so that the cells are now fully embedded in plastic. An insulating backing film is then applied. This not only prevents short circuits, but provides additional protection from the effects of weather and climatic conditions. Incidently, our experienced employees can intervene at any time during the production process to rectify any possible potential issues.
Step 3: Solar modules are laminated
Many parts now come together to complete the cycle. The individual components of the raw module are consolidated into a laminate under precisely defined pressure conditions at 143 degrees Celsius. The EVA film then melts under these conditions and envelops the solar cell strings. We use the lamination process to protect the sensitive cells, especially from moisture and ultraviolet light. This way, we also increase the strength of the module making it suitable for everyday use in a wide range of climatic conditions: This hardened laminates will withstand a load of over 500 kg per square metre at any time, making it resistant also to snow and wind.
Step 4: The frame – plug-connected, not screwed together
The frame is a special feature which gives our modules the unique aleo sturdiness. The particularly light but robust and warp-resistant aluminium frame is precisely plug-fitted and not screwed together. We also place drainage holes in the 50mm-thick frames so that standing water can drain off easily. Lastly, the modules are equipped with an outlet.
Step 5: The output check
At the end of the manufacturing process comes what we call the “flash test”: We determine the exact output of each and every premium module using a light simulator. Based on these results, we then assign the modules to a predefined output class. Incidently: At aleo solar, we exclusively classify the measured output in a positive manner - for instance, if a module is measured at 189 watts upon production, we assign it to the 185-watt category. This is an added value which our customers perceptibly benefit from with each module.