A solar panel is a glass laminate inside an aluminium frame, and the frame corner is where every transport impact lands. Modules travel in pallets of twenty to thirty, tilted and strapped, so the pack load runs through the frame edges and the corners. Protection has to keep the frame corner square and keep the strap off the glass edge.
Profile data for module packs
| Position | Profile | Purpose |
|---|
| Strap crossing | L 60 x 60, 5 mm | Spread strap load, clear the glass |
| Pack corner | L 50 x 50, 4 mm, full height | Keep pack square |
| Top and bottom rim | Rim board 60 mm, 4 mm | Separate module frames |
| Two-high stack | Top cap 4 mm | Carry the upper pallet |
| Long sea leg | Coated face 5 mm | No water mark on frame |
The pack, not the module, is the unit to protect
Modules are shipped as a pack: a pallet, a vertical or near-vertical stack, corner posts, and two or three straps. The straps are the load path, and they cross the frame at the corners. Without a protector the strap bears on the aluminium corner and on the glass edge that sits a few millimetres inside it.
The glass edge is the part that cannot be repaired. A chip at the edge of a laminate is a potential crack initiation point, and a module with an edge chip is normally rejected even if it tests well.
What the protector has to do at each position
At the strap crossing, the protector spreads the strap load along the frame so the aluminium does not deform and the strap does not touch glass. A 50-60 mm leg with 4-5 mm wall is the usual quote.
At the pack corners, a corner board keeps the stack square and stops the pack from leaning when the straps settle. If the pack leans, the modules rub against each other and the frames scuff the glass.
Along the long edges, a rim board keeps the modules apart at the top and bottom of the pack, where the frame sections touch.
Sea freight and the aluminium frame
Aluminium and paper are both hygroscopic in different ways: a damp paper board against an anodised frame can leave a water mark that is visible on inspection. Keep the boards wrapped until the pack is closed, and specify a coated face on a long sea leg.
Where packs are stacked two high in a container, add a top cap so the upper pallet bears on the cap rather than on the module frame of the lower pack.
Questions buyers ask before ordering
Does the protector touch the glass?
The leg is sized to sit on the frame, not on the laminate. If the frame is narrow, we narrow the leg rather than let the board ride onto the glass.
How many protectors per pack?
One per strap crossing on each face, plus four corner boards and two rim boards for a standard 30 module pack.
Can the boards be printed with the module model?
Yes, one or two colours, which helps at the installation site.
Are they suitable for bifacial modules?
Yes, provided the rear face is not loaded. Use a rim board that sits on the frame, not on the rear glass.
What is the lead time for a container quantity?
7-15 working days after approval, with samples in 3-5 days.
Quote requests with cut length and quantity reach us at mona@hengnicepacking.com and are answered within one working day.
