Panel trends have a way of quickly becoming mainstream. IHS Markit predicted that passivated emitter rear cells (PERC) technology would go from a blip in the market in to mainstream by &#;a prediction confirmed by anyone looking at panel models released this year. PERC is here to stay.
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The next technology on that mainstream path is half-cell designs. The ninth edition of the International Technology Roadmap for Photovoltaic (ITRPV) predicts the market share of half cells will grow from 5% in to nearly 40% in .
Half-cell modules have solar cells that are cut in half, which improves the module&#;s performance and durability. Traditional 60- and 72-cell panels will have 120 and 144 half-cut cells, respectively. When solar cells are halved, their current is also halved, so resistive losses are lowered and the cells can produce a little more power. Smaller cells experience reduced mechanical stresses, so there is a decreased opportunity for cracking. Half-cell modules have higher output ratings and are more reliable than traditional panels.
&#;When considering a solar installation, the idea of &#;more&#; is at the forefront&#;produce more energy, save (or earn) more money and do more good for the environment,&#; said Cemil Seber, VP of global marketing and product management for module manufacturer REC. &#;In the case of rooftops where there is a limited amount of space available, using solar panels with half-cut cell technology can help.&#;
REC is a half-cell pioneer, first introducing the design in . The company&#;s TwinPeak half-cell module series effectively turns each panel into two twin panels. Since the cells are smaller, inter-cell spacing doesn&#;t have to be as wide and they can be placed closer together. This allows REC to separate the panel into two. Independent upper and lower module halves lead to improved shading response. If the bottom half of a module is shaded, the top half will still perform.
REC has pushed the boundaries with half-cell designs in polycrystalline modules. REC&#;s half-cell PERC polycrystalline modules have reached 300 W, and they can compete with full-cell modules in the more efficient monocrystalline class. The company has been so impressed by the advantages of half-cells, it is transitioning all its manufacturing lines to the new technology.
&#;Since , REC has been continuously transferring its production lines to half-cut cell technology,&#; Seber said. &#;Today, all but one of our module production lines in Singapore have been equipped for half-cut cell technology.&#;
During the tradeshow swing, REC released its new N-Peak series of modules, the company&#;s first stab at monocrystalline half-cells for even higher efficiency and output&#;up to 330 W in a traditional 60-cell footprint.
Other manufacturers have also started half-cell designs in the monocrystalline class. LONGi Solar recently exceeded 360 W in testing with its 120-cell half-cut monocrystalline PERC module. Hanwha Q CELLS received the Intersolar Award Photovoltaics category for its Q.PEAK DUO-G5 solar module&#;a 120-half-cell, six-busbar monocrystalline module. The Hanwha module uses round wires instead of flat ribbons for busbars to reduce shading on the cells. Hanwha also has half-cut designs for the 72-cell market, although in polycrystalline. Its Q. PLUS DUO L-G5.2 is a polycrystalline half-cell module with a maximum output of 370 W.
Since half-cell designs are the hottest trend right now, a manufacturer just has to update a few things on its lines to keep up. The two challenges with switching full-cell manufacturing to half-cell designs is the cell cutting and the stringing process. Since half-cells are usually PERC cells to begin with, the cell itself is quite fragile. Laser-cutting the cell down the middle without cracking it is a delicate process. Half-cells often use four or more busbars. Stringing these very narrow connection strips across a smaller footprint requires the use of precise equipment. Junction boxes are also different on half-cell modules. Most brands use multiple, smaller junction boxes so each module half can function as its own. Otherwise, half-cell module assembly is like full-cell production.
Since half-cell modules produce more power and are more efficient and reliable than their full-cell counterparts, their use can lead to time and money savings for the installer.
&#;By delivering more power per square meter, fewer panels are required to generate the same power,&#; Seber said. &#;This means quicker installation times and the need for fewer components such as clamps and racks&#;all of which reduces the overall costs.&#;
Half-cut solar cells are a relatively new innovation for the solar industry. These solar panels have gained steady popularity in the last few years.
As the name suggests, a half-cut solar panel is made with half-cut solar cells, doubling the total number of cells. Standard solar panels will typically have 60 or 72 cells, while half-cut solar panels will have 120 or 144 cells.
These solar cells are literally cut in half using a unique laser cutting technique. This innovation helps generate higher power output from the same size solar panel.
Half-cut solar cells and traditional, full-size solar cells generate electricity from the sun in the same way. But half-cut solar cells only produce half the amount of amps as a full cell.
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Current, which is measured in amps, causes resistive losses. One of the most significant advantages of half-cut solar panels is that they have fewer internal resistive losses, resulting in a higher panel efficiency rating versus a standard solar panel.
Half-cut solar panels are also wired differently, so they have a higher shade tolerance.
A standard solar panel uses all-series wiring, meaning the solar cells are wired in parallel rows. Three bypass diodes divide a standard solar panel into thirds. So if a solar cell is shaded, you only lose one-third of the solar panel&#;s output.
On the other hand, a half-cut solar panel has double the number of rows &#; six. Therefore, when a half-cut solar panel is shaded, you only lose one-sixth of the power output instead of one-third.
Lastly, half-cut solar panels have fewer issues with hot spots. In traditional panels, shaded or faulty cells can cause overheating. However, half-cut solar cells carry half the amount of current, so the temperature of any hot spot will be lower, likely causing less damage and reducing electrical losses.
Let&#;s break down the top benefits and disadvantages of half-cut solar panels.
The biggest advantage of half-cut solar panels is their higher efficiency rating. Higher efficiency means you&#;ll get more power output from the same size solar panel.
If you have limited roof space for your solar panel system, then a high-efficiency panel might benefit you. (If you have plenty of room on your roof or ground for your solar panels, there is no need to use high-efficiency panels.)
Another advantage of a half-cut PV module is the reduced effects of shade. If some of your solar panels are partially shaded, you may want to consider using half-cut solar panels for the reasons mentioned earlier.
The biggest downside of half-cut solar panels is that they are more expensive than standard solar panels because they are more challenging to make.
Solar cells are fragile to begin with, and half-cut cells require a high-tech laser cutter. Half-cut solar panels also require a more complex busbar configuration for wiring.
Most solar distributors carry a selection of solar panels with half-cut cells. Many popular solar manufacturers like QCells, Phono, REC Solar and Trina Solar make a variety of half-cut solar panels.
Half-cut solar cells were first introduced in by REC Solar, and other solar manufacturers quickly adopted the technology. But because of the complex manufacturing process, it is unlikely that these panels will take over the solar panel market.
Standard solar panels will remain popular as they are less expensive to make and work well in applications where high efficiency ratings are unnecessary.
Overall, half-cut solar cells are innovative and effective if you need more efficient panels or shade tolerance. To learn more about whether or not half-cut solar panels are right for you, contact the experts at GoGreenSolar. We are solar veterans and experts in the latest solar technology and can guide you through the process of going solar!
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