Solar Module with Half Size Solar Cells

Smaller solar cells with smaller currents have the potential to reduce series resistance losses in the interconnection tabs of solar modules. Laser scribing and subsequent cleaving of cells has proved to be a high yield processes for cutting solar cells in half and appears to be an industrially compatible process. Some companies already introduce half-cell solar modules. In this paper we give an overview on mechanical and electrical characterization of the solar cell cutting process, simulation results for a new circuit design with half size solar cells, processing experience and results with large half-cell modules, as well as investigations on the impact on mechanical strength of half size cells in solar laminates under mechanical stress. The mechanical reliability was reduced for half solar cells after laser processing, which results in smaller fracture forces in module laminates. In modules with 144 half-cells, we found the module power to increase from 315 W to 330 W by almost 5 %rel. Detailed investigation on series resistance, fill factor and short circuit current contributions to this performance gain are discussed.