Advancements in Module DesignFollowing an analysis of cell-to-module (CTM) power loss simulation results from Fraunhofer ISE for a TOPCon module, JA Solar focused on 3 primary routes to recover power losses: geometrical loss, optical loss, and electrical loss. Geometrical losses can arise from factors such as wafer size, cell-to-cell gap changes, and metallization busbar configurations. Starting last year, JA Solar began using M10R (182 mm) size rectangular wafers to produce various modules by cutting them symmetrically or asymmetrically. The DeepBlue 4.0 Pro series module, equipped with M10R wafers, offers a power output of up to 650 W.On the metallization front, the company has significantly increased the number of busbars, transitioning from multi-busbar to super multi-busbars (SMBB) and, ultimately, zero busbars (0BB). The 0BB metallization, which uses ultrafine round ribbons and electrical conductive adhesive (ECA) stringing technology, saves up to 20% of silver paste compared to traditional SMBB metallization. JA Solar explained that the busbarless layout, which reduces shading by 5% to 25% compared to SMBB cells, leads to higher light absorption rates and reduced incident angle modifier (IAM) losses, resulting in enhanced power output by up to 5 W and higher efficiency.From an electrical loss perspective, the use of thin metallization wires reduces series resistance due to a shorter current transmission length on both sides of the cell busbar, boosting power output by minimizing series resistance losses. The 0BB metallization technology also improves contact between the wires and fingers, reducing power loss due to fewer microcracks, lower welding temperatures, and localized stress.Additionally, with the 0BB high-efficiency module solution, JA Solar has achieved up to a 5% reduction in carbon emissions by optimizing auxiliary materials such as paste and welding wire films, in line with the company’s sustainable manufacturing practices. The company has also adopted advanced welding technologies that lower welding temperatures by 15% to 40%.Advanced Module CharacterizationBeyond technology optimization at both the cell and module levels, JA Solar has adopted advanced module characterization processes, including AI-driven data analysis, in-field high-power performance with the best levelized cost of energy (LCOE), self-cleaning and anti-glare properties, and in-depth degradation pattern analysis.
