Solar Module Varieties

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Solar Module Varieties: Cell Types and Module Designs

In this lesson, we'll explain the most common cell types and module designs used in today's solar industry. You will see how different cell formats and layouts influence power, efficiency, and overall module size. This understanding helps to plan production lines and select the right equipment for each design.

Half Cell Concept: The Industry Standard
One of the most common module designs today is the half cell concept. Instead of using full-size cells, each cell is divided into two halves.

How Half Cells Work
This design reduces the current in each electrical path and lowers resistive losses inside the module. The result is:

Higher efficiency
Better thermal behavior
Reduced internal power losses

Why Half Cells Have Become Standard
Modern wafers are getting larger, which increases the electrical current. Higher current means more internal loss and heat. By splitting the cells in half, these losses are reduced and the electrical efficiency improves.

That is why half cell designs have become the industry standard for modern solar module production.

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Wafer Sizes and Their Impact
Different wafer sizes lead to different module dimensions and power classes. Common formats include:

As the wafer size increases, each cell produces more power, but fewer cells are needed per module. This affects the final size, weight, and mechanical design of the panel.

String Configuration Options
Each module design can be produced in various lengths. Typical configurations use 8, 9, 10, 11, or 12 half cells per string.

The choice depends on:

Required voltage
Desired power output
Physical limits of the glass or frame size

Typical Power Outputs by Wafer Format
Typical maximum module sizes with half cell design depend on the wafer format:
M6 wafers: Modules reach around 470 W
M10 wafers: Modules go up to about 580 W
M12 wafers: The largest designs can achieve roughly 690 W
Lower power outputs are possible with fewer cells per string, allowing manufacturers to create modules for different market segments and applications.

Custom Electrical Layouts
Some modules use custom electrical layouts such as:

Parallel connections
Cross string connections

Applications for Custom Layouts

These are applied for specific cases, for example:

Building-integrated photovoltaics (BIPV)
Lightweight constructions
Special architectural applications

They allow flexible dimensions and electrical properties but are usually produced in smaller volumes compared to standard designs.

Choosing the Right Design for Your Production
Understanding these module varieties is essential for planning your production line. The choice of cell format and module design directly impacts:

Equipment selection
Production capacity
Market positioning
Manufacturing costs
Target customer segments

When planning a new factory, it's important to consider which wafer sizes and module designs will best serve your target market and align with available equipment technology.

Start Your Solar Module Production

If you plan to start your own factory, we are ready to support you from the first idea to full production. Our team can help you select the optimal module design and equipment configuration for your specific market needs and production goals.