Breakthrough progress in ribbon connection technology for back-contact cell assemblies

Summary

The Fraunhofer Institute for Solar Energy Systems (ISE) in Germany, in collaboration with Comax, has developed a groundbreaking technology for connecting high-efficiency MWT (Multi-Wire Tied) cells. This innovative approach offers significant cost advantages and extremely low energy losses, making it a promising solution for the next generation of photovoltaic modules.

Introduction

In today’s highly competitive solar energy market, PV module manufacturers are constantly seeking ways to differentiate their products. The primary goal is to achieve the highest possible module efficiency at the lowest cost. While many companies claim to have mature technologies and products, most fail to deliver consistent performance when subjected to detailed analysis. Numerous examples show that technological advantages in one area—such as reduced cell costs or improved cell efficiency—do not always translate into real benefits for the final module. For instance, even if the cell itself becomes cheaper, the overall module cost might not decrease significantly. Similarly, higher cell efficiency may not always result in higher module efficiency due to other factors like connection losses.

The Challenge of Front vs. Back Contact Technology

When examining various cell interconnection methods, it becomes clear that front-contact technologies face inherent limitations. The challenge lies in balancing two conflicting requirements: minimizing current transfer loss (CTM) by using thicker ribbons or wires, while also reducing the shading effect on the cell’s front surface. Although multi-strand wires help reduce this issue, they do not fully resolve the problem. Technologies such as BSF, PERC, and HIT all suffer from this trade-off. Only back-contact cell designs allow for thick interconnections without casting shadows on the front side of the cell.

This makes back-contact technologies like IBC, EWT, and MWT more appealing for achieving higher efficiency. These designs enable large cross-sectional connections with minimal CTM losses and no front-side shading. While conductive backplanes provide the foundation for these connections, the industry continues to search for a low-cost method to achieve similar performance. That’s where the new HIP component technology comes in.

A New Interconnection Solution

Comax, in partnership with the Fraunhofer Institute for Solar Energy Systems, has developed a new interconnection method known as the HIP (High-Efficiency Module) technology. This approach uses traditional ribbons combined with an innovative cell interconnect technique. The resulting CTM losses and module power output have been verified by independent certification bodies, confirming its reliability and performance.

One of the key advantages of HIP technology is its low material and equipment costs, with CTM losses potentially below 1%. At the SNEC 2013 exhibition in Shanghai, Comax will showcase standard 60-cell modules produced using this new technology at Booth No. E3-520. During the event, Comax and the Fraunhofer Institute will demonstrate the clear cost-per-watt advantage of the HIP technology, highlighting its potential for widespread adoption.

Additionally, the production of high-performance MWT cells and HIP modules can be carried out on both existing and new production lines. The necessary technology, equipment, and materials are readily available. Compared to other emerging technologies, Comax’s solution requires minimal changes to current production processes and incurs little additional cost. This flexibility allows manufacturers to quickly transition to producing more efficient modules, giving them a competitive edge in the market.

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