Module Tech 03 | High-Density Encapsulation Technology

In traditional modules, the spacing between solar cells is typically 2mm. As the industry increasingly demands higher module efficiency, maximizing the number of cells within a given module area has become crucial. This led to the advent of high-density encapsulation technology, driven by advancements in ribbon technology and welding processes. High-density encapsulation increases the total cell area in a module, thereby enhancing its power output and efficiency. Key approaches include shingling technology, overlapping welding technology, and tight spacing technology.

Shingling Technology

Shingling technology uses laser cutting to divide the entire cell into multiple small strip-shaped slices, and uses conductive adhesive to stack and connect these small cell slices front to back and arrange them closely together. This method significantly increases power density. However, its complexity, high production costs, and challenging maintenance limit its widespread adoption, despite its potential.

Overlapping welding technology

Overlapping welding technology employs special round wire welding ribbons to "overlap" half-cut cells with minimal spacing, creating a overlap (0.2–0.5mm) between cells. The key challenge lies in ensuring uniform thickness across overlapping and non-overlapping regions. Any inconsistency during lamination could result in microcracks or cell breakage. Over time, mechanical stresses in real-world conditions may exacerbate these defects, affecting module reliability.

Tight Spacing Technology

Tight Spacing technology compresses the inter-cell spacing to 0.5–0.9mm by flattening the interconnection ribbon while maintaining a safe gap between cells. This approach minimizes the risk of yield loss from manufacturing deviations and reduces the likelihood of microcracks or cell damage during usage, enhancing module durability.

Among these high-density encapsulation techniques, Gstar has adopted tight spacing technology, which achieves an optimal balance between cost, power enhancement, production yield, and product reliability. Through this technology, Gstar's N-type modules have improved module efficiency by 0.2% to 0.3% while maintaining almost the same yield level, demonstrating excellent performance advantages.

Gstar has always integrated technological innovation into the core of group development. By continuously optimizing photovoltaic system costs and lowering the Levelized Cost of Energy (LCOE), Gstar delivers more efficient, reliable, and cost-effective solar solutions, ensuring long-term benefits for its customers.