Zero-busbar Modules Triumph Over Traditional Structures - The Irresistible Momentum of 0BB Technology

No Busbars Triumph Over Busbars" - The Irresistible Momentum of 0BB Technology

In 2004, the global photovoltaic industry experienced a breakthrough year, marking the beginning of an era of rapid growth. At the same time, China's photovoltaic sector entered a vibrant period of growth, characterized by fierce competition and diverse innovations. From polycrystalline to monocrystalline silicon cells, and from the dominance of PERC to the competitive race among various N-type cell technologies, the past twenty years have seen a dizzying array of new technologies evolving from concepts to mature applications, driving the rapid growth of the industry.

Today, the photovoltaic industry has entered a new cycle. The influx of new players and the expansion of production capacity by existing companies have led to a significant oversupply in the market. This has resulted in severe overcapacity, prompting companies to compete on price to attract customers. As profit margins continue to decline, many photovoltaic module companies are under immense pressure to reduce costs and urgently need cost-saving measures to restore profitability.

Module manufacturers all know that silver paste accounts for a high proportion of non-silicon costs, making it the most expensive material after silicon wafers. Over the course of module development, the number of busbars has evolved from 4BB and 5BB to MBB, SMBB, and finally to 0BB. The gradual thinning of the main busbars has effectively reduced silver consumption and minimized shading, achieving cost reduction and efficiency improvement. The 0BB (no busbars) solution not only reduces the amount of silver paste used and lowers module costs but also increases the number of thinner ribbons, reducing electrical losses and enhancing module power output. The 0BB technology is widely applicable to mainstream N-type cell technologies and can be used in HJT, TOPCon, and BC. In recent years, module manufacturers have recognized the tremendous potential of 0BB technology for cost reduction and efficiency improvement, making this year the potential starting point for the industrialization of 0BB technology.

The implementation of the 0BB solution relies on further advancements in encapsulation film technology, requiring higher standards for the formulation and processes of encapsulation materials. Unlike traditional encapsulants, the connection method between the ribbons and cells in 0BB modules has changed, eliminating the use of traditional welding processes and placing higher demands on the adhesion and fluidity of the film. During the module lamination process, excessive adhesive fluidity can lead to issues like EL darkening, caused by flowing into the gaps between the cells and ribbons, while insufficient flow can reduce adhesion, causing bubbles around the module edges.

Current mainstream 0BB solutions include soldering with dispensing, pure dispensing, overlay film, and Smartwire, each with its own benefits and shortcomings. Cybrid Technologies Inc. has developed comprehensive solutions for various 0BB technical routes. For the overlay film and Smartwire (with overseas patents) solutions, Cybrid Technologies Inc. has introduced the "skin film + low-weight encapsulation film" solution. The skin film, made of pre-crosslinked single-layer EVA resin, weighs around 80-100g, is inexpensive, and has no patent conflicts. By precisely controlling the degree of pre-crosslinking, it achieves high adhesion between the film and cells while perfectly encapsulating the ribbons during lamination, improving module manufacturing yield and product stability. The encapsulation film, made of EVA or EPE material, ensures low weight and uniform thickness.

For the technical roadmap of 0BB adhesive dispensing, Cybrid Technologies Inc has creatively developed an integrated encapsulation film. The integrated film is produced through a co-extrusion process that forms all film layers at once. Precise pre-crosslinking control ensures optimal film flow around the cells during lamination, ensuring perfect adhesion between the film, ribbons, and cells. Additionally, as the producer of the globally unique Raybo? light-conversion encapsulation film, Cybrid Technologies Inc. has rapidly developed the Integrated light-conversion film encapsulation technology for 0BB applications. This solution combines integrated film and light-conversion technologies, incorporating light-converting agents into the film formulation to convert harmful UV light into useful blue light for electricity generation, thereby enhancing module efficiency while maintaining low aging peel strength, strong UV stability, and high manufacturing yield.

As mentioned previously, the photovoltaic is entering a new phase, characterized by an increased pursuit of cost reduction and efficiency improvement. Against this backdrop, 0BB technology stands out as an inevitable trend. Cybrid Technologies Inc, focused on innovation and leading technology development, is poised to seize the initiative in future technological advancements of the photovoltaic industry. Currently, UV-curing adhesives and other products for the 0BB dispensing solution are being tested by leading module manufacturers. We welcome industry peers to participate in Cybrid's internal product discussions, as there will be more exciting innovations and presentations for these emerging technologies in the future.