Half-Cut Solar Panels: Pros & Cons | Worth Your Investment?

Half-cut solar cell technology represents a significant advancement in the design of traditional crystalline silicon solar cells. This evolving technology mitigates major power losses commonly found in standard PV modules, thereby enhancing the overall performance of solar panels and PV systems.

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Half-cut solar cells bring several significant benefits without notable downsides when compared to traditional modules. This article will explore the technology behind half-cut solar cells, their operation, advantages and disadvantages, and a comparison with traditional and PERC technologies.

What is a Half-Cut Solar Panel?

Half-cell modules, also known as half-cut solar panels, are emerging as a new manufacturing trend. If you’re curious about what a half-cut solar panel is, read on for a detailed explanation.

Components and Materials of the Half-Cut Solar Cell

Half-cut solar cell technology doesn't involve new or innovative materials. Instead, it relies on conventional crystalline silicon (c-Si) solar cells. The same components and materials used in c-Si solar cells are employed in half-cut cells, including:

• Printed silver paste (front contact)
• Anti-reflective coating or glass
• Doped semiconductor with c-Si (P-N junction)
• Back Surface Field
• Printed aluminum paste (rear contact)

The distinctive feature of half-cut solar cells is not their composition but their design, which aims to enhance performance and decrease electrical losses.

Cutting the Solar Cell in Half

Half-cut solar cells are divided using a process called cleaving. High-tech laser technology cuts the cells in half, yielding the same voltage but half the current.

Since this technique involves dividing a traditional crystalline silicon solar cell, the conversion efficiency remains comparable to that of a traditional c-Si cell. Different solar cell types, such as PERC and bifacial, can also be used to create half-cut solar cells.

Structure of Half-Cut Solar Panels

Half-cut solar panels contain double the cells within the same module area. For instance, a standard 60-cell module becomes a 120-cell module with half-cut technology, distributed into six substrings of 20 cells connected in parallel. The parallels connected instances apply to modules with 72 or more cells.

Working Mechanism

Half-cut solar panels function like whole-cell panels but with added substrings. Connected in series or parallel, these panels' primary differences are reduced current per cell and improved tolerance against partial shading.

Advantages of Half-Cut Solar Panels

What are the advantages of half-cut solar panels? Below, we elaborate on the multiple benefits of incorporating half-cut solar cell technology:

Reduced Power Losses

Half-cut solar cells significantly diminish electrical losses due to Joule's Law. Producing half the current reduces power losses by approximately 75%. Overall, the modules' current output increases by 2-4%, thereby enhancing power output equivalently.

Increased Partial Shading Tolerance

Partial shading in PV modules generally leads to major power losses. With twice the substrings, half-cut cells minimize shading-induced losses, potentially reducing power losses by up to 50%.

Reduced Hot Spots and Temperature

Partial shading creates hot spots due to some cells acting as resistors. Half-cut cells lower cell current and, consequently, hot spot temperatures, potentially reducing peak temperatures by up to 20°C.

Higher Cell-to-Module Power

Though single half-cut cell efficiency depends on solar cell technology, they generally offer a higher Cell-to-Module (CTM) power, translating to higher power output. The half-cut CTM power stands at 99.4% before considering laser-cut losses or 98.4% after.

Integration with Various Solar Cell Technologies

Half-cut cell technology can integrate with conventional c-Si, PERC, or bifacial technologies, enhancing PV modules' power output and reducing various losses.

How About Their Disadvantages?

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Despite the advantages, half-cut solar cells come with a couple of downsides:

High Manufacturing Investment

Producing half-cut solar cells requires significant investments in additional manufacturing equipment, including doubling tabbers & stringers and acquiring equipment for cleaving cells. Although half-cell modules cost 0.6-1.2% more, their power increase reduces the cost per watt by 0.8-1%.

Increased Risk of Defects

Doubling the soldered connections and halving cells heightens the likelihood of bad contacts or defective cells. However, efficient quality control can mitigate most of these risks.

Half-Cut vs. Standard Solar Panels (Comparison Table)

To fully grasp the scope of half-cut solar technology, it’s essential to compare it with standard Al-BSF technology regarding cell count, voltage, current, etc.

Traditional c-Si panels often suffer from numerous losses and poor CTM power. By contrast, half-cut technology minimizes electrical losses by 75%, boosts CTM power by 3.6%, enhances shading resistance, reduces operational temperature, and mitigates hot spots by up to 20°C. Its minor drawbacks include slightly higher costs and potentially compromised aesthetics.

Half-Cut vs. PERC Solar Panels

PERC solar technology optimizes the design of Al-BSF c-Si cells by reducing surface recombination losses, increasing efficiency with rear-surface reflecting metal, and minimizing heat absorption. Though PERC cells deliver 6% more power than standard modules, they still suffer from shading and electrical losses similar to traditional cells.

Half-cut panels may not outshine PERC cells in surface recombination efficiency, but they offer superior partial shading performance and reduced ohmic losses—a crucial advantage for residential sectors affected by frequent shading.

Fortunately, there’s no need to choose between PERC and half-cut cells, as both technologies can be combined. This hybrid model maximizes benefits such as reduced electrical losses, increased shading tolerance, lower heat absorption, and improved overall CTM power.

Are Half-Cut Solar Panels Worth Your Investment?

Half-cut technology is among the latest solar industry efforts to boost PV module efficiency. Though it costs only 0.6-1.2% more than standard c-Si modules, it delivers a 2-4% higher power output, making it ideal for limited space installations.

These panels also excel in shaded locations, offering better performance by integrating more substrings. Although concerns may arise over their durability due to smaller cell sizes, the protective glass ensures they remain as durable as regular panels. Therefore, investing in half-cut technology is a smart move in the solar panel industry.

It's crucial to maintain half-cut solar panels for optimal performance and longevity. Here are some maintenance tips:

Regular Cleaning: Remove dirt, dust, leaves, or debris using a soft brush or sponge and mild detergent. Avoid abrasive materials or harsh chemicals.

Check for Damage: Perform regular inspections for cracks, chips, or loose connections. If issues are found, consult a professional technician for repairs.

Shading Management: Monitor surroundings for shading issues. Trim overhanging branches or remove objects blocking sunlight, as shading reduces energy output.

Wiring and Connections: Ensure wiring and connections are tight and corrosion-free. Loose or damaged connections can affect performance. Seek professional help if needed.

Monitoring Performance: Regularly check energy production. Use monitoring software to track output and identify significant performance drops, indicating potential issues.

Professional Maintenance: Schedule regular maintenance visits with a qualified technician for thorough checks and professional repairs.

Safety Precautions: Prioritize safety when performing maintenance tasks. Turn off the system and follow manufacturer's safety guidelines. If uncertain, seek professional assistance.

Adhering to these maintenance practices ensures optimal performance and efficiency for your half-cut solar panels. Regular maintenance maximizes your solar investment, providing sustainable energy for years.

Since 2008, Maysun Solar has specialized in producing high-quality photovoltaic modules. Offering a variety of half-cut solar panels, they boast superior performance and stylish designs to seamlessly integrate with any structure.

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