JA Solar’s special application offshore PV modules feature double-coated glass to reduce light transmittance losses
Floating PV module’s polyurethane frames offer high weather resistance, strength, and electrical insulation
JA Solar has incorporated a double-embossed front glass surface for anti-glare PV modules
Apart from power and efficiency – 2 major performance metrics driven by advancements in cell technology and module design – durability and reliability under specific long-term environmental conditions are becoming significant concerns for PV module manufacturers. By optimizing the bill of materials (BOM) for a PV module, such as glass, frame, encapsulants, and other components, manufacturers can effectively address the application-specific needs of PV modules.
Francesco Liuzza, Senior Technical Sales Engineer at JA Solar, provided an overview of the company’s specialized application modules at the TaiyangNews Advanced Solar Module Applications 2024 Conference (see JA Solar presentation here). JA Solar, a vertically integrated PV manufacturer with an annual capacity of 100 GW for ingot, wafer, and module production, and 90 GW for cell production has made significant strides in both cell and module technology, shipping up to 224 GW of modules.
Advancement in Cell & Module Technology
Since 2022, JA Solar has been advancing its cell technology, starting with the 25% mass production-efficient n-type TOPCon cell technology, known as Bycium+ cell technology. Liuzza explained that following the 25.25% efficient BCM2.0 version – which features a front-side P++ region with front laser SE technology – the incumbent BCM3.0 version further optimized the boron diffusion process and fine-tuned the grid line structure, achieving a mass production efficiency of up to 25.65% by July 2023. The next advancement, the BCM4.0 version, featured optimized front metallization and a p+ emitter in combination with a rear passivation layer optimization, boosting mass-scale efficiency to 26.30% by December 2023. The latest innovation, the BCM5.0 TOPCon cell, boasts a mass-scale efficiency of up to 26.50%, incorporating a rear-side thick-thin poly structure. Along with advancements in the M10 cell size and the evolution of busbar technology from SMBB to ultra-fine round ribbon over low-stress thin wafers, module power has reached up to 650 W. Furthermore, the use of both symmetrical and asymmetrical M10 TOPCon cell cutting has enabled the production of multiple sizes of the DeepBlue 4.0 Pro series modules, making them suitable for various application scenarios, including residential, commercial & industrial (C&I), and utility-scale applications, added Liuzza.
In parallel with advancements in cell and module technology, JA Solar has optimized the BOM to meet the needs of various environmental stress factors. Liuzza outlined how the company addressed potential reliability risks for PV applications in ocean or lake environments by adopting highly weather-resistant double-layer coated glass (front and back), waterproof junction boxes (JB) and connectors, and polyurethane frames. For the desert, or hot and dry environments, JA Solar optimized the glass with a double-layer coated version and used dust-plug-type connectors and fluorinated backsheets. For high-altitude applications in plateaus or extreme cold regions, the company used double-layer coated glass and dustproof, snowproof frames.
After briefly reviewing the BOM optimization across different environmental scenarios, Liuzza discussed the company’s latest specialized application modules: offshore, anti-dust, and anti-glare modules.
Offshore PV applications, such as floating solar, offer many advantages, but the complex marine environment – exposed to seawater, sea ice, sea wind, waves, hail, UV radiation, and halobios – presents significant challenges. These include high salt mist, intense UV exposure, high mechanical load (vibrations from sea breeze, waves, and hail), high humidity and heat, and hot spot risks. JA Solar addressed these challenges by launching 2 types of DeepBlue 4.0 Pro series modules: SkyBlue (for pile-mounted installations) and OceanBlue (for floating applications). The SkyBlue module features double-layer coated front glass for moisture and salt-mist resistance, moisture-resistant encapsulation, MC4 connectors combined with waterproof plugs, and a high-thickness oxide film frame. For the OceanBlue version, JA Solar incorporated polyurethane frames for high weather resistance, strength, and electrical insulation. Additionally, this module uses high-water-resistant sealants to ensure resilience against moisture ingress and UV degradation. Liuzza explained that seawater infiltration can lead to Na+ and Ca+ precipitation in the glass, reducing light transmittance. According to in-house light transmittance loss and degradation tests, high-weather-resistant double-coated (DLC) glass showed significantly lower transmittance loss and light degradation. Both offshore PV modules’ reliability and durability have been validated through the TÜV NORD offshore module sequence test.
JA Solar's anti-dust modules feature a patented short-frame design with drainage holes to prevent dust accumulation. This frame design offers several benefits, including high load strength, high reliability, ease of manufacturing, and compatibility with various installation types. The high-generation capability of this anti-dust module has been validated by third-party inspection agencies, such as TÜV NORD.
Liuzza then explained the advantages of JA Solar’s anti-glare modules. Glare, caused by the reflection of strong outdoor light, can lead to visual discomfort. PV module installations in areas such as freeways, highways, or airport premises require glare- and flicker-free performance to minimize visual hazards for pilots, air traffic controllers, workers, and drivers. JA Solar addressed these potential issues by adopting a double-embossed front glass surface, rather than conventional anti-reflective coating (ARC) glass. This special glass features an enhanced rough surface, which disperses reflected light and reduces the brightness of reflected light spots, thus minimizing glare. The company offers a wide range of anti-glare DeepBlue 4.0 Pro series modules, all certified by independent third-party agencies.
On April 10 and 11, 2025, TaiyangNews will hold the TaiyangNews Solar Technology Conference India 2025, an in-person event in New Delhi. It will bring together technologists and scientists working on creating a resilient solar manufacturing industry in India. Registrations are open here.