JA’s DeepBlue 5.0 TOPCon module, featuring butyl sealant and reduced creepage distance, is certified to IEC 61730-1:2023 standard
This module offers higher resilience against humidity ingress, lower WVTR, and enhanced wet leakage and insulation resistance compared to the earlier version
It also earned Class A+ partial shading resistance certification from TÜV Rheinland in five shading scenarios
Improving PV module reliability involves either changing PV material components, such as encapsulant, frame, and junction boxes, or refining the module design using established materials.
Djamel Eddine Mansour, Product Manager at JA, briefly explained how the company combines these two approaches at the TaiyangNews Reliable PV Module Design Conference, aiming to enhance the reliability of its DeepBlue 5.0 module.
Mansour highlighted the key features of these mass-produced modules (starting in Q2 2026) before going into recent advancements. First is the adoption of multi-cut G12R TOPCon cells in 2,382 × 1,134 mm module dimensions. The company calls these cells ‘Bycium+ 5.0’ and cuts them into three equal slices along the length side. JA says its multi-cut architecture provides an optimal balance between power loss, process stability during edge passivation, and cutting loss. These strips are then interconnected by overlapping their cut edges, creating a gapless cell-to-cell interconnection. The company uses a buffer film between these strips to absorb mechanical stress during field operation and prevent potential microcrack formation.
This patented technology also eliminates the visual gap between cells and enhances active cell areas. Additionally, flipping the ribbon interconnection section to the rear side of the module saves around 25 mm of module length compared with conventional PV modules. In the latter types, the ribbon interconnection section is positioned on the front side, either in the middle or along the top or bottom edge. To ensure uniform thickness around the perimeter, the module features composite structure enhancement (CSE) technology. It helps to maintain a uniform laminate thickness between the module edge and the middle section.
Additionally, JA incorporated high-insulation boundary sealing technology in 2026 to improve the module’s reliability and safety insulation along the frame edges. This aligns with the latest IEC 61730 safety standard, which includes cemented joints, and allows a reduced minimum creepage distance of 3.5 mm compared to the traditional 10.4 mm.
Creepage distance is the shortest distance allowed between cell edges and glass. Instead of using an adhesive, the company incorporates butyl sealant along aluminum frame slots to make a cemented joint. Mansour explained that this butyl rubber is a copolymer that has insulating properties and is chemically compatible with conventional encapsulating materials. It enables a larger cell size while maintaining the same module dimensions (2,382 × 1,134), resulting in an active area gain of around 1%. Compared with EVA and POE, this non-polar molecular material also offers a higher barrier against humidity and other gases that can penetrate from the module edges and compromise reliability. Lastly, its stable volume resistivity enhances the module’s wet leakage and insulation resistance. According to the company, this module is tested and certified according to the revised IEC 61730-1:2023 standard.
Next, Mansour highlighted an innovative rear glass design (triangle shaped) that shifts ribbon holes farther apart, rather than grouping them at the center in a butterfly-shaped arrangement. He claimed that this design shows up to 14% less mechanical stress on hole sections under extreme mechanical load testing. He added that this design is also compatible with different module mounting structures and trackers.
Lastly, Mansour shared the module’s resilience against partial shading under different external obstacles. It has been tested and verified by TÜV Rheinland for five different shading scenarios and achieved a partial shading resistance class A+.