Against the backdrop of accelerated global energy transition, the photovoltaic (PV) industry, as a core pillar of clean energy, is advancing toward higher conversion efficiency and lower manufacturing costs. Leveraging advantages such as high precision, low loss, and flexible processing, laser cutting machines have been deeply integrated into the entire industrial chain of PV cell manufacturing, module packaging, and recycling. They have become key equipment driving the iteration of PV technologies and capacity upgrading, with their technological innovations directly influencing the performance and economy of PV products.
I. Breaking Through the Bottleneck of Cell Cutting to Facilitate the Implementation of High-Efficiency Cell Technologies
PV cells are the core power-generation units of PV modules, and their cutting precision and efficiency directly determine the power generation efficiency and manufacturing costs of modules. Traditional mechanical cutting faces issues such as high cutting loss and easy occurrence of edge chipping and cracks. In contrast, laser cutting machines, through innovations in different wavelengths and cutting processes, provide key support for the implementation of high-efficiency cell technologies.
In the processing of PERC (Passivated Emitter and Rear Cell) cells, laser cutting solves the cutting challenges of "half-cut" and "third-cut" cells. By using fiber lasers of specific wavelengths combined with high-speed scanning galvanometers, narrow cutting seam processing can be achieved, and the cutting speed is significantly increased. At the same time, the heat-affected zone of laser cutting is controlled within an extremely small range, effectively avoiding cell cracking, which enhances the power of half-cut PERC modules and reduces the attenuation rate. After leading PV enterprises introduced laser cutting, the production yield and cost control of PERC cells have been significantly improved.
For next-generation high-efficiency cells such as HJT (Heterojunction) and TOPCon (Tunnel Oxide Passivated Contact), laser cutting machines are even more indispensable core equipment. HJT cells are manufactured using low-temperature processes, and traditional cutting easily causes the peeling of thin film layers.
However, ultraviolet lasers, with their "cold processing" characteristics, can achieve cutting without thermal damage, helping HJT cells improve open-circuit voltage and conversion efficiency. The polysilicon layer of TOPCon cells is relatively thin; laser stealth dicing technology forms a modified layer inside the cell to achieve stress-free separation, greatly reducing the cutting loss rate and improving the mass-production economy of TOPCon cells.
II. Optimizing Module Packaging Processes to Enhance the Reliability and Lifespan of PV Modules
The PV module packaging process requires the precise assembly of cells, glass, backsheets, and other materials. Through refined processing, laser cutting machines solve problems such as dimensional deviations and edge damage in traditional packaging processes, significantly improving the long-term reliability and lifespan of modules.
In the processing of module frames, laser cutting machines realize the integrated high-precision cutting and drilling of aluminum alloy frames. Traditional sawing methods result in large dimensional errors of frames, which easily lead to uneven installation gaps of modules. In contrast, laser cutting offers higher dimensional precision; combined with automatic positioning systems, it minimizes the deviation of drilling positions, improving the fit between frames and glass and effectively reducing the risk of rainwater penetration. Meanwhile, the edge roughness of aluminum alloy frames cut by lasers is better, eliminating the need for subsequent grinding processes, increasing production efficiency, and reducing the generation of metal waste.
Backsheet cutting is another key link in module packaging. As the protective layer of modules, backsheets need to have excellent weather resistance and insulation. Traditional mechanical cutting easily causes defects such as delamination and tearing of backsheets, affecting module lifespan. Laser cutting machines use fiber lasers with adjustable power and automatically adjust cutting parameters according to the backsheet material, achieving burr-free and delamination-free cutting. The aging resistance of the cut edges is consistent with that of the original material. Tests by module manufacturers show that backsheets cut by lasers show no cracking in extreme temperature cycle tests, extending the expected lifespan of modules.
In addition, in the cutting process of PV junction boxes, laser cutting machines can realize the precision drilling and contour cutting of plastic casings. The higher drilling precision ensures the accurate matching between terminals and casings, reducing contact resistance and heat loss, which lowers the power loss of junction boxes and further improves the overall power generation efficiency of modules.
III. Empowering PV Waste Recycling to Promote Green Circular Development of the Industry
As the first batch of PV modules gradually enters the retirement phase, PV waste recycling has become an important issue for the sustainable development of the industry. Relying on the advantage of non-contact processing, laser cutting machines can achieve efficient separation and recycling of glass, metals, and silicon materials in PV modules, reducing recycling costs and promoting the formation of a green circular system in the PV industry.
In the recycling of glass from retired modules, traditional crushing methods easily break glass into small pieces, and the adhesive film attached to the surface is difficult to completely remove, resulting in low recycling efficiency. Laser cutting technology uses lasers of specific wavelengths to heat the adhesive film, softening and peeling it off. At the same time, low-power lasers are used to cut along the edges of modules, realizing the non-destructive separation of glass and aluminum frames.
This significantly improves the glass recycling rate, and the light transmittance of recycled glass has little difference from that of new glass, allowing it to be directly used in the production of new modules. Practices by recycling enterprises show that after adopting laser cutting recycling technology, the recycling profit of glass from retired modules is increased, and the recycling cycle is shortened.
For the recycling of silicon materials from retired cells, laser cutting machines play a key role. By using ultraviolet lasers to peel off the silver paste, electrodes, and thin film layers on the cell surface layer by layer, the complete recycling of silicon wafers can be achieved, and the purity of the recycled silicon materials meets the standards of PV-grade silicon materials.
Traditional chemical peeling methods produce a large amount of acid-base wastewater, while laser recycling processes generate no pollutant emissions, reducing the amount of wastewater treatment during silicon material recycling. Data shows that when recycled silicon materials are used in the manufacturing of new cells, their conversion efficiency has little difference from that of virgin silicon materials, and the cost is reduced, providing an economically feasible solution for the circular utilization of PV silicon materials.
At the same time, laser cutting machines can also accurately separate and cut aluminum frames and copper wires in retired modules. The metal recycling rate is relatively high, and the cut metals can be directly sent to steel mills for remelting, reducing the waste of metal resources and promoting the PV industry to achieve full-lifecycle green development covering "manufacturing - use - recycling".
IV. Driving Technological Iteration to Lead the PV Industry in Cost Reduction and Efficiency Improvement
Continuous innovations in laser cutting technology are constantly breaking through the processing limits of the PV industry. From equipment intelligence to process integration, they are driving the PV industry to reduce costs and improve efficiency, injecting impetus into the large-scale development of the industry.
In terms of equipment intelligence, laser cutting machines are deeply integrated with AI and machine vision technologies to achieve full-process automated processing.
High-resolution line-scan cameras collect cell images in real time, and AI algorithms automatically identify cell defects and plan optimal cutting paths, significantly shortening the parameter debugging time. Meanwhile, the adaptive cutting systems equipped in the equipment can automatically adjust laser power and cutting speed according to the thickness of cells, improving the switching efficiency of cells of different specifications and meeting the needs of multi-variety and large-batch production in the PV industry.
Process integration is another important development direction of laser cutting technology. Next-generation laser cutting machines can integrate multiple processes such as cutting, chamfering, and drilling, realizing "one-time clamping and multi-process processing". This reduces the number of cell handling operations, lowering the risk of damage.
For example, in the processing of HJT cells, laser equipment can complete cell cutting, edge chamfering, and electrode drilling in one go, improving processing efficiency and reducing equipment floor space, which significantly lowers the investment costs of enterprises in workshops and equipment.
In addition, the energy consumption of laser cutting machines continues to decrease, promoting green manufacturing in the PV industry.
The adoption of new fiber lasers results in higher electro-optical conversion efficiency, reducing energy consumption compared with traditional lasers and achieving significant electricity savings in the cell processing process. At the same time, the non-cutting fluid processing technology adopted by the equipment reduces the amount of hazardous waste treatment, conforming to the low-carbon development trend of the PV industry.
--Rayther Laser Jack Sun--