Solar shingle production

The technique of laying out solar cells in a module so that their edges overlap like shingles on a house roof is called »shingling« With the shingled layout, there are fewer gaps between the individual solar cells so more of the sunlight that is incident on the module can be absorbed.

The flexible, automated production allows Swiss project partner Freesuns to produce its newly developed matrix shingle roof tiles on a pilot scale before moving into mass production. The 450 x 510 mm Freesuns matrix shingle solar roof tile consists of a glass-glass module with TOPCon solar cells. Image: Fraunhofer ISE/Sophia Baechle

The power output of each solar roof shingle varies greatly, from as little as 13 watts to as high as 114 watts. All solar roof shingles are designed to be lightweight and weatherproof. Output is affected by the direction of the sun facing the solar shingles.

With the shingled layout, there are fewer gaps between the individual solar cells so more of the sunlight that is incident on the module can be absorbed. Instead of using external connectors to transport the current from one cell to the next, the area of the cell overlap is used as an electrical connector.

In addition, shingled solar cells reflect less light, and thus generate more electricity. The adaptation of solar cell production from the conventional approach to shingled solar cells requires some dedicated optimizations, however. In recent years, we have tested and further developed these techniques in a pilot line production at Fraunhofer ISE.

The average cost of a single solar shingle is about $4 for most brands, except Tesla's at only $2 per watt. The highest cost is close to $7 per watt.