How to Prevent a Sharp Power Drop When One of Your 10 Solar Cells is Blocked?

To prevent a sharp power drop when one of your 10 solar cells is blocked, you should install Schottky bypass diodes in parallel with each small group of solar cells (e.g., one diode for every 2 to 3 solar cells) and connect a Maximum Power Point Tracker (MPPT) to the output.

How Shading Affects a Solar Panel?

A solar panel acts like a series string of solar cells where the current output is limited by the weakest (or most shaded) solar cell. If just one solar cell is blocked, it stops producing power and begins acting like a high resistance, forcing the entire solar panel’s output to drop near zero.

Solutions to Mitigate Power Loss

1. Implement Bypass Diodes

  • How it works: A bypass diode is wired in parallel to a group of solar cells, but in reverse polarity. Under normal light, the solar cell voltage keeps the diode off (as an open circuit). If a solar cell is shaded, its voltage drops; the diode then turns on, creating a low-resistance path for the current to bypass the shaded solar cell(s) entirely.
  • The effect: You will only lose the power of the specific blocked substring rather than the whole solar panel.
  • Which diode to use: Use Schottky diodes (such as the 1N5817 or similar series) because they have a low forward voltage drop (approx 0.4 V), which prevents excess power from being wasted as heat. Ensure the diode’s current rating is at least 1.4 x higher than the solar panel’s short-circuit current.

2. Use a Boost MPPT Charge Controller

  • How it works: Bypass diodes cause the voltage-current (V-I) curve of your solar panel to have multiple peaks (or “steps”). A basic charge controller will lock onto an inefficient local peak during shading events.
  • The effect: An MPPT module is designed to continuously sweep the V-I curve to find the new true maximum power point, ensuring you extract the absolute highest possible wattage from the unshaded solar cells.
  • Hardware: For 5.5V, modules like the LTC3105 or similar ultra-low-power boost converters work very well for harvesting micro-solar energy.

3. Parallel String Configuration

  • If your 10 small solar cells are accessible, an alternative to standard series strings is wiring them into smaller, parallel-connected blocks. In this configuration, you would also need to add blocking diodes so that heavily shaded blocks don’t drain power from the illuminated ones.

What is a Schottky Diode?

A Schottky diode (also known as a Schottky barrier diode or hot-carrier diode) is a highly efficient semiconductor device that allows current to flow in only one direction. Unlike standard diodes made from two semiconductors (P-type and N-type), it is formed by joining a metal with an N-type semiconductor.

Key Characteristics

  • Low Forward Voltage Drop: Traditional silicon diodes require about 0.7 V to start conducting, whereas Schottky diodes require only 0.15 V to 0.45 V. This significantly reduces power loss and heat generation.
  • Fast Switching Speeds: Because they use majority carriers (electrons) rather than minority carriers, they do not suffer from charge-storage delays. They can switch on and off almost instantly.
  • High Frequency: Their ultra-fast response time makes them ideal for high-frequency applications like RF (radio frequency) circuits and microwave communications.

Common Applications
Because of their efficiency and speed, Schottky diodes are heavily used in modern electronics:

  • Power Supplies: Used in switching power regulators and DC-DC converters to maximize energy efficiency.
  • Solar Panels: Act as blocking diodes to prevent reverse current from discharging the battery when the sun isn’t shining.
  • Overvoltage Protection: Used in clamping circuits and logic gates (like Schottky TTL) to protect sensitive digital components from voltage spikes.

Limitations
While highly capable, Schottky diodes are generally more sensitive to temperature changes and usually exhibit a higher reverse leakage current (meaning tiny amounts of electricity might flow backward) compared to standard PN junction diodes.

Posted by Carrie Wong / WSL Solar

WSL Solar has been a quality and professional manufacturer of custom solar panels, solar mini panels, IoT solar panels and solar solution provider in China since 2006.

https://www.wsl-solar.com

Source of origin: https://www.wsl-solar.com/Product_News/2026/0706/how-to-prevent-sharp-power-drop.html

2V 2W Solar Panel

Key Features:
– Utilize high efficiency mono solar cell, up to 23% efficiency
– Laminated by ETFE film, lightweight, thin and portable
– Waterproof, scratch resistant, and UV resistant
– Customized solar panels for industrial use

Description:
2V 2W Solar Panel
 
This 2W solar panel utilizes high efficiency mono PERC solar cells with efficiency up to 23%, to ensure its high output. It is laminated by ETFE film to protect the solar cells inside, making it lightweight, thin and portable. This custom solar panel is waterproof, scratch resistant, and UV resistant, it is ideal for use in off grid applications such as solar powered GPS tracking, educational kits, road studs, solar chargers etc.
 
Applications:
ETFE solar panels are widely used in IoT applications, marine buoys, wireless sensors, GPS devices, asset tracking, solar chargers and educational DIY kits etc.

Solar Panel Specification

Item No.WSL-C047
Solar Panel Size115x115x2.2mm
Peak Power (Pmax)2W
Voltage at Pmax (Vmp)2.2V
Current at Pmax (Imp)0.9A
Open Circuit Voltage (Voc)2.64V
Short Circuit Current (Isc)0.96A
Solar Cell TypeMono Solar Cell
Power Tolerance±5%
Encapsulation methodETFE film
Back sheetPCB
Product Warranty2 Years
Lead time25 Days
Storage temperature-20°C ~ 45°C
Working temperature-20°C ~ 65°C
Standard Test Conditions (STC)1000W/m2, 1.5AM, 25°C Cell temperature

Source of Origin: https://www.wsl-solar.com/2v-2w-solar-panel.html

WSL Solar has been a quality and professional manufacturer of custom solar panels, solar mini panels, IoT solar panels and solar solution provider in China since 2006.

https://www.wsl-solar.com

Automated Production and Testing Equipment for Custom Solar Panels

WSL Solar continuously introduces industry-leading production and testing equipment – ​​this not only significantly improves production efficiency but also ensures that every product possesses highly consistent and superior performance. It is this dedication to quality and technology that allows us to consistently deliver high-quality, high-efficiency customized solar panels, while providing reliable solar solutions, earning the trust of a growing number of customers.

Choosing WSL Solar means choosing high efficiency, stability, and long-term value. Welcome to contact us for high quality custom solar panels. 

WSL Solar has been a quality and professional manufacturer of custom solar panels, solar mini panels, IoT solar panels and solar solution provider in China since 2006.

Email: info@wsl-solar.com

https://www.wsl-solar.com

9V 2.3W Solar Panel

Key Features:
– Utilize high efficiency mono PERC solar cell,  up to 23.5% efficiency
– Laminated by tempered glass, rigid, durable and long lasting
– Waterproof, scratch resistant, and UV resistant
– Customized solar panels for industrial use

Description:
9V 2.3W Solar Panel
 
This 2.3W solar panel utilizes high efficiency mono PERC solar cells with efficiency up to 23.5%, to ensure its high output. It is laminated by tempered glass to protect the solar cells inside, making it rigid, durable and long lasting. This tailor-made solar panel is waterproof, scratch resistant, and UV resistant, specially designed for long term outdoor use in any challenging condition.
 
Applications:
Tempered glass solar panels are widely used in IoT applications, marine buoys, wireless sensors, traffic warning devise, GPS devices, asset tracking, electric fence chargers, outdoor lighting systems, weather monitoring systems etc.

 Solar Panel Specification

Item No.WSL-C044
Solar Panel Size128.84×128.84×3.5mm
Peak Power (Pmax)2.3W
Voltage at Pmax (Vmp)9V
Current at Pmax (Imp)256mA
Open Circuit Voltage (Voc)10.8V
Short Circuit Current (Isc)282mA
Solar Cell TypeMono PERC Solar Cell
Power Tolerance±5%
Encapsulation method3.2mm Tempered glass
Back sheetTPT
Product Warranty5 Years
Lead time25 Days
Storage temperature-40°C ~ 85°C
Working temperature-40°C ~ 85°C
Standard Test Conditions (STC)1000W/m2, 1.5AM, 25°C Cell temperature

What Materials are Solar Panels Made of?

Solar panels are composed of several materials, each playing a crucial role in the panel’s functionality, durability, and efficiency. Here are the primary materials used in the construction of solar panels:

1. Photovoltaic (PV) Cells:
   – Silicon: The most common material for PV cells. It can be monocrystalline, polycrystalline, or amorphous.
   – Cadmium Telluride (CdTe): Used in thin-film solar panels.
   – Copper Indium Gallium Selenide (CIGS): Another material used in thin-film solar panels.
   – Perovskite: An emerging material with high potential efficiency, still under research and development.

2. Encapsulation Material:
   – Ethylene-Vinyl Acetate (EVA): A transparent polymer that encapsulates the PV cells, protecting them from moisture and mechanical damage.

3. Backsheet:
   – Polymer Films: Typically made from materials like Tedlar (PVF), polyester, or polyvinyl fluoride (PVDF). The backsheet provides electrical insulation and protects the back of the panel from environmental factors.

4. Frame:
   – Aluminum: The most common material for the frame due to its lightweight, durability, and resistance to corrosion. The frame provides structural support and facilitates mounting.

5. Glass Cover:
   – Tempered Glass: High-strength, low-iron tempered glass is used as the front cover. It protects the PV cells from physical damage and environmental factors while allowing maximum light transmission.

6. Junction Box:
   – Plastic and Metal: The junction box is typically made from durable plastics and contains metal connectors. It houses the electrical connections and provides a safe interface for wiring.

7. Interconnectors:
   – Copper or Silver: These materials are used for the thin strips that connect individual solar cells within the panel, facilitating the flow of electricity.

8. Adhesives and Sealants:
   – Silicone and Other Polymers: Used to bond different layers of the solar panel together and to seal edges, ensuring durability and protection against moisture ingress.

9. Anti-Reflective Coating:
   – Silicon Nitride or Titanium Dioxide: Applied to the surface of the glass to reduce reflection and increase light absorption by the PV cells.

Summary of Material Functions:
– PV Cells: Convert sunlight into electricity.
– EVA Encapsulation: Protects cells and ensures durability.
– Backsheet: Provides electrical insulation and environmental protection.
– Frame: Offers structural support and facilitates installation.
– Glass Cover: Protects the panel and maximizes light transmission.
– Junction Box: Houses electrical connections.
– Interconnectors: Facilitate electrical flow between cells.
– Adhesives and Sealants: Ensure panel integrity and protection.
– Anti-Reflective Coating: Enhances light absorption.

These materials work together to ensure that solar panels are efficient, durable, and capable of withstanding various environmental conditions over their lifespan.

Posted by Carrie Wong / WSL Solar
WSL Solar has been a quality and professional manufacturer of custom solar panels, solar mini panels, IoT solar panels and solar solution provider in China since 2006.
https://www.wsl-solar.com

What is the Assembly Process of a Custom Solar Panel?

The assembly process of a small, custom solar panel involves preparing the materials, electrically connecting the solar cells, encapsulating them for protection, framing the unit, and performing final testing. 

Materials Needed

  • Solar cells: The core components that convert light into electricity. Monocrystalline or polycrystalline, typically 0.5V each. The number determines the voltage (e.g., 36 cells for an ~18V panel).
  • Encapsulant (EVA film): Ethylene Vinyl Acetate, a clear material that bonds and protects the cells. They become clear when heated.
  • Cover (Tempered glass or clear plastic): Protects the front from weather and impact.
  • Backsheet: A durable polymer layer on the back for insulation and moisture protection.
  • Frame (Aluminum or wood): Provides structural integrity and a mounting point.
  • Tabbing and bus wire: Flat, coated copper wires for electrical connections.
  • Junction box: Houses the electrical connections and bypass diodes.
  • Sealant (Silicone/Epoxy): Used for sealing edges and the junction box to prevent water intrusion.
  • Soldering iron and solder: For making the electrical connections. 

Assembly Steps

  1. Preparation and Template Creation: A template is created to ensure the correct and even placement of the solar cells on a backing board.
  2. Cell Stringing (Connecting Cells): Individual solar cells are connected in series (positive to negative) using tabbing wire and a soldering iron to achieve the desired voltage. The size of the cell determines the amperage, while the number of cells in series determines the voltage.
  3. Laying Up the Panel: The stack of materials is layered in the following order: glass, a layer of EVA film, the interconnected solar cells, a second layer of EVA film, and finally the backsheet.
  4. Bussing Soldering: The strings of cells are connected to each other using a thicker bus wire to form the complete electrical circuit.
  5. Lamination: The layered panel assembly is placed in a laminator (or sealed manually with even pressure and a clear cover) under vacuum and high temperature. This melts the EVA, encapsulating the cells and bonding all the layers together for durability and weather resistance.
  6. Trimming and Framing: Any excess encapsulant material around the edges is trimmed off. The laminated unit is then fitted into a protective aluminum or wooden frame.
  7. Junction Box Installation: A junction box is attached to the back of the panel and the main positive and negative output wires are connected to it. A blocking diode may be included here to prevent current backflow. The box and edges are sealed with silicone or epoxy.
  8. Testing and Quality Control: The finished panel undergoes electrical tests, such as a sun simulator test and an electroluminescence (EL) test, to measure its performance and check for any micro-cracks or defects.
  9. Final Steps: The panel is cleaned, labeled with its specifications, and packaged for use. 

Posted by Carrie Wong / WSL Solar
WSL Solar has been a quality and professional manufacturer of custom solar panels, solar mini panels, IoT solar panels and solar solution provider in China since 2006.
https://www.wsl-solar.com

Manufacturer of Custom Solar Panels – WSL Solar

WSL Solar has been a quality and professional manufacturer of custom solar panels and solar solution provider in China since 2006.

With our in-house R&D team and management team for over 20 years’ experience in solar industry, we can design and develop a customized solar panel in a variety of sizes, shapes and outputs to meet our client’s specific requirement, and provide solution support start from initial product development stage.

Our product categories include tempered glass solar panels, ETFE solar panels, and amorphous solar panels.

Welcome to contact us for high quality custom solar panels.

Email: info@wsl-solar.com

https://www.wsl-solar.com

What Is the Photovoltaic Conversion Efficiency of Solar Panels?

The photovoltaic conversion efficiency of solar panels refers to the effective ratio of solar panels to convert received sunlight energy into electrical energy, usually expressed as a percentage (%). It is one of the key indicators for measuring the performance of solar panels.

Calculation formula:

Photovoltaic conversion efficiency = output power (W) \ incident solar power (W) x 100%

– Output power: The maximum power (such as peak power Pmax) generated by the solar panel under standard test conditions (STC).

– Incident solar power: Usually based on the solar irradiance \(1000 W/m 2) under standard test conditions (i.e. “1 sun” intensity).

Key point analysis:

1. Efficiency range:

– Commercial solar panels: The efficiency of mainstream crystalline silicon cells (monocrystalline silicon/polycrystalline silicon) is 15%~24%, and the efficiency of thin-film cells (such as cadmium telluride and copper indium gallium selenide) is about 10%~15%.

– Laboratory technology: For example, the efficiency of perovskite cells and multi-junction stacked cells can exceed 30%, but they have not yet been commercialized on a large scale.

2. Influencing factors:

– Material properties: Different semiconductor materials (such as silicon and gallium arsenide) have different abilities to absorb photons and excite electrons.

– Temperature: Rising temperature will lead to a decrease in efficiency (crystalline silicon cells have an efficiency decrease of 0.3%~0.5% for every 1°C increase in temperature).

– Spectral response: The ability of solar panels to utilize light of different wavelengths (such as ultraviolet light, visible light, and infrared light).

– Optical loss: Surface reflection, glass cover transmittance, etc.

– Electrical losses: resistance losses, shadowing, series/parallel mismatch, etc.

3. Standard Test Conditions (STC):

– Irradiance 1000 W/m2, spectrum AM1.5, temperature 25℃, used to fairly compare the efficiency of different products.

Why is efficiency important?

– Higher efficiency means more power can be generated in the same area, reducing installation costs (such as when roof space is limited).

– But there is a trade-off between efficiency and cost: high-efficiency technologies (such as N-type TOPCon, HJT cells) are usually more expensive, and the cost-effectiveness needs to be considered comprehensively.

Future trends:

– Technology breakthroughs: Perovskite-silicon stacked cells, quantum dot cells, etc. are expected to push efficiency to 30%~40%.

– Cost reduction and efficiency improvement: Optimize existing technologies through processes such as passivated emitter (PERC) and back contact (IBC).

10V 7.5W Custom Solar Panel

Key Features:

– Utilize high efficiency mono PERC solar cell,
  up to 24% efficiency
– Laminated by tempered glass, rigid, durable
   and long lasting
– Waterproof, scratch resistant, and UV resistant
– Customized solar panels for industrial use

Description:
10V 7.5W Solar Panel
 
This 7.5W solar panel utilizes high efficiency mono PERC solar cells with efficiency up to 24%, to ensure its high output. It is laminated by tempered glass to protect the solar cells inside, making it rigid, durable and long lasting. This custom solar panel is waterproof, scratch resistant, and UV resistant, specially designed for long term outdoor use in any challenging condition.
 
Applications:
Tempered glass solar panels are widely used in IoT applications, marine buoys, wireless sensors, traffic warning devise, GPS devices, asset tracking, electric fence chargers, outdoor lighting systems, weather monitoring systems etc.

 Solar Panel Specification

Item No.WSL-C041
Solar Panel Size260x183x15mm
Peak Power (Pmax)7.5W
Voltage at Pmax (Vmp)10V
Current at Pmax (Imp)0.75A
Open Circuit Voltage (Voc)12V
Short Circuit Current (Isc)0.82A
Solar Cell TypeMono PERC Solar Cell
Power Tolerance±5%
Encapsulation method3.2mm Tempered glass
Back sheetTPT
Product Warranty5 Years
Lead time25 Days
Storage temperature-40°C ~ 85°C
Working temperature-40°C ~ 85°C
Standard Test Conditions (STC)1000W/m2, 1.5AM, 25°C Cell temperature

Click here to watch the video of this type of custom solar panels. 

View More Custom Solar Panels

5V Solar Panels   |  6V Solar Panels   |  9V Solar Panels

WSL Solar has been a quality and professional manufacturer of custom solar panels and solar solution provider in China since 2006. 

18V 25W Solar Panel

Key Features:

– Utilize high efficiency mono PERC solar cell, up to   24% efficiency
– Laminated by tempered glass, rigid, durable and long lasting
– Waterproof, scratch resistant, and UV resistant
– Customized solar panels for industrial use

Description:
18V 25W Solar Panel
 
WSL Solar’s 25W solar panel utilizes high efficiency mono PERC solar cells with efficiency up to 24%, to ensure its high output. It is laminated by tempered glass to protect the solar cells inside, making it rigid, durable and long lasting. This custom solar panel is waterproof, scratch resistant, and UV resistant, specially designed for long term outdoor use in any challenging condition.
 
Applications:
Tempered glass solar panels are widely used in IoT applications, marine buoys, wireless sensors, traffic warning devise, GPS devices, asset tracking, electric fence chargers, outdoor lighting systems, weather monitoring systems etc.

Solar Panel Specification

Item No.WSL-C040
Solar Panel Size350x450x25mm
Peak Power (Pmax)27W
Voltage at Pmax (Vmp)13.4V
Current at Pmax (Imp)2.01A
Open Circuit Voltage (Voc)16V
Short Circuit Current (Isc)2.13A
Solar Cell TypeMono PERC Solar Cell
Power Tolerance±5%
Encapsulation method3.2mm Tempered glass
Back sheetTPT
Product Warranty5 Years
Lead time25 Days
Storage temperature-40°C ~ 85°C
Working temperature-40°C ~ 85°C
Standard Test Conditions (STC)1000W/m2, 1.5AM, 25°C Cell temperature

WSL Solar has been a quality and professional manufacturer of custom solar panels, solar mini panels, IoT solar panels and solar solution provider in China since 2006.

https://www.wsl-solar.com