Solar + Power Awards is produced by Angel Business Communications - the organisers of the Solar Ireland, Smart Solar and Solar UK conferences. The awards ceremony will take place Brussels in September 2018.
PV Materials Enabling Award |
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3M |
Solar Mirror Film 1100 |
Description Solar Mirror Film 1100 is a flexible, reflective film designed to provide a high-performance, durable and cost-competitive solution for use in Concentrating Solar Power (CSP) installations. Product Challenge The primary roadblock to expanding the CSP market lies in the high cost and low durability of glass mirrors. Problem Solved Solar Mirror Film 1100 is 75% lighter and 15 % cheaper than glass mirrors while maintaining a reflectance of more than 93 % over 14 years. Solar Mirror Film 1100 is the result of extensive materials research, in-field studies and cooperative work with the National Renewable Energy Laboratory (NREL) dating back to the early 1990s. Product In Detail 3M Solar Mirror Film 1100 combines a tough and durable polymer front-side with silver as its highly reflective layer. The film is then coated with a pressure-sensitive adhesive on the backside, which includes a liner. An opaque pre-mask on the front surface protects Solar Mirror Film 1100 during assembly. The film is also lead-free, circumventing the environmental challenges associated with the disposal of traditional mirrors. Innovation Solar Mirror Film 1100 has proven to hold a variety of benefits for solar concentrating applications. The film exhibits a total hemispherical reflectance greater than 94 % and a specular reflectance above 95 % (at 25 milliradian acceptance angle), making it suitable for a broad range of solar concentrating applications. Furthermore, testing with the National Renewable Energy Laboratory (NREL) has demonstrated the films ability to maintain reflectance of more than 93 % over 14 years. When Introduced 3M Solar Mirror Film 1100 was commercially introduced in 2010. Customer Benefits 3M Solar Mirror Film 1100 enables greater design flexibility than standard glass, allowing for larger geometry reflectors than previously possible. The lightweight, large-area assemblies possible with Solar Mirror Film 1100 have the potential to reduce the total installed cost of CSP systems by more than 15 %. Additionally, reflective film-based reflectors are up to 75 % lighter than glass mirrors, significantly reducing transportation costs while easing the installation process. ![]() |
GP Solar GmbH |
GP ALKA-TEX .Plus |
![]() Description GP ALKA-TEX .Plus is a surface active additive for the improvement of the alkaline texturing of monocrystalline silicon wafers. The addition of this product to the standard alkaline texture process with KOH/NaOH and IPA (2-propanol) increases the optical yield of the solar cell due to a more homogeneous surface structure. The cell efficiencies can be increased by around 0.3% absolute. Product Challenge One problem of the standard alkaline texture process with KOH/NaOH and IPA is a small process window. With the standard alkaline texturing process it is impossible to adjust one recipe for different wafer qualities. There are always significant differences in the texture quality from wafer to wafer. The challenge is to develop a stable, reproducible and reliable process with better optical characteristics. Another challenge is to decrease the total costs of the texturing process by increasing the throughput and minimizing the consumption of chemicals. Problem Solved With GP ALKA-TEX .Plus one texture recipe works for different wafer qualities. The number of recipes is reduced to a basic recipe by making only small adjustments. Moreover the appearance of the texture can be improved. The wafer surface becomes more homogenous and the amount of defects can be reduced. On the other hand the bath life time can be increased significantly and the process time could be reduced, which allows a higher throughput and leads to a lower total chemical consumption. A positive side-effect is the fact that the lower consumptions cause less impact on the environment. Noteworthy The use of GP ALKA-TEX .Plus allows a better controlling of the texturing process. This process makes a stable run to run repeatability possible. The pyramid size which has a great impact of the optical yield and therefore of the cell efficiency is tunable with GP ALKA-TEX .Plus. Moreover, defects and contamination on the surface can be handled and removed during the texturing process. Product In Detail The first step in the silicon solar cell production is the texture. The two main processes are the alkaline texturing for monocrystalline wafers and the acid texturing for multicrystalline wafers. This first step removes the saw damage of the wafer and creates a homogenous surface with low reflectivity. In the standard alkaline texturing process, KOH or NaOH and IPA are used at a process temperature of 80°C in order to etch the surface anisotropically, resulting in a pyramid-shaped surface. The lifetime of one bath is with ~4 to ~30 runs relatively low, for the most wafer qualities a different recipe is needed, and the process is not very reproducible. The product GP ALKA-TEX .Plus is a chemical additive that improves the alkaline texturing of monocrystalline silicon wafers. Its addition to the bath mainly results in a very homogenous silicon surface with a lower reflectivity compared to the standard alkaline process. These improved optical characteristics increase the total efficiency of the cells. Another big advantage of GP ALKA-TEX .Plus is that the number of recipes for different wafer qualities can be reduced to a basic recipe. In addition, the process in general can be controlled more easily and with a more stable run to run repeatability when using GP ALKA-TEX .Plus. The additive also allows a tunable pyramid size and reduces the amount of chemicals required. Furthermore, the lifetime of the alkaline bath is increased significantly to approximately 30-60 runs. Together with the reduced process time the throughput increases. It is an ESH (environmental, safety and health) compliant as well as a water soluble additive. The appearance of the additive is liquid with a boiling point of 100°C and a density of ~1.1 g/cm3. The waste disposal procedures are the same as for the alkaline texturing bath. Innovation GP ALKA-TEX .Plus solves the main problems of the standard alkaline texturing process. These disadvantages are short bath life times, significant differences in the texture performance with different wafer qualities and visible defects on the wafer surface. Moreover the additive has several positive side-effects which are shorter process times, less chemical consumption and most important for a higher cell efficiency an increased optical yield. There are no disadvantages of the product known, and due to the many advantages the total cost of ownership of the texturing process is better with GP ALKA-TEX .Plus than without it. When Introduced GP ALKA-TEX .Plus was introduced to the market in March 2009. Customer Benefits The customers benefit from a higher efficiency of the solar module. The improved front side of the solar cells leads to a higher optical yield. The cost savings of a lower chemical consumption and a higher throughput of wafers should also be noticeable in the module price. |
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plasmasun® |
Description plasmasun® is a new and unique metallization tool for in-line processing of silicon solar cells. The unique metallization system has been developed for rear busbardesposition based on our patented plasmadust® coating technology which is a combination of cold plasma and specific micro scale powders under ambient pressure. The system allows depositing metal films with a thickness of 1 up to 100 µm. Challenge Creating a new, more greencoating technology for solar cell production was our main target. Towards this goal it´s another challenge to gain more cell efficiency due to a totally new metallization process. In addition our product should be able to reduce process costs for rear side busbar metallization of silicon wafers as well as the footprint compared with existing screen printing and drying combinations significantly. Actual used screen printing technology is based on expensive Si and Al pastes. They contain none environmentally sound solvents. Layers coated with plasmasun® have to feature high conductivity, adhesion (onto Si and Al), solderability. Problem Solved The named challenges are solved directly by our new technology. Screenprinters use solvent-based pastes. Using powders plasmasun® is solvent free and thus more green. Pastes are expensive because of a high proportion of silver. We offer more favorable and cheaper microscale metal powders ([email protected] / Cu). This leads to a 50% cost reduction. Thin wafers have to face pressure during screenprinting which means a mechanical stress and can lead to wafer breakage. Our product offers a contact-free metallization and reduces waste rate. After screenprinting the layers have to get dry during fast firing. This step is not necessary with plasmasun®. Noteworthy Reinhausen Plasma developed this revolutionary low temperature coating process being the first company to bring a new metallization solution based on cold.active plasma combined with microscale powders for more efficient and green production to the photovoltaic market. Compared to PVD processes the technology allows in-line metallization under ambient pressure. In Detail The plasmasun® - tool has been specially developed for the rear coating of solar wafers. It enables the application of a freely selectable number of busbars onto mono and polycrystalline wafers of any size and thickness. The position of our solution is before laser edge isolation and the final testing and sorting step. It is possible using the dry, solvent-free coating process to deposit various solderable metal alloys as micropowders directly onto the aluminium and silizium layer from a cold.active plasma at atmospheric pressure. This may be in the form of lines or dots according to the cell design. Regardless of the busbar's shape, it is possible to achieve reliably reproducible layer thicknesses that exhibit adhesion values greater than 2 N in the peel test. The Regensburg-based company has developed a further plasma generator for layer deposition which works at ambient pressure and in which it is possible to control the energy input into the plasma over wide areas. This means that the temperature of the plasma hitting the surface of the solar wafer can be kept very low: it is measurably below 100 °C. The result is very gentle coating of the substrate with a comparatively low energy requirement. The principle of the developed powder feeding technology was therefore to destroy the agglomerates by a mixture of mechanical and pneumatical energy and feed the powder dust continuously into the plasma plume. This principle allows an adjustable, continuous powder flow into the plasma plume which is a necessary condition for coating reproducible layers. Specially developed atomizer/conveyor technology ensures a continuous supply of the coating powder. At the same time, the powder agglomerates are only broken up by the input of energy immediately prior to their injection into the plasma jet. This ensures that the powder particles are introduced into the plasma absolutely evenly. The particle flow can be adjusted according to the specific requirements. Powders of copper and tin as well as silver alloys are currently available as coating materials for the application of busbars. Compared to conventional silver pastes, this means noticeable cost savings because considerably less silver or no silver at all is required in the plasmadust process. Copper, for example, offers greater wettability and adhesive strength at lower costs. Tin, as the most cost-effective alternative, also delivers impressive results. Innovation The plasmasun® system should not be confused with thermal spraying or PVD-sputtering processes. Thermal spraying works with a plasma temperature beyond 10.000°C, with high currents >100A and Granulates D50 around 50µm. plasmasun® works with D50 around 100nm 20 µm pulsed currents below 10A and heats up the surface of the substrate at an average of 70°C. This is why the plasma is called cold. PVD solutions are based on vacuum chambers. Generating vacuum is intensive in time, money and in addition slowing down cycle-times. Another advantage of plasmasun®: Tin based alloys or copper layers can be directly deposited onto the Al-layer without damaging the cell. When Introduced We introduced the coating system to the market in 2010. Customer Benefits Customers benefit from a 50% cost reduction for rearsidebusbar deposition process compared to screenprinting. They profit from more environmentally sound cell metallization technology. A pre- and aftertreatment, especially fast fining is not needed. The output of plasmasun® is on the same level as state of the art printers. It can be fully integrated in-line and reduces the footprint compared to screenprinting and drying combination. According to the possibility to deposit directly on the Al-layer there is high potential to gain more efficiency of the cell. Patents The following patents had been awarded: Pulverdispergierer DE 102009032908.0-51 Pulverdispergierer INT PCT/EP2010/059452 Metallisierung DE 102010032187.7 GepulsterPlasmaerzeuger DE 102009015510.4 GepulsterPlasmaerzeuger INT PCT/EP2010/053816 |
Saint Gobain Solar |
SolarBond® InFrame |
![]() Description SolarBond® InFrame is an intelligent, innovative and instant solution for solar module manufacturing. An advanced framing concept for automated PV assembly lines, it is a revolutionary material developed by Saint-Gobain Solar. It combines the best attributes of liquid silicone sealants and frame tapes to create a pumpable material with the immediate adhesion advantage of tape solutions. This technology provides a fast; clean application for a durable seal that ensures a high-quality solar module, all while minimizing the costs associated with waste and production inefficiencies. Product Challenge SolarBond® InFrame helps manufacturer’s meets growing demand for solar modules while minimizing waste and related costs. Problem Solved SolarBond® InFrame is applied warm in a continuous motion, ensuring both accuracy and high bonding strength immediately after contact with the glass, backsheet and frame. This eliminates the setting time needed for silicone products to cure by offering the instant adhesion of frame tapes coupled with a highly automated application process, shortening production cycles, reducing product waste and minimizing the associated production costs. Additionally, the precision application eliminates the cleaning labour and costs incurred by the runoff cause by silicone sealants. The foamed material fills the aluminium channel in the frame completely, even in the corners, eliminating the risk of water collecting in the frame as experienced with tape solutions. What results is a strong, long-term, weather-resistant bond for a durable final product. Used with Saint-Gobain Solar’s patented single-piece frame, it also reduces the number of corner keys required for framing the module, using just one instead of four as required for both, tapes and silicones, further reducing module costs. Noteworthy SolarBond® InFrame is the only framing solution of its kind on the market today. It is the first of its kind to combine the pumpable application of liquid silicone with the instant adhesion of tapes in such a unique automated application. Product in Detail SolarBond® InFrame is a new generation framing material that brings increased performance while reducing the overall production costs for PV module manufacturers. It is heated, foamed and extruded directly into the frame channel using an automated system (robot or fixed nozzle under moving frames). Frame and module assembly should be completed within two minutes of sealant application. Once assembled, modules can be handled immediately. The foamed material is non-toxic, environmentally friendly and does not require special ventilation to meet industry safety standards. The material does not contain any substance subject to declaration in the International Material Data System list. No special labelling is required to comply with EC Guidelines. Foaming saves costs in two ways. First, the reduction in density reduces material usage and lowers sealant cost per module. Foaming is achieved using conventional foaming equipment designed for reactive materials. Additionally, the risk of overflowing the channel after the laminate is inserted into the frame is minimized as the foamed material will not be displaced (unlike non-foamed wet sealant materials). No overflow means no need for post processing cleaning, lower labour cost and no production bottlenecks. SolarBond® InFrame is processed like a hot melt adhesive providing for excellent wetting of different surfaces and high initial adhesion. Designed with optimum open time (1-2 minutes), the material has very short time to set once the laminate is inserted (under 15 seconds), thus enabling modules to be handled immediately after framing is completed. Chemical crosslinking then further improves adhesion and internal strength providing for excellent long-term performance, even after exposure to severe environmental conditions. Innovation Incorporating SolarBond® InFrame into a PV module manufacturing line presents several long-term advantages: Allows high-speed production, ideal for advanced lines. Reduces costs by minimizing production inefficiencies caused by slower acting adhesives and reducing labour, SolarBond® InFrame presents significant cost savings, helping PV module manufacturers to produce high-quality products faster and at a lesser expense than with traditional framing solutions. In addition, used with Saint-Gobain Solar’s patented single-piece frame, it also reduces the number of corner keys required for framing the module, using just one instead of four as required for both tapes and silicones, further reducing module costs. When Introduced The product was launched in September 2010 at EU PVSEC 2010. It was re-launched under the new brand name SolarBond® InFrame in June 2011 at Intersolar. |
Thin Film Innovation Award |
Abound Solar |
AB1-series modules and manufacturing process |
![]() Description Abound Solar manufactures solar photovoltaic (PV) modules in the U.S. using proprietary, high-quality, low-cost solar manufacturing technology. Its modules are backed by a robust 25-year power output warranty and are UL, CE and CEC listed. Abound modules are each 26lb (12kg), ~24 x 48(60cm x 120cm) and can be installed by a single person. Each module has a tempered back glass and heat-strengthened front glass, both of which provide superior physical strength. Its frameless design prevents moisture and soil pooling at low angles and facilitates snow clearing, and it’s the proprietary TruLock edge-seal makes it highly robust and resistant to moisture ingress. Abound modules are compatible with racking from Schletter, Sunlink, FlexRack, APAlternatives, Unirac, DPW and more. The semiconductor, cadmium telluride (CdTe) thin-film, is the fastest growing, most successful semiconductor on the market. Proven stable and reliable in the long run, it allows for ~10% module efficiency with line-of-sight to the teens and is compatible with inverters from most leading manufacturers. Abounds facility is fully-automated, converting glass and semiconductor materials into complete modules beneath its roof. This enables tighter quality control and reduces waste. A glass panel enters the factory every 10 seconds and emerges as a completed module two hours later. Product Challenge Abounds CdTe thin-film PV modules address a number of solar industry and market challenges, including perhaps the greatest obstacle of all: the conventionally high cost of solar technology. Abound Solars modules offer the lowest-cost solar technology. Abound also addresses the other common challenge of maximizing module and system efficiency. For example, although crystalline silicon PV modules make up 80 % of the solar market, its performance wanes in both high temperature and low-light conditions. Abounds modules perform better than crystalline silicon in such conditions. Additionally, the company’s industry-leading recycling program addresses environmental concerns of module materials. Problem Solved Cost: CdTe thin-film modules offer the lowest-cost solar technology, allowing systems using Abounds modules to deliver the lowest levelized cost of electricity. Abound manufacturing process also provides a cost advantage over competitors because it can produce millions of modules per year at an industry-leading low cost. Performance: Abounds modules produce more energy than crystalline silicon in hot, cloudy environments, resulting in greater electricity output per watt of installed capacity. Environment: Abounds industry-leading module recycling program is pre-funded by Abound for full cradle-to-cradle stewardship. Abounds modules also offer the fastest energy payback and lowest carbon footprint in the industry. Noteworthy Various thin-film module manufacturers have struggled in their efforts to commercialize complex and expensive production technologies as production ramps take longer than expected and venture capital and other sources of funding run dry. Abounds module production process, a closed-space deposition of the cadmium telluride semiconductor film without the traditional industry lamination process, has enabled Abound to a ramp module conversion efficiency from 6% to 10%, as well as increase production throughput up to 2.5 MW/month faster than competitors. The proprietary manufacturing process also results in faster throughput, higher yields, and lower manufacturing and capital equipment costs than other thin-film products. Product in Detail Abound ensures that both the manufacturing process and the product are optimized in order to deliver a cost advantage over competitors. Product: Abound SolarsCdTe thin-film modules offer class-leading efficiencies of greater than 10 % at industry-leading low prices. The company’s modules are frameless, glass-glass modules that are optimized for large-scale commercial and utility installations to reduce the cost of solar PV. They feature lower voltages and high-performance ratios in a robust, all-back module. The modules have better performance in low-light and high-temperature conditions than crystalline silicon. They eliminate the risk of underperformance, have tight power output bins (+2.5 / -0 W) and better field performance. The TruLock seal provides enhanced dual moisture and vapour barrier which increases reliability and module life for long-term installations. In addition, its lower voltages at a given power output enable longer module strings and lower balance of system costs. Its industry-leading warranty provides five year materials and workmanship and a 25-year power output guarantee for 90 % of nominal output during first 10 years, and 80 % over 25 years. Manufacturing process: As panel manufacturers hunt for costs to eliminate, some have cut back on product testing, quality control and certification. Abounds streamlined manufacturing process, on the other hand, eliminates several steps that contribute to lowered cost, without sacrificing quality. Abounds manufacturing process can be divided into two general sections: Front End and Back End. The Front-End consists of the following steps: Prior to the semiconductor tool glass loading, washing, and scribing Semiconductor tool deposition of the CdS and CdTe layers and other proprietary treatments After the semiconductor tool rinse, scribing, sputtering of back metal contact, scribing, and laser edge deletion. The Back-End system consists of the encapsulation of the semiconductor layers, performance measurements, electrical integrity tests, labelling and packaging. Variance in production processes is an inherent characteristic that needs to be managed in any successful high-volume manufacturing line. Abound has implemented in-line metrology as a baseline capability within its factory to minimize the impact on quality such variances may have. The fundamental goal is to control processes from within the tools themselves and to employ preventative systems at the tool control level to maintain highly robust processes. This approach is a key aspect of the process and product development procedure that starts with a product/process FMEA to identify key risks. Once key production risks have been identified, the process controls and critical metrology points are defined to mitigate those risks and to measure in real-time critical aspects of product quality. Another example of how Abounds manufacturing process reduces costs: one of our strategic partners is a leader in the glass industry that has helped us understand how to manage the volatility in glass, our largest cost component. In addition, thanks to a $400 million U.S. Department of Energy loan guarantee, Abound is currently building the largest thin-film solar module manufacturing plant in the United States. This scaling will allow for a further reduction of costs that will also reflect in retail prices of Abounds product. Innovation The innovative aspect of Abounds manufacturing technology is the use of a proprietary closed space sublimation process (CSS) in the semiconductor manufacturing step. The use of CSS enables a once-through steady state thin-film photovoltaic process within a single tool. As a result of our novel manufacturing process, our production is significantly less complex, faster and more efficient than all other thin-film PV manufacturers. Compared to competing CdTe module manufacturers, Abound has optimized its manufacturing and assembly process such that it eliminates five steps (edge grind, chemical etching, photoresist scribe fill, interfacial layer and post metal heat treat), combines six wet and dry semiconductor processes into one single step of semiconductor coating with one tool without breaking vacuum, and improves two back-end module assembly steps (edge delete and module encapsulation). All of this allows for the significant reduction of manufacturing costs without doing away with quality control. When Introduced Abound Solar’s AB1-series modules were introduced to the market in January 2010. Customer Benefits Abound’s low-cost manufacturing and assembly processes allow for the modules to be sold to customers at industry-leading costs. Abound Solar is actively working with customer and partners in the Abound Alliance to optimize the system designs and components to reduce the cost of installation. For example, Abound recently signed a deal with Thesan, an Italian roofing and PV specialist. They have designed a mounting system specifically for Abound Solar modules that reduces installation time by over 50% compared to existing solutions. |
3M |
Ultra Barrier Solar Film |
![]() Product Challenge For years, solar companies have searched for ways to produce lightweight, flexible modules that are cheaper to ship and easier to install. These efforts have been hindered by a lack of affordable, quality glass substitutes. Problem Solved 3M Ultra Barrier Solar Film efficiently replaces glass layers to enable lower manufacturing, shipping and balance of systems (BOS) costs. Noteworthy The product is the result of more than a decade of development in transparent barrier technology. Product in Detail Typical solar modules are created by sandwiching cells between two pieces of glass. This method leads to bulky, rigid modules that can be expensive to ship and install. Designed to address the needs of flexible thin film solar manufacturers, 3M Ultra Barrier Solar Film acts as a replacement for glass. The result is a product with high light transmission, superb moisture barrier performance, and unparalleled durability. 3M Ultra Barrier Solar Film has proven to provide moisture vapor transmission rates (MVTR) below 5 * 10-4 g/m2/day. Innovation Compared with glass-glass modules, the large-area, lightweight, flexible PV modules manufactured with 3M Ultra Barrier Solar Film can achieve lower balance of systems (BOS) costs by requiring less installation time, removing the need for metal racking and reducing logistics expenses. When Introduced 3M Ultra Barrier Solar Film first appeared on the market in 2010. Customer Benefits 3M Ultra Barrier Solar Film facilitates lower module manufacturing costs by allowing manufacturers to produce large area modules, effectively reducing costs associated with module production by assembling them in a continuous, roll-to-roll process. |
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THINFAB |
![]() Product Description Oerlikon Solars next generation fab THINFAB will enable total module production cost at or below 0.5 €/Wp and a 120 MWp output capacity. Oerlikon recognized that for PV to become a significant source for energy amongst the traditional energy sources, solar power had to become economically viable. With the THINFAB with module manufacturing cost at 0.5 €/Wp, energy can be produced at 0.10 €/kWh in for example Southern Europe. In many regions of the world this allows energy production at or below grid parity level. Due to highest equipment availability, reduced process steps in the backend and highly optimized line concept (to balance frontend and backend takt times), Oerlikon Solars THINFAB reaches highest uptime with lowest non-productive time. The performance figures of this thin film silicon turnkey solution are as following: - Module Efficiency 10 % - Yield 97 % - Annual Output 120 MWp - 0.5 €/Wp Product Challenge Oerlikon Solars THINFAB addresses the challenge to reduce manufacturing cost by 60%. The first generation of thin film silicon manufacturing lines launched 2007 allowed modules to be produced at approximately 1.2 €/Wp. To reach grid parity level in sunny regions to make solar power economically viable, manufacturing cost have to cut down to no more than 0.5 €/Wp. Problem Solved Oerlikon Solars next generation fab THINFAB will enable total module production costs at or below 0.5 €/Wp and 120 MWp output capacity. With the THINFAB with module manufacturing cost at or below 0.5 €/Wp, energy can be produced at 0.10 €/kWh in for example Southern Europe. In many regions of the world this allows energy production at or below grid parity level. Noteworthy The key performance drivers to make solar power economically viable are module efficiency, high productivity of the manufacturing line and low module material costs. Recent champion modules on full scale with over 11 % initial efficiency and the world record stable cell efficiency for Micromorph® of over 11.8 % form the foundation for 10 % efficiency in average production. In less than 3 years since the market introduction of Oerlikon Solars Micromorph® technology 2007 in Milan the productivity of an Oerlikon Solar fab has been increased by more than 100 % which helps to significantly drive down the CAPEX per Wp. The continuous optimization of core equipment, line concept, module design and qualification of new materials drives down costs and increases the manufacturing robustness by simplifying the production steps. Product In Detail Oerlikon Solar has demonstrated ground-breaking milestones for the highest efficiency thin film silicon technology worldwide. To achieve highest efficiency modules in a cost effective mass production, several improvements in layer technology and module design had to be combined within the Oerlikon Solars THINFAB. 1) Thinnest Absorber The quality of the absorber layer and consequently the degradation of the efficiency of the cell are influenced by different factors. One factor is the deposition process, a second factor is the deposition rate (typically layers deposited at lower rate have higher quality) and a third factor is the layer thickness. Oerlikon Solar found in its THINK THIN strategy a match between increased efficiency and cost effective mass production. Thin absorber layers allow for reduced deposition rate and thus improved material quality; in parallel, time gas and energy consumption are lower and the light induced degradation is reduced. The net result is higher stabilized module efficiency. 2) Thinnest Laser Dead Band Oerlikon Solar introduces the next generation of laser scribing systems with eight beam high-speed processing for more than 2x increase in throughput and improvement of scribing accuracy to reduce laser dead band to 180 um. Highly accurate laser scribing systems maximize the active area of the module by reducing the area lost to the cell interconnects. c) Highest Front Contact Transmittance Oerlikon Solars TCO provides high total transmittance of over 86 % in the visible and near infrared spectrum range and recipe tunable surface morphology enabling light scattering with haze between 10 and 25 % and tunable sheet resistance between 10 and 25 Square Ohm Best in class transmission and enhanced light scattering are the perquisites to get the maximum amount of light into the absorber and allow further reduction of the absorber thickness. d) KAI MT The core of the Oerlikons THINFAB remains the absorber deposition tool. All key technologies and improvements from the previous generation KAI 1200 like 40 MHz VHF technology and Isothermal Plasmabox® were adapted to the next generation KAI MT. The KAI MT is designed to serve the low cost demands for mass production. By implementing a third process chamber the deposition area is increased by 50 % from 28 m2 to 42 m2. Doubled cleaning speed is achieved by improving the design through shortening vacuum pipes and implementing a remote plasma source (RPS). The combination of amorphous and Micromorph® layer deposition in one single process equipment eliminates the breaking of vacuum between top and bottom cell depositions which leads to improved process control. e) Backend Equipment With the THINFAB Oerlikon Solar launches the second generation of backend with a multiple contacted low voltage module design. The new edge isolation system allows a smaller accurately removed edge area with high isolation and improved module active area. Full automation avoids handling errors and results in robust manufacturing processes and high module reliability. g) Yield The yield improvement of the end-to-end solution is a significant lever to reduce overall production cost. Thanks to the high robustness of thin film silicon process technology together with Oerlikon Solars industry proven mass production equipment and smart line concept, Oerlikon Solar's THINFAB guarantees best in class yield of over 97 % in average. h) Lowest material cost As over 50 % of the module costs can be attributed to direct materials (e.g. glass, foil, junction-box, etc.) these represent large cost reduction potential. As the equipment and technology provider Oerlikon Solar does not limit cost reduction initiatives to deposition technology and equipment innovations, but also drives the development of the module design towards more lean (thin) architectures and evaluates and qualifies new material suppliers. Innovation With Oerlikon Solars THINFAB thin film silicon solar power becomes economically viable first time. In less than 3 years since the market introduction of Oerlikon Solars Micromorph® technology 2007 in Milan the productivity of an Oerlikon Solar fab has been increased by more than 100 % which helps to significantly drive down the CAPEX per Wp. The continuous optimization of module design and qualification of new materials drives down costs and increases the manufacturing robustness by simplifying the production steps. Radical innovations in the core equipment of the end-to-end manufacturing line contribute to the reduction in cost per Wp by offering higher efficiency, higher throughput per capital invested as well as lower energy and material consumption. Oerlikon Solars unique line concept includes but is not limited to improved central handling system renewed manufacturing execution system and considers all aspects of material logistics. In a cross-functional development approach every detail is optimized for the THINFAB, Oerlikon Solars most advanced turnkey photovoltaic thin film silicon manufacturing line. When Introduced 25th EU PVSEC 2010, Valencia 6th of September 2010 Customer Benefits With the THINFAB with module manufacturing cost at or below 0.5 €/Wp, energy can be produced at 0.10 €/kWh in for example Southern Europe. In many regions of the world this allows energy production at or below grid parity level. Therefore thin film silicon solar power becomes economically viable first time. |
Dipartimento di Ingegneria Elettrica, Universita di Bologna |
A New Approch to Valence and Conduction Band Grading in CIGS Thin Film Solar Cells |
Cu (In,Ga)(S,Se2) (CIGS) thin film solar cells have low cost and potentially high efficiency. The record efficiency of about 19.9% has been achieved in laboratory scale . To improve the device performance, the electronic and optical properties of the cell have to be optimized. Band gap grading of the cell materials is effective on reducing the recombination losses and amplifying the carrier collection in the cell. In this paper, we briefly review the characteristics of the last proposed graded band-gap profiles and then, due to valence and conduction band widening effects on the performance parameters of the cell, we present a new graded profile in which the band gap widening of the absorber is included both in Conduction Band (CB) and Valence Band (VB). Widening the band edges at front and back regions of the cell is considered. Furthermore, we discuss the benefits of the CB grading of the window material near the interface region to enhance the carrier passivation and transferring through the cell Normal Grading: In this case, the bandgap of the absorber linearly increases to the back contact and creates a gradient in the quasi electrical field through the cell. Therefore, at the back contact the recombination rate reduces but the Open-Circuit Voltage (VOC) increases which cause to the small enhancement in efficiency. Unfortunately, the Short-Circuit Current density (Jsc) decreases steadily by linearly increasing the band gap as the absorption coefficient depending on position decreases. The other possibility to grade the band gap can be grading the VB of the absorber. In this case, we can lower the saturation current in the SCR and enhance the hole transfer in the absorber edges. In these cases, the band gap of the absorber at the surface region of the cell is at least 0.1 eV greater than that of the bulk region. For example, this shift in the VB can be produced by Cu-poor surface phases (i.e. by Cu(In,Ga)3Se5 or by intentional Ga/In/Se/S grading. VB widening is effective on the main parameters of the cell, where the Voc will improve by enlarging the barrier high at the surface. This is due to the hole concentration which is a limiting parameter for recombination rate on the junction surface and can be controlled by VB grading. When sufficient holes are supplied at the interface, they can limit the Voc. From the curves, we prove that the VB widening will improve the cell parameters by reducing the carrier loss and hole depletion at the surface regions (Fig. 1, left). Therefore, based on the above approaches, we present an improved graded profile, (Fig. 1, right) which consider the real changes in VB and CB together. At front region of this profile, VB widening will enlarge the hole depletion as a limiting factor for Voc, CB grading will reduce the recombination rate of the carriers at the interface. At the back region, VB grading will enhance the transfer ability of the majority carriers and CB will improve carrier collection probability of the carriers to contribute to the current. However, this profile can better define the grading changes on the valence and conduction bands, i.e., for a S-graded absorber material. We also discuss the possibility of the grading the front region of the window layer to enhance the passivation and transferring of the electrons coming from the absorber. This is an effective factor on the performance of the CIGS solar cells where the CB offset between the window layer and absorber layer at the interface can affect on the flow of the electrons from the absorber to the window. |
Silicon Innovation Award |
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REC's "fluidized bed reactor" (FBR) process |
Description RECs proprietary Fluidized Bed Reactor (FBR) process represents the cutting edge technology in silicon production. After 15 years of R&D, REC has developed a process that produces silicon in a continuous process (vs. a batch process) and results in a ready-to-use output that requires no post-processing. The NextSi Granular Polysilicon, which is produced by the environmentally-conscious FBR process gives REC-produced solar modules an industry-leading payback time of one year, 20% less time than competing products Challenge A major part of the energy consumption associated with producing solar cells is related to the purification of silicon. The "Fluidized Bed Reactor" (FBR) technology, used by REC for the silicon purification process, consumes significantly less energy for producing high purity silicon used for high performance solar products. Moreover, the FBR process lowers the cost of making solar products, whilst saving large amounts of electricity. Problem Solved With the "Fluidized Bed Reactor (FBR) process, REC can produce solar-grade silicon, while using 80-90% less energy than the traditional Siemens method for converting silane gas to high purity silicon. Firstly, it does not waste energy by placing heated gas and silicon in contact with cold surfaces. Secondly, it produces more silicon per cubic meter of reactor space because the silicon crystals have a larger total surface area than the rods used in the Siemens process. Thirdly, it is a continuous process rather than a batch process so there is less wasted downtime or setup effort required. And finally, unlike other processes which require the breaking of polysilicon rods, FBR granular is harvested in a ready to use form. Noteworthy RECs Fluidized Bed Reactor (FBR) process uses less energy to produce silicon than competing technologies, making it a more environmentally-sound choice. It also gives a payback time of one year, 20% less time than competing products. The company is also committed to reducing waste, using closed processes wherever possible and capturing 95-99% of the remaining production by-products and repurposing them. REC also uses only hydroelectric and wind power to power the production process. In Detail The basic technology behind RECs Fluidized Bed Reactor(FBR) process is as follows: Reactor bed is heated and fluidized solid particles in constant motion Process gases are introduced from bottom of reactor Polysilicon seed crystals are introduced from the top of the reactor Thermal decomposition of silane gas onto polysilicon on seed crystalsPolysilicon crystals grow in diameter then drop from bottom of reactor due to force of gravity When comparing the FBR process to the existing, traditional silicon production process, the differences are as follows: RECs Proprietary FBR Process Low Energy Consumption Continuous Process Output Is Ready To Use High Logistics Efficiency Consistent Form Factor Flowable Form Factor - High Automation Potential High Process Efficiency Traditional Process High Energy Consumption Batch Process Output Requires Post Processing Higher Manufacturing Cost Lower Logistics Efficiency Irregular Form Factor Non-Flowable Form Factor - Lower Automation Potential Lower Process Efficiency Innovation RECs Fluidized Bed Reactor (FBR) process requires less energy to produce than other silicon production processes, giving REC silicon modules an industry-leading payback time of one year. The process produces silicon in a continuous process (vs. a batch process) and results in a ready-to-use output that requires no post-processing. RECs Fluidized Bed Reactor (FBR) process produces NextSigranular polysilicon, which is easier to handle. The FBR process is an efficient, continuous production cycle and has a ready-to-use output product, as opposed to existing solutions which are inefficient batch production and require additional post-production processing. Improved logistics automation (no manual breaking or packaging) reduces the potential for external contamination resulting in poorer product quality and performance. Granular polysilicon is packaged in bulk containers and because they round and can flow freely, it enables automated material transport and crucible loading. These factors combined amount to a significant reduction in the cost of solar ingot manufacturing compared to the traditional method further reducing the cost of solar energy. Moreover, there are a number of technological advantages to the RECs Fluidized Bed Reactor (FBR) process. Practical manufacturing advantages include:
When Introduced The silicon purification process, utilizing a Fluidized Bed Reactor (FBR), was launch in March 2010. REC Silicons FBR products are targeted to supplement or replace all existing and emerging crystalline based photovoltaic polysilicon requirements. Customer Benefits Overall, the RECs Fluidized Bed Reactor (FBR) process is an economically-sound choice because it maximizes productivity. Advantages of FBR-produced silicon include: Increased Process Efficiency maximizes crucible load, ability to top-off and/or recharge crucible, highly repeatable, controlled process, mitigates process problems, increases productivity Optimized logistics reduces amount of shipping and handling, increases operational efficiency, High Automation Potential reduces handling, increases operational efficiency, increases productivity |
SCHOTT Solar AG |
Silicon Innovation |
The solar manufacturer from Mainz, Germany, SCHOTT Solar, has developed a new technique that will allow for high-performance multi crystalline solar cells to be manufactured on a large-scale industrial basis. The solar cells produced in an industrial environment achieve peak efficiency of above 18 %. In combination with improved module technology, record efficiency of 17.6 %t was achieved on the surface of the aperture and confirmed independently by ESTI (European Solar Test Installation). The innovative high-performance cells used in the champion module feature a front side that corresponds with the current standard in industrial manufacturing. The backside, on the other hand, has been passivated by using a combination of different dielectric layers that feature local contacts, better known in the industry as the PERC structure. Commercially available multi crystalline silicon wafers from its subsidiary SCHOTT Solar Wafer GmbH in thicknesses of 180-200 µm are the starting material. This made it possible for the researchers who work for the Mainz-based company to produce cells in the standard size 156x156mm² that offer efficiency of more than 18 % in pilot production. Conventional silkscreen printing technology was then used to create the contacts. According to the solar manufacturer, this technique successfully links new manufacturing steps with a mature and cost-efficient production sequence. New approaches to increasing performance were used during manufacturing of these modules to reduce both optical and electrical losses while the solar cell was being turned into a module. Confirmed efficiency of 17.6 % that the world that has never seen before was achieved using a conventional layout involving 60 multi crystalline cells. The photovoltaic industry is still pursuing two basic approaches when it comes to lowering costs even further: improving the production processes, on the one hand, and increasing efficiency, on the other. This innovative approach to industrial manufacturing of high-performance cells and modules, will help achieve higher efficiency." |
AEG Power Solutions |
Thyrobox™ PI |
AEG Power Solutions (AEG PS) Thyrobox™ PI power system sets efficiency standards in polysilicon production. Using proprietary technology developed by AEG PS, the Thyrobox™ PI, allows manufacturers of polysilicon, to increase the production output of their existing polysilicon reactors by 10% to 20%, depending on reactor configuration and process condition. Polysilicon is the base material used in the manufacturing of solar cells. With decreasing poly silicon prices, manufactures are under ever increasing pressure to lower operational manufacturing costs. Thyrobox™ PI can easily be added to existing AEG Power Solutions Thyrobox power systems. That way it allows for permanently lowered operational costs with minimal investment as no new or additional deposition reactors are needed. In addition to increased polysilicon productivity the Thyrobox™ PI reduces internal thermal stresses thus preventing rod cracks, allows for more uniform growth, improves rod joint bridge shaping and minimizes hot spots. AEG Power Solutions partnered with GT Solar to offer the Thyrobox™ PI as part of a turnkey solution using GTSolar's SDR™ series of CVD reactors. This next generation power system is designed to be integrated with GT's SDR-400 to enable reactor capacities over 500 MTA The vision is to deliver sustained value to customers by lowering the cost of PV manufacturing. ![]() |
Industry Development Award |
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All Eco Energy |
Description Chris Sutor of All Eco Energy has worked tirelessly to build a company which supplies quality products to the industry on a wholesale basis as well as completing residential and commercial installations. From a standing start the company has installed over 500 installations in 6 months and is now offering the Free carbon Solar programme removing the final barrier for commercial organisations to join in with the solar revolution, the upfront cost. All this has been done without any outside help and in the most positive and gentle manner. Challenge Removing the barrier of cost to commercial organisations. Problem Solved Funding is used to provide the equipment, the FIT is used to pay the funding and so the virtuous circle continues. Noteworthy It allows commercial organisations to reduce their carbon footprint without any investment. Product In Detail All Eco Energy check the suitability of the roof then take out a lease on the roof (paying the legal costs of the client). This helps the UK hit its targets re the reduction of CO2, it helps educate the persons within the organisations who take it up and promotes the whole programme of the local production of electricity in a carbon Free manner. Innovation This whole programme is not dependant on any grants other than the fit and thier are few barriers to the scheme. Customer Benefits Customer benefit with carbon free electricity at no cost to themselves and the scheme is self financing. |
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Description A novel planar antenna by using a panel of photovoltaic cells as a metamaterial FSS radome for dual-band operation is presented (the prototype of product is shown in Fig.1 of attached file). A 10-Watt, 72-cell unmodified commercial photovoltaic panel is applied as a transparent layer in the first operation band and as a semi-transparent layer for λ/2 Fabry-Pérot cavity in the second operation band to achieve high antenna gain. The proposed prototype achieves remarkable 17.3 dBi and 6.6 dBi antenna gain at 3.5 GHz and 1.23 GHz, respectively by feeding a dual-band dipole. With the aid of PV panel, the antenna can support an upper band at about 3550 MHz to cover the WiMAX 3.5 GHz (3400-3600 MHz) operation band and a lower band at about 1185 MHz to cover the 70 MHz operation bandwidth. The very combination of photovoltaic cell and antenna exhibits high fill factor, high-gain, and simple construction characteristics. This integration of PV panel and antenna is suitable for outdoor wireless communication devices such as IEEE 802.11 a/b or WiMAX (IEEE 802.16e) access points, 3GPP LTE femtocells. Challenge The main challenge is to overcome the EM interference when conducting the integration of antenna and PV panels. Since the conductivity of a commercial PV cell is so high to about 100-200 s/m that it is treated as a conductor which will block the EM wave when incidents into the PV panels. To treat the PV panel as an interference load or as a RF antenna ground is currently, the only solution to reach the coexistence of the PV panel and antenna. Therefore, a unique method is proposed to solve the integration of PV panel and antenna EM compatible issue. The goal is to maintain both the PV panel and the antenna area ratio. Problem Solved Inspired by the concept of metamaterialFabry-Pérot resonator, we treat the PV cell as a sub-wavelength periodic structure which having the proper frequency selective characteristic in the desired operation band and construct a novel high gain antenna. A dual-band high-gain antenna is fabricated in a very reasonable, area-saving manner without any major modification of PV cells construction. In other words, the filling factor (or area ratio) of PV cell can be well-maintained in our proposed integration design. That also means it contains the same optical efficiency as the ordinary PV cell. In addition, owing to the PV-cell-FSS arrangement and the proper calculation of Fabry-Pérot resonance condition, its very promising for antenna gain improvement (~10 dB comparing to an ordinary single patch antenna) and industrial manufacturing. Noteworthy The Electromagnetic inference must be taken into account while constructing the PV-Antenna integrating structure. In our proposed design, the parameters of PV-Cell area ratio has been improved to 90% and the antenna efficiency to more than 80% in contrast of 20% and 39% from SOLANT project supported by the European Space Agency[1] whose PV cell and antenna are arranged in interlacing mode , 50% and 50% from Institute for Solar Energy Supply Technology (ISET)[2] as an antenna radiator and 90% and 32% of Dublin Institute of Technology [3] as an antenna ground. For more detailed structure, please see our comparison table 1 in the attached PDF file. It should be noted that the PV panels/cells area ratio and antenna efficiency is a trade off in all of the designs in [1-3]. None of them can be treated as well arranged matrix in sub-wavelength periodic structure. In Detail Under the huge demand of alternative energy resources, the deploying area of photovoltaic (PV) panels increases dramatically. However, the roofs of buildings in urban area are sometimes mounted with wireless communication infrastructures, such as base stations for cellular phones, point-topoint transfer spots, satellite receivers, radio communication stations and wireless TV receiving antennas, etc. PV cells and wireless communication infrastructures scramble for the roof area and interfere with each other in the point of view of operation. It’s necessary to integrate these two equipments to maximize the usage of valuable roof area. The design procedure of our product prototype (full picture is shown in Fig.3) is as follows: First we calculate the electromagnetic characteristic (in GHz band) of PV panels. In the attached PDF file, Fig. 2(a) and (b) shows the detailed structure of the poly-Si PV cell element in our EM model, which includes cover glass (thick of 2 mm), Poly-Si layers contained with P-N junctions, finger electrodes and bus-bar, back electrodes and cell-to-cell connecting electrodes. Although the real structure is composed of thin layered fine finger electrodes, to reduce the computing time, they can be ignored as show in Fig. 2 (c). Furthermore, rectangular metallic patch linked with straight metal strip with poly-Si layer and glass cover is also removed, as show in Fig. 2 (d). Fig. 3 shows the reflection and transmission response of the 80 mm × 28 mm unit-cell with periodic boundary conditions. The plane wave is normally incident to the structures and the E-field is polarized in the x-direction. It is seen that two pass-bands are existed and centred at about 1.2 GHz and 3.5 GHz in the observation of frequency range. It also can be observed that responses of these two different models (Fig. 2(c) and Fig. 2(d)) only exhibit slight frequency shift, which generally represent that both of them are suitable for full wave simulation. This is because the particle structures of PV cells are too small with respect to the operation frequency to affect our simulation results. According to our frequency selective unit-cell analysis, the PV panels EM-wave transmission response exhibits multiple pass bands. Our design can have antenna operate at 1.2/3.5 GHz. Secondary, we select first pass band (1.20 GHz) and second pass band (3.50 GHz) as our dual-band operation frequencies. Considering the finite panel size compared to the wavelength at low frequency and the different transmission characteristics of PV cell, we use different mechanisms for each band. At 3.50 GHz, the transmission level of unit-cell is not very high, but the panel size reaches 4.20λ0 × 3.73λ0. In this configuration, Fabry-Pérot cavity mechanism is applied to achieve high antenna gain. The parallelepiped FabryPérot cavity is composed of one semi-transparent surface, one reflective mirror surface and a suitable gap, usually half-wavelength, in-between. The PV panel is treated as a semi-transparent surface. A copper plate, served as reflective mirror, is parallel placed beneath the PV panel with 44 mm (approximate 0.5 wavelength at 3.50 GHz) air gap. A central fed microwave power propagates transversely with slow-varying phase to fill in the cavity and achieve high gain. At 1.20 GHz, the PV panel only reaches the size of 1.44;0 × 1.28;0. It’s hard to apply resonant cavity for this small size. Fortunately, the transmission level is so high that we can treat PV panel as a transparent radome at this band. The parallelepiped structure is not in the state of resonance at this frequency. It becomes a simple antenna with a back-reflector. It should be noted that the PV panel remains unchanged in our design in order to retain its optical efficiency. Innovation Our technology is Electromagnetic Metamaterial. Since the pioneer theoretical work by Veselago in 1968 [4] and later the experimental realization by Smith et al. [5], there has been an exploding research interest in metamaterialsubstances that exhibit simultaneously negative permittivity and permeability. This is mainly due to the fact that this new class of artificial material opens up new opportunities in EM design that were not possible before. Researchers have been done and applied in not only fundamental electromagnetic theory but also applied to variety of RF applications. One of those popular studies is metamaterial high gain antenna structure. A FSS (frequency selective surface) is used in these works as a semi-transparent layer at desired operating band to cover on a large reflective ground surface with a single feeding element, which could be a patch-type or dipole-type antenna. Related methods to improve antenna performance by using metamaterial super-strate can be approximately differentiated into three categories according to the antenna height, which are half-wavelength designs [6-9], quarter-wavelength designs [10-11] and the lowest height profile (smaller than 0.1 wavelength) designs [12-13] respectively. The proposed structure with the aid of PV panel given in Fig. 4 was fabricated and studied. Full models are simulated by commercial EM software, Ansys HFSS. Loss of materials and conductivity of PV cells are all taken into consideration. Fig. 5 shows the measured S-parameter of the proposed structure. It can be clearly seen that two resonate modes, which are centred at about 1185 MHz (dipole mode) and 3550 MHz (FabryPérot mode) are excited successfully. For the frequencies over the obtained operating band formed by the two modes, the impedance matching is all better than 3:1 VSWR. The fractional bandwidth of lower mode is about 5.9% (70 MHz) and the upper bandwidth is about 7.3% (260 MHz), which can cover the WiMAX 3.5 GHz (3400-3660 MHz) operation. The simulated and measured radiation patterns at 1.2 GHz and 3.5 GHz, around the centre frequencies of the excited dipole and FabryPérot modes for the proposed antenna are presented in Fig. 6. Also, the radiating patterns over those two modes across the operating band are studied. Although similar results are obtained yet they are not shown for brevity. The gain variation characteristics of the proposed antenna are also studied (Fig. 7), it could be observed that the proposed structure performs a peak gain of 17.3 dBi at 3.50 GHz and 6.6 dBi at 1.23 GHz in broadside direction. Fig.8 shows the distributions of E-field. The E field magnitude is strongest at the centre of the superstrateand the spread of the E-field strength is even throughout the entire superstrate. In other words, the superstrate and substrate well perform a role as a cavity capturing an electromagnetic energy. Unique Antenna-PV-Panel integration technology originated from metamaterialFabryPérot cavity which is capable of 1.2/3.5 GHz dual-band operation is proposed. Extraordinary integration of proposed antenna structure shortens the distance between antenna and PV panel to 1/2 wavelength of 3.5 GHz, which is half-wavelength resonant mode of FabryPérot cavity can be achieved and mutual interference could be eliminated as well by using this technology. Both very high antenna gain of 17.8 dBi in secondary operation band and remaining the same PV panel performance could be achieved comparing with current known literature. In addition, this work successfully turns a PV panel into an integrated dual-band antenna with very little additional structures and fabrication cost, which makes it very promising for industrial manufacturing. Furthermore, this concept could be applied to another type of solar cell, such as thin-film PV cell. When Introduced The prototype of product has been constructed at year end of 2010. Customer Benefits 1. High antenna efficiency Novel high efficiency PV-panel-Antenna Integration technology will create a brand new market.2. Small form factor PV-panel and antenna are stacked and integrated perfectly with each other without sacrificing any performance. 3. Cost-effective the manufacturing process of PV-cell remains unchanged which means no additional cost will happen. |
SEMI PV Group |
International Technology Roadmap for PV (ITRPV) |
Description Leading crystalline silicon (c-Si) wafer, solar cell and module manufacturers are working on a technology roadmap for c-Si photovoltaics (PV). The aim of this roadmap is to inform suppliers and customers and set a basis to intensify the dialog about required improvements and standards. Between 2011 and 2014 new technologies need to be implemented in production. Details of requirements for advancement of c-Si solar cell manufacturing will be described and technological barriers will be identified. This information shall enable future growth and significant cost reduction per piece. Product Challenge The International Technology Roadmap for PV does provide important and significant key parameters of todays solar cell mass production showing their development for the upcoming years. Problem Solved The International Technology Roadmap for Photovoltaics (ITRPV) organized by the Crystalline Silicon PV Technology and Manufacturing (CTM) Group* aims to inform suppliers and customers about expected technology trends in the field of crystalline silicon (c-Si) photovoltaics and sets a basis to intensify the dialog on required improvements and standards. Noteworthy Currently no technology roadmap for PV is exists on the market. In Detail The International Technology Roadmap for Photovoltaics (ITRPV) organized by the Crystalline Silicon PV Technology and Manufacturing (CTM) Group* aims to inform suppliers and customers about expected technology trends in the field of crystalline silicon (c-Si) photovoltaics and sets a basis to intensify the dialog on required improvements and standards. The present second edition of the ITRPV was jointly prepared by leading European c-Si solar cell manufacturers, module manufacturers, and wafer suppliers. Feedback and input from various institutes, equipment suppliers and providers of production materials was also included. The present publication consequently covers a wider range of the PV value chain compared to the first edition. Due to the historical learning curve as well as industry growth, the specific costs per Watt peak (Wp) of PV modules are expected to decrease by 8%-12% per year. This corresponds to a significant cost reduction per module. To reach this purpose, current technology will be optimized, but new technologies also need to be implemented in production between 2013 and 2015. Detailed requirements for c-Si solar cell manufacturing such as more effective use of material, more productive manufacturing equipment and more advanced processes are given in key parameters. This not only affects the cell production but also the complete value chain. One example is the wafer dimension: to be able to handle thinner and larger wafers, not only the method of making the wafer needs to be modified, but also the cell process and the technology to build the module - rear contact cells will probably be used. In case of cell size the inverter also needs to be adapted to a new current/voltage range. The roadmap activity is carried out in cooperation with SEMI PV Group and updated information will be published each year in Spring to ensure good communication between manufacturers and suppliers throughout the value chain. Innovation The experience in the semiconductor and other related industries has clearly shown the necessity of a roadmap. The ITRPV is the international approach of combining technical visions along the supply chain. When Introduced The first edition was published during the 4th PV Fab Managers Forum in March 2010, the second edition was recently published during the 5th PV Fab Managers Forum in March 2011. Customer Benefits The ITRPV indicates at an early stage the technological development of the mass production of solar cells and modules. This allows any supplier to react early on future market needs. |
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Matrix 2.0 |
Description Matrix 2.0 - is an unique interactive tool is becoming the industrys central resource for information as to how PV is manufactured and how companies fit within the complete value chain of manufacturers, suppliers and users of PV equipment. The Matrix remains at www.matrix.ipvea.org, it will be also soon accessible via an app for mobile devices, such as the iPhone, iPad, Android phone or a Blackberry. Challenge Matrix 2.0 organizes solar technology into four main segments: silicon, organic, R&D, and installation & power generation. Each illustrated segment expands to show categories within that technology. Problem Solved Matrix 2.0 For example, silicon expands to raw material to wafer, wafer to cell and cell to modules. From there, each subsection further breaks down. This is beneficial because it simplifies technology and allows visitors to find specific information and locate key suppliers, who can now more easily interact with each other companies. Noteworthy As far as we know, there is no other tool similar to the Matrix 2.0 relating to any industry. Customer Benefits One stop shop for information |
Petra Solar |
SunWave System |
![]() Description Combining highly distributed solar generation with smart grid functionality; Petra SolarsSunWave system mounts on existing public infrastructure, including 95,000 utility poles (and counting) across New Jersey. Petra Solar leverages existing public infrastructure to provide scalable, utility-grade clean power along with smart grid benefits. Product Challenge Until now, solar power has only truly been economic in large solar arrays, but these are subject to land use battles, their power output can be affected by local weather events (such as passing clouds), and their value proposition is almost entirely defined by the cost of solar panels. Problem Solved Petra Solar pioneers a new technology and a completely new value proposition by combining widely distributed solar generation (not affected by local weather; no new transmission lines required) with smart grid infrastructure. The technology pairs well with utility customers business models, scales gracefully, and improves grid reliability and disaster preparedness. Noteworthy We create the equivalent of hundreds of football fields of solar arrays out of thin air and offer smart grid functionality without an expensive overhaul. What once required tremendous amounts of space is achievable in dense cities where power demands are high and a smart grid is critical. Product In Detail Petra Solar pioneers a cutting-edge approach to solar power generation and smart grid deployment. Its technology is being leveraged right now to create innovative solar, smart grid, and grid reliability solutions for utilities filling a unique niche with close to immediate dispatchability. For decades, the approach to harnessing the power of the sun has been to install large solar arrays: hundreds of panels in a field. Petra Solar explodes that model: its SunWave system installs on existing utility poles and attaches to existing lines, feeding renewable energy directly into the electric grid without need for new sites or transmission. This use of existing assets for solar power eliminates the need to acquire and permit vast tracts of land and avoids other costs and difficulties that often impede the deployment of renewable energy. SunWave systems do not only generate clean, renewable energy, but also serve as intelligent units that communicate with each other and with the grid to build a Smart Grid infrastructure. It improves the efficiency and reliability of the grid by providing two-way communication and control between the solar generators in the field and a utilitys control center. The system monitors grid operations and provides distributed reactive power compensation, as well as volt-VAR optimization. These capabilities bring the performance of the grid into the 21st century, whereby installation costs are shared with renewable power generation lines on a utility balance sheet. Innovation Petra Solar is the first company to implement virtual power plants, or highly geographically distributed renewable energy generation systems. The level of distribution of a solar generation system is its best insurance against intermittency, i.e., how much the system is limited by passing clouds or storms. By mounting solar panels on utility poles throughout a utilitys territory (which can even include an entire state), the company achieves a level of distribution never before met by a unified solar project. Further, these virtual power plants are packaged in a new, compelling value proposition that combines power generation, smart grid functionality, and siting/permiting cost savings, which are better suited to the particular needs of utilities than any existing solar generation offering. SunWave is also novel because it reacts to similarly novel times in the utility industry. With the advent of electric vehicles and other technology that places new demands on the electric grid, utilities will increasingly focus on enabling smart grid solutions that will facilitate grid reliability and stability. Petra Solar has pioneered a partnership approach with utilities to address, maintain and improve power quality and reliability. When Introduced The product was initially released May 2008. Customer Benefits At the most basic level, we see the SunWave solution paving the way for two main changes in the field: the evolution of solar powers value proposition to include other functionalities (such as smart grid) and greater distribution of renewable energy generation. Both offer such clear technical and economic benefits that they cannot be ignored for long, and we enjoy a position of first mover in both areas of change. This unique packaged approach to distributed energy generation with smart grid capabilities allows for more effective use of public infrastructure to enable efficient, effective data gathering and communications, as well as an ability to recover quickly when emergencies strike. This means that as utilities seek to invest in solutions that will help to upgrade the electric grid into a smart, responsive system, they have access to a future-proof solution that ensures more reliable delivery of energy. Moreover, the technology also offers utilities an easy toehold on the smart, renewable energy grid of the future. A recent Electric Power Resources Institute (EPRI) 2011 report states that a complete smart grid overhaul of our existing transmission and distribution electric system will cost upwards of $476 billion a daunting task but necessary to ensure a secure energy future. However, compared to an expected $2 trillion ROI over time after these upgrades have been performed, Petra Solars solution eases critical pain points in an enormous market that enables profitable, direct utility ownership of solar. This unique combination accelerates ROI and payback to become the natural path of least resistance that leverages the utility core business model to build Smart Grid infrastructure of tomorrow. SunWave also advances smart grid functionality. For example, its dynamic reactive power control automatically offsets abnormal voltage fluctuation from the power supply, making it much more difficult to cripple the entire grid by localizing system failures in the event of disaster. This is of particular interest to the industry in light of the recent earthquake in Japan. |
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Wagner Academy Solar Training School |
Description Wagner Solar UK Ltd has set up a training school for UK based solar installers. This training school is specifically aimed at solar installers who are already MCS accredited. The training school is run at different venues depending on the content and number of people expected to attend. As a company, we have invested considerably in resources / material, for example we have built 2 indoor training roofs to provide practical hands-on training. All our courses are offered free of charge on a first come first served basis. Challenge Currently, the majority of solar training schools in the UK are specifically focused on MCS accreditation training. As commercially run training schools, these establishments must operate to make a profit, so have commercial partnerships in place for supply of training technology etc. With commercial partnerships in place, unsurprisingly the schools are failing to provide an unbiased view of the industry. Once the installer is accredited, they have a narrow view of the industry. This is one challenge. Another is the pace of advance currently being experienced by the solar industry, which leaves these freshly accredited installers behind, as they struggle to build up experience. Our training school is specifically focused on already accredited installers to provide them with ongoing training. Problem Solved As a distributor, we are in a unique position with direct relationships with global manufacturers. Our intention is to invite manufacturers to our training, for them to give product training themselves. Working with a range of manufacturers covering different types of technology, we are playing a role in giving installers a holistic overview of the industry. We have carefully selected our suppliers based on quality and performance, so we believe that this initiative will play its role in delivering quality to the industry. Noteworthy We are operating in the field of microgeneration. The vast majority of installation outfits are small local companies who do more than just install. These companies are responsible for marketing their services, advising customers on technology/options and selling solar into the mass market. As a result, they shoulder a great responsibility for ensuring the process is carried out professionally and correctly. If not, they will taint the industry and paint a negative picture in the minds of the general public. Our training school therefore plays a role in delivering education and knowledge to the installer, so they in turn can do so in their role of speaking to the general public - outcome is a better quality industry for all concerned. In Detail Broadly speaking, our PV training covers two main areas. The first is advanced installation training. When individuals wish to become an installer of solar, they will usually attend a course run by a training school somewhere in the country. These schools will teach the individual how to mount a PV system on a roof, how to wire / connect it to an inverter and how to connect it to the grid. They will rarely speak about calculations. A PV system must remain on the roof for 25 years and beyond to outlast the FIT. This means it must withstand extreme weather conditions such as heavy snow / extreme wind. The last think we want is for systems to fall off roofs in 10 years time, so we must train installers to calculate weather loads, tension and expansion from changing temperature. The installation element of our training is designed to teach calculations, since we expect installers to complete a safe and quality assured installation. The second area of our training covers product training. Product technology is advancing so quickly that it is difficult for all installers to keep up. We have decided to use our position as a distributor to facilitate conversation between manufacturers and installers, by way of inviting manufacturers to sessions to provide product training. This allows installers to learn about the discrete benefits of products which in turn will allow them to use/install them at an optimum level. This benefits homeowners with having a fine tuned system that produces maximum possible electricity. An additional benefit to this exchange is the possibility for manufacturers to learn about installers' challenges directly from the installers themselves, so that feedback can be incorporated in future product development. We have decided to specifically open the training school to target already accredited solar installers. Once the MCS accreditation is complete, installers are alone. It is up to them to source product, market their services, advice homeowners about technology and sell/install a solar system. Our training school is unique in that now, the installers are no longer alone. They have the possibility to keep up with product technology / advanced installation techniques through attendance, which ultimately will help the industry at large by delivering a better quality image, service and reputation. When Introduced Wagner Solar UK Ltd is the UK subsidiary of Wagner & Co, the German Solar company. Our parent company has been involved in providing training for over a decade now. Many of our in-house trainers who train installers in the UK come from our HQ, so we have the advantage of years of experience which is well appreciated in the current young market. Customer Benefits A key intention of our training is to openly share knowledge and information to create a better quality industry. As it is the installer who markets their services to homeowners, advises homeowners about technology and ultimately sells/installs a solar system, by improving quality in the industry, we are benefiting customers (homeowners) from having a better installed and better performing solar system. |
SPG Solar, Inc. |
Floatovoltaics® |
Description When SPG Solar Inc.®, the company that introduced the worlds first operational floating solar array in 2007, announced earlier this year the availability of its next generation in floating solar technology, SPG SolarsFloatovoltaics®, it generated worldwide interest in the solar industry and international media coverage, ranging from the New York Times http://www.nytimes.com/2011/04/20/business/energy-environment/20float.html) to Forbes Magazine. (http://blogs.forbes.com/kerryadolan/2011/04/20/solars-new-twist-panels-that-float-on-water) This floating solar technology makes it possible to float solar power generating systems on water. Floatovoltaics has changed the way solar power is now considered, making it an option where never before possible. SPG Solar Floatovoltaics ® makes it possible for commercial and government users with little available rooftop or land space to float solar on water instead, and at the same time gain triple benefits: conserving land and water, while generating clean, renewable energy. Using proven and cost effective floating technology; fresh water irrigation ponds, lakes, or reservoirs become revenue-generating, power producing platforms. Challenge The challenges of developing large-scale renewable energy solutions where land and rooftop space are at a premium and for conserving increasingly scarce water resources around the world. Problem Solved The solutions provided SPG SolarsFloatovoltaics include: 1. Eliminates the need for land or rooftops. 2. Reduces water evaporation under the floating arrays by up to 70 percent. 3. Improves water quality by providing coverage from the sun that minimizes algae growth and reduces the need for water treatment chemicals and associated labor costs. 4. Provides shade below the panels, lowering the water temperature and 5. Improves power output from the solar panels up to 1% more power generated using Floatovoltaics. SPG Solar Floatovoltaics provides these solar generated power solutions agribusinesses, water agencies, wastewater treatment facilities, mining ponds, and hydroelectric reservoirs and utilities; among others. Noteworthy SPG SolarsFloatovoltaics®, has changed the way solar power is now considered, making it an option where never before possible. Solar customers around the world can now install a floating system that is priced competitively to ground based, single axis tracking solar systems. In Detail 1. Structure a. Steel frame with HDPE floatation b. All steel is Galvalume (AZ-55) or hot dip galvanized c. No structural steel is in contact with water 2. Engineering a. Designed per 2010 IBC, 85mph, Exposure C b. All electrical components are NEMA 4X or IP67/68 c. Reports available: d. ZFA Structural Engineers (stamped) e. Bill Brooks Electrical Engineering (stamped) f. JDH Corrosion Engineering (stamped) g. Environ Environmental Engineering h. MDI Marine Electrical, shock 3. Flotation a. HDPE is NSF approved. NSF approval of the finished product is in process. b. 100% recyclable and approved by the U.S. Corp of Engineers c. The marine wire is typically submerged but can be floated with HDPE floats to avoid contact with water if necessary d. Only other components in contact with the water are polyester mooring line, galvanized steel cables and shackles, and aluminum grounding plates 4. Array Layout and Site Parameters a. 3acres per MW b. pH between 6.0-10 c. No walkway to the array for security, safety and cost d. Accommodate a wide water level variation e. Mooring can be installed on land or submerged 5. Maintenance a. Standard 10 year comprehensive O&M contract with annual inspection included in system cost. Extended O&M is available. b. Wires protected from abrasion c. Wireway protected by steel shed d. Stainless, brass and galvanized mooring hardware e. Upsized polyester mooring line with UV protection f. No additional maintenance is expected with Floatovoltaicsvs. other PV deployment systems Innovation Redesigned and engineered to be cost competitive, SPG Solar Floatovoltaics� makes it possible for commercial, industrial and government users with little available rooftop or land space to float solar on water. When Introduced SPG Solar Inc.®, the company that introduced the worlds first operational floating solar array in 2007 at the Far Niente Winery in California, introduced this reengineered, redesigned, cost competitive next generation of floating solar in January of 2011 |
PV Tool Award |
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Eclipse |
![]() Description DEK Solar is the global provider of screen printing equipment and processes for fuel cell and solar cell manufacture. The Eclipse platform is a very high throughput complete metallization solution for commercial solar cell production. Challenge Given the growing importance of solar as an alternative energy source, manufacturers around the world are facing a demand to supply silicon solar cells in abundance. They need to maximise utilisation, yield and productivity whilst also achieving a low total cost of ownership. Additionally, as market demand continues to fluctuate, manufacturers need to be available to scale production as necessary. New processes that reduce shadowing of the cell surface boost cell efficiency, and these demand special applications capability and absolute print precision. Eclipse helps to address each of these challenges. Problem Solved Fully modular & configurable metallization line allow manufacturers to scale production from 1200 to 3600 wafers per hour, as demand dictates Parallel print head processing options maximise productive uptime Integrated vision inspection for ultimate process and quality control Fast yet sensitive handling; high speed, zero edge contact for negligible breakage rates Multiple conveying, flipping, buffering & stacking options Superior positional accuracy for high yield precision Industry-leading repeatability for Print on Print applications; capability (PoP) - +/- 12.5 microns at 2 Cpk Selective Emitter Accuracy - +/- 12.5 microns at 2 Cpk Multi-language intuitive GUI control industry-leading delivery times backed up by worldwide service teams and 24/7 spare parts availability Noteworthy Eclipses primary advantage lies in an unprecedented and highly flexible modular design concept. Featuring a series of field-retrofittable process modules, Eclipse enables manufacturers to easily scale production to 1200, 2400 or 3600 wph as demand dictates. Furthermore, for manufacturers who foresee a production ramp, the metallization line can be designed accordingly, by inserting spacer process modules equipped with conveyors where future production modules will be added in. When production demands an increased throughput capability, these spacers can simply be swapped out for additional functional capacity. The primary process modules, including the print head and unloader, incorporate full control systems and are designated as master units. Additional field retrofittable process expansion modules operate as secondary slaves, hooking up to the master control units in the primary modules. By eliminating the cost of additional control units, the scaling process is simple, fast and cost effective. With the Eclipse platform, manufacturers can plan an easy, non-disruptive, cost-effective scale up and future proofed path. In Detail Deploying patented multiple print heads operating in parallel for its high throughput configurations, Eclipse maximises productivity; if one head halts for operator attention the others continue to print, boosting operational efficiency and dramatically reducing downtime. Eclipse features a series of field-retrofittable process modules that allow manufacturers to scale production from 1200 to 2400 or 3600 wafers per hour, as demand dictates. In its smallest configuration, the Eclipse 1200, a single print head operates at six-sigma accuracies, delivering handling and process functionality that maximises yields at throughputs of 1200 wph. Scaling up to 2400 or 3600 wph, the user simply deploys additional print head and loader modules. Here, Eclipse extends the end-of-line productivity benefit beyond higher throughput multiple print heads operate independently in parallel to all but eliminate downtime. If one printer halts for attention, the others continue to print. With the Eclipse platform, manufacturers can plan an easy, nondisruptive and cost-effective scale-up path. An Eclipse line can be configured with spacer modules for future capacity. Spacer modules feature conveyors, and are simply replaced on-site with slave printer and loader modules that link to the existing master modules, boosting throughput capability and eliminating changes to factory plant and utility supplies. On the production floor, resolute productivity is the target for the Eclipse platform. The intrinsic repeatability that comes from ±12.5 micron accuracy and 2 Cpk capability is vital to confidently process finer lines and print twice or more with absolute repeatability to create higher aspect ratio conductors. To safeguard the high yields manufacturers expect, Eclipse features a pioneering perforated belted platen that cuts breakage to less than 0.2%, even with wafers of 120 microns (well below the industry norm). Wafers are transported to the print area and anchored using vacuum hold-down. The belt also self-cleans, using dynamic contamination control to remove particulates and present a clean surface. To fully exploit the platforms accuracy, twin cameras precisely align wafers using edge detection for standard printing or fiducials for intricate processes like print-on- print. Coupled with print speeds up to 600mm per second and innovative zero-edge contact handling, Eclipse guarantees exceptional output. Such productivity, modularity and field-scalability backed by worldwide service teams and 24/7 spare parts availability make the Eclipse platform the ideal choice for manufacturers chasing demanding production targets today and into the future. Innovation Perhaps the most compelling aspect of Eclipse is the fact that it has been designed with change very much in mind. Todays manufacturers know that their future success lies in being ready to embrace and run with changing circumstances, be they new market demands, technologies, customer locations, government policy or any of the myriad factors that impact the solar industry. Recognising this, DEK Solar has developed a solution that can be reconfigured on an ongoing basis according to budgetary and production needs. After all, why should a manufacturer invest in equipment before it is really necessary? This unique approach to manufacturing configurability satisfies the demands of even the most progressive solar cell manufacturers, allowing them to protect their initial investments into the future, no matter how unclear that future may be, and enabling them to build their capabilities as their needs grow, with a selection of capabilities that make Eclipse quite simply the most versatile, best-designed metallisation solution for the solar industry today. When Introduced The Eclipse platform was introduced at EU PVSEC in September 2010 Customer Benefits Customers benefit from DEKs process knowledge and applications expertise, which has been gathered over more than 40 years. Eclipse adds value by maximising utilisation, yield and productivity. DEKs global infrastructure, built expressly to support DEKs print platforms and process products in every market sector and any part of the world, gives customers confidence that support and parts are available whenever they need it. |
Edwards Vacuum, Ltd |
STP-iXA 2206/iXA3306 Family of MagLevTurbomolecular Pumps |
![]() Description The STP-iXA2206/iXA3306 are a family of fully-integrated magnetically-levitated turbomolecular vacuum pumps developed for CIGS solar, glass coating, semiconductor and LCD applications. The iXA 3306 offers an industry-leading pumping performance of 3200 liters per second and improved throughput at high gas flows. The STP-iXA2206 offers a pumping performance of up to 2200 liters per second. These mag-levturbopumps have a small footprint and are easy to install. They feature an integrated onboard controller that eliminates the need for control rack unit mounting and a connection cable between the pump and the control unit, saving installation time, space and cost. Their compact design and size compatibility with previous models simplifies upgrades from existing pumps. Challenge They specifically address the risk to aluminium pump parts posed by the use of gallium and selenium in CIGS manufacturing operations. These two elements readily diffuse into aluminium, reducing its strength. In the case of rapidly spinning pump rotors, this can lead to catastrophic failure. Critical aluminium parts in this family of pumps are coated with nickel which protects against damage. In addition, they offer a hot running option that reduces the risk of undesirable deposition on pump surfaces. Problem Solved The STP-iXA2206/iXA3206 address this problem by coating critical aluminum pump parts with nickel, which protects against gallium and selenium diffusion, and with their hot running option. This option, which permits operation at precisely controlled elevated temperatures, without degrading pumping capability, has been shown to extend pump lifetimes by two times or more, depending on the gas being pumped. Noteworthy They are fully integrated mag-lev TMP pumps that deliver best-in-class performance in an easy-to-install pump with a small footprint that can provide a pumping solution to all application tools. They have integrated controllers that allow the tool manufacturer to save valuable rack space, while eliminating cumbersome cable runs. They have been optimized for CIGS manufacturing applications. Product In Detail Magnetically levitated turbomolecular pumps use a proven vacuum-pumping technology that is already in wide use in the semiconductor and flat panel industries. This type of vacuum pump employs a multi-axis magnetic bearing system to suspend the rotor during operation, requiring no lubrication eliminating any risk of contamination, while also minimizing friction, vibration, noise and maintenance requirements. Pump noise and vibration increase the cost and complexity of the vacuum system by requiring the pump to be installed farther from the process tool. Excessive noise is also a hazard to personnel. Mag-lev TMPs offer longer maintenance intervals than ball-bearing turbo pumps, while providing a cleaner vacuum environment than diffusion pumps. They also deliver extended operating lifetimes. Edward�siXA TMPs, for example, have a mean time between failures greater than 9.5 years. Their ability to rapidly evacuate the process chamber to the desired level of vacuum also helps reduce process time. Unlike ball bearing pumps, mag-lev TMPs can be installed in any configuration, including inverted mounting. This provides greater installation ease and flexibility, as well as helping to save valuable factory real estate. Advance mag lev TMPs incorporate built-in diagnostic capabilities that provide real-time information regarding pump health and rotor balance, preventing unforeseen maintenance problems, thereby increasing process tool uptime. They also integrate the controller and power supply, reducing space requirements and eliminating awkward cable runs. Mag-lev TMPs are very energy efficient, consuming only 230 W at a pumping speed of 3,000 slm. A diffusion pump uses 5,000 W at the same speed. Given the geographic location of many solar manufacturing operations, pumps should be designed to handle humid, dusty conditions. The International Protection Rating, defined in international standard IEC 60529, classifies the degree of protection provided against the intrusion of solid objects, dust, accidental contact and water in electrical enclosures. Pumps rated IP54 are certified to offer protection against dust (IP5) and against water spray (IP4). Such pumps can be safely used in humid and dusty environments and help reduce air conditioning requirements within the fab. Innovation The combination of high technology features, IP54 rating, and materials compatibility combined into a single package is special in itself, but when coupled with superior flow capability, the STP-iXA2206/3306 series of pumps provides significant advantages to users. When Introduced Dec. 1, 2010 Customer Benefits The nickel coating on critical pump parts, combined with the hot running option can double the operating lifetime of the pump. They also offer best-in-class pumping performance, a superior vacuum environment, and extended maintenance intervals, all of which help reduce manufacturing costs. At the same time, these pumps are easy to install, in a variety of configurations, and have a small footprint, thereby helping to save valuable fab real estate, as well as installation costs. |
GP Solar GmbH |
GP ISO-TEST .Waf |
![]() Description The GP ISO-TEST .Waf is a compact tool for testing the isolation resistance between front side and rear side of diffused wafers after wet chemical edge isolation. The testing tool is a successor of GP Solars existing measuring tool GP ISO-TEST .Waf. In addition to a completely new design, the measuring tool offers numerous updates in technology and handling. The system is an ad-line tool for fast process control and optimization of wet chemical edge isolation process. It is specially recognized in semi-automated production lines with easy option to sample wafer and test during process run. Challenge The p/n junction for light-generated charge carriers is usually created by diffusion of phosophor. During the process an unwanted emitter is created on the back of the cell which if not separated from the front could cause a short circuit. For etch isolation, plasma etching as well as wet chemical etching is applied directly after diffusion. The most problematic topic is secure contacting of the wafer to measure isolation quality. The GP ISO-TEST .Waf is specially designed for testing edge isolation directly after the wet chemical or plasma-based process to improve the stability of the isolation process and increase the yield. Problem Solved The tool features two plates made of synthetic material with leveled metallic contact tips for monitoring the edge isolation directly after diffusion with the top contacts integrated into the swinging closing lids. The special design of the contacting unit achieves almost zero breaking losses. A proprietary electronic control box was designed for measuring by adjusted, constant current. Up to 4 different currents can be applied to the tips and the edge resistance for all four edges can be measured and displayed separately and interconnected in parallel. Noteworthy There is no product in the market which may be compared to GP ISO-TEST .Waf. It tests edge isolation by wet chemical etching reliably. The soft- and hardware design allows detailed classification settings for process engineers and very easy operation procedures. Therefore it is a reliable easy-to-use tool for operators in PV production. The GP ISO-TEST .Waf may be used inline as well as separately. Product In Detail The GP ISO-TEST .Waf is a reliable contacting tool for testing the wafer edge isolation resistance between front side and rear side of diffused wafers after wet chemical edge isolation. Spring loaded contact pins which are recessed in suspended plates contact the wafer from top to bottom directly after diffusion. The top contacting pins are integrated into the swinging closing lids. Measurement electronics, control buttons and the graphical display are integrated in the unit. All functions are configurable in a guided setup mode. For testing the isolation resistance, the wafers are placed into the GP ISO-TEST .Waf in a position defined by mechanical position bars. The measurement starts automatically when the contact tips contact the wafer surface after closing the flexible lid. A constant current is applied to the tips and the edge resistance may be measured simultaneously or parallel for all edges. The results are displayed instantaneously. By configuring limited measuring values the sample classification based on the defined limits can be indicated with colored LED and acoustical signal. Innovation The GP measuring tool is the first and only inspection system on the market to measure the edge isolation process by wet chemical etching. The GP ISO-TEST .Waf is unique and captivates with its design and the ease of handling. The measuring tool delivers reliable process monitoring result and increases production efficiency. When Introduced The predecessor was introduced in 2002. The successor GP ISO-TEST .Waf entered the market in February 2011. Customer Benefits The customers benefit from reliable results, easy handling and improved wafer quality. |
PV Process Improvement Award |
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EVA extrusion line |
Description Extrusion system for manufacturing EVA encapsulant Product Challenge The production of EVA on conventional extrusion systems which are using calendars the production speed is limited because the EVA film is very sensitive to get tension included. This tension leads to a strong shrinkage after heat up the film again during the laminating process. Conventional extrusion systems are using annealing ovens to eliminate the shrinkage. The Breyer "process unit" allows a higher speed compared to a calendar production by keeping the tension resp the shrinkage much lower. No annealing devices are necessary. Due to a special surface of the EVA film no interlayer or carrier paper is necessary. In this way the new process safes space, resources and energy. Problem Solved In the downstream process the way of cooling in the especially developed process unit avoids the later shrinkage. By special screw and flat die design the material will be molten very carefully. Product in Detail Extrusion of 300 - 600 kg/h, using filtering systems and meltpump for a low temperature production.Carefully cool down of the melt when applying to the cooling surface. This in general allows a low tension resp low shrinkage extrusion. Innovation No calendar, no annealing, no interlayer, no carrier layer is necessary. When Introduced End of 2009 Customer Benefits Customer can produce an encapsulation film with higher quality. Means the film has lower shrinkage, does not need interlayer film or carrier paper. The system consumes lower energy as regular extrusion systems because no annealing is necessary |
Crosslight |
APSYS TCAD modelling tool |
Description APSYS is a TCAD modelling tool designed for the semiconductor industry. It includes many advanced models and can provide accurate predictions of semiconductor device behaviour. This can be used to optimize device design and test new ideas while avoiding the expenses of experimental trial-and-error. Challenge In multi-junction III-V concentrator solar cells, it is important to match the current of all the sub-cells to reach maximum efficiency. This can depend on a number of factors including the layer thicknesses, material quality, doping profiles, incoming light spectrum, etc... Problem Solved APSYS can include all important effects in the model and predict the I-V curve, EQE spectrum and internal temperature and current flow of the device. It can help a cell designer optimize their design and investigate the causes of device failures. Noteworthy APSYS has very reliable interband tunnelling models with numerical convergence and physical accuracy that are superior to that of our competitors. APSYS is also capable of 3D modeling and is the only TCAD solver that can boast of hardware GPU acceleration to speed up computations of large problems. In Detail APSYS is based on a finite element solution of the Poisson and drift-diffusion equations. It includes a number of important physical models including but not limited to: trap (SRH), radiative and Auger recombination mechanisms, interband and intraband quantum tunnelling. It also includes quantum mechanical solvers for quantum wells and quantum dots Optical modelling is done using a plane wave transfer matrix method for layered structure and finite-difference time-domain (FDTD) for textured surfaces. Innovation APSYS is known for its very efficient mesh allocation mechanisms and its sturdy numerical convergence under a variety of bias conditions. When Introduced APSYS was introduced around 1995. However, the numerical models needed to model III-V multi-junction concentrator cells were introduced in 2006. Customer Benefits Customers benefit from being able to optimize their device designs without having to pay for numerous wafer growths to iteratively improve the design using experiments. It can also help investigate the causes of device failures or explain various phenomenons that might not be apparent in simpler analytical models. |
Vincent Industrie & Appollon Solar |
New Industrial Cells Encapsulation (NICE) |
New Industrial Cells Encapsulation (NICE) process represents an innovative and alternative to the module encapsulation.
The Nice Module production line is designed to produce double glass and glass/metal modules up to 6x10 cells with front and back contracts or or with back contacts only, as well as thin modules. |
Meier Solar Solutions GmbH |
STACOLAM |
![]() Description The STACOLAM is a highly efficient encapsulation system for solar modules and PV equipment. This Meier Solar Solutions innovation is a 10-level stack laminator for thin-film and crystalline processes that replaces more than four conventional laminators. Challenge Solar module material is extremely sensitive. However, laminating the modules can ensure a longer service life. The aim is to protect them from the negative effects of weather. Problem solved The laminator encapsulates and laminates the sensitive material of the modules, thereby providing long-term protection of the solar modules from the negative effects of weather. Noteworthy The new STACOLAM stack laminator is the most effective laminator worldwide, capable of laminating 1.1 million modules in a single year. In detail. The STACOLAM is a highly efficient encapsulation system for solar modules and PV equipment. This Meier Solar Solutions innovation is a 10-level stack laminator for thin-film and crystalline processes that replaces more than four conventional laminators. The STACOLAM stack laminator represents the latest generation in laminating and encapsulating technology and is justifiably considered to be a stepping stone to the future. With up to ten levels, the STACOLAM can achieve a capacity of 250 MW per year, making it the most effective laminator worldwide. The STACOLAM can simultaneously laminate a total of 40 modules per cycle with just about the same space requirements as a conventional laminator. The STACOLAM boasts a yearly capacity of 1.1 million modules. Countless technical features make the STACOLAM, which is available in a range of sizes, unique throughout the industry. An easy-to-remove membrane frame and cutting-edge heating plate technology mean the STACOLAM is extremely simple to service, saving time and money. A servo motor ensures high-precision positioning of the solar modules. STACOLAM also boasts an extremely fast transport rate (max. 25 m/min.). An active pneumatic pin hub at every level ensures the required laminating process reliability. Thanks to technical improvements, the STACOLAM provides our customers with immense advantages in terms of space, speed and encapsulating capacity. Furthermore, it improves environmental and working conditions for our partners and clients over the long term. Introduced to market The first STACOLAM was launched onto the market in 2007. Customers benefit The new STACOLAM provides our customers with immense advantages in terms of space, speed and encapsulating capacity, whilst improving environmental and working conditions for our partners and clients. |
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Rehm Thermal Oxidiser |
Description A new thermal oxidation process from Rehm Thermal Systems has eliminated the challenge of residue contamination from photovoltaic metallization. In order to minimise maintenance and provide a cleaner process chamber, Rehm has created the Thermal Oxidiser to enhance the performance of its RDS Drying Systems. Thermal oxidation is a process during which the volatile organic constituents and the hydrocarbons (VOCs) in the metallization pastes react with oxygen, and are decomposed. The goal is to burn the long-chain molecules in the vapour or smoke and transform them into readily volatile, non-condensable substances. These are then easily discharged from the system, to significantly reduce the potential of condensation and in turn, minimise system maintenance. Due to the arrangement of the heater and the granulate pack in Rehm�s RDS Drying Systems results in a very compact, thermal reactor which requires little additional energy to reduce energy consumption even further. Rehm�s thermal oxidation process involves heating the gas to a temperature greater than 500°C. The molecules crack at these high temperatures and combine with atmospheric oxygen which is present within the system. In order to oxidise hydrocarbons in an energy-efficient manner at low reaction temperatures of approximately 500°C, catalyzers are installed downstream from the heating chamber. This results in a thermal reactor which is dimensioned for solar dryers such that a gas exchanger of greater than 40-fold assures reliable removal of the vapour or smoke which occurs in the process chamber. Challenge During the 200°C to 350°C curing process involved in metallization, significant quantities of vapour and smoke are produced which must be reliably exhausted from the process chamber in order to avoid contamination and yield loss. However, since there is a wide variation in paste compositions associated with solar metallization, it is not always possible to customise a suitably effective filter or condenser to manage the released vapour or smoke. Problem Solved The introduction of Rehms Thermal Oxidiser uses an innovative thermal oxidation process to reduce emissions from solar dryers and firing systems during the metallization of crystalline solar cells. With the Thermal Oxidiser, emissions remain well below the statutory limitations for emissions of pollutants e.g. TA-Luft, Germanys Clean Air Act. The collection efficiency reaches 99.5%, making a significant contribution to lower maintenance costs for solar dryers and firing systems. Noteworthy In general, thermal oxidation systems can be used for almost all organic pollutants and are thus a very good alternative to condensate discharges. The main advantage over the condensate separation is significantly reduced maintenance costs of solar dryers and firing systems. In Detail The composition of pastes for the metallisation of solar cells can be highly varied. This does not concern the actual metal content (silver or aluminium powder) but the other additives that are key to the printing properties of the paste and the baking and sintering characteristics. The proportion of these substances can be up to about 25 % by weight, of which the largest share is the organic medium in which the solids (metal powders, metal oxides, inorganic binders such as glass frit) are dispersed. Typically, after being printed onto the solar cell, the paste is dried at temperatures from 200 to 350 °C and, in a subsequent firing process, baked into the solar cell at temperatures of 800 to 1000 °C. During drying and firing of the pastes, fumes and smoke are generated. These must be safely extracted from the process chamber to avoid contamination of the system as far as possible. The fumes/smoke arise from the volatile components of the organic medium, which can consist of various organic liquids that typically also contain thickeners and stabilisers. The operator of a conveyor dryer does not usually know the exact composition of the metallisation paste used and its volatile constituents. Therefore, a filter/collection unit for the vapours/fumes cannot be custom-made, but must be designed for a broad range of deposition of various ingredients. At the same time, it need be expected that after passing through the filter/collection unit, the emissions will fall substantially below the limitations set by legislation. Very often, so-called condensate separators are used in this process. On the one hand, the collection efficiency is limited, and on the other hand, the mandatory disposal of the accumulated condensates is expensive. For these reasons, Rehm has taken the known method of thermal oxidation for solar systems and implemented it in an innovative way. The thermal oxidation is a process that takes the volatile organic components and hydrocarbons from the metallisation paste and binds them with oxygen, essentially breaking them down into water vapour and carbon dioxide. The goal is to burn the long-chain molecules in the vapours/fumes and convert them into easily volatile substances that condense only with difficulty. These can then be easily removed from the system, which thus drastically reduces the potential for condensation within the drying system. The thermal oxidation is initiated by the heat of the exhaust gas at a temperature >750 °C. At the high temperatures the molecules break down and bind to the available oxygen in the system. To achieve these high temperatures, Rehm deploys strictly electrical heating systems; the use of open flames is deliberately avoided. The risk of NOx gases forming is thus ruled out as far as possible. With thermal oxidation, emissions are well below the legal limits set for emissions (e.g. Germanys Clean Air Act). Good separation behaviour was achieved not only for volatile organic hydrocarbons (VOCs), but also for the particulate distribution. A clean gas value of particles below 0.2 microns was gravimetrically determined by ILK (the Institute of Air Handling and Refrigeration in Dresden) to be about 2 mg/m³. The oxidiser also copes well with different concentrations, as other measurements by ILK document. At five times the concentration of the model pollutant toluene, the collection efficiency remained > 99.5 %. The oxidiser contributes significantly to minimising the condensation potential, thus significantly reducing the cost of maintenance for dryer systems. As no more condensate can be formed on the clean gas side, the main extraction system of the fabrication plant remains visibly cleaner. A highly positive side effect is the markedly lower odour of solar dryers with an integrated oxidiser. Innovation In general, thermal oxidation systems can be used for almost all organic pollutants and are thus a very good alternative to condensate discharges. The main advantage over the condensate separation is significantly reduced maintenance costs of solar dryers and firing systems. When Introduced Operating since January 2011. Customer Benefits The main advantages of thermal oxidation are: Reduction in maintenance costs, no disposal of condensate Secure compliance with the legal requirements for emissions Universally applicable for various metallisation pastes Proven, broadband method Robust systems engineering Low energy consumption, low operating costs Decreased odour of solar dryers |
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Soldering Table |
![]() Description The soldering table is a stand-alone soldering station for solar cells (identical soldering station as the Somont stringers) for material testing and qualification under production conditions. The station is compact and cost-efficient. New materials (cells, ribbons, flux) can be tested and verified much faster. This leads to a drastic time and cost reduction for the development process which would be normally carried out on the production machines. Challenge Until now the R&D departments have been faced with following issue: If there has been f.i. a new cell development, this new cell has to be tested for solderability on the stringer. But the production has the target to produce a certain amount of modules/day. Consequently it is difficult for the R&D to get valuable production time on a stringer for testing new materials (cells, ribbons, flux...) Problem Solved The soldering station is a cost and space-saving solution for every laboratory /development department. The station delivers excellent quality soldering results with high peeling forces. New developments (cells, ribbons, pastes, flux) can be tested more intense and without any time pressure on the soldering table and verified much faster afterwards on the stringer. This leads to a drastic cost reduction. Noteworthy The soldering table is a compact, cost-efficient tool, which can be set up in every laboratory/development department. We have not found a similar product on the market. Product In Detail The soldering table is a self-contained soldering station for solar cells at which materials can be tested under conditions similar to those of actual production, since the soldering unit is identical to those on Somont stringers. Thanks to its compact size and economical price, the new equipment is suitable for use in any laboratory or development unit. Newly developed technology and/or materials can be tested and subsequently verified on the stringer much more quickly than was previously possible. This results in drastically reducing the time and costs in terms of the equipment and production capacity required for development processes. Until now, for example, development departments were always faced with the problem that the solderability of new solar cells for the market had to be tested directly on the stringer in the companys production line. This meant that valuable production time was lost for testing purposes. The new soldering table allows fast, and cost-effective verification of new developments (solar cells, ribbons, flux, pastes etc.) without having to interrupt production. There will no longer be a conflict of interest between development and production departments, and large numbers of materials will be able to be tested without any time pressure. Innovation The soldering table is the ideal tool for various target customers: For module, cell, ribbon, flux, paste manufacturers as well as institutes and laboratories. Until now most of the above mentioned target customers have tested/soldered their new developed materials manually or as mentioned under point 1 on a stringer which is very expensive and difficult to get the testing time of the production. To draw conclusions from manual soldering/testing for later automated stringer production is therefore difficult. With the soldering table the customer receive high quality and reproducible soldering results with excellent peeling forces due to Somont Soft Touch Soldering. Testing phases can be done more cost effective (no more valuabe production time on the stringer is necessary anymore). Consequently testing phases can be done more intense without any time pressure. It is time saving as the customer does not need to wait to get a stringer in the production for his testing periods. Thus new developments can be introduced on the market faster. Customer Benefits The customer benefits are: - Cost effective - no loss of valuable production time / output - High quality and reproducible soldering results with excellent peeling forces due to Somont Soft Touch Soldering - Recipe pre-qualification and simulation - all stringer recipes can be pre-tested --> faster material validations are possible - Time saving for the R&D department - no more conflict of interests between R&D and production, no more waiting to get a stringer for testing new materials --> new developments can be introduced much faster on the market than in the past - Flexible - a variety of different materials can be tested without any time pressure, test phases can be done more intense - Easy to handle due to intuitive HMI (same as on Somont stringers) to set up parameters - Space saving - can be set up in any laboratory or development department - Fast reaction time to material changes - innovations on the market can be introduced and tested immediately |
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