CIGS, thin film solar cells of Copper, Indium, Gallium, and Selenium semiconductors have long been a potential challenger to conventional solar cells. The hope has been that an inexpensive printing process (Roll to Roll) would lead to electric power from photo voltaic system that would compete in cost per watt with other sources.
This blog reported before on improvements in the manufacturing process. As manufacturing gears up, efforts continue to improve the efficiency of flexible, photo voltaic laminates. FC Business Intelligence reports that “scientists under the leadership of Dr. Ayodhya N. Tiwari at the Laboratory of Thin Film and Photovoltaics, EMPA in Switzerland have been developing thin-film solar cells based on Cu(In,Ga)Se2 semiconductor material.”

“Flexible thin-film solar cells on polymer film with a new record efficiency of 17.6% have been developed by the scientists at the Swiss Federal Laboratories for Material Science and Technology (EMPA). The conversion efficiency record has been independently certified by the Fraunhofer Institute for Solar Energy Systems (ISE) in Freiburg, Germany.” Because of their lower cost, TFPV (Thin Film Photo Voltaic) panels are becoming the choice for BIPV (Building Integrated Photo Volatic), whereas developers so far rarely choose these less-efficient panels for utility-scale solar farms.
The research group at EMPA working in close collaboration with FLISOM Company, has developed a process that resulted in a remarkably high 17.6% efficiency solar cell which is an independently certified highest efficiency record for any type of flexible solar cell on polymer film reported up to now.
This development is challenging because most of the polymer films used as substrate, lack thermal stability for growth of high electronic and structural quality CIGS solar cell layers at high temperatures. High thermal expansion coefficient of polymer causes a large stress in the layers deposited at high substrate temperature, resulting in cracks and delamination of the solar cells from the substrate. Adrian Chirila and other colleagues, working under the supervision of Dr. Tiwari have been developing a vacuum evaporation process for growth of high quality CIGS absorber layers at sufficiently low temperature of about 450 °C. This is suitable for polyimide film as a flexible substrate for roll-to-roll manufacturing.
Moving from a previous record value of 14.1% to a new record of 17.6% was achieved by reducing the optical and electronic losses in the CIGS solar cell structure. The most important factor was the optimisation of the composition gradient of Ga across the CIGS layer thickness and an appropriate incorporation of Na for doping during the final stage of the growth process. Consequently, an optimum band gap grading and larger grain size in CIGS layer resulted in a substantial increase in the efficiency of flexible solar cells. The photovoltaic measurements performed under the standard test condition at ISE Freiburg confirmed 17.6% efficiency with Voc = 688 mV, Isc = 34.8 mA/cm2, FF = 73.6%.

“Lower thermal budget and roll-to-roll manufacturing of high-efficiency flexible CIGS solar cells will pave the way for substantial reduction in production cost of next generation of solar modules produced on large industrial scale in future.
The low temperature process for CIGS deposition offers a unique advantage that the same process and equipment can be used for polymer as well as metal foils. Flexible CIGS solar cells on metal foils with highest efficiency of ca 17.5% are generally grown at high temperatures above 550 °C, while lower efficiencies were obtained on polymer films because of lower deposition temperature. This successful development has closed the efficiency gap between the solar cells on polymer and metal foils. This solar cell processing can be adapted for roll-to-roll manufacturing of monolithically connected solar modules on polymer films.

As the efficiency of flexible, photo voltaic laminates improves, their application will expand. An experimental solar-powered plane successfully completed a 24-hour test flight, demonstrating that an aircraft can collect enough energy from the sun during the day to stay aloft all night.



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Speaking of staying aloft, Network World reports that DARPA (Defense Advanced Research Projects Agency) “inked an agreement with Boeing to build the SolarEagle.
“One of the more unique unmanned aircraft concepts took a giant step toward reality… the project will build a UAV (Unmanned Aerial Vehicle) “capable of remaining at heights above 60,000ft for over five years.”
“Boeing says the first SolarEagle under the $89 million contract could fly as early as 2014.”
“Walmart has announced that it would install 15 megawatts’ worth of solar arrays on as many as 30 of its stores in California and Arizona… The world’s biggest retailer specified that many of the new solar installations should use thin-film photovoltaic panels.”
Photo: Walmart
“Walmart installed thin-film solar cells on their store in Mountain View, Calif.”
Instead of attacking the world’s biggest retailer directly, Emperor Fossil’s minions try to stop the supply of low-cost Chinese-made solar panels by hook or by
Republicratcrook.Image credit: Pink Dispatcher/Flickr
Solar photovoltaic (PV) cell manufacturers produced a record 10,700 megawatts of PV cells globally in 2009—an impressive 51-percent increase from the year before. While growth in 2009 slowed from the remarkable 89-percent expansion in 2008, it continued the rapid rise of an industry that first reached 1,000 megawatts of production in 2004. By the end of 2009, nearly 23,000 megawatts of PV had been installed worldwide, enough to power 4.6 million U.S. homes. Solar PV, the world’s fastest-growing power technology, now generates electricity in more than 100 countries.
“World installed PV capacity has grown 16-fold over the past decade in large part due to government incentives encouraging the use of solar power. Although PV production and installation costs have fallen substantially over time, government support will be necessary until solar reaches grid parity (price competitiveness) with heavily subsidized fossil fuels. Incorporating fossil fuels’ largely externalized costs, such as climate change and pollution-related illnesses, into the price of fossil-generated electricity would further accelerate PV’s march to grid parity.”
Read more Treehugger posts about solar production:
I can hear Arlo singing it now:
“Comin’ into Los Angeles
Bringin’ a few Megawatts Chinese
Don’t touch my bags, if you please
Doktor Chu”
O.K. so in this imagining Donald Fagen and Walter Becker are sitting in
BTW: J.Matthew Roney at the Earth Policy Institute provided an excellent summary of TFPV in the Eco-Economy Indicator that he wrote for HuffPo.
Renewable Energy World reports that several firms are “racing to market with micro-inverters, devices that convert direct current (DC) from a single solar module (panel) to alternating current (AC).”
Micro inverters and AC modules are overcoming the drawbacks in central inverter architecture, which now dominates photo voltaic installations.
One advantage for the BIPV consumer is that Asian development and production is driving down the price. Susan Kraemer relays word from 3S Swiss Solar Systems.
Another report on flexible thin-film solar cells on polymer film. “Researchers from Iowa State University and the Ames Laboratory have developed a process capable of producing a thin and uniform light-absorbing layer on textured substrates that improves the efficiency of polymer solar cells by increasing light absorption.”
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