Flexible Thin Film Solar Cells on Polymer Film

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.”

Wyandot Solar Farm
“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%.

Flexible PV Laminate
“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.

Solar Impulse
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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7 Comments

  1. jcwinnie
    Posted 2010-9-18 at 8:49 am | Permalink

    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.”

  2. jcwinnie
    Posted 2010-9-21 at 6:40 pm | Permalink

    “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.”

    Solar panels
    Photo: Walmart

    “Walmart installed thin-film solar cells on their store in Mountain View, Calif.”

    Thin-film solar currently accounts for just about 20 percent of the solar market. The most technologically advanced versions have had a difficult time grabbing market share due to competition with low-cost Chinese crystalline silicon manufacturers and a recession that has dried up investor funding.

    Enter Walmart.

    “By leveraging our global scale to become a more efficient company, we are able to lower our expenses and help develop markets for new technologies,” Kim Saylors Laster, Walmart’s vice president of energy, said in a statement. “Developing and incorporating new renewable energy sources, like thin film, reduces energy price risk and aligns very well with our commitment to solving business challenges through technology.”

    Walmart signed a deal with SolarCity, a leading Silicon Valley solar installer, to manage the project. SolarCity will install and own the photovoltaic arrays on Walmart stores and sell the electricity to the retailer.

    SolarCity’s chief executive, Lyndon Rive, told me Monday that the company will install thin-film solar arrays made by First Solar and Miasolé.

    First Solar, which makes an older variant of the technology called cadmium telluride, is the world’s biggest thin-film manufacturer and Walton family members were early investors in the Tempe, Ariz., company. First Solar is also an investor in SolarCity, which already uses its photovoltaic panels.

    Miasolé, a Silicon Valley startup, is one of a number of companies that has developed a type of thin-film solar cell called copper indium gallium selenide, or CIGS, that offers the promise of higher efficiencies and lower costs.

    “Walmart wanted to see thin-film be adopted and made that a requirement in the bidding process,” says Rive.

    He noted that the retailer did not dictate the percentage of stores that should receive thin-film solar arrays but expects the technology will account for the majority of installations over the next year.

    “There’s no hard and fast number but they’d like us to do as much as possible,” said Rive.

    Another twist in the Walmart deal is that the company collaborated with the Environmental Defense Fund (EDF) to develop the criteria used to select SolarCity. (EDF, which maintains an office near Walmart’s headquarters in Bentonville, Ark., has long worked with the retailer on sustainability initiatives.)

    The goal, Walmart said in a statement, “was to identify the most innovative solar technologies that would create benefits on three fronts — to the environment, technology, and financial viability.”

    The bigger ambition, though, is to shape the solar market, as Walmart acknowledged.

    “The company’s large scale on-site installation of CIGS could help further the development of this technology and bring it to market quicker, while use of cadmium telluride thin film could help make the case for other businesses to adopt the technology for on-site commercial use.”

  3. jcwinnie
    Posted 2010-9-21 at 7:18 pm | Permalink

    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 Republicrat crook.

    solar panel photo
    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.

    China produced 3,800 megawatts of PV in 2009, leading all countries for the second straight year. Together China and third place Taiwan accounted for 49 percent of all PV manufacturing, a share that should keep climbing as companies there grow larger and more quickly than competitors based in countries where operating costs are higher. Rounding out the top five producers in 2009 were Japan in second place, Germany in fourth, and the United States in fifth. (See data.) These traditional industry leaders have lost significant market share with the recent ascent of China and Taiwan. Indeed, Japan, which dominated the global market in 2004, controls just 14 percent today.

    While China now manufactures more than a third of the world’s PV cells, most Chinese consumers cannot yet afford the technology. Ninety-five percent of its production is exported, much of it bound for Germany, the world leader in using PV. Germany installed a record 3,800 megawatts of PV in 2009, more than half the 7,200 megawatts added worldwide. This brought Germany’s overall PV generating capacity to 9,800 megawatts, nearly three times as much as the next closest country, Spain. Already in the first half of 2010, Germany added another 3,800 megawatts.

    Italy was first runner-up in newly installed PV in 2009 with 730 megawatts, more than doubling its total installed capacity. Japan and the United States, third and fourth in both new and overall PV generating capacity, each installed close to 500 megawatts in 2009. (See data.)

    Graph on World Cumulative Solar Photovoltaics Installations, 1998-2009
    “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.”

    The most important solar incentive to date is the feed-in tariff, which guarantees generators of renewable electricity–including homeowners, private firms, and utilities–a long-term purchase price for each kilowatt-hour they produce. This powerful incentive to invest in renewables has now been adopted by some 50 countries, including Ecuador, Israel, Japan, Kenya, Pakistan, Thailand, and most of the European Union. Deutsche Bank estimates that feed-in tariffs had driven 75 percent of world PV installations as of 2008.

    Nowhere has the feed-in tariff been more effective than in Germany. In a country that on average receives about as much sunlight as cloudy Seattle, this premium payment for solar electricity has not only spurred Germany to preeminence in installed PV capacity, it has also helped grow a domestic solar industry with more than 10 billion euros ($13 billion) in annual sales.

    With PV system prices plummeting, including a 30-percent drop in 2009 alone, the German government announced in mid-2010 that in order to control costs and bring support levels in line with market conditions, it would reduce tariff rates further than the annual cuts originally stipulated by law. While industry stakeholders warn of job losses and reduced demand, the government believes that other changes, including allowing larger systems to qualify for the premium, will ensure further growth. Electricity from PV could reach grid parity in Germany by 2013.

    The United States, where total PV connected to the grid is doubling every two years, has no national feed-in policy. Instead, federal tax credits along with various state and local programs, including renewable portfolio standards (RPS) that require utilities to get a certain percentage of the electricity they sell from renewables, have been the main drivers of U.S. PV growth. With an RPS mandating 33-percent renewable electricity by 2020, California has 60 percent of the total 1,260 megawatts of grid-tied PV in the United States. Although this state still leads by a wide margin, others are growing more rapidly. Five states doubled their installed PV in 2009, including Florida, home of the new 25-megawatt DeSoto plant, currently the country’s largest PV park.

    While interest in small-scale installations keeps growing in industrial and developing countries, the PV landscape is evolving to include utility-scale, multiple-megawatt solar parks of the DeSoto variety. In September 2010, a newly-expanded 80-megawatt park in Ontario, Canada, overtook a plant in central Spain to become the largest operational PV power plant in the world. Spain and Germany currently account for 8 of the top 10 plants, but that list could soon change dramatically as ambitious projects in other countries come online. China, with scarcely 300 megawatts of installed PV at the end of 2009, has a pipeline of large projects worth a total of 12,000 megawatts. The United States has 23 projects ranging from 100 to 5,000 megawatts under development in the arid Southwest. But these simply scratch the surface of that region’s potential: harnessing a mere 2.5 percent of the annual solar radiation striking the Southwestern land suitable for solar power plants could produce as much energy as the country currently uses.

    India also is bidding to become a major player in the solar market, having announced its Jawaharlal Nehru National Solar Mission in November 2009. Named for India’s first prime minister, the Mission envisions 20,000 megawatts of grid-connected solar power and 2,000 megawatts of distributed, off-grid solar installations by 2022. The planned capacity build-out will be roughly half PV and half concentrating solar thermal power, another budding solar technology. If India meets its target, it would be a tremendous boost for a country with vast solar resources but an estimated 400 million people who lack electricity.

    Even with the lingering effects of the global recession, more than 16,000 megawatts of PV are slated to be installed in 2010. Germany will likely again account for half of the newly added capacity, as developers rush to finish projects before cuts in the feed-in tariff fully take hold. Beyond 2010, analysts expect annual PV installations to be more evenly distributed among an expanding roster of countries. With costs dropping, economies of scale growing, and governments realizing the benefits of this limitless, climate-friendly resource, the future for solar power looks bright.

    Read more Treehugger posts about solar production:

  4. jcwinnie
    Posted 2010-9-21 at 7:37 pm | Permalink

    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.

    Made of semiconductor materials, PV cells convert solar radiation directly into electricity. Rectangular panels consisting of numerous PV cells can be linked into arrays of various sizes and power output capabilities—from rooftop systems of one to several kilowatts to ground-mounted arrays of hundreds or even thousands of megawatts. (One megawatt equals 1,000 kilowatts.)

    There are two broad categories of PV: crystalline silicon and thin-film. Crystalline silicon cells account for more than 80 percent of the annual PV market. But thin-film PV, a relatively new technology that is less efficient but also less expensive to make and potentially adaptable to more applications, is gaining ground. In fact, First Solar, a thin-film company headquartered in Arizona but with most of its production capacity in Malaysia, was the top PV manufacturing firm in 2009, contributing roughly 10 percent of world PV production.

  5. jcwinnie
    Posted 2010-9-30 at 8:08 am | Permalink

    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.

    Shortcomings inherent to the central inverter architecture are creating opportunities for a range of new technologies, with a growing number of companies developing products and technology to generate more power from the PV panels already on the market.

    Unlike a central, or string inverter, that aggregates and converts the power generated by an entire array of solar modules, a micro-inverter converts the DC power from a single solar module to AC. When connected to a central or string inverter, modules are typically connected in series; when they have micro-inverters, the modules are all connected in parallel.

  6. jcwinnie
    Posted 2010-11-26 at 8:26 am | Permalink

    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.

    [They make] a combination solar electric and heating module that is certified by the TÜV and available in the US through SunSlates. The company’s heavy duty MegaSlate modular roof system is tough enough to walk on, making it easy to remove and replace modules if needed. Every 100 square feet of coverage produces 1KW of power, making these comparable to regular solar panels in output, unlike most BIPV, which generally is less efficient (takes more space to make equivalent power).

    They are designed to go together in an overlapping system, with reinforced plastic sections in-between, which serve both as supporting rails for the solar laminates and as gutters. The laminates are suspended from holding hooks on the prepared roof construction, and are wired with plugs and sockets (tech details).

    The slates have matching components that can be used to cover skylight openings as well.

    Each MegaSlate module makes either electricity or a solar heated gas. The solar thermal collectors are filled with inert gas that feed into heat pump systems for heating. This means homeowners can produce both electricity and also heating, by warming water for use in radiant heating systems.

    The solar thermal collectors have the same dimensions as the photovoltaic modules, are functional and are have the added advantage of perfectly integrated appearance. The modular construction makes installation quick and easy, keeping costs to a minimum.

    This double benefit already has the effect of reducing price, by providing two sources of energy off one rooftop installation. Weight and price are the main issues with BIPV.

    But 3S Swiss Solar Systems has also been able to reduce the price, by 18% – along with the weight – from 22 kilograms to 17 kilograms.

  7. jcwinnie
    Posted 2010-12-3 at 6:55 pm | Permalink

    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.”

    “Our technology efficiently utilizes the light trapping scheme,” said Sumit Chaudhary, an Iowa State assistant professor of electrical and computer engineering and an associate of the U.S. Department of Energy’s Ames Laboratory. “And so solar cell efficiency improved by 20 percent.”
    Details of the fabrication technology were recently published online by the journal Advanced Materials.

    Chaudhary said the key to improving the performance of solar cells made from flexible, lightweight and easy-to-manufacture polymers was to find a textured substrate pattern that allowed deposition of a light-absorbing layer that’s uniformly thin — even as it goes up and down flat-topped ridges that are less than a millionth of a meter high.

    The result is a polymer solar cell that captures more light within those ridges — including light that’s reflected from one ridge to another, he said. The cell is also able to maintain the good electrical transport properties of a thin, uniform light-absorbing layer.

    Tests indicated the research team’s light-trapping cells increased power conversion efficiency by 20 percent over flat solar cells made from polymers, Chaudhary said. Tests also indicated that light captured at the red/near infrared band edge increased by 100 percent over flat cells.

    Researchers working with Chaudhary on the solar cell project are Kai-Ming Ho, an Iowa State Distinguished Professor of Physics and Astronomy and an Ames Laboratory faculty scientist; Joong-Mok Park, an assistant scientist with the Ames Laboratory; and Kanwar Singh Nalwa, a graduate student in electrical and computer engineering and a student associate of the Ames Laboratory. The research was supported by the Iowa Power Fund, the Ames Laboratory and the Department of Energy’s Office of Basic Energy Sciences.

    Science Daily via Climate Progress

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  2. By Solar Shingles – After Gutenberg on 2010-11-9 at 12:18 pm

    [...] companies scale up R2R (Roll-To-Roll) manufacture of PVL (Photo Voltaic Laminates), a.k.a., TFPV (Thin Film PV), there [...]

  3. [...] are a form of BIPV (Building Integrated Photo Voltaic), which is a favorite AG topic. With PVL (Photovoltaic Laminate) costs falling, BIPV increasingly becomes low-hanging fruit in California and [...]

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