The SELFLEX project aims to demonstrate at industrial scale cost-effective manufacturing technology for crystalline silicon (c-Si) solar cells based on self-formation, a highly innovative manufacturing concept. Self-formation has proven itself proposing industrially feasible technological solutions for c-Si solar cells with complicated spatial structure. The fundamental
principle of self-formation is an increase in complexity through structured object and chaotic media interaction.

To become competitive with conventional energy sources, new improved solar cell concepts must be developed to facilitate further growth of the photovoltaic sector. Silicon technology represents some 90 % of the world’s photovoltaic market. Using selfformation manufacturing concept enables optimization of manufacturing processes in a cost-effective way. This concept is based on the selected groups of planar bottom-up processes (‘self-formation processes’) able to form the structure of objects. Therefore, a group of processes has to be chosen, defining new and particular structures.

Approach
The SELFLEX project addresses the common issues among all different cell technologies, which are related to manufacturing and scaling up:
• Equipment: the SELFLEX proposed approach is flexible and adaptable to any technological
infrastructure used for crystalline solar cells manufacturing.
• Patterning: by applying self-formation, crystalline solar cell structures with efficiency from 16 % to 24 % could be manufactured with patterning processes reduced to two or even one. Therefore, significant decreases in manufacturing costs for solar cell can be expected.
• Quality control: the quality management system for performance of qualifying tests of novel manufacturing technology will be integrated for unprejudiced evaluation and proof of this solution.

Application of self-formation manufacturing concept  enables twofold manufacturing cost reductions:
• Direct reductions in manufacturing costs: by applying a self-formation manufacturing concept, crystalline solar cell structures with efficiency ranging from 16 % to 24 % could be manufactured, while the number of most costly patterning (top-down) processes can be reduced to two (or even one) and the optimized (in costs approach) manufacturing route based on bottom-up techniques is developed.
• Reductions in costs associated with implementation of new PV manufacturing technology:
the project’s approach ensures that a low rate of investments is needed for technological transfer to novel manufacturing technologies and allowing the time and cost reduction of ‘research-development- prototyping-manufacturing’ cycle needed for the introduction of the new product.

Results

During the time of project implementation, new developments in solar cell technology state of the art emerged. Thus, the SELFLEX consortium has adopted recent achievements in the area of the technology under development. Such novel solutions are for example the development of
single step selective emitters using self-formation processes, and recent laser techniques for patterning processes. They were adopted in SELFLEX technology for ensuring that most recent developments will be covered by the project activities.
Taking into account results obtained in the project so far (based on 12-month project results), possibilities to introduce into industry proposed modified technology were evaluated positively and decisions regarding launching projects for photovoltaic production plant were made. The first stage of the project was dedicated to introducing a pilot line of 2 MW for which application
to national ERDF funding schemes was submitted and successfully evaluated.
The next stage of the project foresees two 25 MW production lines development with private capital participation placing Lithuania back on the photovoltaic producers’ map.
Future prospects
Technology developed under the SELFLEX project is expected to go into production at the end of 2009, starting from capacities up to 2 MW per year and increasing capacities up to 50 MW per year within 2-3 years.
Bringing SELFLEX results to the European photovoltaic industry projects can help to reduce costs in existing and newly launched photovoltaic plants and contribute to increase the profitability of photovoltaic sector.

More information:http://selflex.protechnology.lt//index.php?option=com_frontpage&Itemid=1

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