FLEXCELLENCE – Resarch Project on roll-to-roll technology for the production of high-efficiency low cost thin film silicon photovoltaic modules.

Thin-film silicon solar modules have high potential in the current booming photovoltaic market. They can be produced by means of chemical vapour deposition (CVD) processes which have high potential for low production costs per watt, and require comparatively low quantities of raw materials and energy. Flexible substrates and roll-to-roll processes go a step further towards higher production capacities and unbeatable prices. The challenge is to develop equipments and processes for cost-effective roll-to-roll production of high-efficiency thin-film modules, involving microcrystalline (μc-Si:H) and amorphous silicon (a-Si:H).

Approach

The consortium focuses on the demonstration of new substrate concepts, new technologies for interconnection and encapsulation, high efficiency and reliable single a-Si:H and tandem μc-Si:H/a-Si:H solar cells and modules. The three most promising CVD technologies (microwave
and very high frequency plasma assisted CVD, hot wire CVD) are being investigated to produce high-rate and high-quality photovoltaic material and the innovative results and concepts are directly implemented in production and in the final blueprint of multi-megawatt production lines.

Results
A back reflector system with high-reflecting and scattering optical properties was developed, produced by roll-to-roll on plastic and metal foils and implemented into solar cells and modules. In the pilot production line at VHF-Technologies, initial efficiencies up to 6.8 % could
be reported for single a-Si:H cells and the first proof of concept for tandem μc-Si:H/a-Si:H cells and modules was successful.
In addition, new insight into cost-effective monolithic series interconnection with low dead area losses was gained for flexible PV modules; a complete encapsulation process was developed and validated with the certification of large area BIPV products, and cost modelling results have shown that the target cost of EUR 0.5/W is reasonably achievable as medium-term target (5-10 years).

Future prospects
The industrial exploitation of the results has been partly achieved with many developments already implemented in production, especially a large-width electrode which is now used for the up-scaling of the production plant at VHF-Technologies. Further improvements could also be made to wards higher efficiency, lower costs, lower environmental imprint and a fair comparison of the different processes.

For More Information:http://www2.unine.ch/flex/

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