SE-PowerFoil – Research Project on roll-to-roll manufacturing technology for high-efficient multi-junction thin-film silicon flexible photovoltaic modules

Compared with wafer-based photovoltaic panels, photovoltaic systems based on thin-film photovoltaic panels already are the lowest cost, despite their (still) lower efficiencies.

Thin-film silicon-based flexible photovoltaic technologies have strong potential. Amorphous silicon based on flexible photovoltaic laminates with aluminium as the superstrate with moderate efficiencies of 5-6 % energy efficiency will be capable of resulting in competitive turnkey system prices. However, with tandem amorphous microcrystalline silicon (a-Si: Hμc-Si:H), tandem devices record R&D cells on glass panels have efficiencies of 13 %, so that this techno logy has the potential of reaching at least 11-12 % in production. Achieving this target for flexible photo voltaic laminates leads to the possibility of turnkey photovoltaic system prices, but issues such as transfer from batch glass process to roll-to-roll foil process and up-scaling have to be overcome.

Approach
SE-PowerFoil aims to develop deposition technology together with analysis methods. This approach seeks to lead towards high-efficiency long-lifetime photovoltaic laminate in intimate interaction with pilot fabrication. The core project activities are the integration of optimized components for a high-efficiency flexible module into the processes at the pilot-line production on 0.35 m wide foil.
Results to date
Considerable progress has been achieved for flexible tandem solar modules. Tandem a-Si:H/μc-Si:H laminates of 60 cm2 aperture with initial efficiency of 9.4 % (active area 10 %) and stabilized efficiency of 7.8 % have been made – a world record for this type of flexible photovoltaic product. Mini-modules based on the same layer configuration on glass superstrates show stabilized efficiencies of 10.1 %.

Furthermore the development of photovoltaic-diagnostics has increased knowledge about optical and electrical performance and the current limitations. In parallel the up-scaling of the silicon deposition has been demonstrated.

Future prospects
Improving roll-to-roll photovoltaic-technology based on tandem a-Si:H/μc-Si:H laminates is not limited to improving the individual materials or processes. With a combined effort, the project continues to integrate these improved materials and processes into modules and to transfer them into the roll-to-roll production line, leading to world-class lifetime and efficiency.

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