Abstract:Thin‐film device processing relies heavily on the integration of a variety of materials and a wide array of process steps. These include in some instances, the integration of ‘wet’ (chemical etching) and ‘dry’ (deposition and plasma etching) process steps. As substrates are stepped through the process sequence, there are many surfaces that ultimately become interfaces that can have a dramatic impact on ultimate device performance. However, in thin‐film R&D, these issues are not always carefully considered. Thi… Show more
“…8,[41][42][43] Among the problems can be the inability to transfer or integrate certain processes from the lab to a manufacturing environment (i.e., from small stationary batch systems to larger areas and volumes at high throughput), poorer control of interfaces or composition profiles in large volume chambers, and need to modify the process for higher yield and through-put causing a trade-off with efficiency. For example, it may be more cost effective to operate at a much higher deposition rate in manufacturing and to accept a lower efficiency compared to a slower process optimized for higher efficiency.…”
Section: Processing and Manufacturing Issues For Tfscmentioning
Thin film solar cells (TFSC) have passed adolescence and are ready to make a substantial contribution to the world's electricity generation. They can have advantages over c-Si solar modules in ease of large area, lower cost manufacturing and in several types of applications. Factors which limit TFSC module performance relative to champion cell performance are discussed along with the importance of increased throughput and yield. The consensus of several studies is that all TFSC can achieve costs below 1 $/W if manufactured at sufficiently large scale >100 MW using parallel lines of cloned equipment with high material utilization and spray-on encapsulants. There is significant new commercial interest in TFSC from small investors and large corporations, validating the thin film approach. Unique characteristics are discussed which give TFSC an advantage over c-Si in two specific markets: small rural solar home systems and building integrated photovoltaic installations. TFSC have outperformed c-Si in annual energy production (kWhrs/kW), have demonstrated outdoor durability comparable to c-Si and are being used in MW scale installations worldwide. The merits of the thin film approach cannot be judged on the basis of efficiency alone but must also account for module performance and potential for low cost. TFSC advocates should promote their unique virtues compared to c-Si: lower cost, higher kWhr/kW output, higher battery charging current, attractive visual appearance, flexible substrates, long-term stability comparable to c-Si, and multiple pathways for deposition with room for innovation and evolutionary improvement. There is a huge market for TFSC even at today's efficiency if costs can be reduced. A brief window of opportunity exists for TFSC over the next few years due the Si shortage. The demonstrated capabilities and advantages of TFSC must be proclaimed more persistently to funding decision-makers and customers without minimizing the remaining challenges.
“…8,[41][42][43] Among the problems can be the inability to transfer or integrate certain processes from the lab to a manufacturing environment (i.e., from small stationary batch systems to larger areas and volumes at high throughput), poorer control of interfaces or composition profiles in large volume chambers, and need to modify the process for higher yield and through-put causing a trade-off with efficiency. For example, it may be more cost effective to operate at a much higher deposition rate in manufacturing and to accept a lower efficiency compared to a slower process optimized for higher efficiency.…”
Section: Processing and Manufacturing Issues For Tfscmentioning
Thin film solar cells (TFSC) have passed adolescence and are ready to make a substantial contribution to the world's electricity generation. They can have advantages over c-Si solar modules in ease of large area, lower cost manufacturing and in several types of applications. Factors which limit TFSC module performance relative to champion cell performance are discussed along with the importance of increased throughput and yield. The consensus of several studies is that all TFSC can achieve costs below 1 $/W if manufactured at sufficiently large scale >100 MW using parallel lines of cloned equipment with high material utilization and spray-on encapsulants. There is significant new commercial interest in TFSC from small investors and large corporations, validating the thin film approach. Unique characteristics are discussed which give TFSC an advantage over c-Si in two specific markets: small rural solar home systems and building integrated photovoltaic installations. TFSC have outperformed c-Si in annual energy production (kWhrs/kW), have demonstrated outdoor durability comparable to c-Si and are being used in MW scale installations worldwide. The merits of the thin film approach cannot be judged on the basis of efficiency alone but must also account for module performance and potential for low cost. TFSC advocates should promote their unique virtues compared to c-Si: lower cost, higher kWhr/kW output, higher battery charging current, attractive visual appearance, flexible substrates, long-term stability comparable to c-Si, and multiple pathways for deposition with room for innovation and evolutionary improvement. There is a huge market for TFSC even at today's efficiency if costs can be reduced. A brief window of opportunity exists for TFSC over the next few years due the Si shortage. The demonstrated capabilities and advantages of TFSC must be proclaimed more persistently to funding decision-makers and customers without minimizing the remaining challenges.
“…Thin films cells are quite attractive due to the fact that many of the proposed fabrication methods are relatively inexpensive and lend themselves well to mass production [2]. Inexpensive, lightweight inorganic materials such as amorphous Si, CuInSe,, and CdTe are currently being explored for space-based energy conversion [3][4][5].…”
Section: Introductionmentioning
confidence: 99%
“…Many believe it is these materials that will hold the key to inexpensive, easily deployed, large area, high mass-specific power arrays. This is due in part to the possibility of roll-to-roll processing using low-cost spray chemical deposition or direct-write approaches to producing thin film solar cells on inexpensive lightweight substrates with these materials [2,4,8].…”
“…Thin films cells are quite attractive due to the fact that many of the proposed fabrication methods are relatively inexpensive and lend themselves well to mass production. 2 Inexpensive, lightweight inorganic materials such as amorphous Si, CuInSe 2 and CdTe are currently being explored for space-based energy conversion. [3][4][5] These cells can be extremely lightweight and flexible, especially if produced on polymeric substrates.…”
Section: Introductionmentioning
confidence: 99%
“…This is due in part to the possibility of roll-to-roll processing using low-cost spray chemical deposition or direct-write approaches to producing thin film solar cells on inexpensive lightweight substrates with these materials. 2,4,8 Alternatively, next generation thin-film technologies may well involve a revolutionary change in materials to organic-based devices. The high-volume, low-cost manufacturability of organic cells will allow for square miles of solar cell production at an estimated one-tenth the cost of conventional inorganic materials.…”
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