commercial flexible cigs technology...global solar energy manufacturer of flexible cigs solar...
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Commercial flexible CIGS technology
Global Solar Energy, IncUrs Schoop
IW‐CIGS Tech 7June 23rd 2016, Munich
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Global Solar Energy
Manufacturer of flexible CIGS solar modules since 1996
40 MW of production capacity / flexible CIGS
Portable flex products since 2002
PowerFLEX™ – first CIGS flex module certified since 2011
Located in Tucson, AZ USA
Light weight metal foil substrate Continuous Roll‐to‐Roll processing Compact deposition equipment Co‐evaporation, 3‐stage process Efficient material utilization High yield robust process
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Product AttributesFlexible CIGS Module Rigid Silicon Glass Module
Flexible• Can fit around curved structures• Can be integrated into materials
Rigid• Not bendable• Requires racking to install
Lightweight (< 3 kg/m2)• Enables solar application on light weight roof
structures• Can be used in applications such as consumer
goods where weight is a concern
Heavy ( > 3x heavier than flex)• Roofs require reinforcement to support weight
Durable• Won’t break• Resistant to vandalism
Breakable• Can shatter
Bonded directly to surface• Lower installation costs• Wind resistant• Resistant to theft
Requires mounting hardware• Drives up installation costs• Subject to theft• No suitable for high wind load applications
Efficiency quickly increasing• Fast development
Silicon efficiency reaches maturity• Early efficiency lead has narrowed• Efficiency increases slowing
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Stainless steel foil Apply PV coatings
PowerFLEXTM module Laminate and package
GSE CIGS Flex Module Production
Cell interconnect
Stainless Steel
Molybdenum
CIGS - Absorber
ITO - TCO
+
-
CdS - Buffer
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GSE Champion Efficiency at Scale
17.7%Total area:1.0 cm2
14.7%aperture area:7870 cm2
Scale
14%
16%
18%
16.8%Total area:68.8 cm2
Efficiency
Device
Cell
PowerFlexMini‐module
15.8%aperture area:
575 cm2
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GSE Production Device Efficiency
15.6% median effall production data
March – June 2016unyielded
16.7% median effsingle km web
produced with BKM unyielded
Excellent progress in efficiency roadmap
Production device efficiency shows a 1% increase per year (median, unyielded)
(small area cells, 1 cm2)
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OpticalCIGS500µm
Low Temperature Stage 1 (In,Ga)2Se3 Growth
Before AfterELDevice1cm
Before After
Before AfterSEM(In,Ga)2Se3100µm
Image courtesy bySteve Johnston et.al.
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Optimized Stage 1 – Device PerformanceEf
ficie
ncy_
Perc
0.550
0.600
0.650
0.700
0.750
Voc_
V
SOP Low Temp Stage 1Process
Oneway Analysis of Voc_V By Process
60.0
65.0
70.0
75.0
80.0
Fill_
Fact
or_P
erc
SOP Low Temp Stage 1Process
Oneway Analysis of Fill_Factor_Perc By Process
0.028
0.030
0.032
0.034
0.036
0.038
Isc_
ASOP Low Temp Stage 1
Process
Oneway Analysis of Isc_A By Process
Median efficiency improved by 0.5% in FF and Voc
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Cross Web Ga Ratio
Improved cross‐web composition and device performance with modified process
Optimized Stage 1 (In,Ga)2Se3 Growth
Cross Web Efficiency
SOPOptimized Stage 1 SOP
Optimized Stage 1
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New Cell Interconnection Technology
ICI is a low cost interconnect method ideally suited for flexible product design
Decrease product BOM cost by > 30%
Increase conversion efficiency by > 1.5% absolute
Increase product robustness / yield
Enable radical, new product forms
ICI submodule
Integrated Cell Interconnect (ICI) –laminating flexible PV cells to a polymer film
with patterned metallic conductors
+ 2% in direct
comparison
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GSE Technology Expansion
Roll of ICI submodulesRoll lamination
Continuous ICI front sheet
Establish GSE capacity (50 MW / yr)
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Next Generation PowerFlex Module
Improve PowerFlexTM product line by converting to ICI technology
Current generationPowerFlexTM
‐ string based ‐
Next generationPowerFlexTM
‐ ICI based ‐
Cost material and process limitations> 30% BOM cost savings
on roadmap to meet $/W 0.50 module cost
Power density > 10% more power / area
Product sizes 100 W / 200 W / 300 W 100 W / 200 W / 300 Wfurther product sizes on roadmap
Product size width: 0.5 mlength: 2 m / 4 m / 6 m
same form factor (plus additional width in future) …….
Fully certified (IEC and UL) since 2011 submitted
Available Now
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Production Yields 2015 ‐ 2016
Yields PowerFlex ICI
2015 97% 87%**
2016 (ytd) 99% 92.8%
** Initial ICI pilot line production ramp in 2015 included in data
ICI pilot line production rampPowerFlexTM module production yield
Demonstrated maturity of PowerFlexTM manufacturing lineICI manufacturing processes stabilized within 4 months
50,0%
60,0%
70,0%
80,0%
90,0%
100,0%
Dez 14 Jul 15 Jan 16 Aug 16
ICI Submodule Actual
50%
60%
70%
80%
90%
100%
Dez 14 Jul 15 Jan 16 Aug 16
PowerFlex
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Vapor barrier front sheet is the single most expensive module material
GSE BOM Cost Analysis
Module back sheet structure
Adhesive
CIGS Cell
Adhesive
Module Vapor Barrier Front Sheet
Mounting adhesive (optional)
Projected BOM cost structure stabilized at ‐ high volume 100‐300 MW‐ automated low cost ICI manufacturing
Cell25%
Inter‐connect12%
Module63%
Vapor Barrier Front Sheet
BOM cost contribution by functional group
BOM cost contribution by individual materials PowerFlex module
structure
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Vapor Barrier Requirements for Different Product Lifetime
Product differentiators are light weight and flexibility, but…Low cost vapor barrier options are critical for commercial success
Flexible Modules Lifetime Certified Weight Barrier
PowerFlexTM 25+ years ISO and UL
(2011)
3 kg/m2
(37 W/kg)
< 1‐4 mg/m2/day (38C, 90% RH)
Consumer, non‐grid 3‐10 years
Not required 50 W/kg < 50 mg/m2/day (38C, 90% RH)
5‐10 x lower barrier price ($/m2)
Consumer non‐grid 1‐2 years Not required
US Mil Std 810(2002)
100 W/kg No vapor barrier neededGSE device optimized for stability
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GSE PowerFlexTM Installations Worldwide
PowerFLEXTM module can be attached to a variety of roofing materials directly，including metal , TPO , EPDM , bitumen , etc.
PowerFLEXTM fully certified since 2011
IEC 61646, IEC 61730
UL1703
C‐UL 1703
CEC‐RPS, CEC, CE
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China ‐ Beijing Hanergy rooftop
China – Jinan covered parking
USA ‐ Landfill
Italy ‐ Milan train station
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Summary
Efficiency and production updateProduction efficiency: 15.6%
Yield: > 90% for ICI and > 99% for module manufacturing
New interconnect method1.5% efficiency and 30% cost gain
Product flexibility
Cost roadmap to $/W 0.50Cost of vapor barrier is critical
Product updateSince 2011 GSE PowerFlexTM installed in fields worldwide
http://www.solartuktuk.com/
