K. Zweibel

Issues in thin film PV manufacturing cost reduction

Thin film PV technologies face a number of hurdles as they advance towards low-cost goals that are competitive with traditional sources of electricity. The US Department of Energy cost goal for thin films is about

Thin film PV manufacturing: Materials costs and their optimization

0.33/Wp, which is based on a module efficiency goal of about 15% and module manufacturing costs of about

High-Efficiency CdTe and CIGS Thin-Film Solar Cells: Highlights and Challenges

50/m2. This paper investigates the issues associated with achieving the

Progress and issues in polycrystalline thin-film PV technologies

50/m2 goal based on opportunities for manufacturing cost reductions. Key areas such as capital costs, deposition rates, layer thickness, materials costs, yields, substrates, and front and back end costs will be examined. Several prior studies support the potential of thin films to reach

Polycrystalline thin film photovoltaics

50/m2. This paper will examine the necessary process research improvements needed in amorphous silicon, copper indium diselenide, cadmium telluride, and experimental thin film silicon PV technologies to reach this ambitious goal. One major conclusion is that materials costs must be reduced because they will dominate in mature technologies. Another is that module efficiency could be the overriding parameter if different thin films each optimize their manufacturing to a similar level.

The role of polycrystalline thin-film PV technologies for achieving midterm market-competitive PV modules

Abstract Thin film PV technologies face a number of hurdles as they advance towards low-cost goals that would make them competitive with traditional sources of electricity. The US Department of Energy cost goal for thin films is about

Technology Choice and the Cost Reduction Potential of Photovoltaics

0.33/Wp, which corresponds to module efficiencies of about 15% and module manufacturing costs of about

Polycrystalline Thin-Film Photovoltaics: From the Laboratory to Solar Fields

50/m2. Past papers have provided a framework for examining thin film efficiencies and manufacturing costs, especially those costs for equipment, labor, materials, utilities, and others. Although materials costs appear to be a large fraction of the total, we have not yet broken them down in enough detail to seek significant improvement. In the future, with more mature thin film production, materials costs such as those from semiconductor layers, contacts, pottants, substrates, and electrical interconnection will dominate total module cost. This paper (1) breaks down the materials costs into two broad categories (active and inactive materials) and then (2) investigates the issues associated with reducing their costs much below todays levels. Materials will likely be such an overwhelming cost-driver for mature manufacturing of thin film PV that issues associated with their optimization should be examined as soon as possible in order to meet the DOE long-term goals for PV module costs.

The DOE/SERI polycrystalline thin film subcontract program

Thin-film photovoltaic (PV) modules of CdTe and Cu(ln,Ga)Se2 (CIGS) have the potential to reach cost-effective PV-generated electricity. These technologies have transitioned from the laboratory to the market place. Pilot production and first-time manufacturing are ramping up to higher capacity and enjoying a flood of venture-capital funding. CIGS solar cells and modules have achieved 19.5% and 13% efficiencies, respectively. Likewise, CdTe cells and modules have reached 16.5% and 10.2% efficiencies, respectively. Even higher efficiencies from the laboratory and from the manufacturing line are only a matter of time. Manufacturing-line yield continues to improve and is surpassing 85%. Long-term stability has been demonstrated for both technologies; however, some failures in the field have also been observed, emphasizing the critical need for understanding degradation mechanisms and packaging options. These two thin-film technologies have a common device/module structure: substrate, base electrode, absorber, junction layer, top electrode, patterning steps for monolithic integration, and encapsulation. The monolithic integration of thin-film solar cells can lead to significant manufacturing cost reduction compared to crystalline Si technology. The CdTe and CIGS modules share common structural elements. In principle, this commonality should lead to similar manufacturing cost per unit area, and thus, the module efficiency becomes the discriminating factor that determines the cost per watt. The long-term potential of the two technologies require R&D emphasis on science and engineering-based challenges to find solutions to achieve targeted cost-effective module performance, and in-field durability. Some of the challenges are common to both, e.g., in-situ process control and diagnostics, thinner absorber, understanding degradation mechanisms, protection from water vapor, and innovation in high-speed processing and module design. Other topics are specific to the technology, such as lower-cost and fast-deposition processes for CIGS, and improved back contact and voltage for CdTe devices

Polycrystalline thin-film photovoltaic technologies: from the laboratory to commercialization

Substantial progress has occurred in polycrystalline thin-film photovoltaic technologies. However, the transition to first-time manufacturing is still under way, and technical problems continue, This paper focuses on the promise and the problems of the copper indium diselenide and cadmium telluride technologies, with an emphasis on continued R&D needs for the near-term transition to manufacturing and for next-generation improvements. In addition, it highlights the joint R&D efforts being performed in the US Department of Energy/National Renewable Energy Laboratory Thin-Film Photovoltaic Partnership Program.