The Research Project SONNE - A shining Example within the German Funding Scheme Innovation Alliance

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1 The Research Project SONNE - A shining Example within the German Funding Scheme Innovation Alliance Paris, 14 th November 2013 H. Neuhaus, SolarWorld Innovations GmbH, Freiberg, Germany

2 Agenda Introduction of the project, its goals, organization and partners Results High Efficiency PERC Cells Fine Line Metallization Half-Cell Modules Glass-Glass Modules Summary The Research Project SONNE D.H. Neuhaus, SolarWorld Innovations GmbH 2

3 Project Goals Power Cost Reduction (LCOE) by 33% through improvements in module power without step cost increase (+3.5% abs) module lifetime (+ 5 years) annual module degradation from 0.7% to 0.35% + 60 WpModule Power increase w/o step cost increase(per module) Status: 2010e + 5 yrslifetime Status: 2013e Technology/ Performance driven effects only Status: 2013e Market Prices (incl. BOM reductions + decreased margins) Assumptions: EnergyYield: 1000 kwh/ kw, WACC: 5.0%, OpEx: 1.5% ofinvest The Research Project SONNE D.H. Neuhaus, SolarWorld Innovations GmbH 3

4 Project Goals Module power gain through improvements in cell efficiency and cell to module losses Module quality improvements through innovations in encapsulation and testing Goal Start Target Status Avg. cell efficiency for Cz Si (%) Avg. cell efficiency for mc Si (%) Module power (%) (b) Module Lifetime (years) Degradation (%/year) 0.7 < 0.5 < 0.35 LCOE ( /kwh) ~ < 0.15 (b) Best value, all other values are mean values! The Research Project SONNE D.H. Neuhaus, SolarWorld Innovations GmbH 4

5 Project Work Packages Si High Efficiency Solar Cells and Modules with best Quality Work package 1 Development High Efficiency Cells Work package 2 Resistivity Losses & Cell Connecting Work package 3 Module Optics & Encapsulation Work package 4 Demonstration & Pilot Production Solar Cells and Modules Improvements based on state-of-the-art Technologies (Evolution of Cell Technologies) Development of Modular Technologies to be integrated in state-of-the-art Production New Encapsulation Materials Light Trapping New Cell Interconnecting Surface Passivation Selective Emitter Laser based Contacts Fine Line Metallization Cell Efficiency + 2 % abs. Reduction optical & electrical Module Losses Increase Module Lifetime and Energy Yield Demonstration Production Readiness Increase Module Efficiency by 3.5 % abs. Increase Module Lifetime by 5 Years Power Cost Reduction (LCOE) by 33 % The Research Project SONNE D.H. Neuhaus, SolarWorld Innovations GmbH 5

6 Project Partners Joint development between universities/institutes (2/2), equipment manufacturers (6) and material vendors(3) Industrial coordination by SolarWorld Innovations GmbH Equipment Universities/ Institutes Material The Research Project SONNE D.H. Neuhaus, SolarWorld Innovations GmbH 6

7 High Efficiency PERC Solar Cells Cell Parameter Production Pilot Eta [%] PERC has the following features: Passivated rear, rear point contacts, selective emitter, screen-printing. Pilot production at SolarWorld completed in Q2/2012. Transfer completed to production in Q4/ % average production efficiency. Module power between 270 and 280 W in production. SolarWorld is 1 st producer of PERC solar cells in high volume manufacturing. Average efficiency of 20.5% demonstrated in pilot production. Best PERC module with W. The Research Project SONNE D.H. Neuhaus, SolarWorld Innovations GmbH 7

8 Fine Line Metallization Print head of extrusion printing machine and 35 µm printed line Extrusion is very close to traditional screen-printing (minor modification of paste, different paste manufactures available). Stable finger width of 30 µm reached instead of 70 µm with screen-printing. Excellent finger geometry with aspect ratio of 0.6. Finger and busbar can be independently optimized (dual print). Printing machine with a throughput of wafer per hour tested in pilot. Technology will enable to reach efficiencies above 21.0%. The Research Project SONNE D.H. Neuhaus, SolarWorld Innovations GmbH 8

9 Fine Line Metallization 6 years International Technology Roadmap for PV (ITRPV) shows the expected evolution of the finger width for front side metallization. Within SONNE developed extrusion technology shows a clear time benefit! The Research Project SONNE D.H. Neuhaus, SolarWorld Innovations GmbH 9

10 Half-Cell Modules Power enhancement with half-cells (reduction of resistive losses and improvement of light back reflection within the cell gaps). P Loss = 2 3 ρcu h b L I 2 Cell Laser scribing machine and its mechanical cracking unit Average power gain of 6W demonstrated. Pilot tool build (laser scribing, mechanical separation, box-to-box handling, full optical inspection). Successfully tested in high volume manufacturing with wafers per hour. The Research Project SONNE D.H. Neuhaus, SolarWorld Innovations GmbH 10

11 Glass-Glass Modules Development of glass-glass module that are not heavier than standard glass-foil module (2 mm glass technology). Market introduction in 10/2013 under the brand name Sunmodule Protect. Improved quality due to avoidance of moisture penetration and less mechanical degradation (symmetrical glass structure). Extended warranty from 25 to 30 years and 0.7% annual degradation to 0.35%. 20% better energy yield and LCOE (costumer benefit). Sunmodule Protect with extended lifetime and reduced degradation The Research Project SONNE D.H. Neuhaus, SolarWorld Innovations GmbH 11

12 Summary Sonne is a joint development program between equipment vendors, material suppliers and institutes under industrial guidance of SolarWorld. Our goal was the cost reduction of PV power by 33% through improvements in module power and quality (lifetime and degradation). We have focused on modular technologies to be integrated in state-of-the-art silicon wafer-based screen-printed solar cell lines currently used in production. Achievements within Sonne were: Average efficiencies of 20.5% demonstrated with PERC/SE Fine line extrusion printing with 35 µm x 20 µm lines Half-cell modules with power gain of 6W Module power of up to > 300W Glass-glass modules with an extended lifetime of 30 years Technologies were demonstrated in high volume pilots or are already transferred to production. Thanks for the financial supported of the German Ministry for Environment, Nature Conservation and Nuclear Safety and the effort of all our partners! The Research Project SONNE D.H. Neuhaus, SolarWorld Innovations GmbH 12

13 Thank you! The Research Project SONNE D.H. Neuhaus, SolarWorld Innovations GmbH 13

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