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PV<br />

Manufacturing<br />

SEPTEMBER <strong>2011</strong><br />

ISSUE N°13<br />

From Equipment and Materials to Solar Business<br />

INDUSTRY REVIEW<br />

The HCPV sector<br />

starts to talk<br />

in megawatts<br />

Courtesy of AZUR SPACE - Printed on recycled paper<br />

COMPANY INSIGHT<br />

Trident Solar:<br />

Progress on solar<br />

inkjet<br />

ANALYST CORNER<br />

The future of<br />

photovoltaics is<br />

inescapably about<br />

efficiency<br />

Free subscription on www.i-micronews.com


S E P T E M B E R 2 0 1 1 I S S U E N ° 1 3<br />

C O N T E N T S<br />

INDUSTRY REVIEW 4<br />

• The HCPV sector starts to talk in megawatts<br />

Makers of concentrating photovoltaic systems are at last installing systems<br />

measured in megawatts, and even getting a few utility power purchase<br />

agreements for future 100+MW systems.<br />

• Maturing HCPV supply chain looks to volume production issues<br />

Once the HCPV industry starts shipping hundreds of megawatts, its supply chain<br />

will have to transition to volume production as well. And a high volume business<br />

can’t be built all on custom components and custom assembly equipment.<br />

COMPANY INSIGHT 12<br />

• Trident Solar: Progress on solar inkjet<br />

Longer lasting print heads and combo processes could make inkjet a viable<br />

alternative for next generation solar cell processing.<br />

• ESI: Progress on laser technology opens new process options<br />

Tailored-pulse laser targets more precise micromachining across PV processes.<br />

ANALYST CORNER 16<br />

• The future of photovoltaics is inescapably about efficiency<br />

As efficiency becomes the key differentiator among solar brands, it means<br />

opportunity for new equipment processes and higher purity materials,<br />

and perhaps even for HCPV.<br />

FROM I-MICRONEWS.COM<br />

Please visit our website to discover the<br />

last top stories in Photovoltaics:<br />

Stay connected with your peers<br />

on i-<strong>Micronews</strong>.com<br />

With 18,000 monthly visitors,<br />

i-<strong>Micronews</strong>.com provides for Photovoltaics<br />

area: current news, market & technological<br />

analysis, key leader interviews, webcasts<br />

section, reverse engineering / costing,<br />

events calendar, latest reports …<br />

> Solopower receives $197 million<br />

loan guarantee from US DOE to<br />

build thin film photovoltaic module<br />

facilities<br />

> GT Advanced Technologies announces<br />

Korea-based polysilicon producer<br />

OCI selects the newest generation<br />

SDR reactors as part of its phase<br />

4 expansion program<br />

> Dow Corning begins monosilane<br />

production<br />

GOLD PARTNERS:<br />

For more information, please contact S. Leroy (leroy@yole.fr) or B. Stinson (stinson@i-micronews.com)<br />

2 P V M a n u f a c t u r i n g


S E P T E M B E R 2 0 1 1 I S S U E N ° 1 3<br />

E D I T O R I A L<br />

Looking outside the mainstream at emerging<br />

approaches to improve PV efficiency<br />

Ramping low cost gigawatt-scale volume production has grown PV to a 40 GWp<br />

business, according to Yole Développement fi gures, but the focus is now turning<br />

to improving effi ciency to gain distinguishing competitive advantage in the crowded<br />

market. In this issue of PVManufacturing we look at the state of some emerging approaches<br />

to higher effi ciency solar installations, from High Concentration PV (HCPV) to developments<br />

in inkjet and laser components for PV equipment.<br />

…When overall enddemand<br />

slows down,<br />

these innovative<br />

solutions can help<br />

companies again<br />

generate growth…<br />

E V E N T S<br />

HCPV remains a tiny business of small-scale installations to date, but the sector made a big<br />

step up from mostly kilowatt-scale to multiple 1-2 megawatt-scale projects last year. The<br />

leading companies now have 10MW-scale or larger projects in the pipeline. Moving to these<br />

volumes means the HCPV sector will need to add volume automated production capacity and<br />

fi gure out how to work more closely with its supply chain to optimize component design for<br />

manufacturing—and that has potential to signifi cantly bring down costs.<br />

Some components suppliers are also trying to jumpstart co-design to improve performance by<br />

getting together to test, optimize and publish data on how different primary optics, secondary<br />

optics and multijunction cells work together. Concentrator Optics, Isuzu Glass and AZUR<br />

SPACE are testing results in mockup test HCPV modules made from their components, and<br />

next plan to work with equipment suppliers to design production systems for the optimal<br />

components.<br />

The recent growth of HCPV installations in the US is partly because of the favorable economics<br />

for the technology of high DNI desert climate conditions conveniently near big population<br />

centers that particularly need power for air conditioning late on summer afternoons when<br />

HCPV outperforms fl at plate PV, but it has also been spurred by government requirements<br />

for aggressive new renewable energy portfolio standards for utilities, and by local efforts to<br />

create manufacturing jobs. If the technology is going to compete more widely with fl at panel<br />

PV, it will now need “muscle, manufacturing and money” as Amonix CTO and chairman<br />

Vahan Garboushian says, to transition to a volume manufacturing business, and to keep<br />

improving effi ciency and cost as fast as the fl at plate PV sector does, when that much larger<br />

industry can pour vastly more resources into the effort.<br />

• European PVSEC<br />

<strong>September</strong> 5 to 9, <strong>2011</strong> – Hamburg, Germany<br />

• Semicon Europa<br />

October 11 to 13, <strong>2011</strong> – Dresden, Germany<br />

• PV Japan<br />

December 5 to 7, <strong>2011</strong> – Tokyo, Japan<br />

PLATINUM PARTNERS:<br />

The fl at panel PV side’s pursuit of higher effi ciencies of course continues to generate<br />

innovative alternatives to the common processes. And when overall end-demand slows<br />

down, these innovative solutions can help companies again generate growth. So we also take<br />

a look in this issue at recent developments in laser and inkjet technology that have interesting<br />

potential for new equipment processes to improve results. Controlled micromachining by<br />

ESI’s tailored-pulse fi ber laser is showing some interesting results for precise scribing and<br />

via drilling. Trident Solar is using its industrial stainless steel inkjet head that holds up to<br />

aggressive chemicals to develop a process for printing etchant and dopant for selective<br />

emitters by one pass of a single ink.<br />

Arnaud Duteil<br />

Market & Technology analyst<br />

Yole Développement<br />

duteil@yole.fr<br />

P V M a n u f a c t u r i n g 3<br />

For more information, please contact S. Leroy (leroy@yole.fr) or B. Stinson (stinson@i-micronews.com)


S E P T E M B E R 2 0 1 1 I S S U E N ° 1 3<br />

INDUSTRY REVIEW<br />

SolFocus HCPV module<br />

(Courtesy of SolFocus)<br />

The HCPV sector starts to talk<br />

in megawatts<br />

Makers of concentrating photovoltaic systems are at last installing systems measured<br />

in megawatts, and even getting a few utility power purchase agreements for future<br />

100+MW systems.<br />

“A year ago at<br />

Intersolar people<br />

asked how CPV<br />

worked, this<br />

year they asked<br />

how much they<br />

could get and<br />

when,” says Vahan<br />

Garboushian,<br />

CTO of Amonix.<br />

4<br />

But the real sign that the HCPV niche may<br />

be becoming a significant solar alternative<br />

is the 100MW-scale capacity HCPV module<br />

manufacturing the industry leaders plan this year.<br />

SolFocus plans to double capacity to 100MW by the<br />

end of the year. Amonix executives have said they<br />

plan to ramp to 100MW capacity by the end of the<br />

year. Though Soitec has yet to finalize the specifics<br />

for its planned new San Diego plant, local papers have<br />

reported a target of 200MW capacity, and production<br />

facilities to support the 300MW in power purchase<br />

agreements from San Diego Gas & Electric will need<br />

to be multiple times larger than the current ~30MWcapacity<br />

Soitec production facility in Germany.<br />

These planned volume plants will help move the<br />

niche HCPV sector towards becoming a more mature<br />

manufacturing business, with significant potential<br />

now to reduce costs by automated production, a<br />

supporting supply chain infrastructure, outsourcing<br />

or production partnerships with established volume<br />

assembly companies, and moving away from all<br />

custom components and production equipment.<br />

Local interest in clean tech jobs from HCPV is also<br />

boosting the sector, as this newer technology on the<br />

verge of ramping mass production currently looks like<br />

a better prospect for local development now that the<br />

flat plate solar manufacturing business is increasingly<br />

a big company game dominated by low-cost regions<br />

of the world. Soitec’s planned HCPV plant in the San<br />

Diego area was apparently a key sweetener for the<br />

PPA deals with San Diego Gas & Electric. The US<br />

government supported Amonix’s new $18M plant<br />

in Nevada with almost $6M in subsidies, then also<br />

guaranteed a $90M loan for its 30MW Alamosa,<br />

Colorado, project. The Chinese province of Gansu’s<br />

deal for 20MW of ZenithSolar HCPV projects also<br />

requires local manufacturing. And several of the<br />

installations at educational institutions are related to<br />

solar job training programs.<br />

P V M a n u f a c t u r i n g


I S S U E N ° 1 3 S E P T E M B E R 2 0 1 1<br />

Amonix aims to put 40MW-50MW<br />

of HCPV in the ground this year<br />

“We’ll put 40MW to 50MW in the ground this<br />

year,” says Amonix founder, CTO and Chairman<br />

Vahan Garboushian, who argues that the sector<br />

is finally turning the corner towards becoming<br />

a volume business. Work is underway on<br />

the 30MW installation in Alamosa, Colorado.<br />

Construction is also finishing up at the 5MW<br />

installation in Hatch, New Mexico, where tracker<br />

posts were in and frames on site back in the<br />

last available public photos of the site back<br />

in March. Amonix was hiring field engineers<br />

for commissioning and running both these<br />

sites earlier this summer. The company also<br />

dedicated a 2MW project in Tucson in April.<br />

Garboushian says customers are now looking for<br />

HCPV demonstration projects in the MW range,<br />

as the focus has moved from demonstrating<br />

the technology to demonstrating how the<br />

technology performs at a particular location.<br />

And he notes Amonix’ recently announced joint<br />

venture in India targeting large distributed<br />

generation projects in an area without the<br />

highest DNI, where HCPV still looks competitive<br />

with flat plate PV costs.<br />

“A year ago at Intersolar people asked how<br />

CPV worked, this year they asked how much<br />

they could get and when,” says Garboushian.<br />

“They’re not asking if the technology is viable<br />

anymore.” The maturing of the technology also<br />

means that the key factor for success moves<br />

from innovation to execution. “Now what it will<br />

require is muscle, manufacturing, and money,”<br />

Garboushian argues.<br />

Amonix’s uses solar grade PMMA treated with UV<br />

retardants for its Fresnel lenses, putting multiple<br />

cells on one receiver plate per Fresnel lens<br />

parquet, and using a secondary reflective optic of<br />

highly polished aluminum. “We’ve experimented<br />

with different materials including glass for many<br />

years, but we’ve been using this same material<br />

in the field since 1994 and it still looks robust,”<br />

he says, noting the acrylic’s better transmissivity<br />

and better manufacturing tolerance. Company<br />

data tests showing 0.3%-0.4% degradation per<br />

year suggest the modules would maintain over<br />

90% of their original efficiency for 25 years if<br />

this rate of change remained constant. Amonix<br />

Amonix HCPV systems (Courtesy of Amonix)<br />

originally produced everything except the<br />

lenses in house, but as production increased it<br />

outsourced its designs to others. Though it can<br />

do cell finishing in house, it buys most of its cells<br />

from Spectrolab and Emcore and assembles<br />

them in the receiver package and on the<br />

receiver plate, then assembles and aligns all the<br />

components into its megamodule.<br />

Compared to the more established flat plate<br />

PV technology, HCPV likely has much more<br />

headroom for improving efficiency and cost,<br />

though the smaller sector has much less total<br />

money and manpower than flat plate PV to<br />

Annual manufacturing capacity of some HCPV companies<br />

(Yole Développement, <strong>2011</strong>, HCPV report)<br />

300<br />

250<br />

200<br />

MW/yr<br />

150<br />

100<br />

50<br />

0<br />

Amonix<br />

Renovalia<br />

Energy<br />

Green<br />

Guascor<br />

Emcore and Gold<br />

Isofoton MagPower Soitec Sol3G SolFocus Suntrix<br />

Foton<br />

Energy<br />

As of <strong>2011</strong><br />

Planned<br />

100 11 10 50 15 10 12 30 12 50 10<br />

100 NA NA NA NA NA 50 280 NA 100 NA<br />

P V M a n u f a c t u r i n g<br />

5


S E P T E M B E R 2 0 1 1 I S S U E N ° 1 3<br />

“Compared to the<br />

more established<br />

flat plate PV<br />

technology, HCPV<br />

likely has much<br />

more headroom<br />

for improving<br />

efficiency<br />

and cost,”<br />

says Milan Rosina,<br />

Yole Développement.<br />

throw at the work. Garboushian ticks off potential<br />

ways to gain a few percentage points improvement<br />

across almost all the various components in the<br />

systems - from better multijunction cell efficiency, to<br />

better pitch angles and more accurate facets in the<br />

Fresnel lenses, up through more accurate alignment<br />

in the balance of systems, which could together<br />

perhaps add up to as much as 50% improvement<br />

overall.<br />

Key to much of this improvement is the growth and<br />

increasing maturity of the supply chain. “While the<br />

solar supply chain continues to mature, there has<br />

been no shortage of innovation,” he says, noting that<br />

the optics and components are constantly improving.<br />

On the cell side, Garboushian notes that the best<br />

cells are already 5% to 10% better than those<br />

from some other suppliers, and spectral tuning for<br />

particular locations can add up to another 5% to 10%<br />

improvement in energy generation. But going beyond<br />

three junction cells won’t be an easy step for the<br />

optics and the rest of the system.<br />

Garboushian and Amonix have been making<br />

concentrating solar for some 20 years, and were<br />

among the pioneers of the big move from silicon to<br />

compound semiconductor triple junction cells for the<br />

boost in efficiency that did much to help create a viable<br />

HCPV market not so very long ago. The company’s<br />

early 7.8 MW-scale HCPV project with Guascor<br />

Foton in Spain in 2006-2008 used silicon cells, and<br />

depended on European government subsidies to be<br />

economic. Working with Emcore and Spectrolab to<br />

stabilize the process, prove the cell reliability, and<br />

redesign the rest of the system took a year, but it cut<br />

costs roughly in half and enabled output to jump from<br />

25kW to 37kW.<br />

SolFocus permitting 30MW project, plans<br />

to double production capacity to 100MW<br />

SolFocus is stepping up to tens-of-megawatt projects<br />

as well, with a 30MW power supply agreement<br />

from San Diego Gas & Electric now in the permitting<br />

process, which may be ready to start installation later<br />

this year. Nancy Hartsoch, VP of marketing, says the<br />

company also plans to increase its production capacity<br />

from the current 50MW to 100MW this year, by adding<br />

a second $10 million robotic assembly cell at its<br />

assembly facilities in China.<br />

The San Jose, California, company has installed<br />

projects in a dozen countries, most so far relatively<br />

small, essentially to test the HCPV performance<br />

under various conditions at different sites around the<br />

world. Recent larger US installations include the 1MW<br />

Victor Valley College project, the 1MW Nichols Farm<br />

pistachio processing plant, and the ~0.5MW Coachilla<br />

water reclamation plant, the latter two particularly<br />

significant because they were put together by heavy<br />

weight project managers Bechtel and Johnson<br />

Controls, suggesting these big companies think it<br />

worthwhile to learn the HCPV business on these<br />

relatively small installations for its future potential.<br />

Another big step: the first performance warranty<br />

insurance for HCPV from Munich Re.<br />

Though the utility market will be the bigger one,<br />

Hartsoch also sees a strong market for HCPV in this<br />

type of distributed generation, for the educational,<br />

agricultural processing, and water treatment markets,<br />

all users that tend to have big electrical bills, extra<br />

land already, and renewable energy goals.<br />

Like most of the other companies in this young<br />

technology, SolFocus designed and originally made<br />

not only its own components, but even much of its<br />

custom production equipment, but as volume has<br />

increased, it has outsourced all production. The<br />

company’s founders decided from the beginning to<br />

focus on proven glass, aluminum and steel materials,<br />

and on designing for manufacturability as the best<br />

way to create a low cost product. Major parabolic<br />

dish glass supplier Flabeg makes the mirrors, using<br />

SolFocus-designed equipment to slump a square<br />

mirror. One of the big electronics assembly houses<br />

assembles the receiver units and optical cones, and<br />

an assembly company in China puts together the final<br />

systems, using a monster press to stamp out the<br />

backpan in one piece, and a three-robot cell designed<br />

to SolFocus specifications by a company from the<br />

automotive assembly industry.<br />

Hartsoch argues that the company’s unique optics<br />

design may add complexity, with its third non-imaging<br />

optic that focuses the light down through a prism to<br />

more evenly illuminate the cell, the unusually wide<br />

1.6° acceptance angle allows more margin for some<br />

misalignment in assembly, installation and tracking.<br />

“You can lose a lot of energy for every 0.25° smaller<br />

acceptance angle,” she argues.<br />

The new generation systems just introduced swap out<br />

the cells for the next generation of more efficient ones,<br />

to boost panel efficiency to 29%, and redesign the<br />

modules for easier field assembly to reportedly reduce<br />

installation costs by cutting field installation time by<br />

half. The new modules add more panels per tracker,<br />

for fewer total trackers, and pre-assemble more panels<br />

into units, for fewer units per tracker to install, and no<br />

need for alignment in the field. The electronics are also<br />

now premounted on the tracker head, so no electronics<br />

assembly is required in the field. Hartsoch says that cut<br />

field assembly time in half. “And that’s with engineers,”<br />

she quips. “In the field with construction people it<br />

should be more than a 50% reduction in assembly<br />

time.” The relatively light dish units can be installed<br />

with cranes or scaffold forklifts, and can go on spread<br />

foundations or steel piers instead of concrete and in<br />

problematic soils like sand or landfills.<br />

6<br />

P V M a n u f a c t u r i n g


I S S U E N ° 1 3 S E P T E M B E R 2 0 1 1<br />

ZenithSolar expects to ship 1MW this<br />

year, two 10MW projects in pipeline<br />

Also now starting to ship systems for multiple new<br />

projects is Israel’s ZenithSolar, whose unique watercooled<br />

HCPV systems also supply significant amounts<br />

of hot water at 75°-80°C or more, hot enough for<br />

industrial as well as household uses. Now that the<br />

three-year-old company’s 250kW demonstration<br />

system at Kibbutz Yavne in Israel has been up and<br />

running for about 18 months, a half dozen other<br />

customers are stepping up to try the systems—<br />

perhaps a sign of the growing maturity of the HCPV<br />

sector. Zenith started shipping its first products to<br />

projects outside of Israel in March. It now has projects<br />

in the pipeline in Australia, Gulf states, Asia and Italy,<br />

for various applications that need a lot of hot water,<br />

ranging from hospitals to utility central heating plants<br />

to water desalinization projects. CEO Roy Segev says<br />

the company expects to ship a total of 1.2MW by the<br />

end of the year. These wattage figures totals include<br />

roughly one third direct production of electricity,<br />

roughly two-thirds the thermal energy of the hot water.<br />

The ZenithSolar system was designed for cogeneration,<br />

giving up some electrical efficiency in<br />

the interests of operating at higher temperature to<br />

create the extremely hot water needed for industrial<br />

applications. The dish mirror optics focus 850x-900x<br />

suns on a dense array of cells developed with Azur<br />

Space. The cell array is attached to a microchannel<br />

heat exchanger, similar to those used in the<br />

automotive industry, which heats the pressurized<br />

cooling water to close to 100°C so it can be piped<br />

away for other uses. That means the cell itself has<br />

to operate at a dauntingly high ~120°C, but Segev<br />

argues that the cells are rated to survive under these<br />

high temperatures, albeit with some loss of efficiency.<br />

Company materials also note that the cell array can<br />

be swapped out to upgrade the system later.<br />

Key to the technology, says Segev, is the company’s<br />

high temperature transparent encapsulation paste,<br />

which seals the glass directly to the cells to protect<br />

them from degradation from air or humidity. The<br />

trackers can be placed close together because they<br />

can tolerate some shading, as the optics consist of<br />

multiple rectangular facets, each about the size of<br />

the receiver array, and each independently continues<br />

to focus its light on the array, so any shading only<br />

reduces the concentration by that of the shaded<br />

facets. Like other companies in this young sector, as<br />

volumes have increased ZenithSolar has outsourced<br />

production of more of its initially internally designed<br />

and produced components.<br />

“A lot of customers were waiting to see the Yanev<br />

data base,” says Segev, referring to the demonstration<br />

project at the Israeli town of ~1000 that gets almost<br />

all its household hot water from the HCPV system,<br />

as well as all the hot water needed for its agricultural<br />

ZenithSolar parabolic dish system<br />

(Courtesy of ZenithSolar)<br />

P V M a n u f a c t u r i n g<br />

7


S E P T E M B E R 2 0 1 1 I S S U E N ° 1 3<br />

processing businesses. The kibbutz uses high volumes of 75°-80°C<br />

water for sterilization in its canning plant and in its dairy, as well as for<br />

the heat for incubating eggs. A 5000 gallon storage tank often provides<br />

enough hot water for residents’ nighttime use, though of course there is<br />

also a backup system. The kibbutz also harvests the wine grapes from<br />

the vineyard under the trackers. Electricity is sold into the grid to earn<br />

Israel’s high feed- in tariff.<br />

ZenithSolar also has an agreement with the government of China’s Gansu<br />

province for two 10MW demonstration installations, one for centralized<br />

water heating for a residential neighborhood, one for a metal processing<br />

plant, even though purely on cost there is no way the HCPV system can<br />

compete with the very low rates for the cheap, low grade coal now used<br />

there. But the very cold and dry climate at 2000M elevation at the edge<br />

of the Gobi desert has very high DNI that should be ideal for HCPV, the<br />

systems would reduce the heavy pollution from burning the low grade<br />

coal, and ZenithSolar has agreed to move manufacturing there for clean<br />

tech local jobs and, presumably, technology development. Details will<br />

take a while longer to work out before production starts.<br />

“Things are changing very fast in China,” says Segev. “China, India and<br />

Africa will be most of the solar market in the future just because most<br />

of the energy need will be there.”<br />

Paula Doe for Yole Développement<br />

Vahan Garboushian, Founder, Chief Technology Officer, and<br />

Chairman of the Board of Directors, Amonix<br />

Mr. Garboushian has pioneered the development of concentrated<br />

photovoltaic (CPV) technology since launching Amonix in 1989;<br />

his passion, vision, and leadership over the past 20 years have made<br />

Amonix the most efficient, reliable CPV technology on the market today.<br />

Nancy Hartsoch, Vice President of Marketing and Business<br />

Development, SolFocus<br />

She is responsibe for the company’s global marketing activities and<br />

ROW business development activities. Nancy is also currently the<br />

Chairman of the CPV Consortium, a global industry organization in the<br />

CPV market segment. Prior to joining SolFocus she was CEO of Pacific<br />

Technology Group which she co-founded in partnership with Taiwan-based Acer<br />

Labs Inc. (ALi) to provide marketing, sales and applications engineering to launch<br />

an existing product line into the global market. Her 25 years of technology<br />

experience include five years as COO and VP of Marketing and Sales for Ali.<br />

Roy Segev, Founder & CEO, ZenithSolar<br />

Roy has close to 20 years of experience in Israeli and global<br />

high-tech businesses. In 2006, Roy founded ZenithSolar in order to<br />

provide comprehensive energy via a distributed network. Prior to<br />

founding ZenithSolar, Roy was a partner at Sadot, a venture capital<br />

fund that invests in early stage technology companies. Previously<br />

Roy was responsible for the finance and business development of “Magink_,<br />

a leading company in the digital ink technology for signs and billboards.<br />

Roy holds a B.Sc. in Physics and Mathematics from Hebrew University and a<br />

M.Sc. from Boston University.<br />

8<br />

P V M a n u f a c t u r i n g


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•Nov.8:<br />

High Concentration<br />

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Technology on<br />

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S E P T E M B E R 2 0 1 1 I S S U E N ° 1 3<br />

INDUSTRY REVIEW<br />

Maturing HCPV supply chain looks<br />

to volume production issues<br />

Once the HCPV industry starts shipping hundreds of megawatts, its supply chain will<br />

have to transition to volume production as well. And a high volume business can’t be<br />

built all on custom components and custom assembly equipment.<br />

step is to work with assembly companies to design<br />

efficient production processes for these components.<br />

Then HCPV makers won’t have to do the iterations of<br />

the optics design themselves, but they can choose<br />

the appropriate balance of performance vs cost, and<br />

the tooling will already be there. “Customers can<br />

then buy components off the shelf, like in a mature<br />

industry,” says Leutz, noting that some users might<br />

for example prefer the lighter weight of PMMA, while<br />

others installing in areas with frequent sandstorms<br />

may prefer more scratch-resistant glass.<br />

Concentrator Optics<br />

Fresnel Lens Parquet<br />

(Courtesy of Concentrator Optics)<br />

“Performance<br />

data that we can<br />

talk about<br />

will help the<br />

bankability of the<br />

whole sector,”<br />

explains Ralf Leutz,<br />

Concentrator Optics.<br />

10<br />

Some helpful steps would be openly available<br />

data on the performance of some HCPV optics<br />

components, coordinated optimization of<br />

the design of the primary and secondary optics to<br />

work together, and coordinated optimization with<br />

manufacturing technologists to design efficient volume<br />

production. So Concentrator Optics founder and GM<br />

Ralf Leutz cooked up a plan to work with secondary<br />

optics supplier Isuzu Glass and cell and receiver maker<br />

AZUR SPACE to make test mockup HCPV modules<br />

to compare various combinations of three different<br />

Fresnel lenses, two different secondary optics and two<br />

different multijunction cells, to get module performance<br />

data that could be released publicly. “With tighter<br />

tolerance budgets, the design of the primary and<br />

secondary optics have to be optimized together with<br />

multiple iterations, but when we make these products<br />

for customers we can’t share how results compare to<br />

other designs or materials,” says Leutz. “Performance<br />

data that we can talk about will help the bankability of<br />

the whole sector.” Aiming for quick results, the three<br />

companies each simply supplied their components for<br />

the mockup modules for testing.<br />

Early results are showing relatively small differences<br />

between PMMA and silicone-on-glass (SOG) Fresnel<br />

lenses, and are quantifying the difference between the<br />

relatively higher performance kaleidoscope secondary<br />

optics and the lower cost half-egg alternatives. With<br />

the data on the optimized optical designs, next<br />

“We’ve played with the process long enough,” asserts<br />

Leutz. “There will have to be some standardization.”<br />

He argues that though leading companies will<br />

continue to distinguish themselves with their<br />

particular technologies, much of the industry will<br />

go to a mainstream volume production option using<br />

Fresnel lenses, secondary optics and triple junction<br />

cells. “Once the HCPV industry gets to a few hundred<br />

megawatts, it will start to look a lot more like the<br />

flat panel PV market,” suggests Leutz. “The key issues<br />

will move beyond technology, to the financing, the<br />

marketing, and the big companies. We have to be<br />

prepared for that.”<br />

While a second tier of upstart HCPV players might<br />

economically ramp production of these more standard<br />

systems, currently all the leading HCPV systems<br />

makers choose quite different options to optimize<br />

their systems. Soitec uses SOG Fresnel lenses but<br />

skips the secondary optic for easier and cheaper<br />

manufacturing, and instead compensates with extra<br />

accuracy in its trackers. Amonix uses lighter acrylic<br />

Fresnel lenses for its large units, but with a low cost,<br />

reflective aluminum secondary optic. SolFocus uses<br />

mirrors for both the primary and secondary optics,<br />

but does use a rod-shaped refractive third optic to<br />

gain a particularly large acceptance angle to allow<br />

more tolerance for imprecision in assembly and<br />

installation.<br />

Isuzu Glass: Design for manufacturing,<br />

optimization with primary, may reduce<br />

secondary optics cost<br />

Systems makers have had to design their solutions<br />

without fully knowing manufacturing costs for their<br />

custom designed components. Molded glass optics<br />

specialist Isuzu Glass reports that many HCPV<br />

companies have come to it with their designs for


I S S U E N ° 1 3 S E P T E M B E R 2 0 1 1<br />

secondary optics to convert the Fresnel spot to more<br />

homogenous light, to avoid hotspots that can damage<br />

the cell, and to allow a wider acceptance angle for<br />

better performance with less strict requirements<br />

for accuracy on the part of the tracker. However,<br />

typically, says Isuzu sales manager Mehmet Sinan<br />

Ata, the module makers provide the glass maker with<br />

the drawings for the glass parts, and then discover<br />

afterwards that their design is not possible to actually<br />

manufacture for anything close to the $1 or so per<br />

unit target price they expected, so few have yet to<br />

move the systems to volume production.<br />

“Then to eliminate<br />

shipping costs, the<br />

optics production<br />

lines will have to<br />

be located close to<br />

the final assembly<br />

of the modules,”<br />

added Leutz.<br />

The high cost of the precision molds and tooling make<br />

high performance molded optics expensive unless<br />

those costs are spread over high volumes, so initial<br />

requests for quotes for relatively small orders are<br />

expensive, and not particularly profitable nor of much<br />

interest to the optics companies that churn out lenses<br />

for projectors and cell phone cameras in serious high<br />

volumes. Costs can however be reduced by making<br />

the lenses as small as possible, and keeping the<br />

shapes simple and rounded for easier molding.<br />

“We’ve gotten many inquiries from different companies<br />

with totally different module designs, and we are<br />

currently supplying several module manufacturers’<br />

pilot plants around the world, but so far none have<br />

moved into high volume production,” says Ata. “We<br />

decided to work with other components suppliers<br />

to help push development ahead faster, instead of<br />

waiting for the market, to help the business move<br />

ahead more quickly.”<br />

Supply chain matures towards<br />

automated production, 20-year<br />

warranty for solar acrylic<br />

Leutz argues that the challenge of high volume, low<br />

cost production of precision optics can effectively be<br />

met only with full automation, and with a parallel<br />

production system to replicate all units from one initial<br />

master, at high speed and high optical quality. “This<br />

automated high volume production system does not<br />

fall out of the sky,” he notes. “Even companies that<br />

wanted to do it in house are needing partners.” Then<br />

to eliminate shipping costs, the optics production lines<br />

will have to be located close to the final assembly<br />

of the modules, which currently realistically means<br />

plants in the southwestern US.<br />

Concentrator Optics makes Fresnel lenses in both<br />

acrylic and silicone on glass, and Leutz argues that<br />

the differences are actually relatively minor. “Concerns<br />

over PMMA yellowing or cracking are issues of the<br />

past,” he asserts. Only PMMA has been under the<br />

sun for 20 years, but accelerated test results on both<br />

materials look good. Major PMMA supplier Evonik and<br />

Concentrator Optics now offer a 20-year performance<br />

warranty for lenses made of their UV-enhanced<br />

material, developed specifically for solar to let in more<br />

P V M a n u f a c t u r i n g<br />

Rod lens (Courtesy of Isuzu Glass)<br />

light and be more stable under extreme temperatures.<br />

Processing that heats the material thoroughly before<br />

embossing to avoid introducing stress also helps to<br />

avoid cracking or corrosion later in the field. SOG<br />

meanwhile remains slightly more expensive because<br />

of the material costs.<br />

AZUR SPACE: Clear roadmap to 45%<br />

cell efficiency<br />

AZUR SPACE also joined the project with Concentrator<br />

Optics and Isuzu Glass to try to help push the HCPV<br />

market along to more serious volumes, designing<br />

the receivers for the systems. “The most important<br />

thing is that HCPV needs to start deploying tens of<br />

megawatt projects,” says Gerhard Strobl, director of<br />

business development, AZUR SPACE Solar Power. “It<br />

needs volume to decrease costs—though it also needs<br />

to decrease costs to get to volume.”<br />

Efficiency of the multivolume cells is key to the<br />

efficiency—and ultimately the cost—of the HCPV<br />

systems, and luckily also perhaps the part of the<br />

system with the clearest roadmap for significant<br />

improvement. AZUR says it is currently shipping 40%<br />

efficient cells, aims at 42% in two years by moving<br />

from lattice matched to metamorphic cells, and then<br />

to four junctions for 45% efficiency in 4-5 years. In<br />

the long run 50% cells will be possible, says Strobl.<br />

AZUR has sufficient capacity to make the terrestrial<br />

cells on its existing lines for space applications, and<br />

steady demand for additional volumes that allowed<br />

the lines to run steadily at higher output would be<br />

key to maintaining tight process control and reducing<br />

costs. Based on optics from Concentrator Optics and<br />

Isuzu Glass, AZUR is able to deliver essentially offthe-shelf<br />

receivers for Fresnel systems and dense<br />

array receivers for mirror systems.<br />

“One gigawatt of HCPV means four square kilometers<br />

of lenses and 160 million secondaries and cells,”<br />

notes Leutz. “This is a challenge the supply chain is<br />

prepared for.”<br />

Paula Doe for Yole Développement<br />

Dr. Ralf Leutz,<br />

co-founder, CTO and<br />

CEO, Concentrator<br />

Optics<br />

He is also author of the<br />

book Nonimaging Fresnel<br />

Lenses: Design and Performance of Solar<br />

Concentrators (Springer, 2001). He<br />

earned his PhD from Tokyo University of<br />

Agriculture and Technology.<br />

Mehmet Sinan Ata,<br />

Sales Manager, Isuzu<br />

Glass Deutschland<br />

Dedicated to the company’s<br />

optical glass, lenses and<br />

color filters across the<br />

optoelectric, medical and photovoltaic<br />

industries. Previously he did overseas<br />

procurement for DMW Corp. in Japan. He<br />

has a masters degree from Rheinische<br />

Friedrich-Wilhelms-University in Bonn,<br />

Germany.<br />

Dr. Gerhard Strobl,<br />

Director Business<br />

Development, AZUR<br />

SPACE Solar Power<br />

GmbH<br />

Dr. Gerhard Strobl is now<br />

with AZUR SPACE (or its predecessor<br />

companies) since 25 years. For many<br />

years he was responsible for the space<br />

silicon solar cell development and later<br />

for the GaAs triple junction development<br />

within AZUR. Under his responsability<br />

AZUR introduced in 2003 the first fully<br />

European space triple cell with 25%<br />

efficiency (AM0, 25°C), in the last years<br />

he and his team improved the technology<br />

and the cells to 30% for space (AM0,<br />

25°C) and 40% for CPV (500x AM1.5d,<br />

25°C).<br />

Since 2007 as director business<br />

development, he is not only responsible<br />

for all R&D topics, but also for bringing<br />

new products such as CPV cells and<br />

receivers to customers and to the<br />

market.<br />

11


S E P T E M B E R 2 0 1 1 I S S U E N ° 1 3<br />

COMPANY INSIGHT<br />

Trident Solar: Progress on solar inkjet<br />

Longer lasting print heads and combo processes could make inkjet a viable alternative<br />

for next generation solar cell processing<br />

Steve Liker,<br />

Director of Sales &<br />

Marketing, Trident Solar -<br />

Trident Industrial Ink Jet<br />

Inkjet printing has been a hard sell to the solar<br />

industry to date, but it’s one possible option<br />

for solving some of the process issues as the<br />

industry moves to thinner wafers, better contacts,<br />

and selective emitter and back contact patterning.<br />

Trident Solar says new inkjet technology may now<br />

be ready to do etching and doping in one step, at<br />

2000-3000 wph, with improved reliability.<br />

There’s likely a limit to how much more the<br />

industry can improve the efficiency of contacts<br />

screen printed with porous paste, pushing the<br />

sector towards electroplating, while efforts to<br />

reduce costs continue to push towards thinner<br />

wafers that require non-contact printing of fineline<br />

seed layers. “We’ll need a non-contact process<br />

and narrower lines,” argues Steve Liker, Trident<br />

director of sales and marketing. “All the arrows are<br />

pointing away from screen and laser.” Trident Solar<br />

is a division of graphics print head and ink supplier<br />

Trident Industrial Inkjet in Brookfield, Connecticut.<br />

The company is introducing a single-step etching<br />

and doping ink for printing selective emitters<br />

in concert with screen printing metallization<br />

fingers. One of the components in the etching<br />

solution is a phosphoric acid, which first etches<br />

through the SiNx layer when heated, then as the<br />

temperature increases further begins to work as a<br />

phosphor n-dopant. Trident worked to develop the<br />

material for a year and half with partner Cookson<br />

Electronics, who will produce the solution. Trident<br />

is working with Roth & Rau’s OTB Solar and other<br />

integrators to provide the wafer handling and<br />

transfer, and to market and service the tools. That<br />

same Roth & Rau unit already markets competing<br />

screen printing and laser systems for these same<br />

applications.<br />

The next step in development is to also add the<br />

chemistry to print a seed layer for electroplating<br />

the contacts with the same etchant/dopant ink,<br />

so all three steps for forming the selective emitter<br />

and seed layer could be printed in the same pass.<br />

It would, however, also be possible to minimize<br />

process steps by a separate print head or a<br />

separate printing pass on the same tool.<br />

The technology is still in the R&D stage at<br />

customers, with most interest currently focused on<br />

selective emitters and emitter wrap through, says<br />

Liker, though some customers are also looking<br />

at patterning back contacts. There’s also some<br />

interest from thin film solar makers for etching and<br />

Trident 256 Jet Solar printhead (Courtesy of Trident)<br />

12<br />

P V M a n u f a c t u r i n g


I S S U E N ° 1 3 S E P T E M B E R 2 0 1 1<br />

metalizing vias. Here too Trident is working on development of an<br />

ink that can do both the etching and the metallization in one pass.<br />

Liker argues that non-contact inkjet processing for etch, doping and<br />

metallization will result in higher yields than either screen printing<br />

or laser processes, especially for high efficiency processes on<br />

thinner wafers. Better lasers do ablation or vias with less damage<br />

than the older lasers, but reportedly still do some damage to the<br />

morphology of the textured silicon top surface for selective emitter<br />

processes, and around the via holes for back contact processes,<br />

while the sector now expects ever less wafer loss. “It used to be<br />

acceptable to have 0.5% to 1% scrap,” notes Liker. “But now the<br />

goal is 0.1% scrap.”<br />

Liker reports the company has solved some of the nagging<br />

reliability issues with inkjet in production by designing a print head<br />

specifically for solar applications, made of stainless steel so it can<br />

hold up to aggressive liquids, from 2-14 pH, for jetting things like<br />

phosphoric acid and KOH etchants. The company claims its head<br />

lasts at least 5x longer in production with acids than earlier print<br />

heads adapted from the graphics industry. Trident’s piezoelectric<br />

piston design draws fluid into the chamber when the piston pulls<br />

back, then pushes forward to eject the fluid out the nozzle. This<br />

high pressure produces droplets as small as 7pl, and enables thicker<br />

fluids to be jetted.<br />

Focus so far has been on single pass, single step process applications,<br />

where one or two of the four-inch heads can cover the entire wafer.<br />

That simplifies handling to merely passing the wafer under the head,<br />

allowing target speeds of typical solar rates of 2000-3000wph.<br />

Patterning can be done on the fly by digitally selecting when to open<br />

which of the 256 holes across the head.<br />

Inkjet printing is of course already a well established high speed<br />

industrial process. Trident Industrial Inkjet has been making ink<br />

jet heads and inks for the graphics printing industry, used in high<br />

speed, low cost printing of thing like packaging and bar codes, for<br />

more than 30 years. The industrial inkjet business is one of the<br />

many businesses of Illinois Tool Works (ITW), a $16B diversified<br />

manufacturer of fasteners, components and materials for everything<br />

from the auto industry to industrial packaging, commercial food<br />

equipment to chemicals.<br />

www.trident-itw.com<br />

Steve Liker, Director of Sales & Marketing, Trident Solar<br />

Trident Industrial Ink Jet<br />

He has 31 years of experience in the engineering and marketing of Piezoelectric<br />

Ink Jet printheads for industrial applications. His experience prior to joining<br />

Trident-ITW was as an Engineer in the field of ink jet development with<br />

Dataproducts and Exxon Office Systems. Mr. Liker holds five patents in ink<br />

jet technology. He has a B.S. degree in Physics from Upsala College in New<br />

Jersey, U S A.<br />

P V M a n u f a c t u r i n g 11


S E P T E M B E R 2 0 1 1 I S S U E N ° 1 3<br />

COMPANY INSIGHT<br />

ESI: Progress on laser technology<br />

opens new process options<br />

Tailored-pulse laser targets more precise micromachining across PV processes<br />

Richard Murison,<br />

CTO and Director<br />

of Product Marketing,<br />

PyroPhotonics Lasers<br />

One interesting option for faster, cleaner<br />

material removal process steps could be<br />

tailoring the temporal shape of the laser<br />

pulse to precisely control the micromachining.<br />

Already in mass production use for DRAM repair,<br />

such tailored pulse lasers are slated to be<br />

integrated into solar scribing production systems<br />

for all three scribes for CIGS thin film solar cells by<br />

the first half of next year.<br />

Supplier ESI says the ability to customize the shape,<br />

height, and width of the laser pulse nanosecond by<br />

nanosecond, independent of the repetition rate,<br />

enables higher quality P2 and P3 scribes on CIGS<br />

at lower cost than the current mechanical scribing.<br />

The company reports encouraging research results<br />

as well for scribing ZnO and CdTe on glass with less<br />

damage, and for drilling holes at high speeds for<br />

emitter wrap through applications.<br />

where it offers higher throughput than the current<br />

needle scribing process, avoids the need to stop<br />

to change the scribing needle as it dulls, and may<br />

potentially allow the scribes to be spaced closer<br />

together as space no longer has to be left to<br />

allow for chipping. Though the system is not yet<br />

in production, PyroPhotonics co-founder and CTO<br />

Richard Murison says the company is talking to<br />

most of the major CIGS makers and almost all of<br />

the thin film solar scribing equipment integrators.<br />

“First we have to convince the CIGS maker that the<br />

process works, and then they hand it off to their<br />

preferred integrator, so the process takes a while,”<br />

notes Murison. His co-founder Tullio Panarello,<br />

now GM, says that some customers trying the<br />

more expensive competing pico-second lasers<br />

are finding issues with heat damage on one of the<br />

scribes so are coming back to consider the tailored<br />

pulse option.<br />

Tullio Panarello, General<br />

Manager of the Laser<br />

Business Unit, ESI<br />

ESI (Portland, Oregon) acquired the technology<br />

by purchasing startup PyroPhotonics Lasers<br />

(Montreal, Canada) to assure its supply of the<br />

lasers for its memory business, but the company<br />

is now targeting the potentially far larger solar<br />

market for laser processes. First market driver<br />

is for P2 and P3 scribing passes for CIGS cells,<br />

Murison also reports some success scribing ZnO<br />

on glass, where the alternative process for the<br />

P1 scribe has been difficult to control precisely<br />

enough to avoid either leaving cracks in the glass<br />

on the one hand, or else not cleanly scribing away<br />

the oxide. But tailoring the laser pulse to start with<br />

a large spike and then reducing to a lower intensity<br />

CIGS scribing by time domain tailored-pulse laser (Courtesy of ESI)<br />

14<br />

P V M a n u f a c t u r i n g


I S S U E 1 3 S E P T E M B E R 2 0 1 1<br />

is said to cleanly remove the oxide without<br />

damaging the glass. Work on the P1 scribe for CdTe<br />

thin film shows potential to reduce process steps<br />

by leaving intact a barrier layer which prevents<br />

sodium from the soda-line glass diffusing into<br />

the scribe and poisoning the CdTe. Typically the<br />

CdTe P1 scribe removes the barrier layer and must<br />

therefore be backfilled with a planarizing filler to<br />

avoid sodium diffusion. The tailored pulse laser,<br />

however, can etch precisely through only the TCO<br />

on the architectural glass substrate, leaving the<br />

underlying SiO 2<br />

barrier layer intact.<br />

Other work with the Fraunhofer Institute in<br />

Michigan found that the shaped beam laser was<br />

much faster than conventional lasers for drilling<br />

the thousands of hole per second across the<br />

wafer needed for emitter wrap through solutions.<br />

Practical mass production of EWT will likely need<br />

drilling some 10,000 holes across the wafer at<br />

one wafer per second without too much damage,<br />

while a conventional 100W laser can only do about<br />

4,300 holes per second. ESI’s 25W tailored-pulse<br />

laser drilled 6,800 holes per second in the tests<br />

in the Fraunhofer lab. Murison says ESI has since<br />

made considerably more improvement in its own<br />

lab as it has learned more about how light actually<br />

interacts with silicon. The solution turns out to be<br />

tailoring the pulse to first heat up the silicon before<br />

hitting it hard, which enables the material to use<br />

the available energy more efficiently. Typically<br />

a laser drills quickly down through the first part<br />

of the hole as the silicon melts, but then about<br />

halfway through the process slows down as the<br />

silicon starts to boil and vaporize, filling the hole<br />

with silicon plasma that absorbs the laser light.<br />

The relatively low 25W power of the ESI pulseshaped<br />

laser currently limits the throughput of<br />

removal processes, and so limits use for a number<br />

of c-Si solar laser applications. The company<br />

is currently working on the tricky business of<br />

developing a higher power version, as pulsetailoring<br />

is typically only possible at relatively<br />

low power. Unlike a standard Q-switching laser,<br />

where the energy is stored up then all released<br />

in one flash that can’t be precisely controlled, the<br />

fiber laser’s low power continuous beam can be<br />

shaped by an optical modulator. The PyroPhotonics<br />

technology controls the modulator by changes in<br />

voltage, for faster response rate than changing<br />

the current. The beam must then be amplified to<br />

be most useful. The founders say their approach<br />

allows very precise control of the shape at low<br />

power, so the beam remains tailored even through<br />

the distortions created by amplification.<br />

www.esi.com<br />

Richard Murison, CTO and Director<br />

of Product Marketing,<br />

PyroPhotonics Lasers<br />

Richard Murison received his BSc in<br />

Physics from Loughborough University of<br />

Technology, UK and is Chief Technology<br />

Officer and Director of Product Marketing<br />

at PyroPhotonics Lasers, a subsidiary of<br />

ESI, Inc.<br />

Tullio Panarello, General Manager<br />

of the Laser Business Unit, ESI<br />

Tullio Panarello serves as the General<br />

Manager of the ESI’s Laser Business Unit.<br />

Mr. Panarello joined ESI in <strong>September</strong><br />

2010 following the acquisition of<br />

PyroPhotonics Lasers, Inc. He co-founded<br />

PyroPhotonics in 2003 and served as the<br />

company’s CEO.<br />

Register<br />

today<br />

To attend editorial webcast<br />

Additional webcast topics:<br />

• Sept. 28:<br />

Benefits and perspectives<br />

of Cu-Pillar bumping<br />

• Oct. 18:<br />

Thin wafer handling<br />

& processing<br />

•Nov.8:<br />

Glass emergence<br />

into the semiconductor<br />

wafer-processing world<br />

Join the live webcast:<br />

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Technical Innovations<br />

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Attend the live webcast to learn about the PV inverter market trends<br />

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P V M a n u f a c t u r i n g<br />

15


S E P T E M B E R 2 0 1 1 I S S U E N ° 1 3<br />

A N A L Y S T C O R N E R<br />

The future of photovoltaics is<br />

inescapably about efficiency<br />

As efficiency becomes the key differentiator among solar brands, it means<br />

opportunity for new equipment processes and higher purity materials, and perhaps<br />

even for HCPV.<br />

Milan Rosina,<br />

Market and Technology<br />

Analyst,<br />

Yole Développement<br />

As gigawatt-scale production in low cost<br />

regions has pushed the cost of solar modules<br />

down sharply, the balance of systems and<br />

installation costs have come to account for a larger<br />

percentage of total system costs, making higher<br />

efficiency for each module an increasingly important<br />

way to reduce all these area-related costs. But with<br />

the current oversupply of commodity modules,<br />

efficiency is also becoming the key differentiator<br />

for solar brands, providing visibility and indicating<br />

quality and reliability.<br />

That means increasing user interest in new process<br />

equipment technologies to improve efficiency,<br />

and in higher purity materials. It also means the<br />

competitive advantage will increasingly accrue<br />

to high volume producers with stable control of<br />

their process, making it harder for small players<br />

to successfully bring alternative technologies to<br />

market. And as all technologies continue to improve<br />

in cost and performance, those with more limited<br />

potential for improving efficiency - like amorphous<br />

silicon - will get left behind, while those with<br />

greater potential efficiency may have the ultimate<br />

advantage.<br />

Demand for higher efficiency opens<br />

opportunity for equipment makers<br />

to supply new processes<br />

The drive for efficiency means increasing customer<br />

interest in low cost solutions for improving<br />

performance, particularly in those areas with big<br />

potential impact from relatively modest changes<br />

to the total cell design or process flow, such as<br />

decreasing the width and increasing the conductivity<br />

of metallization lines, adding selective emitters, and<br />

going to some back-contact designs. Screen printing<br />

will likely hit a wall in 2-3 years, to be replaced by<br />

some sort of plating. The industry is also going to<br />

move to thinner wafers, not just to reduce costs, but<br />

also to improve efficiency by reducing the impact of<br />

defects: by reducing thickness of the material with<br />

defects through which the photons and electrons<br />

must travel. That will open opportunities for gentler,<br />

non-contact processes like inkjet printing and laser<br />

ablation.<br />

Development status for different PV technologies showing an increasing potential<br />

for high efficiency PV technologies<br />

(Yole Développement, <strong>2011</strong>, HCPV report)<br />

Efficiency at module level<br />

30%<br />

22%<br />

14%<br />

12%<br />

11%<br />

10%<br />

9%<br />

8%<br />

6%<br />

Very high efficiency - Low<br />

volume production<br />

High efficiency - Mass<br />

production<br />

Medium to low efficiency -<br />

Mass production<br />

Very low efficiency - Very low<br />

production (R&D stage)<br />

DSSC<br />

-V<br />

HCPV<br />

CIGS<br />

C-Si<br />

CdTe<br />

a-Si/μc-SI<br />

a-Si<br />

“Moving<br />

target”<br />

5%<br />

Organic<br />

Fundamental<br />

research<br />

Industrial<br />

research<br />

Pilot Medium volumes<br />

Development status<br />

Mass production<br />

>1GW<br />

16 P V M a n u f a c t u r i n g


I S S U E N ° 1 3 S E P T E M B E R 2 0 1 1<br />

Inkjet has high potential for non-contact deposition<br />

of etchants, dopants and metals, though the process<br />

can be slow, and the fast-drying materials can easily<br />

clog the tiny nozzles to limit performance, presenting<br />

needs for new inks, new head designs and cleaning<br />

processes, and perhaps new solutions to recognize<br />

and correct print areas where blocked nozzles<br />

have impacted deposition quality. Lasers also have<br />

considerable potential for innovative improvements<br />

to solar manufacturing, as their highly-localized<br />

heating allows precise control of micromachining<br />

with little thermal stress or mechanical damage for<br />

fine geometry features on delicate thin wafers. Both<br />

inkjet and laser production processes are already<br />

well established in other high volume industries,<br />

which could accelerate the development of solar<br />

applications.<br />

Higher quality cells require purer,<br />

higher-performance materials, more<br />

controlled processes<br />

Improving solar efficiency will also require purer<br />

materials and more careful control of processes<br />

for contamination. As cell efficiency starts to get<br />

closer to theoretical limits, after 18% or so, eking<br />

out the next round of gains will mean paying<br />

more careful attention to the small stuff. The PV<br />

industry will need to evolve beyond its focus on<br />

high speed automation modeled on that of the<br />

automotive industry, to start to look more like the<br />

semiconductor industry - with its obsession with<br />

contamination control and process monitoring, and<br />

its practices of filter use, cleaning technologies, and<br />

keeping humans away from the processing. Gases,<br />

de-ionized water and other standard materials<br />

for PV production will all move to higher levels of<br />

purity and quality. On the cost reduction front,<br />

replacing silver metallization with copper could gain<br />

a significant advantage, but some reliability issues<br />

with corrosion and Cu migration into the silicon<br />

remain, necessitating additional buffer and capping<br />

steps that add back costs.<br />

Demand will move to higher purity<br />

polysilicon as well<br />

PV makers are increasingly demanding higher<br />

quality polysilicon as well, for higher efficiency cells.<br />

Yole Développement projects that demand will<br />

move to semiconductor grade material—9 nines to<br />

11 nines purity—essentially displacing solar-grade<br />

poly almost entirely in the market. With a backlog<br />

of solar module supply built up in inventory, and<br />

slowing demand from the cutbacks in government<br />

incentives, demand for poly this year looks likely<br />

to come in considerably below last year’s 160,000<br />

MT, leaving an oversupply in the sector. The four<br />

leading suppliers Wacker Chemie (Germany),<br />

Hemlock Semiconductor (Michigan, US), OCI<br />

(Korea) and GCL Poly (China), who are all providing<br />

semiconductor-grade material, together have enough<br />

P V M a n u f a c t u r i n g<br />

capacity among them to supply the entire PV<br />

industry demand this year. With no constraints<br />

on availability, it will be the higher purity material<br />

from these leading suppliers that sells, and enough<br />

demand for it to maintain poly prices stable at<br />

around $50/kg this year. Many of the new entrants<br />

who more recently added poly capacity have found<br />

it harder than expected to optimize this complex<br />

chemical process to match the leading pure-play<br />

players in quality and cost, and many will likely<br />

quietly get out of the business.<br />

HCPV efficiency could provide an edge,<br />

if sector and supply chain can scale to<br />

volume<br />

Long term trends towards efficiency could bode<br />

well for the future of HCPV, and this still barely<br />

commercial technology has wide margin to bring<br />

down costs if it moves to volume production. HCPV<br />

now reaches 29% efficiency at the module level at<br />

leading suppliers, compared to 17%-20% for the<br />

top flat panels, and it has even more of an edge in<br />

hot climates, as its performance degrades less at<br />

temperature.<br />

Plenty of hurdles remain, however, for this<br />

complicated new technology. Appropriately sunny<br />

locations remain limited, long term reliability remains<br />

unproven and actual commercial production so far<br />

remains insignificant. Though HCPV suppliers claim<br />

that the technology can deliver the lowest levelized<br />

cost of energy with the least use of land on some<br />

sites, the actual results can vary significantly for<br />

particular location, climate and topography, so even<br />

big users first want to try small test installations on<br />

their sites, and this small installation stage could<br />

continue for some time. Meanwhile, the large flat<br />

panel PV sector is continually investing its far bigger<br />

resources into improving its efficiency and bringing<br />

down its costs. While HCPV may have big potential<br />

with enough investment, with the market still so<br />

small, the sector has limited resources to put into<br />

development.<br />

The supply chain of key components on which<br />

HCPVsystems depend has even less to invest, as the<br />

total markets for each of the various components,<br />

from epi wafers to lenses to trackers, remain even<br />

smaller still. Progress will depend on getting to big<br />

projects to get volumes up to bring down costs,<br />

by spreading the fixed costs of the 25MW-50MW<br />

capacity HCPV plants over megawatt and not just<br />

kilowatt-scale projects, and fully automating both<br />

component production and system assembly - and<br />

finding the significant capital to invest to do so.<br />

Perhaps even more important will be finding the<br />

solutions for the most effective business models or<br />

working partnerships among the parts of the supply<br />

chain. As volumes grow, HCPV systems makers<br />

17<br />

“Lasers also have<br />

considerable<br />

potential for<br />

innovative<br />

improvements<br />

to solar<br />

manufacturing,<br />

as their highlylocalized<br />

heating<br />

allows precise<br />

control of<br />

micromachining<br />

with little<br />

thermal stress<br />

or mechanical<br />

damage,”<br />

says Milan Rosina,<br />

Yole Développement


S E P T E M B E R 2 0 1 1 I S S U E N ° 1 3<br />

HCPV supply chain - Positioning of the HCPV players: three scenarios<br />

(Yole Développement, <strong>2011</strong>, HCPV report)<br />

“HCPV systems<br />

makers are largely<br />

outsourcing<br />

production of their<br />

custom component<br />

designs to<br />

optics makers,<br />

tracker makers<br />

and electronics<br />

contract<br />

assemblers,”<br />

says Milan Rosina,<br />

Yole Développement<br />

are largely outsourcing production of their custom<br />

component designs to optics makers, tracker makers<br />

and electronics contract assemblers. But it is difficult<br />

for the system makers to best optimize the system<br />

cost and performance without knowing exactly how<br />

design choices will impact manufacturing costs at<br />

the supplier, or how one component can best be<br />

optimized to work with another component made<br />

by someone else. Optimizing the system requires<br />

careful balancing of all the parts, trading off more<br />

complicated and expensive optical systems for less<br />

accurate trackers or vice versa, or adjusting the<br />

characteristics of the primary optic to those of the<br />

secondary optic, and that’s hard to do by separate<br />

players.<br />

The fragmented sector is equally a problem from the<br />

supplier side. Suppliers argue that the components<br />

could be better designed for efficient low cost<br />

manufacture if the designer knew something about<br />

the manufacturing process, and that components<br />

could be better optimized to work together if they<br />

were designed together. Tracker makers complain<br />

that they have no visibility into if the market is big<br />

enough to support development of custom trackers<br />

for modules of entirely different size, weight, and need<br />

for accuracy. Designing custom components for each<br />

separate system maker’s kilowatt-scale projects is a<br />

very low volume business, with volumes sometimes<br />

only in the hundreds of units, often too small a<br />

business to be of much interest for the supplier, and<br />

too small for efficient volume production.<br />

Much depends on the successful performance of the<br />

early megawatt-scale HCPV projects now coming<br />

on line to build credibility for the technology. But<br />

building the first larger 10s and 100s of megawattscale<br />

installations will also require business<br />

models that enable optimized system design and<br />

foster a viable supply chain to support volume<br />

manufacturing.<br />

www.yole.fr<br />

Milan Rosina is analyst at Yole Développement for<br />

photovoltaic market & technologies. He received<br />

his Ph. D. in 2002 from the INPG in France. He<br />

gained experience as a research scientist in several<br />

renowned R&D institutions & industrial companies<br />

where he worked in the field of microelectronics, PV,<br />

LED & nanotechnology.<br />

18 P V M a n u f a c t u r i n g


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S E P T E M B E R 2 0 1 1 I S S U E N ° 1 3<br />

About Yole Développement<br />

Beginning in 1998 with Yole Développement, we have grown to become a group of companies providing market research, technology analysis,<br />

strategy consulting, media in addition to finance services. With a solid focus on emerging applications using silicon and/or micro manufacturing<br />

Yole Développement group has expanded to include more than 40 associates worldwide covering MEMS and Microfluidics, Advanced Packaging,<br />

Compound Semiconductors, Power Electronics, LED, and Photovoltaic. The group supports companies, investors and R&D organizations worldwide<br />

to help them understand markets and follow technology trends to develop their business.<br />

CONSULTING SERVICES<br />

• Market data, market research and marketing analysis<br />

• Technology analysis<br />

• Reverse engineering and reverse costing<br />

• Strategy consulting<br />

• Corporate Finance Advisory (M&A and fund raising)<br />

REPORTS<br />

• Collection of market & technology reports<br />

• Players & market databases<br />

• Manufacturing cost simulation tools<br />

• Component reverse engineering & costing analysis<br />

More information on www.yole.fr<br />

MEDIA<br />

• Critical news, Bi-weekly: <strong>Micronews</strong>, the magazine<br />

• In-depth analysis & Technology Magazines: MEMS Trends – 3D Packaging – PV Manufacturing – iLED - Power Dev’<br />

• Online disruptive technologies website: www.i-micronews.com<br />

• Exclusive Webcasts<br />

• Live event with Market Briefings<br />

CONTACTS<br />

For more information about :<br />

• Services : Jean-Christophe Eloy (eloy@yole.fr)<br />

• Reports: David Jourdan (jourdan@yole.fr)<br />

• Media : Sandrine Leroy (leroy@yole.fr)<br />

Editorial Staff<br />

Board Members: Jean-Christophe Eloy & Jeff Perkins – Media Activity, Editor in chief:<br />

Dr Eric Mounier – Editor in chief: Arnaud Duteil- Editors: Arnaud Duteil, Milan Rosina,<br />

Paula Doe – Media & PR Manager: Sandrine Leroy – VP New Media Development: Bill<br />

Stinson - Assistant: Camille Favre - Production: atelier JBBOX<br />

20 P V M a n u f a c t u r i n g

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