SOLARAWARDS2011 SHORTLISTED


deposition of the cadmium telluride semiconductor film without the traditional lamination process, has enabled Abound to a ramp module conversion efficiency from 6% to 10% and increase production throughput up to 2.5 MW/month faster.


Innovation


The innovative aspect of Abounds manufacturing technology is the use of a proprietary closed space sublimation process (CSS) in the semiconductor manufacturing step. The use of CSS enables a once-through steady state thin-film photovoltaic process within a single tool. As a result of our novel manufacturing process, our production is significantly less complex, faster and more efficient than all other thin-film PV manufacturers. Compared to competing CdTe module manufacturers,


Abound has optimized its manufacturing and assembly process such that it eliminates five steps (edge grind, chemical etching, photoresist scribe fill, interfacial layer and post metal heat treat), combines six wet and dry semiconductor processes into one single step of semiconductor coating with one tool without breaking vacuum, and improves two back-end module assembly steps (edge delete and module encapsulation). All of this allows for the significant reduction of manufacturing costs without doing away with quality control.


Customer Benefits


Abound’s low-cost manufacturing and assembly processes allow for the modules to be sold to customers at industry-leading costs. Abound Solar is actively working with customer and partners in the Abound Alliance to optimize the system designs and components to reduce the cost of installation.


For example, Abound recently signed a deal with Thesan, an Italian roofing and PV specialist. They have designed a mounting system specifically for Abound Solar modules that reduces installation time by over 50% compared to existing solutions.


THINFAB


Oerlikon Solars next generation fab THINFAB will enable total module production cost at or below 0.5€/Wp and a 120 MWp output capacity.


Oerlikon recognized that for PV to become a significant source for energy amongst the traditional energy sources, solar power had to become economically viable. With the THINFAB with module manufacturing cost at 0.5€ /Wp, energy can be produced at 0.10€/kWh in for example Southern Europe. In many regions of the world this allows energy production at or below grid parity level.


Due to highest equipment availability, reduced process steps in the backend and highly optimized line concept (to balance frontend and backend takt times), Oerlikon Solars THINFAB reaches the highest uptime with lowest level of non-productive time.


Product Challenge Oerlikon Solars THINFAB addresses the challenge to reduce manufacturing cost by 60%. The first generation of thin film silicon manufacturing lines launched 2007 saw modules produced around 1.2€/Wp. To reach grid parity level in sunny regions to make solar power economically viable, manufacturing cost have to cut down to no more than 0.5€/Wp.


Problem Solved Oerlikon Solars THINFAB will enable total module production costs at or below 0.5€ /Wp and 120 MWp output capacity. With the THINFAB with module manufacturing cost at or below 0.5€/Wp, energy can be produced at 0.10€/kWh in for example Southern Europe. In many regions of the world this allows energy production at or below grid parity level.


Noteworthy


The key performance drivers to make solar power economically viable are module efficiency, high productivity of the


manufacturing line and low module material costs. Recent champion modules on full scale with over 11% initial efficiency and the world record stable cell efficiency for Micromorph® of over 11.8% form the foundation for 10% efficiency in average production. Since introducing the Micromorph® technology the productivity of an Oerlikon Solar fab has been increased by more than 100% which helps to significantly drive down the CAPEX per Wp.


Innovation With THINFAB thin film silicon solar power is economically viable first time. Less than 3 years since the market introduction of Oerlikon Solars Micromorph® technology 2007 in Milan the productivity of an Oerlikon Solar fab has been increased by more than 100% which helps to significantly drive down the CAPEX per Wp.


The continuous optimization of module design and qualification of new materials drives down costs and increases the manufacturing robustness by simplifying the production steps. Radical innovations in the core equipment of the end-to-end manufacturing line contribute to the reduction in cost per Wp by offering higher efficiency, higher throughput per capital invested as well as lower energy and material consumption.


Oerlikon Solars unique line concept includes but is not limited to improved central handling system renewed manufacturing execution system and considers all aspects of material logistics. In a cross-functional development approach every detail is optimized for the THINFAB, Oerlikon Solars most advanced turnkey photovoltaic thin film silicon manufacturing line.


Customer Benefits With THINFAB module manufacturing cost at or below 0.5€/Wp, energy can be produced at 0.10€/kWh in for example Southern Europe. In many regions of the world this allows energy production at or below grid parity level. Therefore thin film silicon solar power becomes truly economically viable first time.


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www.solar-pv-management.com Issue VII 2011


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