r&d on innovative solar cells koichi sakuta pv in aist

8/6/2019 R&D on Innovative Solar Cells Koichi SAKUTA PV in AIST

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Photovoltaic Research in AIST

Koichi Sakuta

Research Center for Photovoltaics, AIST


2/24

New Sunshine Project initiated

New Sunshine Project Completed

1974

1980

1997

2000

1993

Establishment of NEDO

Residential PV System Technology

Low Cost SOG-Si Production Process

Basic Technology for SiliconSolar Cells (wafer, cell-process)

500 KW Pilot Production- Line for

mc-Si Solar Cells

Technology for a-Si Solar Cells Production

1MW PV Power Plant

Low Cost mc-Silicon Solar Cells Production Technology

(Efficiency = 17.2%, 189 JPY/W)

Thin Film Silicon Solar Cells (140 JPY/W)

R&D Items

R&D Results

Sunshine Project initiated 0

500

1000

1500

2000

2500

3000

3500

4000

19909 1 92 93 94 95 96 97 98 99 0 0 01 02 03 04 05 06 0 7

Road MapPV2030

2004

Progress of PV R&D in Japan


3/24

World PV Module Production

(Source: PV News)

0

500

1000

1500

2000

2500

3000

3500

4000

Producton(MW)

93 94 95 96 97 98 99 00 01 02 03 04 05 06 07

Year

Others

USA

Europe

Japan


4/24

[PV System Deployment Images] (Examples)

Industrial

Residential

Overseas

7 Yen/kWh

23 Yen/kWh

2002 2007 2010 2020 2030

14 Yen/kWh

E

lectricityCost

30 Yen/ kWh

~50 Yen/kWh

Bulk Si &Thin Film Si/Compound

Grid-Connectedwith Higher Degree

of Autonomy

>Less-dependent to Grid

from Individual to Clustered

ActiveGrid Control

Cost Reduction by Tech.Generation Change

Emergence ofNew Material

Large SystemLong Life BOS

Very-Thin Cell/Multi-junction

New Material/ StructureEx.: Dye-sensitized

Rechargeable BatteryBack up system

Conventional Grid-Connected

Community PV- ClusterdBroader Area Clusterd PVRenewable Energy Network

In-Factory High Voltage-Connected/ Captive Load/Building Integrated PV

Solar Home System (SHS)Hydrogen Production

Very Large Scale PV (VLS-PV)

[PV System Deployment Images] (Examples)

Industrial

Residential

Overseas

7 Yen/kWh

23 Yen/kWh

2002 2007 2010 2020 2030

14 Yen/kWh

E

lectricityCost

30 Yen/ kWh

~50 Yen/kWh

Bulk Si &Thin Film Si/Compound

Grid-Connectedwith Higher Degree

of Autonomy

>Less-dependent to Grid

from Individual to Clustered

ActiveGrid Control

Cost Reduction by Tech.Generation Change

Emergence ofNew Material

Large SystemLong Life BOS

Very-Thin Cell/Multi-junction

New Material/ StructureEx.: Dye-sensitized

Rechargeable BatteryBack up system

Conventional Grid-Connected

Community PV- ClusterdBroader Area Clusterd PVRenewable Energy Network

In-Factory High Voltage-Connected/ Captive Load/Building Integrated PV

Solar Home System (SHS)Hydrogen Production

Very Large Scale PV (VLS-PV)

PV2030 Long-term Roadmap for PV R&D and Introduction


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Mission and Policy Statement of RCPV(1) R&D for new materials and devices

Cost reduction, lower environmental impacts(2) Characterization, testing, standardization Infrastructure for industry(3) System operation, evaluation Infra technology for energy source(4) International cooperation Collaboration and competition

- Rapid technology transfer using integrating platform- Impartial evaluation and advice to policymakers


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Organization Chart of RCPV

Advanced Crystalline

SiliconNovel Silicon

Materials

Advanced Organic

Material

Thin Film

Compoundsemiconductor

Characterization, Testing and System

Seeds

Needs

Infra for Industries

Strategic

Industrialization


7/24

Crystalline Silicon Cells

Plasma Slicing

High efficiency thin substrate cells

Hetero junction cells, Light trapping structure

HIT

50 m cell

Advanced Crystalline Silicon Team

Thinner Cells < 100m

Sliced silicon ingot(kerf loss: 120m ditch depth: 8.2mm)

Sliced silicon ingot(kerf loss: 120m ditch depth: 8.2mm)

Cell thickness ( m )

Single -crystalline

Poly-crystalline150 m 120 m 100 m

(5X5cm, 2X2cm)

(2X2cm)

200 m 100 m

Commercial cells

Cell thickness ( m )

Single -crystalline

Poly-crystalline150 m 120 m 100 m

(5X5cm, 2X2cm)

(2X2cm)

200 m 100 m

Commercial cells


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Amorphous Si

Microcrystalline Si

Small absorption coefficient ininfrared region

Wavelength (nm)

400 600 800 1000 1200 1400

QE(a

.u.) a-Si

c-Si

AM1.5G

p

n

i

p

n

ic-Sia-Si

a-Si:H c-Si:H c-Si1-xGex:H

i

p

nc-Si1-xGe x

c-Si1-x

Gex

Microcrystalline Si1-xGex

Higher IR response with

narrower Eg material

double =12-13% triple = 16%

Jsc(SiGe) >>30 mA/cm2

Triple Tandem Solar CellNovel Silicon Materials Team


9/24

18.1% Wide-gap Cell

Thin Film Compound Semiconductor Team

15.9%

17.7%

CIGS Cell

Integrated Sub-module

Flexible Cell

10cm x 10cm


10/24

Polymer Cell (P3HT:PCBM)

PCE = 3.8 % @ 1cm2

JSC = 9.68 mA cm-2

VOC

= 0.62 V, FF = 0.64

-1.0 -0.5 0.0 0.5 1.0

-10

0

10

Currentdensity/mAcm

-2

Voltage / V

LightDark

S

S

S

S

C6H13 C6H13

nC6H13 C6H13

ITO

Sub-module and Flexible Cell

Advanced Organic Material Team


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Strategic Industrialization Team

Flexible solar-cell substrates

consortium

NIPPON GOHSEI

FilmsFilms

MachinesMachines

ProcessingProcessing

Observer: Industrial Research Inst of Ishikawa, PV manufacturer

First Phase: 2006.6.1 - 2008.3.31

NIPPON GOHSEI

FilmsFilms

MachinesMachines

ProcessingProcessing

Observer: Industrial Research Inst of Ishikawa, PV manufacturer

First Phase: 2006.6.1 - 2008.3.31

Plasma CVD apparatus for thin-filmsilicon solar cells with a substrate size of

310 mm 410 mm.

Rapid transfer of basic technologiesPractice of Open Innovation

Example of Apparatus


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SR measurements of each cell in a module

Calibration System for

Primary Reference Cell

Accredited for primary reference

cell calibrations required byISO/IEC17025 in global MRA

AIST

AIST

Long term reliability test of PV modules

Combined stressesacceleration test

equipment

Characterization, Testing and System Team


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Detection of failure byPassive Diagnostic

(compare mes. vs calc.)

Separation of problem( PCS / PV Array )

Identify failure point and typeby Active Diagnostic

In case of PV array problem

0 3 6 9 12 15 18 21 24

PVBase powerpower demand

Time [hour]

Minimum power of coalpower of geothermal

Base power + PV < Power Demand

power of hydro

power of nuclear0.0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

0.9

1.0

1.1

5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

Hour

Irrad

iance[kW/m2]

-20

-10

0

10

20

30

40

50

60

70

80

90

PVModuleTemperature[oC]

OKE, FineDaily Irradiation:

7.6 [kWh/m2]

PV Module Temp.*

43.7 [oC]

Energy Rating of PV Systems

Characterization, Testing and System Team

Estimation of PV Introduction Potential

Performance Diagnostic of PV Systems


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Mega-SolarTownMegaMegaMega---SolarTownSolarTownSolarTown


15/24

Mega-SolarTown: Overview

Start operation: April 2004

Total capacity

DC: 869kWp (approx. 5,600 PV modules) AC: 844kW (211 units of 4kW power conditioner)

First MW-scale PV in Japan (including existing 150kW PV systems)

Commercial PV modules / systems showcase Mono-crystalline Si, poly-crystalline Si, amorphous Si and hetero

junction Si modules

Aggregation of 4kW residential PV systems

Power generation:106kWh / year = 0.8% of total demand in the area

= 300 tons of CO2 reduction / year


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17/24

EfficientLNG-fired plants

Superconductingpower transmission

SolarOil LNG Coal Nuclear Power BiomassEfficiency improvement Low carbon Tech

Efficient coal-firedpower plant

Advancednuclear power

Wind

Powergeneration/

transmission

Powergeneration/

transmission CCS

InnovativePhotovoltaics

Suppl

yside

Dem

andside

Hydrogen production/

storage/transportPower storage Power electronics

Cross-sectoral

Cross-sectoral

HEMS/BEMS/Regional EMS

Efficienthouses/bldgs.

Efficientlighting

Superheat pumps

Low energy ITdevices/networks

Fuel cells for

residential use

Residence

/Building

Residence

/Building

Innovative materials/manufacturing process

Steel-making process withhydrogen

IndustryIndustry

Key Innovative Energy Technologies toward Cool Earth 50

PHEV/EVITS FCVTransportTransport Biofuel


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2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014Year

PV sys.PromotedPractical

Tech.

R&D on Innovative Solar Cellsfor 2050)

Verification of Grid Stabilization

with Large-scale PV PowerGeneration Systems

R&D for

Next Generation PV

Sys. (target at 2030)

Advanced Solar Cell Tech.

(target at 2010)

Grid-interconnection of clusteredPhotovoltaic Power Generation

PV Sys. Advanced

Manufacturing

Technology

PV Sys. Adv.

Practical Tech.

Grid

Co

nnection

Sho

rtterm

pro

gram

Innovative PV Tech.

(target at 2020, 2030)Mid-Long

term

program

Overview of NEDOs PV R&D program


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Objective:To achieve a photovoltaic power generation with a

conversion efficiency of more than 40% and an electricitygeneration cost of 7 JPY/kWh or less in around 2050.

Scheme:

Three Core Research Centers were selected (July 2008).

1. RC for Adv. Sci. & Tech., The University of Tokyo

2. RC for Photovoltaics, AIST

3. Tokyo Institute of Technology

Period: FY2008 - FY2014 (7 years)

Budget: 2.2 billion yen / 14 million euro (FY2008)

R&D on Innovative Solar Cells(International COE Program)


20/24

Univ. Tokyo Group: Prof. Y. Nakano

Post-silicon solar cells for ultra-high efficiencies

Multi Junction, High concentrator, III-V Compounds, Intermediate Band,Quantum dots, New Concepts, New Materials

AIST Group: Dr. M. Kondo

Exploring novel thin multi-junction solar cells with highly-ordered structure Multi Junction, No concentrator, Thin ()c-Si(Ge), CIS, Light Management andTCO, Quantum dots, New Concepts, New Materials

Tokyo Tech Group: Prof. M. Konagai

Thin film full spectrum solar cells with low concentration ratios

Multi Junction, Low concentrator, Thin Films, Light Management and TCO,Quantum dots, New Concepts, New Materials

R&D on Innovative Solar Cells(FY2008-2014)


21/24

AIST Group: Dr. M. Kondo

Exploring novel thin multi-junction solar cells with highly-ordered structure

Multi Junction, No concentrator, Thin ()c-Si(Ge), CIS, Light Management andTCO, Quantum dots, New Concepts, New Materials

TargetSolar cells with efficiency over 40% andSolar cells with cost below 7 yen/kWh

by 2050 with international collaboration.

TargetOver 25% efficiencies in 2015for Si-based triple-junction and compound-semiconductor-based

four-junction thin-film solar cells10% efficiencies in 2015

for single-junction solar cells using new concepts.

Usefulness of light-management technologies

will be shown by fabricating solar cells.


22/24

Smart stack structure

Mechanicalstack Monolithic(latticematching)

smartstackstructure 22

TCO

Top cell

middle cell

bottom cell

Materials Component cells Stacked cell

Intermediatesubstrate

bonding

bonding

Back contact

h> 1.8 eV

1.8 >h> 1eV

1 >h> 0.7 eV

Mechanically

OpticallyElectrically

bonded

TCO

Top cell

middle cell

bottom cell

Materials Component cells Stacked cell

Intermediatesubstrate

bonding

bonding

Back contact

h> 1.8 eV

1.8 >h> 1eV

1 >h> 0.7 eV

Mechanically

OpticallyElectrically

bonded


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CIS-based 4Jcells

Si-based 3J cells

Novel conceptsand materials

Advanced lightmanagement

Wideand

narrow-g

ap

materials

Structure of project


24/24

Scenario for industrializationWafer base c-Si

Thin film (Si, CIGS, CdTe)

1stGen.2

nd

Gen.3.1 Gen. 3.2 Gen.

X

20031954

B.C.

2014 2030 2050

New comers

Thin filmbase MJ

Waferbase MJThis project

Before c-Si

Feedback to current technology

r&d on innovative solar cells koichi sakuta pv in aist

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