l'industrie photovoltaïque : comment la recherche ... · 2008 2020 silicon km2 0 200 400 600...

L'industrie Photovoltaïque : Comment la recherche contribue à l'atteinte du seuilde compétitivité

Dr. Philip BoydellTechnology Manager EMEADuPont Photovoltaics Solutions

Ecole Polytechnique8 novembre 2010

2

DuPont Photovoltaic Solutions © DuPont

Ordre du jour

• DuPont

• L’Industrie Photovoltaique

• Les Innovations de DuPont pour l’Industrie Photovoltaique

3


Megatrends �� OpportunitiesMegatrendMegatrend DuPont SolutionsDuPont Solutions

Increasing Food Production

Seeds, Crop Protection Products, Food and Nutrition Products,Food Packaging Materials

Decreasing Dependence on Fossil Fuels

PV, Fuel Cell Components, Energy Efficient Tyvek® Materials, Light Weight Polymer Composites for Transportation, Biofuels, Biomaterials

Protecting Lives and theEnvironment

Kevlar®, Nomex® and Tyvek® for Worker Protection, SentryGlas®, Safety Services, Environmental Protection Material Solutions

Growing in Emerging Markets

Agricultural Products, Materials for Construction and Infrastructure Projects, Coatings, Photovoltaics, Food Packaging

4


R&D Investment: $1.4 billion in 2009

Electronics: 9%

Chemicals and Materials: 14%

Protecting Lives and the Environment: 12%

Decreasing Dependenceon Fossil Fuels : 15%

Increasing Food Production: 50%

5


Fiber Science& Engineering

PrecisionPatterning

Coating& Color Science

Particle &Dispersion

Science

Surface &Colloidal Science

Catalysis

FluoroChemical &

PolymerSynthesis

Inorganic /Organic

Synthesis

RheologyControl

Inorganic-Organic

Composites

PolymerProcessing

FormulationScience

Polymer Synthesis

FermentationEngineering

MolecularBiology

ConventionalBreeding

Microbiology

Molecular Breeding

PlantGenetics

ProteinEngineering

Bio-informatics

Genomics

Cell / TissueCulture

Plant Physiology/

Disease

Agronomy

MetabolicEngineering

GeneRecombination& Regulation

Entomology

Biochemistry

Film Fabrication

ChemicalEngineering

Nanoscience

Enabling TechnologiesChemical Sciences Biological Sciences Materials Science

Engineering, Analytical Science, Scientific Computing, Modeling & Simulation, Toxicology, Environmental Science, Regulatory Science, Application Development

DuPont Core Technologies

© 2010 E.I. du Pont de Nemours and Company. All rights reserved,

Fiber Science& Engineering

PrecisionPatterning

Coating& Color Science

Particle &Dispersion

Science

Surface &Colloidal Science

Catalysis

FluoroChemical &

PolymerSynthesis

Inorganic /Organic

Synthesis

RheologyControl

Inorganic-Organic

Composites

PolymerProcessing

FormulationScience

Polymer Synthesis

FermentationEngineering

MolecularBiology

ConventionalBreeding

Microbiology

Molecular Breeding

PlantGenetics

ProteinEngineering

Bio-informatics

Genomics

Cell / TissueCulture

Plant Physiology/

Disease

Agronomy

MetabolicEngineering

GeneRecombination& Regulation

Entomology

Biochemistry

Film Fabrication

ChemicalEngineering

Nanoscience

Enabling TechnologiesChemical Sciences Biological Sciences Materials Science

Engineering, Analytical Science, Scientific Computing, Modeling & Simulation, Toxicology, Environmental Science, Regulatory Science, Application Development


© 2010 E.I. du Pont de Nemours and Company. All rights reserved,


6


Solar Resource Dwarfs All Other Energy Sources

Source: SunEdison April 2008

© Richard Perez, et al.

Coal

SOLAR

World Energy Use

Petroleum

Natural Gas

Wind

Biomass

Hydro

Waves

Uranium

PV is only ~0.1% of Total Global Generating Capacity

Fossil Fuels &Nuclear

Other Renewables

7


DuPont Materials in the History of PV

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9


10


Grid Parity

Leve

lized

cost

of

elec

tric

ity

time

From PV

From grid

Market

Today

Primary FuelDistribution

Market structure

Incentivized

TechnologyScale

‘Free market’

Grid parity

11


12


2.86.2

7.9

126.8

129.9

18.6

7.6

14.4

0

10

20

30

40

50

60

70

2008 2012

Materials Play a Critical Role in Total Cost

PV Industry Value Breakdown

35

MarketValue($bn)

63

System Design/ Install (~20%)

Balance of System(~30%)

Modules/Cells (~20%)

Poly-Silicon

Other Materials

All Materials(~30%)

All Materials(~30%)

Source: Photon Consulting, Linx Consulting 1Q 2009 Reports

13


Market Growth Driving Strong Materials Demand

kt

0

200

400

600

800

2008 2020

Silicon

km2

0

200

400

600

800

2008 2020

Glass

t

0

2000

4000

6000

8000

2008 2020

Silver Paste

km2

0

200

400

600

800

2008 2020

Backsheet

km2

0

500

1000

1500

2008 2020

Encapsulant

t

0

5,000

10,000

15,000

20,000

2008 2020

Aluminum Paste

600kt600kt 650km2650km2

600km2600km2 1,300km21,300km2

6,000t6,000t 12,000t12,000t

Global materials volume projections (assuming growth to 100GWp in 2020)

14


Major Investments Needed to Support Growth

15


16


DuPont Apollo ‘C’ series

amorphous silicon / microcrystalline silicon>9% efficiency

17


Key Drivers for Photovoltaics competitiveness

Cost€ installed

Yield kWh/y

R&D must deliver improvements in these areas

Quality &Reliability

years to amortize

18


PV Innovation Pipeline

19


Cost€ installed

Yield kWh/y


years to amortize

•N-type silicon wafers•Improved cell metallization•Higher aspect ratio metallization•Improved anti-reflective coatings•Textured tabbing ribbons•Improved transparent conductive oxides•Better reflector films•Higher blue light transparent materials•More temperature resistant substrates•Thermally conductive substrates


20


Ag Metal

Al Metal

Emitter Layern-type Base Layer

p-type

Antireflective Coating

SiNx:H 80nm n-pjunction

Frontside Ag pastes

Backside Al Backside Ag tabbing

��

�� λλλλ��

��

��

21


Improving Cell Performance: Metallization Roadmap

22


Local BSF with rear surface passivation

Two problems affect all Al pastes

1) Al has poor adhesion to the SiNx unless it has some glass frit 2) If the Al paste has glass frit voids form at the edge of the Al-Si contact area

We are working to maximize adhesion and minimize the voids

Aluminium

BSF

23


Higher Efficiency Metallization Pastes

24


Polymeric Frontsheet Materials

�� A flexible, protective, durable transparent film as frontsheet for PV modules.

Desired Features

• High light transmission

• Easier-cleaning• Lightweight• Flexible• Anti-glare• UV resistant• Cut Resistance • Good adhesion

Benefits

• Higher Power output• Less breakage• Easier handling• More design options• Low maintenance

costs• Long-life durability• Light weight

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Polymeric Frontsheet Materials

EVA

DuPont Fluoropolymer / rigid substrate

DuPont Fluoropolymer

Rigid substrate

Conventional Glass/ Back sheet

c-Si Cell

3.8mm Glass

1mm EVA

Backsheet

9kg/m2Photo ‘Lumeta PowerPly’ courtesy DRI Industries

26


Frontsheet Materials with Better transmission

Transmission:

1-3% Improvement

Weatherability:

20yr Outdoor Aging

Teflon® FEP FilmsHigh durabilityLow moisture permeabilityHigh transparencyWide operating temperature

Integrated Frontsheets with Teflon®FEP

Frontsheet + encapsulants

27


Power Improvement and Durability

� ��

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Damp Heat Aging Heat-FreezeCycling

UV Aging

Film yield point

Pass / Fail point

Pmax W

77.4

76.877.0

78.4

76.0

77.0

78.0

79.0

Teflon®2mil FEP

Teflon®2mil ETFE

Competitive 2mil ETFE

Competitive 2mil PVDF

Power output for Commercial BIPV Modules 1:

1-2% Improvement

0.94

0.96

0.98

1.00

1.02

1.04

1.06

1.08

ETFE/EVA FEP/EVA

Frontsheet Type

Pp

(Arb

itrar

y)

Power output for Commercial BIPV

Modules 2:5% Improvement

28


Reflective Back Encapsulant

Thin film Si module

Source: DuPont

avant après

Whitepaint

PVB

White PVB

“DuPont™ PV5223”

• PV5223 0250100 reflective encapsulant films introduced to market in April 2010

29


Lower material consumption

0.45mm thick new DuPont™ PV5223 – 0250100 white PVB encapsulant sheetMore than 40% lighter than traditional 0.76mm clear PVB.

30


0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

0.9

1

350 450 550 650 750 850 950 1050Wavelength, nm

Ref

lect

ance

PV5223 - 0250100

White paint

Increase power output

Higher Reflection

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DuPont™ Kapton® films for flexible thin film substrates

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Cost€ installed

Yield kWh/y


years to amortize


Thinner Si wafersLower quality UMG (upgraded metallurgical grade) siliconFaster lamination cycle timeSimpler mounting & racking systemsLess moisture sensitive encapsulantsThinner encapsulant filmsThinner backsheet filmsNew backsheet constructions Lighter weight materials

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10kg/ 1.1m x 1.4m module15kg/ 1.1m x 1.4m module > 30% WeightReduction

1.8mm PV5300

PV5300 with 2 x Ultrafine float Glass

1.1 mm UFF

1.1 mm UFF

Conventional Glass/ Back sheet

c-Si Cell

3.8mm Glass

1mm EVA

Backsheet

DuPont™ PV5300 ionomer

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Glass robustness with polymer lightweighting

Tougher (5x), stiffer (100x) than PVB

DuPontTM PV5300 Ionomer Ultrafine float glass

0.3mm to 1.1mm

Laminationtechnology

35


0

50

100

150

200

250

-20 -10 0 10 20 30 40 50 60

Glass/Ionomer/Glass Glass/EVA/Glass Glass/PVB/Glass

EVA

PVB

Temperature (deg.C)

��

(N)

Fig. Shimadzu Autograph (AG-X)1kN load cell, 3 point bending, Sample : 15*90*t3.0mm

The bending test showed highest strength for laminated glass with ionomer

142N

65N 51N

Bending test

(PV5300)

36


DuPont™ Gevity™ PV Intégré

37


Ses avantages

Peu de pièces

Peu de bois (liteau et planche) à rajouter lors de l’installation

Pas de mise à la terre requise

Pas de cote à prendre (gabarits)

Pas de vis apparente, donc possibilité de bâcher, si besoin, en coursd’installation

Coins spéciaux facile à mettre en place

38


Cost€ installed

Yield kWh/y


years to amortize

Improved encapsulantsImproved anti-soiling/fouling coatingsMore durable backsheetsBetter edge sealingHigher reliability invertersThermally conductive substratesMicroinvertersFlexible moisture barriers


39


PV Module Lifetime – Reliable Power Generation

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JRC study shows consistent low power loss of TPT backsheetin PV modules over the >20 year test period

40


Backsheet Adhesion to Encapsulant After Damp Heat

pull

EVAglass

Backsheet

EVA: Bixby BixCure®

* Adhesion not measurable due to backsheet break+ EVA peel from glass indicating strong EVA/backsheet adhesion

0

20

40

60

80

100

120

140

160

PET THV PFAVE PVDF G1 TPT G2 TPT G3 TPT G2 TPE

EV

A p

eel (

N/c

m)

0h

500h

1000h

* * * * + *

Loss of EVA adhesion for PET and other fluoropolymerbased backsheets

THV

PET

EVA

PVDF

PET

PE

PFAVE

PET

EVA

PVF1

PET

PVF1

PVF2

PET

PVF2

PVF3

PET

PVF3

PVF2

PET

EVA

PET

PET

primer

PFV1=PV2000 seriesPVF2=PV2100 seriesPVF3=PV2400 series

41


Transparent Flexible Ultrabarrier

Enables flexible CIGS modules

42


PV5300 limits Moisture Ingress v EVA

ASTM D7191 - Moisture analysis (uncalibrated)

0.000

0.001

0.002

0.003

0.004

0.005

0.006

0 2 4 6 8 10 12Distance from Edge (cm)

Moi

stur

e (g

H2O

/gto

tal )

1000h - Fickian Diffusion for EVA

1002h Commercial EVA Encap B

1020h - Encap C

1003h - Encap D

1005h - Encap E

1006h - PV5300

Cost savings of $3/panel by elimination of edge sealing

43



Cost Yield

R&D is and must continue to deliver improvements in these areas


44


Material Innovation will play a critical role in driving the industry to grid parity this decade.

• Importance of a system approach

• The key role of Open Innovation and collaborative partnerships

PV Application Lab, Meyrin (Switzerland)Opened Feb 1, 2010

45


l'industrie photovoltaïque : comment la recherche ... · 2008 2020 silicon km2 0 200 400 600...

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