Record Efficiency of 18.7 Percent for Flexible Solar Cells on Plastics, Swiss Researchers Report

The measurements have been independently certified by the Fraunhofer Institute for Solar Energy Systems in Freiburg, Germany.

It's all about money. To make solar electricity affordable on a large scale, scientists and engineers worldwide have long been trying to develop a low-cost solar cell, which is highly efficient, easy to manufacture and has high throughput. Now a team at Empa's Laboratory for Thin Film and Photovoltaics, led by Ayodhya N. Tiwari, has made a major step forward."The new record value for flexible CIGS solar cells of 18.7% nearly closes the"efficiency gap" to solar cells based on polycrystalline silicon (Si) wafers or CIGS thin film cells on glass," says Tiwari. He is convinced that"flexible and lightweight CIGS solar cells with efficiencies comparable to the"best-in-class" will have excellent potential to bring about a paradigm shift and to enable low-cost solar electricity in the near future."

One major advantage of flexible high-performance CIGS solar cells is the potential to lower manufacturing costs through roll-to-roll processing while at the same time offering a much higher efficiency than the ones currently on the market. What's more, such lightweight and flexible solar modules offer additional cost benefits in terms of transportation, installation, structural frames for the modules etc., i.e. they significantly reduce the so-called"balance of system" costs. Taken together, the new CIGS polymer cells exhibit numerous advantages for applications such as facades, solar farms and portable electronics. With high-performance devices now within reach, the new results suggest that monolithically-interconnected flexible CIGS solar modules with efficiencies above 16% should be achievable with the recently developed processes and concepts.

At the forefront of efficiency improvements

In recent years, thin film photovoltaic technology based on glass substrates has gained sufficient maturity towards industrial production; flexible CIGS technology is, however, still an emerging field. The recent improvements in efficiency in research labs and pilot plants -- among others by Tiwari's group, first at ETH Zurich and since a couple of years now at Empa -- are contributing to performance improvements and to overcoming manufacturability barriers.

Working closely with scientists at FLISOM, a start-up company who is scaling up and commercializing the technology, the Empa team made significant progress in low-temperature growth of CIGS layers yielding flexible CIGS cells that are ever more efficient, up from a record value of 14.1% in 2005 to the new"high score" of 18.7% for any type of flexible solar cell grown on polymer or metal foil. The latest improvements in cell efficiency were made possible through a reduction in recombination losses by improving the structural properties of the CIGS layer and the proprietary low-temperature deposition process for growing the layers as well as in situ doping with Na during the final stage. With these results, polymer films have for the first time proven to be superior to metal foils as a carrier substrate for achieving highest efficiency.

Record efficiencies of up to 17.5% on steel foils covered with impurity diffusion barriers were so far achieved with CIGS growth processes at temperatures exceeding 550°C. However, when applied to steel foil without any diffusion barrier, the proprietary low temperature CIGS deposition process developed by Empa and FLISOM for polymer films easily matched the performance achieved with high-temperature procedure, resulting in an efficiency of 17.7%. The results suggest that commonly used barrier coatings for detrimental impurities on metal foils would not be required."Our results clearly show the advantages of the low-temperature CIGS deposition process for achieving highest efficiency flexible solar cells on polymer as well as metal foils," says Tiwari.

The projects were supported by the Swiss National Science Foundation (SNSF), the Commission for Technology and Innovation (CTI), the Swiss Federal Office of Energy (SFOE), EU Framework Programmes as well as by Swiss companies W.Blösch AG and FLISOM.

Scaling up production of flexible CIGS solar cells

The continuous improvement in energy conversion efficiencies of flexible CIGS solar cells is no small feat, says Empa Director Gian-Luca Bona."What we see here is the result of an in-depth understanding of the material properties of layers and interfaces combined with an innovative process development in a systematic manner. Next, we need to transfer these innovations to industry for large scale production of low-cost solar modules to take off." Empa scientists are currently working together with FLISOM to further develop manufacturing processes and to scale up production.

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Improving Photosynthesis? Solar Cells Beat Plants at Harvesting Sun's Energy, for Now

Plants are less efficient at capturing the energy in sunlight than solar cells mostly because they have too much evolutionary baggage. Plants have to power a living thing, whereas solar cells only have to send electricity down a wire. This is a big difference because if photosynthesis makes a mistake, it makes toxic byproducts that kill the organism. Photosynthesis has to be conservative to avoid killing the organisms it powers.

"This is critical since it's the process that powers all of life in our ecosystem," said Kramer, a Hannah Distinguished Professor of Photosynthesis and Bioenergetics."The efficiency of photosynthesis, and our ability to improve it, is critical to whether the entire biofuels industry is viable."

The annually averaged efficiency of photovoltaic electrolysis based on silicon semiconductors to produce fuel in the form of hydrogen is about 10 percent, while a plant's annually averaged efficiency using photosynthesis to form biomass for fuel is about 1 or 2 percent.

Plants, following the path of evolution, are primarily interested in reproducing and repairing themselves. The efficiency at which they produce stored solar energy in biomass is secondary.

Still, things can change.

Just as early Native Americans manipulated skinny, non-nutritious Teosinte into fat, juicy kernel corn, today's plants can be manipulated to become much better sources of energy.

Researcher Arthur J.Nozik, a NREL senior research fellow, and Senior Scientist Mark Hanna working at DOE's National Renewable Energy Laboratory (NREL), recently demonstrated how a multi-junction, tandem solar cell for water splitting to produce hydrogen can provide higher efficiency -- more than 40 percent -- by using multiple semiconductors and/or special photoactive organic molecules with different band gaps arranged in a tandem structure.

The coupling of different materials with different gaps means photons can be absorbed and converted to energy over a wider range of the solar spectrum.

"In photovoltaics, we know that to increase power conversion efficiency you have to have different band gaps (i.e., colors) in a tandem arrangement so they can more efficiently use different regions of the solar spectrum," Nozik said."If you had the same gap, they would compete with each other and both would absorb the same photon energies and not enhance the solar conversion efficiency."

Photosynthesis does use two gaps based on chlorophyll molecules to provide enough energy to drive the photosynthesis reaction. But the two gaps have the same energy value, which means they don't help each other to produce energy over a wider stretch of the spectrum of solar light and enhance conversion efficiency.

Furthermore, most plants do use the full intensity of sunlight but divert some of it to protect the plant from damage. Whereas photovoltaics use the second material to gain that photoconversion edge, plants do not, Nozik noted.

One of NREL's roles at the DOE workshop was to help make it clear how the efficiency of photosynthesis could be improved by re-engineering the structure of plants through modern synthetic biology and genetic manipulation based on the principles of high efficiency photovoltaic cells, Nozik said. In synthetic biology plants can be built from scratch, starting with amino acid building blocks, allowing the formation of optimum biological band gaps.

The newly engineered plants would be darker, incorporating some biological pigments in certain of nature's flora that would be able to absorb photons in the red and infrared regions of the solar spectrum.

As plants store more solar energy efficiently, they potentially could play a greater role as alternative renewable fuel sources. The food that plants provide also would get a boost. And that would mean less land would be required to grow an equivalent amount of food.

The new information in theSciencemanuscript will help direct the development of new plants that have a better propensity for reducing carbon dioxide to biomass. This could spur exploration of blue algae, which not only comprise about one quarter of all plant life, but are ideal candidates for being genetically engineered into feedstock, because they absorb light from an entirely different part of the spectrum compared to most other plants.

"It would be the biological equivalent of a tandem photovoltaic cell," said Robert Blankenship, one of the lead authors in theSciencepaper who studies photosynthesis at Washington University in St. Louis."And those can have very high efficiencies."

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'Swiss Cheese' Design Enables Thin Film Silicon Solar Cells With Potential for Higher Efficiencies

One long-term option for low-cost, high-yield industrial production of solar panels from abundant raw materials can be found in amorphous silicon solar cells and microcrystalline silicon tandem cells (a.k.a. Micromorph) -- providing an energy payback within a year.

A drawback to these cells, however, is that the stable panel efficiency is less than the efficiency of presently dominate crystalline wafer-based silicon, explains Milan Vanecek, who heads the photovoltaic group at the Institute of Physics in Prague.

"To make amorphous and microcrystalline silicon cells more stable they're required to be very thin because of tight spacing between electrical contacts, and the resulting optical absorption isn't sufficient," he notes."They're basically planar devices. Amorphous silicon has a thickness of 200 to 300 nanometers, while microcrystalline silicon is thicker than 1 micrometer."

The team's new design focuses on optically thick cells that are strongly absorbing, while the distance between the electrodes remains very tight. They describe their design in the American Institute of Physics' journalApplied Physics Letters.

"Our new 3D design of solar cells relies on the mature, robust absorber deposition technology of plasma-enhanced chemical vapor deposition, which is a technology already used for amorphous silicon-based electronics produced for liquid crystal displays. We just added a new nanostructured substrate for the deposition of the solar cell," Vanecek says.

This nanostructured substrate consists of an array of zinc oxide (ZnO) nanocolumns or, alternatively, from a"Swiss cheese" honeycomb array of micro-holes or nano-holes etched into the transparent conductive oxide layer (ZnO).

"This latter approach proved successful for solar cell deposition," Vanecek elaborates."The potential of these efficiencies is estimated within the range of present multicrystalline wafer solar cells, which dominate solar cell industrial production. And the significantly lower cost of Micromorph panels, with the same panel efficiency as multicrystalline silicon panels (12 to 16 percent), could boost its industrial-scale production."

The next step is a further optimization to continue improving efficiency.

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New Mineral Discovered: One of Earliest Minerals Formed in Solar System

This particular grain is known affectionately as"Cracked Egg" for its distinctive appearance. Dr. Harold C. Connolly, Jr. and student Stuart A. Sweeney Smith at the City University of New York (CUNY) and the American Museum of Natural History (AMNH) first recognized the grain to be of a very special type, known as a calcium-aluminum-rich refractory inclusion. ("Refractory" refers to the fact that these grains contain minerals that are stable at very high temperature, which attests to their likely formation as very primitive, high-temperature condensates from the solar nebula.)

Cracked Egg refractory inclusion was sent to Dr. Chi Ma at California Institute of Technology (Caltech) for very detailed nano-mineralogy investigation. Dr. Ma then sent it to Dr. Anthony Kampf, Curator of Mineral Sciences at the Natural History Museum of Los Angeles County (NHM), for X- ray diffraction study. Kampf's findings, confirmed by Ma, showed the main component of the grain was a low-pressure calcium aluminum oxide (CaAl2O4) never before found in nature. Kampf's determination of the atomic arrangement in the mineral showed it to be the same as that of a human-made component of some types of refractory (high-temperature) concrete.

What insight can we get from knowing that a common human-made component of modern concrete is found in nature only as a very rare component of a grain formed more than 4.5 billion years ago? Such investigations are essential in deciphering the origins of our solar system. The creation of the human-made compound requires temperature of at least 1,500°C (2,732°F). This, coupled with the fact that the compound forms at low pressure, is consistent with krotite forming as a refractory phase from the solar nebula. Therefore, the likelihood is that krotite is one of the first minerals formed in our solar system.

Studies of the unique Cracked Egg refractory inclusion are continuing, in an effort to learn more about the conditions under which it formed and subsequently evolved. In addition to krotite, the Cracked Egg contains at least eight other minerals, including one other mineral new to science.

TheAmerican Mineralogistpaper is authored by Chi Ma (Caltech), Anthony R. Kampf (NHM), Harold C. Connolly Jr. (CUNY and AMNH), John R. Beckett (Caltech), George R. Rossman (Caltech), Stuart A. Sweeney Smith (who was a NSF funded Research for Undergraduate (REU) student at CUNY/AMNH) and Devin L. Schrader (University of Arizona). Krotite is named for Alexander N. Krot, a cosmochemist at the University of Hawaii, in recognition of his significant contributions to the understanding of early solar system processes.

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Solar-Thermal Flat-Panels That Generate Electric Power: Researchers See Broad Residential and Industrial Applications

Two technologies have dominated efforts to harness the power of the sun's energy. Photovoltaics convert sunlight into electric current, while solar-thermal power generation uses sunlight to heat water and produce thermal energy. Photovoltaic cells have been deployed widely as flat panels, while solar-thermal power generation employs sunlight-absorbing surfaces feasible in residential and large-scale industrial settings.

Because of limited material properties, solar thermal devices have heretofore failed to economically generate enough electric power. The team's introduced two innovations: a better light-absorbing surface through enhanced nanostructured thermoelectric materials, which was then placed within an energy-trapping, vacuum-sealed flat panel. Combined, both measures added enhanced electricity-generating capacity to solar-thermal power technology, said Boston College Professor of Physics Zhifeng Ren, a co-author of the paper.

"We have developed a flat panel that is a hybrid capable of generating hot water and electricity in the same system," said Ren."The ability to generate electricity by improving existing technology at minimal cost makes this type of power generation self-sustaining from a cost standpoint."

Using nanotechnology engineering methods, the team combined high-performance thermoelectric materials and spectrally-selective solar absorbers in a vacuum-sealed chamber to boost conversion efficiency, according to the co-authors, which include MIT's Soderberg Professor of Power Engineering Gang Chen, Boston College and MIT graduate students and researchers at GMZ Energy, a Massachusetts clean energy research company co-founded by Ren and Chen.

The findings open up a promising new approach that has the potential to achieve cost-effective conversion of solar energy into electricity, an advance that should impact the rapidly expanding residential and industrial clean energy markets, according to Ren.

"Existing solar-thermal technologies do a good job generating hot water. For the new product, this will produce both hot water and electricity," said Ren."Because of the new ability to generate valuable electricity, the system promises to give users a quicker payback on their investment. This new technology can shorten the payback time by one third."

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Hydrogen Fuel Tech Gets Boost from Low-Cost, Efficient Catalyst

The discovery is an important development in the worldwide effort to mimic the way plants make fuel from sunlight, a key step in creating a green energy economy. It was reported inNature Materialsby theorist Jens Nørskov of the Department of Energy's SLAC National Accelerator Laboratory and Stanford University and a team of colleagues led by Ib Chorkendorff and Søren Dahl at the Technical University of Denmark (DTU).

Hydrogen is an energy dense and clean fuel, which upon combustion releases only water. Today, most hydrogen is produced from natural gas which results in large CO₂-emissions. An alternative, clean method is to make hydrogen fuel from sunlight and water. The process is called photo-electrochemical, or PEC, water splitting. When sun hits the PEC cell, the solar energy is absorbed and used for splitting water molecules into its components, hydrogen and oxygen.

Progress has so far been limited in part by a lack of cheap catalysts that can speed up the generation of hydrogen and oxygen. A vital part of the American-Danish effort was combining theory and advanced computation with synthesis and testing to accelerate the process of identifying new catalysts. This is a new development in a field that has historically relied on trial and error."If we can find new ways of rationally designing catalysts, we can speed up the development of new catalytic materials enormously," Nørskov said.

The team first tackled the hydrogen half of the problem. The DTU researchers created a device to harvest the energy from part of the solar spectrum and used it to power the conversion of single hydrogen ions into hydrogen gas. However, the process requires a catalyst to facilitate the reaction. Platinum is already known as an efficient catalyst, but platinum is too rare and too expensive for widespread use. So the collaborators turned to nature for inspiration.

They investigated hydrogen producing enzymes -- natural catalysts -- from certain organisms, using a theoretical approach Nørskov's group has been developing to describe catalyst behavior."We did the calculations," Nørskov explained,"and found out why these enzymes work as well as they do." These studies led them to related compounds, which eventually took them to molybdenum sulfide."Molybdenum is an inexpensive solution" for catalyzing hydrogen production, Chorkendorff said.

The team also optimized parts of the device, introducing a"chemical solar cell" designed to capture as much solar energy as possible. The experimental researchers at DTU designed light absorbers that consist of silicon arranged in closely packed pillars, and dotted the pillars with tiny clusters of the molybdenum sulfide. When they exposed the pillars to light, hydrogen gas bubbled up -- as quickly as if they'd used costly platinum.

The hydrogen gas-generating device is only half of a full photo-electrochemical cell. The other half of the PEC would generate oxygen gas from the water; though hydrogen gas is the goal, without the simultaneous generation of oxygen, the whole PEC cell shuts down. Many groups -- including Chorkendorff, Dahl and Nørskov and their colleagues -- are working on finding catalysts and sunlight absorbers to do this well."This is the most difficult half of the problem, and we are attacking this in the same way as we attacked the hydrogen side," Dahl said.

Nørskov looks forward to solving that problem as well."A sustainable energy choice that no one can afford is not sustainable at all," he said."I hope this approach will enable us to choose a truly sustainable fuel."

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Chemist Designs New Polymer Structures for Use as 'Plastic Electronics'

Those tricks improve the properties of certain organic polymers that mimic the properties of traditional inorganic semiconductors and could make the polymers very useful in organic solar cells, light-emitting diodes and thin-film transistors.

Conductive polymers date back to the late 1970s when researchers Alan Heeger, Alan MacDiarmid and Hideki Shirakawa discovered that plastics, with certain arrangements of atoms, can conduct electricity. The three were awarded the 2000 Nobel Prize in Chemistry for the discovery.

Jeffries-EL, an Iowa State assistant professor of chemistry, is working with a post-doctoral researcher and nine doctoral students to move the field forward by studying the relationship between polymer structures and the electronic, physical and optical properties of the materials. They're also looking for ways to synthesize the polymers without the use of harsh acids and temperatures by making them soluble in organic solvents.

The building blocks of their work are a variety of benzobisazoles, molecules well suited for electrical applications because they efficiently transport electrons, are stable at high temperatures and can absorb photons.

And if the polymers are lacking in any of those properties, Jeffries-EL and her research group can do some chemical restructuring.

"With these polymers, if you don't have the properties you need, you can go back and change the wheel," Jeffries-EL said."You can change the chemical synthesis and produce what's missing."

That, she said, doesn't work with silicon and other inorganic materials for semiconductors:"Silicon is silicon. Elements are constant."

The National Science Foundation is supporting Jeffries-EL's polymer research with a five-year,$486,250 Faculty Early Career Development grant. She also has support from the Iowa Power Fund (a state program that supports energy innovation and independence) to apply organic semiconductor technology to solar cells.

The research group is seeing some results, including peer-reviewed papers over the past two years inPhysical Chemistry Chemical Physics, Macromolecules, the Journal of Polymer Science Part A: Polymer Chemistry,and theJournal of Organic Chemistry.

"This research is really about fundamental science," Jeffries-EL said."We're studying the relationships between structure and material properties. Once we have a polymer with a certain set of properties, what can we do?"

She and her research group are turning to the molecules for answers.

"In order to realize the full potential of these materials, they must be engineered at the molecular level, allowing for optimization of materials properties, leading to enhanced performance in a variety of applications," Jeffries-EL wrote in a research summary."As an organic chemist, my approach to materials begins with small molecules."

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