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Modular thinking may lead to cheaper, more efficient and reliable solar power

While Holman’s top cell research is in its very early stages, another project supported by SunShot may have a much more immediate impact on the industry.

“In this project, we’re working at the module scale, or product scale, if you will,” says Holman of the project. “We’re trying to figure out how to take good, commercially-manufactured silicon cells and do a better job of turning them into a module that is not only efficient and cheap, but reliable.”

The $800,000 award supports research to lower the cost of photovoltaic electricity generation in less than five years by developing a module comprised of back-contact silicon solar cells. While such cells commonly feature interlocking metal fingers on their reverse sides and no metal on their face, the researchers have chosen to eschew metal componentry entirely and instead utilize a “flex-circuit” to connect the cells. The flex-circuit is made of two layers of aluminum foil separated by an insulated layer.

By doing so, there is a reduced use of expensive silver or copper in the modules, which eliminates the need for failure-prone solder points. This will increase the reliability of the module, dramatically reducing the cost of modules and the electricity produced.

“Right now, modules come with a 25-year warranty,” explains Holman. “To calculate the cost of electricity from a solar module, you basically take how much electricity it will put out over 25 years divided by how much it cost. If you were to make a module that had a warranty of 40 years, it would cost roughly the same amount, but produce the electricity over a longer period of time. Just like that, the cost of solar energy would go down by a considerable amount.”

If the project is successful, Holman estimates the cost of rooftop photovoltaic energy generation could drop to just four cents a kilowatt hour. Currently, the average cost rests around 10 cents per kilowatt hour.

Holman is collaborating with Mariana Bertoni, assistant professor of electrical engineering, and Govindasamy Tamizhmani, associate research professor at the Polytechnic School on the project. He’s also formed a relationship with NREL to model the project cost to determine market viability. In addition, solar company Natcore Technologies is collaborating on the research.

Holman attributes the project’s core idea to long-time solar industry veteran Charlie Gay, who recently stepped into the role of director at the SunShot Initiative. Gay previously served as president of Applied Solar at Applied Materials Inc., a semiconductor, solar and display support services provider.

“He’s helped my group in many ways over the past two years, and he ended up coming to me with the idea for solar module manufacturing,” recalls Holman.

Reflecting on both awards, Holman notes both tie into larger research goals he’s established for himself and his group.

“I have tried to position my group as the go-to group for silicon-based tandem solar cells and modules, at least in the U.S.,” says Holman. “I’ve been committed to this topic for about two years now and I’m really excited to get started on the work that needs to be done.”

https://fullcircle.asu.edu/research/fulton-schools-takes-lions-share-solar-research-funding-sunshot/