PFI-TT: Highly Flexible and Bendable Photovoltaic Module Architectures for Enhanced Usability

该创新技术转化伙伴关系（PFI-TT）项目的更广泛影响/商业潜力是开发一种灵活、可弯曲的光伏组件技术，该技术具有晶体硅的优点，效率高，使用寿命长，弯曲半径比目前最先进的晶体硅组件小七倍。所选择的技术使这些模块具有25年的保修期，这对于刚性太阳能电池板来说是很常见的。可弯曲模块可以用于传统刚性模块不能使用的地方，因为没有安装空间，面板太重，无法支撑结构，模块无法承受风力，或者不美观。该项目开发的模块将实现以前不可能实现的光伏项目，例如建筑集成光伏或以能量收集为特色的智能城市基础设施。这项技术有助于扩大现有的光伏能源收集市场，并开辟新的市场机会。非刚性模块可以很容易地安装到曲面上，使这些面板的安装更容易，更有吸引力，用于娱乐甚至住宅用途。拟议中的项目旨在开发薄硅晶片，这种晶片可以在加工过程中不会造成破损和缺陷，这可能会影响组件中光伏电池的可靠性。了解缺陷的本质以及在制造过程中如何引入缺陷是减少浪费和降低制造成本的关键，这将最终影响模块的价格。目标是确定生产过程中的问题，并将制造成品率提高到用于刚性太阳能电池板的厚硅晶圆加工的常见水平。将调查使用处理晶圆和工艺工具修改等缓解措施之间的权衡。第二个需要解决的问题是柔性太阳能组件中电气互连的可靠性。刚性面板中的电气互连是由于机械应力断裂而导致问题的常见来源。该团队将研究可替代的电动总线连接，这种连接对机械应力具有弹性，并且具有减少太阳能模块中银资源消耗的额外好处。将进行环境测试，以确定这些柔性和可弯曲模块的可靠性，以确保其使用寿命与刚性晶体硅太阳能电池板竞争。该奖项反映了美国国家科学基金会的法定使命，并通过使用基金会的知识价值和更广泛的影响审查标准进行评估，被认为值得支持。

The broader impact/commercial potential of this Partnerships for Innovation - Technology Translation (PFI-TT) project is the development of a flexible, bendable photovoltaic module technology that features the benefits of crystalline silicon, efficiency and long service lifetime, and a bending radius that is seven times smaller than the current state-of-the-art crystalline silicon module. The technology chosen enables a 25-year warranty on these modules, which is common for rigid solar panels. Bendable modules can be used where traditional rigid modules cannot because there is no space for mounting, the panel is too heavy for the supporting structure, the module will not withstand wind forces, or it is not aesthetically pleasing. The modules developed in this project will enable photovoltaic projects that were impossible previously, for example building-integrated photovoltaics or smart city infrastructure that features energy harvesting. The technology helps to grow the existing market of photovoltaic energy harvesting and opens new market opportunities. Non-rigid modules can be easily mounted to curved surfaces, making installation of these panels much easier and more attractive for recreational and even residential use.The proposed project seeks to develop thin silicon wafers that can be processed without causing breakage and defect, which could affect the reliability of the photovoltaic cells in the modules. Understanding the nature of defects and how defects are introduced in the manufacturing process is key to reducing waste and keeping manufacturing costs down, which will ultimately affect the module price. The goal is to identify issues in the production process and improve the manufacturing yield to levels common for thick silicon wafer processing, used in rigid solar panels. The trade-off between using mitigations like handle wafers and process tool modifications will be investigated. A second problem to be addressed is the reliability of electrical interconnects in flexible solar modules. Electrical interconnects in rigid panels are a common source of problems due to mechanical stress fractures. The team will investigate alternative electrical bus connections that are resilient to mechanical stress and have the added benefit of reducing silver resource consumption in solar modules. Environmental tests will be conducted to determine the reliability of these flexible and bendable modules to ensure a service life that is competitive with rigid crystalline silicon solar panels.This award reflects NSF's statutory mission and has been deemed worthy of support through evaluation using the Foundation's intellectual merit and broader impacts review criteria.