STTR Phase I: Feasibility Demonstration & Performance Optimization of an Ultra-High-Efficiency, Thin-Film, Crystalline Si Solar Cell for Cost-Effective, Grid-Connected Electric

这项小型企业技术转移（STTR）第一阶段研究项目通过展示、优化和商业化超高效率和超低成本的太阳能电池/模块技术，解决了快速增长的全球太阳能市场。昂贵而不可靠的化石燃料供应，以及全球不断增长的能源需求，催生了对一种可替代的、可广泛获得的、具有成本效益的可再生能源的需求。关键的太阳能属性是丰富的，全球范围的，使用点的阳光供应和它的环境友好性。该项目的目标是通过实施创新的超高效率电池和模块设计，以低材料使用量和低成本制造，同时利用硅光伏的成熟度和环境接受度，降低并网电力市场的太阳能电力成本。该项目预计将产生比同类最佳晶体硅晶片电池更高的效率。该团队的方法改进了电池模块结构，从而提高了效率，降低了成本。提出的解决方案包括：(1)显著减少硅的消耗；(2)优化电池设计，实现超高电池模块效率；(3)低成本超自校准电池制造；(4)降低了晶圆片材料的消耗；(5)独特的模块设计和组装，实现fab自动化；(6)由于更高的面积利用率和更低的欧姆损耗，减少了电池模块效率之间的性能差距；(7)降低人工成本；(8)基于50多年硅基学习和成熟制造供应链的电池技术。到2010年，光伏市场（2005年约15亿美元）将以35%以上的年复合增长率增长至350亿美元，这表明市场对成本效益解决方案的吸引力。该项目提供以下全球效益：(1)具有成本效益的太阳能组件，满足可负担、安全、分布式电力的行业路线图；(2)环境友好型太阳能电池及组件材料和晶圆工艺，实现环境可持续发展；(3)能源回收期缩短至1年；(4)减少了终端用户的盈亏平衡时间。通过拟议的技术，一个安装了4kWp光伏的住宅客户每年将减少400公斤的二氧化碳排放（或在光伏系统的至少30年寿命内减少12,000公斤）。该项目将为扩大美国太阳能技术和并网光伏市场的晶圆厂基础设施做出可衡量的贡献。该项目的目的是通过实施一种创新的超高效太阳能电池和组件，简化制造，同时保持晶体硅光伏的高效率，从而降低成本。该项目将作为在美国建立一系列光伏晶圆厂的先驱，其产量将在4年内从2.5兆瓦扩大到100兆瓦以上，预计将为美国的光伏制造基础设施和创造就业机会做出重大贡献。

This Small Business Technology Transfer (STTR) Phase I research project addresses the rapidly growing world-wide solar energy market, by demonstrating, optimizing, and commercializing an ultra-high-efficiency and ultra-low-cost solar cell / module technology. Expensive and unreliable fossil fuel supplies and escalating global demand for energy have created the need for an alternate, widely available, cost-effective, and renewable source. Key solar attributes are the abundant, worldwide, point-of-use supply of sunlight and its environmental friendliness. The goal of this project is to reduce solar electricity cost for grid-connected electricity markets by implementation of an innovative ultra-high-efficiency cell and module designs with a low material usage & cost-reduced manufacturing, while leveraging the maturity and environmental acceptance of Si PV. This project is expected to result in efficiencies higher than best-of breed crystalline Si-wafer cells. The team's approach improves the cell & module structures, resulting in enhanced efficiency & reduced cost. The proposed solution includes: (1) a significant reduction of Si consumption; (2) optimal cell design for ultra-high cell & module efficiencies; (3) low-cost super-selfaligned cell fabrication; (4) decreased consumption of fab materials; (5) unique module design & assembly, enabling fab automation; (6)) reduced performance gap between the cell & module efficiencies due to higher area utilization & lower ohmic losses; (7) reduced labor cost; and (8) cell technology based on 50+ years of Si-based learning and a mature manufacturing supply chain. The PV market (~$1.5B in 2005) will grow 35+% CAGR to $35B by 2010, indicating the market-pull for cost-effective solutions. This project provides the following global benefits: (1) cost-effective solar modules to meet industry roadmap for affordable, secure, distributed electricity; (2) environmentally-benign solar cell & module materials and fab processes for sustainable environment; (3) shortened energy payback time to 1 year; (4) reduced breakeven time for end-users. Through the proposed technology, a residential customer with 4kWp installed proposed PV will reduce CO2 emissions by 400 kg/year (or by 12,000 kg over the minimum 30-year lifetime of PV systems). This project will make a measurable contribution to an expanding U.S.-based solar energy technology and fab infrastructure for grid-connected PV markets. It is the intent of this project to reduce cost by implementation of an innovative ultra-high-efficiency solar cell and module with simplified manufacturing while retaining the high-efficiency of crystalline Si PV. This project will serve as the precursor for establishing a cascade of U.S.-based PV fabs with production volumes scaled from 2.5 MWp to 100+ MWp over 4 years, making significant projected contributions to the U.S.-based PV manufacturing infrastructure and creation of U.S.-based jobs.