NICE Technologyfor Bifacial PV Modules

‘New Industrial Cell Encapsulation’

Workshop on bifacial photovoltaics implemented in theAtacama Desert Solar Platform

15/01/2015

Roland Einhaus, R&D Director

APOLLON SOLAR

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Outline

- Brief Company presentation

- Motivation for new module technology

- NICE Module technology and process

- Bifacial NICE modules

- NICE production line at Energy Industrie, Tunisia

- Qualification results

APOLLON SOLAR

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� APOLLON SOLAR

� Creation in 2001, located in Lyon, France

� Founders: 4 PV experts with longstanding experience in the fields

R&D, process development, industrialisation, project

management

� APOLLON SOLAR’s objectives and functioning

� Development and Patenting of PV related innovativetechnologies

� Cooperations with external partners

� Implementation and Industrialisation

Company presentation

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� ITRPV Roadmap 2014:

Motiviation (1): Cost shares in PV value chain

Ref.: ITRPV – Roadmap 2014

� Module manufacturing still the dominating cost contributor

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Motiviation (2): Disruptive Module technology

� Product Sustainability + Performance

- Increased module quality

- Prolonged module lifetime, more kWh

- Better compatibility with new cell designs

� Added values:

- Reduced environmental footprint

(Bill of material, re-use and recycling at end life,

Carbon footprint)

- Safety and Security (production environment)

- Aesthetics

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CellCell

Background: State of the art PV modules

EVA (Ethylene-Vinyl Acetate)

Ribbons/tabs soldered to

the cell

Front glass

Tedlar

EVA (Ethylene-Vinyl Acetate)

• Soldering/tabbing for electrical interconnection of cell

• Lamination for environmental protection and structural support

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� Sealing by PolyIsoButylene (PIB), well established in insulating glass industry

� No encapsulant, no soldering: Under-pressure in the module to assure electrical series contacts

� Glass/Glass module by definition

� Invented and patented by AS in 2002

Principle : NICE Module

Rear glass

Cell Cell

Interconnection ribbons

pressed on the cellUnder-pressure

+ Neutral Gas N2

Pressure force due to the inside

under-pressure

Front glass

PIB Sealing

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R&D NICE: Underpressure optimization

Initial setting of underpressure during pressing

� Daily thermal cycles during module operation change the

underpressure inside the module

Glass

Cell Cell

Glass

� High temperature => low underpressure, risk of contact disconnection

� Low temperature => high underpressure, risk of mechanical damage

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� Influence of glass flatness on cell/ribbon contacts:

- 3 test modules with different glasses produced

- Experimental set up: Inner volume of module connected

to vacuum pump to be able to vary underpressure

R&D NICE: Underpressure vs electrical contact / glass

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R&D NICE: Potential for cells without busbars (front)

�Full Size (60 cells) Module with « PhosTop » cells without

busbars

� Cell realisation by Semco Engineering*

� Full Al rear surface metallisation

� No Ag busbars on front surface

� Ag consumption strongly reduced

Pmax [W] Isc [A] Voc [V] FF [%]

Phos Top 230,0* 8,1* 38,1 74,9

(* Cells without busbars difficult to characterise – potential current mismatch)

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� Results of extended thermal Cycling tests (-40°C / 85°C)

R&D NICE: Thermal cycling results

Power degradation < 3% after 1000 thermal cycles

High long term stability of electrical parameters

-6-5-4-3-2-1012

0 200 400 600 800 1000

Pow

er

Var

iatio

n (%

)

Thermal Cycles (-40°C to +85°C)

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NICE : Sealing quality – Risk of humidity ingress

-5,00

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0 2000 4000 6000 8000 10000

FF

Va

ria

tio

n [

%]

Po

we

r V

ari

ati

on

[%

]

Hours @ +85°C 85%rH

Power Variation [%]

FF Variation [%]

� Extended damp heat test

- Long term exposure at +85°C and 85% humidity at INES (ongoing)

- Test module with Heterojunction cells (sensible to humidity)

IEC 61215 Criteria

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NICE: PID tests at NREL - Methodology

NICE modules have been tested for potential PID using the

in house test-to-failure protocol at NREL

�The NICE modules under test were industrial multi-c

modules with 60 cells.

�The PID tests were carried out between 01/2013 and

12/2013 according to the following sequence:

� Alternating sequences of 1000h DH @ -600V and 200 TC

� Total of 6 rounds

� EL inspection and IV characterisation after every round

� 2 modules exposed to degradation cycles, 1 module kept for reference

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�Power evolution after each round

compared to 6 other standard

modules (EVA + crystalline Si cells)

�NICE modules perform 2nd best

�According to NREL no signs of PID related degradation on NICE

modules

NICE: PID tests at NREL - Results

NICE

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�Manufacturing of NICE – BiSoN modules:

NICE – Bifacial modules with ISC BiSoN cells

Illumination Voc[V]

Isc[A]

FF[%]

Pmax[W]

Front 38.84 8.52 74.91 248

Rear 38.35 6.32 77.9 189

Grey back 39.05 9.26 74.92 271

White back 39.11 9.69 75.10 285

2 NICE modules from 60 BiSoN cells (19.2% – 19.9%) manufactured

with the following constraints:

• SiN on cells not optimised for EVA free modules

• No cell binning (risk of Imp and FF mismatch)

• Standard glass on rear side (lower transparency that extra white PV glass)

�STC IV data (by PI Berlin):

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�Outdoor test results from ISC site El Gouna, Egypt

NICE – Bifacial modules with ISC BiSoN cells

• Monofacial Reference Module: Standard technology, STC Power 256W

• Bifaciality gain in energy yield (Wh/Wp): 14.3%

• Instantaneous peak power of 313 W at irradiance of 1214 W/m2

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�Edge Junction box co-development with Multi-Contact

�Characteristics:

NICE – Bifacial modules – New Junction Box

� Dimension: L x W x H: 192 x 34.2 x19.5mm

� Width from the glass edge: 30mm (for increased active module surface)

� Rated current: 17A (Ribbon temp. at module edge max. 90°C)

� Max. current: 20 A

� Rated voltage: 80V

� System voltage:

� 1000V IEC / 1000V UL

� Ambient temperature:

� -40°C to 85°C

� Certification pending:

� EN50548

� UL3730 / UL1703

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NICE – Bifacial modules – R&D work in progress

� Influence of soiling (dry/hot climate zones) – how to best install bifacial modules

�Realisation of more test installations to monitor

bifacial NICE modules for energy yield and power

production

�Frameless module design, new mechanical rear

support for bifacial modules

�Bifacial modules with busbar-free cells:

comparative studies

�Best suitable degradation tests for NICE bifacial

modules, especially in extrem climats (desert,

snow rich regions etc.)

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Glue deposition

Cells and connectors

placement

Placement of

external connectors

Placement of

module busbars

Placement of front

glass + transport of

assembly to press for

argon flooding and

creation of

underpressure

Pressing of

assembly

Deposition of

sealing

Placement of rear

sheet

Deposition of

secondary sealing

NICE Manufacturing: Process Animation

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Station for sealing

deposition

Pick & Place stations for

ribbons and cells

Busbar deposition

station

Module press

NICE Industrialisation – Energy Industrie, Tunisia

Station for gluing

� First Industrial 30 MW NICE line in Bousalem, Tunisia

• NICE technology + process development: Apollon Solar• Automated production line for NICE modules: Vincent Industrie• NICE module production in Tunisia : Energy Industrie

Partnership/ NICE consortium:

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NICE Industrialisation – Energy Industrie, Tunisia

� Production started in 2014 � 250 W modules with mono-c Silicon, mono-facial cells.

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� Certifications

� Four versions of modules were successfully certified according to IEC 61215 and IEC 61730 standards (TÜV Rheinland)� June 2010 : 36 multi-c cells modules (frameless)� November 2011 : 60 multi-c cells module (framed)� May 2012 : 60 multi-c cells module (frameless)� October 2013: 60 mono-c Cells (framed + frameless)� December 2014: Factory inspection of Energy Industrie by TÜV Rheinland� Q1/2015: 60 mono-c Cells, bifacial + new edge junction box + glasses without holes

new frame design

� Certification results - observations

� No significant degradation of module power� Average around -1.0 % (different modules , different tests)� Only one combined test gave an important degradation of – 4.0%

� Detailed results on following slide

NICE Industrialisation: Certification

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NICE – Certification results by TÜV - details

-8,0%

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0,0%

1,0%

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Pm

ax v

ari

atio

n

Pmax variations after IEC 61215 (TÜV)

IEC 61215 Rev. 1 Rev. 2 Rev.3 Rev.3 bis

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NICE Advantages - Conclusion

RELIABLE

• Glass-Glass module with new sealing technology and soldering free cell interconnection

• Fully automated inline production with high reproducibility and narrow distribution of output power

• IEC 61215 & 61730 qualified by TÜV Rheinland(Germany)

HIGH PERFORMANCE

• Long module lifetime of 30+ years• Very low power degradation even in extreme

climatic conditions• Higher performance ratio within the module

lifetime

COST EFFICIENCY

• Less consumables required• Reduced industrial footprint• Less manpower needed

RELIABLE

• Glass-Glass module with new sealing technology and soldering free cell interconnection

• Fully automated inline production with high reproducibility and narrow distribution of output power

• IEC 61215 & 61730 qualified by TÜV Rheinland(Germany)

HIGH PERFORMANCE

• Long module lifetime of 30+ years• Very low power degradation even in extreme

climatic conditions• Higher performance ratio within the module

lifetime

COST EFFICIENCY

• Less consumables required• Reduced industrial footprint• Less manpower needed

AESTHETICS

• Frameless version• Lighter visual appearance• Transparent in between cells

PRODUCTION ENVIRONMENT

• Clean Factory• No evaporation of solvents (solder flux)• Room temperature processes

SAFETY

• Front and rear glasses fully tempered• Few flammable organic components• Inherent DC current interruption in case of fire

ENVIRONMENTALLY FRIENDLY

• Module components easy to separate and recycle

• Less toxic components• Low carbon footprint

AESTHETICS

• Frameless version• Lighter visual appearance• Transparent in between cells

PRODUCTION ENVIRONMENT

• Clean Factory• No evaporation of solvents (solder flux)• Room temperature processes

SAFETY

• Front and rear glasses fully tempered• Few flammable organic components• Inherent DC current interruption in case of fire

ENVIRONMENTALLY FRIENDLY

• Module components easy to separate and recycle

• Less toxic components• Low carbon footprint

INNOVATIVE

New industrial encapsulation and electrical interconnection of solar cells based on long term technological expertise

INNOVATIVE

New industrial encapsulation and electrical interconnection of solar cells based on long term technological expertise

APOLLON SOLAR

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Thank you very much for your attention

NICE Modules