Rice University: New Process Reduces Solar Cell Costs
In traditional solar cell manufacturing, a cryogenic liquid deposition process is used to add an anti-reflective film to the silicon wafer to help absorb more light. At the same time, a variety of quantum dots are used to effectively absorb the sunlight in the whole wavelength band.
A novel method allows for the preparation of thin uniform coatings, developed by Rice University, which can reduce the cost of conventional silicon solar cells and open up the way for the preparation of new solar cells that are more efficient Cheaper than traditional batteries.
This technology deposits coatings using a low temperature liquid phase process rather than the currently used high temperature gas phase process. Now, Natcore Technology is commercializing this new startup in New Jersey (New Jersey). Red Bank. The company plans to use this technology to replace the standard steps in the traditional solar cell manufacturing, adding an anti-reflective film, added to the wafer to help them absorb more light. This will also bring about a more advanced anti-reflection technology called black silicon.
At the same time, Netkauer is developing more advanced processing applications, including the use of carbon nanotubes or nanocrystals when manufacturing solar cells, which are called quantum dots. This solar cell takes several years to be commercialized, but it is far superior to traditional solar cells. Nano solar cells have been tried before, but the company believes that its new manufacturing technology can make them cheaper.
Because of the high temperature process that replaces traditional production lines, this liquid-based process can reduce manufacturing costs. Knight Charles president Charles. Charles Provini estimates that replacing traditional coating machines with their company's machines can save solar manufacturers about $1 million in electricity costs each year.
Manufacturers currently do not use liquid phase processes to prepare anti-reflective films, partly because it is difficult to make the coating sufficiently uniform for use in solar cells. The problem lies in the way the liquid process usually operates. This coating forms a reactant that interacts with the surface in the liquid. When this reactant is depleted, the deposition rate changes, resulting in a change in coating thickness. Rice University researchers solved this problem by developing a system that could continuously replenish this reactant while closely monitoring the thickness of the film.
Knightech's advanced nano solar cell design requires the deposition of a quantum dot layer on a silicon solar cell. This quantum dot design absorbs some of the color that silicon cannot absorb, which may double solar cell efficiency. This has been tried before, but forming a layer of quantum dots requires expensive processing techniques and proves difficult to arrange the quantum dot pitches to avoid unnecessary discharges between them. Knightech's process is inexpensive and it provides a way to control the arrangement of quantum dots. When smearing them, a layer of silica is used to form the spacer. The company has decided to apply traditional silicon solar cells first to make it more convenient and easier for the industry to adopt this technology. However, it may eventually give up silicon wafers and make solar cells that completely rely on quantum dots. A variety of quantum dots are used to effectively absorb the sunlight at the full wavelength band.
In another design, the Natkauer company is co-developing with Kodak to use a liquid deposition process to deposit carbon nanotube networks and use a solar semiconductor material to produce very thin flexible solar cells. Netkauer said that solar cells use this design and can have the same efficiency as conventional silicon solar cells, but the cost is only about half that can be produced. To a large extent, this is because of their preparation, using Kodak. The company’s equipment is the same kind of equipment used to make photographic film. Because this kind of solar battery is light and pliable, it is also easier to install and the installation cost will be cut in half, Knightel estimates.
Andrew Barron, a professor of chemistry and materials science at Rice University, developed the liquid deposition technique. He said that this carbon nanotube design is closer to commercialization and more than a sub-dot design. He said that researchers have made prototypes of small solar cells, and the remaining development work must continue to work out the details of the production. This quantum dot solar cell is still in its early stages, and researchers have so far only used this liquid process to show that the distribution of these quantum dots can be met. They haven't made solar cells yet.
Netkauer has raised about $6 million because of public offerings on the Canadian stock exchange. It also signed joint venture agreements with some companies in China and Italy. The company plans to license its technology to others instead of making its own solar cells. The company is currently testing a prototype model of a commercial-grade liquid deposition machine. According to Provini, the company already has four solar cell manufacturers and is queuing to purchase this commercial version of the machine, as long as the company meets certain technical standards.
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