Reimagining Photovoltaics Manufacturing
Lead Research Organisation:
Northumbria University
Department Name: Fac of Engineering and Environment
Abstract
This programme, Reimagining Photovoltaics Manufacturing, is an adventurous and ambitious follow-on programme to an initial feasibility study, Photovoltaic Paint. It focuses on achieving the manufacturing research breakthroughs needed to enable a design-led approach to photovoltaics (PV) manufacturing which will result in much tighter aesthetic integration of PV with products in the built environment and automotive sectors. Ultimately, this will substantially increase the global deployment of sustainable electricity and disrupt the current model of PV manufacturing, creating significant commercial opportunities for the UK.
Current PV manufacturing relies critically on economies of scale with around two-thirds of manufacturing occurring in Asia. The problem with this approach is that PV modules are now highly standardised and only near-term competitive in large-scale, solar farm applications. This limits the rate at which PV deployment can grow globally in a period when tangible carbon dioxide savings are vital. A further disadvantage is that PV manufacturing is 95% based on silicon wafer technology which is brittle and requires capital intensive facilities. In turn, this limits the opportunities for seamless product integration to niche applications which are currently not cost effective.
Our central research hypothesis is that these barriers can be overcome using the manufacturing research outcomes from the initial Photovoltaic Paint programme. More specifically, in Reimagining Photovoltaics Manufacturing, we will apply new capabilities in slot-die coating and inkjet materials printing to create patterned and nature-inspired solar cells that are unlike anything available today. Furthermore, by replacing a carbon-intensive thermal processing step commonly used in the manufacturing of inorganic thin film solar cells with targeted laser annealing, we will be able to manufacture these solar cells on a wide range of useful substrates that allow aesthetic and economically viable integration of PV with products.
An important feature of our design-led approach to PV manufacturing is that it inherently prioritises sustainability. More specifically, we are targeting scalable, rapid and energy efficient manufacturing processes with low wastage and non-toxic materials. We will also assess the opportunity to recover and reuse valuable components of our solar cells as part of their end-of-life decommissioning.
The programme has two key routes to impact. Firstly, its design-led principles can be applied to several promising PV materials being developed by other research groups in the UK and around the world. Secondly, we will involve product designers and engineers with specific knowledge of innovation in key sectors, in our manufacturing research. This is novel and an important distinction to the current model which focuses on technology development and ultimately, the combination of these routes will create compelling new products and accelerate carbon savings worldwide.
Current PV manufacturing relies critically on economies of scale with around two-thirds of manufacturing occurring in Asia. The problem with this approach is that PV modules are now highly standardised and only near-term competitive in large-scale, solar farm applications. This limits the rate at which PV deployment can grow globally in a period when tangible carbon dioxide savings are vital. A further disadvantage is that PV manufacturing is 95% based on silicon wafer technology which is brittle and requires capital intensive facilities. In turn, this limits the opportunities for seamless product integration to niche applications which are currently not cost effective.
Our central research hypothesis is that these barriers can be overcome using the manufacturing research outcomes from the initial Photovoltaic Paint programme. More specifically, in Reimagining Photovoltaics Manufacturing, we will apply new capabilities in slot-die coating and inkjet materials printing to create patterned and nature-inspired solar cells that are unlike anything available today. Furthermore, by replacing a carbon-intensive thermal processing step commonly used in the manufacturing of inorganic thin film solar cells with targeted laser annealing, we will be able to manufacture these solar cells on a wide range of useful substrates that allow aesthetic and economically viable integration of PV with products.
An important feature of our design-led approach to PV manufacturing is that it inherently prioritises sustainability. More specifically, we are targeting scalable, rapid and energy efficient manufacturing processes with low wastage and non-toxic materials. We will also assess the opportunity to recover and reuse valuable components of our solar cells as part of their end-of-life decommissioning.
The programme has two key routes to impact. Firstly, its design-led principles can be applied to several promising PV materials being developed by other research groups in the UK and around the world. Secondly, we will involve product designers and engineers with specific knowledge of innovation in key sectors, in our manufacturing research. This is novel and an important distinction to the current model which focuses on technology development and ultimately, the combination of these routes will create compelling new products and accelerate carbon savings worldwide.
Publications
Campbell S
(2023)
Enhanced Carrier Collection in Cd/In-Based Dual Buffers in Kesterite Thin-Film Solar Cells from Nanoparticle Inks
in ACS Applied Energy Materials
Matheson E
(2023)
A comparison of ZnO nanowires grown using hexamethylenetetramine and ammonium hydroxide on Al:ZnO nanoparticle seed layer
in Journal of Materials Science: Materials in Electronics
Description | Collaboration with Loughborough University |
Organisation | Loughborough University |
Country | United Kingdom |
Sector | Academic/University |
PI Contribution | Provided samples to co-investigators as part of EP/W010062/1. These samples were thin film solar cell light absorbers on different substrates. We also performed initial lifecycle analysis of nanoparticle inks for solar cell applications. |
Collaborator Contribution | LU team performed laser annealing to assess potential recrystallisation of absorbers and effect on defects. LU team also provided LCA advice including contributions to PhD student supervision. |
Impact | This is a multidisciplinary collaboration: Northumbria provides physics, materials science and engineering while Loughborough provides manufacturing expertise. |
Start Year | 2022 |
Description | Conference poster presentation at 49th IEEE PVSC, Philadelphia |
Form Of Engagement Activity | A talk or presentation |
Part Of Official Scheme? | No |
Geographic Reach | International |
Primary Audience | Postgraduate students |
Results and Impact | Poster presentation viewed by >50 PhD students. Poster nominated for Best Poster Award. |
Year(s) Of Engagement Activity | 2022 |
Description | Tackling climate change with solar photovoltaics |
Form Of Engagement Activity | A talk or presentation |
Part Of Official Scheme? | No |
Geographic Reach | Regional |
Primary Audience | Schools |
Results and Impact | Talk as part of an evening lecture series organised by NUSTEM. Purpose of the talk was to inspire and engage students studying physics and science in research. |
Year(s) Of Engagement Activity | 2022 |
URL | https://nustem.uk/eveninglectures/ |