Photovoltaic Paint

Lead Research Organisation: Northumbria University
Department Name: Fac of Engineering and Environment

Abstract

This programme assesses the feasibility of applying photovoltaic paint directly to product surfaces during the manufacturing process. The result will be seamlessly integrated photovoltaic elements which generate clean electricity (zero carbon emissions) at the point-of-use of the product. Not only will this enable more sustainable applications but it will also enable applications where automatic battery charging, reliability and mobility are critically important. The research is transformative because it will define a new manufacturing sub-field: product integrated photovoltaics (PIPV) which crosses sectors and length scales and therefore has strong disruptive potential.

Planned Impact

This programme assesses the feasibility of applying photovoltaic paint to product surfaces during manufacture to create compelling, new products with significant added value. In addition to defining the new manufacturing sub-field of product integrated photovoltaics (PIPV), it crosses sectors and length scales and will therefore have strong impact. This impact can be categorised as industrial, societal and academic and these are summarised as follows.

INDUSTRIAL IMPACT
Enabling sustainability applications is an important outcome from the proposed manufacturing process innovation and to that end, several key industrial players spanning automotive and construction sectors are closely involved in the programme. Engagement with these players will provide key criteria for promising applications such as completely integrated and essentially invisible PV vehicle panels which are manufactured cost-effectively and in situ on an automotive production line. These panels will reduce range anxiety and thereby enable the transition to zero carbon (emissions) vehicles. Similarly in the construction sector, commercialisation of the photovoltaic paint concept will enable the UK to take the lead in a new kind of high-value manufacturing which relies on high-level knowledge and skills. The industrial impact extends well beyond sustainability applications however, and relationships with employer and manufacturing networks will be leveraged to identify opportunities in consumer products and healthcare.

SOCIETAL IMPACT
Two key impact activities built into the programme are engagement with school pupils and the public. The former will be achieved through my institution's official outreach programme NUSTEM, and an important aim is to work with school pupils to develop their understanding of the link between science, technology, engineering and mathematics subjects and manufacturing. This will introduce the concept of innovation as a discipline and promote compelling case studies highlighting the benefits to the UK of high value manufacturing. Impact activities with the public will occur via national science fairs and events using interactive manufacturing demonstrators which bring the benefits of photovoltaic paint to life.

ACADEMIC IMPACT
The definition of the new manufacturing sub-field of PIPV is transformative and will stimulate global research efforts to address the most challenging problems identified in the programme. The impact will be achieved by dissemination at prestigious national and international conferences as well as leading peer-reviewed journals. More broadly, membership of and engagement with key EPSRC energy networks will create additional opportunities to develop new collaborations and connect UK energy materials and manufacturing communities. The involvement of a PDRA in the programme creates a unique opportunity for an individual to work at the interface between disciplines and gain industrially relevant experience to the strong benefit of their career.
 
Description An important step in the manufacturing of solar cells is the fabrication of high-quality polycrystalline semiconductor layers that are capable of absorbing light from the sun. Typically, a high-temperature heating step is used to achieve this. During this project, we have investigated alternative treatments using light (photonic curing) rather than a conventional heat oven. Our initial results show that we can achieve a higher quality light absorbing layer when we combine the two treatments i.e. first exposing the sample to light before a high temperature heat treatment in an oven. This is potentially transformative because it can be applied to a very wide variety of solar cells. This result is now the subject of intense further investigations.

We have built on initial results to develop a novel process involving slot-die coating of light absorbing semiconductors. The result of our process is that we now have the capability to manufacturing small-scale solar cells in any two-dimensional geometry and pattern. This includes using inkjet printing to create nature-inspired top electrical contact designs such as a leaf venation. Currently, the efficiency of these prototype devices is very low and we will address this in a follow-up award to this feasibility study. The importance of this finding is that it potentially enables better integration of photovoltaic devices with products primarily in the built environment and transport sectors.
Exploitation Route Other research groups may use the heating protocol we have developed to improve the quality of their solar photovoltaic absorbers. This has the potential to contribute to a wide range of improved solar cell performance from R&D through to commercial products.

We have recently presented (March 2022) new research outcomes from this award at a significant UK national meeting (ESPRC Supersolar: PV in the Circular Economy). Our process in not limited to a single technology and therefore we hope that the approach stimulates other academic and industrial groups to apply it to different PV technologies.
Sectors Aerospace, Defence and Marine,Construction,Energy,Transport

 
Description This programme has led to follow-on EPSRC funding (Reimagining Photovoltaics Manufacturing, EP/W010062/1) and a case study (https://www.northeastlep.co.uk/wp-content/uploads/2022/03/NEL1221c-Energy-for-Growth-case-study-3-Northumbria-University-Fabrication-002.pdf, together with another non-UKRI grant award) with the North East Local Enterprise Partnership. The new UKRI programme has created 3 jobs: two at Northumbria University and one at Loughborough University. A further important impact is that PDRA from the programme obtained full-time permanent employment in he hi-tech sector in Oxford and moved from the NE of England to take up this role. Note that the new programme has attracted new industrial programme partners, including a UK SME. Other impacts are anticipated as the new programme evolves. Note that the programme was severely disrupted by the global COVID-19 pandemic. It began in September 2019 and was disrupted by laboratory closures and a serious cyber-security attack at the host institution.
First Year Of Impact 2021
Sector Construction,Energy
Impact Types Economic

 
Description Northumbria University Fabrication (NU-FAB)
Amount £113,000 (GBP)
Organisation North East Combined Authority 
Sector Public
Country United Kingdom
Start 04/2020 
End 03/2021
 
Description Reimagining Photovoltaics Manufacturing
Amount £986,018 (GBP)
Funding ID EP/W010062/1 
Organisation Engineering and Physical Sciences Research Council (EPSRC) 
Sector Public
Country United Kingdom
Start 09/2021 
End 09/2024
 
Description Photonic Curing 
Organisation NovaCentrix
Country United States 
Sector Private 
PI Contribution Through the NECEM project, Northumbria University has provided NovaCentrix with solar cell absorber layers for photonic curing.
Collaborator Contribution NovaCentrix has performed photonic curing on Northumbria samples and participated in data analysis and review meetings.
Impact The outcomes are 36 samples that have been subjected to photonic curing. The aim is to characterise this parameter space and then build solar cells using the technique.
Start Year 2019
 
Description 47th IEEE Photovoltaic Specialists Conference 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Professional Practitioners
Results and Impact This international conference is organised by the IEEE and is perhaps the most important international conference in the area of photovoltaics. It occurred for the first time, virtually in 2020 and reached a large number of professionals and students.
Year(s) Of Engagement Activity 2020
URL https://ieee-pvsc.org/PVSC47/login.php
 
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 EPSRC Supersolar: PV in the Circular Economy (webinar) 
Form Of Engagement Activity Participation in an activity, workshop or similar
Part Of Official Scheme? No
Geographic Reach National
Primary Audience Professional Practitioners
Results and Impact The PI was invited to arranged this Supersolar webinar and created a panel of 5 speakers from: Cambridge, Exeter, Northumbria, Nanyang Technological University and Eindhoven University of Technology. This included a range of career stages and a gender balance that was majority female. The objective of the event was to brief industry and academia on recent research results.
Year(s) Of Engagement Activity 2022
URL https://www.supersolar-hub.org/event/photovoltaics-in-the-circular-economy/
 
Description Physics talk at FE College 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach Local
Primary Audience Schools
Results and Impact Talk to encourage an inspire A-level students in physics.
Year(s) Of Engagement Activity 2022
 
Description Renewables talk to Northumberland Secondary School 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach Local
Primary Audience Schools
Results and Impact Renewable energy and STEM careers talk to Year 9 students.
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/
 
Description Talk at Newcastle Primary School 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach Local
Primary Audience Schools
Results and Impact Talk to Early Years on clean electricity and solar photovoltaics.
Year(s) Of Engagement Activity 2022