TECH TO MARKET

11% 12%

17%

25%

35%

Commercial Roof Load Capacities (NYS)

< 1 psf 1 to < 2 psf 2 to < 3 psf 3 to < 6 psf 6+ psf

Pradeep  Haldar  SUNY  College  of  Nanoscale  Science  and  Engineering  

U.S.  Photovoltaic  Manufacturing  Consor=um  

U.S.  Photovoltaic  Manufacturing  Consor=um  (PVMC)  

Market Analysis •  Evaluating the market potential for

roof-mounted LPV in high-value US regions

Mounting Mechanisms •  Developing and testing new

mounting mechanisms for LPV systems

Prototype Demonstrations •  Deploying LPV systems to evaluate

installation costs, system reliability, and PV performance

Module Integration •  Reducing LPV deployment costs via

targeted module characteristics and module and materials integration

Ligh

twei

ght P

V (L

PV)

Measurement Standards •  Establishing standard performance

measurements to fairly compare different modules and PV types

Metrology for Manufacturing •  Establishing in-line metrology for

thickness and composition control for stack layers

Outdoor Performance •  Establishing CIGS-specific

capabilities for regional and customer-sited testing

Indoor Accelerated Testing •  Identifying failure mechanisms

and developing models to estimate lifetime

Met

rolo

gy

Perf

orm

ance

The U.S. Photovoltaic Manufacturing Consortium (PVMC), headquartered in New York State, is an industry-led consortium for cooperative R&D among industry, university, and government partners to accelerate the development, commercialization, manufacturing, field testing and deployment of next-generation solar PV systems.

Outdoor Performance

Objectives: 1.  Identify and prioritize the most viable U.S.

states for rooftop LPV 2.  Determine LPV potential (sq. ft.) in

commercial and industrial (C&I) segments in top 5 states – total available market (TAM)

3.  Within one of the most attractive states, determine serviceable available market (SAM) for specific building and roof type

Ongoing PVMC Projects

LPV Market Analysis

TAM

?

? ?

?

?SAM

NYS as example, only

X ft2, X MW

LPV Mounting Mechanisms and Prototype Demos LPV Integrated Module Packaging Metrology Objectives: 1.  Develop innovative mounting mechanisms to attach lightweight

PV modules to roofing materials 2.  Evaluate durability of LPV systems via accelerated testing 3.  Benchmark material and labor installation costs via time &

motion studies 4.  Determine the effect of mounting mechanisms on outdoor

performance of modules 5.  Compare outdoor failures with indoor testing failures (Mounting

Mechanisms project)

Courtesy: Johns Manville Courtesy: coolflatroof.com

Objectives: 1.  Quantify reduced BOS costs for LPV installations through an

LPV targeted module architecture including a sacrificial membrane integrated into existing industry module fabrication processes

2.  Utilize cost analysis, prototype module development and test site installation(s) for cost reduction validation achieving a LPV BOS reduction equal to 30% of hardware labor costs at the MW scale

Figure: PVMC Cost Analysis Tool (CAT)

Objectives: 1.  Evaluate performance measurement protocols and their

application to CIGS performance parameters in order to better predict outdoor performance under various illumination and temperature conditions

2.  Establish protocols to compare CIGS to other PV technologies 3.  Establish spectral reflectometry or polarimetry as a thickness

and composition metrology technique for CIGS layers 4.  Demonstrate feasibility of process control analytics for CIGS 5.  Build a database relating growth conditions and layer properties 6.  Analyze deployment of a full demo system at a manufacturing

facility

Panels inside PVMC light-soaking chamber

PVMC Partners

Indoor and Outdoor Performance Testing C-Si Program

PVMC Overview

Current Projects: 1.  Diamond wire (DW) sawing of mono-crystalline ingots

•  Understanding failure modes associated with diamond wire sawing and correlating to developed test methods

•  Improving wire longevity to reduce cost •  Evaluating feasibility of real-time monitoring of wear level

2.  Crack formation and location as a function of incoming wafer properties •  Establishing correlations between crack length/location, failure strength, and:

•  initial stress distribution of incoming wafers •  thickness of incoming wafers •  total thickness variation of incoming wafers •  bow/warp of incoming wafers

3.  Optical and electronic characterization of wafers and passivation layers •  Correlating material properties and c-Si/dielectric interface characteristics to

passivation performance •  Evaluating characterization methods for tracking the evolution of minority

carrier lifetime through the various cell manufacturing process steps. •  Demonstrating feasibility of extracting spatially-resolved recombination and

electronic/electrical about wafers and cells using PL and EL 4.  Metrology needs for emerging c-Si technologies

•  Identifying new metrology-related challenges associated with emerging c-Si technologies (e.g., n-type wafers, thin wafers, Ag-free metallization, new passivation materials)

Establish  Indoor  ALTs    

Compare  with  

outdoor  data    

Perform  Failure  Analysis  

Develop  Accelerated  kine=c  models  

e.g., Arrhenius, Coffin Manson, Eyring model

Outdoor Testing Objectives: 1.  Monitor the performance of instrumented PV arrays over time

and compare to the predicted performance and improving the predictive tools specific to CIGS , correlate array data to parallel PVMC programs, such as indoor accelerated testing.

2.  Enable direct comparisons between ground-mounted, tracker-equipped, and roof-based arrays

3.  Publish aggregate anonymous CIGS PV array data