Organic Photovoltaics- From Materials to Product

Transcription

1 Organic Photovoltaics- From Materials to Product Boston IEEE Photonics Society November 3, 2011 Stuart Spitzer, VP Engineering

2 Organic Photovoltaics- From Materials to Product Outline PV History Introduction to Konarka Device Structure Manufacturing OPV Properties Product Applications

3 PV History

4 Source: NREL The Solar Electric Cell is Born Photovoltaic (PV) Cell Photo - Voltaic Light Voltage Bell Labs. First Public Viewing of the Solar Cell, 1953 Chapin, Fuller, Pearson 4 Konarka Technologies, Inc.

5 Space to Earth to Product First Launch, 1958 First Repeater, 1974 ARCO Solar, Carrisa Plains, CA 6 MW, Konarka Technologies, Inc.

6 History of PV First Generation- Silicon (mono- and poly-crystalline) Rigid panels made with glass; production starting in 1960s Efficiencies of 15+%; work best with direct, intense light Currently ~$2/watt and coming down 80-90% of the market today Second Gen- Thin Film (amorphous silicon, CIGS, CdTe) Less material used slightly lower costs (First Solar CdTe) Manufactured through vapor deposition (batch processing) Efficiencies from 2-8%, with CdTe at ~11% a-si slightly more sensitive to moderate light levels About 10% of market today Third Generation- Organic Carbon-based nano-engineered semiconductors Can be made in continuous low cost printing process NREL Certified Efficiency of 8.3%, theoretical >20% More sensitive to moderate and low-light levels Very lightweight and flexible 6 Different colors & semi-transparent versions available Konarka Technologies, Inc.

7 PV Growth WW PV Production (MW) Global PV Total Production? 7 Konarka Technologies, Inc.

8 Large Opportunity for Growth in Solar 2005 World Energy Usage (14.8 TW) Solar 2015 World Energy Usage (18.5 TW) Solar represents less than 0.1% of the world energy market today Even with 35% annual growth, solar would still only represent less than half of a percent of the market in Source: US Energy Information Agency Konarka Technologies, Inc.

9 Earth at Night, NASA, out of 3 people on earth do not have electricity Addressable Market: 2.3 billion people 9 Konarka Technologies, Inc.

10 Introduction to Konarka 10

11 Company Overview Founded in 2001 as spin-out from the University of Massachusetts (Lowell) Leading IP position with over 350 patents/applications/licenses worldwide (Nobel Laureate) Strong 100+ person team with technical and industrial expertise $200M+ private funding with backing from large corporations such as Total SA and Konica-Minolta. Sales Offices: Japan USA Germany Shanghai Headquarters: Lowell, MA Manufacturing: New Bedford, MA Nurnberg, Germany

12 Investment & Commercial Partners Konarka Technologies, Inc.

13 Why Organic PV Design features: Flexible Thin Light-weight Impact Resistant Low light sensitivity (indoor/outdoor) Multiple colors: red, green, gray Transparent Customized voltages Truly Green: Recyclability Environmental impact on a per Watt peak basis which is 80-95% lower than silicon

14 OPV Device Structure 14

15 3rd Generation PV Silicon PV Systems Organic PV Systems Bulk heterojunction solar cell which is molecularly designed and nano-engineered

16 Bulk Heterojunction (OPV) ~ nm Active layer Poly-3(hexylthiophene) Main components of the active layer: Semiconducting polymer and Fullerene Phenyl-C61-Butyric-Acid-Methyl Ester 16 Konarka Technologies, Inc.

17 SEM of Bulk Heterojunction Polymer/Fullerene 17 Konarka Technologies, Inc.

18 OPV Manufacturing Process Technology Overview Monolithically integrated module Buss Bar Electrode Roll-to-roll process Active Layers Encapsulation Substrate 18 Konarka Technologies, Inc.

19 Engineering of Semiconductors Large choice of active materials with specific properties KONARKA Technologies Inc. Konarka Technologies, Inc.

20 Key Technology Features Advantages of OPV flexible thin-film solar technologies: Tuneable cell chemistry can absorb specific wavelengths of light as well as broad spectrum Generates energy from a greater angle of solar incidence Positive thermal efficiency coefficient 20 Konarka Technologies, Inc.

21 Manufacturing 21

22 Manufacturing Plant New Bedford MA Total area: 250,000 ft 2 1GW/year nameplate capacity 22 Konarka EU PVSEC September Konarka Technologies, 9 th 2010 Inc.

23 Low-Cost, Scalable Manufacturing Patented roll-to-roll process: Continuous printing/coating Flexible substrates Lower capital & labor costs Low-temp/low-energy/low carbon manufacturing Uses existing coating & printing equipment 23 Konarka Technologies, Inc.

24 Leverage Existing Capacity Retrofit existing printing facilities: Low CAPEX: 3-5 X Fast Ramp-up Output Quantity: Web Width: 1 meter Speed: 30 m/min Output equals: 1.0 GW/yr* * Note: 6000 hours 5% module efficiency 24 Konarka Technologies, Inc.

25 Power Plastic Standard Products 20 Series ( W p ) 40 Series ( W p ) Konarka Technologies, Inc. Confidential

26 Performance Specifications for OPV Measurement Criteria Bend 5.5 cm 1000 cycles Dynamic Flex 50mm, 400 cycles Torsion Tabor Abrasion Light & UV Exposure Temperature & Thermal Shock Accelerated Lifetime Testing Weather, Humidity, Rain & Outdoor Lifetime +15/-15 o C, 4sec-1, 100 cycles 200 cycles Light Soak 1000 hrs 1Sun -40/80 o C, 3 hour cycle 85 o C/85% RH; 65/ 1Sun 1000 hrs IEC, IEEE, ASTM Standards Conformable, Thin, Lightweight, Durable Plastic Solar Panel

27 Sustainability Perspective: Lifecycle Assessment Technology Energy for production (kwh.wp -1 ) Cost of Energy for Production (@12c/kWh) CO 2 footprint (g CO 2 -eq.wp -1 ) Energy payback time (years) mc-si 6.9 $ CdTe CIS Flex OPV A. L. Roes et al, Progress in Photovoltaics 17, 372 (2009) Konarka Technologies, Inc. Confidential

28 Functional Properties 28

29 Normalized Energy (watt hours) Solar Irradiance (W/m 2 ) Competitive Testing - Energy Collection on 08/29/ Konarka OPV Panel asi Panel csi Panel CIGS Panel Solar Irradiance Nominal 5 Watt Panels 1,400 1, , AM 6 AM 7 AM 8 AM 9 AM 10 AM 11 AM 12 PM 1 PM 2 PM 3 PM 4 PM 5 PM 6 PM 7 PM 8 PM 9 PM Time of Day Konarka Technologies, Inc.

30 Energy Performance Superior performance in low light Superior performance at high temperature 30 Konarka Technologies, Inc.

31 Normalized Energy (watt hours) Solar Irradiance (W/m 2 ) Competitive Testing - Energy Collection on 08/01/10 Konarka OPV Panel a-si Nominal 5 Watt Panels csi CIGS Solar Irradiance 1,400 1,200 1, AM 6 AM 7 AM 8 AM 9 AM 10 AM 11 AM 12 PM 1 PM 2 PM 3 PM 4 PM 5 PM 6 PM 7 PM 8 PM 9 PM Time of Day Konarka Technologies, Inc.

32 Example of one month daily testing Aug. 1, Sept

33 Konarka s 1 st BIPV installation on Arch Headquarters in FL 33 Konarka Technologies, Inc.

34 Energy Production (kwh) Arch Curtain Wall Energy Production by Month for East & South Curtain Walls East Wall 0 Dec '10 Jan '11 Feb '11 Mar '11 Aug '10 Sep '10 Oct '10 Nov '10 South Wall Apr '10 May '10 Jun '10 Jul '10 Mar '10 Totals: East Wall 534 South Wall Konarka Technologies, Inc.

35 Konarka Technologies, Inc. Confidential

36 BIPV Glass Facade Arch Glass, Florida USA Colors & Transparency

37 Urban Architecture Bus Shelter Example San Francisco, USA 3Form (A Hunter Douglas Company) Film Encapsulated in Polycarbonate Electrification provides lighting, scheduling, advertising

38 Carports West Palm Beach, Florida, USA

39 Army Tent

40 Ideal for Curved Surfaces Solar Awning at Selangor Science Park at 1st Solar Valley in Malaysia by L2E. Solar Kiosk in Singapore (Polymeur) for Ascendas Ltd. Next Generation Transit Shelter, California Louvers for building attached PV

41 Flexible Fabric and Stand-alone BAPV Café Umbrella Semi-transparent structures HiBird Solar Brella Shanghai California Solar Tension, Germany Louvers for building attached PV

42 Solar Tension Munich Germany, 2011

43 Solar Tension Frankfurt Auto Show, Germany, 2011

44 Portable Power 44

45 Portable Chargers For charging batteries and small electronics

46 Remote Power Remote Power Africa

47 Bags & Chargers Big Bubble Bag (Italy), light-weight ecofashion

48 Greenhouses

49 Greenhouse Installation Collecting about 2.5KWhr/day Hollis, NH 2011

50 Crop Comparison

51 Power Plastic takes solar from the rooftop to the trail Portable Light weight All lighting conditions Durable Environmentally Friendly Colors & Transparency

52 Discussion

53 Back-up Slides 53

54 OCH 3 O S n P3HT Long chain polymer poly-3(hexylthiophene) PCBM Fullerene Phenyl-C61-Butyric-Acid-Methyl Ester Konarka Technologies, Inc.

55 Building Integrated PV for commercial buildings At least 45% of all energy used in the US and Europe is consumed directly in buildings. Energy management for commercial buildings is key to lower energy costs BIPV may be able to provide PV power solutions that lower total building costs [...] ** * Greening our built world; G.Kats Island Press. **Nanomarkets: Building Integrated Photovoltaics: Opportunities 2010