Helianthos
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Helianthos is a program focused on the development of solar cell modules that can be manufactured via roll-to-roll processes on long foil substrates. Helianthos is run by a core group of industrial partners and is supported by universities, technology institutes, and other partners. Since 2006, Helianthos is a wholly owned subsidiary of Nuon, an energy company from the Netherlands.
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[edit] Process Technology
The process uses a temporary substrate on which flexible thin film solar cells are deposited. The use of the temporary substrate allows relatively high processing temperatures while using (semi-)continuous roll-to-roll (or reel-to-reel) production processes and cost-efficient, abundantly available materials.
The active layers of such solar cells comprise a transparent conductive oxide layer (TCO), an active absorbent layer (e.g. thin film silicon), and a back contact layer (e.g. a reflective metal layer).
[edit] Process Sequence
The key steps in the process sequence are:
- Deposit the TCO layer on a temporary metal substrate foil using chemical vapor deposition (CVD) at about 500 °C (932 °F) .
- Deposit the active absorber layer (e.g. thin film silicon layer) using plasma enhanced CVD
- Deposit the reflective back contact by means of physical vapor deposition
- Pattern for monolithic interconnection
- Laminate to a permanent carrier foil
- Remove the temporary substrate foil by means of wet etching
- Confectioning, contact application and encapsulation
[edit] Applications
Using this process, flexible photovoltaic (PV) laminates will be fabricated that can substantially reduce the per-kilowatt hour costs of solar electricity. Further, the resulting photovoltaic laminates are lightweight, unbreakable, aesthethic, and offer freedom of design.
PV laminates have the potential to be used for a range of applications, including:
- Large area roofing and other large area applications to generate electricity
- Rural electrification
- Industrial applications
- Consumer applications, e.g. solar cells for portable applications.
