Quality and Capacity for Rapid German PV Module Production

The aim of the „Quelle“ project is to develop reliant PV module concepts and flexible production strategies for Heckert Solar and Stannol for the European solar market. To this end, the project is focusing on concepts such as BIPV, PV markets with restricted-access and large-scale power plant modules, including module materials, production  equipment and process developments. In particular, the project supports the lead-free interconnection of high-efficiency solar cells using round wires, as well as the development of alternative frame concepts, supported by cost calculations and life-cycle analysis. 

Initial Situation

Standard PV modules from outside Europe are currently being offered and sold at very low prices, thereby significantly restricting sales for domestic module manufacturers. Consequently, European module manufacturers are shifting their focus towards specialised applications (BIPV, markets with restricted-access, large-scale power plant modules) where higher requirements are demanded that cannot be met by standard module designs.

Objective

The module manufacturer Heckert Solar, based in Chemnitz, plans to adapt its production capacities in a sustainable and flexible manner to meet these new requirements. The focus is on developing innovative, resilient module concepts that are competitive on the European market against non-European module manufacturers. The currently prevalent high-efficiency solar cell technologies (TOPCon & SHJ) are being utilised for the development of innovative module concepts. Key aspects include the manufacture of prototype modules using the developed processes for interconnection, encapsulation and framing, including ageing tests, supported by cost calculations and a carbon footprint assessment via life-cycle analysis.

Approach

The main areas of focus in materials and process development are solar cell interconnection and module encapsulation. In the case of solar cell interconnection, process development involves the use of thin round wires, with a focus on sustainable materials. Processes developments using lead-free solders and low solvent up to solvent free, water based fluxes developed by Stannol are pursued. For a state-of-the art interconnection line the infrastructure is being upgraded for the interconnection of solar cells with more than 16 busbars for M10 and G12 formats. Material components are being evaluated for the development of glass backsheet as well as for glass-glass module concepts. In particular, the degradation properties of encapsulation materials are being investigated with regard to the long-term stability of modules. In addition improvements of module frames , simulation-based approaches using cell-to-module (CTM) analysis and FEM are being carried out to support the work. The processes and materials developed are analysed in detail in cost calculations, and the carbon footprint is assessed on the basis of comprehensive life-cycle analyses.

The “Quelle” project is funded by the Federal Ministry of Economic Affairs and Energy (BMWE).