Laura Abrardi, Onefive, CH (Appolo)

ULTRAFAST LASERS IN THE SOLAR INDUSTRYProject: APPOLO

23rd and 24th of June – Amsterdam

INDEX

1. PROBLEM AND SOLUTION

2. HOW I4MS HELPED

3. IMPACT

Hub of Application Laboratories for Equipment Assessment in Laser Based Manufacturing

onefiveUltrafast Industrial Lasers

I4MS 2016: FOSTERING DIGITAL INDUSTRIAL INNOVATION IN EUROPE · 23rd and 24th of June – Amsterdam

2005 - Founded 2007 - First product released 2008 - Acquisition of A.L.S GmbH, Berlin 2013 - Shipped 1000th laser modules 2015 - 2000+ ultrafast lasers in 24/7 operation 2015 - ISO 9001 + ISO 13485 2016 - Moved to new facility covering > 2500 m2

Based in Zürich, Switzerland & Berlin, Germany Class 10‘000 and class 1’000 clean rooms Class 100 assembly stations Operating a worldwide distribution and sales network Completely independent – no VCs, investors or Business Angels

PROBLEM AND SOLUTION


Laser Based Manufacturing – MAIN ISSUES AND CHALLENGES Increasing power level of pulsed lasers Laser beam delivery Laser-Machine integration/ Automation Laser robustness and reliability (24/7 operation in harsh environments) Built-In safety control features Low cost of ownership Analysis/testing/characterization of processed materials

Laser Based Manufacturing – MAIN TARGETS Reduce manufacturing costs Increase production speed Increase manufacturing efficiency

Manufacturing Line

Mondragon GmbH20 MW PV Panel Manufacturing Line


CIGS thin-film structuring for solar cells - NEED

High-efficiency solar modules based on Cu(In,Ga)Se2 thin film technology Thin-film patterning allows monolithic integration of cell-cell interconnects Replacement of needle-scribing with laser scribing

CIGS thin-film structuring for solar cells - BENEFITS

Reduced width of interconnections Increased scribe quality Increased production speed Reduced manufacturing costs






Customized picosecond fiber laser for scribing processes in thin film CIGS solar cells

CIGS thin-film structureTCO: Transparent Conductive Oxide layer (front contact)CIGS: Cu(InGa)Se2 (absorber layer)Moly: Molybdenum (back contact)

LASER-BASED CIGS thin-film structuring for LARGE SOLAR CELL MODULES Large solar modules: high Ohmic losses due to high current densities in TCO Cell must be divided into strips connected in series to reduce losses Requires electrical interconnection between cells Interconnects can be realized by scribing on individual layers Laser scribing allows selective material removal to produce the connections P1 and P3 based on fast laser processes P2 remains slow and often based on mechanical needle scribes

P1 – P2 – P3 scribingP1: creates cell separation in the Moly substrateP2: removes the CIGS and exposes the Moly back contactP3: creates cell separation in the TCO front contact : electrical back-to-front contact (Moly to TCO)

A. Burn et al. Physics Procedia 41 (2013) 713-722

8-cell thin film mini moduleEMPA, SwitzerlandMo/CIGS/TCO grown on glass substrate



P2 scribe on Mo/CIGS/TCO on glass substrate Clear exposure of the Moby layer No micro-cracks No melting Further increase of scribe velocity possible

A. Burn et al., Pro. SPIE 9735 (2016) 973504-1:13

Microscope image of P2 scribe Bern University of Applied Science

P2 scribe on Mo/CIGS/IZO on glassRealized with the Genki XP laser

Customized picosecond fiber laser for scribing processes in thin film CIGS solar cells

Genki – 10 XPOnefive GmbH, Switzerland

High-energy picosecond fiber laser

Genki XP picosecond laser for P2 scribing achieving 390 mm/s scribing velocity Pulse energy increased from 100 mJ to 400 mJ Pulse duration 10 ps Operate at <50 kHz REPETITION RATE Provide high AMPLITUDE STABILITY SYNCHRONIZED with the system Provide full CONTROLLABILITY, RELIABILITY and optimal performance Provide Built-In SAFETY CONTROL features OPERATE 24/7 in harsh environments

HOW I4MS HELPED


Lab scribing machine based on x-y linear motion systemBern University of Applied Sciences BFH, SwitzerlandALPS – Applied Laser, Photonics and Surface technologies group

SMEs have limited resources for development and market penetration of new solutions

Global approach to complexity through the hub of application laboratories

Fiber lasers represent a cost-competitive solution (Laser manufacturing) Lasers must be tested in a close-to-industry scribing machine (System integrators) High quality, commercial samples are required (Component providers) Industrial integration and automation are required (Large integrators) Scribe procedure must be evaluated, defined, tested and standardized (App. Labs)

EMPA, SwitzerlandThin Film Solar Cells on flexible and rigid substrates

Flisom AG, SwitzerlandThin Films on flexible polyimide substrate

HOW I4MS HELPED


Onefive GmbH, SwitzerlandHigh energy picosecond laser system

Bern University of Applied Sciences BFH, SwitzerlandEquipment assembly, system evaluation, process implementation, process analysis and testing, process validation

Cluster allows fast validation of process feasibility and equipment integration

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IMPACT


Target large penetration in the solar market

Standardization of laser-based solar cell scribing Bring a cost-effective solution into the market Bring higher efficiency in solar cell production Increase the volume capability solar cell production Induce higher solar installation capability Increase Onefive market share in the solar industry

Exploitation plan

Expected evolution of global solar PV cumulative installed capacity 2000-2019

40 GW of PV systems globally installed in 2014 178 GW global cumulative capacity reached in 2014

540 GW expected globally by 2019 Solar Power could grow 80% in Europe by 2019

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IMPACT


Expected significant revenue increase 2016-2019

Shortened development time by 30% Reduced system implementation, test and analysis costs by 70% Shortened time to process validation by 50% Fastened solar market access Created already 2 new technical jobs in the company Expected sales increase to 20 units/year in the next 3 years Expected 2-4 new technical jobs in the next 5 years Expected revenue increase by 3M€ in the next 3 years

Business impact and market access for Onefive

THANK YOUFOR YOUR ATTENTION

Small Business & Entrepreneurship

Laura Abrardi, Onefive, CH (Appolo)