This summary of the current status, challenges and opportunities in ACAP's Device to Module Program Package is drawn from the presentation delivered by Program Lead Professor Bram Hoex (UNSW) at the ACAP 2024 Conference.
Scroll to the end to watch a video of the presentation.
Rapid technology changes in cell and module technologies create potential challenges in long term performance and reliability, but ACAP is uniquely well positioned to support the PV industry to deal with them.
UNSW, ANU CSIRO and Monash University are all active in this program.
Current technology status in Device to Module Program
Rapid technological development
TOPCon and heterojunction technology now dominate the market, overtaking PERC.
Bifacial modules have a large market share.
Back contact cells are now in the market (Sunpower, Maxeon, LONGi, Aiko).
Professor Bram Hoex provides and update on ACAP's Device to Module Program at the ACAP Conference
Cost pressures drive changes in the bill of materials (BOM), such as:
Using thinner wafers and alternative encapsulants like EPE or EVA instead of POE.
Shifting from aluminium to steel or composite materials for module frames, with some modules becoming frameless.
Increased focus on long-term stability Efforts are being made to address the long-term performance of solar modules as cost-cutting in materials impacts durability.
Larger modules Utility-scale modules continue to become larger and heavier and require updated testing and manufacturing infrastructure.
Modules for special environments There’s a growing focus on modules optimised for special conditions e.g. desert, tropical, floating PV or lightweight modules.
Tandem technologies Tandem technologies present new challenges and will likely require different BOM for long term stability.
Challenges
Increased failure modes The sophistication of silicon and tandem solar cells has expanded the number and extent of failure modes.
Reliability issues in emerging technologies
TOPCon technology faces UV sensitivity and corrosion concerns, affecting durability.
Heterojunction cells require low-temperature metallisation, presenting sensitivity challenges in terms of corrosion in addition to UV sensitivity.
Outdated testing standards
Current test protocols primarily target short-term failures caused by one stress factor, overlooking long-term and combined-stress failure modes like corrosion, thermal stress, and light degradation. Modules tailored for specific climates require bespoke testing approaches.
Rapidly changing cell and module sizes
The PV industry upgrades production lines every three years, but research labs like ACAP’s can only afford to update facilities only every decade, creating a lag.
Performance complexities
The correlation between module power rating and system energy yield is increasingly complex (e.g. temperature co-efficient, degradation) and have become a key focus area.
Australia does not have onshore testing of imported modules This is unlike the US, which has very strict testing. Australia needs to create a barrier for lower-grade imported modules.
Opportunities
ACAP is competitively placed to support the domestic and global PV industry to deal with the main challenges in the device to module area.
ACAP’s collaboration model and strong Chinese industry ties
Researchers at ACAP have access to the most current industry samples, a competitive advantage compared with most US and EU research institutes.
ACAP’s industry partnerships, national coordinated research program and sharing of facilities give it a competitive edge.
Upgrading ACAP's module testing and fabrication facilities to a state-of-the-art level could be accomplished relatively quickly and at a lower cost compared to device fabrication facilities. This would:
support domestic module producers and developers (in line with Solar SunShot)
enable testing of emerging BOMS and cell technologies, including tandems
allow the development of modules customised for Australia's harsh climates to extend lifespans to 40-50 years.
Current testing facilities in the ACAP network
CSIRO’s Parachute LED based solar simulator - the world’s most sophisticated solar simulator for module testing, LED based, with an almost perfect spectrum
ANU’s new outdoor testing facility.
Expanding and consolidating ACAP’s outdoor testing facilities
This would enable:
testing of performance and durability under Australian conditions of commercial and proof of concept technologies
test advanced diagnostic tools, both hardware and software
testing data to be made available.
Consolidate characterisation, modelling and simulation activities
This would accelerate and increase ACAP’s impact e.g., in collaboration with PV Lighthouse and activities at ACAP Nodes.
Customised module development
ACAP can lead the creation of modules for specific environments, such as desert or floating PV systems, by leveraging materials optimised for UV resistance and humidity.
Localised standards and testing
Establishing region-specific testing facilities and standards will improve the quality and reliability of imported and domestic modules.
ACAP highlights
Novel materials and methods Research on encapsulants, back sheets and interconnections will enhance module reliability and reduce costs.
Improvements in cell stability Professor Bram Hoex’s team at UNSW has pioneered new techniques, like laser-assisted firing and barrier layers, to improve the stability of TOPCon and heterojunction cells, respectively.
Bifacial modules potential
Bifacial module technologies show significant performance boosts, up to 30%, even on rooftops, with innovative modelling and yield optimisation.
State-of-the-art testing facilities
ACAP has unique capability with the LED-based module simulator at CSIRO, which enables unparalleled precision in measuring tandem and silicon module performance, and ANU’s Advanced Outdoor Testing facility.
Watch the video
Readers will find details on progress and activities in each program in Chapter 5 of ACAP’s Annual Report. ACAP's Annual Report for 2024 will be published in May 2025.
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