Sharp Solar Panels – Thin Film Technology Is Coming

Despite of the recent advances in solar panel manufacturing process, the production costs of the traditional crystalline silicon solar cells remain high and there is a significant room for energy and material efficient technologies to be involved. The dominant process nowadays includes three main steps: 1) treatment of the silicon wafers with dopants (mainly phosphorus containing substances); 2) imprinting/soldering of the metal contacts (silver and aluminium) into the resulting photoactive plates and 3) deposition of an anti-reflective coating for the solar cell (silicon nitride). All procedures require high-temperature regimes (furnaces): the doping at the first stage typically runs at 800 – 900 ºC and the final deposition – at 260 ºC, most of the processes subjected to oxygen-free conditions.

A few years ago SHARP came up with a new technology based on so called tandem-type silicon thin-films. The manufacturing process was found to be more ecologically and energy sustainable: the new cells use only 1% of the silicon needed for traditional solar panels. These films are mainly prepared by chemical vapour deposition without the standard thermal multi-step treatment of the bulky silicon wafers. In addition to the light-weight version available, the thin-layer technology allows the cells to be semitransparent to the light. This way electricity generating layers can be introduced into windows, tinting efficiently from the direct sunshine and UV-irradiation.

Thin-film silicon solar panels are expected to expand tremendously the potential of solar energy. The SHARP production facility in Japan (Osaka, Sakai Plant) is one of the world's most advanced eco-factories, started operation in 2010. The “super green factory” is capable of producing thin-film solar modules to generate up to 1 billion watt of electricity every year. Another two production facilities will be settled in Catania, Italy (2011) and on the base of SHARP UK plant in Wrexham. All facilities incorporate green factory design principles, where attention is paid to the environment in the manufacture of superior products. SHARP thin-film solar panels provide an excellent alternative for traditional power plants, bringing down the cost of solar energy. And we can all benefit from replacing coal burners with non-polluting energy sources.

SHARP thin-film technology versus traditional silicon crystalline for solar cells.
Pros: lower cost and environmental impact; transparent, light-weight, efficiency is less temperature-dependent (works great in hot seasons);
Cons: typical efficiency around 10% (14% for traditional panels), comes as glass panels, which are not easy to incorporate into residential roofs.

The total production of solar panels in 2009 was estimated to be 9.6 billions watts in capacity, up 19% from 2008. Silicon thin-film market share was about 5% and expected to grow up to 8-9% in 2010 with an overall production aiming 12 billion watts (+ 25% Y/Y, Dispaybank).

We think solar panels based on thin-film technologies will boost the market in 2011-2012. The retail price for such panels can reach 2.2 – 2.4 USD/W (maximum capacity). Thus, Sharp solar panels will bring more value to your home and business. Thin-film photovoltaic cells are included in the TIME's Best Inventions of 2008.

Useful links:
http://solartopower.com/sharp-production
http://solartopower.com/solar-cost-estimator