The SunFab™ integrated production lines use amorphous silicon (a-Si) based thin film technology to deliver the world's largest and most powerful thin film panels with excellent long-term reliability.

THIN FILM TECHNOLOGY

Proven Reliability of Thin Film Panel Technology

The long-term reliability of thin film panel technology has been proven with field data from commercial applications deployed over 15 years ago, and is supported by numerous research studies. There are two misconceptions about the long-term reliability of thin film technology: light induced degradation (LID) Light Induced Degradation (LID)
At first exposure to light, new thin film panels experience a one-time, initial efficiency loss. This effect, called Light Induced Degradation (LID), causes the thin film panel to undergo a fairly rapid initial decrease in power output over approximately 3-6 months. After this initial period, the panel achieves its “stabilized,” commercially rated power output. LID is well understood by panel manufacturers and is accounted for in how panels are rated for power output. As a result, the short-term LID phenomenon is rendered much less relevant. and gradual lifetime reduction of performance; Long-Term Thin Film Panel Performance
The high performance and durability of thin film panels of various origins have been well documented by independent studies. In 2002, researchers evaluated tandem junction thin film systems operating for several years in climatic zones as diverse as Brazil, China, Spain, Switzerland, and the UK. Once stabilized, these amorphous silicon systems performed as well or better than crystalline silicon solar panels. but in fact, neither are significant issues.

Superior Performance in Hot Conditions

Solar photovoltaic systems are most valuable to utilities if they can work reliably and consistently during the hottest time of the day when energy demand is at its peak. Panels fabricated with crystalline silicon (c-Si), another type of solar panel technology, tend to experience a decrease in power generation when they get very hot. In contrast, thin film panels actually produce more power when they are heated, making them ideally suited for summer utility peak loads.

Exceptional Diffused Light Performance

Conventional c-Si panels require almost direct sunlight to generate power. For utility scale solar farms, c-Si panels often need to be installed on tracking systems to maximize power output. Thin film panels have much better performance in diffused light, producing energy during cloudy days as well as morning and late afternoon hours when the sun is not perpendicular to the panels.

Increasing Device Efficiency

Today, SunFab tandem junction lines can produce solar PV panels with a stabilized conversion efficiency of 8%. Applied is on track to achieve at least 10% efficiency by 2010. In addition, efforts are underway to enhance the light trapping properties of the tandem junction stack, which will also increase the panel's overall efficiency, resulting in lower cost per watt.

Frameless Design

The SunFab thin film panel is optimized to deliver the highest possible power output over the long term. SunFab’s 5.7m² panels utilize a frameless design made possible by state-of-the-art laminating technology. This frameless design provides significant advantages over framed panels by eliminating two predominant field reliability challenges for thin film panels: water penetration and weakened structure integrity over time.

Inexpensive galvanized steel bonded rails eliminate the need for a frame.

Panel Reliability Testing

Applied conducts rigorous internal testing of the 5.7m² solar panel to establish long-term reliability projections. Applied operates a 670m² panel reliability test facility where it conducts comprehensive environment and mechanical tests. This testing aggressively accelerates the aging process of a solar panel to ensure that extreme conditions will not cause the panel to fail over time. This lab augments Applied’s test facilities in Germany and California.

IEC Certification

IEC, the international standards body, has tested SunFab panels for a battery of environmental conditions that simulate years of exposure to sunlight, extreme temperatures, wind and precipitation. In January 2009, Applied Materials achieved IEC certification for both single junction and tandem junction 5.7m² panels, meeting IEC 61646 and 61730 standards.