Dow Corning seeks key to solar puzzle

Dow Corning said today it has increased efficiency and production of solar panels by using a specialized manufacturing process and new silicon materials.

“Efficiency is one of the advantages, along with extended life and durability,” said Gaetan Borgers, global industry director of Dow Corning's solar market business unit.

Dow Corning also said the equipment for the new process requires less capital and less factory space (see What silicon shortage, asks Hemlock).

In order to achieve the advancements, the manufacturing process is paired with Dow Corning's PV-6100 encapsulant series. These materials are clear laminates used to protect solar cells in panels. The series was designed to replace commonly used ethyl vinyl acetate resin.

Borgers said researchers have not established the exact efficiency gains, but think the materials can yield anywhere from 1.5 percent to 3 percent improvements. The cumulative impact of several million modules can make a significant difference.

The company claims the silicon-based material provides optimum ultra violet resistance. The silicon laminate permits more light to pass through and reach solar cells. That means silicon-based cells can leverage all spectrums of light, he said.

"We do not have ultraviolet blockers in our material and that means more light reaches the cell and hence more efficiency,” Borgers said.

The process and encapsulant series are being piloted by solar partners in the new Dow Corning Solar Application Center in Freeland, Mich., and are expected to be commercially available in mid-2009.

Dow Corning currently provides silicon-based solutions that span the photovoltaic product set. Dow Corning said it continues to invest in expanding its portfolio of products for solar cell manufacturing, module assembly and installation. These solution packages are built on high-performance silicon products such as encapsulants, adhesives, coatings, potting agents and sealants, as well as next-generation solar grade silicon.

“Our goal is to become the material house for the solar industry,” Borges said.

Borgers said there are challenges in the next six to nine months, including that it takes several months to test modules for durability  and bring the full solution to market. The company has prioritized this area of research and development by doubling its R&D staff.