DayStar Technologies Unveils TerraFoil Solar Cells

DayStar Technologies Unveils TerraFoil Solar Cells

DayStar Technologies, Inc., a developer and manufacturer of proprietary high-performance, silicon-free solar cells on specialty metal foils, has unveiled TerraFoil for use in traditional flat-plate photovoltaic (PV) modules. The product is the second addition in the company's portfolio of planned Photovoltaic Foil offerings and complements the high specific power LightFoil product introduced in March.

Targeted for use by module manufacture companies (Modco's), TerraFoil is an alternative to wafer silicon solar cells. The product is presently in the pilot manufacturing stage and is a key component of the company's long-term product sales strategy.

"The company's Copper Indium Gallium Selenide (CIGS)-based TerraFoil has been designed to comply with the technical requirements of Modco's. We are currently encountering a large and growing demand for our products, in part, based on the present and forecasted silicon cell supply shortages," said Terry Schuyler, director of sales and product management, DayStar. "As with LightFoil, our ultra-light PVFoil product, the flexible form factor of TerraFoil cells will also enable intriguing new consumer products outside of the flat- plate module environment, including use in unique building integrated materials."

TerraFoil consists of a CIGS solar cell deposited on thin stainless steel foil with electrical performance characteristics comparable to silicon-based products, but without the breakage issues of fragile wafers. Although the company has previously achieved near 17 percent efficiency in a laboratory setting, DayStar is targeting TerraFoil to be manufactured at 10 percent to 14 percent efficiency, depending on intended applications and cost requirements.

The product will be available in 100mm -150mm square sizes, similar to the majority of the silicon cells produced today, and can be assembled into conventional flat-plate PV modules with the automated machinery used commonly by Modco's. A range of alternative cell sizes and shapes will be available for the emerging consumer product markets.

To achieve cost and quantity benchmarks, the Company produces its Photovoltaic Foil products using proprietary, low-cost, high-volume manufacturing processes adapted from the commodity computer component manufacturing industry. DayStar's TerraFoil is not expected to provide significant cost advantages for Modco's until the company’s GEN-III continuous in-line manufacturing is operational. DayStar believes that the success of this manufacturing ramp combined with this product strategy could lead to a dramatic expansion of new worldwide markets for PV.

Published 05/26/2005