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Innovation Drives the Solar Industry
By Jenny Bieksha, Bishop & Associates Inc.

Solar energy has had a bumpy ride this year. Prices continue to fluctuate, programs have been put on hold, and there is a saturation of PV modules on the market. On top of this, companies such as Solyndra have cast a negative shadow on the industry. Solar cell manufacturer Solyndra is a case of a manufacturing venture that saw the market price of its product collapse before its rollout. Third quarter results from leading solar companies indicate that the ride is not going to smooth out any time soon. The ongoing turmoil in the euro zone and lack of project financing has led to reduced forecasts for 2012.

When you mention solar energy, most people think about commercial or residential solar photovoltaic (PV) panels. Interconnects for these products are considered unique or “application specific,” including PV connectors and junction boxes. Large-scale solar CPV/CSP parks provide opportunity for a wider range of interconnect products. Taking it one step further, consider the use of solar products crossing across multiple market segments. As we ride out the volatility of the PV solar market, there is still an abundance of opportunity for interconnect suppliers.

The solar industry has been pushing out innovations, some of which have the potential to make a serious (and positive) impact on our energy systems. To close the year, we thought it would be interesting to give you a snapshot of the innovation taking place in the solar industry. Many of these are commercial in nature and some, very specialized, providing potential design-in opportunities for the future.

• Efficiencies in solar thin film technology have led to reduced sizes of solar panels. These solar films can be “printed” in rolls, greatly reducing the cost and the installation, as well as opening up more opportunities for placement of these solar power producers (such as being integrated into the roofing materials of buildings).

• Many companies have begun to look into electronics that can track performance and minimize losses at the panel level before the DC-to-AC conversion takes place. Power optimizers are being placed at each solar panel. Other companies have created microinverters, combining power tracking and optimization with DC-to-AC conversion. These companies are also designing cables and other fixtures to make it easier for installers to attach microinverters to each panel. Companies are beginning to integrate their microinverters into solar panels at production lines. These pre-assembled, microinverter-attached solar panels could further reduce installation time, and therefore cost.

• Solar windows, which have been treated with a new electricity-generating coating, remain transparent, yet have the ability to convert sunshine to energy. The coating on these solar windows consists of the world’s smallest functional solar cells (measuring less than ¼ the size of a grain of rice) and can be applied at room temperature, with no need for specialized production facilities.

• Solar energy harvested by current solar panels comes entirely from the visible spectrum. Infrared spectrum solar panels utilize new materials added to solar semiconductors that allow solar panels to capture some of the infrared spectrum and turn it into electricity.

• Nanostructures:

Hairy Solar Panels use light-absorbing nanowires on carbon-nanotube fabric. The nanowires can absorb more energy from the sun than silicon can, which may allow for more efficient energy harvesting.





Solar “Sea Urchins” are the creation of polystyrene microspheres that resemble the shape of sea urchins. The 3D nanostructures are filled with deposits of semiconductive material to create nanowires within the shells. Once the nanowires are created, the microspheres are removed. These formations can be installed in solar cells in place of silicon or other semiconductive materials. Other planned uses for the “sea urchin” nanowire structures are in the manufacture of LED lights and other optoelectronics.

Crossing into New Markets: Solar Energy for Military Applications
Increased access to clean and reliable energy has become a leading priority for the U.S. Department of Defense (DOD) and the military arena. A large number of casualties have been associated with fuel transport, motivating the military to cut risks, and costs, by implementing self-sufficient fuel strategies. The various branches of the DOD combine to form the single-largest consumer of energy in the world; greater than 100 other nations. Projects range from the utilization of solar and wind power for electricity generation, to the adoption of fuel cells for portable power, to the deployment of microgrids for forward base operations, and the use of alternative fuels for land, air, and sea transport.

Military solar projects in the various stages of development include:

• The U.S. Defense Department is evaluating mobile solar and wind generators to replace fuel trucks in combat zones.

• The U.S. Army has developed a solar kit that consists of a panel and different adapters that allow soldiers to recharge any military battery.

• The PowerShade is a large solar tarp that fits over a standard Marine Corps tent, which can provide enough energy to power the tent’s lighting system.

• The U.S. Army is developing a 500 MW solar power generation plant in Fort Irwin, California, that will help power the base and reduce its vulnerability to power supply disruptions as well as using solar shades with tents to better insulate them in an effort to reduce cooling costs. The army believes this could cut energy usage by up to 50% by reducing the need for air conditioning.

• The U.S. Air Force plans to eventually receive over 25% of the power used at the Nellis Air Force base from the Nellis Solar Power Plant near Las Vegas, Nevada. This facility is operational and covers a 57 hectare area of land. Its ground-mounted PV modules employ a sun-tracking system, with around 70,000 solar panels, and the peak power generation capacity of the plant is approximately 13 MW.

Much of the technology currently being used by the U.S. military is commercially available or has been adapted for the battlefield from civilian models. However, the military is starting to look at more innovative technologies. An example is the use of solar-powered hydrogen production as a way of powering vehicles and to store energy generated from wind until there is demand for it. Solar powered hydrogen generation could also be used to power military bases.

Boeing Phantom Works is working on a solar-powered unmanned aerial vehicle (UAV). The SolarEagle will have solar panels that its designers say will allow it to remain airborne for five years at a time. With a wingspan of 400-feet, the Boeing Solar Eagle will be able to stay at altitudes of 60,000 feet while carrying 1,000 pounds of equipment using solar energy and ultra-efficient electric motors and propellers. Solar energy absorbed during daylight hours will be stored in fuel cells for continued use of the renewable resource overnight. Because of the glider-like design of the Solar Eagle, the plane will be able to stay at high altitudes for long periods of time without the need to refuel. The solar airplane is due to be launched in 2013.

The military has the buying power to create products and markets. Solar and wind technologies have already benefited from government subsidies and are becoming cheaper. The main beneficiaries of the military’s fervent approach to renewables are technologies that have a tremendous potential but are not yet commercially viable. By stepping in as an early adopter with immense purchasing power, the military has the ability to make such technologies practical and affordable, and therefore help move them into the mainstream.

Solar Innovation in Commercial Applications
Solar products cross market sectors and play in multiple industries. This provides interconnect suppliers an opportunity to participate in the solar movement without necessarily having to develop a solar specific connector. Some of these applications are custom and the volume is limited. Others are commercial with high volume potential.

• Portable solar chargers (laptops, cell phones, laptop cases, backpacks)

• Smart meters

• Solar parking lot structures

• Solar golf carts

• Recreational vehicles, motor homes, ATVs

• Vehicle-charging systems and stations

• Hydrogen-powered cars

• Fuel cells

Examples of Connectors in Unique Solar Applications

Molex contributed interconnects for a solar car, which placed third in the 2011 World Solar Challenge in Australia. The University of Michigan’s solar car, called Quantum, featured several advanced electronic components from Molex, as well as a variety of solderless terminals. Molex interconnect products included:

• The MX150 sealed connector system, a high-performance, submersible interconnect solution for automotive, off-road, and other harsh duty applications.

• The MX150L environmentally sealed connector system supports high-power applications and long-voltage runs to eliminate voltage drops.

• The Mini MI II system is a space-saving solution designed for use in high-density wire harness applications.

SOURIAU is providing power and signal electrical composite connectors for the Solar Impulse, a solar powered aircraft, which is planned to circle the earth only propelled by solar energy. Solar Impulse uses SOURIAU composite connectors to supply and monitor the four electrical motors powered with solar panels and high performance battery.







Tyco Electronics has its SOLARLOK Junction Boxes used on the solar modules of a sculpture in front of the town center in Ajax, Ontario, Canada. The nautical sail uses TE junction boxes on the 17 individually custom designed solar modules (designed by SolarScape Innovations Inc. and Solera Sustainable Energies Company Ltd.).









While not as rapid as in past years, growth is expected in all renewable energy sectors, with projects at various stages of development around the world. The important issues facing the solar industry in the upcoming year are not new, but as with demand over the past five years, they are accelerating. New cell designs, advances in materials, and higher throughput manufacturing techniques will continue to drive down the cost of solar, making installation more attractive, despite the scaling back of some government-funded initiatives.

Jenny Bieksha Director, Renewable Energy, Medical, and Military, Bishop & Associates Inc. Jenny Bieksha joined Bishop & Associates in 2008 as its market segment director for the renewable energy, and the test, measurement, and instrumentation markets. She is currently a management consultant specializing in strategic business planning, with an emphasis on the development of program, market, and product plans. Bieksha has more than 20 years of experience in the electronics industry, with a background in market management, business development, channel sales, product management, and operations for ITT Corporation, Delphi Connection Systems, and Hughes Aircraft Company. Bieksha has a bachelor of science degree in marketing from the University of Wyoming, and also holds a certificate as a project management professional. She can be reached at jbieksha@bishopinc.com.