UNITED STATES


 





 


 


 


Vanguard Letter of Interest to Solar America
Initiative (SAI) PV Technology 

Pre-Incubator 

Solicitation for Letters of Interest (LOI) No. REU-9-99010 

March 2009


 


 


 


 


 


Article referenced as support for the following
sections: 


Page 7: Third Full Paragraph on Production Costs











Letter of Interest (LOI)

“Solar America Initiative (SAI) PV Technology 

  Pre-Incubator”

In support of:

National Renewable Energy Laboratory 

  Solicitation for Letters of Interest (LOI) 

  No. REU-9-99010

Submitted by:

Vanguard Solar, Inc.


	
  
 	
  
 	
  
 
	
 365 Boston Post
 Road #303
 	
  
 	
 Principal
 Investigator:
 
	
 Sudbury, MA
 01776-3003
 	
  
 	
 Dr. Dennis J.
 Flood
 
	
 Tel:
 508.361.1463
 	
  
 	
 Executive Vice
 President, Chief Technology
 
	
 Fax:
 978.443.9983
 	
  
 	
 Officer,
 Co-Founder
 
	
 Principal email:
 	
  
 	
 Tel:
 440.774.2551
 
	
 jpalmer@vanguardsolar.com
 	
  
 	
 djflood@vanguardsolar.com
 





A
novel nanostructured II/VI semiconductor-based thin-film photovoltaic cell
produced by Chemical Bath Deposition process at room temperature and having
crystalline Si-like efficiency with one-tenth the production costs and
one-twentieth the capital costs of high-efficiency solar cells.


This
LOI includes data that shall not be disclosed outside the government or NREL
and shall not be used or disclosed – in whole or in part – for any purpose
other than to evaluate this LOI. If, however, a subcontract is awarded to this
Responder as a result of – or in connection with – the submission of this data,
the government or NREL shall have the right to use or disclose the data to the
extent provided in the resulting subcontract. This restriction does not limit
the government or NREL’s right to use information contained in this data if
obtained from another source without restriction. The data subject to this
restriction are contained on pages 2-11, 13-14 and 16 of this LOI.










Statement
  of Work

I.
  BACKGROUND

Vanguard Solar is developing a
  paradigm-shifting technology for the production of high efficiency thin film
  solar cells at manufacturing costs far below anything achieved by the industry
  to-date. The cost reduction comes from both the Company’s technology and from
  its manufacturing plan. 

Vanguard Solar’s patented and
  proprietary technology enables the growth of polycrystalline II-VI
  semiconductor compounds from Chemical Bath Deposition (CBD) at room temperature
  and pressure. Figures I.a-d demonstrate the Company’s breakthrough technology.
  Figure I.a shows a “forest” of CNTs coated with a film of CdSe grown using the
  Company’s patented process1. Figure I.b shows a close-up of the
  sidewall of the forest revealing the conformal, crystalline nature of the film.
  Figure I.c shows the absorbance of the film in I.b and yields the textbook
  value of 1.74eV for hexagonal CdSe2. Figure I.1.d shows a cross
  section of a solid CdSe layer that has been grown from a mat of CNTs. 



Figure
  I.a. CdSe crystalline film on CNTs.



Figure
  I.b. Magnified view of sidewall of CdSe coated CNTs.



Figure
  I.c. Absorbance of film in I.1.b.



Figure
  I.d. Cross section of solid CdSe film on CNTs

The Company can grow the
  semiconductor films on a wide variety of both rigid and highly flexible
  substrates and has the ability to simultaneously optimize performance and cost.
  The substrates of choice will be those that are compatible with standard
  roll-to-roll (RTR) film coating production lines now found worldwide with
  excess capacity - casualties of the growth of digital photography and its
  displacement of photographic film. Vanguard Solar’s manufacturing strategy is
  to develop the (CBD) equipment needed for absorber layer and window layer
  growth and insert it in existing industrial film coating production lines as
  part of a toll-manufacturing contract. The Company has already held discussions
  with several film coating manufacturers and has assurance that seamless
  integration of its equipment into such production lines is indeed 

Use or disclosure of data
  contained on this page is subject to the restriction on the title page of this
  LOI. 

2









possible and in fact represents how
  RTR companies currently operate in the toll manufacturing mode we propose to
  use. Figure I.e shows the basic components of a typical commercial film coating
  manufacturing line with Vanguard Solar’s deposition equipment inserted at the
  appropriate locations. 



Figure
  I.e. Vanguard Solar proposed toll manufacturing process. Company equipment 

  indicated by arrows; all other equipment & facilities are pre-existing

Engineering studies demonstrate the
  cost of the deposition equipment needed to sustain a manufacturing rate of 1
  million square meters per year per film coating line (100-150MW/yr output) at
  between $5M and $7M3. This is about one-twentieth the capital
  expense of setting up an equivalent silicon solar cell production line4.

Materials for the absorber and CNT
  mesh are similarly inexpensive; per square meter costs are estimated to be: Cadmium
  <$0.01; Selenium $0.16; CNTs $0.055. The costs are based on
  growing a one micron thick CdSe layer on and embedding a 0.5 micron thick CNT
  mesh with about 80% open area. 

Further, the Company anticipates
  lower energy costs, reduced equipment costs and faster throughput for module
  fabrication because of its one-piece, pre-monolithically integrated and
  encapsulated cell array. It will avoid expensive wafer pick`n place robotics,
  cell stringing/connecting and separate encapsulent steps 

The combination of low
  semiconductor and module fabrication cost, low operating cost and reduced
  capital expense will enable the Company to accomplish module production at a
  fraction of today’s cost/watt compared not only to silicon modules but also
  especially compared to any of the currently available thin film modules
  (including recent First Solar cost projections). Vanguard Solar believes its
  technology can achieve module energy costs of $0.50-0.60/WattP. 

Vanguard Solar both jointly owns
  and has exclusive rights to the patent awarded to Rice University for
  nucleating and growing semiconductor thin films on the surfaces of carbon
  nanotubes (CNTs) and other fullerenes. The CNTs are used not only as templates
  to initiate the growth of crystalline films on their surfaces, they also serve
  as an interlaced support from which the film growth fronts move outward from
  each nanotube until they ultimately merge to form a solid film; see Figure I.f.

Use or disclosure of data
  contained on this page is subject to the restriction on the title page of this
  LOI. 

3









Same-cnt
  SEM sequence 

  demonstrates ion-by-ion CBD 

  deposition of CdSe in a manner similar 

  to ALD, CVD or MBE.



Figure
  I.f. Sequential hexagonal CdSe crystal growth

Once formed, the solid film
  continues to add thickness until it reaches a desired value. The film fully
  encapsulates the embedded nanotube mesh (see again Figure I.d.) and becomes the
  absorber layer for the cell. (See Figure I.g. for a simple depiction of the
  film and CNT mesh.) A suitable window layer is then added in a straightforward
  CBD process to form a heterojunction. 



Figure
  I.g.

The Company has chosen cadmium
  selenide for the absorber layer and has investigated several potential window
  layer materials. CdSe is a CBD-grown n-type, direct bandgap material. At
  present the cell design uses a CuSe window layer (also a CBD-grown p-type)
  direct bandgap material with a bandgap of 2.66eV6. 

The choice to use CdSe is driven by
  two factors: the nature of the chemistry in the CBD process (based on
  proprietary information the Company has developed) and the predicted maximum
  efficiency in the terrestrial solar spectrum for a 1.74eV bandgap absorber.
  While not at the peak of the plot of efficiency vs. wavelength, calculations
  show such material to be capable of efficiencies in the mid to upper 20% range7.
  Vanguard Solar has estimated that AM1.5 conversion efficiencies in the range
  from 14% to 16% are achievable. Given that open circuit voltage can reasonably
  be expected to reach 60% of the bandgap value, a 1.74eV bandgap implies about
  1V open circuit voltage. 

Use
  or disclosure of data contained on this page is subject to the restriction on
  the title page of this LOI. 

4









Given also that high bandgap
  semiconductors typically have high fill factors, we assumed 80% as our goal for
  device performance. Photocurrent densities in the range 18ma/cm2 to 20ma/cm2
  have been measured on our samples in both the “forest” and mat configuration.
  An efficiency exceeding 20% appears possible with a second generation product
  enhancement that is not part of the current effort. 

Thin films performing in the
  efficiency range cited with the manufacturing costs we have identified directly
  address two of the key TIOs for terrestrial thin film photovoltaic solar energy
  conversion systems: module efficiency and cost, with a major emphasis on cost.
  The KPP’s we expect to achieve by the end of a full pilot line
  demonstration of our technology are 1) an LCOE equal to or less than that
  produced on average by conventional energy sources in the U.S.; 2) the ability
  to maintain an annual manufacturing capacity per line of at least 100MW per
  year; and 3) direct manufacturing costs in the range of $40 to $60 per square
  meter of finished solar blanket material. The solar blanket is defined to be a
  flexible, fully encapsulated, module sized sheet of monolithically
  interconnected cells with specified current and voltage outputs ready for array
  wiring and inverter hookup. 

The KPPs for the current project
  are to demonstrate window layer and absorber films that will produce the open
  circuit voltages, short circuit densities and fill factors necessary to achieve
  device efficiencies in the range cited: Voc = 1.0V; Jsc = 18-20 ma/sq.cm; and
  FF=0.8 or better. The related critical TIO is a prototype cell that achieves at
  least 80% of our targeted commercial cell efficiency of 16% under standard
  terrestrial test conditions. 

The Company expects that its first
  generation product will consist of its solar blanket mounted in a hermetically
  sealed aluminum frame with glass cover analogous to a standard silicon cell
  module. Water ingress-resistant, flexible, transparent (for the top)
  encapsulating materials are not presently available; once such materials are
  available we will augment the rigid frame module with a fully flexible,
  field-deployable product. During the course of this project the Company will
  quantify the cost savings resulting from replacing the cell pick and place,
  tabbing, interconnecting and encapsulating operations and associated equipment
  used for module manufacturing. These are expected to be significant and will
  enhance the cost savings already realized by the lower cost thin film cell
  blanket. The combination of all these cost reductions ensures that the Company
  can meet and ultimately exceed the LCOE KPP cited above. 

The Company’s first generation
  technology will also enable balance-of-system cost reductions. Such system
  costs are driven by module price but also by piece part count, installation
  labor and materials and by the cost of land (or surface area) for large
  grid-connected arrays. Unlike current thin film modules available in the market
  today Vanguard Solar’s product, with its silicon-like efficiencies, will not
  eat into the savings derived from lower module costs by requiring the purchase
  of more modules to reach the same energy output as a standard silicon solar
  array. 

Efficiencies in the range 4% to 5%
  have been measured on prototype small area devices. These measurements serve to
  validate the Company’s basic concept that room temperature growth of electronic
  quality semiconducting films on CNTs is possible with a chemical bath
  deposition process. 

Use
  or disclosure of data contained on this page is subject to the restriction on
  the title page of this LOI.

5









II. OBJECTIVES 

Vanguard Solar to date has
  demonstrated: 


	
  
 	
  
 	
  
 
	
  
 	
 1.
 	
 Nucleation and growth of hexagonal phase CdSe from CNTs in
 a room temperature, ambient pressure, aqueous, chemical bath deposition (CBD)
 process on 0.25 sq.cm areas of multiwall CNTs in forest-like arrays.
 
	
  
 	
  
 	
  
 
	
  
 	
 2.
 	
 CdSe growth scaled up to 10sq.cm area bucky papers.
 
	
  
 	
  
 	
  
 
	
  
 	
 3.
 	
 Growth of absorber layer/window layer combinations on
 10sq.cm bucky paper substrates.
 
	
  
 	
  
 	
  
 
	
  
 	
 4.
 	
 CdSe layer growth scaled up to 130 sq.cm bucky paper
 substrates.
 
	
  
 	
  
 	
  
 
	
  
 	
 5.
 	
 Small area efficiencies up to 5%.
 



This project has the following
objective: 


To move key elements of the
Company’s technology from its current proof-of-concept stage to fabrication of
multiple numbers of prototype cells with performances approaching that required
for commercial production devices. We are specifically targeting efficiencies
greater than or equal to 12%, representing 80% of our projected commercial cell
efficiency and more than double our current performance level. 


While the Company believes it has
paradigm-changing technology that will result in polysilicon/silicon-like
module efficiencies at costs low enough to meet or exceed SAI LCOE targets,
there are several developments that must be completed to achieve that goal. The
project will address the following TIOs that lie on the critical path: 


	
  
 	
  
 	
  
 
	
  
 	
 1.
 	
 Absorber efficiency
 
	
  
 	
  
 	
  
 
	
  
 	
 2.
 	
 Cell efficiency and cost
 
	
  
 	
  
 	
  
 
	
  
 	
 3.
 	
 Module cost
 



The KPPs that measure progress
toward each of the above TIOs are the following: 


	
  
 	
  
 	
  
 	
  
 
	
  
 	
 1.
 	
 Large area CdSe films on nanostructured back contacts on
 flexible substrates and window layer films with electronic properties that
 demonstrate the ability to achieve the following KPPs: 
 
	
  
 	
  
 	
  
 
	
  
 	
  
 	
 a.
 	
 1.0V open circuit voltage 
 
	
  
 	
  
 	
  
 	
  
 
	
  
 	
  
 	
 b.
 	
 18-20 mamps/sq.cm short circuit current densities 
 
	
  
 	
  
 	
  
 	
  
 
	
  
 	
  
 	
 c.
 	
 0.80 fill factor 
 
	
  
 	
  
 	
  
 	
  
 
	
  
 	
 2.
 	
 Predicted module costs based on achieved measured cell
 performance values and validated computer models for manufacturing cost
 analysis that enable PV systems using this technology to equal or exceed
 currently cited LCOE values. 
 



III. SCOPE OF WORK 


The scope of work for the project
has been broken down into five (5) task sets. Key resources, including
Lower-tier subcontractors, responsible for each task are identified. 


Task 1: Nanostructured Back
Contact Development (Vanguard Solar – Dr. Dennis Flood/Lockheed Martin
Nanosystems – Dr. Andrew Guzelian) 


	
  
 	
  
 
	
  
 	
 Objective: Develop flexible substrate with
 nanostructured back contact suitable for use in presently existing commercial
 roll-to-roll film processing pilot line. 
 
	
  
 	
  
 
	
  
 	
 TIO addressed: Cell and module efficiency 
 
	
  
 	
  
 
	
      Subtask 1.1: 
 
	
  
 	
  
 
	
  
 	
 Determine requirements for, screen, characterize and
 select CNTs for use in nanostructured back contact and for nucleation of CdSe
 film growth using Vanguard Solar’s patented CBD process. 
 


Use
or disclosure of data contained on this page is subject to the restriction on
the title page of this LOI.


6











	
  
 	
  
 	
  
 
	
      Subtask 1.2:
 
	
  
 	
  
 	
  
 
	
  
 	
 Determine requirements for, screen, characterize and
 select conductive substrate suitable for deposition of CNT mat to form
 nanostructured solar cell back contact. Subtask 1.3: 
 
	
  
 	
  
 	
  
 
	
  
 	
 Demonstrate a fully assembled, flexible conductive
 substrate with CNT mat suitable for use in CBD RTR processing. 
 
	
  
 	
  
 	
  
 
	
  
 	
 R&D procedures for Task 1:
 
	
  
 	
  
 	
  
 
	
  
 	
 •
 	
 Establish criteria for electrical, electronic and mechanical
 properties of the back contact/substrate material. 
 
	
  
 	
  
 	
  
 
	
  
 	
 •
 	
 Examine electrical and mechanical properties of potential
 conductive substrates. 
 
	
  
 	
  
 	
  
 
	
  
 	
 •
 	
 Investigate multiple methods for CNT mesh formation,
 including spray on, roll on, printing and use of a preformed mesh. 
 
	
  
 	
  
 	
  
 
	
  
 	
 •
 	
 Select CNT mesh/conductive substrate combination(s) that
 meet criteria. 
 
	
  
 	
  
 	
  
 
	
  
 	
 Risk factor(s) addressed: 1) CNTs adhere well to
 one another, but poorly to metallic surfaces. Nanostructured back contact
 must remain intact through subsequent chemical bath immersions; 2) improved
 thin absorber layer light collection and reduced electron-hole recombination
 
	
  
 	
  
 	
  
 
	
 Task 2: Film Manufacturing Process Development (Vanguard
 Solar – Dr. Dennis Flood/Chasm Technologies – Dr. John Ferguson) 
 
	
  
 	
  
 	
  
 
	
  
 	
 Objective: Demonstrate simulated RTR deposition of
 suitable CdSe absorber layer and selected window layer(s) on substrate(s)
 from Task 1 using Vanguard Solar’s patented CBD process. 
 
	
  
 	
  
 	
  
 
	
  
 	
 TIO addressed: Cell cost. 
 
	
  
 	
  
 	
  
 
	
      Subtask 2.1: 
 
	
  
 	
  
 	
  
 
	
  
 	
 Develop, build and test pre-pilot scale hardware to
 simulate RTR CBD of CdSe nanostructured absorber layer and selected window
 layers. Incorporate results from Task 3 when available. 
 
	
  
 	
  
 	
  
 
	
      Subtask 2.2: 
 
	
  
 	
  
 	
  
 
	
  
 	
 Demonstrate pre-pilot scale RTR CBD process parameters
 required to achieve optimum absorber layer and window layer performance under
 standard laboratory AM1.5 solar test conditions. 
 
	
  
 	
  
 	
  
 
	
  
 	
 R&D procedures for Task 2: 
 
	
  
 	
  
 	
  
 
	
  
 	
 Build and test a chemical bath solution tank capable of
 maintaining constant bath concentrations using minimum solution volume to
 achieve full CdSe layer thickness desired with minimum dwell time in tank. 
 
	
  
 	
  
 	
  
 
	
  
 	
 Risk factor addressed: Non-uniformity of film
 growth, slow RTR line speed. 
 
	
  
 	
  
 	
  
 
	
 Task 3: Chemical Bath Optimization (Vanguard Solar
 – Dr. Dennis Flood/Rice University – Dr. Andrew Barron, Post-Doctoral
 Researcher)
 
	
  
 	
  
 	
  
 
	
  
 	
 Objective: Develop CBD process parameters for
 growing absorber layer and window layer films with optimized performance,
 maximum film growth rates and minimum materials waste. 
 
	
  
 	
  
 	
  
 
	
  
 	
 TIO addressed: Cell efficiency 
 


Use
or disclosure of data contained on this page is subject to the restriction on
the title page of this LOI.


7











	
  
 	
  
 
	
      Subtask 3.1: 
 
	
  
 
	
  
 	
 Determine CBD solution components and concentrations
 required to demonstrate high efficiency devices and highly efficient
 materials utilization. 
 
	
  
 	
  
 
	
      Subtask 3.2: 
 
	
  
 
	
  
 	
 Investigate use of elevated temperatures to accelerate
 growth rates of absorber and window layers. 
 
	
  
 	
  
 
	
      Subtask 3.2: 
 
	
  
 
	
  
 	
 Investigate recovery and recycling of CBD solution
 components. 
 
	
  
 	
  
 
	
  
 	
 R&D procedures for Task 3: 
 
	
  
 	
  
 
	
  
 	
 Use static bath setup to explore alternate chemical
 precursors and effects of deposition temperature on film growth rates;
 analyze films via SEM, TEM, XPS, XRD, other. 
 
	
  
 	
  
 
	
  
 	
 Risk factor(s) addressed: 1) Insufficient line
 speed to meet annual production goals in a single film coating line; 2) ESH
 & recycling compliance; 3) materials costs.
 
	
  
 	
  
 
	
 Task 4: Module Assembly and Cost Studies (Vanguard
 Solar – Mr. John Palmer/Spire Corporation – Mr. Michael Nowlan, Mr. Robert
 Bradford) 
 
	
  
 
	
  
 	
 Objective: Determine manufacturing steps and
 related costs required to integrate Vanguard Solar’s flexible thin film
 blanket into standard aluminum frame/glass cover module assemblies. 
 
	
  
 	
  
 
	
  
 	
 TIO addressed: Module costs 
 
	
  
 	
  
 
	
      Subtask 4.1: 
 
	
  
 
	
  
 	
 Use existing computer model for manufacturing process flow
 and cost analysis to assess impact of substituting module-sized Vanguard
 Solar thin film blanket for pick and place silicon cell panel assembly. 
 
	
  
 	
  
 
	
      Subtask 4.2: 
 
	
  
 
	
  
 	
 Assess impact on full system installation costs using
 Vanguard Solar modified Spire (SpiVS) modules, predict LCOE for grid-tied
 central utility and commercial rooftop arrays.
 
	
  
 	
  
 
	
  
 	
 R&D procedures for Task 4:
 
	
  
 	
  
 
	
  
 	
 Modify existing computer modeling capability as needed to
 predict and compare module costs using Vanguard Solar technology 
 
	
  
 	
  
 
	
  
 	
 Risk factor addressed: Ability to meet LCOE goals
 with Vanguard Solar module technology. 
 
	
  
 	
  
 
	
 Task 5: Device Development and Characterization (Vanguard
 Solar – Dr. Dennis Flood, Mr. John Palmer/Rice University – Dr. Andrew
 Barron, Post-Doctoral Researcher) 
 
	
  
 
	
  
 	
 Objective: Demonstrate prototype cell with
 efficiencies equal to or greater than 12% (80% of targeted 15% commercial
 cell efficiency) on nanostructured back contact selected in Task 1. 
 
	
  
 	
  
 
	
      Subtask 5.1: 
 
	
  
 
	
  
 	
 Demonstrate separate absorber layers and window layers
 with desired electrical, optical and electronic properties to achieve desired
 cell performance. 
 
	
  
 	
  
 
	
      Subtask 5.2: 
 
	
  
 
	
  
 	
 Investigate and select potential transparent top contact
 materials compatible with p-type window layer selected in subtask 5.1 
 
	
  
 	
  
 
	
      Subtask 5.3: 
 
	
  
 
	
  
 	
 Fabricate prototype devices incorporating optimized
 absorber layer, window layer and top contact required to achieve 12%
 efficiency under standard test conditions at NREL. 
 


Use
or disclosure of data contained on this page is subject to the restriction on
the title page of this LOI.


8











	
  
 	
  
 
	
  
 	
 R&D procedures for Task 5: Fully characterize
 films grown in Task 3 using standard materials science and electronic
 materials analytical techniques such as SEM, TEM, XPS, standard electronic
 properties measurements and standard solar cell diagnostic measurements. 
 
	
  
 	
  
 
	
  
 	
 Risk factor addressed: Achieving critical cell efficiency
 TIO by demonstrating KPP of at least 12% efficiency under standard
 terrestrial measurement conditions. 
 



IV. Deliverables and Project
Plan 


Funding resources required by task
are as follows: 


	
  
 	
  
 	
  
 
	
  
 	
 •
 	
 Task 1 - $200K
 
	
  
 	
  
 	
  
 
	
  
 	
 •
 	
 Task 2 - $150K
 
	
  
 	
  
 	
  
 
	
  
 	
 •
 	
 Task 3 - $100K
 
	
  
 	
  
 	
  
 
	
  
 	
 •
 	
 Task 4 - $75K
 
	
  
 	
  
 	
  
 
	
  
 	
 •
 	
 Task 5 - $100K
 



Total funding required - $625K.
Team will provide a total of $125K price participation; NREL contract amount
requested - $500K. 


	
  
 	
  
 	
  
 	
  
 	
  
 	
  
 	
  
 	
  
 	
  
 	
  
 	
  
 	
  
 	
  
 
	
 Task Plan and
 Milestone Schedule
 
	
 Month:
 	
 1
 	
 2
 	
 3
 	
 4
 	
 5
 	
 6
 	
 7
 	
 8
 	
 9
 	
 10
 	
 11
 	
 12
 
	  	  	  	  	  	  	  	  	  	  	  	  	  
	
 Task:
 	
  
 	
  
 	
  
 	
  
 	
  
 	
  
 	
  
 	
  
 	
  
 	
  
 	
  
 	
  
 
	
 Task 1 Nano-Back Contact
 	
 ^
 	
 ...
 	
 ...
 	
 ...
 	
 ...
 	
 ...
 	
 ...
 	
 ...
 	
 v
 	
  
 	
  
 	
  
 
	
 Task 2 Film Mfg. Process
 	
 ^
 	
 ...
 	
 ...
 	
 ...
 	
 ...
 	
 ...
 	
 ...
 	
 ...
 	
 ...
 	
 v
 	
  
 	
  
 
	
 Task 3 CBD Optimization
 	
 ^
 	
 ...
 	
 ...
 	
 ...
 	
 ...
 	
 ...
 	
 ...
 	
 ...
 	
 ...
 	
 ...
 	
 ...
 	
 v
 
	
 Task 4 Module Assy & Costs
 	
  
 	
  
 	
  
 	
 ^
 	
 ...
 	
 ...
 	
 ...
 	
 ...
 	
 ...
 	
 ...
 	
 ...
 	
 v
 
	
 Task 5 Device Fab & Testing
 	
  
 	
  
 	
  
 	
  
 	
  
 	
  
 	
 ^
 	
 ...
 	
 ...
 	
 ...
 	
 ...
 	
 v
 
	
 Quarterly Technical
 	
  
 	
  
 	
 R
 	
  
 	
  
 	
 R
 	
  
 	
  
 	
 R
 	
  
 	
  
 	
  
 
	
 Progress
 Report (R)
 	
  
 	
  
 	
  
 	
  
 	
  
 	
  
 	
  
 	
  
 	
  
 	
  
 	
  
 	
  
 
	
 Draft/Final Technical
 	
  
 	
  
 	
  
 	
  
 	
  
 	
  
 	
  
 	
  
 	
  
 	
  
 	
  
 	
 R
 
	
 Progress
 Report (R)
 	
  
 	
  
 	
  
 	
  
 	
  
 	
  
 	
  
 	
  
 	
  
 	
  
 	
  
 	
  
 
	
 Prototype (P)
 	
  
 	
  
 	
  
 	
  
 	
  
 	
  
 	
  
 	
  
 	
  
 	
  
 	
  
 	
 P
 






	
  
 	
  
 	
  
 	
  
 	
  
 	
  
 
	
  
 	
 Deliverable
 	
  
 	
 Due Date
 	
  
 	
 % of Subcontract Price
 
	
  
 	  	
  
 	  	
  
 	  
	
 *
 	
 Hardware Baseline
 	
  
 	
 1st Month
 	
  
 	
 20% of subcontract
 
	
 *
 	
 Task 1 (Sub 1.1 & 1.2)
 	
  
 	
  
 	
  
 	
  
 
	
  
 	
 Task 2 (Sub 2.1)
 	
  
 	
 6th Month
 	
  
 	
 15% of subcontract
 
	
 *
 	
 Task 1 (Sub 1.3)
 	
  
 	
  
 	
  
 	
  
 
	
  
 	
 Task 2 (Sub 2.2)
 	
  
 	
  
 	
  
 	
  
 
	
  
 	
 Task 3
 	
  
 	
 9th Month
 	
  
 	
 15% of subcontract
 
	
 *
 	
 Prototype
 	
  
 	
 12th Month
 	
  
 	
 30% of subcontract
 
	
 **
 	
 Quarterly Report
 	
  
 	
 3rd Month
 	
  
 	
 5% of subcontract
 
	
 **
 	
 Quarterly Report
 	
  
 	
 6th Month
 	
  
 	
 5% of subcontract
 
	
 **
 	
 Quarterly Report
 	
  
 	
 9th Month
 	
  
 	
 5% of subcontract
 
	
 **
 	
 Final Report
 	
  
 	
 12th Month
 	
  
 	
 5% of subcontract
 






	
  
 	
  
 
	
 _______________
 
	
 (*
 	
 Price allocated to% of work effort associated with this
 deliverable) 
 
	
 (**
 	
 Total of these deliverables must not exceed 20% of the
 total subcontract price) 
 


Use
or disclosure of data contained on this page is subject to the restriction on
the title page of this LOI.


9









Business
  Strategy

This ‘Pre-Incubator’ program will
  enable Vanguard Solar to move its innovative technology forward to a
  pilot-ready production capability. Through accomplishment of the project’s
  TIOs, the company will have developed several critical capabilities required
  for prototype production: 


	
  
 	
  
 	
  
 
	
  
 	
 •
 	
 Selection/sourcing of optimum carbon nanotube and
 conductive substrate materials 
 
	
  
 	
  
 	
  
 
	
  
 	
 •
 	
 Development of RTR-compatible CBD process 
 
	
  
 	
  
 	
  
 
	
  
 	
 •
 	
 Optimum CBD processes for Absorber and Window Layer films 
 
	
  
 	
  
 	
  
 
	
  
 	
 •
 	
 Module design and fabrication processes and cost
 projections 
 
	
  
 	
  
 	
  
 
	
  
 	
 •
 	
 Prototype device fabrication and characterization 
 



These capabilities will directly
leverage our technology into manufacturing scale-up. 


At this stage product develop then
moves quickly to pilot production development. The Company intends to
incorporate Vanguard Solar’s film production directly into existing
industrial-scale roll-to-roll film coating facilities for toll manufacturing.
Vanguard Solar is in discussions with Eastman Kodak and other film coating
production companies; the Company and Kodak anticipate partnering for
subsequent participation in NREL’s ‘Incubator Program’ upon successful
completion of this Pre-Incubator project. 


Studies conducted to date demonstrate
relatively modest equipment requirements for establishing a Vanguard Solar
production line within existing contract film-coating companies like Kodak.
Substantial film production capacities – on the order of 100-200MW – can be
produced from a single line with an equipment investment of between $5-7
million ... roughly one-twentieth the cost of a dedicated PV cell plant. And this
‘line capacity’ can be duplicated quickly and cheaply around the world. This is
possible because this CBD technology operates at room temperature and pressure
and fits into pre-existing roll-production facilities,
accelerating the normal two-year factory construction schedule (and $100
million investment) to as little as six-months for Vanguard Solar. 


This manufacturing strategy – using
existing film production capacity (photographic, printing, packaging, etc.) –
enables contracted plants to maintain jobs currently at risk and train
‘old-production’ employees in the new technologies of solar energy and
nanotechnology. There are over 200 plants in the US alone where such capacities
– and jobs at risk – exist. Retaining these manufacturing jobs while training
these employees for the new industries of the future is a major – and unique -
benefit of Vanguard Solar’s technology! 


Competitive Advantage The
Vanguard Solar PV module will provide competitive advantages to the solar
energy marketplace in four ways:


Low PV Electricity Costs. The low materials and production costs of Vanguard Solar’s PV film, along with
its high efficiency profile, will enable LCOE targets to not only be achieved
on an accelerated basis but also to be exceeded. Further, simplified module
assembly and lower related equipment and factory investment charges will
support total ‘module costs’ for LCOE goals. 


Rapid & Large Production
Capacity. Our innovative process and using existing very-large-scale
facilities can quickly scale up to produce global-scale PV capacities with
minimal time and investment compared to all existing technologies. This
capability is flexible, can be duplicated quickly across all geographic regions
of the world at low investment risk. 


Balance of System Costs Reduced.
Versus other thin-film modules, Vanguard Solar will reduce Balance of System
costs in two ways: 


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or disclosure of data contained on this page is subject to the restriction on
the title page of this LOI.


10











	
  
 	
  
 	
  
 
	
  
 	
 •
 	
 Higher Space Efficiency ... fewer Vanguard Solar PV
 modules are needed for a given installation space and/or for given energy
 goal ... means lower installation costs and lower ‘real estate’ costs per watt; 
 
	
  
 	
  
 	
  
 
	
  
 	
 •
 	
 Lower Piece Count ... fewer Vanguard Solar modules to
 interconnect, fewer inverters required, less array yield losses ... means lower
 array maintenance costs for same space or output. 
 



Highly Flexible = Innovative
Uses. The low temperature process of this technology enables use of
innovative materials (e.g., conductive and transparent polymers) as
alternatives to glass, ITO and stainless steel for use in conformally flexible
applications. Such novel PV materials – enhanced by Vanguard Solar’s high
and stable efficiency (e.g., vs. Konarka) - can open entirely new
markets. Discussions are on-going with Lockheed Martin and Honda regarding
aeronautic and automotive vehicle applications (Lockheed Martin Nanosystems’
role as a Lower-tier Subcontractor in this project reflects Lockheed Martin’s
corporate interests). 


Target Markets Vanguard
Solar’s innovative thin-film material will support all forms of ‘module’
formatted product specifications. Thus it will target all major PV markets – Residential
and Commercial/Industrial Rooftops and Utility Markets. The film
is highly stable (unlike OPV systems), it is highly efficiency (unlike most
thin-films) and lightweight and durable. It can be fitted into rigid framed
modules of all sizes and/or rolled out with existing (and future) TCO
materials. Its flexibility, durability and stability also make it ideal for
building-integrated (BIPV) applications.


Potential Risks The
key risk to this program is scaling up the CBD process – to be addressed by
this funding project. Lab scale film quality and performance has been
demonstrated, confirming the capabilities of the materials and the concept of
Vanguard Solar’s cell design. Large scale chemical bath deposition has been
broadly demonstrated in other industries and in huge industrial roll-to-roll
processes. We will adapt these techniques to the company’s materials – CNTs,
CdSe, etc. – to generate similarly large PV supplies.


Market Interest
Numerous potential customers and partners have expressed interest in - and many
are now working with - Vanguard Solar to develop its unique photovoltaic
product: 


	
  
 	
  
 	
  
 
	
  
 	
 •
 	
 For testing when prototype available: SunEdison, UPC Solar
 
 
	
  
 	
  
 	
  
 
	
  
 	
 •
 	
 For module fabrication design: Spire Corporation 
 
	
  
 	
  
 	
  
 
	
  
 	
 •
 	
 For space/aeronautical applications: Lockheed Martin 
 
	
  
 	
  
 	
  
 
	
  
 	
 •
 	
 For automotive/transportation applications: Honda 
 
	
  
 	
  
 	
  
 
	
  
 	
 •
 	
 For pilot and commercial production: Eastman Kodak 
 



Kleiner Perkins (KPCB) - an
investor in Vanguard Solar - has numerous energy & utility contacts
appraised of Vanguard Solar’s technology who are prepared to work with us as
our prototype becomes available (including the energy & ‘cleantech’ sector
assistance of Vice President Al Gore and General Colin Powell, who are KPCB
Partners). 


Environmental Compliance Three
factors support the company operating in an environmentally safe manner: 


	
  
 	
  
 	
  
 
	
  
 	
 1.
 	
 Company films produced by existing permit-holding film
 manufacturers 
 
	
  
 	
  
 	
  
 
	
  
 	
 2.
 	
 Large-scale II/VI materials protocols by NREL and First
 Solar are known/demonstrated 
 
	
  
 	
  
 	
  
 
	
  
 	
 3.
 	
 Process is low-temperature/non-vapor (easy containment)
 and completely recyclable 
 


Use
or disclosure of data contained on this page is subject to the restriction on
the title page of this LOI.


11









References
  and Bibliography


	
  
 	
  
 
	
 1.
 	
 US Patent 7,253,014, “Fabrication of light emitting film
 coated fullerenes and their application for in-vivo light emission.” 
 
	
  
 	
  
 
	
 2.
 	
 “Properties of Wide Bandgap Semiconductors”, R. Bhargava,
 Ed. INSPEC, London, UK 1997. Absorbance data courtesy of R. Raffaelle,
 Rochester Institute of Technology. 
 
	
  
 	
  
 
	
 3.
 	
 Chasm Technologies, Inc., Westwood, MA, study November,
 2007 and preliminary equipment specification discussions with Infinity
 Precision, LLC., Chanhassen, Minnesota, February, 2008. 
 
	
  
 	
  
 
	
 4.
 	
 Solar Buzz Website. 
 
	
  
 	
  
 
	
 5.
 	
 US Geological Survey database re: Cadmium and Selenium;
 ten-year price data and several laboratory and industry chemical supplier
 communications, October 2007 through November 2008. Re: Carbon Nanotubes,
 costs based on averaged data from numerous commercial MWNT productions. 
 
	
  
 	
  
 
	
 6.
 	
 Ambade, et al, Applied Surface Science 253 (2006)
 2,123-2,126. 
 
	
  
 	
  
 
	
 7.
 	
 Nelson, Jenny, “The Physics of Solar Cells”, Imperial
 College Press (2003), London, UK, Page 33. 
 


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or disclosure of data contained on this page is subject to the restriction on
the title page of this LOI.


12









Resumes

Vanguard Solar
  (Responder) 

Vanguard Solar is a two-year-old
  startup company commercializing technology developed by its technical founders
  at Rice University and NASA. Its team has extensive and complimentary
  experience in both the PV and the related nano-chemistry technologies involved
  and all individuals have substantial government contract experience – both
  inside and outside government itself. The company’s technology is now well-positioned
  for this Pre-Incubator opportunity. Principal project resources: 

Dr. Dennis Flood –
  Co-Founder/EVP/Chief Technology Officer, PhD, Physics, Michigan State U.
  33-year career at NASA/Glenn in power systems, 24 years in photovoltaics
  R&D, 16 years as Branch Chief, Photovoltaic Branch. Extensive management
  responsibility for both terrestrial and space-based power/solar technology
  projects. Responsible for NASA worldwide photovoltaic R&D, including
  establishing the international technical advisory body for the ISO for solar
  cell measurement and calibration. Over 90 articles/publications in advanced
  solar cell R&D. Organized/chaired first IEEE World Conference on PV Energy
  Conversion, chaired WCPEC Int’l. Advisory Committee and serves on several national
  and international PV-related technical and policy organizations. 

Dr. Andrew Barron –
  Co-Founder/Science Advisor, Endowed Chair, Chemistry, Professor of Materials
  Science, Rice University. PhD. & D.I.C., Imperial College of Science and
  Technology, U. of London. Fellow, Royal Society of Chemistry, Scientific
  Advisor to The Library of Congress. Research interest: development of soft
  chemical approaches to nanomaterial fabrication. Extensive patents and over 100
  publications in field of inorganic chemistry and nanomaterials; recruited to
  Rice by Dr. Richard Smalley (Nobel Laureate – ‘Buckyballs’). Substantial and
  ongoing work with ARPA, DOE, EPA, NSF, NASA, and ONR. Founder/Co-founder of
  five commercial technology companies 

John Palmer – Co-Founder,
  Chief Executive Officer, MBA, Wharton School, University of Pennsylvania.
  Thirty years technology management, marketing, business development, including
  17 years at biotech leader Biogen Idec, last as SVP/GM Immunology Business
  Unit. Manufacturing and supply chain creation and management and international
  startup operations in Europe, Asia and Australia. 

Lockheed Martin Nanosystems
  (Lower-tier subcontractor) 

Lockheed Martin Nanosystems
  specializes in electrical and optical applications of nanomaterial coatings and
  films. It has extensive experience with many US government contracting
  agencies – as does its parent, Lockheed Martin Corporation – and will aid
  Vanguard Solar in optimizing the carbon nanotube/conductive substrate ‘ back
  contact’ film for the Chemical Bath Deposition process. Project resources: 

Dr. Andrew Guzelian – Staff
  Scientist, PhD., Chemistry, U. of California, Berkeley (Dr. Paul Alivisatos),
  MBA, Babson College. R&D on carbon nanotube materials including nanotube
  surface chemistry, thin film deposition and electrical and optical properties.
  Patents & publications in field of chemical coatings/films on
  nanostructures for electrical and photovoltaic properties. Experience in
  production of CMOS-grade carbon nanotube solutions and research at Office of
  Naval Research in optical applications of semiconductor nanocrystals. 

Use
  or disclosure of data contained on this page is subject to the restriction on
  the title page of this LOI.

13









Particular expertise in nanotube
  surface chemistry, dispersion behavior and thin film deposition. Prior
  experience working with Vanguard Solar (Responder) technology and scientists. 

Chasm Technologies
  (Lower-tier subcontractor) 

Chasm Technologies is a
  roll-to-roll production engineering design and development company, with
  extensive background in film/film coating and wet chemistry production systems
  at large scale. The company – and key individuals involved with Vanguard Solar
  – have worked on many US government-contracted projects in several fields,
  including with other PV-related companies, and will assist in developing a
  scaleable RTR process for the Responder’s novel Chemical Bath Deposition
  process. Project resources: 

Bob Praino – Co-Founder, MS,
  Chemical Engineering, Worcester Polytechnic Institute, MBA, Boston University.
  20 years Polaroid Corporation plus 10 years in related coating, thin film and
  automated process control technologies. Focus on web handling, fluid
  interfacial science and process drying. Experience as Plant Manager for $200
  million coating manufacturing facility, including design, construction and
  start-up. Extensive current work in nanomaterial-based films, displays,
  electronic and optical coatings. 

Dr. John Ferguson - Senior
  Scientist, PhD. Chemistry, Brandeis University. R&D on nanoparticle
  dispersion and nanotube nucleation kinetics. 30 years Polaroid Corporation,
  inorganic film deposition, process engineering and tech transfer, manufacturing
  plant scale-up of numerous roll-to-roll film coating processes. Particular
  expertise in inorganic crystalline film nucleation processes and production
  systems and extensive work with carbon nanotube materials. 

Spire Corporation
  (Lower-tier subcontractor) 

Spire Corporation is a world
  leading designer and supplier of PV module equipment and facilities globally
  and a major competitor in every form of PV technology. The company has
  extensive and successful experience in contracting with numerous government
  agencies. Its role with Vanguard Solar will be to assist in the design of
  module production systems compatible with this innovative technology and to
  prepare manufacturing plans for subsequent commercial operations. Project
  resources: 

Michael Nowlan – Advanced
  Technology Manager. B.A., Physics, U. Massachusetts-Boston. Engineering and
  development supervision for improving photovoltaic module production techniques
  and design of related automated production lines for module manufacturing. 25
  years experience in PV module fabrication. Patents and numerous publications.
  Responsible for assessment, design and incorporation of all new module-related
  technologies and production concepts. Extensive experience with modularization
  of thin film photovoltaics, including use of flexible panel materials, and in
  cell interconnecting, encapsulation, framing and module testing. 

Robert Bradford – PV Module
  Product and Line Leader. B.S. Industrial Engineering/Operations Research, U.
  Massachusetts-Amherst, MBA, Northeastern U. Product development project
  management, including cost modeling, for PV module manufacturing operations for
  new technologies and fabrication facility design and start-up. Supervisor for
  engineering and development efforts for automated production lines for
  crystalline and thin film PV module manufacturing. 25 years engineering/design
  experience at Spire, Helix Technology and General Electric Company. 

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  or disclosure of data contained on this page is subject to the restriction on
  the title page of this LOI.

14









List
  of Contracts

Vanguard Solar has no NREL
  contract(s) currently and has not been awarded any US Government contracts in
  the past five years. 

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  or disclosure of data contained on this page is subject to the restriction on
  the title page of this LOI.

15









Price
  Summary Sheet


	
  
 	
  
 	
  
 	
  
 
	
  
 	
 Description
 	
  
 	
 12-Month Total
 
	
  
 	  	
  
 	  
	
  
 	
  
 	
  
 	
  
 
	
 A.
 	
 Direct Materials ($)
 	
  
 	
 $50K
 
	
  
 	
  
 	
  
 	
  
 
	
 B.
 	
 Direct Labor ($)
 	
  
 	
 $125K
 
	
  
 	
  
 	
  
 	
  
 
	
 C.
 	
 Labor Overhead & Fringe ($)
 	
  
 	
 $25K
 
	
  
 	
 (Specify Rates)
 	
  
 	
 (20%)
 
	
  
 	
  
 	
  
 	
  
 
	
 D.
 	
 Special Testing ($)
 	
  
 	
 $25K
 
	
  
 	
  
 	
  
 	
  
 
	
 E.
 	
 Equipment ($)
 	
  
 	
 $15K
 
	
  
 	
  
 	
  
 	
  
 
	
 F.
 	
 Travel ($)
 	
  
 	
 $30K
 
	
  
 	
  
 	
  
 	
  
 
	
 G.
 	
 Consultant(s) ($)
 	
  
 	
 $20K
 
	
  
 	
  
 	
  
 	
  
 
	
 H.
 	
 Lower-Tier Subcontractor(s) ($)
 	
  
 	
 $290K
 
	
  
 	
  
 	
  
 	
  
 
	
 I.
 	
 Other Direct Costs ($)
 	
  
 	
 $30K
 
	
  
 	
  
 	
  
 	
  
 
	
 J.
 	
 G&A ($)
 	
  
 	
 $15K
 
	
  
 	
 (Specify Rate)
 	
  
 	
 (2%)
 
	
  
 	
  
 	
  
 	
  
 
	
 K.
 	
 TOTAL PRICE ($)
 	
  
 	
 $625K
 
	
  
 	
  
 	
  
 	
  
 
	
 L.
 	
 Responder’s Price Participation
 	
  
 	
 $125K
 
	
  
 	
  
 	
  
 	
  
 
	
 M.
 	
 NREL’s Price Participation
 	
  
 	
 $500K
 
	
  
 	
  
 	
  
 	
  
 
	
  
 	
  
 	
  
 	
  
 


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or disclosure of data contained on this page is subject to the restriction on
the title page of this LOI.


16