OUR SOLAR cell TECHNOLOGY
It’s no secret that the traditional solar cell manufacturing process is inefficient, wasteful and too reliant on silicon.
- During silicon wafer production for solar cell use, high grade, thin-film silicon can be used to make a small number of solar panels, but the manufacturing process is lengthy, inefficient, and expensive.
- The industry standard method of cutting silicon crystalline is itself wasteful and inefficient.
- Current solar technology based on this technique and class of raw materials is not efficient enough to power EVs and other electronics for the masses.
In contrast, Rayton Solar is using advanced particle accelerator technology to develop solar cells consisting of a thin layer of gallium arsenide (GaAs)— a far more efficient semiconductor material— and it’s doing so at a significantly reduced cost. This will finally bring affordable and efficient solar power to new solar applications, including cell phones, the rooftops of EVs, smart home devices, headphones, drones and more, thereby taking them completely off the grid.
RAYTON'S SOLAR CELL MANUFACTURING PROCESS
Our cutting technique allows for solar panel manufacturers to make solar panels 60% cheaper and 25% more efficient.
A proton beam is accelerated and directed into a thin layer of GaAs film. The protons penetrate to a depth of two microns below the surface.
The implanted GaAs is bonded, annealed and exfoliated to separate the top layer of GaAs from the ingot.
The exfoliated GaAs film is fabricated to create solar cells using standard semiconductor processing including metallization, doping, and anti-reflective coating.
How is rayton solar different?
Particle Accelerator Technology
Rayton Solar holds a significant cost and technological advantage over both conventional crystalline solar silicon cutting methods and the few particle accelerators previously used in solar energy applications. We use a high current, high voltage proton particle accelerator from Phoenix Nuclear Labs to slice GaAs wafers, reducing waste by 50%. Our accelerators cost less and operate at a much more efficient level of 300 KeV over competing for particle accelerator methods— avoiding high volume machine breakdowns. Our particle accelerators are capable of making up to 100 times as many solar panels with the same amount of semiconductor material as our competitors use to make just one panel.
Cost-Effective Semiconductor Material
We only produce solar cells from semiconductor materials like gallium arsenide that, in the absence of our technology, would be 10x more expensive using the solar cell manufacturing process steps typically used today. Solar cells that use GaAs hold the record for solar cell efficiency, but it comes at a hefty price. The ion implanter that is currently being developed for us is the first way to economically create modules that use 2 microns of gallium arsenide.
Solar Cell Manufacturing Efficiency
Precision wire saws are currently the standard for cutting semiconductor materials for solar cell manufacturing. We are able to use 100x less material than the current industry standard method of cutting raw materials with a diamond wire saw, which wastes half the processed materials and cannot cut materials down to this reduced wafer thickness without significant yield loss.
HOW GALLIUM ARSENIDE OUTPERFORMS SILICON
See the 5 ways in which gallium arsenide solar cells outperform silicon.
Industry standard silicon cells have a ~17% efficiency versus gallium arsenide (GaAs) that can attain 27%+. Gallium arsenide has been used for space and military applications such as satellites, but due to cost restrictions, significant manufacturing challenges still exist to unlock the value of GaAs in the solar market. GaAs is the ideal material for single junction solar cells because its bandgap is almost optimal for solar energy conversion, and high-quality GaAs crystal can be mass produced in a similar method as a silicon crystal. GaAs-based solar cells have a record efficiency of 28.8%, the highest among single junction cells. See the 5 ways in which gallium arsenide solar cells outpeform silicon.
The Growing Value of US Solar Power
The global energy market is projected to grow to over $10.4 trillion by the year 2020.
Furthermore, the 2018 solar tariffs on imported panels will place an increased importance on U.S. solar cell manufacturers like Rayton Solar.
By 2040, renewables will command 60% of new capacity and 2/3 of power investment globally. In order to compete with the average solar module price in China (hovering at 0.43 cents per watt in 2016), a viable alternative is needed out of American manufacturers hoping to become a global sustainable energy player. Cheaper domestic solar panels will drive an increase in demand for solar as well as the demand for solar installations, thereby leading to job creation.
Federal energy requirements mandate an increase in the production of renewable energy (solar, wind, tidal, and others), and California has set their renewable portfolio standards to 1/3 of its energy portfolio by 2020.
Rayton Solar is uniquely positioned to be an industry leader as these trends continue across the country and around the world, creating the perfect legislative environment for its growth, as the global population is primed to surpass 7.5 billion people.
Ready to Test our Solar Cell Wafers? Sign up for Rayton Solar Product Alerts.