Community Research and Development Information Service - CORDIS


ADVANCED-BIPV Report Summary

Project ID: 666507


Reporting period: 2015-04-01 to 2016-03-31

Summary of the context and overall objectives of the project

ADVANCED BIPV (New Generation of BIPV glass with advanced integration properties) is a EU/H2020 funded R&D project aiming to increase the competitiveness of Building Integrated Photovoltaics (BIPV) technology by means of developing a new generation of PV glazing, satisfying the well-defined market demanded architectural trends. According to the mail goal of SME instrument-Phase 2 in terms of financial supporting conditions, within ADVANCED-BIPV project ONYX decided strategically to support the development of a new family of optimized BIPV glass products, which can be classified as:
• Novel XL-BIPV Glazing Units,
• High- Mechanical Resistance PV units
• High Performing Vision Glazing.

These improvements will be an inflection point for increasing PV glass competitiveness for its use in skyscrapers, hotels, offices, corporate headquarters, hospitals, schools, real state, malls, museums, sport facilities, airports or public headquarters.

Work performed from the beginning of the project to the end of the period covered by the report and main results achieved so far

An overview of the work performed by ONYX during the first period of the project (M1-M12) is summarized as follows:

WP1. Project Management and Coordination
The aim of this WP is to provide effective management and coordination to all project activities.
During this period, a continuous work to identify the roles of the participating working teams from ONYX and responsible persons has been done. The plan addressing the time schedule and quality standard related to the individual WPs and tasks, procedures for reporting and standards for the reports, deliverables and other associated documents has been established. On the other hand, not just Kick off Meeting but also several organizing meetings with project staff have been celebrated in order to accomplish the schedule of the project.
Furthermore, and according to Annex 1 of Advanced BIPV project, commonly used communication routes between ONYX and external parties (European Commission, third parties and coaching staff) as meetings, video-conferences, e-mail, Participant Portal Tool or phone has been used. At the same time, general administrative services provided by ONYX management staff, in terms of financial and any related administrative issues, as timesheets, costs management, reports, etc., have been handled.
Finally, the election of the coach was done during this period and nowadays four coaching sessions have been already held.

WP2. Development Large Format and High Resistance BIPV glazing
The objective of this WP is the simultaneously development of large dimensions and high mechanical resistance BIPV glazing.
The design of large format PV laminator prototype capable to manufacture high-dimensions (width x length; m) 4,5 X 2,2 and high-resistance PV glasses of minimum thickness (mm) of 30 per double laminated units has been accomplished. This development has been carried out in collaboration with key technical and industrial partners and also ONYX has used as a basis of design the existing inputs of our 3S PV laminator (back-up pressures, historical recipes and cycling conditions from already complex executed projects and prototypes manufacturing conditions). The results of this development are included in deliverable D2.1 Manual and Design specifications of a PV laminator prototype for large format glazing Units.
On the other hand, and once ERNs were established and the main specifications defined, the development of the XL-Laminator prototype was initiated. XL-prototype laminator has been delivery in ONYX facilities the last week of May 2016 and main results will be reported in D2.2 PV laminator prototype.
Finally, ONYX has started working in the Optimization and improvement of XL-PV glazing resistance. The idea is to improve the mechanical strength of double/triple laminated glass. For this aim, ONYX has been testing several encapsulants of different chemical nature and results found will be provided in the forthcoming Deliveries 2.3 XL and 30 mm thick BIPV units as double laminated solution and 2.4 XL and 40 mm thick BIPV units as triple laminated solution.

WP3: Development of new architectural vision glass
The main objective of this working package is the manufacturing of BIPV vision glass of high quality and stable PV performance showing light transmission (LT) as high as 50%.
ONYX has produced high quality vision glass at 30% and 40% see-thru level. 100 pieces of 30cmX30cm 30% and 40% have been fabricated from a-Si opaque substrates (reference) and fully characterized by different characterization tools. These results are included in Deliverable D3.1 Improved 30% and 40% see-thrus vision glass.
On the other hand, a first generation of samples of 50% see-thru has been developed and Task 3.2 Scaling from 30% and 40% improved samples to 50% see-thrus has been already accomplished. Those findings will be reported in D3.2 50% LT vision glass with optimized PV performance. The same deliverable will include results coming from Task 3.3 Manufacturing of 50% see-thru glazing at scale in-line process, which is ongoing now but the accomplishment of the fabrication of Functional 1245 mm X 635mm 50% LT samples has been already reached.

WP4: Full testing, standardization and demonstrative cases of new advanced BIPV solutions
The main goal of this WP is to analyze the technical behavior of the innovations developed in WP2 and WP3. Although this WP is supposed to start in month 12, ONYX has initiated the testing of several samples developed in those WPs. In this sense, triple laminated a-Si films and double laminated crystalline Si showing thickness as high as 28mm haven been successfully passed mechanical tests. Also these samples have been fire tested under UL-790 and ASTM 84. Detailed results will be shown in D.4.1 Two family product certification.
On the other hand, the two proposed DEMOS (a) Canopy for large format/high resistance crystalline solution and (b) curtain-wall based on high vision 50% LT a-Si solution have been already designed. Main findings will be reported in D.4.2 Canopy demo for Large Format/High resistance PV and D4.3 High Quality PV Vision Glass Demo.

WP5: Implementation of dissemination, communication and exploitation plan and IPR protection plan
This WP is allowing ONYX to develop a scientific and commercial strategy in order to reach all the different stakeholders but mainly the market.
Regarding the Dissemination and Communication activities (Task 5.1), and according to Annex 1, ONYX has designed and implemented Advanced BIPV logo. Once it was created, ONYX has produced some complementary Dissemination Material as flyers and newsletter covering project information on public communication. At the same time, ONYX is using Web Communication channels to reach the public. In this sense, project website is currently available. Furthermore, ONYX is using its website, blog and web2.0 communication channels (LinkedIn, Twitter and Facebook) to promote Advanced BIPV project.
Finally, ONYX has taken part representing the project in several events, from national and international conferences to fairs. More information can be found along this document and also in Advanced BIPV website.
Within Task 5.2 Intellectual property and knowledge protection plan and as part of the commercial exploitation plan, ONYX team is constantly carrying out an intensive patent searching to fulfill the objectives of WP5 and to make sure of the novelty features of the project actions. Results of these findings will be reported in D5.2 Intellectual Property Protection Plan.
As part of the objectives of Task 5.3 Preparation of commercial exploitation strategy, it is needed to train ONYX distribution channels before new solutions coming from Advanced BIPV project are launched to the market. Thus, ONYX has started carrying out this activity and also increasing this distribution network in order to reach as much more markets as possible to keep ONYX as one of the main leaders of BIPV market.

Progress beyond the state of the art and expected potential impact (including the socio-economic impact and the wider societal implications of the project so far)

"Nowadays, Limiting Dimensions and robustness are serious constrains for BIPV market. Per today, PV laminators in the market are designed with a maximum active area of 3,4mX2,2m dimensions limiting the maximum BIPV glazing dimensions to units of 3mX1,7m in the best case. This is a critical limitation for buildings applications for two main reasons: BIPV glazing cannot not compete with large format conventional glass when it is prescribe in vertical glazing or skylights over that dimensions and also BIPV cannot compete with conventional glass due to structural building needs in certain applications. In addition to dimensions, other limiting factor for BIPV to become an extendedly used building material is glazing thickness, per today, limited to 22-25mm. BIPV cannot compete with conventional architectural glass as structural building needs become more important. Mechanical restrictions in terms of wind loads at high buildings or certain applications as canopies usually require thickness over this limit.
On the other hand, in terms of transparency, as see-thru is gained, PV active material is reduced, so efficiency is decreased. But the decrease is not fully linear, since the PV respond is altered in terms of series resistance and Shunt Resistance. Up to 40% the series resistance maintains its zero value and the shunt resistance is considerable large. However, when achieving values of 50% laser etching, it is observed that the Rs increases and R-shunt decreases indicating that the laser etching is affecting the PV performance. However, it is clear that if vision PV glass is willing to compite with conventional vision glass this limitation should be overcome: a simple brief survey over prescribed vision glass in outstanding projects clearly shows that visible light transmissions over 50% are requested in cold weathers, in most of west and east façades, and buildings end use (hotels, office, commercial stores). Moreover, several BIPV market reports clearly point out the low visible transmission level of PV see-thru products as a key growth market constrain of BIPV.
In this sense, ADVANCED BIPV project will allow ONYX to overcome these limitations by developing:
- Novel high-dimensions PV glass-glass based on crystalline and amorphous silicon technologies: the key product to develop on a large scale basis will be BIPV glazing units of dimmensions up to 4,5m (Length) X 2.2m (Width) in both crystalline and amorphous silicon technologies
- Novel high-resistance PV glass-glass based on crystalline and amorphous silicion technologies: related to the first concept, since as we gain dimmensions it is mandatory to gain robustness.The product to be developed will be BIPV glazing units in both technologies showing enhanced structural properties. By means of different technological approaches, the idea is to fabricated in a large scale manner BIPV robust laminates leading to XL-30mm thick BIPV units as double laminates and XL- 40mm thick BIPV units as triple laminates
- New performed see-thru patterns for PV glass-glass based on amorphous silicion technology: New see-thru vision BIPV glazing showing light transmission (LT) as high as 50% will be developed as ready for market.

As a result, ONYX expects to optimize the mentioned three improvement areas through the implementation of ADVANCED-BIPV project. Thereby, the present multifunctional advantages associated to a usual BIPV constructive solution will be reinforced. In particular, the energy performance of active property focused on producing electricity in-situ will be improved for higher see-thru patterns (between 30-60%). In parallel, passive properties as natural daylight entrance will be optimized through the increase of see-thru degree range according to the light transmittance requirements coming from envelope architectural demands such as curtain walls or skylights. In this sense, the clients will feel free to integrate a fully-integrated multifunctional product in all buildings regardless of their location or surrounding area conditions due to the customization capacity will be extended reaching the maximum sizes and thickness required by glass industry for the construction of large buildings. In summary, ONYX will be ready to fulfill the new challenges and main trends of Architectural Glazing and Green Building sector.

In this sense, ONYX has defined the fulfillment of specific objectives as impact indicators within the accomplishment of this project:
- Objective 1: Achieving as a main target by year 2020 a 4,3% market share leading to a Turnover of 122 Million € and 270 direct employees (in accelerated growth scenario) or 2,3% market share, a Turnover of 63 Million € and 158 direct employees (in a moderated growth scenario) of the global BIPV business.
- Objective 2: By developing Advanced-BIPV materials to overtake all the limiting factors of actual BIPV market pointing as a key target material cost parity with similar performing conventional glazing
- Objective 3: The new Advanced-BIPV products will represent a total of 40% of ONYX sales volume in a moderate growth scenario and even a 70% in the case of the accelerated growth scenario by year 2020
- Objective 4: A key objective is reaching the "Blue Ocean"concept"

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