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Advanced Materials and Devices The Advanced Materials and Devices effort carries out research in semiconductor material properties, device mechanisms, and fabrication processes to improve the efficiency, stability, and cost of photovoltaic energy conversion. The effort focuses on thin-film materials and modules (which hold promise for major reductions in PV costs), module manufacturing methods, and module reliability. The Thin-Film PV Partnership has formed strong research teams to focus R&D on promising thin-film candidates, such as amorphous silicon, cadmium telluride, copper indium diselenide, and thin silicon. These research teams are comprised of laboratory, industry, and university researchers who work to solve generic issues as well as industry-specific problems. In PV Manufacturing R&D, strong partnerships with the U.S. PV industry have been formed with the goal of retaining and enhancing the industry’s leadership in the development and manufacture of PV modules. Many problems in manufacturing R&D exist whose solutions are critical to further reducing the cost of PV. The overall objective of the PV Module Reliability Project is to work with industry to develop PV modules that have 30-year service lifetimes. This project also provides critical performance and reliability testing and benchmarking of modules to validate the progress and accomplishments of the Solar Program’s investments in PV module technology R&D. Achievements in FY 2004 include the following. Thin Film PV Partnership • Shared an R&D 100 Award (Global Solar Energy and NREL) for the development of flexible CIS modules on stainless steel (the seventh such award for the Partnership). • Carried out the Thin Film PV Partnership recompetition. • Made major advancements in first-time manufacturing of all three thin films, with technology partners taking fiscal year U.S. production levels up from about 12 MW in FY 2003 to about 20 MW in FY 2004: o Shell Solar and Global Solar sold about 3 and 1 MW of CIS modules, respectively. o First Solar sold about 4 MW of CdTe modules. o Uni-Solar Ovonic sold about 12 MW of a-Si modules. PV Manufacturing R&D • Completed renewal for active “In-Line Diagnostics and Intelligent Processing” subcontracts. • Completed LOI review, source selection, and initiated negotiations for awards under “Large- Scale Module and Component Yield, Durability, and Reliability” solicitation. PV Module Reliability R&D • Continued an intensive effort in support of NREL’s thin-film module hot and humid, long- term outdoor reliability-testing program. NREL and SNL provided detailed baseline characterizations of more than 180 modules from 4 manufacturers prior to field deployment at the hot and humid test sites (Florida and Texas). • Evaluated more than 20 module backsheet and encapsulant materials for their moisture- barrier and adhesion properties and reported results to industry.PDF Image | FY 2004 ANNUAL REPORT DOE Solar
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