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PV Manufacturing R&D Performing Organization: National Renewable Energy Laboratory Key Technical Contact: Richard Mitchell, 303-384-6479, Richard_Mitchell@nrel.gov DOE HQ Technology Manager: Jeffrey Mazer, 202-586-2455, Jeffrey.Mazer@hq.doe.gov FY 2004 Budget: $9,264K _____________________________________________________________________________________ Objectives Assist the U.S. PV industry by: • Improving PV manufacturing processes and products for terrestrial applications • Accelerating PV manufacturing cost reductions • Increasing commercial product performance and reliability • Laying the foundation for significantly increased production capacity • Achieving these goals in an environmentally safe manner. Accomplishments • Completed analysis of FY 2003 U.S. PV industry cost/capacity/recapture data and reported progress. • 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. • Shell Solar Industries implemented bar-code scribing on its CIS manufacturing line, leading to increased capacity, improved yield, and significant cost reductions in manufacturing process. • AstroPower achieved a 40% reduction in silicon feedstock used on Silicon-Film wafer production with a molded-wafer formation process. • BP Solar demonstrated production-scale slicing and processing of ultra-thin (110 micron thick) polycrystalline silicon wafers into cells and modules. • PowerLight achieved a 20% reduction in labor required for PowerGuard, Gen II tiles along with improving its “design for manufacturability,” reducing per-watt cost by 18%. • ITN Energy Systems demonstrated process improvements on the Global Solar production line, including significant improvements in CIGS uniformity, thickness control, yield, and throughput. • Sinton Consulting developed the in-line, minority-carrier monitoring tool for process control during fabrication of crystalline silicon cells with measurements as fast as 0.6 s/measurement, and actual data acquisition, analysis, and logging requiring less than 0.4 s. • Evergreen Solar developed the Project Gemini dual-ribbon growth production system, resulting in dramatic cost reduction based on dual output capacity. • Energy Photovoltaics increased the throughput of deposition system by 20%, reduced per-watt module cost by 25%, and increased the stabilized module power output of a-Si modules by 20%. • Xantrex Technology developed three advanced, high-impact PV inverter products for grid-tied applications and reduced weight, size, cost, and conversion losses of new inverters. • RWE Schott Solar completed development of prototype, large-diameter EFG furnace and laser- cutting station for production of 12.5-cm x 12.5-cm wafers. • Specialized Technology Resources developed formulation and optimized extrusion for super-fast- cure and flame-retardant EVA-based encapsulants.PDF Image | FY 2004 ANNUAL REPORT DOE Solar
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