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Fig. 3. Recapture of industry investment in PVMR&D 3.2 In-Line Diagnostics and Intelligent Processing Under this subtask, the PVMR&D milestone for “renewal of remaining IDIP subcontracts” focused on preventing interruptions in the research in IDIP subcontracts, supporting the MYTP Milestone 25, Task 6 (due in FY 2005). This milestone was completed in September of 2004. Other significant achievements under this subtask were accomplishments by the individual subcontractors, which include the following: Shell Solar Industries – “PV Manufacturing R&D - Integrated CIS Thin-Film Manufacturing Infrastructure” • Developed specifications for CIS absorber formation reactors for high-throughput manufacturing levels. • Implemented bar-code scribing equipment, resulting in increased capacity, improved yield, and significant cost reductions in manufacturing. • Implemented x-ray florescence feedback control for CIS deposition, leading to increased machine utilization. RWE SCHOTT Solar, Inc. (formerly SCHOTT Applied Power) – “Plug and Play Components for Building-Integrated Systems” • Completed optimization of new flat-roof mounting system for commercial PV array installations. Completed improved design of Photovoltaic Source Circuit Protectors and initiated listing process with Underwriters Laboratory. • Initiated design effort with Phillips Lighting to develop improved SunSine AC module. • Evergreen Solar, Inc. – “Innovative Approaches to Low-Cost Module Manufacturing of String Ribbon Si PV Modules” • Developed production-ready dual-ribbon growth system known as Project Gemini, resulting in dramatically reduced manufacturing costs from dual output capacity. • Made progress in developing wrap-around contacts for monolithic modules, achieving a record wrap-around cell efficiency of 13.6%. • Developed production machine to produce cell contacts using unique contact-printing technology, attaining a gain in yield of 3%, overall efficiency improvement of 0.3% absolute, and throughput increase of 70%. BP Solar International, LLC – “Large-Scale PV Module Manufacturing Using Ultra-Thin Polycrystalline Silicon Solar Cells” • Demonstrated good yields and cell efficiencies using a mix of 25% solar-grade silicon and 75% intrinsic silicon feedstock. • Demonstrated slicing of 110-micron-thick wafers. • Demonstrated 2.5% to 3% increase in module output power using AR-coated glass; qualified glass through environmental testing. • Built modules using 110-micron-thick silicon cells. Sinton Consulting, Inc. – “Development of an In- Line Minority-Carrier Monitoring Tool for Process Control During Fabrication of Crystalline Silicon Solar Cells” • Developed improved, fast-data analysis for multicrystalline wafers, including corrections for trapping, a common artifact in multicrystalline wafer measurements. • Demonstrated performance measurements as fast as 0.6 s/measurement. Actual data acquisition, analysis, and logging required less than 0.4 s. • Commercialized prototype through sale of six units to PV manufacturers.PDF Image | FY 2004 ANNUAL REPORT DOE Solar
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