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ITN Energy Systems, Inc. – “Trajectory Oriented and Fault Tolerant Based, Intelligent Process Control for Flexible CIGS PV Module Manufacturing” • Developed physics-based and empirical models for CIGS deposition processing and physics-based model for Mo deposition processing. • Improved process control through in-situ sensor development, indicating further potential for enhanced status monitoring and control of deposition. • Demonstrated process improvements, including significant improvement in CIGS uniformity, thickness control, yield, and throughput. PowerLight Corporation – “PowerGuard Lean Manufacturing” • Developed new version of PowerGuard, Gen II, in which the cementitious coating on the foam backerboard was replaced by a metal or plastic cover, reducing product lead time. • Improved manufacturing yield to 99.7%, reduced product lead time, required labor, floor space, and inventory levels, exceeding company goals. • Achieved 20% reduction in labor required to produce Gen II tiles with improved manufacturing. • Improved “design for manufacturability,” reducing per-watt cost by 18%. AstroPower, Inc. – “High-Volume Manufacturing of Silicon-Film Solar Cells and Modules” • Developed and implemented continuous back- metallization, screen-printing, and laser- scribing systems. • Achieved 40% reduction in silicon feedstock used per wafer following introduction of near net shape wafer-formation process. • Addressed feedstock supply by developing continuous unidirectional solidification process to upgrade metallurgical-grade silicon to Silicon-Film purity requirements. • Achieved overall increase of 5% in relative power and nearly 15% in mechanical and visual yield. Specialized Technology Resources, Inc. – “Development of New Low-Cost, High- Performance PV Module Encapsulant/Packaging Material” • Completed research under this work effort on thin-film module technology including device performance/failure analysis, glass stability, and device encapsulation for thin-film technologies. • Developed analytical models for the individual interfacial components for thin-film type modules both “as manufactured” and after field exposure or laboratory aging. • Completed pre-commercialization activities for the formulation and extrusion optimization for the super-fast-cure and flame-retardant EVA-based encapsulants designed for the PV module market. Energy Conversion Devices, Inc. – “Implemen- tation of a Comprehensive On-Line Closed-Loop Diagnostic System for Roll-to-Roll Amorphous Silicon Solar Cell Production” • Completed installation of second-generation a- Si reflection spectrometer in production equipment. • Completed fabrication of first-generation closed-loop, thickness-control systems for ITO and ZnO. • Completed installation of retrofitted component cell PV capacitive diagnostic in production equipment. • Completed initial investigation of plasma- cleaning parameters and correlation with QA/QC data. Spire Corporation – “Development of Automated Production Line Processes for Solar Brightfield Modules” • Completed design effort for a large-area, 800-W PV module and associated production line with goal of minimizing total installed- system cost for multi-megawatt, utility- connected brightfield PV arrays. • Continued development process of an automated cell string inspection process to detect visible and microcrack defects.PDF Image | FY 2004 ANNUAL REPORT DOE Solar
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