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RWE SCHOTT Solar, Inc. – “EFG Technology and Diagnostics R&D for Large-Scale PV Manufacturing” • Completed R&D of prototype, large-diameter EFG furnace and laser-cutting station for producing 12.5-cm x 12.5-cm wafers. • Completed design and prototypes of reflector module (based on concept of replacing fraction of cells with lower-cost reflecting module backskin), which may result in reduced module costs. • Demonstrated Computer Management and Maintenance System to improve operation efficiency and reduce overall manufacturing cost. Energy Photovoltaics, Inc. – “Productivity Enhancement for Manufacturing of Amorphous Silicon PV Modules” • Completed thorough evaluation of single- junction and tandem a-Si modules to determine the best option, as a function of application, based on EPV’s proprietary batch deposition process. • Reduced a-Si deposition cycle time for tandem devices by 20%. • Increased the throughput of the deposition system by 20%. • Reduced per-watt module cost from EPV production line by 25%. • Increased stabilized module power output of a-Si modules by 20%. Xantrex Technology, Inc. – “PV Inverter Products Manufacturing and Design Improvements for Cost Reductions and Performance Enhancements” • Developed three advanced, high-impact PV inverter products for grid-tied applications. • Reduced weight, size, cost, and conversion losses of new inverters by nearly 50% when compared to current technology. • Developed DSP-based control boards for each of the three PV inverter topologies that were designed for universal application at virtually any power level for any inverter with the same electrical topology. 3.3 Yield, Durability, and Reliability The “Large-Scale Module and Component Yield, Durability, and Reliability” LOI issued in FY 2003 focused on addressing the needs of two categories. Category A, PV System and Component Technology, largely addresses non-module aspects of PV systems component manufacturing processes. Category B, PV Module Manufacturing Technology, primarily addresses aspects of module manufacturing processes. During FY 2004, the Source Evaluation Board completed an assessment of the 29 responses to the solicitation and determined that 17 responses were in the competitive range. These competitive LOIs represented a wide spectrum of the value chain in the PV industry, ranging from BOS work to PV module manufacturing. The competitive LOIs represent a total of more than $82M, DOE and industry cost share, of research over three years, with a total proposed cost share by industry of nearly 53%. A milestone under this subtask was to “Initiate new PV Manufacturing R&D projects directed to areas identified in FY 2003 and partners solicited in FY 2004.” This milestone supports research advancements to further aid DOE and NREL decision makers in support of the MYTP Go/No Go Decision Point 9, which is due in early FY 2006. The top-ranked responders were contacted and progress has been made in the preparation of subcontract statements of work. Individual subcontract negotiations are under way, with several awards expected in the first few months of FY 2005. 4. Planned FY 2005 Activities PVMR&D procurements are framed to specifically address milestones under the MYTP. Under the continuing IDIP procurement, PVMR&D focused on integrating state-of-the-art process controls with current production technology in support of MYTP Task I.3, Milestone 14 (Reduce direct module- manufacturing costs to $1.75 and achieve module- manufacturing processes capable of $1.50/watt direct module-manufacturing costs with 500- megawatt production capacity) and Task I.6, Milestone 25 (Complete development [achieve manufacturing-line-ready status] for at least threePDF Image | FY 2004 ANNUAL REPORT DOE Solar
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