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The Thin Film PV Partnership supported the transition to successful first-time manufacturing of key thin-film technologies during the fiscal year. This is viewed as the Partnership’s most important activity in the short term, because it will help establish thin films in the marketplace, improve their chances of future growth and success, and help define the transition of technologies that have been successfully developed by DOE funding to the private sector. Global Solar Energy fabricated a 10.2%-efficient, 88.9-W thin-film CIGS power module, the highest- wattage CIGS module in the world. First Solar and United Solar Ovonic broke ground on major thin-film factory expansions (50 MWp of cadmium telluride and 25 MWp of amorphous silicon, respectively). Overall, production of thin films in the United States grew from 12 MWp in 2003 to an estimated >40 MWp in 2005. The PV Manufacturing R&D Project received a 2005 R&D 100 Award with Sinton Consulting for a quasi-steady-state photoconductance Silicon Evaluation System. This process gives manufacturers information to identify substandard silicon before it is made into PV cells, thereby increasing the number of efficient cells produced, boosting yields, and reducing manufacturing costs. The evaluation system will enable the solar industry to keep up with product demand and growth and to produce consistently better silicon at the lowest possible price. Manufacturing R&D achieved major technical progress in other areas, as well, by: implementing production-line improvements that resulted in an 85% increase in yield and a 13% increase in cell efficiency (ITN Energy Systems); demonstrating the integration of diagnostic equipment and statistical methods for high-speed monitoring of wafers, cells, and processes in 60-MW manufacturing facility, resulting in a 15% increase in throughput (RWE Schott Solar); and initiating manufacturing of PV modules using new Gemini II-based String Ribbon silicon wafers (Evergreen Solar). Construction of the Science and Technology Facility (S&TF) at NREL is well under way, with the grand opening of the completed facility expected in May 2006. The new facility will provide 71,000 square feet of office and laboratory space. The S&TF includes a substantial investment in new equipment that will be capable of greater process integration. Researchers will be able to experiment in conditions much closer to the situation likely to be found in manufacturing. This will dramatically narrow the gap between discoveries in the laboratory and their application in the market. The second Solar Decathlon, an intercollegiate competition that tests which team can build the most effective solar-powered home, began in late September, just as FY 2005 was drawing to a close. Eighteen teams brought their houses to the National Mall in Washington, D.C., where they competed in ten contests encompassing architecture, livability, and power generation to heat and cool space, heat water, and power lights, appliances, and an electric car. The Solar Decathlon reaches out to the public in a major way. Between the two Decathlons (held in 2002 and 2005), as many as a quarter of a million people have come to learn about the architectural appeal and myriad benefits of solar energy in the built environment. A Growth Industry For the past decade, the average growth of the world PV market has exceeded 30%, which makes the PV industry one of the most consistent high-growth industries in the world. Critical to the success of PV technologies in the marketplace has been DOE’s role in advancing module efficiencies, costs, and reliability; inverter performance, reliability, and cost; and improvements in balance of systems. Continued success will depend on a strong government R&D program and the resources, scientific and technological approaches, and continued efforts of the “best and brightest” among industry, laboratory research organizations, and our educational institutions. Photovoltaic R&D 2PDF Image | DOE Solar Energy Technologies Program
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