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Advanced Materials and Devices The Advanced Materials and Devices effort carries out research in semiconductor material properties, device mechanisms, and fabrication processes to improve the efficiency, stability, and cost of photovoltaic energy conversion. The effort focuses on thin-film materials and modules (which hold promise for major reductions in PV costs), module manufacturing methods, and module reliability. The Thin-Film PV Partnership has formed strong research teams to focus R&D on promising thin- film candidates, such as amorphous silicon, cadmium telluride, copper indium diselenide, and thin silicon. These research teams are comprised of laboratory, industry, and university researchers who work to solve generic issues as well as industry-specific problems. In PV Manufacturing R&D, strong partnerships with the U.S. PV industry have been formed with the goal of retaining and enhancing the industry’s leadership in the development and manufacture of PV modules. Many problems in manufacturing R&D exist whose solutions are critical to further reducing the cost of PV. The overall objective of the PV Module Reliability Project is to work with industry to develop PV modules that have 30-year service lifetimes. This project also provides critical performance and reliability testing and benchmarking of modules to validate the progress and accomplishments of the Solar Program’s investments in PV module technology R&D. The Inverter and BOS Development Project seeks to improve inverters and balance of systems (BOS) through the High- Reliability Inverter Initiative. Achievements in FY 2005 include the following. Thin Film PV Partnership • With Global Solar Energy, fabricated a 10.2%-efficient, 88.9-W thin-film CIGS power module, the highest wattage CIGS module in the world. • With First Solar and United Solar Ovonic, broke ground on major manufacturing expansions (First Solar 50 MWp and Uni-Solar 25 MWp). • Overall, production of thin films in the United States grew from 12 MWp in 2003 to an estimated >40 MWp in 2005. PV Manufacturing R&D • With Sinton Consulting, received an R&D 100 Award for the quasi-steady-state photoconductance Silicon Evaluation System developed under an FY 2004 “In-Line Diagnostics and Intelligent Processing in Manufacturing Scale-Up” subcontract for the measurement of bulk minority-carrier lifetime. • With ITN Energy Systems, implemented production-line improvements that resulted in an 85% increase in yield and a 13% increase in cell efficiency. • With PowerLight Corporation, completed a prototype foamless PV roof tile design and implemented production of PowerGuard tiles that do not require added insulation. PV Module Reliability R&D • Initiated unique high-voltage stress testing experiment that measures module leakage currents to ground on a bipolar array supplied by Shell Solar consisting of CIGSS modules. • Initiated cooperative reliability testing program for SunPower’s high-efficiency c-Si modules, including light soaking, thermal cycling, and damp heat exposure indoors and real-time outdoor exposure. Inverter and BOS Development • Completed Phase II of the High-Reliability Inverter Initiative with hardware deliverables from GE and Xantrex. • Initiated “High-Tech Inverter, Balance-of-System, and Systems R&D” project with a FedBizOps announcement and draft of a request for proposal to begin the project. Photovoltaic R&D 41 Advanced Materials and DevicesPDF Image | DOE Solar Energy Technologies Program
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