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PV Manufacturing R&D Performing Organizations: National Renewable Energy Laboratory (NREL) Key Technical Contact: Richard Mitchell, 303-384-6479, richard_mitchell@nrel.gov DOE HQ Technology Manager: Jeffrey Mazer, 202-586-2455, jeffrey.mazer@ee.doe.gov FY 2005 Budget: $7,922K (NREL) ____________________________________________________________________________________ Objectives • Improving PV manufacturing processes and products for terrestrial applications • Accelerating PV manufacturing cost reductions • Increasing commercial product performance and reliability • Laying the foundation for significantly increased production capacity • Achieving these goals in an environmentally safe manner. Accomplishments • Conducted an evaluation of manufacturing progress in crystalline silicon technologies by U.S. industry participants in the PV Manufacturing R&D Project as part of annual Solar Program Review (1st quarter Joule milestone). • Conducted stage-gate assessment of the need for additional manufacturing R&D as part of annual Solar Program Review—determined “In-Line Diagnostics and Intelligent Processing in Manufacturing Scale-Up” (IDIP) subcontracted efforts should be continued and “Large-Scale Module and Component Yield, Durability, and Reliability” (YDR) subcontracted efforts should continue awards. • Completed mid-year conversion and efficiency measurements for crystalline silicon modules with a 12.9% module demonstrating progress toward the annual goal (2nd quarter Joule milestone). • Analyzed U.S. PV industry cost/capacity data to produce capacity-weighted, industry-average results. • Achieved a DOE Solar Program milestone with a 13.7%-efficient U.S-made, commercial crystalline silicon PV module (4th quarter Joule milestone). • Implemented stage-gate processes and a Systems-Driven Approach in managing all PV Manufacturing R&D project activities. • BP Solar – Completed process equipment specifications for sawing, demounting, and handling 100-μm wafers cut on 290-μm centers. • Energy Conversion Devices – Completed testing of on-line PV capacitive diagnostic system to stabilize and optimize a-Si deposition. • Evergreen Solar – Initiated manufacturing of PV modules using new Gemini II-based String Ribbon silicon wafers. • ITN Energy Systems – Implemented improved process controls and fault-tolerance procedures on the production line, resulting in an 85% increase in yield and a 13% increase in cell efficiency. • RWE Schott Solar – Demonstrated 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 wafer and cell operational throughput. • Sinton Consulting – Received an R&D 100 Award for the quasi-steady-state photoconductance Silicon Evaluation System developed under an FY 2004 IDIP subcontract for the measurement of bulk minority-carrier lifetime. • Specialized Technology Resources – Developed flame-retardant encapsulant (passed UL 1703 Class B flammability test); a faster-cure encapsulant; and a new thin-film encapsulant formulation, which is thinner and has improved glass adhesion. • Schott Applied Power – Completed the development of an updated line of wiring junction boxes and the second-generation design of the meter-interconnect device. Photovoltaic R&D Advanced Materials and Devices 50PDF Image | DOE Solar Energy Technologies Program
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