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• Spire – Completed development and testing of large-area Brightfield PV module automated process systems, including a module lay-up process system for large-area modules; a robotic string busing system; an advanced lamination process tool for encapsulating large modules; and a large-area solar simulator for testing large modules or multiple small modules. • Completed a stage-gate review of remaining proposed subcontracts under the YDR solicitation and determined negotiations and subcontract awards should continue on a delayed schedule. • Completed the award of 7 out of the 11 proposed subcontracts under the “Large-Scale Module and Component Yield, Durability, and Reliability” solicitation on a delayed schedule. • Dow Corning Corporation – Developed prototype encapsulant materials with fast lamination speed (e.g., 20% greater than typical ethylene vinyl acetate [EVA] lamination times) and the potential for non-laminator assembly methods such as pinch rollers. • PowerLight Corporation – Completed prototype foamless PV roof tile design and implemented production of PowerGuard tiles without the need for added insulation. • Shell Solar – Introduced a thin (125 μm) wafer-cutting wire to pilot-production mode, giving an increase of almost 8% in watts out per kg of silicon input for a significant cost improvement. • SunPower – Developed a new cell interconnect improving long-term field reliability and eliminating Pb in the module, a module with >220 W power and 17.5% total-area efficiency, and identified an automated bonding technique suited to thin, back-contact cells. Future Directions • Assess and determine the needs for additional PV Manufacturing R&D and select areas for elimination or support. • Complete development (achieve manufacturing-line-ready status) for at least three in-line diagnostic processes initiated in FY 2002 awards from IDIP subcontracts. • Complete stage-gate review of individual progress versus milestones and required redirection for YDR subcontracts. • Conduct end-of-year measurements to meet the FY 2006 EERE Efficiency Joule Milestone for U.S.-made, commercial crystalline silicon PV modules of 14.0% conversion efficiency. • Analyze U.S. PV industry cost/capacity data and verify PV industry has reached FY 2006 EERE cost goal of $1.85/Wp. ____________________________________________________________________________________ 1. Introduction The PV Manufacturing R&D (PVMR&D) Project assists the U.S. PV industry through a cost-shared manufacturing R&D partnership with the U.S. DOE and members of the U.S. PV industry. Subcontracted research focuses on U.S. industry improvement of processes and products, resulting in: (1) a substantial reduction of associated manufacturing costs; (2) providing a technology foundation that supports significant manufacturing scale-up (500 MW total U.S. capacity); and (3) positioning the industry to meet rapidly emerging large-scale deployment opportunities. This focus directly supports the DOE Solar Program Multi- Year Technical Plan (MYTP) Tasks 3 and 6 under “Advanced Materials and Devices.” Each subcontractor enhances existing manufacturing technologies through cost-shared development efforts geared toward achieving the overriding PVMR&D goals. Work areas include: improvement of module manufacturing processes to increase module reliability; system and system- component packaging, system integration, manufacturing, and assembly; product manufacturing flexibility; and balance-of-systems (BOS) development, including storage and quality control. 2. Technical Approach The PVMR&D Project is a government/industry partnership through cost-shared, subcontracted research on PV manufacturing technologies. The approach for the FY 2005 work effort was divided into three areas: (1) Project Management and Support; (2) research subcontracts under the FY 2001 competitive solicitation for “In-Line Diagnostics and Intelligent Processing in Manufacturing Scale-Up” (IDIP); and (3) research subcontracts under the FY 2003 competitive solicitation for “Large-Scale Module and Component Yield, Durability, and Reliability (YDR).” Photovoltaic R&D Advanced Materials and Devices 51PDF Image | DOE Solar Energy Technologies Program
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