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• Installed a tension-management-system winder to minimize material usage during the manufacture of encapsulant sheets, resulting in enhanced dimensional stability. • Developed a new thin-film encapsulant formulation, which is thinner and has improved glass adhesion. ITN Energy Systems • Developed a new design for free-standing mounting system bracket, allowing module to be completely free to rotate to shallower angles in response to wind forces and preventing it from over-rotation; this design has been evaluated/validated rigorously, including wind tunnel testing on scale-model array design. RWE Schott Solar “EFG Technology and Diagnostics R&D for Large- Scale Manufacturing” 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. “Trajectory-Oriented and Fault-Tolerant-Based Intelligent Process Control for Flexible CIGS PV Module Manufacturing” • 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. • Developed Abaqus models to predict thermal behavior with the metal sources. • Developed robust effusion source, which enabled rapid (non-equilibrium) start-up based on trajectory control, as well as chamber • dynamic simulations to optimize system design; and provided model-based diagnosis for fault detection. BP Solar International, LLC “Large-Scale PV Module Manufacturing Using Ultra Thin Polycrystalline Silicon Solar Cells” • • Completed process equipment specifications for sawing, demounting, and handling 100-μm wafers cut on 290-μm centers. • Reduced wafer thickness in production from 250 μm to 220 μm. • Introduced lead-free interconnects on all BP Solar multicrystalline Si modules. • Introduced new junction boxes on all commercial products. Schott Applied Power “Plug and Play Components for Building- Integrated PV Systems” • Completed the development of an updated line of wiring junction boxes, or PV Source Circuit Protectors. Improvements include upgrading to superior fused and non-fused terminal blocks and ground lugs and overall cost reduction. • Completed the second-generation design of the meter interconnect device, a simplified means for interconnecting a residential PV system's AC output to the electrical service at a dwelling. The device has been approved for use by National Grid (Massachusetts Electric) in its service territory, where five demonstration systems will be completed in early FY 2006. Photovoltaic R&D Advanced Materials and Devices Developed a computer management and maintenance system for remote in-line process monitoring and for application to SPC and monitoring equipment PLC functions. It is fully implemented and being used for process control, maintenance, and performance tracking. Raised yield in Edge-defined, Film-fed Growth (EFG) wafer production, demonstrated high- yield processes for 250-μm EFG wafer, and implemented higher-cutting-speed laser (+60%) and cutting-cycle time reduction (~20%). • Implemented techniques for in-line diagnostics. • Scaled up reflector module prototypes to 50-W module size to demonstrate 25% reduction in cell utilization; identified deficiencies in module materials and reliability using stress analysis and materials and qualification testing. Spire Corporation “Development of Automated Production Line Processes for Solar Brightfield Modules” • Built and tested a module lay-up process system for large-area modules. • Built and tested a robotic string busing system, which automatically connects solar cell strings together and installs bypass diodes in the cell circuit before lamination. • Demonstrated a method for forming shallow, fine-pitch corrugations in copper ribbon to relieve stress and maintain high yield in the cell string soldering process. • Designed a large-area solar simulator for testingmodulesupto2mx4minarea. Demonstrated a single-flash, long-pulse xenon 54PDF Image | DOE Solar Energy Technologies Program
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