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light source for this simulator. Developed new electronics that actively controls lamp intensity, significantly improving light intensity during the flash. Evergreen Solar “Innovative Approaches to Low-Cost Module Manufacturing of String Ribbon Si PV Modules” Initiated manufacturing of PV modules using new Gemini II-based String Ribbon silicon wafers, resulting in a 15-MW capacity with significantly reduced wafer and cell costs. The key achievement was a 33% reduction in direct manufacturing costs throughout the factory. Individual accomplishments that contributed to this achievement include: • 10% improvement in machine uptime by reducing hot zone change time by a factor of 3, simplifying seeding process, and reducing time to steady state by a factor of 2.5. • 12% improvement in yield, surpassing 10% goal. • 80% increase in run length (time to crucible change). • Improved ribbon surface quality by tighter control of the ambient surrounding the solid- liquid interface. • Developed very reliable conductive adhesive for monolithic module technology. Energy Conversion Devices “Implementation of a Comprehensive On-Line Closed-Loop Diagnostic System for Roll-to-Roll Amorphous Silicon Solar Cell Production” • Completed testing of on-line PV capacitive diagnostic system to stabilize and optimize a- Si deposition, improving both solar cell efficiency and production yield. • Conducted plasma studies that resulted in the correction of the germane cross-web non- uniformity problem. • Developed optical reflection spectrometers for online QA/QC and closed-loop control of film thickness and cross-web uniformity of the sputtered ZnO layer in the back reflector, the sputtered ITO top conductive oxide/anti- reflectivity layer, and a-Si layers. 3.3 Yield, Durability and Reliability The “Large-Scale Module and Component Yield, Durability, and Reliability” Letter of Interest issued in FY 2003 focused on addressing the needs of two categories. Category A, PV System and Component Technology, largely addresses non- 55 module aspects of PV systems component manufacturing processes. Category B, PV Module Manufacturing Technology, primarily addresses aspects of module manufacturing processes. During FY 2005, 11 of the 17 responses to the YDR solicitation that were ranked in the competitive range were selected for funding. These projects represented a wide spectrum of the value chain in the PV industry, ranging from BOS work to PV module manufacturing. PV Manufacturing R&D Project management is currently in the process of awarding these subcontracts. As of September 30, 2005, 7 of these 11 YDR subcontracts have been awarded. Other significant achievements under this subtask were accomplishments by the individual subcontractors, and are described in the following SunPower Corporation “Automated Manufacturing of High Efficiency Modules” • Introducing an AR-coated cover glass to SunPower’s standard module design, and produced an NREL-verified 17.9%-efficient module; tested stability of coating with promising results. • Studied handling yield and effect on cell efficiency of thin silicon wafers; confirmed an expected 0.25% efficiency increase for 190- μm wafers compared to 240 μm. • Developed and successfully tested a lead-free interconnect system; found additional benefit of increased resistance to fatigue failure. • Evaluated six different automated soldering approaches for use on thin, back-contact cells, and down-selected to one for further testing. Dow Corning Corporation “High Performance Packaging Solutions for Low- Cost, Reliable PV Modules” • • • Developed prototype encapsulant materials with fast lamination speed (20% greater than typical EVA lamination times) and the potential for non-laminator assembly methods such as pinch rollers. Demonstrated samples with dynamic cut resistance at 5–15 micron cut depth (compared to 40 micron for EVA/Tedlar®) and static cut resistance at 130–160 micron cut depth (compared to 100 micron for EVA/Tedlar®). Completed initial prototype laminations to determine minimum thickness for the adhesive and encapsulant layers by demonstrating Photovoltaic R&D Advanced Materials and DevicesPDF Image | DOE Solar Energy Technologies Program
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