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bubble-free laminates and suitable samples for cut and voltage breakthrough testing. Evergreen Solar – “Low-Cost Manufacturing of High-Efficiency, High- Reliability String Ribbon Si PV Modules” • Designed and bench tested a new in-situ ribbon-cutting apparatus. Based on the success of the tests, company will be moving into pilot production. • A move to thinner (170 μm) wafers is under development, focusing on process yield improvement in the glass etch, decal application, and tabbing and stringing steps. • Identified two approaches for high-throughput, high-quality front and back contacts: (1) find an outside vendor as a drop-in replacement for in-house made decals for the front contact; (2) study various pastes for both front and rear contacts, even using direct screen printing instead of decals to form contacts. Shell Solar Corporation “Photovoltaic Module Manufacturing Technology” • 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. • Effects of light-induced degradation of cells and glass characterized; both effects found to be significant and of comparable magnitude. • Ran the thinner wire in pilot production mode, demonstrating a production increase of >6% for >500 saw runs. • Initiated studies of thinner cells; identified boron coat process, the phosphorous diffusion process, and the printing processes as areas of concern for future study. PowerLight Corporation “Accelerating PV Cost Effectiveness Through Systems Design, Engineering, and Quality Assurance” • Completed design of prototype foamless PV roof tile and implemented production of PowerGuard tiles without the need for added insulation. • Started the first large-scale commercial installation of the RFT-10 product with the improvements accomplished under this contract. • Implemented modifications in the production of PowerGuard tiles to reduce the cost of the mortar coating of the foam backer-boards, with input from accelerated testing. Photovoltaic R&D Advanced Materials and Devices • Planned modifications to the PowerGuard manufacturing process to improve quality and reduce labor. Established a team to streamline supply chain logistics and to reduce the cost inventory. GEEnergy “Solar Cell Design for Manufacturability” This project started on Aug. 26, 2005, and thus was active for only a month in FY 2005. Xantrex Technology “Advanced, High Reliability, System Integrated 500kW Photovoltaic Inverter Development” This project started on September 29, 2005, and thus was not active during FY 2005. 4. Planned FY 2006 Activities PVMR&D Project procurements are framed to specifically address milestones under the Solar Program MYTP . Under the continuing IDIP procurement, PVMR&D will continue to focus on integrating state-of-the-art process controls with current production technology in support of the FY 2006 EERE cost goal of $1.85/Wp and conduct end-of-year measurements to meet the FY 2006 EERE Joule milestone for U.S.-made, commercial crystalline silicon PV modules of 14.0% conversion efficiency. The focus of the subcontracts under the YDR procurement will be on enhancing field reliability and durability, as well as manufacturing yield, which also supports the FY 2006 EERE milestones mentioned above. The major task milestones and expected accomplishments of this project during FY 2006 include: • Analyzing the FY 2005 U.S. PV industry cost/capacity/recapture data to identify the capacity-weighted, industry average. (05/06) • Assessing and determining the need for additional PV Manufacturing R&D, and selecting areas for elimination or support. (09/06) • Completing the development of at least three in-line diagnostic processes from research subcontract awards under the FY 2001 IDIP solicitation (achieve manufacturing-line-ready status). (12/05) • Renewing remaining subcontracts under the “In-Line Diagnostics and Intelligent Processing in Manufacturing Scale-Up” solicitation. (07/06) • Completing eligible subcontract awards under the “Large-Scale Module and Component 56PDF Image | DOE Solar Energy Technologies Program
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