Science.gov

Sample records for photovoltaic manufacturing cost

  1. Manufacturing cost analysis for photovoltaic concentrator tracking structures

    NASA Astrophysics Data System (ADS)

    Heller, B.; Pass, N.; Blackwell, R.

    1983-11-01

    Detailed manufacturing, transportation and installation costs are developed for the current design of three different photovoltaic concentrator tracking structures at a production rate of 10 to the 5th power/sq m per year. These costs are combined with array field performance estimates to obtain cost per watt and levelized energy costs for 500 kW fields. Installed structure costs for the three arrays (including G and A and profit but not module FOB costs) range from $166 to $208/sqm, or $1.04 to $1.28/W sub ap in 1982 dollars. The pedestal tracking structure has a lower cost than the post/frame or pylon/torque tube arrays.

  2. Assessment of low-cost manufacturing process sequences. [photovoltaic solar arrays

    NASA Technical Reports Server (NTRS)

    Chamberlain, R. G.

    1979-01-01

    An extensive research and development activity to reduce the cost of manufacturing photovoltaic solar arrays by a factor of approximately one hundred is discussed. Proposed and actual manufacturing process descriptions were compared to manufacturing costs. An overview of this methodology is presented.

  3. Photovoltaic manufacturing technology

    SciTech Connect

    Wohlgemuth, J.H.; Whitehouse, D.; Wiedeman, S.; Catalano, A.W.; Oswald, R. )

    1991-12-01

    This report identifies steps leading to manufacturing large volumes of low-cost, large-area photovoltaic (PV) modules. Both crystalline silicon and amorphous silicon technologies were studied. Cost reductions for each step were estimated and compared to Solarex Corporation's manufacturing costs. A cost model, a simple version of the SAMICS methodology developed by the Jet Propulsion Laboratory (JPL), projected PV selling prices. Actual costs of materials, labor, product yield, etc., were used in the cost model. The JPL cost model compared potential ways of lowering costs. Solarex identified the most difficult technical challenges that, if overcome, would reduce costs. Preliminary research plans were developed to solve the technical problems. 13 refs.

  4. Flat plate vs. concentrator solar photovoltaic cells - A manufacturing cost analysis

    NASA Technical Reports Server (NTRS)

    Granon, L. A.; Coleman, M. G.

    1980-01-01

    The choice of which photovoltaic system (flat plate or concentrator) to use for utilizing solar cells to generate electricity depends mainly on the cost. A detailed, comparative manufacturing cost analysis of the two types of systems is presented. Several common assumptions, i.e., cell thickness, interest rate, power rate, factory production life, polysilicon cost, and direct labor rate are utilized in this analysis. Process sequences, cost variables, and sensitivity analyses have been studied, and results of the latter show that the most important parameters which determine manufacturing costs are concentration ratio, manufacturing volume, and cell efficiency. The total cost per watt of the flat plate solar cell is $1.45, and that of the concentrator solar cell is $1.85, the higher cost being due to the increased process complexity and material costs.

  5. Photovoltaic Manufacturing Technology

    NASA Astrophysics Data System (ADS)

    Easoz, J. R.; Herlocher, R. H.

    1991-12-01

    This report examines the cost-effective manufacture of dendritic-web-based photovoltaic modules. It explains how process changes can increase production and reduce manufacturing costs. Long-range benefits of these improved processes are also discussed. Problems are identified that could impede increasing production and reducing costs; approaches to solve these problems are presented. These approaches involve web growth throughput, cell efficiency, process yield, silicon use, process control, automation, and module efficiency. Also discussed are the benefits of bifacial module design, unique to the dendritic web process.

  6. Costs of controlling emissions from the manufacture of silicon photovoltaic cells using dendritic web technology

    SciTech Connect

    Wilenitz, I.

    1983-11-01

    Detailed analyses were conducted to determine environmental control costs associated with the production of silicon dendritic web photovoltaic (PV) cells. In these analyses (i) likely manufacturing processing steps were identified, (ii) material inputs and uncontrolled material outputs were estimated, (iii) need for and capability of environmental control equipment were examined, and (iv) capital and operation and maintenance costs for environmental controls for integrated and disaggregated plant designs were estimated. These estimates were developed for a hypothetical facility with a yearly output of PV cells capable of producing 10 MWp. Analysis suggested that the annualized incremental environmental control costs, based on capital recovery over a 10 year plant life, would be 1.4 cents and 2.8 cents per watt for integrated and disaggregated plant designs, respectively. Capital costs ranged from 50% to 55% (integrated) and 36% to 40% (disaggregated) of the estimated costs; the ranges reflected differences in assumed real discount rates. Because of the small emission flows projected, treatment equipment to be used, for the most part, represents the smallest size readily available from equipment manufacturers. Consequently, larger emission flows could be accommodated without additional capital costs. Total control costs are small in comparison with current production costs for silicon photovoltaic devices ($5/watt), but may be of greater importance at projected production cost of $0.5 to 1.0/watt. These conclusions may not apply to other material or process options.

  7. Photovoltaic manufacturing technology, Phase 1

    SciTech Connect

    Not Available

    1992-10-01

    This report describes subcontracted research by the Chronar Corporation, prepared by Advanced Photovoltaic Systems, Inc. (APS) for Phase 1 of the Photovoltaic Manufacturing Technology Development project. Amorphous silicon is chosen as the PV technology that Chronar Corporation and APS believe offers the greatest potential for manufacturing improvements, which, in turn, will result in significant cost reductions and performance improvements in photovoltaic products. The APS Eureka'' facility was chosen as the manufacturing system that can offer the possibility of achieving these production enhancements. The relationship of the Eureka'' facility to Chronar's batch'' plants is discussed. Five key areas are also identified that could meet the objectives of manufacturing potential that could lead to improved performance, reduced manufacturing costs, and significantly increased production. The projected long-term potential benefits of these areas are discussed, as well as problems that may impede the achievement of the hoped-for developments. A significant number of the problems discussed are of a generic nature and could be of general interest to the industry. The final section of this document addresses the cost and time estimates for achieving the solutions to the problems discussed earlier. Emphasis is placed on the number, type, and cost of the human resources required for the project.

  8. Photovoltaic manufacturing technology, Phase 1

    SciTech Connect

    Izu, M. )

    1992-03-01

    This report examines manufacturing multiple-band-gap, multiple- junction solar cells and photovoltaic modules. Amorphous silicon alloy material is deposited (using microwave plasma-assisted chemical vapor deposition) on a stainless-steel substrate using a roll-to-roll process that is continuous and automated. Rapid thermal equilibration of the metal substrate allows rapid throughput of large-area devices in smaller production machines. Potential improvements in the design, deposition, and module fabrication process are described. Problems are also discussed that could impede using these potential improvements. Energy Conversion Devices, Inc. (ECD) proposes cost and time estimates for investigating and solving these problems. Manufacturing modules for less than $1.00 per peak watt and stable module efficiencies of greater than 10% are near-term goals proposed by ECD. 18 refs.

  9. Research on advanced photovoltaic manufacturing technology

    SciTech Connect

    Jester, T.; Eberspacher, C. )

    1991-11-01

    This report outlines opportunities for significantly advancing the scale and economy of high-volume manufacturing of high-efficiency photovoltaic (PV) modules. We propose to pursue a concurrent effort to advance existing crystalline silicon module manufacturing technology and to implement thin film CuInSe{sub 2} (CIS) module manufacturing. This combination of commercial-scale manufacturing of high-efficiency crystalline silicon modules and of pilot-scale manufacturing of low-cost thin film CIS technology will support continued, rapid growth of the US PV industry.

  10. The Capital Intensity of Photovoltaics Manufacturing

    SciTech Connect

    Basore, Paul

    2015-10-19

    Factory capital expenditure (capex) for photovoltaic (PV) module manufacturing strongly influences the per-unit cost of a c-Si module. This provides a significant opportunity to address the U.S. DOE SunShot module price target through capex innovation. Innovation options to reduce the capex of PV manufacturing include incremental and disruptive process innovation with c-Si, platform innovations, and financial approaches. and financial approaches.

  11. Photovoltaic Manufacturing Technology, Phase 1, Final report

    SciTech Connect

    Easoz, J.R.; Herlocher, R.H. )

    1991-12-01

    This report examines the cost-effective manufacture of dendritic-web-based photovoltaic modules. It explains how process changes can increase production and reduce manufacturing costs. Long-range benefits of these improved processes are also discussed. Problems are identified that could impede increasing production and reducing costs; approaches to solve these problems are presented. These approaches involve web growth throughput, cell efficiency, process yield, silicon use, process control, automation, and module efficiency. Also discussed are the benefits of bifacial module design, unique to the dendritic web process.

  12. Self Aligned Cell: Scaling Up Manufacture of a Cost Effective Cell Architecture for Multicrystalline Silicon Photovoltaics

    SciTech Connect

    Gabor, A.; van Mierlo, F.

    2010-12-01

    Two areas of technology for fabrication of higher efficiency Si-wafer solar cells were addressed: (1) the formation of structured texturing that is an improvement over the industry-standard isotexture process for multicrystalline wafers. (2) the formation of fine line (<50 micron) metallization seed layers in a self-aligned manner where the fingers can be automatically and perfectly lined up to a selective emitter and where expensive silver screen printing paste can be mostly replaced by plating up the seed layers with silver or copper. The benefits are: a) Lower reflectivity , b) Decoupling the performance of the texture from the saw damage, thus allowing for better advances in sawing and a more robust wet process. 1366 Technologies developed 2 pilot machines for 1) deposition and patterning of low-cost resist layers to enable simultaneous Honeycomb front texturing and groove formation for multicrystalline Si wafers, and 2) fine-line dispensing of materials that are self aligned to the grooves.

  13. International photovoltaic products and manufacturers directory, 1995

    SciTech Connect

    Shepperd, L.W.

    1995-11-01

    This international directory of more than 500 photovoltaic-related manufacturers is intended to guide potential users of photovoltaics to sources for systems and their components. Two indexes help the user to locate firms and materials. A glossary describes equipment and terminology commonly used in the photovoltaic industry.

  14. Photovoltaic Manufacturing Cost and Throughput Improvements for Thin-Film CIGS-Based Modules; Phase II Annual Subcontract Technical Report, July 1999 - August 2000

    SciTech Connect

    Wendt, T.G.; Wiedeman, S.

    2001-03-12

    Thin-film photovoltaics (PV) has expanded dramatically in the last five years, but commercial use remains limited by performance, cost, and reliability. Of all the thin-film systems, copper indium gallium diselenide (CIGS) has demonstrated the greatest potential for achieving high performance at a low cost. The highest-quality CIGS has been formed by multi-source co-evaporation, a technique pioneered in this country by researchers at NREL. Multi-source co-evaporation is also potentially the fastest and most cost-effective method of CIGS absorber deposition. Global Solar Energy (GSE) has adapted multi-source co-evaporation of CIGS to large-area, roll-to-roll processing on flexible substrates, enabling several manufacturing and product capability advantages. Roll-to-roll processing enables a low-cost, automated continuous manufacturing process. Flexible substrates enable product application in unique, as well as traditional, areas. The primary objectives of the GSE Photovoltaic Manufacturing Technology (PVMaT) subcontract are to reduce cost and expand the production rate of thin-film CIGS-based PV modules on flexible substrates. Improvements will be implemented in monolithic integration, CIGS deposition, contact deposition, and in-situ CIGS control and monitoring. Specific goals of the three-year contract are: - Monolithic Integration - Increase integration speed by developing high-speed, all-laser scribing processes that are more than 100% faster than the baseline process and offer clean, selective scribing; increase capacity and substantially reduce module area losses by insulating materials with high accuracy into laser scribes. - Absorber Deposition - Increase absorber-layer deposition rate by 75% in the large-area, continuous GSE process, increasing throughput and reducing labor and capital costs. Integrate a parallel detector spectroscopic ellipsometer (PDSE) with mathematical algorithms for in-situ control of the CIGS absorber, enabling runs of over 300 meters

  15. Photovoltaic manufacturing technology, Phase 1

    SciTech Connect

    Somberg, H. )

    1991-11-01

    This report describes existing integrated processes for solar cell manufacturing and lists as the primary opportunity for improvement the following areas: low-cost silicon sheets with improved characteristics; improved large-scale and automated solar cell processes that can lead to cell efficiencies in the range of 14% (encapsulated) for direct-cast wafers; improved handling and lamination of large-area modules for the emerging utility market. The proposed solutions can lead to finished module costs on the order of $1.55 per square meter or a selling price of less than $2.00/Watt. The problems that may be considered generic to the industry and that have been addressed in this work are as follows: gettering and passivation of silicon wafers; spray-on passivation layers; dual antireflection coatings; ink-jet printing of metallizations; and automated handling of large-area modules and associated vertical lamination. 14 refs.

  16. Solid state laser applications in photovoltaics manufacturing

    NASA Astrophysics Data System (ADS)

    Dunsky, Corey; Colville, Finlay

    2008-02-01

    Photovoltaic energy conversion devices are on a rapidly accelerating growth path driven by increasing government and societal pressure to use renewable energy as part of an overall strategy to address global warming attributed to greenhouse gas emissions. Initially supported in several countries by generous tax subsidies, solar cell manufacturers are relentlessly pushing the performance/cost ratio of these devices in a quest to reach true cost parity with grid electricity. Clearly this eventual goal will result in further acceleration in the overall market growth. Silicon wafer based solar cells are currently the mainstay of solar end-user installations with a cost up to three times grid electricity. But next-generation technology in the form of thin-film devices promises streamlined, high-volume manufacturing and greatly reduced silicon consumption, resulting in dramatically lower per unit fabrication costs. Notwithstanding the modest conversion efficiency of thin-film devices compared to wafered silicon products (around 6-10% versus 15-20%), this cost reduction is driving existing and start-up solar manufacturers to switch to thin-film production. A key aspect of these devices is patterning large panels to create a monolithic array of series-interconnected cells to form a low current, high voltage module. This patterning is accomplished in three critical scribing processes called P1, P2, and P3. Lasers are the technology of choice for these processes, delivering the desired combination of high throughput and narrow, clean scribes. This paper examines these processes and discusses the optimization of industrial lasers to meet their specific needs.

  17. Progress update on the US photovoltaic manufacturing technology project

    SciTech Connect

    Mitchell, R.L.; Witt, C.E.; Thomas, H.P.

    1997-10-01

    The Photovoltaic Manufacturing Technology (PVMaT) project is helping the U.S. photovoltaic (PV) industry extend its world leadership role in manufacturing and stimulate the commercial development of PV modules and systems. Initiated in 1990, PVMaT is being carried out in several directed and staggered phases to support industry`s continued progress. Thirteen subcontracts awarded in FY 1996 under Phase 4A emphasize improvement and cost reduction in the manufacture of full-system PV products. Areas of work in Phase 4A included, but were not limited to, issues such as improving module-manufacturing processes; system and system-component packaging, integration, manufacturing, and assembly; product manufacturing flexibility; and balance-of-system development with the goal of product manufacturing improvements. These Phase 4A, product-driven manufacturing research and development (R&D) activities are now completing their second phase. Progress under these Phase 4A and remaining Phase 2B subcontracts from the earlier PVMaT solicitation are summarized in this paper. Evaluations of the success of this project have been carried out in FY 1995 and late FY 1996. This paper examines the 1997 cost/capacity data that have been collected from active PVMaT manufacturers.

  18. Economics of Future Growth in Photovoltaics Manufacturing

    SciTech Connect

    Basore, Paul A.; Chung, Donald; Buonassisi, Tonio

    2015-06-14

    The past decade's record of growth in the photovoltaics manufacturing industry indicates that global investment in manufacturing capacity for photovoltaic modules tends to increase in proportion to the size of the industry. The slope of this proportionality determines how fast the industry will grow in the future. Two key parameters determine this slope. One is the annual global investment in manufacturing capacity normalized to the manufacturing capacity for the previous year (capacity-normalized capital investment rate, CapIR, units $/W). The other is how much capital investment is required for each watt of annual manufacturing capacity, normalized to the service life of the assets (capacity-normalized capital demand rate, CapDR, units $/W). If these two parameters remain unchanged from the values they have held for the past few years, global manufacturing capacity will peak in the next few years and then decline. However, it only takes a small improvement in CapIR to ensure future growth in photovoltaics. Any accompanying improvement in CapDR will accelerate that growth.

  19. Photovoltaic Cell And Manufacturing Process

    DOEpatents

    Albright, Scot P.; Chamberlin, Rhodes R.

    1996-11-26

    Provided is a method for controlling electrical properties and morphology of a p-type material of a photovoltaic device. The p-type material, such as p-type cadmium telluride, is first subjected to heat treatment in an oxidizing environment, followed by recrystallization in an environment substantially free of oxidants. In one embodiment, the heat treatment step comprises first subjecting the p-type material to an oxidizing atmosphere at a first temperature to getter impurities, followed by second subjecting the p-type material to an oxidizing atmosphere at a second temperature, higher than the first temperature, to develop a desired oxidation gradient through the p-type material.

  20. Photovoltaic manufacturing cost and throughput improvements for thin-film CIGS-based modules: Phase 1 technical report, July 1998--July 1999

    SciTech Connect

    Wiedeman, S.; Wendt, R.G.

    2000-03-01

    The primary objectives of the Global Solar Energy (GSE) Photovoltaic Manufacturing Technology (PVMaT) subcontract are directed toward reducing cost and expanding the production rate of thin-film CuInGaSe{sub 2} (CIGS)-based PV modules on flexible substrates. Improvements will be implemented in monolithic integration, CIGS deposition, contact deposition, and in-situ CIGS control and monitoring. In Phase 1, GSE has successfully attacked many of the highest risk aspects of each task. All-laser, selective scribing processes for CIGS have been developed, and many end-of-contract goals for scribing speed have been exceeded in the first year. High-speed ink-jet deposition of insulating material in the scribes now appears to be a viable technique, again exceeding some end-of-contract goals in the first year. Absorber deposition of CIGS was reduced corresponding to throughput speeds of up to 24-in/min, also exceeding an end-of-contract goal. Alternate back-contact materials have been identified that show potential as candidates for replacement of higher-cost molybdenum, and a novel, real-time monitoring technique (parallel-detector spectroscopic ellipsometry) has shown remarkable sensitivity to relevant properties of the CIGS absorber layer for use as a diagnostic tool. Currently, one of the bilayers has been baselined by GSE for flexible CIGS on polymeric substrates. Resultant back-contacts meet sheet-resistance goals and exhibit much less intrinsic stress than Mo. CIGS has been deposited, and resultant devices are comparable in performance to pure Mo back-contacts. Debris in the chamber has been substantially reduced, allowing longer roll-length between system cleaning.

  1. PVMaT cost reductions in the EFG high volume PV manufacturing line: Annual report, 5 August 1998--4 August 1999[PhotoVoltaic Manufacturing Technology, Edge-defined Film-fed Growth

    SciTech Connect

    Bathey, B.; Brown, B.; Cao, J.; Ebers, S.; Gonsiorawski, R.; Heath, B.; Kalejs, J.; Kardauskas, M.; Mackintosh, B.; Ouellette, M.; Piwczyk, B.; Rosenblum, M.; Southimath, B.

    1999-11-16

    This report describes work performed by ASE Americas researchers during the first year of this Photovoltaic Manufacturing Technology 5A2 program. Significant accomplishments in each of three task are as follows. Task 1--Manufacturing Systems: Researchers completed key node analysis, started statistical process control (SPC) charting, carried out design-of-experiment (DoE) matrices on the cell line to optimize efficiencies, performed a capacity and bottleneck study, prepared a baseline chemical waste analysis report, and completed writing of more than 50% of documentation and statistical sections of ISO 9000 procedures. A highlight of this task is that cell efficiencies in manufacturing were increased by 0.4%--0.5% absolute, to an average in excess of 14.2%, with the help of DoE and SPC methods. Task 2--Low-Cost Processes: Researchers designed, constructed, and tested a 50-cm-diameter, edge-defined, film-fed growth (EFG) cylinder crystal growth system to successfully produce thin cylinders up to 1.2 meters in length; completed a model for heat transfer; successfully deployed new nozzle designs and used them with a laser wafer-cutting system with the potential to decrease cutting labor costs by 75% and capital costs by 2X; achieved laser-cutting speeds of up to 8X and evaluation of this system is proceeding in production; identified laser-cutting conditions that reduce damage for both Q-switched Nd:YAG and copper-vapor lasers with the help of a breakthrough in fundamental understanding of cutting with these short-pulse-length lasers; and found that bulk EFG material lifetimes are optimized when co-firing of silicon nitride and aluminum is carried out with rapid thermal processing (RTP). Task 3--Flexible Manufacturing: Researchers improved large-volume manufacturing of 10-cm {times} 15-cm EFG wafers by developing laser-cutting fixtures, adapting carriers and fabricating adjustable racks for etching and rinsing facilities, and installing a high-speed data collection

  2. Photovoltaic-system costing-methodology development. Final report

    SciTech Connect

    Not Available

    1982-07-01

    Presented are the results of a study to expand the use of standardized costing methodologies in the National Photovoltaics Program. The costing standards, which include SAMIS for manufacturing costs and M and D for marketing and distribution costs, have been applied to concentrator collectors and power-conditioning units. The M and D model was also computerized. Finally, a uniform construction cost-accounting structure was developed for use in photovoltaic test and application projects. The appendices contain example cases which demonstrate the use of the models.

  3. The photovoltaic manufacturing technology project: A government/industry partnership

    SciTech Connect

    Mitchell, R.L.; Witt, C.E.; Mooney, G.D.

    1991-12-01

    The Photovoltaic Manufacturing Technology (PVMaT) project is a government/industry photovoltaic manufacturing research and development (R&D) project composed of partnerships between the federal government (through the US Department of Energy) and members of the US photovoltaic (PV) industry. It is designed to assist the US PV industry in improving manufacturing processes, accelerating manufacturing cost reductions for PV modules, increasing commercial product performance, and generally laying the groundwork for a substantial scale-up of US-based PV manufacturing plant capabilities. The project is being carried out in three separate phases, each focused on a specific approach to solving the problems identified by the industrial participants. These participants are selected through competitive procurements. Furthermore, the PVMaT project has been specifically structured to ensure that these PV manufacturing R&D subcontract awards are selected with no intention of either directing funding toward specific PV technologies (e.g., amorphous silicon, polycrystalline thin films, etc.), or spreading the awards among a number of technologies (e.g., one subcontract in each area). Each associated subcontract under any phase of this project is, and will continue to be, selected for funding on its own technical and cost merits. Phase 1, the problem identification phase, was completed early in 1991. Phase 2 is now under way. This is the solution phase of the project and addresses problems of specific manufacturers. The envisioned subcontracts under Phase 2 may be up to three years in duration and will be highly cost-shared between the US government and US industrial participants. Phase 3, is also under way. General issues related to PV module development will be studied through various teaming arrangements. 25 refs.

  4. The photovoltaic manufacturing technology project: A government/industry partnership

    SciTech Connect

    Mitchell, R.L.; Witt, C.E.; Mooney, G.D.

    1991-12-01

    The Photovoltaic Manufacturing Technology (PVMaT) project is a government/industry photovoltaic manufacturing research and development (R D) project composed of partnerships between the federal government (through the US Department of Energy) and members of the US photovoltaic (PV) industry. It is designed to assist the US PV industry in improving manufacturing processes, accelerating manufacturing cost reductions for PV modules, increasing commercial product performance, and generally laying the groundwork for a substantial scale-up of US-based PV manufacturing plant capabilities. The project is being carried out in three separate phases, each focused on a specific approach to solving the problems identified by the industrial participants. These participants are selected through competitive procurements. Furthermore, the PVMaT project has been specifically structured to ensure that these PV manufacturing R D subcontract awards are selected with no intention of either directing funding toward specific PV technologies (e.g., amorphous silicon, polycrystalline thin films, etc.), or spreading the awards among a number of technologies (e.g., one subcontract in each area). Each associated subcontract under any phase of this project is, and will continue to be, selected for funding on its own technical and cost merits. Phase 1, the problem identification phase, was completed early in 1991. Phase 2 is now under way. This is the solution phase of the project and addresses problems of specific manufacturers. The envisioned subcontracts under Phase 2 may be up to three years in duration and will be highly cost-shared between the US government and US industrial participants. Phase 3, is also under way. General issues related to PV module development will be studied through various teaming arrangements. 25 refs.

  5. Overview of the Photovoltaic Manufacturing Technology (PVMaT) project

    SciTech Connect

    Witt, C E; Mitchell, R L; Mooney, G D

    1993-08-01

    The Photovoltaic Manufacturing Technology (PVMaT) project is a historic government/industry photovoltaic (PV) manufacturing R&D partnership composed of joint efforts between the federal government (through the US Department of Energy) and members of the US PV industry. The project`s ultimate goal is to ensure that the US industry retains and extends its world leadership role in the manufacture and commercial development of PV components and systems. PVMaT is designed to do this by helping the US PV industry improve manufacturing processes, accelerate manufacturing cost reductions for PV modules, improve commercial product performance, and lay the groundwork for a substantial scale-up of US-based PV manufacturing capacities. Phase 1 of the project, the problem identification phase, was completed in early 1991. Phase 2, the problem solution phase, which addresses process-specific problems of specific manufacturers, is now underway with an expected duration of 5 years. Phase 3 addresses R&D problems that are relatively common to a number of PV companies or the PV industry as a whole. These ``generic`` problem areas are being addressed through a teamed research approach.

  6. Benefits from the U.S. photovoltaic manufacturing technology project

    SciTech Connect

    Mitchell, R.L.; Witt, C.E.; Thomas, H.P.

    1996-05-01

    This paper examines the goals of the Photovoltaic Manufacturing Technology (PVMaT) project and its achievements in recapturing the investment by the photovoltaic (PV) industry and the public in this research. The PVMaT project was initiated in 1990 with the goal of enhancing the world-wide competitiveness of the U.S. PV industry. Based on the authors analysis, PVMaT has contributed to PV module manufacturing process improvements, increased product value, and reductions in the price of today`s PV products. An evaluation of success in this project was conducted using data collected from 10 of the PVMaT industrial participants in late fiscal year (FY) 1995. These data indicate a reduction of 56% in the weighted average module manufacturing costs from 1992 to 1996. During this same period, U.S. module manufacturing capacity has increased by more than a factor of 6. Finally, the analysis indicates that both the public and the manufacturers will recapture the funds expended in R&D manufacturing improvements well before the year 2000.

  7. Cost and Performance Model for Photovoltaic Systems

    NASA Technical Reports Server (NTRS)

    Borden, C. S.; Smith, J. H.; Davisson, M. C.; Reiter, L. J.

    1986-01-01

    Lifetime cost and performance (LCP) model assists in assessment of design options for photovoltaic systems. LCP is simulation of performance, cost, and revenue streams associated with photovoltaic power systems connected to electric-utility grid. LCP provides user with substantial flexibility in specifying technical and economic environment of application.

  8. Photovoltaic industry manufacturing technology. Final report

    SciTech Connect

    Vanecek, D.; Diver, M.; Fernandez, R.

    1998-08-01

    This report contains the results of the Photovoltaic (PV) Industry Manufacturing Technology Assessment performed by the Automation and Robotics Research Institute (ARRI) of the University of Texas at Arlington for the National Renewable Energy laboratory. ARRI surveyed eleven companies to determine their state-of-manufacturing in the areas of engineering design, operations management, manufacturing technology, equipment maintenance, quality management, and plant conditions. Interviews with company personnel and plant tours at each of the facilities were conducted and the information compiled. The report is divided into two main segments. The first part of the report presents how the industry as a whole conforms to ``World Class`` manufacturing practices. Conclusions are drawn from the results of a survey as to the areas that the PV industry can improve on to become more competitive in the industry and World Class. Appendix A contains the questions asked in the survey, a brief description of the benefits to performing this task and the aggregate response to the questions. Each company participating in the assessment process received the results of their own facility to compare against the industry as a whole. The second part of the report outlines opportunities that exist on the shop floor for improving Process Equipment and Automation Strategies. Appendix B contains the survey that was used to assess each of the manufacturing processes.

  9. Manufacturing improvements in the Photovoltaic Manufacturing Technology (PVMaT) Project

    SciTech Connect

    Witt, C.E.; Mitchell, R.L.; Thomas, H.P.; Symko, M.I.; King, R.; Ruby, D.S.

    1998-08-01

    The Photovoltaic Manufacturing Technology Project (PVMaT) is a government/industry research and development (R and D) partnership between the US federal government (through the US Department of Energy [DOE]) and members of the US PV industry. The goals of PVMaT are to help the US PV industry improve module manufacturing processes and equipment; accelerate manufacturing cost reductions for PV modules, balance-of-systems components, and integrated systems; increase commercial product performance and reliability; and enhance the investment opportunities for substantial scale-ups of US-based PV manufacturing plant capacities. The approach for PVMaT has been to cost-share risk taking by industry as it explores new manufacturing options and ideas for improved PV modules and other components, advances system and product integration, and develops new system designs, all of which will lead to overall reduced system life-cycle costs for reliable PV end products. The PVMaT Phase 4A module manufacturing R and D projects are just being completed and initial results for the work directed primarily to module manufacture are reported in this paper. Fourteen new Phase 5A subcontracts have also just been awarded and planned R and D areas for the ten focused on module manufacture are described. Finally, government funding, subcontractor cost sharing, and a comparison of the relative efforts by PV technology throughout the PVMaT project are presented.

  10. Photovoltaic Manufacturing Technology report, Phase 1

    SciTech Connect

    Mason, A.V.; Lillington, D.R.

    1992-10-01

    This report describes subcontracted research by Spectrolab, Inc., to address tasks outlined in the National Renewable Energy Laboratory's (NREL) Letter of solicitation RC-0-10057. These tasks include the potential of making photovoltaics (PV) a more affordable energy source, as set forth in the goal of the PVMaT project. Spectrolab believes that the DOE cost goals can be met using three different types of cells: (1) silicon concentrator cells, (2) high efficiency GaAs concentrator cells, and (3) mechanically stacked multijunction cells.

  11. Photovoltaic manufacturing: Present status, future prospects, and research needs

    SciTech Connect

    Wolden, C.A.; Fthenakis, V.; Kurtin, J.; Baxter, J.; Repins, I.; Shasheen, S.; Torvik, J.; Rocket, A.; Aydil, E.

    2011-03-29

    In May 2010 the United States National Science Foundation sponsored a two-day workshop to review the state-of-the-art and research challenges in photovoltaic (PV) manufacturing. This article summarizes the major conclusions and outcomes from this workshop, which was focused on identifying the science that needs to be done to help accelerate PV manufacturing. A significant portion of the article focuses on assessing the current status of and future opportunities in the major PV manufacturing technologies. These are solar cells based on crystalline silicon (c-Si), thin films of cadmium telluride (CdTe), thin films of copper indium gallium diselenide, and thin films of hydrogenated amorphous and nanocrystalline silicon. Current trends indicate that the cost per watt of c-Si and CdTe solar cells are being reduced to levels beyond the constraints commonly associated with these technologies. With a focus on TW/yr production capacity, the issue of material availability is discussed along with the emerging technologies of dye-sensitized solar cells and organic photovoltaics that are potentially less constrained by elemental abundance. Lastly, recommendations are made for research investment, with an emphasis on those areas that are expected to have cross-cutting impact.

  12. Silicon Film[trademark] photovoltaic manufacturing technology

    SciTech Connect

    Bottenberg, W.R.; Hall, R.B.; Jackson, E.L.; Lampo, S.; Mulligan, W.E.; Barnett, A.M. )

    1993-04-01

    This report describes work on a project to develop an advanced low-cost manufacturing process for a new utility-scale flatplate module based on thin active layers of polycrystalline silicon on a low-cost substrate. This is called the Silicon-Film[trademark] process. This new power module is based on a new large solar cell that is 675 cm[sup 2] in area. Eighteen of these solar cells form a 170-W module. Twelve ofthese modules form a 2-kW array. The program has three components: (1) development of a Silicon-Film[trademark] wafer machine that can manufacture wafer 675 cm[sup 2] in size with a total product cost reductionof 70%; (2) development of an advanced solar cell manufacturing process that will turn the Silicon-Film[trademark] wafer into a 14%-efficient solar cell; and (3) development of an advanced module design based on these large-area, efficient silicon solar cells with an average power of 170 watts. The completion of these three tasks will lead to a new power module designed for utility and other power applications with asubstantially lower cost.

  13. Cost and Performance of Distributed Photovoltaic Systems

    NASA Technical Reports Server (NTRS)

    Borden, C. S.; Davisson, M. C.

    1985-01-01

    Lifetime Cost and Performance (LCP) model assists in design of Photovoltaic (PV) systems. LCP simulation of performance, cost and revenue streams associated with distributed PV power systems. Provides user with substantial flexibility in specifying technical and economic environment of PV application.

  14. Photovoltaics

    NASA Astrophysics Data System (ADS)

    Seippel, R. G.

    This book attempts to provide the reader with a cursory look at solar energy from a quarry of quartz to a sophisticated solar system. The progression of the theories of light is discussed along with the progression of photoelectricity, light rays, the optical spectrum, light reception, photodetection, aspects of photometry and radiometry, preferred terms in radiometric measurement, semiconductor physics, and light energy availability. Other subjects explored are related to manufacturing processes, photovoltaic materials, crystal growing, slicing techniques, wafer finishing, solar cell fabrication, photovoltaic cell types, concentrators, module fabrication, problems of quality assurance, photovoltaic systems, and the photovoltaics hierarchy. Attention is given to the polycrystalline cell, insulator cells, cadmium sulfide cells, amorphous silicon cells, an electrochemical cell, and the low-cost solar array project.

  15. Photovoltaic cost reduction powered by nuclear spending

    NASA Astrophysics Data System (ADS)

    Smith, Timothy; Deinert, Mark

    2013-04-01

    Between 1975 to 2010, Japan has spent an average of 2700 Million per year on nuclear R&D and 74 Million per year on solar energy R&D (2010 dollars). While the cost of photovoltaics dropped by a factor of 30 during that time, the overnight cost to build a nuclear power plant has doubled between 2003 and 2009. The price of commercially available photovoltaics has been shown to follow a power law reduction with the number of units produced. This begs the question as to what the current price of these systems would be had some of the available funds used for nuclear R&D been spent on the acquisition of photovoltaics. Here we show the reduction in price for single crystal photovoltaic panels if the Japanese government spent some of their nuclear R&D funds on the installation of these systems. We use historical cost and cumulative production for the world and Japan to build a learning curve model for PV. If the government had spent only 0.07% of its nuclear R&D budget toward PV technology since 1975, photovoltaics would now have reached 1/Watt, the point at which they are cost competitive with conventional resources.

  16. Method of manufacturing a large-area segmented photovoltaic module

    DOEpatents

    Lenox, Carl

    2013-11-05

    One embodiment of the invention relates to a segmented photovoltaic (PV) module which is manufactured from laminate segments. The segmented PV module includes rectangular-shaped laminate segments formed from rectangular-shaped PV laminates and further includes non-rectangular-shaped laminate segments formed from rectangular-shaped and approximately-triangular-shaped PV laminates. The laminate segments are mechanically joined and electrically interconnected to form the segmented module. Another embodiment relates to a method of manufacturing a large-area segmented photovoltaic module from laminate segments of various shapes. Other embodiments relate to processes for providing a photovoltaic array for installation at a site. Other embodiments and features are also disclosed.

  17. Printing Processes Used to Manufacture Photovoltaic Solar Cells

    ERIC Educational Resources Information Center

    Rardin, Tina E.; Xu, Renmei

    2011-01-01

    There is a growing need for renewable energy sources, and solar power is a good option in many instances. Photovoltaic solar panels are now being manufactured via various methods, and different printing processes are being incorporated into the manufacturing process. Screen printing has been used most prevalently in the printing process to make…

  18. Lessons Learned from the Photovoltaic Manufacturing Technology/PV Manufacturing R&D and Thin Film PV Partnership Projects

    SciTech Connect

    Margolis, R.; Mitchell, R.; Zweibel, K.

    2006-09-01

    As the U.S. Department of Energy's (DOE's) Solar Energy Technologies Program initiates new cost-shared solar energy R&D under the Solar America Initiative (SAI), it is useful to analyze the experience gained from cost-shared R&D projects that have been funded through the program to date. This report summarizes lessons learned from two DOE-sponsored photovoltaic (PV) projects: the Photovoltaic Manufacturing Technology/PV Manufacturing R&D (PVMaT/PVMR&D) project and the Thin-Film PV Partnership project. During the past 10-15 years, these two projects have invested roughly $330 million of government resources in cost-shared R&D and leveraged another $190 million in private-sector PV R&D investments. Following a description of key findings and brief descriptions of the PVMaT/PVMR&D and Thin-Film PV Partnership projects, this report presents lessons learned from the projects.

  19. Experience Scaling Up Manufacturing of Emerging Photovoltaic Technologies

    SciTech Connect

    Braun, G. W.; Skinner, D. E.

    2007-01-01

    This report examines two important generic photovoltaic technologies at particularly revealing stages of development, i.e., the stages between R&D and stable commercial production and profitable sales. Based on two historical cases, it attempts to shed light on the difference between: (1) costs and schedules validated by actual manufacturing and market experience, and (2) estimated costs and schedules that rely on technology forecasts and engineering estimates. The amorphous Silicon case also identifies some of the costs that are incurred in meeting specific market requirements, while the Cadmium Telluride case identifies many of the operational challenges involved in transferring R&D results to production. The transition between R&D and commercial success takes a great deal of time and money for emerging energy conversion technologies in general. The experience reported here can be instructive to those managing comparable efforts, and to their investors. It can also be instructive to R&D managers responsible for positioning such new technologies for commercial success.

  20. Photovoltaic manufacturing technology, Phase 1. Final technical report, 1 May 1991--10 May 1991

    SciTech Connect

    Not Available

    1992-10-01

    This report describes subcontracted research by the Chronar Corporation, prepared by Advanced Photovoltaic Systems, Inc. (APS) for Phase 1 of the Photovoltaic Manufacturing Technology Development project. Amorphous silicon is chosen as the PV technology that Chronar Corporation and APS believe offers the greatest potential for manufacturing improvements, which, in turn, will result in significant cost reductions and performance improvements in photovoltaic products. The APS ``Eureka`` facility was chosen as the manufacturing system that can offer the possibility of achieving these production enhancements. The relationship of the ``Eureka`` facility to Chronar`s ``batch`` plants is discussed. Five key areas are also identified that could meet the objectives of manufacturing potential that could lead to improved performance, reduced manufacturing costs, and significantly increased production. The projected long-term potential benefits of these areas are discussed, as well as problems that may impede the achievement of the hoped-for developments. A significant number of the problems discussed are of a generic nature and could be of general interest to the industry. The final section of this document addresses the cost and time estimates for achieving the solutions to the problems discussed earlier. Emphasis is placed on the number, type, and cost of the human resources required for the project.

  1. Multijunction photovoltaic device and method of manufacture

    DOEpatents

    Arya, Rejeewa R.; Catalano, Anthony W.; Bennett, Murray

    1995-04-04

    A multijunction photovoltaic device includes first, second, and third amorphous silicon p-i-n photovoltaic cells in a stacked arrangement. The intrinsic layers of the second and third cells are formed of a-SiGe alloys with differing ratios of Ge such that the bandgap of the intrinsic layers respectively decrease from the first uppermost cell to the third lowermost cell. An interface layer, composed of a doped silicon compound, is disposed between the two cells and has a lower bandgap than the respective n- and p-type adjacent layers of the first and second cells. The interface layer forms an ohmic contact with the one of the adjacent cell layers of the same conductivity type, and a tunnel junction with the other of the adjacent cell layers.

  2. Thin film photovoltaic device and process of manufacture

    DOEpatents

    Albright, Scot P.; Chamberlin, Rhodes

    1997-10-07

    Provided is a thin film photovoltaic device and a method of manufacturing the device. The thin film photovoltaic device comprises a film layer having particles which are smaller than about 30 microns in size held in an electrically insulating matrix material to reduce the potential for electrical shorting through the film layer. The film layer may be provided by depositing preformed particles onto a surrogate substrate and binding the particles in a film-forming matrix material to form a flexible sheet with the film layer. The flexible sheet may be separated from the surrogate substrate and cut into flexible strips. A plurality of the flexible strips may be located adjacent to and supported by a common supporting substrate to form a photovoltaic module having a plurality of electrically interconnected photovoltaic cells.

  3. Thin film photovoltaic device and process of manufacture

    DOEpatents

    Albright, Scot P.; Chamberlin, Rhodes

    1999-02-09

    Provided is a thin film photovoltaic device and a method of manufacturing the device. The thin film photovoltaic device comprises a film layer having particles which are smaller than about 30 microns in size held in an electrically insulating matrix material to reduce the potential for electrical shorting through the film layer. The film layer may be provided by depositing preformed particles onto a surrogate substrate and binding the particles in a film-forming matrix material to form a flexible sheet with the film layer. The flexible sheet may be separated from the surrogate substrate and cut into flexible strips. A plurality of the flexible strips may be located adjacent to and supported by a common supporting substrate to form a photovoltaic module having a plurality of electrically interconnected photovoltaic cells.

  4. Thin film photovoltaic device and process of manufacture

    DOEpatents

    Albright, S.P.; Chamberlin, R.

    1997-10-07

    Provided is a thin film photovoltaic device and a method of manufacturing the device. The thin film photovoltaic device comprises a film layer having particles which are smaller than about 30 microns in size held in an electrically insulating matrix material to reduce the potential for electrical shorting through the film layer. The film layer may be provided by depositing preformed particles onto a surrogate substrate and binding the particles in a film-forming matrix material to form a flexible sheet with the film layer. The flexible sheet may be separated from the surrogate substrate and cut into flexible strips. A plurality of the flexible strips may be located adjacent to and supported by a common supporting substrate to form a photovoltaic module having a plurality of electrically interconnected photovoltaic cells. 13 figs.

  5. Thin film photovoltaic device and process of manufacture

    DOEpatents

    Albright, S.P.; Chamberlin, R.

    1999-02-09

    Provided is a thin film photovoltaic device and a method of manufacturing the device. The thin film photovoltaic device comprises a film layer having particles which are smaller than about 30 microns in size held in an electrically insulating matrix material to reduce the potential for electrical shorting through the film layer. The film layer may be provided by depositing preformed particles onto a surrogate substrate and binding the particles in a film-forming matrix material to form a flexible sheet with the film layer. The flexible sheet may be separated from the surrogate substrate and cut into flexible strips. A plurality of the flexible strips may be located adjacent to and supported by a common supporting substrate to form a photovoltaic module having a plurality of electrically interconnected photovoltaic cells. 13 figs.

  6. Photovoltaic Manufacturing Technology (PVMaT) improvements for ENTECH's concentrator module

    SciTech Connect

    O'Neill, M.J.; McDanal, A.J.; Perry, J.L.; Jackson, M.C.; Walters, R.R. )

    1991-11-01

    This final technical report documents ENTECH's Phase 1 contract with Photovoltaic Manufacturing Technology (PVMaT) project. Under this project we prepared a detailed description of our current manufacturing process for making our unique linear Fresnel lens photovoltaic concentrator modules. In addition, we prepared a detailed description of an improved manufacturing process, which will simultaneously increase module production rates, enhance module quality, and substantially reduce module costs. We also identified potential problems in implementing the new manufacturing process, and we proposed solutions to these anticipated problems. Before discussing the key results of our program, however, we present a brief description of our unique photovoltaic technology. The key conclusion of our PVMAT Phase 1 study is that our module technology, without further breakthroughs, can realistically meet the near-term DOE goal of 12 cents/kWh levelized electricity cost, provided that we successfully implement the new manufacturing process at a production volume of at least 10 megawatts per year. The key recommendation from our Phase 1 study is to continue our PVMaT project into Phase 2A, which is directed toward the actual manufacturing technology development required for our new module production process. 15 refs.

  7. Development of Inorganic Precursors for Manufacturing of Photovoltaic Devices: Cooperative Research and Development Final Report, CRADA Number CRD-08-308

    SciTech Connect

    van Hest, M.; Ginley, D.

    2013-06-01

    Both NREL and Rohm and Haas Electronic Materials are interested in the development of solution phase metal and semiconductive precursors for the manufacturing of photovoltaic devices. In particular, we intend to develop material sets for atmospheric deposition processes. The cooperation between these two parties will enable high value materials and processing solutions for the manufacturing of low cost, roll-to-roll photovoltaics.

  8. Cost-effective applications of photovoltaics

    SciTech Connect

    Thornton, J.P.

    1996-05-01

    When photovoltaic (PV) cells were first developed at Bell Laboratories in the mid-1950s, their inventors envisioned widespread terrestrial use. However, PV cells were rapidly adopted for space applications, not only because of their reliability, but because they were generally the most cost- effective power sources for satellites in spite of their high cost. Concern over oil supply and price during the 1970s once again turned people`s thoughts toward the use of PV cells and other renewable energy technologies to help meet the nation`s energy demands. A partnership was developed between the federal government and private industry to drive the cost of PV technologies down to where they could compete in commercial markets. This partnership, which continues today, has been highly successful in achieving its goal. Today`s photovoltaic modules-more efficient and reliable than ever-have dropped to about 1/100th of their 1972 prices. From $500 or more per peak watt in those early days, module prices have dropped to about $5 per peak watt. Figure 1 illustrates the expansion of PV into commercial 2 effective markets as cost (and price) decreases. Once cost only in space, military, or consumer (primarily calculators and watches) applications, PV has now penetrated into both international and domestic markets. Currently cost-effective domestic uses, which are the primary subject of this paper, include applications in the residential, municipal, remote, and utility market sectors. The price of an installed PV system now ranges from $7 per watt to as high as $15 or $20 per watt, depending on factors such as the quantity purchased, size of the unit, amount of storage, and whether output is a.c. or d.c. This translates to a life-cycle energy cost of about 25 cents to 40 cents per kilowatt hour (kWh). Even at these seemingly high prices, PV technologies are gaining significant penetration into many U.S. markets.

  9. Recent progress in the Photovoltaic Manufacturing Technology Project (PVMaT)

    NASA Astrophysics Data System (ADS)

    Witt, C. Edwin; Mitchell, Richard L.; Thomas, Holly; Herwig, Lloyd O.; Ruby, Douglas S.; Sellers, Rick

    1994-12-01

    The Photovoltaic Manufacturing Technology (PVMaT) Project was initiated in 1990 to help the US photovoltaic (PV) industry extend its world leadership role in manufacturing and commercially developing PV modules and systems. It is being conducted in several phases, staggered to support industry progress. The four most recently awarded subcontracts (Phase 2B) are now completing their first year of research. They include two subcontracts on CdTe, one on Spheral Solar(trademark) Cells, and one on cast polysilicon. These subcontracts represent new technology additions to the PVMaT Project. Subcontracts initiated in earlier phases are nearing completion, and their progress is summarized. An additional phase of PVMaT, Phase 4A, is being initiated which will emphasize product-driven manufacturing research and development. The intention of Phase 4A is to emphasize improvement and cost reduction in the manufacture of full-system PV products. The work areas may include, but are not limited to, issues such as improvement of module manufacturing processes; system and system component packaging, integration, manufacturing, and assembly; product manufacturing flexibility; and balance-of-system development with the goal of product manufacturing improvements.

  10. Recent progress in the photovoltaic manufacturing technology project (PVMaT)

    SciTech Connect

    Witt, C.E.; Mitchell, R.L.; Thomas, H. ); Herwig, L.O. ); Ruby, D.S. ); Sellers, R.

    1994-12-09

    The Photovoltaic Manufacturing Technology (PVMaT) Project was initiated in 1990 to help the US photovoltaic (PV) industry extend its world leadership role in manufacturing and commercially developing PV modules and systems. It is being conducted in several phases, staggered to support industry progress. The four most recently awarded subcontracts (Phase 2B) are now completing their first year of research. They include two subcontracts on CdTe, one on Spheral Solar[trademark] Cells, and one on cast polysilicon. These subcontracts represent new technology additions to the PVMaT Project. Subcontracts initiated in earlier phases are nearing completion, and their progress is summarized. An additional phase of PVMaT, Phase 4A, is being initiated which will emphasize product-driven manufacturing research and development. The intention of Phase 4A is to emphasize improvement and cost reduction in the manufacture of full-system PV products. The work areas may include, but are not limited to, issues such as improvement of module manufacturing processes; system and system component packaging, integration, manufacturing, and assembly; product manufacturing flexibility; and balance-of-system development with the goal of product manufacturing improvements.

  11. A preliminary 'test case' manufacturing sequence for 50 cents/watt solar photovoltaic modules in 1986

    NASA Technical Reports Server (NTRS)

    Bickler, D. B.

    1979-01-01

    The paper describes a 'test case' manufacturing process sequence for solar photovoltaic modules which will cost 50 cents/watt in 1986. The process, which starts with the purification of silicon grown into 75-mm-wide thin ribbons, is discussed, and the plant layout is depicted; each department is sized to produce 250 MW of modules/per year. The cost of this process sequence is compared to present technology at various companies showing considerable spread for each process; data are tabulated in a composite state-of-the-art cell processing cost summary for these processes.

  12. Capital intensity of photovoltaics manufacturing: Barrier to scale and opportunity for innovation

    SciTech Connect

    Powell, Douglas M.; Fu, Ran; Horowitz, Kelsey; Basore, Paul A.; Woodhouse, Michael; Buonassisi, Tonio

    2015-09-07

    In this study, using a bottom-up cost model, we assess the impact of initial factory capital expenditure (capex) on photovoltaic (PV) module minimum sustainable price (MSP) and industry-wide trends. We find capex to have two important impacts on PV manufacturing. First, capex strongly influences the per-unit MSP of a c-Si module: we calculate that the capex-related elements sum to 22% of MSP for an integrated wafer, cell, and module manufacturer. This fraction provides a significant opportunity to reduce MSP toward the U.S. DOE SunShot module price target through capex innovation.

  13. Photovoltaic system costs using local labor and materials in developing countries

    NASA Astrophysics Data System (ADS)

    Jacobson, E.; Fletcher, G.; Hein, G.

    1980-05-01

    The use of photovoltaic (PV) technology in countries that do not presently have high technology industrial capacity was investigated. The relative cost of integrating indigenous labor (and manufacturing where available) into the balance of the system industry of seven countries (Egypt, Haiti, the Ivory Coast, Kenya, Mexico, Nepal, and the Phillipines) was determined. The results were then generalized to other countries, at most levels of development. The results of the study imply several conclusions: (1) the cost of installing and maintaining comparable photovoltaic systems in developing countries is less than in the United States; (2) skills and some materials are available in the seven subject countries that may be applied to constructing and maintaining PV systems; (3) there is an interest in foreign countries in photovoltaics; and (4) conversations with foreign nationals suggest that photovoltaics must be introduced in foreign markets as an appropriate technology with high technology components rather than as a high technology system.

  14. Photovoltaic system costs using local labor and materials in developing countries

    NASA Technical Reports Server (NTRS)

    Jacobson, E.; Fletcher, G.; Hein, G.

    1980-01-01

    The use of photovoltaic (PV) technology in countries that do not presently have high technology industrial capacity was investigated. The relative cost of integrating indigenous labor (and manufacturing where available) into the balance of the system industry of seven countries (Egypt, Haiti, the Ivory Coast, Kenya, Mexico, Nepal, and the Phillipines) was determined. The results were then generalized to other countries, at most levels of development. The results of the study imply several conclusions: (1) the cost of installing and maintaining comparable photovoltaic systems in developing countries is less than in the United States; (2) skills and some materials are available in the seven subject countries that may be applied to constructing and maintaining PV systems; (3) there is an interest in foreign countries in photovoltaics; and (4) conversations with foreign nationals suggest that photovoltaics must be introduced in foreign markets as an appropriate technology with high technology components rather than as a high technology system.

  15. Photovoltaic Czochralski silicon manufacturing technology improvements. Annual subcontract report, 1 April 1993--31 March 1994

    SciTech Connect

    Jester, T.

    1995-03-01

    This report describes work performed under a 3-year, 3-phase, cost-share contract to demonstrate significant cost reductions and improvements in manufacturing technology. The objective of the program is to reduce costs in photovoltaic manufacturing by approximately 10% per year. The work was focused in three main areas: (1) silicon crystal growth and thin wafer technology; (2) silicon cell processing; and (3) silicon module fabrication and environmental, safety, and health issues. During this reporting period, several significant improvements were achieved. The crystal growing operation improved significantly with an increase in growth capacity due to larger crucibles, higher polysilicon packing density, and high pull speeds. Wafer processing with wire saws progressed rapidly, and the operation is completely converted to wire saw wafer processing. The wire saws yield almost 50% more wafers per inch in production, thus improving manufacturing volume by 50% without any additional expense in crystal growth. Cell processing improvements focused on better understanding the contact paste and firing processes. Module designs for lower material and labor costs began with the focus on a new junction box, larger modules with larger cells, and a less costly framing technique. In addition, chlorofluorocarbon (CFC) usage was completely eliminated in the Siemens manufacturing facility during this period, resulting in significant reductions in the cost of caustic waste treatment.

  16. Recent developments in the economic modeling of photovoltaic module manufacturing

    NASA Technical Reports Server (NTRS)

    Chamberlain, R. G.

    1979-01-01

    Recent developments in the solar array manufacturing industry costing standards (SAMICS) are described. Consideration is given to the added capability to handle arbitrary operating schedules and the revised procedure for calculation of one-time costs. The results of an extensive validation study are summarized.

  17. Next Generation Print-based Manufacturing for Photovoltaics and Solid State Lighting

    SciTech Connect

    Sue A. Carter

    2012-09-07

    For the grand challenge of reducing our energy and carbon footprint, the development of renewable energy and energy efficient technologies offer a potential solution. Energy technologies can reduce our dependence on foreign oil as well as the energy consumed by the petroleum industry, the leading consumer of energy by a U.S. industry sector. Nonetheless, the manufacturing processes utilized to manufacture equipment for alternative energy technologies often involve energy-intensive processes. This undermines some of the advantages to moving to 'green' technologies in the first place. Our answer to the Industrial Technology Program's (ITP) Grand Challenge FOA was to develop a transformational low cost manufacturing process for plastic-based photovoltaics that will lower by over 50% both energy consumption and greenhouse emissions and offer a return-of-investment of over 20%. We demonstrated a Luminescent Solar Concentrator fabricated on a plastic acrylic substrate (i.e. no glass) that increases the power output of the PV cell by 2.2x with a 2% power efficiency as well as an LSC with a 7% power efficiency that increased the power output from the PV cells by 35%. S large area 20-inch x 60-inch building-integrated photovoltaic window was fabricated using contract manufacturing with a 4% power efficiency which improved the power output of the PV cell by over 50%. In addition, accelerated lifetimes of the luminescent material demonstrate lifetimes of 20-years.

  18. Glass as encapsulation for low-cost photovoltaic solar arrays

    NASA Technical Reports Server (NTRS)

    Bouquet, F. L.

    1981-01-01

    In photovoltaic systems, the encapsulant material that protects the solar cells should be highly transparent and very durable. Glass satisfies these two criteria and is considered a primary candidate for low-cost, photovoltaic encapsulation systems. In this paper, various aspects of glass encapsulation are treated that are important for the designer of photovoltaic systems. Candidate glasses and available information defining the state of the art of glass encapsulation materials and processes for automated, high volume production of terrestrial photovoltaic devices and related applications are presented. The desired characteristics of glass encapsulation are (1) low degradation rates, (2) high transmittance, (3) high reliability, (4) low-cost, and (5) high annual production capacity. The glass design areas treated herein include the types of glass, sources, prices, physical properties and glass modifications, such as antireflection coatings.

  19. High-throughput manufacturing of thin-film CdS/CdTe photovoltaic modules. Annual subcontract report, 16 September 1996--15 January 1998

    SciTech Connect

    Sandwisch, D.W.

    1998-08-01

    Cadmium telluride (CdTe) is recognized as one of the leading materials for low-cost photovoltaic modules. Solar Cells, Inc., has developed this technology and is scaling its pilot production capabilities to a multi-megawatt level. The Photovoltaic Manufacturing Technology (PVMaT) subcontract supports these efforts. Activities during the third phase of the program concentrated on process development, equipment design and testing, quality assurance, ES and H programs, and large-scale next-generation coating-system prototype development. These efforts broadly addressed the issues of the manufacturing process for producing thin-film, monolithic CdS/CdTe photovoltaic modules.

  20. Cost Models for MMC Manufacturing Processes

    NASA Technical Reports Server (NTRS)

    Elzey, Dana M.; Wadley, Haydn N. G.

    1996-01-01

    Processes for the manufacture of advanced metal matrix composites are rapidly approaching maturity in the research laboratory and there is growing interest in their transition to industrial production. However, research conducted to date has almost exclusively focused on overcoming the technical barriers to producing high-quality material and little attention has been given to the economical feasibility of these laboratory approaches and process cost issues. A quantitative cost modeling (QCM) approach was developed to address these issues. QCM are cost analysis tools based on predictive process models relating process conditions to the attributes of the final product. An important attribute, of the QCM approach is the ability to predict the sensitivity of material production costs to product quality and to quantitatively explore trade-offs between cost and quality. Applications of the cost models allow more efficient direction of future MMC process technology development and a more accurate assessment of MMC market potential. Cost models were developed for two state-of-the art metal matrix composite (MMC) manufacturing processes: tape casting and plasma spray deposition. Quality and Cost models are presented for both processes and the resulting predicted quality-cost curves are presented and discussed.

  1. Photovoltaic balance-of-system designs and costs at PVUSA

    SciTech Connect

    Reyes, A.B.; Jennings, C.

    1995-05-01

    This report is one in a series of 1994-1995 PVUSA reports that document PVUSA lessons learned at demonstration sites in California and Texas. During the last 7 years (1988 to 1994), 16 PV systems ranging from 20 kW to 500 kW have been installed. Six 20-kW emerging module technology (EMT) arrays and three turnkey (i.e., vendor designed and integrated) utility-scale systems were procured and installed at PVUSA`s main test site in Davis, California. PVUSA host utilities have installed a total of seven EMT arrays and utility-scale systems in their service areas. Additional systems at Davis and host utility sites are planned. One of PVUSA`s key objectives is to evaluate the performance, reliability, and cost of PV balance-of-system (BOS). In the procurement stage PVUSA encouraged innovative design to improve upon present practice by reducing maintenance, improving reliability, or lowering manufacturing or construction costs. The project team worked closely with suppliers during the design stage not only to ensure designs met functional and safety specifications, but to provide suggestions for improvement. This report, intended for the photovoltaic (PV) industry and for utility project managers and engineers considering PV plant construction and ownership, documents PVUSA utility-scale system design and cost lessons learned. Complementary PVUSA topical reports document: construction and safety experience; five-year assessment of EMTs; validation of the Kerman 500-kW grid-support PV plant benefits; PVUSA instrumentation and data analysis techniques; procurement, acceptance, and rating practices for PV power plants; experience with power conditioning units and power quality.

  2. Nanoengineered CIGS thin films for low cost photovoltaics

    NASA Astrophysics Data System (ADS)

    Eldada, Louay; Taylor, Matthew; Sang, Baosheng; McWilliams, Scott; Oswald, Robert; Stanbery, Billy J.

    2008-08-01

    Low cost manufacturing of Cu(In,Ga)Se2 (CIGS) films for high efficiency photovoltaic devices by the innovative Field-Assisted Simultaneous Synthesis and Transfer (FASST®) process is reported. The FASST® process is a two-stage reactive transfer printing method relying on chemical reaction between two separate precursor films to form CIGS, one deposited on the substrate and the other on a printing plate in the first stage. In the second stage these precursors are brought into intimate contact and rapidly reacted under pressure in the presence of an applied electrostatic field. The method utilizes physical mechanisms characteristic of anodic wafer bonding and rapid thermal annealing, effectively creating a sealed micro-reactor that ensures high material utilization efficiency, direct control of reaction pressure, and low thermal budget. The use of two independent ink-based or PVD-based nanoengineered precursor thin films provides the benefits of independent composition and flexible deposition technique optimization, and eliminates pre-reaction prior to the second stage FASST® synthesis of CIGS. High quality CIGS with large grains on the order of several microns are formed in just several minutes based on compositional and structural analysis by XRF, SIMS, SEM and XRD. Cell efficiencies of 12.2% have been achieved using this method.

  3. Continuous roll-to-roll a-Si photovoltaic manufacturing technology

    SciTech Connect

    Izu, M. )

    1993-04-01

    This report describes work performed by ECD to advance its roll-to-roll, triple-junction photovoltaic manufacturing technologies; to reduce the module production costs; to increase the stabilized module performance; and to expand the commercial capacity utilizing ECD technology. The 3-year goal is to develop advanced large-scale manufacturing technology incorporating ECD's earlier research advances with the capability of producing modules with stable 11% efficiency at a cost of approximately $1/W[sub p]. Major efforts during Phase I are (1) the optimization of the high-performance back-reflector system, (2) the optimization of a-Si-Ge narrow band-gap solar cell, and (3) the optimization of the stable efficiency of the module. The goal is to achieve a stable 8% efficient 0.3-m [times] 1.2-m (1-ft [times] 4-ft) module. Also, the efforts include work on a proprietary, high-deposition-rate, microwave plasma, CVD manufacturing technology; and on the investigation of material cost reduction.

  4. Numerical modeling of uncertainty and variability in the technology, manufacturing, and economics of crystalline silicon photovoltaics

    NASA Astrophysics Data System (ADS)

    Ristow, Alan H.

    2008-10-01

    Electricity generated from photovoltaics (PV) promises to satisfy the world's ever-growing thirst for energy without significant pollution and greenhouse gas emissions. At present, however, PV is several times too expensive to compete economically with conventional sources of electricity delivered via the power grid. To ensure long-term success, must achieve cost parity with electricity generated by conventional sources of electricity. This requires detailed understanding of the relationship between technology and economics as it pertains to PV devices and systems. The research tasks of this thesis focus on developing and using four types of models in concert to develop a complete picture of how solar cell technology and design choices affect the quantity and cost of energy produced by PV systems. It is shown in this thesis that high-efficiency solar cells can leverage balance-of-systems (BOS) costs to gain an economic advantage over solar cells with low efficiencies. This advantage is quantified and dubbed the "efficiency premium." Solar cell device models are linked to models of manufacturing cost and PV system performance to estimate both PV system cost and performance. These, in turn, are linked to a model of levelized electricity cost to estimate the per-kilowatt-hour cost of electricity produced by the PV system. A numerical PV module manufacturing cost model is developed to facilitate this analysis. The models and methods developed in this thesis are used to propose a roadmap to high-efficiency multicrystalline-silicon PV modules that achieve cost parity with electricity from the grid. The impact of PV system failures on the cost of electricity is also investigated; from this, a methodology is proposed for improving the reliability of PV inverters.

  5. Manufacturing injection-moleded Fresnel lens parquets for point-focus concentrating photovoltaic systems

    SciTech Connect

    Peters, E.M.; Masso, J.D.

    1995-10-01

    This project involved the manufacturing of curved-faceted, injection-molded, four-element Fresnel lens parquets for concentrating photovoltaic arrays. Previous efforts showed that high-efficiency (greater than 82%) Fresnel concentrators could be injection molded. This report encompasses the mold design, molding, and physical testing of a four-lens parquet for a solar photovoltaic concentrator system.

  6. Glass for low-cost photovoltaic solar arrays

    SciTech Connect

    Bouquet, F.L.

    1980-02-01

    In photovoltaic systems, the encapsulant material that protects the solar cells should be highly transparent and very durable. Glass satisfies these two criteria and is considered a primary candidate for low-cost, photovoltaic encapsulation systems. In this report, various aspects of glass encapsulation are treated that are important for the designer of photovoltaic systems. Candidate glasses and available information defining the state of the art of glass encapsulation materials and processes for automated, high volume production of terrestrial photovoltaic devices and related applications are presented. The criteria for consideration of the glass encapsulation systems were based on the LSA (Low-cost Solar Array) Project goals for arrays: (a) a low degradation rate, (b) high reliability, (c) an efficiency greater than 10 percent, (d) a total array price less than $500/kW, and (e) a production capacity of 5 x 10/sup 5/ kW/yr. The glass design areas treated herein include the types of glass, sources and costs, physical properties and glass modifications, such as antireflection coatings. 78 references.

  7. Cost and Potential of Monolithic CIGS Photovoltaic Modules

    SciTech Connect

    Horowitz, Kelsey A.; Woodhouse, Michael

    2015-06-14

    A bottom-up cost analysis of monolithic, glass-glass Cu(In,Ga)(Se,S)2 (CIGS) modules is presented, illuminating current cost drivers for this technology and possible pathways to reduced cost. At 14% module efficiency, for the case of U.S. manufacturing, a manufacturing cost of $0.56/WDC and a minimum sustainable price of $0.72/WDC were calculated. Potential for reduction in manufacturing costs to below $0.40/WDC in the long-term may be possible if module efficiency can be increased without significant increase in $/m2 costs. The levelized cost of energy (LCOE) in Phoenix, AZ under different conditions is assessed and compared to standard c-Si.

  8. Cost and Potential of Monolithic CIGS Photovoltaic Modules

    SciTech Connect

    Horowitz, Kelsey; Woodhouse, Michael

    2015-06-17

    A bottom-up cost analysis of monolithic, glass-glass Cu(In,Ga)(Se,S)2 (CIGS) modules is presented, illuminating current cost drivers for this technology and possible pathways to reduced cost. At 14% module efficiency, for the case of U.S. manufacturing, a manufacturing cost of $0.56/WDC and a minimum sustainable price of $0.72/WDC were calculated. Potential for reduction in manufacturing costs to below $0.40/WDC in the long-term may be possible if module efficiency can be increased without significant increase in $/m2 costs. The levelized cost of energy (LCOE) in Phoenix, AZ under different conditions is assessed and compared to standard c-Si.

  9. Optimized low-cost-array field designs for photovoltaic systems

    SciTech Connect

    Post, H.N.; Carmichael, D.C.; Castle, J.A.

    1982-01-01

    As manager of the US Department of Energy Photovoltaic Systems Definition Project, Sandia National Laboratories is engaged in a comprehensive program to define and develop array field subsystems which can achieve the lowest possible lifecycle costs. The major activity of this program is described, namely, the design and development of optimized, modular array fields for photovoltaic (PV) systems. As part of this activity, design criteria and performance requirements for specific array subsystems including support structures, foundations, intermodule connections, field wiring, lightning protection, system grounding, site preparation, and monitoring and control have been defined and evaluated. Similarly, fully integrated flat-panel array field designs, optimized for lowest lifecycle costs, have been developed for system sizes ranging from 20 to 500 kW/sub p/. Key features, subsystem requirements, and projected costs for these array field designs are presented and discussed.

  10. Manufacturing Large Membrane Mirrors at Low Cost

    NASA Technical Reports Server (NTRS)

    2007-01-01

    Relatively inexpensive processes have been developed for manufacturing lightweight, wide-aperture mirrors that consist mainly of reflectively coated, edge-supported polyimide membranes. The polyimide and other materials in these mirrors can withstand the environment of outer space, and the mirrors have other characteristics that make them attractive for use on Earth as well as in outer space: With respect to the smoothness of their surfaces and the accuracy with which they retain their shapes, these mirrors approach the optical quality of heavier, more expensive conventional mirrors. Unlike conventional mirrors, these mirrors can be stowed compactly and later deployed to their full sizes. In typical cases, deployment would be effected by inflation. Potential terrestrial and outer-space applications for these mirrors include large astronomical telescopes, solar concentrators for generating electric power and thermal power, and microwave reflectors for communication, radar, and short-distance transmission of electric power. The relatively low cost of manufacturing these mirrors stems, in part, from the use of inexpensive tooling. Unlike in the manufacture of conventional mirrors, there is no need for mandrels or molds that have highly precise surface figures and highly polished surfaces. The surface smoothness is an inherent property of a polyimide film. The shaped area of the film is never placed in contact with a mold or mandrel surface: Instead the shape of a mirror is determined by a combination of (1) the shape of a fixture that holds the film around its edge and (2) control of manufacturing- process parameters. In a demonstration of this manufacturing concept, spherical mirrors having aperture diameters of 0.5 and 1.0 m were fabricated from polyimide films having thicknesses ranging from <20 m to 150 m. These mirrors have been found to maintain their preformed shapes following deployment.

  11. Consortia Focused on Photovoltaic R&D, Manufacturing, and Testing: A Review of Existing Models and Structures

    SciTech Connect

    Coggeshall, C.; Margolis, R. M.

    2010-03-01

    As the U.S. Department of Energy's (DOE's) Solar Energy Technologies Program prepares to initiate a new cost-shared research and development (R&D) effort on photovoltaic (PV) manufacturing, it is useful to review the experience to date with consortia focused on PV R&D, manufacturing, and testing. Information was gathered for this report by conducting interviews and accessing Web sites of 14 U.S. consortia and four European consortia, each with either a primary focus on or an emerging interest in PV technology R&D, manufacturing, or testing. Additional input was collected from several workshops held by the DOE and National Academy of Sciences (NAS) in 2009, which examined the practical steps -- including public-private partnerships and policy support -- necessary to enhance the United States' capacity to competitively manufacture photovoltaics. This report categorizes the 18 consortia into three groups: university-led consortia, industry-led consortia, and manufacturing and testing facilities consortia. The first section summarizes the organizations within the different categories, with a particular focus on the key benefits and challenges for each grouping. The second section provides a more detailed overview of each consortium, including the origins, goals, organization, membership, funding sources, and key contacts. This survey is a useful resource for stakeholders interested in PV manufacturing R&D, but should not imply endorsement of any of these groups.

  12. Cost of photovoltaic energy systems as determined by balance-of-system costs

    NASA Technical Reports Server (NTRS)

    Rosenblum, L.

    1978-01-01

    The effect of the balance-of-system (BOS), i.e., the total system less the modules, on photo-voltaic energy system costs is discussed for multikilowatt, flat-plate systems. Present BOS costs are in the range of 10 to 16 dollars per peak watt (1978 dollars). BOS costs represent approximately 50% of total system cost. The possibility of future BOS cost reduction is examined. It is concluded that, given the nature of BOS costs and the lack of comprehensive national effort focussed on cost reduction, it is unlikely that BOS costs will decline greatly in the next several years. This prognosis is contrasted with the expectations of the Department of Energy National Photovoltaic Program goals and pending legislation in the Congress which require a BOS cost reduction of an order of magnitude or more by the mid-1980s.

  13. Glass for low-cost photovoltaic solar arrays

    NASA Technical Reports Server (NTRS)

    Bouquet, F. L.

    1980-01-01

    Various aspects of glass encapsulation that are important for the designer of photovoltaic systems are discussed. Candidate glasses and available information defining the state of the art of glass encapsulation materials and processes for automated, high volume production of terrestrial photovoltaic devices and related applications are presented. The criteria for consideration of the glass encapsulation systems were based on the low-cost solar array project goals for arrays: (1) a low degradation rate, (2) high reliability, (3) an efficiency greater than 10 percent, (4) a total array price less than $500/kW, and (5) a production capacity of 500,000 kW/yr. The glass design areas discussed include the types of glass, sources and costs, physical properties, and glass modifications, such as antireflection coatings.

  14. Cadmium telluride photovoltaic manufacturing technology. Annual subcontract report, 7 January 1994--6 January 1995

    SciTech Connect

    Weisiger, D.; Albright, S.P.; Brines, J.; Thompson, R.

    1995-11-01

    This report describes work performed by Golden Photon, Inc. (GPI), to conduct research under the PVMaT program, Phase 2B. The objective of the research is to advance GPI`s manufacturing technology, reduce module production costs, increase average module performance, and identify ways to expand production capacity. More specifically, the tasks established for Phase I were to design and install leasehold improvements for the 2-MW production line; to improve and develop product design, efficiency, and marketability; to ensure uninterrupted qualified supplies and raw materials for production; to address environmental, health, and safety issues encountered during production of photovoltaic modules; and to reduce the cost of manufacturing modules. During the first half of this reporting period, the development, design, and debugging of cell interconnection equipment critical to start-up was completed. During the second and third quarters, the primary focus was on the substrate deposition steps (tin oxide, cadmium sulfide, and cadmium telluride) and cell interconnection steps (division). In general, process development, engineering, and quality teams continued to focus on identifying, baselining, and improving (through redesign) actual process equipment operation parameters to meet the required PV panel specifications and improve process throughput rates and yields.

  15. Cost Models for MMC Manufacturing Processes

    NASA Technical Reports Server (NTRS)

    Elzey, Dana M.; Wadley, Haydn N. G.

    1996-01-01

    The quality cost modeling (QCM) tool is intended to be a relatively simple-to-use device for obtaining a first-order assessment of the quality-cost relationship for a given process-material combination. The QCM curve is a plot of cost versus quality (an index indicating microstructural quality), which is unique for a given process-material combination. The QCM curve indicates the tradeoff between cost and performance, thus enabling one to evaluate affordability. Additionally, the effect of changes in process design, raw materials, and process conditions on the cost-quality relationship can be evaluated. Such results might indicate the most efficient means to obtain improved quality at reduced cost by process design refinements, the implementation of sensors and models for closed loop process control, or improvement in the properties of raw materials being fed into the process. QCM also allows alternative processes for producing the same or similar material to be compared in terms of their potential for producing competitively priced, high quality material. Aside from demonstrating the usefulness of the QCM concept, this is one of the main foci of the present research program, namely to compare processes for making continuous fiber reinforced, metal matrix composites (MMC's). Two processes, low pressure plasma spray deposition and tape casting are considered for QCM development. This document consists of a detailed look at the design of the QCM approach, followed by discussion of the application of QCM to each of the selected MMC manufacturing processes along with results, comparison of processes, and finally, a summary of findings and recommendations.

  16. High-throughput manufacturing of thin-film CdS/CdTe photovoltaic modules. Annual subcontract report, 16 November 1994--15 November 1995

    SciTech Connect

    Sandwisch, D.W.

    1997-02-01

    The objectives of this subcontract are to advance Solar Cells, Inc.`s (SCI`s) photovoltaic manufacturing technologies, reduce module production costs, increase module performance, and provide the groundwork for SCI to expand its commercial production capacities. Activities during the second year of the program concentrated on process development, equipment design and testing, quality assurance, and ES and H programs. These efforts broadly addressed the issues of the manufacturing process for producing thin-film monolithic CdS/CdTe photovoltaic modules.

  17. Recycling of cadmium and selenium from photovoltaic modules and manufacturing wastes

    SciTech Connect

    Moskowitz, P.D.; Zweibel, K.

    1992-01-01

    Since the development of the first silicon based photovoltaic cell in the 1950's, large advances have been made in photovoltaic material and processing options. At present there is growing interest in the commercial potential of cadmium telluride (CdTe) and copper indium diselenide (CIS) photovoltaic modules. As the commercial potential of these technologies becomes more apparent, interest in the environmental, health and safety issues associated with their production, use and disposal has also increased because of the continuing regulatory focus on cadmium and selenium. In future, recycling of spent or broken CdTe and CIS modules and manufacturing wastes may be needed for environmental, economic or political reasons. To assist industry to identify recycling options early in the commercialization process, a Workshop was convened. At this Workshop, representatives from the photovoltaic, electric utility, and nonferrous metals industries met to explore technical and institutional options for the recycling of spent CdTe and CIS modules and manufacturing wastes. This report summarizes the results of the Workshop. This report includes: (1) A discussion of the Resource Conservation and Recovery Act regulations and their potential implications to the photovoltaic industry; (2) an assessment of the needs of the photovoltaic industry from the perspective of module manufacturers and consumers; (3) an overview of recycling technologies now employed by other industries for similar types of materials; and, (4) a list of recommendation.

  18. Recycling of cadmium and selenium from photovoltaic modules and manufacturing wastes. A workshop report

    SciTech Connect

    Moskowitz, P.D.; Zweibel, K.

    1992-10-01

    Since the development of the first silicon based photovoltaic cell in the 1950`s, large advances have been made in photovoltaic material and processing options. At present there is growing interest in the commercial potential of cadmium telluride (CdTe) and copper indium diselenide (CIS) photovoltaic modules. As the commercial potential of these technologies becomes more apparent, interest in the environmental, health and safety issues associated with their production, use and disposal has also increased because of the continuing regulatory focus on cadmium and selenium. In future, recycling of spent or broken CdTe and CIS modules and manufacturing wastes may be needed for environmental, economic or political reasons. To assist industry to identify recycling options early in the commercialization process, a Workshop was convened. At this Workshop, representatives from the photovoltaic, electric utility, and nonferrous metals industries met to explore technical and institutional options for the recycling of spent CdTe and CIS modules and manufacturing wastes. This report summarizes the results of the Workshop. This report includes: (1) A discussion of the Resource Conservation and Recovery Act regulations and their potential implications to the photovoltaic industry; (2) an assessment of the needs of the photovoltaic industry from the perspective of module manufacturers and consumers; (3) an overview of recycling technologies now employed by other industries for similar types of materials; and, (4) a list of recommendation.

  19. SOLID OXIDE FUEL CELL MANUFACTURING COST MODEL: SIMULATING RELATIONSHIPS BETWEEN PERFORMANCE, MANUFACTURING, AND COST OF PRODUCTION

    SciTech Connect

    Eric J. Carlson; Yong Yang; Chandler Fulton

    2004-04-20

    The successful commercialization of fuel cells will depend on the achievement of competitive system costs and efficiencies. System cost directly impacts the capital equipment component of cost of electricity (COE) and is a major contributor to the O and M component. The replacement costs for equipment (also heavily influenced by stack life) is generally a major contributor to O and M costs. In this project, they worked with the SECA industrial teams to estimate the impact of general manufacturing issues of interest on stack cost using an activities-based cost model for anode-supported planar SOFC stacks with metallic interconnects. An earlier model developed for NETL for anode supported planar SOFCs was enhanced by a linkage to a performance/thermal/mechanical model, by addition of Quality Control steps to the process flow with specific characterization methods, and by assessment of economies of scale. The 3-dimensional adiabatic performance model was used to calculate the average power density for the assumed geometry and operating conditions (i.e., inlet and exhaust temperatures, utilization, and fuel composition) based on publicly available polarizations curves. The SECA team provided guidance on what manufacturing and design issues should be assessed in this Phase I demonstration of cost modeling capabilities. They considered the impact of the following parameters on yield and cost: layer thickness (i.e., anode, electrolyte, and cathode) on cost and stress levels, statistical nature of ceramic material failure on yield, and Quality Control steps and strategies. In this demonstration of the capabilities of the linked model, only the active stack (i.e., anode, electrolyte, and cathode) and interconnect materials were included in the analysis. Factory costs are presented on an area and kilowatt basis to allow developers to extrapolate to their level of performance, stack design, materials, seal and system configurations, and internal corporate overheads and margin

  20. Low cost modular designs for photovoltaic array fields

    SciTech Connect

    Post, H.N.; Carmichael, D.C.; Castle, J.A.

    1982-01-01

    Described are the design and development of optimized, modular array fields for photovoltaic (PV) systems. Design criteria and performance requirements have been defined and evaluated for specific array subsystems. These subsystems include support structures, foundations, intermodule connection, field wiring, lightning protection, system grounding, site preparation, and monitoring and control. Fully integrated flat-panel array-field designs, optimized for lowest life-cycle costs, have been developed for systems ranging in size from 20 to 500 kW/sub p/. These designs are applicable for near-term implementation (1982 to 1983) and reduce the array-field balance-of-system (BOS) costs to a fraction of previous costs. Key features, subsystem requirements, and projected costs are presented and discussed.

  1. Space power using solar photovoltaic panels: costs and limitations

    SciTech Connect

    Williams, K.A.

    1986-03-01

    Solar photovoltaic panels (SPPs) have been suggested as a possible prime space power source for multi-kilowatt applications within a ballistic missile defense (BMD) system. As a first step in an attempt to assess the affordability of possible BMD space power sources, the limitations and costs of space power satellites using SSPs in conjunction with an electrochemical energy storage system have been investigated. Both high and low earth orbital missions are considered. An extensive literature search was conducted to determine values for the principal technology-driven performance and cost figures of merit. A small computer code was then developed to evaluate the total power cost, including launch, in dollars per watt of desired space power load. The unit costs obtained were found to be heavily influenced by the nature of the mission (altitude) and the attainable specific power for the two major system components.

  2. Waste reduction options for manufacturers of copper indium diselenide photovoltaic cells

    SciTech Connect

    DePhillips, M.P.; Fthenakis, V.M.; Moskowitz, P.D.

    1994-03-01

    This paper identifies general waste reduction concepts and specific waste reduction options to be used in the production of copper indium diselenide (CIS) photovoltaic cells. A general discussion of manufacturing processes used for the production of photovoltaic cells is followed by a description of the US Environmental Protection Agency (EPA) guidelines for waste reduction (i.e., waste minimization through pollution prevention). A more specific discussion of manufacturing CIS cells is accompanied by detailed suggestions regarding waste minimization options for both inputs and outputs for ten stages of this process. Waste reduction from inputs focuses on source reduction and process changes, and reduction from outputs focuses on material reuse and recycling.

  3. Progress of the Photovoltaic Technology Incubator Project Towards an Enhanced U.S. Manufacturing Base: Preprint

    SciTech Connect

    Ullal, H.; Mitchell, R.; Keyes, B.; VanSant, K.; von Roedern, B.; Symko-Davies, M.; Kane, V.

    2011-07-01

    In this paper, we report on the major accomplishments of the U.S. Department of Energy's (DOE) Solar Energy Technologies Program (SETP) Photovoltaic (PV) Technology Incubator project. The Incubator project facilitates a company's transition from developing a solar cell or PV module prototype to pilot- and large-scale U.S. manufacturing. The project targets small businesses that have demonstrated proof-of-concept devices or processes in the laboratory. Their success supports U.S. Secretary of Energy Steven Chu's SunShot Initiative, which seeks to achieve PV technologies that are cost-competitive without subsidies at large scale with fossil-based energy sources by the end of this decade. The Incubator Project has enhanced U.S. PV manufacturing capacity and created more than 1200 clean energy jobs, resulting in an increase in American economic competitiveness. The investment raised to date by these PV Incubator companies as a result of DOE's $ 59 million investment totals nearly $ 1.3 billion.

  4. Manufacturing R&D Initiative Lowers Costs and Boosts Quality

    SciTech Connect

    2015-06-30

    Fact sheet that provides an overview of DOE's Manufacturing R&D Initiative, which supports projects aimed at developing better-performing, lower-cost solid-state lighting while encouraging engineering and manufacturing in the United States.

  5. Manufacturing cost/design system: A CAD/CAM dialogue

    NASA Technical Reports Server (NTRS)

    Loshigian, H. H.; Rachowitz, B. I.; Judson, D.

    1980-01-01

    The development of the Manufacturing Cost/Design System (MC/DS) will provide the aerospace design engineer a tool with which to perform heretofore impractical design manufacturing cost tradeoffs. The Air Force Integrated Computer Aided Manufacturing (ICAM) Office has initiated the development and demonstration of an MC/DS which, when fully implemented, will integrate both design and manufacturing data bases to provide real time visibility into the manufacturing costs associated with various design options. The first release of a computerized system will be made before the end of 1981.

  6. Detailed cost estimate of reference residential photovoltaic designs

    SciTech Connect

    Palmer, R.S.; Penasa, D.A.; Thomas, M.G.

    1983-04-01

    This report presents estimated installation costs for four reference residential photovoltaic designs. Installation cost estimates ranged from $1.28 to $2.12/W/sub p/ for arrays installed by union labor (4.1 to 6.07 kW/sub p/-systems), and from $1.22 to $1.83 W/sub p/ for non-union installations. Standoff mounting was found to increase costs from $1.63/W/sub p/ to $2.12/W/sub p/ for a representative case, whereas 25 kWh of battery storage capacity increased installation costs from $1.44/W/sub p/ to $2.08/W/sub p/. Overall system costs (union-based were $6000 to $7000 for a 4.1 kW array in the northeast, to approx. $9000 for a 6.07 kW/sub p/ array in the southwest. This range of installation costs, approx. $1 to $2/W/sub p/ (in 1980 dollars), is representative of current installation costs for residential PV systems. Any future cost reductions are likely to be small and can be accomplished only by optimization of mounting techniques, module efficiencies, and module reliability in toto.

  7. Study of photovoltaic cost elements. Volume 5: Installation cost model for intermediate PV systems: Users manual

    NASA Astrophysics Data System (ADS)

    Ayers, J. B.

    1981-07-01

    A cost modeling methodology is presented for estimating installation costs associated with intermediate photovoltaic (PV) systems. With only a parametric description of an intermediate power system, the model can be used to develop an installation cost estimate for that system. The model is based on conventional cost-estimating procedures widely used by the construction industry and was validated by comparing estimates for the same 10 systems made independently by a cost engineering firm. A description of the model is included as well as an example of its use with a 200 KW solar breeder plant design to be located in Rockville, Maryland.

  8. Photovoltaic Manufacturing Technology (PVMaT) improvements for ENTECH`s concentrator module. Final technical report, 9 January 1991--14 April 1991

    SciTech Connect

    O`Neill, M.J.; McDanal, A.J.; Perry, J.L.; Jackson, M.C.; Walters, R.R.

    1991-11-01

    This final technical report documents ENTECH`s Phase 1 contract with Photovoltaic Manufacturing Technology (PVMaT) project. Under this project we prepared a detailed description of our current manufacturing process for making our unique linear Fresnel lens photovoltaic concentrator modules. In addition, we prepared a detailed description of an improved manufacturing process, which will simultaneously increase module production rates, enhance module quality, and substantially reduce module costs. We also identified potential problems in implementing the new manufacturing process, and we proposed solutions to these anticipated problems. Before discussing the key results of our program, however, we present a brief description of our unique photovoltaic technology. The key conclusion of our PVMAT Phase 1 study is that our module technology, without further breakthroughs, can realistically meet the near-term DOE goal of 12 cents/kWh levelized electricity cost, provided that we successfully implement the new manufacturing process at a production volume of at least 10 megawatts per year. The key recommendation from our Phase 1 study is to continue our PVMaT project into Phase 2A, which is directed toward the actual manufacturing technology development required for our new module production process. 15 refs.

  9. Low Cost Manufacturing of Composite Cryotanks

    NASA Technical Reports Server (NTRS)

    Meredith, Brent; Palm, Tod; Deo, Ravi; Munafo, Paul M. (Technical Monitor)

    2002-01-01

    This viewgraph presentation reviews research and development of cryotank manufacturing conducted by Northrup Grumman. The objectives of the research and development included the development and validation of manufacturing processes and technology for fabrication of large scale cryogenic tanks, the establishment of a scale-up and facilitization plan for full scale cryotanks, the development of non-autoclave composite manufacturing processes, the fabrication of subscale tank joints for element tests, the performance of manufacturing risk reduction trials for the subscale tank, and the development of full-scale tank manufacturing concepts.

  10. Economics of Future Growth in Photovoltaics Manufacturing; NREL (National Renewable Energy Laboratory)

    SciTech Connect

    Basore, Paul; Chung, Donald; Buonassisi, Tonio

    2015-06-14

    The past decade’s record of growth in the photovoltaic manufacturing industry indicates that global investment in manufacturing capacity for photovoltaic modules tends to increase in proportion to the size of the industry. The slope of this proportionality determines how fast the industry will grow in the future. Two key parameters determine this slope. One is the annual global investment in manufacturing capacity normalized to the manufacturing capacity for the previous year (capacity-normalized capital investment rate, CapIR, units $/W). The other is how much capital investment is required for each watt of annual manufacturing capacity, normalized to the service life of the assets (capacity-normalized capital demand rate, CapDR, units $/W). If these two parameters remain unchanged from the values they have held for the past few years, global manufacturing capacity will peak in the next few years and then decline. However, it only takes a small improvement in CapIR to ensure future growth in photovoltaics. Any accompanying improvement in CapDR will accelerate that growth.

  11. US manufacturers of commercially available stand-alone photovoltaic lighting systems

    SciTech Connect

    McNutt, P

    1994-05-01

    This report introduces photovoltaic (PV) lighting systems, gives some specifications for ordering these systems, and provides a list of some of the manufacturers of these systems in the United States. These PV lighting systems are all commercially available. They are stand-alone systems because they are not tied to the electric utility power grid.

  12. MANUFACTURE OF PHOTOVOLTAIC SOLAR CELL USING PLANT CHLOROPHYLL

    EPA Science Inventory

    To date, we have successfully manufactured working chlorophyll sensitized solar cells using chlorophyll (and b mixture) from spinach leaves. We have evaluated the electronic characteristics (voltage, current, and power outputs using different loading resistors) of this solar c...

  13. A review of the solar array manufacturing industry costing standards

    NASA Technical Reports Server (NTRS)

    1977-01-01

    The solar array manufacturing industry costing standards model is designed to compare the cost of producing solar arrays using alternative manufacturing processes. Constructive criticism of the methodology used is intended to enhance its implementation as a practical design tool. Three main elements of the procedure include workbook format and presentation, theoretical model validity and standard financial parameters.

  14. Practical aspects of photovoltaic technology, applications and cost (revised)

    NASA Technical Reports Server (NTRS)

    Rosenblum, L.

    1985-01-01

    The purpose of this text is to provide the reader with the background, understanding, and computational tools needed to master the practical aspects of photovoltaic (PV) technology, application, and cost. The focus is on stand-alone, silicon solar cell, flat-plate systems in the range of 1 to 25 kWh/day output. Technology topics covered include operation and performance of each of the major system components (e.g., modules, array, battery, regulators, controls, and instrumentation), safety, installation, operation and maintenance, and electrical loads. Application experience and trends are presented. Indices of electrical service performance - reliability, availability, and voltage control - are discussed, and the known service performance of central station electric grid, diesel-generator, and PV stand-alone systems are compared. PV system sizing methods are reviewed and compared, and a procedure for rapid sizing is described and illustrated by the use of several sample cases. The rapid sizing procedure yields an array and battery size that corresponds to a minimum cost system for a given load requirement, insulation condition, and desired level of service performance. PV system capital cost and levelized energy cost are derived as functions of service performance and insulation. Estimates of future trends in PV system costs are made.

  15. Practical aspects of photovoltaic technology, applications and cost (revised)

    NASA Astrophysics Data System (ADS)

    Rosenblum, L.

    1985-08-01

    The purpose of this text is to provide the reader with the background, understanding, and computational tools needed to master the practical aspects of photovoltaic (PV) technology, application, and cost. The focus is on stand-alone, silicon solar cell, flat-plate systems in the range of 1 to 25 kWh/day output. Technology topics covered include operation and performance of each of the major system components (e.g., modules, array, battery, regulators, controls, and instrumentation), safety, installation, operation and maintenance, and electrical loads. Application experience and trends are presented. Indices of electrical service performance - reliability, availability, and voltage control - are discussed, and the known service performance of central station electric grid, diesel-generator, and PV stand-alone systems are compared. PV system sizing methods are reviewed and compared, and a procedure for rapid sizing is described and illustrated by the use of several sample cases. The rapid sizing procedure yields an array and battery size that corresponds to a minimum cost system for a given load requirement, insulation condition, and desired level of service performance. PV system capital cost and levelized energy cost are derived as functions of service performance and insulation. Estimates of future trends in PV system costs are made.

  16. Prototyping and Development of Commercial Nano Crystalline and Thin Film Silicon for Photovoltaic Manufacturing

    SciTech Connect

    Haldar, Pradeep, Ph.D.; Pethuraja, Gopal, Ph.D.; Efstathiadis, Haralabos, Ph.D.

    2011-12-02

    The College of Nanoscale Science and Engineering (CNSE) at the University at Albany received funding from the Department of Energy for its proposal Prototyping and Development of Commercial Nanocrystalline and Thin Film Si for Photovoltaic Manufacturing. This project was created to identify growth rate, texture uniformity, process window, economics, composition and thickness uniformity solutions related to fabricating large area, high efficiency thin film silicon based solar cells. This document serves as a final report for the closure of this program and details the deliverables from CNSE against its original scope of work. Thin-film silicon solar cells are a promising candidate for electricity generation applications because of a combination of advantages. Nanocrystalline and poly-Si based thin films, reduces the use of expensive semiconductor material content, can be deposited onto a foreign substrate (e.g. glass or flexible stainless steel) and enables use of the cells in wide variety of applications. In addition, nano and poly-Si films have higher carrier mobility as well as reduce recombination effects, relative to traditional amorphous-silicon films. They can be mass-produced at low cost, and expected to have a strong position in the international photovoltaic industry, which is experiencing a compounded annual growth of 25%. The objectives included: • Demonstration of high rate VHF (Very High Frequency) growth of nc-Si over large areas with uniform thickness. • Demonstration of single chamber device growth that allows mass production processing. • Demonstration of uniform segmented electrodes. • Development of computer models to accelerate efforts. • Demonstration of large grain thin film polycrystalline silicon films fabrication. • Utilizing the AIC (Aluminum Induced Crystallization) process for large grain silicon film

  17. Cast polycrystalline silicon photovoltaic module manufacturing technology improvements. Annual subcontract report, 1 January 1996--31 December 1996

    SciTech Connect

    Wohlgemuth, J.

    1997-10-01

    This report describes Solarex`s accomplishments during this phase of the Photovoltaic Manufacturing Technology (PVMaT) program. During this reporting period, Solarex researchers converted 79% of production casting stations to increase ingot size and operated them at equivalent yields and cell efficiencies; doubled the casting capacity at 20% the cost of buying new equipment to achieve the same capacity increase; operated the wire saws in a production mode with higher yields and lower costs than achieved on the ID saws; purchased additional wire saws; developed and qualified a new wire-guide coating material that doubles the wire-guide lifetime and produces significantly less scatter in wafer thickness; ran an Al paste back-surface-field process on 25% of all cells in manufacturing; completed environmental qualification of modules using cells produced by an all-print metallization process; qualified a vendor-supplied Tedlar/ethylene vinyl acetate (EVA) laminate to replace the combination of separate sheets of EVA and Tedlar backsheet; substituted RTV adhesive for the 3M Very High Bond tape after several field problems with the tape; demonstrated the operation of a prototype unit to trim/lead attach/test modules; demonstrated the use of light soldering for solar cells; demonstrated the operation of a wafer pull-down system for cassetting wet wafers; and presented three PVMaT-related papers at the 25th IEEE Photovoltaic Specialists Conference.

  18. Cost analysis of advanced turbine blade manufacturing processes

    NASA Technical Reports Server (NTRS)

    Barth, C. F.; Blake, D. E.; Stelson, T. S.

    1977-01-01

    A rigorous analysis was conducted to estimate relative manufacturing costs for high technology gas turbine blades prepared by three candidate materials process systems. The manufacturing costs for the same turbine blade configuration of directionally solidified eutectic alloy, an oxide dispersion strengthened superalloy, and a fiber reinforced superalloy were compared on a relative basis to the costs of the same blade currently in production utilizing the directional solidification process. An analytical process cost model was developed to quantitatively perform the cost comparisons. The impact of individual process yield factors on costs was also assessed as well as effects of process parameters, raw materials, labor rates and consumable items.

  19. Photovoltaics for municipal planners. Cost-effective municipal applications of photovoltaics for electric power

    SciTech Connect

    Not Available

    1993-04-01

    This booklet is intended for city and county government personnel, as well as community organizations, who deal with supplying, regulating, or recommending electric power resources. Specifically, this document deals with photovoltaic (PV) power, or power from solar cells, which is currently the most cost-effective energy source for electricity requirements that are relatively small, located in isolated areas, or difficult to serve with conventional technology. Recently, PV has been documented to be more cost-effective than conventional alternatives (such as line extensions or engine generators) in dozens of applications within the service territories of electric, gas, and communications utilities. Here, we document numerous cost-effective urban applications, chosen by planners and utilities because they were the most cost-effective option or because they were appropriate for environmental or logistical reasons. These applications occur within various municipal departments, including utility, parks and recreation, traffic engineering, transportation, and planning, and they include lighting applications, communications equipment, corrosion protection, irrigation control equipment, remote monitoring, and even portable power supplies for emergency situations.

  20. You`ve got to pay to play: Photovoltaics and transaction costs

    SciTech Connect

    Berry, D.

    1995-03-01

    Development of photovoltaics requires supply-and demand side entrepreneurship. Market institutions can foster this entrepreneurship to implement cost-effective applications of photovoltaics, but only if the costs of transactions are not prohibitively high. Major barriers persist, primarily in applications by the large but risk-averse utility sector.

  1. Low Cost Lithography Tool for High Brightness LED Manufacturing

    SciTech Connect

    Andrew Hawryluk; Emily True

    2012-06-30

    The objective of this activity was to address the need for improved manufacturing tools for LEDs. Improvements include lower cost (both capital equipment cost reductions and cost-ofownership reductions), better automation and better yields. To meet the DOE objective of $1- 2/kilolumen, it will be necessary to develop these highly automated manufacturing tools. Lithography is used extensively in the fabrication of high-brightness LEDs, but the tools used to date are not scalable to high-volume manufacturing. This activity addressed the LED lithography process. During R&D and low volume manufacturing, most LED companies use contact-printers. However, several industries have shown that these printers are incompatible with high volume manufacturing and the LED industry needs to evolve to projection steppers. The need for projection lithography tools for LED manufacturing is identified in the Solid State Lighting Manufacturing Roadmap Draft, June 2009. The Roadmap states that Projection tools are needed by 2011. This work will modify a stepper, originally designed for semiconductor manufacturing, for use in LED manufacturing. This work addresses improvements to yield, material handling, automation and throughput for LED manufacturing while reducing the capital equipment cost.

  2. Low-Cost High-Concentration Photovoltaic Systems for Utility Power Generation

    SciTech Connect

    McConnell, R.; Garboushian, V.; Gordon, R.; Dutra, D.; Kinsey, G.; Geer, S.; Gomez, H.; Cameron, C.

    2012-03-31

    Under DOE's Technology Pathway Partnership (TPP) program, Amonix, Inc. developed a new generation of high-concentration photovoltaic systems using multijunction technology and established the manufacturing capacity needed to supply multi-megawatt power plants buing using the new Amonix 7700-series solar energy systems. For this effort, Amonix Collaborated with a variety of suppliers and partners to complete project tasks. Subcontractors included: Evonik/Cyro; Hitek; the National Renewable Energy Laboratory (NREL); Raytech; Spectrolab; UL; University of Nevada, Las Vegas; and TUV Rheinland PTL. The Amonix TPP tasks included: Task 1: Multijunction Cell Optimization for Field Operation, Task 2: Fresnel Lens R&D, Task 3: Cell Package Design & Production, Task 4: Standards Compliance and Reliability Testing, Task 5: Receiver Plate Production, Task 6: MegaModule Performance, Task 7: MegaModule Cost Reduction, Task 8: Factory Setup and MegaModule Production, Task 9: Tracker and Tracking Controller, Task 10: Installation and Balance of System (BOS), Task 11: Field Testing, and Task 12: Solar Advisor Modeling and Market Analysis. Amonix's TPP addressed nearly the complete PV value chain from epitaxial layer design and wafer processing through system design, manufacturing, deployment and O&M. Amonix has made progress toward achieving these reduced costs through the development of its 28%+ efficient MegaModule, reduced manufacturing and installation cost through design for manufacturing and assembly, automated manufacturing processes, and reduced O&M costs. Program highlights include: (1) Optimized multijunction cell and cell package design to improve performance by > 10%; (2) Updated lens design provided 7% increased performance and higher concentration; (3) 28.7% DC STC MegaModule efficiency achieved in Phase II exceeded Phase III performance goal; (4) New 16' focal length MegaModule achieved target materials and manufacturing cost reduction; (5) Designed and placed into

  3. Sensitivities of projected 1980 photovoltaic system costs to major system cost drivers

    NASA Astrophysics Data System (ADS)

    Zimmerman, L. W.; Smith, J. L.

    1984-12-01

    The sensitivity of projected 1990 photovoltaic (PV) system costs to major system cost drivers was examined. It includes: (1) module costs and module efficiencies; (2) area related balance of system (BOS) costs; (3) inverter costs and efficiencies; and (4) module marketing and distribution markups and system integration fees. Recent PV system cost experiences and the high costs of electricity from the systems are reviewed. The 1990 system costs are projected for five classes of PV systems, including four ground mounted 5-MWp systems and one residential 5-kWp system. System cost projections are derived by first projecting costs and efficiencies for all subsystems and components. Sensitivity analyses reveal that reductions in module cost and engineering and system integration fees seem to have the greatest potential for contributing to system cost reduction. Although module cost is clearly the prime candidate for fruitful PV research and development activities, engineering and system integration fees seem to be more amenable to reduction through appropriate choice of system size and market strategy. Increases in inverter and module efficiency yield significant benefits, especially for systems with high area related costs.

  4. Sensitivities of projected 1980 photovoltaic system costs to major system cost drivers

    NASA Technical Reports Server (NTRS)

    Zimmerman, L. W.; Smith, J. L.

    1984-01-01

    The sensitivity of projected 1990 photovoltaic (PV) system costs to major system cost drivers was examined. It includes: (1) module costs and module efficiencies; (2) area related balance of system (BOS) costs; (3) inverter costs and efficiencies; and (4) module marketing and distribution markups and system integration fees. Recent PV system cost experiences and the high costs of electricity from the systems are reviewed. The 1990 system costs are projected for five classes of PV systems, including four ground mounted 5-MWp systems and one residential 5-kWp system. System cost projections are derived by first projecting costs and efficiencies for all subsystems and components. Sensitivity analyses reveal that reductions in module cost and engineering and system integration fees seem to have the greatest potential for contributing to system cost reduction. Although module cost is clearly the prime candidate for fruitful PV research and development activities, engineering and system integration fees seem to be more amenable to reduction through appropriate choice of system size and market strategy. Increases in inverter and module efficiency yield significant benefits, especially for systems with high area related costs.

  5. Manufacturing Cost Levelization Model – A User’s Guide

    SciTech Connect

    Morrow, William R.; Shehabi, Arman; Smith, Sarah Josephine

    2015-08-01

    The Manufacturing Cost Levelization Model is a cost-performance techno-economic model that estimates total large-scale manufacturing costs for necessary to produce a given product. It is designed to provide production cost estimates for technology researchers to help guide technology research and development towards an eventual cost-effective product. The model presented in this user’s guide is generic and can be tailored to the manufacturing of any product, including the generation of electricity (as a product). This flexibility, however, requires the user to develop the processes and process efficiencies that represents a full-scale manufacturing facility. The generic model is comprised of several modules that estimate variable costs (material, labor, and operating), fixed costs (capital & maintenance), financing structures (debt and equity financing), and tax implications (taxable income after equipment and building depreciation, debt interest payments, and expenses) of a notional manufacturing plant. A cash-flow method is used to estimate a selling price necessary for the manufacturing plant to recover its total cost of production. A levelized unit sales price ($ per unit of product) is determined by dividing the net-present value of the manufacturing plant’s expenses ($) by the net present value of its product output. A user defined production schedule drives the cash-flow method that determines the levelized unit price. In addition, an analyst can increase the levelized unit price to include a gross profit margin to estimate a product sales price. This model allows an analyst to understand the effect that any input variables could have on the cost of manufacturing a product. In addition, the tool is able to perform sensitivity analysis, which can be used to identify the key variables and assumptions that have the greatest influence on the levelized costs. This component is intended to help technology researchers focus their research attention on tasks

  6. Eco green flexible hybrid photovoltaic-thermoelectric solar cells with nanoimprint technology and roll-to-roll manufacturing

    NASA Astrophysics Data System (ADS)

    Varadan, Vijay K.; Choi, Sang H.

    2010-04-01

    This paper explores the technical and commercial feasibility of nanotechnology based, high-efficiency, photovoltaic-thermoelectric hybrid solar cells as an environmentally-friendly, renewable energy source for residential and commercial buildings. To convert as much as possible of the usable photovoltaic (58% of the Energy Density) and thermoelectric (42% of the Energy Density) solar spectrum into electricity, a hybrid multilayer system is presented which comprises of 1) carbon nanotube (CNT) embedded in conducting polymers such as P3HT (poly(3-hexylthiophene) or P3OT (poly3-octylthiophene), 2) 3D gold nanostructures exhibiting plasmonic resonances for energy conversion, 3) nanoantenna architecture to capture IR energy, 4) a composite of Bi2Te3, SiGe nanocrystals and Au nanoshells as thermoelectric energy conversion layer, 5) configuration of the above items engineered in the form of meta-material designs that by virtue of their 3D structures ensure that incident light is neither reflected nor transmitted, but is rather all absorbed, 6) a multilayer arrangement of the above layers in a fractal architecture to capture all the wavelengths from 200 to 3000 nm8 and the matching electronic interface for each layer. The roll-to-roll manufacturing method presented will enable economical large-scale production of solar panels. This potentially transformational technology has the ability to replace the Si solar cell technology by reducing costs from 0.18/KWh to 0.003/KWh while introducing a more environmentally-friendly manufacturing process.

  7. Comparison of indirect cost multipliers for vehicle manufacturing

    SciTech Connect

    Vyas, A.; Santini, D.; Cuenca, R.

    2000-05-16

    In the process of manufacturing and selling vehicles, a manufacturer incurs certain costs. Among these costs are those incurred directly as a part of manufacturing operations and those incurred indirectly in the processes of manufacturing and selling. The indirect costs may be production-related, such as R and D and engineering; business-related, such as corporate staff salaries and pensions; or retail-sales-related, such as dealer support and marketing. These indirect costs are recovered by allocating them to each vehicle. Under a stable, high-volume production process, the allocation of these indirect costs can be approximated as multipliers (or factors) applied to the direct cost of manufacturing. A manufacturer usually allocates indirect costs to finished vehicles according to a corporation-specific pricing strategy. Because the volumes of sales and production vary widely by model within a corporation, the internal corporate percent allocation of various accounting categories (such as profit or corporate overheat) can vary widely among individual models. Approaches also vary across corporations. For these purposes, an average value is constructed, by means of a generic representative method, for vehicle models produced at high volume. To accomplish this, staff at Argonne National Laboratory's (ANL's) Center for Transportation Research analyzed the conventional vehicle cost structure and developed indirect cost multipliers for passenger vehicles. This memorandum summarizes the results of an effort to compare and put on a common basis the cost multipliers used in ANL's electric and hybrid electric vehicle cost estimation procedures with those resulting from two other methodologies. One of the two compared methodologies is derived from a 1996 presentation by Dr. Chris Borroni-Bird of Chrysler Corporation, the other is by Energy and Environmental Analysis, Inc. (EEA), as described in a 1995 report by the Office of Technology Assessment (OTA), Congress of the United

  8. Photovoltaic manufacturing technology (PVMaT) improvements for ENTECH{close_quote}s fourth-generation concentrator systems

    SciTech Connect

    ONeill, M.J.; McDanal, A.J.

    1997-02-01

    This paper describes recent improvements in manufacturing technology for fourth-generation photovoltaic concentrator systems. The fourth-generation systems are firmly based on prior generations of a field-proven, high-efficiency, stable photovoltaic technology. The fourth-generation manufacturing process has been streamlined and validated through pilot runs and field deployments. Future plans include a 1.5 MW installation in 1998, as part of the Solar Enterprise Zone (SEZ) program in Nevada. {copyright} {ital 1997 American Institute of Physics.}

  9. Low-Cost, Class D Testing of Spacecraft Photovoltaic Systems Can Reduce Risk

    NASA Technical Reports Server (NTRS)

    Forgione, Joshua B.; Kojima, Gilbert K.; Hanel, Robert; Mallinson, Mark V.

    2014-01-01

    The end-to-end verification of a spacecraft photovoltaic power generation system requires light! Specifically, the standard practice for doing so is the Large Area Pulsed Solar Simulation (LAPSS). A LAPSS test can characterize a photovoltaic system's efficiency via its response to rapidly applied impulses of simulated sunlight. However, a Class D program on a constrained budget and schedule may not have the resources to ship an entire satellite for a LAPSS test alone. Such was the case with the Lunar Atmospheric and Dust Environment Explorer (LADEE) program, which was also averse to the risk of hardware damage during shipment. When the Electrical Power System (EPS) team was denied a spacecraft-level LAPSS test, the lack of an end-to-end power generation test elevated to a project-level technical risk. The team pulled together very limited resources to not only eliminate the risk, but build a process to monitor the health of the system through mission operations. We discuss a process for performing a low-cost, end-to-end test of the LADEE photovoltaic system. The approach combines system-level functional test, panel-level performance results, and periodic inspection (and repair) up until launch. Following launch, mission operations tools are utilized to assess system performance based on a scant amount of data. The process starts in manufacturing at the subcontractor. The panel manufacturer provides functional test and LAPSS data on each individual panel. We apply an initial assumption that the per-panel performance is sufficient to meet the power generation requirements. The manufacturer's data is also carried as the performance allocation for each panel during EPS system modeling and initial mission operations. During integration and test, a high-power, professional theater lamp system provides simulated sunlight to each panel on the spacecraft, thereby permitting a true end-to-end system test. A passing test results in a step response to nearly full-rated current

  10. Luminescent Solar Concentrators - a low cost photovoltaics alternative

    NASA Astrophysics Data System (ADS)

    van Sark, W. G. J. H. M.

    2012-10-01

    Luminescent solar concentrators (LSCs) are being developed as a potentially low cost-per-Wp photovoltaic device, suited for applications especially in the built environment. LSCs generally consist of transparent polymer sheets doped with luminescent species, either organic dye molecules or semiconductor nanocrystals. Direct and diffuse incident sunlight is absorbed by the luminescent species and emitted at redshifted wavelengths with high quantum efficiency. Optimum design ensures that a large fraction of emitted light is trapped in the sheet, which travels to the edges where it can be collected by one or more mono- or bifacial solar cells, with minimum losses due to absorption in the sheet and re-absorption by the luminescent species. Today's record efficieny is 7%, however, 10-15% is within reach. Optimized luminescent solar concentrators potentially offer lower cost per unit of power compared to conventional solar cells. Moreover, LSCs have an increased conversion efficiency for overcast and cloudy sky conditions, having a large fraction of diffuse irradiation, which is blueshifted compared to clear sky conditions. As diffuse irradiation conditions are omnipresent throughout mid- and northern-European countries, annual performance of LSCs is expected to be better in terms of kWh/Wp compared to conventional PV.

  11. Thick-film materials for silicon photovoltaic cell manufacture

    NASA Technical Reports Server (NTRS)

    Field, M. B.

    1977-01-01

    Thick film technology is applicable to three areas of silicon solar cell fabrication; metallization, junction formation, and coating for protection of screened ohmic contacts, particularly wrap around contacts, interconnection and environmental protection. Both material and process parameters were investigated. Printed ohmic contacts on n- and p-type silicon are very sensitive to the processing parameters of firing time, temperature, and atmosphere. Wrap around contacts are easily achieved by first printing and firing a dielectric over the edge and subsequently applying a low firing temperature conductor. Interconnection of cells into arrays can be achieved by printing and cofiring thick film metal pastes, soldering, or with heat curing conductive epoxies on low cost substrates. Printed (thick) film vitreous protection coatings do not yet offer sufficient optical uniformity and transparency for use on silicon. A sprayed, heat curable SiO2 based resin shows promise of providing both optical matching and environmental protection.

  12. SAMICS: Input data preparation. [Solar Array Manufacturing Industry Costing Standards

    NASA Technical Reports Server (NTRS)

    Chamberlain, R. G.; Aster, R. W.

    1979-01-01

    The Solar Array Manufacturing Industry Costing Standards (SAMICS) provide standard formats, data, assumptions, and procedures for estimating the price that a manufacturer would have to charge for the product of a specified manufacturing process sequence. A line-by-line explanation is given of those standard formats which describe the economically important characteristics of the manufacturing processes and the technological structure of the companies and the industry. This revision provides an updated presentation of Format A Process Description, consistent with the October 1978 version of that form. A checklist of items which should be entered on Format A as direct expenses is included.

  13. Laser processing of organic photovoltaic cells with a roll-to-roll manufacturing process

    NASA Astrophysics Data System (ADS)

    Petsch, Tino; Haenel, Jens; Clair, Maurice; Keiper, Bernd; Scholz, Christian

    2011-03-01

    Flexible large area organic photovoltaic (OPV) is currently one of the fastest developing areas of organic electronics. New light absorbing polymer blends combined with new transparent conductive materials provide higher power conversion efficiencies while new and improved production methods are developed to achieve higher throughput at reduced cost. A typical OPV is formed by TCO layers as the transparent front contact and polymers as active layer as well as interface layer between active layer and front contact. The several materials have to be patterned in order to allow for a row connection of the solar cell. 3D-Micromac used ultra-short pulsed lasers to evaluate the applicability of various wavelengths for the selective ablation of the indium tin oxide (ITO) layer and the selective ablation of the bulk hetero junction (BHJ) consisting of poly(3-hexylthiophene):phenyl-C61-butyric acid methyl ester (P3HT:PCBM) on top of a Poly(3,4-ethylenedioxythiophene) poly(styrenesulfonate) (PEDOT:PSS) without damaging the ITO. These lasers in combination with high performance galvanometer scanning systems achieve superior scribing quality without damaging the substrate. With scribing speeds of 10 m/s and up it is possible to integrate this technology into a roll-to-roll manufacturing tool. The functionality of an OPV usually also requires an annealing step, especially when using a BHJ for the active layer consisting of P3HT:PCBM, to optimize the layers structure and therewith the efficiency of the solar cell (typically by thermal treatment, e.g. oven). The process of laser annealing was investigated using a short-pulsed laser with a wavelength close to the absorption maximum of the BHJ.

  14. Development of a Low Cost Insulated Foil Substrate for Cu(InGaSe)2 Photovoltaics

    SciTech Connect

    ERTEN ESER

    2012-01-22

    The project validated the use of stainless steel flexible substrate coated with silicone-based resin dielectric, developed by Dow Corning Corporation, for Cu(InGa)Se2 based photovoltaics. The projects driving force was the high performance of Cu(InGa)Se2 based photovoltaics coupled with potential cost reduction that could be achieved with dielectric coated SS web substrate.

  15. Manufacturing and Cost Considerations in Multidisciplinary Aircraft Design (Research on Mathematical Modeling of Manufacturability Factors)

    NASA Technical Reports Server (NTRS)

    Rais-Rohani, Masoud

    1996-01-01

    The identification of airframe Manufacturability Factors/Cost Drivers (MFCD) and the method by which the relationships between MFCD and designer-controlled parameters could be properly modeled are described.

  16. Report of an exploratory study: safety and liability considerations for photovoltaic modules/panels, Low Cost Solar Array Project

    SciTech Connect

    Weinstein, A.S.; Meeker, D.G.

    1981-01-01

    Product safety and product liability considerations are explored for photovoltaic module/array devices. A general review of photovoltaic literature was made using computerized literature searches. A literature search was also made of relevant legal material as it applies to design. Recommendations are made to minimize or eliminate perceived hazards in manufacture and use of a photovoltaic module/array. (MHR)

  17. Productivity and Labor Costs Trends in Manufacturing, 12 Countries.

    ERIC Educational Resources Information Center

    Dean, Edwin; And Others

    1986-01-01

    Manufacturing productivity, as measured by output per hour, rose in 1984 in the United States and 11 other industrial countries studied. (Statistics are presented in the following areas: productivity trends, employment and hours, hourly compensation, unit labor costs, and relative productivity and labor cost trends.) (CT)

  18. Cost Estimation of Laser Additive Manufacturing of Stainless Steel

    NASA Astrophysics Data System (ADS)

    Piili, Heidi; Happonen, Ari; Väistö, Tapio; Venkataramanan, Vijaikrishnan; Partanen, Jouni; Salminen, Antti

    Laser additive manufacturing (LAM) is a layer wise fabrication method in which a laser beam melts metallic powder to form solid objects. Although 3D printing has been invented 30 years ago, the industrial use is quite limited whereas the introduction of cheap consumer 3D printers, in recent years, has familiarized the 3D printing. Interest is focused more and more in manufacturing of functional parts. Aim of this study is to define and discuss the current economic opportunities and restrictions of LAM process. Manufacturing costs were studied with different build scenarios each with estimated cost structure by calculated build time and calculating the costs of the machine, material and energy with optimized machine utilization. All manufacturing and time simulations in this study were carried out with a research machine equal to commercial EOS M series equipment. The study shows that the main expense in LAM is the investment cost of the LAM machine, compared to which the relative proportions of the energy and material costs are very low. The manufacturing time per part is the key factor to optimize costs of LAM.

  19. Dark current-voltage measurements on photovoltaic modules as a diagnostic or manufacturing tool

    SciTech Connect

    King, D.L.; Hansen, B.R.; Quintana, M.A.; Kratochvil, J.A.

    1997-10-01

    Dark current-voltage (dark I-V) measurements are commonly used to analyze the electrical characteristics of solar cells, providing an effective way to determine fundamental performance parameters without the need for a solar simulator. The dark I-V measurement procedure does not provide information regarding short-circuit current, but is more sensitive than light I-V measurements in determining the other parameters (series resistance, shunt resistance, diode factor, and diode saturation currents) that dictate the electrical performance of a photovoltaic device. The work documented here extends the use of dark I-V measurements to photovoltaic modules, illustrates their use in diagnosing module performance losses, and proposes their use for process monitoring during manufacturing.

  20. Cost-efficient manufacturing of composite structures

    NASA Technical Reports Server (NTRS)

    Freeman, W. Tom; Davis, John G.; Johnston, Norman J.

    1991-01-01

    The Advanced Composites Technology (ACT) program is seeking research breakthroughs that will allow structures made of graphite epoxy materials to replace metals in the wings and fuselages of future aircrafts. NASA's goals are to reduce acquisition cost by 20 to 25 percent, structural weight for a resized aircraft by 40 to 50 percent, and the number of parts by half compared to current production aluminum aircraft. The innovative structural concepts, materials, and fabrication techniques emerging from the ACT program are described, and the relationship between aerospace developments and industrial, commercial, and sporting goods applications are discussed.

  1. Photovoltaic manufacturing technology monolithic amorphous silicon modules on continuous polymer substrates: Final technical report, July 5, 1995--December 31, 1999

    SciTech Connect

    Jeffrey, F.

    2000-03-28

    Iowa Thin Film Technologies is completing a three-phase program that has increased throughput and decreased costs in nearly all aspects of its thin-film photovoltaic manufacturing process. The overall manufacturing costs have been reduced by 61 percent through implementation of the improvements developed under this program. Development of the ability to use a 1-mil substrate, rather than the standard 2-mil substrate, results in a 50 percent cost-saving for this material. Process development on a single-pass amorphous silicon deposition system has resulted in a 37 percent throughput improvement. A wide range of process and machine improvements have been implemented on the transparent conducting oxide deposition system. These include detailed parameter optimization of deposition temperatures, process gas flows, carrier gas flows, and web speeds. An overall process throughput improvement of 275 percent was achieved based on this work. The new alignment technique was developed for the laser scriber and printer systems, which improved registration accuracy from 100 microns to 10 microns. The new technique also reduced alignment time for these registration systems significantly. This resulted in a throughput increase of 75 percent on the scriber and 600 percent on the printer. Automated techniques were designed and implemented for the module assembly processes. These include automated busbar attachment, roll-based lamination, and automated die cutting of finished modules. These processes were previously done by hand labor. Throughput improvements ranged from 200 percent to 1200 percent, relative to hand labor rates. A wide range of potential encapsulation materials were evaluated for suitability in a roll lamination process and for cost-effectiveness. A combination material was found that has a cost that is only 10 percent of the standard EVA/Tefzel cost and is suitable for medium-lifetime applications. The 20-year lifetime applications still require the more expensive

  2. Additive Manufacturing of Low Cost Upper Stage Propulsion Components

    NASA Technical Reports Server (NTRS)

    Protz, Christopher; Bowman, Randy; Cooper, Ken; Fikes, John; Taminger, Karen; Wright, Belinda

    2014-01-01

    NASA is currently developing Additive Manufacturing (AM) technologies and design tools aimed at reducing the costs and manufacturing time of regeneratively cooled rocket engine components. These Low Cost Upper Stage Propulsion (LCUSP) tasks are funded through NASA's Game Changing Development Program in the Space Technology Mission Directorate. The LCUSP project will develop a copper alloy additive manufacturing design process and develop and optimize the Electron Beam Freeform Fabrication (EBF3) manufacturing process to direct deposit a nickel alloy structural jacket and manifolds onto an SLM manufactured GRCop chamber and Ni-alloy nozzle. In order to develop these processes, the project will characterize both the microstructural and mechanical properties of the SLMproduced GRCop-84, and will explore and document novel design techniques specific to AM combustion devices components. These manufacturing technologies will be used to build a 25K-class regenerative chamber and nozzle (to be used with tested DMLS injectors) that will be tested individually and as a system in hot fire tests to demonstrate the applicability of the technologies. These tasks are expected to bring costs and manufacturing time down as spacecraft propulsion systems typically comprise more than 70% of the total vehicle cost and account for a significant portion of the development schedule. Additionally, high pressure/high temperature combustion chambers and nozzles must be regeneratively cooled to survive their operating environment, causing their design to be time consuming and costly to build. LCUSP presents an opportunity to develop and demonstrate a process that can infuse these technologies into industry, build competition, and drive down costs of future engines.

  3. Development of a High Volume Capable Process to Manufacture High Performance Photovoltaic Cells: Cooperative Research and Development Final Report, CRADA Number CRD-08-322

    SciTech Connect

    Geisz, J. F.

    2012-11-01

    The intent of the work is for RFMD and NREL to cooperate in the development of a commercially viable and high volume capable process to manufacture high performance photovoltaic cells, based on inverted metamorphic (IMM) GaAs technology. The successful execution of the agreement will result in the production of a PV cell using technology that is capable of conversion efficiency at par with the market at the time of release (reference 2009: 37-38%), using RFMD's production facilities. The CRADA work has been divided into three phases: (1) a foundation phase where the teams will demonstrate the manufacturing of a basic PV cell at RFMD's production facilities; (2) a technology demonstration phase where the teams will demonstrate the manufacturing of prototype PV cells using IMM technology at RFMD's production facilities, and; (3) a production readiness phase where the teams will demonstrate the capability to manufacture PV cells using IMM technology with high yields, high reliability, high reproducibility and low cost.

  4. Operation and maintenance cost data for residential photovoltaic modules/panels

    NASA Technical Reports Server (NTRS)

    Oster, J. R., Jr.; Zaremski, D. R., Jr.; Albert, E. M.; Hawkins, S. L.

    1980-01-01

    Costs associated with the operation and maintenance of residential photovoltaic modules and arrays are studied. Six basic topics related to operation and maintenance to photovoltaic arrays are investigated: maintenance; cleaning; panel replacement; gasket repair/replacement; wiring repair/replacement; and termination repair/replacement. The effects of the mounting types (rack mount, stand off mount, direct mount and integral mount) and the installation/replacement type (sequential, partial interruption and independent) are identified and described. Methods of reducing maintenance costs are suggested.

  5. Validated Feasibility Study of Integrally Stiffened Metallic Fuselage Panels for Reducing Manufacturing Costs: Cost Assessment of Manufacturing/Design Concepts

    NASA Technical Reports Server (NTRS)

    Metschan, S.

    2000-01-01

    The objective of the Integral Airframe Structures (IAS) program was to demonstrate, for an integrally stiffened structural concept, performance and weight equal to "built-up" structure with lower manufacturing cost. This report presents results of the cost assessment for several design configuration/manufacturing method combinations. The attributes of various cost analysis models were evaluated and COSTRAN selected for this study. A process/design cost evaluation matrix was developed based on material, forming, machining, and assembly of structural sub-elements and assembled structure. A hybrid design, made from high-speed machined extruded frames that are mechanically fastened to high-speed machined plate skin/stringer panels, was identified as the most cost-effective manufacturing solution. Recurring labor and material costs of the hybrid design are up to 61 percent less than the current built-up technology baseline. This would correspond to a total cost reduction of $1.7 million per ship set for a 777-sized airplane. However, there are important outstanding issues with regard to the cost of capacity of high technology machinery, and the ability to cost-effectively provide surface finish acceptable to the commercial aircraft industry. The projected high raw material cost of large extrusions also played an important role in the trade-off between plate and extruded concepts.

  6. Continuous roll-to-roll amorphous silicon photovoltaic manufacturing technology. Semiannual subcontract report, 1 April 1993--30 September 1993

    SciTech Connect

    Izu, M.

    1994-06-01

    This report describes work for this reporting period under a 3-year program to advance Energy Conversion Device`s (ECD) roll-to-roll, triple-junction photovoltaic (PV) manufacturing technologies, to reduce the module production costs, to increase the stabilized module performance, and to expand commercial production capacity utilizing ECD technology. The specific 3-year goal is to develop advanced large-scale manufacturing technology incorporating ECD`s earlier research advances with the capability of producing modules with stable 11% efficiency at a cost of approximately $1.00 per peak watt. Major accomplishments during this reporting period include (1) the design, construction. amd testomg of a continuous roll-to-roll multipurpose amorphous silicon alloy solar cell deposition machine that incorporates improvements necessary to obtain higher efficiency solar cells; (2) development of a photothermal deflection spectroscopy (PDS) technique for evaluating back-reflector systems; (3) the development of an improved textured Ag/ZnO back-reflector system demonstrating 25% gain in J{sub sc} over previous textured Al back-reflector systems; and (4) the design of a serpentine web continuous roll-to-roll deposition chamber.

  7. Cost effective flat plate photovoltaic modules using light trapping

    NASA Technical Reports Server (NTRS)

    Bain, C. N.; Gordon, B. A.; Knasel, T. M.; Malinowski, R. L.

    1981-01-01

    Work in optical trapping in 'thick films' is described to form a design guide for photovoltaic engineers. A thick optical film can trap light by diffusive reflection and total internal reflection. Light can be propagated reasonably long distances compared with layer thicknesses by this technique. This makes it possible to conduct light from inter-cell and intra-cell areas now not used in photovoltaic modules onto active cell areas.

  8. Letting the Sun Shine on Solar Costs: An Empirical Investigation of Photovoltaic Cost Trends in California

    SciTech Connect

    Wiser, R.; Bolinger, M.; Cappers, P.; Margolis, R.

    2006-01-01

    This report provides a comprehensive analysis of grid-connected solar photovoltaic (PV) cost trends in California, which is by far the largest PV market in the United States. The findings of this work may help stakeholders to understand important trends in the California PV market, and policymakers to design more effective solar incentive programs--a particularly important objective given the recent announcement from the California Public Utilities Commission (CPUC) to establish an 11-year, $3.2 billion incentive program for customer-sited solar. The study statistically analyzes the installed cost of grid-connected PV systems funded by the state's two largest solar rebate programs, overseen by the California Energy Commission (CEC) [operating since 1998] and the CPUC [operating since 2001].

  9. Development of low-cost modular designs for photovoltaic array fields

    SciTech Connect

    Noel, G.T.; Carmichael, D.C.

    1985-05-01

    A low-cost modular photovoltaic array field design developed for commercial/industrial installations is discussed. Key features of the design include minimum site preparation requirements, circuit designs which result in low life-cycle maintenance costs, low cost easily installed support structures, and economical approaches to lightning protection, grounding and electromagnetic interference (EMI) suppression.

  10. Reducing the Manufacturing Cost of Tubular SOFC Technology

    SciTech Connect

    George, R.A.; Bessette, N.F.

    1997-12-31

    In recent years, Westinghouse Electric Corporation has made great strides in advancing tubular solid oxide fuel cell (SOFC) technology towards commercialization by the year 2001. In 1993, Westinghouse initiated a program to develop a `MWe Class` (1-3 MWe) pressurized SOFC (PSOFC) gas turbine (GT) combined cycle power system for distributed power applications because of its: (1) ultra high efficiency (approx. 63% net AC/LHV CH{sub 4}), (2) its compatibility with a factory packaged, minimum site work philosophy, and (3) its cost effectiveness. Since then two cost studies on this market entry product performed by consultants to the U.S. Department of Energy have confirmed Westinghouse cost studies that fully installed costs of under $1300/kWe can be achieved in the early commercialization years for such small PSOFC/GT power systems. The paper will present the results of these cost studies in the areas of cell manufacturing cost, PSOFC generator manufacturing cost, balance-of-plant (BOP) cost, and system installation cost. In addition, cost of electricity calculations will be presented.

  11. Toxicology of tetramethyltin and other organometals used in photovoltaic cell manufacture

    NASA Astrophysics Data System (ADS)

    Hamilton, L. D.; Medeiros, W. H.; Moskowitz, P. D.; Rybicka, K.

    1988-07-01

    In photovoltaic cell fabrication, organometals (alkyl metals) may be used in such processes as metalorganic chemical vapor deposition, transparent contact oxide deposition, doping, and ion implantation. Although these compounds offer potential performance advantages over earth metals and possibly greater safety in handling than metal hydrides, they are not without risk to health and property. Most organometals can ignite spontaneously in air. Some also react violently with water. Oxidation by-products from these reactions are hazardous to health. Of the organometals used in photovoltaic cell fabrication, only the toxicology of organotins (triethyl-, trimethyl- and tetramethyltin) was studied extensively. In mammalian systems, tetramethyltin is rapidly dealkylated to trimethyltin. Although tin was classified by some investigators as an essential trace element, the effects of organotin compounds on humans are poorly known. Animal studies show that the most prominent effects of trimethyltin are on the central nervous system. Several observations of poisoning were reported; effects ranged from reversible neurologic disorders to death. Limited available data suggest that humans respond to single acute doses and more alarmingly to repeated sub-toxic doses, suggesting a cumulative effect. Toxicologic properties of diethyltelluride also were evaluated in animal experiments. The compound had toxic effects on the blood, liver, kidney, heart, and skin. Based on these studies and others of related compounds (e.g., methylmercury, tributyltin) extreme caution should be exercised in using organometal compounds in photovoltaic cell manufacturing.

  12. Toxicology of tetramethyltin and other organometals used in photovoltaic cell manufacture

    SciTech Connect

    Hamilton, L.D.; Medeiros, W.H.; Moskowitz, P.D.; Rybicka, K.

    1988-01-01

    In photovoltaic cell fabrication, organometals (alkyl metals) may be used in such processes as metalorganic chemical vapor deposition, transparent contact oxide deposition, doping, and ion implantation. Although these compounds offer potential performance advantages over earth metals and possibly greater safety in handling than metal hydrides, they are not without risk to health and property. Most organometals can ignite spontaneously in air. Some also react violently with water. Oxidation by-products from these reactions are hazardous to health. Of the organometals used in photovoltaic cell fabrication, only the toxicology of organotins (triethyl-, trimethyl- and tetramethyltin) was studied extensively. In mammalian systems, tetramethyltin is rapidly dealkylated to trimethyltin. Although tin was classified by some investigators as an essential trace element, the effects of organotin compounds on humans are poorly known. Animal studies show that the most prominent effects of trimethyltin are on the central nervous system. Several observations of poisoning were reported; effects ranged from reversible neurologic disorders to death. Limited available data suggest that humans respond to single acute doses, and more alarmingly, to repeated sub-toxic doses, suggesting a cumulative effect. Toxicologic properties of diethyltelluride also were evaluated in animal experiments. The compound had toxic effects on the blood, liver, kidney, heart, and skin. Based on these studies and others of related compounds (e.g., methylmercury, tributyltin) extreme caution should be exercised in using organometal compounds in photovoltaic cell manufacturing. 54 refs., 3 tabs.

  13. Toxicology of tetramethyltin and other organometals used in photovoltaic cell manufacture

    SciTech Connect

    Hamilton, L.D.; Medeiros, W.H.; Moskowitz, P.D.; Rybicka, K.

    1988-07-15

    In photovoltaic cell fabrication, organometals (alkyl metals) may be used in such processes as metalorganic chemical vapor deposition, transparent contact oxide deposition, doping, and ion implantation. Although these compounds offer potential performance advantages over earth metals and possibly greater safety in handling than metal hydrides, they are not without risk to health and property. Most organometals can ignite spontaneously in air. Some also react violently with water. Oxidation by-products from these reactions are hazardous to health. Of the organometals used in photovoltaic cell fabrication, only the toxicology of organotins (triethyl-, trimethyl- and tetramethyltin) was studied extensively. In mammalian systems, tetramethyltin is rapidly dealkylated to trimethyltin. Although tin was classified by some investigators as an essential trace element, the effects of organotin compounds on humans are poorly known. Animal studies show that the most prominent effects of trimethyltin are on the central nervous system. Several observations of poisoning were reported; effects ranged from reversible neurologic disorders to death. Limited available data suggest that humans respond to single acute doses and more alarmingly to repeated sub-toxic doses, suggesting a cumulative effect. Toxicologic properties of diethyltelluride also were evaluated in animal experiments. The compound had toxic effects on the blood, liver, kidney, heart, and skin. Based on these studies and others of related compounds (e.g., methylmercury, tributyltin) extreme caution should be exercised in using organometal compounds in photovoltaic cell manufacturing.

  14. 1366 Direct Wafer: Demolishing the Cost Barrier for Silicon Photovoltaics

    SciTech Connect

    Lorenz, Adam

    2013-08-30

    The goal of 1366 Direct Wafer™ is to drastically reduce the cost of silicon-based PV by eliminating the cost barrier imposed by sawn wafers. The key characteristics of Direct Wafer are 1) kerf-free, 156-mm standard silicon wafers 2) high throughput for very low CAPEX and rapid scale up. Together, these characteristics will allow Direct Wafer™ to become the new standard for silicon PV wafers and will enable terawatt-scale PV – a prospect that may not be possible with sawn wafers. Our single, high-throughput step will replace the expensive and rate-limiting process steps of ingot casting and sawing, thereby enabling drastically lower wafer cost. This High-Impact PV Supply Chain project addressed the challenges of scaling Direct Wafer technology for cost-effective, high-throughput production of commercially viable 156 mm wafers. The Direct Wafer process is inherently simple and offers the potential for very low production cost, but to realize this, it is necessary to demonstrate production of wafers at high-throughput that meet customer specifications. At the start of the program, 1366 had demonstrated (with ARPA-E funding) increases in solar cell efficiency from 10% to 15.9% on small area (20cm2), scaling wafer size up to the industry standard 156mm, and demonstrated initial cell efficiency on larger wafers of 13.5%. During this program, the throughput of the Direct Wafer furnace was increased by more than 10X, simultaneous with quality improvements to meet early customer specifications. Dedicated equipment for laser trimming of wafers and measurement methods were developed to feedback key quality metrics to improve the process and equipment. Subsequent operations served both to determine key operating metrics affecting cost, as well as generating sample product that was used for developing downstream processing including texture and interaction with standard cell processing. Dramatic price drops for silicon wafers raised the bar significantly, but the

  15. Study of locally manufactured motor vehicle batteries in stand alone home photovoltaic systems

    SciTech Connect

    Fernandez, S.

    1999-07-01

    Analysis of voltage, current, specific gravity, and temperature was performed on locally manufactured lead acid batteries operating in stand alone home photovoltaic (SAHPV) systems in the Dominican Republic. While voltage, charge/discharge current, and specific gravity of most batteries were within reasonable limits, there were indications of batteries spending an excessive time discharged and some incidents of overcharge. During charging above 1 amp, ambient temperatures were 6 to 13 C above the optimal operating temperature (25 C) and battery temperatures were 9 to 20 C above 25 C. Examination of worn out batteries from these SAHPV systems revealed that the majority had deteriorated positive plates and/or sulfation, while a smaller number showed signs of spalling. High temperature was determined to be a significant factor contributing to the premature failure of locally manufactured lead acid batteries operating in these systems.

  16. Non-Epitaxial Thin-Film Indium Phosphide Photovoltaics: Growth, Devices, and Cost Analysis

    NASA Astrophysics Data System (ADS)

    Zheng, Maxwell S.

    In recent years, the photovoltaic market has grown significantly as module prices have continued to come down. Continued growth of the field requires higher efficiency modules at lower manufacturing costs. In particular, higher efficiencies reduce the area needed for a given power output, thus reducing the downstream balance of systems costs that scale with area such as mounting frames, installation, and soft costs. Cells and modules made from III-V materials have the highest demonstrated efficiencies to date but are not yet at the cost level of other thin film technologies, which has limited their large-scale deployment. There is a need for new materials growth, processing and fabrication techniques to address this major shortcoming of III-V semiconductors. Chapters 2 and 3 explore growth of InP on non-epitaxial Mo substrates by MOCVD and CSS, respectively. The results from these studies demonstrate that InP optoelectronic quality is maintained even by growth on non-epitaxial metal substrates. Structural characterization by SEM and XRD show stoichiometric InP can be grown in complete thin films on Mo. Photoluminescence measurements show peak energies and widths to be similar to those of reference wafers of similar doping concentrations. In chapter 4 the TF-VLS growth technique is introduced and cells fabricated from InP produced by this technique are characterized. The TF-VLS method results in lateral grain sizes of >500 mum and exhibits superior optoelectronic quality. First generation devices using a n-TiO2 window layer along with p-type TF-VLS grown InP have reached ˜12.1% power conversion efficiency under 1 sun illumination with VOC of 692 mV, JSC of 26.9 mA/cm2, and FF of 65%. The cells are fabricated using all non-epitaxial processing. Optical measurements show the InP in these cells have the potential to support a higher VOC of ˜795 mV, which can be achieved by improved device design. Chapter 5 describes a cost analysis of a manufacturing process using an

  17. Cost effective manufacturing of the SEA 10X concentrator array

    SciTech Connect

    Kaminar, N.; McEntee, J.; Curchod, D. )

    1991-11-01

    This report describes a low-cost, mass-producible 10X concentrator system that has been claimed to produce electricity at $0.04/kWh. It details changes in manufacturing techniques that could produce a concentrator system at a selling price of $0.71/W. (A simple design and a minimum number of parts and manufacturing steps reduced production costs.) Present production techniques, changes to improve these techniques, impediments to changes, and solutions to the impediments are described. This 10X concentrator system uses available components and manufacturing processes and one-sun solar cells in conjunction with inexpensive plastic lenses to generate about eight times the amount of electricity normally produced by these cells.

  18. Cost-effectiveness of conservation upgrades in manufactured homes

    SciTech Connect

    Lee, A.D.; Conner, C.C.; Englin, J.E.; Hadley, D.L.; Lucas, R.G.; Miller, N.E.; Monroe, W.H.

    1988-09-01

    This study addresses the costs of upgrading the efficiency of electrically heated manufactured homes in the Bonneville Power Administration's (Bonneville's) service territory. It was prepared by the Battelle Pacific Northwest Laboratory (PNL) for Bonneville under a Related Services Agreement with the US Department of Energy, Contract AC06-76RLO1830. Manufactured homes (commonly called mobile homes) represent a significant lost conservation resource in the region. Manufactured homes are required to meet national energy standards that do not reflect the recent increases in energy prices, and the preemptive nature of the national standards prevents local jurisdictions from establishing stricter requirements. Bonneville has undertaken several programs to analyze the efficiency of manufactured homes and encourage the industry to produce more efficient homes and consumers to increase their demand for efficient units. This study constitutes one portion of Bonneville's overall strategy. 45 refs.

  19. LCP- LIFETIME COST AND PERFORMANCE MODEL FOR DISTRIBUTED PHOTOVOLTAIC SYSTEMS

    NASA Technical Reports Server (NTRS)

    Borden, C. S.

    1994-01-01

    The Lifetime Cost and Performance (LCP) Model was developed to assist in the assessment of Photovoltaic (PV) system design options. LCP is a simulation of the performance, cost, and revenue streams associated with distributed PV power systems. LCP provides the user with substantial flexibility in specifying the technical and economic environment of the PV application. User-specified input parameters are available to describe PV system characteristics, site climatic conditions, utility purchase and sellback rate structures, discount and escalation rates, construction timing, and lifetime of the system. Such details as PV array orientation and tilt angle, PV module and balance-of-system performance attributes, and the mode of utility interconnection are user-specified. LCP assumes that the distributed PV system is utility grid interactive without dedicated electrical storage. In combination with a suitable economic model, LCP can provide an estimate of the expected net present worth of a PV system to the owner, as compared to electricity purchased from a utility grid. Similarly, LCP might be used to perform sensitivity analyses to identify those PV system parameters having significant impact on net worth. The user describes the PV system configuration to LCP via the basic electrical components. The module is the smallest entity in the PV system which is modeled. A PV module is defined in the simulation by its short circuit current, which varies over the system lifetime due to degradation and failure. Modules are wired in series to form a branch circuit. Bypass diodes are allowed between modules in the branch circuits. Branch circuits are then connected in parallel to form a bus. A collection of buses is connected in parallel to form an increment to capacity of the system. By choosing the appropriate series-parallel wiring design, the user can specify the current, voltage, and reliability characteristics of the system. LCP simulation of system performance is site

  20. Photovoltaic array performance and life-cycle cost simulation using new software tools

    NASA Technical Reports Server (NTRS)

    Daniel, R. E.; Burger, D. R.; Reiter, L. J.

    1985-01-01

    The three computer models, SAMICS, PVARRAY, and LCP can be used together as a single analytical tool to compare the lifetime economic value of a photovoltaic (PV) array. This evaluation can be used to compare various module and array configurations and the performance characteristics of different module manufacturing technologies.

  1. EPA'S PHOTOVOLTAIC DEMAND-SIDE MANAGEMENT COST-SHARED DEMONSTRATIONS

    EPA Science Inventory

    The paper discusses an investigation of how photovoltaics (PV) may be used as both a pollution-mitigating energy replacement for fossil fuels and a demand-side management (DSM) option to reduce peak electrical demands of commercial and residential buildings. leven electric utilit...

  2. Cost Estimation in Engineer-to-Order Manufacturing

    NASA Astrophysics Data System (ADS)

    Hooshmand, Yousef; Köhler, Peter; Korff-Krumm, Andrea

    2016-02-01

    In Engineer-to-Order (ETO) manufacturing the price of products must be defined during early stages of product design and during the bidding process, thus an overestimation of product development (PD) costs may lead to the loss of orders and an underestimation causes a profit loss. What many ETO systems have in common is that the products have to be developed based on different customer requirements so that each order usually results in a new variant. Furthermore, many customer requirement change-requests may arise in different phases of the PD, which is to be considered properly. Thus it is utmost important for ETO systems to have an accurate cost estimation in first stages of the product design and to be able to determine the cost of customer requirement changes in different phases of PD. This paper aims to present a cost estimation methodology as well as a cost estimation model, which estimate the cost of products by relative comparison of the attributes of new product variants with the attributes of standard product variants. In addition, as a necessity in ETO manufacturing, the cost calculation of customer requirement changes in different phases of PD is integrated in the presented method.

  3. Cast polycrystalline silicon photovoltaic module manufacturing technology improvements. Semiannual technical report, 1 January 1996--30 June 1996

    SciTech Connect

    Wohlgemuth, J

    1997-01-01

    Two specific objectives of Solarex`s program are to reduce the manufacturing cost for polycrystalline silicon photovoltaic modules to less than $1.20/watt and to increase the manufacturing capacity by a factor of three. This report highlights accomplishments during the period of January 1 through June 30, 1996. Accomplishments include: began the conversion of production casting stations to increase ingot size; operated the wire saw in a production mode with higher yields and lower costs than achieved on the ID saws; developed and qualified a new wire guide coating material that doubles the wire guide lifetime and produces significantly less scatter in wafer thickness; completed a third pilot run of the cost-effective Al paste back-surface-field (BSF) process, verifying a 5% increase in cell efficiency and demonstrating the ability to process and handle the BSF paste cells; completed environmental qualification of modules using cells produced by an all-print metallization process; optimized the design of the 15.2-cm by 15.2-cm polycrystalline silicon solar cells; demonstrated the application of a high-efficiency process in making 15.2-cm by 15.2-cm solar cells; demonstrated that cell efficiency increases with decreasing wafer thickness for the Al paste BSF cells; qualified a vendor-supplied Tedlar/ethylene vinyl acetate (EVA) laminate to replace the combination of separate sheets of EVA and Tedlar backsheet; demonstrated the operation of a prototype unit to trim/lead attach/test modules; and demonstrated the operation of a wafer pull-down system for cassetting wet wafers.

  4. Structural cost optimization of photovoltaic central power station modules and support structure

    NASA Technical Reports Server (NTRS)

    Sutton, P. D.; Stolte, W. J.; Marsh, R. O.

    1979-01-01

    The results of a comprehensive study of photovoltaic module structural support concepts for photovoltaic central power stations and their associated costs are presented. The objective of the study has been the identification of structural cost drivers. Parametric structural design and cost analyses of complete array systems consisting of modules, primary support structures, and foundations were performed. Area related module cost was found to be constant with design, size, and loading. A curved glass module concept was evaluated and found to have the potential to significantly reduce panel structural costs. Conclusions of the study are: array costs do not vary greatly among the designs evaluated; panel and array costs are strongly dependent on design loading; and the best support configuration is load dependent

  5. Cost Analysis of a Concentrator Photovoltaic Hydrogen Production System

    SciTech Connect

    Thompson, J. R.; McConnell, R. D.; Mosleh, M.

    2005-08-01

    The development of efficient, renewable methods of producing hydrogen are essential for the success of the hydrogen economy. Since the feedstock for electrolysis is water, there are no harmful pollutants emitted during the use of the fuel. Furthermore, it has become evident that concentrator photovoltaic (CPV) systems have a number of unique attributes that could shortcut the development process, and increase the efficiency of hydrogen production to a point where economics will then drive the commercial development to mass scale.

  6. Cost-effective flat-plate photovoltaic modules using light trapping. Final report

    SciTech Connect

    Bain, C.N.; Gordon, B.A.; Knasel, T.M.; Malinowski, R.L.

    1981-04-01

    Work in optical trapping in thick films is extended to form a design guide for photovoltaic engineers. Details of the methods, techniques, and considerations that are used in the definition and analysis of light trapping photovoltaic panels are provided. Assumptions, sources of data, optical and cost modeling methods and the techniques used in the analysis are included. The ways to use light trapping are discussed, and methods are described to use simplified design and costing equations to predict performance and cost benefits. Four significant ways to use the findings presented are: a minimum design change module; an optimum packing factor module concept; roof or wall integrated panels; and modules using light trapping from cell grids. Finally, a design guide is included which shows how to construct photovoltaic modules to exploit light trapping. It is claimed that up to 20% improvements in standard module performance can be expected. (LEW)

  7. Photovoltaic manufacturing technology (PVMaT). Annual subcontract report, March 31, 1994--June 30, 1995

    SciTech Connect

    Holley, W A

    1996-01-01

    This report describes work performed under a subcontract to the National Renewable Energy Laboratory under the Photovoltaic Manufacturing Technology Project. The objectives of this subcontract are to (1) define the problem of yellowing/browning of EVA-based encapsulants; (2) determine probable mechanisms and the role of various parameters such as heat, UV exposure, module construction, EVA interfaces, and EVA thickness, in the browning of EVA-based encapsulants; (3) develop stabilization strategies for various module constructions to protect the encapsulant from degradative failure; (4) conduct laboratory, accelerated outdoor, and field testing of encapsulant, laminated test coupons, and full modules to demonstrate the functional adequacy of the stabilization strategies; and (5) implement these strategies. This report summarizes the accomplishments related to the above goals for the reporting period.

  8. Method of Manufacturing a Light Emitting, Photovoltaic or Other Electronic Apparatus and System

    NASA Technical Reports Server (NTRS)

    Ray, William Johnstone (Inventor); Lowenthal, Mark David (Inventor); Shotton, Neil O. (Inventor); Blanchard, Richard A. (Inventor); Lewandowski, Mark Allan (Inventor); Fuller, Kirk A. (Inventor); Frazier, Donald Odell (Inventor)

    2014-01-01

    The present invention provides a method of manufacturing an electronic apparatus, such as a lighting device having light emitting diodes (LEDs) or a power generating device having photovoltaic diodes. The exemplary method includes depositing a first conductive medium within a plurality of channels of a base to form a plurality of first conductors; depositing within the plurality of channels a plurality of semiconductor substrate particles suspended in a carrier medium; forming an ohmic contact between each semiconductor substrate particle and a first conductor; converting the semiconductor substrate particles into a plurality of semiconductor diodes; depositing a second conductive medium to form a plurality of second conductors coupled to the plurality of semiconductor diodes; and depositing or attaching a plurality of lenses suspended in a first polymer over the plurality of diodes. In various embodiments, the depositing, forming, coupling and converting steps are performed by or through a printing process.

  9. Method of Manufacturing a Light Emitting, Photovoltaic or Other Electronic Apparatus and System

    NASA Technical Reports Server (NTRS)

    Ray, William Johnstone (Inventor); Lowenthal, Mark D. (Inventor); Shotton, Neil O. (Inventor); Blanchard, Richard A. (Inventor); Lewandowski, Mark Allan (Inventor); Fuller, Kirk A. (Inventor); Frazier, Donald Odell (Inventor)

    2013-01-01

    The present invention provides a method of manufacturing an electronic apparatus, such as a lighting device having light emitting diodes (LEDs) or a power generating device having photovoltaic diodes. The exemplary method includes forming at least one first conductor coupled to a base; coupling a plurality of substantially spherical substrate particles to the at least one first conductor; converting the substrate particles into a plurality of substantially spherical diodes; forming at least one second conductor coupled to the substantially spherical diodes; and depositing or attaching a plurality of substantially spherical lenses suspended in a first polymer. The lenses and the suspending polymer have different indices of refraction. In some embodiments, the lenses and diodes have a ratio of mean diameters or lengths between about 10:1 and 2:1. In various embodiments, the forming, coupling and converting steps are performed by or through a printing process.

  10. Method of Manufacturing a Light Emitting, Photovoltaic or Other Electronic Apparatus and System

    NASA Technical Reports Server (NTRS)

    Ray, William Johnstone (Inventor); Lowenthal, Mark D. (Inventor); Shotton, Neil O. (Inventor); Blanchard, Richard A. (Inventor); Lewandowski, Mark Allan (Inventor); Fuller, Kirk A. (Inventor); Frazier, Donald Odell (Inventor)

    2013-01-01

    The present invention provides a method of manufacturing an electronic apparatus, such as a lighting device having light emitting diodes (LEDs) or a power generating device having photovoltaic diodes. The exemplary method includes forming at least one first conductor coupled to a base; coupling a plurality of substrate particles to the at least one first conductor; converting the plurality of substrate particles into a plurality of diodes; forming at least one second conductor coupled to the plurality of spherical diodes; and depositing or attaching a plurality of substantially spherical lenses suspended in a first polymer, with the lenses and the suspending polymer having different indices of refraction. In some embodiments, the lenses and diodes have a ratio of mean diameters or lengths between about 10:1 and 2:1. In various embodiments, the forming, coupling and converting steps are performed by or through a printing process.

  11. Method of manufacturing a light emitting, photovoltaic or other electronic apparatus and system

    NASA Technical Reports Server (NTRS)

    Ray, William Johnstone (Inventor); Lowenthal, Mark D. (Inventor); Shotton, Neil O. (Inventor); Blanchard, Richard A. (Inventor); Lewandowski, Mark Allan (Inventor); Fuller, Kirk A. (Inventor); Frazier, Donald Odell (Inventor)

    2012-01-01

    The present invention provides a method of manufacturing an electronic apparatus, such as a lighting device having light emitting diodes (LEDs) or a power generating device having photovoltaic diodes. The exemplary method includes depositing a first conductive medium within a plurality of channels of a base to form a plurality of first conductors; depositing within the plurality of channels a plurality of semiconductor substrate particles suspended in a carrier medium; forming an ohmic contact between each semiconductor substrate particle and a first conductor; converting the semiconductor substrate particles into a plurality of semiconductor diodes; depositing a second conductive medium to form a plurality of second conductors coupled to the plurality of semiconductor diodes; and depositing or attaching a plurality of lenses suspended in a first polymer over the plurality of diodes. In various embodiments, the depositing, forming, coupling and converting steps are performed by or through a printing process.

  12. Operation and maintenance cost data for residential photovoltaic modules/panels

    SciTech Connect

    1980-07-01

    Burt Hill Kosar Rittelmann Associates has conducted a study to identify and estimate costs associated with the operation and maintenance of residential photovoltaic modules and arrays. Six basic topics related to operation and maintenance to photovoltaic arrays were investigated - General (Normal) Maintenance, Cleaning, Panel Replacement, Gasket Repair/Replacement, Wiring Repair/Replacement, and Termination Repair/Replacement. The effects of the mounting types - Rack Mount, Stand-Off Mount, Direct Mount, and Integral Mount - and the installation/replacement type - Sequential, Partial Interruption, and Independent - have been identified and described. Recommendation on methods of reducing maintenance costs are made.

  13. Cost analysis of composite fan blade manufacturing processes

    NASA Technical Reports Server (NTRS)

    Stelson, T. S.; Barth, C. F.

    1980-01-01

    The relative manufacturing costs were estimated for large high technology fan blades prepared by advanced composite fabrication methods using seven candidate materials/process systems. These systems were identified as laminated resin matrix composite, filament wound resin matrix composite, superhybrid solid laminate, superhybrid spar/shell, metal matrix composite, metal matrix composite with a spar and shell, and hollow titanium. The costs were calculated utilizing analytical process models and all cost data are presented as normalized relative values where 100 was the cost of a conventionally forged solid titanium fan blade whose geometry corresponded to a size typical of 42 blades per disc. Four costs were calculated for each of the seven candidate systems to relate the variation of cost on blade size. Geometries typical of blade designs at 24, 30, 36 and 42 blades per disc were used. The impact of individual process yield factors on costs was also assessed as well as effects of process parameters, raw materials, labor rates and consumable items.

  14. Low cost and efficient photovoltaic conversion by nanocrystalline solar cells

    SciTech Connect

    Graetzel, M.

    1996-09-01

    Solar cells are expected to provide environmentally friendly solutions to the world`s energy supply problem. Learning from the concepts used by green plants we have developed a molecular photovoltaic device whose overall efficiency for AM 1.5 solar light to electricity has already attained 8-11%. The system is based on the sensitization of nanocrystalline oxide films by transition metal charge transfer sensitizers. In analogy to photosynthesis, the new chemical solar cell achieves the separation of the light absorption and charge carrier transport processes. Extraordinary yields for the conversion of incident photons into electric current are obtained, exceeding 90% for transition metal complexes within the wavelength range of their absorption band. The use of molten salt electrolytes together with coordination complexes of ruthenium as sensitizers and adequate sealing technology has endowed these cells with a remarkable stability making practical applications feasible. Seven industrial cooperations are presently involved in the development to bring these cells to the market. The first cells will be applied to supply electric power for consumer electronic devices. The launching of production of several products of this type is imminent and they should be on the market within the next two years. Quite aside from their intrinsic merits as photovoltaic device, the mesoscopic oxide semiconductor films developed in our laboratory offer attractive possibilities for a number of other applications. Thus, the first example of a nanocrystalline rocking chair battery will be demonstrated and its principle briefly discussed.

  15. Low-Cost Manufacturing of High- Temperature Polymer Composites

    NASA Technical Reports Server (NTRS)

    Sutter, James K.

    1998-01-01

    Major goals of NASA and the Integrated High Performance Turbine Engine Technology (IHPTET) initiative include improvements in the affordability of propulsion systems, significant increases in the thrust/weight ratio, and increases in the temperature capability of components of gas turbine engines. Members of NASA Lewis Research Center's HITEMP project worked cooperatively with Allison Advanced Development Corporation to develop a manufacturing method to produce low-cost components for gas turbine engines. Affordability for these polymer composites is defined by the savings in acquisition and life-cycle costs associated with engine weight reduction. To lower engine component costs, the Lewis/Allison team focused on chopped graphite fiber/polyimide resin composites. The high-temperature polyimide resin chosen, PMR-II-50, was developed at NASA Lewis.

  16. Photovoltaic device with increased light absorption and method for its manufacture

    SciTech Connect

    Glatfelter, Troy; Vogeli, Craig; Call, Jon; Hammond, Ginger

    1993-07-20

    A photovoltaic cell having a light-directing optical element integrally formed in an encapsulant layer thereof. The optical element redirects light to increase the internal absorption of light incident on the photovoltaic device.

  17. Development of low-cost silicon crystal growth techniques for terrestrial photovoltaic solar energy conversion

    NASA Technical Reports Server (NTRS)

    Zoutendyk, J. A.

    1976-01-01

    Because of the growing need for new sources of electrical energy, photovoltaic solar energy conversion is being developed. Photovoltaic devices are now being produced mainly from silicon wafers obtained from the slicing and polishing of cylindrically shaped single crystal ingots. Inherently high-cost processes now being used must either be eliminated or modified to provide low-cost crystalline silicon. Basic to this pursuit is the development of new or modified methods of crystal growth and, if necessary, crystal cutting. If silicon could be grown in a form requiring no cutting, a significant cost saving would potentially be realized. Therefore, several techniques for growth in the form of ribbons or sheets are being explored. In addition, novel techniques for low-cost ingot growth and cutting are under investigation.

  18. Innovative manufacturing and materials for low cost lithium ion batteries

    SciTech Connect

    Carlson, Steven

    2015-12-29

    This project demonstrated entirely new manufacturing process options for lithium ion batteries with major potential for improved cost and performance. These new manufacturing approaches are based on the use of the new electrode-coated separators instead of the conventional electrode-coated metal current collector foils. The key enabler to making these electrode-coated separators is a new and unique all-ceramic separator with no conventional porous plastic separator present. A simple, low cost, and high speed manufacturing process of a single coating of a ceramic pigment and polymer binder onto a re-usable release film, followed by a subsequent delamination of the all-ceramic separator and any layers coated over it, such as electrodes and metal current collectors, was utilized. A suitable all-ceramic separator was developed that demonstrated the following required features needed for making electrode-coated separators: (1) no pores greater than 100 nanometer (nm) in diameter to prevent any penetration of the electrode pigments into the separator; (2) no shrinkage of the separator when heated to the high oven heats needed for drying of the electrode layer; and (3) no significant compression of the separator layer by the high pressure calendering step needed to densify the electrodes by about 30%. In addition, this nanoporous all-ceramic separator can be very thin at 8 microns thick for increased energy density, while providing all of the performance features provided by the current ceramic-coated plastic separators used in vehicle batteries: improved safety, longer cycle life, and stability to operate at voltages up to 5.0 V in order to obtain even more energy density. The thin all-ceramic separator provides a cost savings of at least 50% for the separator component and by itself meets the overall goal of this project to reduce the cell inactive component cost by at least 20%. The all-ceramic separator also enables further cost savings by its excellent heat stability

  19. Development of a fixed abrasive slicing technique (FAST) for reducing the cost of photovoltaic wafers

    SciTech Connect

    Schmid, F. )

    1991-12-01

    This report examines a wafer slicing technique developed by Crystal Systems, Inc. that reduces the cost of photovoltaic wafers. This fixed, abrasive slicing technique (FAST) uses a multiwire bladepack and a diamond-plated wirepack; water is the coolant. FAST is in the prototype production stage and reduces expendable material costs while retaining the advantages of a multiwire slurry technique. The cost analysis revealed that costs can be decreased by making more cuts per bladepack and slicing more wafers per linear inch. Researchers studied the degradation of bladepacks and increased wirepack life. 21 refs.

  20. Cast polycrystalline silicon photovoltaic module manufacturing technology improvements. Semiannual subcontract report, January 1--June 30, 1995

    SciTech Connect

    Wohlgemuth, J.

    1996-02-01

    The objective of this three-year program is to advance Solarex`s cast polycrystalline silicon manufacturing technology, reduce module production cost, increase module performance and expand Solarex`s commercial production capacities. Two specific objectives of this program are to reduce the manufacturing cost for polycrystalline silicon PV modules to less than $1.20/watt and to increase the manufacturing capacity by a factor of three. To achieve these objectives, Solarex is working in the following technical areas: casting, wire saws, cell process, module assembly, frameless module development, and automated cell handling. Accomplishments reported include: Cast first successful larger ingot producing 73% larger volume of usable Si; Increased the size of the ingot even further and cast an ingot yielding nine 11.4 {times} 11.4 cm bricks, representing a 125% increase in usable Si from a single casting; Operated the wire-saw in a semi-operational mode, producing 459,000 wafers at 94.1% overall yield; Reduced the cost of wire-saw consumables, spare parts, and waste disposal; Developed a cost-effective back surface field process that increases cell efficiency by 5% and began production trials; Developed a plan for increasing the capacity in the module assembly area; Completed qualification testing of modules built using Spire`s automated tabbing and stringing machine; Selected, tested, and qualified a low-cost electrical termination system; Completed long-term UV testing of experimental back sheets; Qualified the structure and adhesive-tape system for mounting frameless modules; and ARRI completed a study of the fracture properties of cast polycrystalline Si wafers and provided the information necessary to calculate the maximum stresses allowable during wafer handling.

  1. Manufacturing and wetting low-cost microfluidic cell separation devices

    PubMed Central

    Pawell, Ryan S.; Inglis, David W.; Barber, Tracie J.; Taylor, Robert A.

    2013-01-01

    Deterministic lateral displacement (DLD) is a microfluidic size-based particle separation or filter technology with applications in cell separation and enrichment. Currently, there are no cost-effective manufacturing methods for this promising microfluidic technology. In this fabrication paper, however, we develop a simple, yet robust protocol for thermoplastic DLD devices using regulatory-approved materials and biocompatible methods. The final standalone device allowed for volumetric flow rates of 660 μl min−1 while reducing the manufacturing time to <1 h. Optical profilometry and image analysis were employed to assess manufacturing accuracy and precision; the average replicated post height was 0.48% less than the average post height on the master mold and the average replicated array pitch was 1.1% less than the original design with replicated posts heights of 62.1 ± 5.1 μm (mean ± 6 standard deviations) and replicated array pitches of 35.6 ± 0.31 μm. PMID:24404077

  2. Breakeven Cost for Residential Photovoltaics in the United States: Key Drivers and Sensitivities (Report Summary) (Presentation)

    SciTech Connect

    Denholm, P.; Margolis, R. M.; Ong, S.; Roberts, B.

    2009-12-01

    "Break-even cost" for photovoltaic (PV) technology is defined as the point where the cost of PV-generated electricity equals the cost of electricity purchased from the grid. Break-even cost is expressed in $/W of an installed system. Achieving break-even cost is a function of many variables. Consequently, break-even costs vary by location and time for a country, such as the United States, with a diverse set of resources, electricity prices, and other variables. In this presentation, we introduce an analysis of PV break-even costs for residential customers in the United States, including an evaluation of some of the key drivers of PV breakeven both regionally and over time. This presentation includes our methodology and presents results for both near-term residential breakeven costs(2009) and future market sensitivities of break-even costs (2015). See also the the report "Break-Even Cost for Residential Photovoltaics in the United States: Key Drivers and Sensitivities". Presentation for NREL/TP-6A2-45991.

  3. Continuous roll-to-roll a-Si photovoltaic manufacturing technology. Annual subcontractor report, 1 April 1992--31 March 1993

    SciTech Connect

    Izu, M.

    1993-12-01

    This report describes work done under a 3-year program to advance ECD`s roll-to-roll, triple-junction photovoltaic manufacturing technologies, to reduce the module production costs, to increase the stabilized module performance, and to expand commercial capacity utilizing ECD technology. The specific 3-year goal is to develop advanced large-scale manufacturing technology incorporating ECD`s earlier research advances with the capability of producing modules with stable 11% efficiency at a cost of approximately $1.00 per peak watt. Accomplishments during Phase 1 included: (1) ECD successfully incorporated a high-performance Ag/metal-oxide back-reflector system into its continuous roll-to-roll commercial production operation. (2) High-quality a-Si-Ge narrow-band-gap solar cells were incorporated into the manufacturing. (3) ECD demonstrated the continuous roll-to-roll production of high-efficiency, triple-junction, two-band-gap solar cells consistently and uniformly throughout a 762-m (2500-ft) run with high yield. (4) ECD achieved 11.1% initial sub-cell efficiency of triple-junction, two-band-gap a-Si alloy solar cells in the production line. (5) The world`s first 0.37-m{sup 2} (4-ft{sup 2}) PV modules were produced utilizing triple-junction spectrum-splitting solar cells manufactured in the production line. (6) As a result of process optimization to reduce the layer thickness and to improve the gas utilization, ECD achieved a 77% material cost reduction for germane and 58% reduction for disilane. Additionally, ECD developed a new low-cost module that saves approximately 30% in assembly material costs.

  4. Manufactured Homes Simulated Thermal Analysis and Cost Effectiveness Report.

    SciTech Connect

    Baylon, David

    1990-05-17

    In 1988 and 1989, 150 manufactured homes were built to comply with Super Good Cents (SGC) specifications adapted from the existing specifications for site-built homes under the Residential Construction Demonstration Project (RCDP). Engineering calculations and computer simulations were used to estimate the effects of the SGC specifications on the thermal performance of the homes. These results were compared with consumer costs to establish the cost-effectiveness of individual measures. Heat loss U-factors for windows, walls, floors and ceilings were established using the standard ASHRAE parallel heat flow method. Adjustments resulted in higher U-factors for ceilings and floors than assumed at the time the homes were approved as meeting the SGC specifications. Except for those homes which included heat pumps, most of the homes did not meet the SGC compliance standards. Nonetheless these homes achieved substantial reductions in overall heat loss rate (UA) compared to UAs estimated for the same homes using the standard insulation packages provided by the manufacturers in the absence of the RCDP program. Homes with conventional electric furnaces showed a 35% reduction in total UA while homes with heat pumps had a 25% reduction. A regression analysis showed no significant relationship between climate zone, manufacturer and UA. A modified version of SUNDAY building simulation program which simulates duct and heat pump performance was used to model the thermal performance of each RCDP home as built and the same home as it would have been built without SGC specifications (base case). Standard assumptions were used for thermostat setpoint, thermal mass, internal gains and infiltration rates. 11 refs., 5 figs., 5 tabs.

  5. Photovoltaic manufacturing technology monolithic amorphous silicon modules on continuous polymer substrates. Annual technical progress report, 5 July 1995--4 June 1996

    SciTech Connect

    Jeffrey, F

    1997-02-01

    Iowa Thin Film Technologies` goal is to develop the most cost-effective photovoltaic manufacturing process possible. During the first year, they developed the capability of sputtering a high-quality (Zn(Al)O) successfully implemented increased deposition rates for the ZnO top contact deposition; improved registration and ink-line width to reduce area loss due to interconnects; developed a new alignment process and sensor to improve the speed and accuracy of registration for the patterning processes; developed a new Silver ink composition that allows finer print lines and lower series resistance; demonstrated an 8% overall improvement in area utilization; evaluated water-based insulator inks for compatibility with their processes; investigated and tested the use of roll-based lamination as a means to reduce the cost of assembly; developed straight roll lamination capability using pressure-sensitive adhesives and thermally activated bonding; and evaluated the use of the standard EVA/Tefzel encapsulant with a roll laminator.

  6. Ultrashort-pulsed laser processing and solution based coating in roll-to-roll manufacturing of organic photovoltaics

    NASA Astrophysics Data System (ADS)

    Hördemann, C.; Hirschfelder, K.; Schaefer, M.; Gillner, A.

    2015-09-01

    The breakthrough of flexible organic electronics and especially organic photovoltaics is highly dependent on cost-efficient production technologies. Roll-2-Roll processes show potential for a promising solution in terms of high throughput and low-cost production of thin film organic components. Solution based material deposition and integrated laser patterning processes offer new possibilities for versatile production lines. The use of flexible polymeric substrates brings along challenges in laser patterning which have to be overcome. One main challenge when patterning transparent conductive layers on polymeric substrates are material bulges at the edges of the ablated area. Bulges can lead to short circuits in the layer system leading to device failure. Therefore following layers have to have a sufficient thickness to cover and smooth the ridge. In order to minimize the bulging height, a study has been carried out on transparent conductive ITO layers on flexible PET substrates. Ablation results using different beam shapes, such as Gaussian beam, Top-Hat beam and Donut-shaped beam, as well as multi-pass scribing and double-pulsed ablation are compared. Furthermore, lab scale methods for cleaning the patterned layer and eliminating bulges are contrasted to the use of additional water based sacrificial layers in order to obtain an alternative procedure suitable for large scale Roll-2-Roll manufacturing. Besides progress in research, ongoing transfer of laser processes into a Roll-2-Roll demonstrator is illustrated. By using fixed optical elements in combination with a galvanometric scanner, scribing, variable patterning and edge deletion can be performed individually.

  7. Effects of design on cost of flat-plate solar photovoltaic arrays for terrestrial central station power applications

    NASA Technical Reports Server (NTRS)

    Tsou, P.; Stolte, W.

    1978-01-01

    The paper examines the impact of module and array designs on the balance-of-plant costs for flat-plate terrestrial central station power applications. Consideration is given to the following types of arrays: horizontal, tandem, augmented, tilt adjusted, and E-W tracking. The life-cycle cost of a 20-year plant life serves as the costing criteria for making design and cost tradeoffs. A tailored code of accounts is developed for determining consistent photovoltaic power plant costs and providing credible photovoltaic system cost baselines for flat-plate module and array designs by costing several varying array design approaches.

  8. Cast polycrystalline silicon photovoltaic cell and module manufacturing technology improvements. Annual subcontract report, 1 December 1993--30 November 1994

    SciTech Connect

    Wohlgemuth, J.

    1995-09-01

    This report describes work performed under a 3-y contract to advance Solarex`s cast polycrystalline silicon manufacturing technology, reduce module production cost, increase module performance, and expand Solarex`s commercial production capacities. Specific objectives are to reduce manufacturing cost for polycrstalline silicon PV modules to less than $1.20/W and to increase manufacturing capacity by a factor of 3. Solarex is working on casting, wire saws, cell process, module assembly, frameless module development, and automated cell handling.

  9. Cast polycrystalline silicon photovoltaic module manufacturing technology improvements. Annual subcontract report, January 1, 1995--December 31, 1995

    SciTech Connect

    Wohlgemuth, J

    1996-06-01

    The objective of this three-year program is to advance Solarex`s cast polycrystalline silicon manufacturing technology, reduce module production cost, increase module performance and expand Solarex`s commercial production capacities. Two specific objectives of this program are to reduce the manufacturing cost for polycrystalline silicon PV modules to less than $1.20/watt and to increase the manufacturing capacity by a factor of three.

  10. Process Development for Nanostructured Photovoltaics

    SciTech Connect

    Elam, Jeffrey W.

    2015-01-01

    Photovoltaic manufacturing is an emerging industry that promises a carbon-free, nearly limitless source of energy for our nation. However, the high-temperature manufacturing processes used for conventional silicon-based photovoltaics are extremely energy-intensive and expensive. This high cost imposes a critical barrier to the widespread implementation of photovoltaic technology. Argonne National Laboratory and its partners recently invented new methods for manufacturing nanostructured photovoltaic devices that allow dramatic savings in materials, process energy, and cost. These methods are based on atomic layer deposition, a thin film synthesis technique that has been commercialized for the mass production of semiconductor microelectronics. The goal of this project was to develop these low-cost fabrication methods for the high efficiency production of nanostructured photovoltaics, and to demonstrate these methods in solar cell manufacturing. We achieved this goal in two ways: 1) we demonstrated the benefits of these coatings in the laboratory by scaling-up the fabrication of low-cost dye sensitized solar cells; 2) we used our coating technology to reduce the manufacturing cost of solar cells under development by our industrial partners.

  11. Amorphous silicon photovoltaic manufacturing technology, Phase 2A. Semiannual subcontract report, 1 May 1993--31 October 1993

    SciTech Connect

    Duran, G.; Mackamul, K.; Metcalf, D.; Volltrauer, H.

    1994-04-01

    Utility Power Group (UPG) and its lower-tier subcontractor, Advanced Photovoltaic Systems, Inc. (APS), continued work to develop their manufacturing lines. UPG focused on the automation of encapsulation and termination processes developed in Phase 1. APS focused on completion of the encapsulation and module design tasks while continuing process quality control, and automation projects. The goal is to produce 55-W (stabilized) EP50 modules in a new facility.

  12. Photovoltaics (Fact Sheet)

    SciTech Connect

    Not Available

    2012-11-01

    The U.S. Department of Energy (DOE) works with industry, academia, national laboratories, and other government agencies to advance solar photovoltaics (PV) domestically. The SunShot Initiative aims to achieve widespread, unsubsidized cost-competitiveness through an applied research and development (R&D) portfolio spanning PV materials, devices, and manufacturing technologies.

  13. Photovoltaics (Fact Sheet)

    SciTech Connect

    Not Available

    2011-10-01

    DOE works with national labs, academia, and industry to support the domestic photovoltaics (PV) industry and research enterprise. SunShot aims to achieve widespread, unsubsidized cost-competitiveness through an applied research and development (R&D) portfolio spanning PV materials, devices, and manufacturing technologies.

  14. Photovoltaics (Fact Sheet)

    SciTech Connect

    DOE Solar Energy Technologies Program

    2011-10-13

    DOE works with national labs, academia, and industry to support the domestic photovoltaics (PV) industry and research enterprise. SunShot aims to achieve widespread, unsubsidized cost-competitiveness through an applied research and development (R&D) portfolio spanning PV materials, devices, and manufacturing technologies.

  15. Impact of Balance Of System (BOS) costs on photovoltaic power systems

    NASA Technical Reports Server (NTRS)

    Hein, G. F.; Cusick, J. P.; Poley, W. A.

    1978-01-01

    The Department of Energy has developed a program to effect a large reduction in the price of photovoltaic modules, with significant progress already achieved toward the 1986 goal of 50 cents/watt (1975 dollars). Remaining elements of a P/V power system (structure, battery storage, regulation, control, and wiring) are also significant cost items. The costs of these remaining elements are commonly referred to as Balance-of-System (BOS) costs. The BOS costs are less well defined and documented than module costs. The Lewis Research Center (LeRC) in 1976/77 and with two village power experiments that will be installed in 1978. The costs were divided into five categories and analyzed. A regression analysis was performed to determine correlations of BOS Costs per peak watt, with power size for these photovoltaic systems. The statistical relationship may be used for flat-plate, DC systems ranging from 100 to 4,000 peak watts. A survey of suppliers was conducted for comparison with the predicted BOS cost relationship.

  16. Low cost silicon-on-ceramic photovoltaic solar cells

    NASA Technical Reports Server (NTRS)

    Koepke, B. G.; Heaps, J. D.; Grung, B. L.; Zook, J. D.; Sibold, J. D.; Leipold, M. H.

    1980-01-01

    A technique has been developed for coating low-cost mullite-based refractory substrates with thin layers of solar cell quality silicon. The technique involves first carbonizing one surface of the ceramic and then contacting it with molten silicon. The silicon wets the carbonized surface and, under the proper thermal conditions, solidifies as a large-grained sheet. Solar cells produced from this composite silicon-on-ceramic material have exhibited total area conversion efficiencies of ten percent.

  17. Low Cost Thin Film Building-Integrated Photovoltaic Systems

    SciTech Connect

    Dr. Subhendu Guha; Dr. Jeff Yang

    2012-05-25

    The goal of the program is to develop 'LOW COST THIN FILM BUILDING-INTEGRATED PV SYSTEMS'. Major focus was on developing low cost solution for the commercial BIPV and rooftop PV market and meet DOE LCOE goal for the commercial market segment of 9-12 cents/kWh for 2010 and 6-8 cents/kWh for 2015. We achieved the 2010 goal and were on track to achieve the 2015 goal. The program consists of five major tasks: (1) modules; (2) inverters and BOS; (3) systems engineering and integration; (4) deployment; and (5) project management and TPP collaborative activities. We successfully crossed all stage gates and surpassed all milestones. We proudly achieved world record stable efficiencies in small area cells (12.56% for 1cm2) and large area encapsulated modules (11.3% for 800 cm2) using a triple-junction amorphous silicon/nanocrystalline silicon/nanocrystalline silicon structure, confirmed by the National Renewable Energy Laboratory. We collaborated with two inverter companies, Solectria and PV Powered, and significantly reduced inverter cost. We collaborated with three universities (Syracuse University, University of Oregon, and Colorado School of Mines) and National Renewable Energy Laboratory, and improved understanding on nanocrystalline material properties and light trapping techniques. We jointly published 50 technical papers in peer-reviewed journals and International Conference Proceedings. We installed two 75kW roof-top systems, one in Florida and another in New Jersey demonstrating innovative designs. The systems performed satisfactorily meeting/exceeding estimated kWh/kW performance. The 50/50 cost shared program was a great success and received excellent comments from DOE Manager and Technical Monitor in the Final Review.

  18. Optical Metrology for CIGS Solar Cell Manufacturing and its Cost Implications

    NASA Astrophysics Data System (ADS)

    Sunkoju, Sravan Kumar

    Solar energy is a promising source of renewable energy which can meet the demand for clean energy in near future with advances in research in the field of photovoltaics and cost reduction by commercialization. Availability of a non-contact, in-line, real time robust process control strategies can greatly aid in reducing the gap between cell and module efficiencies, thereby leading to cost-effective large-scale manufacturing of high efficiency CIGS solar cells. In order to achieve proper process monitoring and control for the deposition of the functional layers of CuIn1-xGaxSe 2 (CIGS) based thin film solar cell, optical techniques such as spectroscopic reflectometry and polarimetry are advantageous because they can be set up in an unobtrusive manner in the manufacturing line, and collect data in-line and in-situ. The use of these techniques requires accurate optical models that correctly represent the properties of the layers being deposited. In this study, Spectroscopic ellipsometry (SE) has been applied for the characterization of each individual stage of CIGS layers deposited using the 3-stage co-evaporation process along with the other functional layers. Dielectric functions have been determined for the energy range from 0.7 eV to 5.1 eV. Critical-point line-shape analysis was used in this study to determine the critical point energies of the CIGS based layers. To control the compositional and thickness uniformity of all the functional layers during the fabrication of CIGS solar cells over large areas, multilayer photovoltaics (PV) stack optical models were developed with the help of extracted dielectric functions. In this study, mapping capability of RC2 spectroscopic ellipsometer was used to map all the functional layer thicknesses of a CIGS solar cell in order to probe the spatial non-uniformities that can affect the performance of a cell. The optical functions for each of the stages of CIGS 3-stage deposition process along with buffer layer and transparent

  19. Cast Polycrystalline Photovoltaic Module Manufacturing Technology Improvements; Final Subcontract Report, 8 December 199330 April 1998

    SciTech Connect

    J. Wohlgemuth.

    1999-06-16

    This report summarizes work performed by Solarex, A Business Unit of Amoco/Enron Solar, under this subcontract. Among the accomplishments during the program are the following: Converting all of the production casting stations to increase ingot size, operating them at equivalent yields and cell efficiencies, and thus doubling the casting capacity at a 20% lower cost than the cost of new equipment. Developing a wire-saw process and transferring the process to production; as a result, more than 80% of wafering is now done using wire saws, at higher yields and lower costs than achieved on the internal diameter saws. Developing an aluminum paste back-surface field (BSF) process to increase cell efficiency by 5%; researchers also designed, procured, and transferred to manufacturing a fully automated printing system to produce the BSF cells. Fabricating 15.2-cm by 15.2-cm polycrystalline silicon solar cells and building modules using these cells. Modifying the module assembly area to increase capacity by a factor of three. Implementing a single-layer Tedlar backsheet that reduced backsheet cost by $0.50/ft2. Selecting, testing, and qualifying a low-cost (< $1.00 per module) electrical termination system. Qualifying the structure and adhesive system for mounting frameless modules and using the system to build several large arrays.

  20. DEVELOPMENT AND MANUFACTURE OF COST EFFECTIVE COMPOSITE DRILL PIPE

    SciTech Connect

    James C. Leslie; Jeffrey R. Jean; Hans Neubert; Lee Truong

    2001-10-30

    This technical report presents the engineering research and data accomplishments that have transpired to date in support of the development of Cost Effective Composite Drill Pipe (CDP). The report discusses and illustrates all progress in the first two years of this NETL/DOE supported program. The following have been accomplished and are reported in detail herein: (1) Specifications for both 5 5/16 inch and 3 3/8 inch composite drill pipe have been finalized. (2) All basic laboratory testing has been completed and has provide sufficient data for the selection of materials for the composite tubing, adhesives, and abrasion coatings. (3) Successful demonstration of composite/metal joint interfacial connection. (4) Upgrade of facilities to provide a functional pilot plant manufacturing facility. (5) Arrangements to have the 3 3/8 inch CDP used in a drilling operation early in C.Y. 2002. (6) Arrangements to have the 5 5/16 inch CDP marketed and produced by a major drill pipe manufacturer.

  1. Development and Manufacture of Cost Effective Composite Drill Pipe

    SciTech Connect

    James C. Leslie; Jeffrey R. Jean; Hans Neubert; Lee Truong; James T. Heard

    2002-09-29

    This technical report presents the engineering research and data accomplishments that have transpired to date in support of the development of Cost Effective Composite Drill Pipe (CDP). The report reiterates the presentation made to DOE/NETL in Morgantown, WV on August 1st, 2002 with the addition of accomplishments made from that time forward until the issue date. The following have been accomplished and are reported in detail herein: {sm_bullet} Specifications for both 5-1/2'' and 1-5/8'' composite drill pipe have been finalized. {sm_bullet} Full scale testing of Short Radius (SR) CDP has been conducted. {sm_bullet} Successful demonstration of metal to composite interface (MCI) connection. {sm_bullet} Preparations for full scale manufacturing of ER/DW CDP have begun. {sm_bullet} Manufacturing facility rearranged to accommodate CDP process flow through plant. {sm_bullet} Arrangements to have the 3 3/8'' CDP used in 4 separate drilling applications in Oman, Oklahoma, and Texas.

  2. Advanced photovoltaic concentrator system low-cost prototype module

    SciTech Connect

    Kaminar, N.R.; McEntee, J.; Curchod, D. )

    1991-09-01

    This report describes the continued development of an extruded lens and the development of a PV receiver, both of which will be used in the Solar Engineering Applications Corporation (SEA) 10X concentrator. These efforts were pare of a pre-Concentrator Initiative Program. The 10X concentrator consists of an inexpensive, extruded linear Fresnel lens which focuses on one-sun cells which are adhesive-bonded to an anodized aluminum heat sink. Module sides are planned to be molded along with the lens and are internally reflective for improved on- and off-track performance. End caps with molded-in bearings complete the module. Ten modules are mounted in a stationary frame for simple, single-axis tracking in the east-west direction. This configuration an array, is shipped completely assembled and requires only setting on a reasonably flat surface, installing 4 fasteners, and hooking up the wires. Development of the 10-inch wide extruded lens involved one new extrusion die and a series of modifications to this die. Over 76% lens transmission was measured which surpassed the program goal of 75%. One-foot long receiver sections were assembled and subjected to evaluation tests at Sandia National Laboratories. A first group had some problem with cell delamination and voids but a second group performed very well, indicating that a full size receiver would pass the full qualification test. Cost information was updated and presented in the report. The cost study indicated that the Solar Engineering Applications Corporation concentrator system can exceed the DOE electricity cost goals of less than 6cents per KW-hr. 33 figs., 11 tabs.

  3. Advanced photovoltaic concentrator system low-cost prototype module

    NASA Astrophysics Data System (ADS)

    Kaminar, N. R.; McEntee, J.; Curchod, D.

    1991-09-01

    This report describes the continued development of an extruded lens and the development of a PV receiver, both of which will be used in the Solar Engineering Applications Corporation (SEA) 10X concentrator. These efforts were part of a pre-Concentrator Initiative Program. The 10X concentrator consists of an inexpensive, extruded linear Fresnel lens which focuses on one-sun cells which are adhesive-bonded to an anodized aluminum heat sink. Module sides are planned to be molded along with the lens and are internally reflective for improved on- and off-track performance. End caps with molded-in bearings complete the module. Ten modules are mounted in a stationary frame for simple, single-axis tracking in the east-west direction. This array configuration is shipped completely assembled and requires only setting on a reasonably flat surface, installing 4 fasteners, and hooking up the wires. Development of the 10-inch wide extruded lens involved one new extrusion die and a series of modifications to this die. Over 76 percent lens transmission was measured, which surpassed the program goal of 75 percent. One-foot long receiver sections were assembled and subjected to evaluation tests at Sandia National Laboratories. A first group had some problem with cell delamination and voids but a second group performed very well, indicating that a full size receiver would pass the full qualification test. Cost information was updated and presented in the report. The cost study indicated that the Solar Engineering Applications Corporation concentrator system can exceed the DOE electricity cost goals of less than 6 cents per KW-hr.

  4. Low cost high power GaSB photovoltaic cells

    NASA Astrophysics Data System (ADS)

    Fraas, Lewis M.; Huang, Han X.; Ye, Shi-Zhong; Hui, She; Avery, James; Ballantyne, Russell

    1997-03-01

    High power density and high capacity factor are important attributes of a thermophotovoltaics (TPV) system and GaSb cells are enabling for TPV systems. A TPV cogeneration unit at an off grid site will compliment solar arrays producing heat and electricity on cloudy days with the solar arrays generating electricity on sunny days. Herein, we project that GaSb cells generating 2 Watts each can be made in 1 MW quantities at 4 per cell. This will allow TPV circuits to be made at 2 per Watt. At this cost, the off-grid cogeneration and self-powered furnace markets will be viable.

  5. 48 CFR 31.205-25 - Manufacturing and production engineering costs.

    Code of Federal Regulations, 2012 CFR

    2012-10-01

    ... 48 Federal Acquisition Regulations System 1 2012-10-01 2012-10-01 false Manufacturing and... Commercial Organizations 31.205-25 Manufacturing and production engineering costs. (a) The costs of manufacturing and production engineering effort as described in (1) through (4) below are all allowable:...

  6. 48 CFR 31.205-25 - Manufacturing and production engineering costs.

    Code of Federal Regulations, 2014 CFR

    2014-10-01

    ... 48 Federal Acquisition Regulations System 1 2014-10-01 2014-10-01 false Manufacturing and... Commercial Organizations 31.205-25 Manufacturing and production engineering costs. (a) The costs of manufacturing and production engineering effort as described in (1) through (4) below are all allowable:...

  7. 48 CFR 31.205-25 - Manufacturing and production engineering costs.

    Code of Federal Regulations, 2013 CFR

    2013-10-01

    ... 48 Federal Acquisition Regulations System 1 2013-10-01 2013-10-01 false Manufacturing and... Commercial Organizations 31.205-25 Manufacturing and production engineering costs. (a) The costs of manufacturing and production engineering effort as described in (1) through (4) below are all allowable:...

  8. Thin film photovoltaic panel and method

    DOEpatents

    Ackerman, Bruce; Albright, Scot P.; Jordan, John F.

    1991-06-11

    A thin film photovoltaic panel includes a backcap for protecting the active components of the photovoltaic cells from adverse environmental elements. A spacing between the backcap and a top electrode layer is preferably filled with a desiccant to further reduce water vapor contamination of the environment surrounding the photovoltaic cells. The contamination of the spacing between the backcap and the cells may be further reduced by passing a selected gas through the spacing subsequent to sealing the backcap to the base of the photovoltaic panels, and once purged this spacing may be filled with an inert gas. The techniques of the present invention are preferably applied to thin film photovoltaic panels each formed from a plurality of photovoltaic cells arranged on a vitreous substrate. The stability of photovoltaic conversion efficiency remains relatively high during the life of the photovoltaic panel, and the cost of manufacturing highly efficient panels with such improved stability is significantly reduced.

  9. Low-cost mirror substrates: manufacturing process evolution

    NASA Astrophysics Data System (ADS)

    Rosala, Francois; Meyer, Michele; Bes de Berc, Jean-Sebastien; Roussel, Andre; Beriot, Emmanuel

    1997-12-01

    In the framework of the Megajoule Laser project driven by the French Atomic Energy Board, one of the most valuable optical programs in term of material volume as well as in term of component size, the actual glasses and production means appear to be inconsistent with the economical objectives. Corning proposed an alternative, based on the use of a low cost glass, together with an evolution of the production process. Combining its experience in quality optical glasses manufacturing and its mastery of forming processes, Corning conducted a production cost reduction program; the objective of this program was to validate the concept of large slab melting (about 2000 kg each), where blocks are cut off, versus the conventional single block (about 100 kg) melting. Economical improvements are based on a reduction of lost time (mold change) and production lead- time by increasing the feeding yield, on a better glass utilization, and a reduced number of molds. The technical issues were: increase the feeding yield maintaining a given glass quality level, reduce the glass allowance, improve the materials of the molds, reinforce the thermal process control, automatism of critical operations, especially at the start-up and at the end of the mold feeding. Despite the long production cycle, about 3 months including melting and annealing, the first results carry the technological options set-up.

  10. Low-cost mirror substrates: manufacturing process evolution

    NASA Astrophysics Data System (ADS)

    Rosala, Francois; Meyer, Michele; Bes de Berc, Jean-Sebastien; Roussel, Andre; Beriot, Emmanuel

    1996-08-01

    In the framework of the megajoule laser project driven by the french atomic energy board, one of the most valuable optical programs in terms of material volume as well as in terms of component size, the actual glasses and production means appear to be inconsistent with the economical objectives. Corning proposed an alternative, based on the use of a low cost glass, together with an evolution of the production process. Combining its experience in quality optical glasses manufacturing and its mastery of forming processes, Corning conducted a production cost reduction program; the objective of this program was to validate the concept of large slab melting, where blocks are cut off, versus the conventional single block melting. Economical improvements are based on a reduction of lost time and production lead-time by increasing the feeding yield, on a better glass utilization, and a reduced number of molds. The technical issues were: increase the feeding yield maintaining a given glass quality level, reduce the glass allowance, improve the materials of the molds, reinforce the thermal process control, automatism of critical operations, especially at the start-up and at the end of the mold feeding.

  11. Low Cost Manufacturing Approach of High Temperature PMC Components

    NASA Technical Reports Server (NTRS)

    Kannmacher, Kevin

    1997-01-01

    The overall objective is to develop a satisfactory sheet molding compound (SMC) of a high temperature polyimide, such as PMR-11-50, VCAP-75, or NB2-76, and to develop compression molding processing parameters for a random, chopped fiber, high temperature, sheet molding compound that will be more affordable than the traditional hand lay-up fabrication methods. Compression molding will reduce manufacturing costs of composites by: (1) minimizing the conventional machining required after fabrication due to the use of full 360 deg matched tooling, (2) reducing fabrication time by minimizing the intensive hand lay-up operations associated with individual ply fabrication techniques, such as ply orientation and ply count and (3) possibly reducing component mold time by advanced B-staging prior to molding. This program is an integral part of Allison's T406/AE engine family's growth plan, which will utilize technologies developed under NASA's Sub-sonic Transport (AST) programs, UHPTET initiatives, and internally through Allison's IR&D projects. Allison is aggressively pursuing this next generation of engines, with both commercial and military applications, by reducing the overall weight of the engine through the incorporation of advanced, lightweight, high temperature materials, such as polymer matrix composites. This infusion of new materials into the engine is also a major factor in reducing engine cost because it permits the use of physically smaller structural components to achieve the same thrust levels as the generation that it replaced. A lighter, more efficient propulsion system translates to a substantial cost and weight savings to an airframe's structure.

  12. The high intensity solar cell: Key to low cost photovoltaic power

    NASA Technical Reports Server (NTRS)

    Sater, B. L.; Goradia, C.

    1975-01-01

    The design considerations and performance characteristics of the 'high intensity' (HI) solar cell are presented. A high intensity solar system was analyzed to determine its cost effectiveness and to assess the benefits of further improving HI cell efficiency. It is shown that residential sized systems can be produced at less than $1000/kW peak electric power. Due to their superior high intensity performance characteristics compared to the conventional and VMJ cells, HI cells and light concentrators may be the key to low cost photovoltaic power.

  13. Low Cost Production of InGaN for Next-Generation Photovoltaic Devices

    SciTech Connect

    Nick M. Sbrockey, Shangzhu Sun, Gary S. Tompa,

    2012-07-09

    The goal of this project is to develop a low-cost and low-energy technology for production of photovoltaic devices based on InGaN materials. This project builds on the ongoing development by Structured Materials Industries (SMI), of novel thin film deposition technology for Group III-Nitride materials, which is capable of depositing Group-III nitride materials at significantly lower costs and significantly lower energy usage compared to conventional deposition techniques. During this project, SMI demonstrated deposition of GaN and InGaN films using metalorganic sources, and demonstrated compatibility of the process with standard substrate materials and hardware components.

  14. 48 CFR 31.205-25 - Manufacturing and production engineering costs.

    Code of Federal Regulations, 2011 CFR

    2011-10-01

    ... 48 Federal Acquisition Regulations System 1 2011-10-01 2011-10-01 false Manufacturing and... ACQUISITION REGULATION GENERAL CONTRACTING REQUIREMENTS CONTRACT COST PRINCIPLES AND PROCEDURES Contracts With Commercial Organizations 31.205-25 Manufacturing and production engineering costs. (a) The costs...

  15. Photovoltaics: New opportunities for utilities

    SciTech Connect

    Not Available

    1991-07-01

    This publication presents information on photovoltaics. The following topics are discussed: Residential Photovoltaics: The New England Experience Builds Confidence in PV; Austin's 300-kW Photovoltaic Power Station: Evaluating the Breakeven Costs; Residential Photovoltaics: The Lessons Learned; Photovoltaics for Electric Utility Use; Least-Cost Planning: The Environmental Link; Photovoltaics in the Distribution System; Photovoltaic Systems for the Rural Consumer; The Issues of Utility-Intertied Photovoltaics; and Photovoltaics for Large-Scale Use: Costs Ready to Drop Again.

  16. TOWARD LOW-COST FABRICATION OF MICROCHANNEL PROCESS TECHNOLOGIES - COST MODELING FOR MANUFACTURING DEVELOPMENT

    SciTech Connect

    Leith, Steven D.; King, Dale A.; Paul, Brian

    2010-11-07

    Chemical and energy conversion systems based on microchannel process technology (MPT) demonstrate high performance in applications in which rates are controlled by diffusive heat and mass transfer flux. The performance of MPT-based heat exchangers, absorbers/desorbers and chemical reactors all benefit from process intensification and have been used in a variety of mobile energy conversion systems including fuel reformers/converters, heat pumps and waste heat scavenging technologies. The service environments typical of MPTs often require the devices to be fabricated from metals such as aluminum, titanium, stainless steel or high temperature super alloys. Flow channels and associated critical dimensions in these devices can be as small as 50 um, but generally range from 100 to 1000 um in width and height with characteristic flow channel lengths normally in the mm to cm range. High surface area architectures (e.g. wicks or textured surfaces) are often included in the flow channels as well for enhanced mass transfer and/or catalytic functionality. Fabrication of MPT devices has historically been performed using a stacked-shim approach in which individual metal sheets are first patterned with micro- and meso-scale flow channels and subsequently bonded in a stack to create an array of miniaturized, parallel flow paths. Typical proof-of-concept fabrication efforts have utilized photo chemical machining (PCM) for shim patterning and diffusion bonding or diffusion brazing for joining of shim stacks. While flexible and capable of supporting technology demonstration, however, these techniques can be expensive at prototyping volumes. The high fabrication cost associated with these prototyping processes has contributed to a perception that MPT technology is expensive and will be relegated to a small application space. Recent work at the Microproducts Breakthrough Institute (MBI) has focused on exploring the cost structure of high volume manufacturing of MPT devices in effort to

  17. Stand-alone flat-plate photovoltaic power systems: System sizing and life-cycle costing methodology for Federal agencies

    NASA Technical Reports Server (NTRS)

    Borden, C. S.; Volkmer, K.; Cochrane, E. H.; Lawson, A. C.

    1984-01-01

    A simple methodology to estimate photovoltaic system size and life-cycle costs in stand-alone applications is presented. It is designed to assist engineers at Government agencies in determining the feasibility of using small stand-alone photovoltaic systems to supply ac or dc power to the load. Photovoltaic system design considerations are presented as well as the equations for sizing the flat-plate array and the battery storage to meet the required load. Cost effectiveness of a candidate photovoltaic system is based on comparison with the life-cycle cost of alternative systems. Examples of alternative systems addressed are batteries, diesel generators, the utility grid, and other renewable energy systems.

  18. Break-Even Cost for Residential Photovoltaics in the United States: Key Drivers and Sensitivities

    SciTech Connect

    Denholm, P.; Margolis, R. M.; Ong, S.; Roberts, B.

    2009-12-01

    Grid parity--or break-even cost--for photovoltaic (PV) technology is defined as the point where the cost of PV-generated electricity equals the cost of electricity purchased from the grid. Break-even cost is expressed in $/W of an installed system. Achieving break-even cost is a function of many variables. Consequently, break-even costs vary by location and time for a country, such as the United States, with a diverse set of resources, electricity prices, and other variables. In this report, we analyze PV break-even costs for U.S. residential customers. We evaluate some key drivers of grid parity both regionally and over time. We also examine the impact of moving from flat to time-of-use (TOU) rates, and we evaluate individual components of the break-even cost, including effect of rate structure and various incentives. Finally, we examine how PV markets might evolve on a regional basis considering the sensitivity of the break-even cost to four major drivers: technical performance, financing parameters, electricity prices and rates, and policies. We find that local incentives rather than ?technical? parameters are in general the key drivers of the break-even cost of PV. Additionally, this analysis provides insight about the potential viability of PV markets.

  19. Photovoltaics

    SciTech Connect

    Deb, S.K.

    1985-01-01

    Photovoltaics, the direct conversion of sunlight into electrical energy, may be the best hope for a relatively clean, secure, and inexhaustible source of energy for the future. To stimulate the growth of this technology as a viable energy supply option, considerable research and development has been directed, in both the private and public sectors, to a variety of materials and devices. The technology has sufficiently matured in recent years to be seriously considered as an alternative to conventional energy sources. Despite phenomenal advances in energy conversion efficiencies, many problems still remain to be solved. It is timely, therefore, to review various technological options available. This review critically assesses the status and promise of this emerging technology by a group of experts, each of whom has presented an extended invited paper on his specific field of expertise. This collection of presentations is intended to be an authoritative review of the technology including its developments, current status, and projections for future direction. The content of this review was carefully chosen to represent most of the leading state-of-the-art technologies; these are divided into four areas: (i) a general overview and discussion of silicon technology; (ii) high efficiency multijunction solar cells; (iii) amorphous silicon solar cells; and (iv) thin film compound semiconductors.

  20. Reliability Research for Photovoltaic Modules

    NASA Technical Reports Server (NTRS)

    Ross, Ronald J., Jr.

    1986-01-01

    Report describes research approach used to improve reliability of photovoltaic modules. Aimed at raising useful module lifetime to 20 to 30 years. Development of cost-effective solutions to module-lifetime problem requires compromises between degradation rates, failure rates, and lifetimes, on one hand, and costs of initial manufacture, maintenance, and lost energy, on other hand. Life-cycle costing integrates disparate economic terms, allowing cost effectiveness to be quantified, allowing comparison of different design alternatives.

  1. Optical Metrology for CIGS Solar Cell Manufacturing and its Cost Implications

    NASA Astrophysics Data System (ADS)

    Sunkoju, Sravan Kumar

    Solar energy is a promising source of renewable energy which can meet the demand for clean energy in near future with advances in research in the field of photovoltaics and cost reduction by commercialization. Availability of a non-contact, in-line, real time robust process control strategies can greatly aid in reducing the gap between cell and module efficiencies, thereby leading to cost-effective large-scale manufacturing of high efficiency CIGS solar cells. In order to achieve proper process monitoring and control for the deposition of the functional layers of CuIn1-xGaxSe 2 (CIGS) based thin film solar cell, optical techniques such as spectroscopic reflectometry and polarimetry are advantageous because they can be set up in an unobtrusive manner in the manufacturing line, and collect data in-line and in-situ. The use of these techniques requires accurate optical models that correctly represent the properties of the layers being deposited. In this study, Spectroscopic ellipsometry (SE) has been applied for the characterization of each individual stage of CIGS layers deposited using the 3-stage co-evaporation process along with the other functional layers. Dielectric functions have been determined for the energy range from 0.7 eV to 5.1 eV. Critical-point line-shape analysis was used in this study to determine the critical point energies of the CIGS based layers. To control the compositional and thickness uniformity of all the functional layers during the fabrication of CIGS solar cells over large areas, multilayer photovoltaics (PV) stack optical models were developed with the help of extracted dielectric functions. In this study, mapping capability of RC2 spectroscopic ellipsometer was used to map all the functional layer thicknesses of a CIGS solar cell in order to probe the spatial non-uniformities that can affect the performance of a cell. The optical functions for each of the stages of CIGS 3-stage deposition process along with buffer layer and transparent

  2. Low-cost photovoltaic inverters incorporating application-specific integrated circuits

    SciTech Connect

    O`Sullivan, G.A.; O`Sullivan, J.A.

    1993-10-01

    The positive impact of designing a power conditioner control system for photovoltaic applications with an application-specific integrated circuit (ASIC) as the main control element was demonstrated with detailed computer simulations in Phase I of a two phase Small Business Innovative Research Grant issued by the US Department of Energy. Completion of the design, building and testing of three prototypes using different power semiconductors was successfully accomplished in Phase II. The power rating for the residential utility intertied Sunverters Model 753-4-200 is 5 kW. A stand-alone inverter suitable for operation from a photovoltaic array with or without a battery for energy storage was also developed in this effort. A much needed intermediate power level 50-kW three-phase power conditioner, Sunverter Model 759-4-200, was the third product to evolve from the research and development. All designs take advantage of the ASIC and a complementary microprocessor sampled-data control system. The ASIC-controlled power conditioners provide the high reliability, high efficiency, and low cost needed for photovoltaic applications. They cover the power range from the residential level to utility-sized installations.

  3. Low-Cost, Class D Testing of Spacecraft Photovoltaic Systems Can Reduce Risk

    NASA Technical Reports Server (NTRS)

    Forgione, Joshua B.; Kojima, Gilbert K.; Hanel, Robert; Mallinson, Mark

    2014-01-01

    The end-to-end verification of a spacecraft photovoltaic power generation system requires light! A lowcost, portable, and end-to-end photovoltaic-system test appropriate for NASA's new generation of Class D missions is presented. High risk, low-cost, and quick-turn satellites rarely have the resources to execute the traditional approaches from higher-class (A-C) missions. The Class D approach, as demonstrated on the Lunar Atmospheric and Dust Environment Explorer (LADEE), utilizes a portable, metalhalide, theatre lamp for an end-to-end photovoltaic system test. While not as precise and comprehensive as the traditional Large Area Pulsed Solar Simulator (LAPSS) test, the LADEE method leverages minimal resources into an ongoing assessment program that can be applied through numerous stages of the mission. The project takes a true Class D approach in assessing the technical value of a costly, highfidelity performance test versus a simpler approach with less programmatic risk. The resources required are a fraction of that for a LAPSS test, and is easy to repeat due to its portability. Further, the test equipment can be handed down to future projects without building an on-site facility. At the vanguard of Class D missions, the LADEE team frequently wrestled with and challenged the status quo. The philosophy of risk avoidance at all cost, typical to Class A-C missions, simply could not be executed. This innovative and simple testing solution is contextualized to NASA Class D programs and a specific risk encountered during development of the LADEE Electrical Power System (EPS). Selection of the appropriate lamp and safety concerns are discussed, with examples of test results. Combined with the vendor's panellevel data and periodic inspection, the method ensures system integrity from Integration and Test (I&T) through launch. Following launch, mission operations tools are utilized to assess system performance based on a scant amount of available data.

  4. Manufacturing of Monolithic Electrodes from Low-Cost Renewable Resources

    SciTech Connect

    McNutt, Nichiolas William; Rios, Orlando; Johs, Alexander; Tenhaeff, Wyatt E; Chatterjee, Sabornie; Keffer, David

    2014-01-01

    Lignin, a low-cost, biomass derived precursor, was selected as an alternative for carbon based free standing anodes in Li-ion batteries. Industrially scalable melt-spinning and melt-blowing synthesis methods were developed at Oak Ridge National Laboratory that are compatible with industrially viable production. Engineering studies predict that LCFs can be manufactured at $3/lb using these technologies, which compares favorably to $12/lb for battery grade graphite. The physical properties of lignin carbon fibers, specifically the tunable electrochemical and thermal transport, are suitable for energy storage applications as both an active material and current collector. The elimination of inactive components in the slurry-coated electrodes was enabled by LCF processing parameters modifications to produce monolithic mats in which the fibers are electrically interconnected. These mats were several hundreds of micrometers thick, and the fibers functioned as both current collector and active material by virtue of their mixed ionic/electronic conductivities. The LCFs were coated onto copper current collectors with PVDF binder and conductive carbon additive through conventional slurry processing. Galvanostatic cycling of the LCFs against Li revealed reversible capacities greater than 300 mAh/g. The coulombic efficiencies were over 99.8%. The mats were galvanostatically cycled in half cells against Li. Specific capacities as high as 250 mAh/g were achieved approximately 17% lower than the capacities of the same fibers in slurries. However, there were no inactive materials reducing the practical specific capacity of the entire electrode construction. Lithiation and delithiation of the LCFs proceeded with coulombic efficiencies greater than 99.9%, and the capacity retention was greater than 99% over 100 cycles at a rate of 15 mA/g. Research sponsored by the Laboratory Directed Research and Development Program of Oak Ridge National Laboratory, managed by UT-Battelle, LLC, for

  5. A reliable, fast and low cost maximum power point tracker for photovoltaic applications

    SciTech Connect

    Enrique, J.M.; Andujar, J.M.; Bohorquez, M.A.

    2010-01-15

    This work presents a new maximum power point tracker system for photovoltaic applications. The developed system is an analog version of the ''P and O-oriented'' algorithm. It maintains its main advantages: simplicity, reliability and easy practical implementation, and avoids its main disadvantages: inaccurateness and relatively slow response. Additionally, the developed system can be implemented in a practical way at a low cost, which means an added value. The system also shows an excellent behavior for very fast variables in incident radiation levels. (author)

  6. The silicon concentrator photovoltaic generator Sophocles - Performance and costs based on material characteristics

    NASA Astrophysics Data System (ADS)

    Esteve, D.; Vialaret, G.; Therez, F.

    1981-08-01

    The purpose of this paper is to show that, in the short term, a solution can be found to enable the immediate exploitation of concentrator photovoltaic systems. The technical requirements, tracking system, optical system and thermal dissipation necessary for concentrator generators are described. A description of the prototype generator 'Sophocles' is presented. The results of various experiments are given. Finally, the prospects of reductions in cost for a concentrator generator using a higher concentration ratio and more efficient solar cells, which can lead to a price of $4/W(p) if all expenses are taken into account, are reviewed.

  7. V1.6 Development of Advanced Manufacturing Technologies for Low Cost Hydrogen Storage Vessels

    SciTech Connect

    Leavitt, Mark; Lam, Patrick; Nelson, Karl M.; johnson, Brice A.; Johnson, Kenneth I.; Alvine, Kyle J.; Ruiz, Antonio; Adams, Jesse

    2012-10-01

    The goal of this project is to develop an innovative manufacturing process for Type IV high-pressure hydrogen storage vessels, with the intent to significantly lower manufacturing costs. Part of the development is to integrate the features of high precision AFP and commercial FW. Evaluation of an alternative fiber to replace a portion of the baseline fiber will help to reduce costs further.

  8. Progress on photovoltaic technologies

    SciTech Connect

    Maycock, P.

    1985-01-01

    This chapter presents the state of the art of photovoltaics, both economic and technological, using 15 tables of data to augment the text. The tables are entitled: (1) World PV Module Shipments; (2) 1984 World Market End-Use Sectors (MW); (3) World PV Module Shipments by Module Type; (4) US PV Module Shipments by Company; (5) US PV Module Shipments by Application; (6) Summary of Technology/Cost for Key Silicon-Based Options (1984 $); (7) Single-Crystal Cells: Manufacturing Process and Costs; (8) Manufactured cost per Watt (10% Module): US 5MWp; (9) Manufactured Cost per Watt (13% Modules): Hoxan 9MW; (10) Single-Crystal Technology Forecast; (11) Concentrators: 1985, 1990, 1995; (12) Si Ribbon: 1985, 1990, 1995; (13) Polysilicon: 1985, 1990, 1995; (14) Amorphous Si: 1985, 1990, 1995; (15) Option: No. of Professionals. Technology and cost forecasts, as well as R and D are included for all pertinent areas. 15 tables.

  9. Manufacturing High-Quality Carbon Nanotubes at Lower Cost

    NASA Technical Reports Server (NTRS)

    Benavides, Jeanette M.; Lidecker, Henning

    2004-01-01

    A modified electric-arc welding process has been developed for manufacturing high-quality batches of carbon nanotubes at relatively low cost. Unlike in some other processes for making carbon nanotubes, metal catalysts are not used and, consequently, it is not necessary to perform extensive cleaning and purification. Also, unlike some other processes, this process is carried out at atmospheric pressure under a hood instead of in a closed, pressurized chamber; as a result, the present process can be implemented more easily. Although the present welding-based process includes an electric arc, it differs from a prior electric-arc nanotube-production process. The welding equipment used in this process includes an AC/DC welding power source with an integral helium-gas delivery system and circulating water for cooling an assembly that holds one of the welding electrodes (in this case, the anode). The cathode is a hollow carbon (optionally, graphite) rod having an outside diameter of 2 in. (approximately equal to 5.1 cm) and an inside diameter of 5/8 in. (approximately equal to 1.6 cm). The cathode is partly immersed in a water bath, such that it protrudes about 2 in. (about 5.1 cm) above the surface of the water. The bottom end of the cathode is held underwater by a clamp, to which is connected the grounding cable of the welding power source. The anode is a carbon rod 1/8 in. (approximately equal to 0.3 cm) in diameter. The assembly that holds the anode includes a thumbknob- driven mechanism for controlling the height of the anode. A small hood is placed over the anode to direct a flow of helium downward from the anode to the cathode during the welding process. A bell-shaped exhaust hood collects the helium and other gases from the process. During the process, as the anode is consumed, the height of the anode is adjusted to maintain an anode-to-cathode gap of 1 mm. The arc-welding process is continued until the upper end of the anode has been lowered to a specified height

  10. Amorphous silicon photovoltaic manufacturing technology - Phase 2A. Annual subcontract report, May 1, 1993--April 30, 1994

    SciTech Connect

    Duran, G.; Mackamul, K.; Metcalf, D.

    1995-01-01

    Utility Power Group (UPG), and its lower-tier subcontractor, Advanced Photovoltaic Systems, Inc. (APS) have conducted efforts in developing their manufacturing lines. UPG has focused on the automation of encapsulation and termination processes developed in Phase I. APS has focused on completion of the encapsulation and module design tasks, while continuing the process and quality control and automation projects. The goal is to produce 55 watt (stabilized) EP50 modules in a new facility. In the APS Trenton EUREKA manufacturing facility, APS has: (1) Developed high throughput lamination procedures; (2) Optimized existing module designs; (3) Developed new module designs for architectural applications; (4) Developed enhanced deposition parameter control; (5) Designed equipment required to manufacture new EUREKA modules developed during Phase II; (6) Improved uniformity of thin-film materials deposition; and (7) Improved the stabilized power output of the APS EP50 EUREKA module to 55 watts. In the APS Fairfield EUREKA manufacturing facility, APS has: (1) Introduced the new products developed under Phase I into the APS Fairfield EUREKA module production line; (2) Increased the extent of automation in the production line; (3) Introduced Statistical Process Control to the module production line; and (4) Transferred-progress made in the APS Trenton facility into the APS Fairfield facility.

  11. Methods and apparatus for manufacturing monocrystalline cast silicon and monocrystalline cast silicon bodies for photovoltaics

    DOEpatents

    Stoddard, Nathan G

    2014-01-14

    Methods and apparatuses are provided for casting silicon for photovoltaic cells and other applications. With such methods and apparatuses, a cast body of monocrystalline silicon may be formed that is free of, or substantially free of, radially-distributed impurities and defects and having at least two dimensions that are each at least about 35 cm is provided.

  12. Methods and apparatuses for manufacturing monocrystalline cast silicon and monocrystalline cast silicon bodies for photovoltaics

    DOEpatents

    Stoddard, Nathan G.

    2011-11-01

    Methods and apparatuses are provided for casting silicon for photovoltaic cells and other applications. With such methods and apparatuses, a cast body of monocrystalline silicon may be formed that is free of, or substantially free of, radially-distributed impurities and defects and having at least two dimensions that are each at least about 35 cm is provided.

  13. Evaluation available encapsulation materials for low-cost long-life silicon photovoltaic arrays

    NASA Technical Reports Server (NTRS)

    Carmichael, D. C.; Gaines, G. B.; Noel, G. T.; Sliemers, F. A.; Nance, G. P.; Bunk, A. R.; Brockway, M. C.

    1978-01-01

    Experimental evaluation of selected encapsulation designs and materials based on an earlier study which have potential for use in low cost, long-life photovoltaic arrays are reported. The performance of candidate materials and encapsulated cells were evaluated principally for three types of encapsulation designs based on their potentially low materials and processing costs: (1) polymeric coatings, transparent conformal coatings over the cell with a structural-support substrate; (2) polymeric film lamination, cells laminated between two films or sheets of polymeric materials; and (3) glass-covered systems, cells adhesively bonded to a glass cover (superstrate) with a polymeric pottant and a glass or other substrate material. Several other design types, including those utilizing polymer sheet and pottant materials, were also included in the investigation.

  14. Commercial/industrial photovoltaic module and array requirement study. Low-cost solar array project engineering area

    NASA Technical Reports Server (NTRS)

    1981-01-01

    Design requirements for photovoltaic modules and arrays used in commercial and industrial applications were identified. Building codes and referenced standards were reviewed for their applicability to commercial and industrial photovoltaic array installation. Four general installation types were identified - integral (replaces roofing), direct (mounted on top of roofing), stand-off (mounted away from roofing), and rack (for flat or low slope roofs, or ground mounted). Each of the generic mounting types can be used in vertical wall mounting systems. This implies eight mounting types exist in the commercial/industrial sector. Installation costs were developed for these mounting types as a function of panel/module size. Cost drivers were identified. Studies were performed to identify optimum module shapes and sizes and operating voltage cost drivers. The general conclusion is that there are no perceived major obstacles to the use of photovoltaic modules in commercial/industrial arrays.

  15. Economic Competitiveness of U.S. Utility-Scale Photovoltaics Systems in 2015: Regional Cost Modeling of Installed Cost ($/W) and LCOE ($/kWh)

    SciTech Connect

    Fu, Ran; James, Ted L.; Chung, Donald; Gagne, Douglas; Lopez, Anthony; Dobos, Aron

    2015-06-14

    Utility-scale photovoltaics (PV) system growth is largely driven by the economic metrics of total installed costs and levelized cost of electricity (LCOE), which differ by region. This study details regional cost factors, including environment (wind speed and snow loads), labor costs, material costs, sales taxes, and permitting costs using a new system-level bottom-up cost modeling approach. We use this model to identify regional all-in PV installed costs for fixed-tilt and one-axis tracker systems in the United States with consideration of union and non-union labor costs in 2015. LCOEs using those regional installed costs are then modeled and spatially presented. Finally, we assess the cost reduction opportunities of increasing module conversion efficiencies on PV system costs in order to indicate the possible economic impacts of module technology advancements and help future research and development (R&D) effects in the context of U.S. SunShot targets.

  16. A database prototype has been developed to help understand costs in photovoltaic systems

    SciTech Connect

    MOORE,LARRY M.

    2000-04-11

    High photovoltaic (PV) system costs hinder market growth. An approach to studying these costs has been developed using a database containing system, component and maintenance information. This data, which is both technical and non-technical in nature, is to be used to identify trends related to costs. A pilot database exists at this time and work is continuing. The results of this work may be used by the data owners to improve their operations with the goal of sharing non-attributable information with the public and industry at large. The published objectives of the DOE PV program are to accelerate the development of PV as a national and global energy option, as well as ensure US technology and global market leadership. The approach to supporting these objectives is to understand what drives costs in PV applications. This paper and poster session describe work-in-progress in the form of a database that will help identify costs in PV systems. In an effort to address DOE's Five-Year PV Milestones, a program was established in the summer of 1999 to study system costs in three PV applications--solar home lighting, water pumping, and grid-tied systems. This work began with a RFQ requesting data from these types of systems. Creating a partnership with industry and other system organizations such as Non-Government Organizations (NGOs) was the approach chosen to maintain a close time to the systems in the field. Nine participants were selected as partners, who provided data on their systems. Two activities are emphasized in this work. For the first, an iterative approach of developing baseline reliability and costs information with the participants was taken. This effort led to identifying typical components in these systems as well as the specific data (metrics) that would be needed in any analysis used to understand total systems costs.

  17. Development and Manufacture of Cost-Effective Composite Drill Pipe

    SciTech Connect

    James C. Leslie

    2008-12-31

    Advanced Composite Products and Technology, Inc. (ACPT) has developed composite drill pipe (CDP) that matches the structural and strength properties of steel drill pipe, but weighs less than 50 percent of its steel counterpart. Funding for the multiyear research and development of CDP was provided by the U.S. Department of Energy Office of Fossil Energy through the Natural Gas and Oil Projects Management Division at the National Energy Technology Laboratory (NETL). Composite materials made of carbon fibers and epoxy resin offer mechanical properties comparable to steel at less than half the weight. Composite drill pipe consists of a composite material tube with standard drill pipe steel box and pin connections. Unlike metal drill pipe, composite drill pipe can be easily designed, ordered, and produced to meet specific requirements for specific applications. Because it uses standard joint connectors, CDP can be used in lieu of any part of or for the entire steel drill pipe section. For low curvature extended reach, deep directional drilling, or ultra deep onshore or offshore drilling, the increased strength to weight ratio of CDP will increase the limits in all three drilling applications. Deceased weight will reduce hauling costs and increase the amount of drill pipe allowed on offshore platforms. In extreme extended reach areas and high-angle directional drilling, drilling limits are associated with both high angle (fatigue) and frictional effects resulting from the combination of high angle curvature and/or total weight. The radius of curvature for a hole as small as 40 feet (12.2 meters) or a build rate of 140 degrees per 100 feet is within the fatigue limits of specially designed CDP. Other properties that can be incorporated into the design and manufacture of composite drill pipe and make it attractive for specific applications are corrosion resistance, non-magnetic intervals, and abrasion resistance coatings. Since CDP has little or no electromagnetic force

  18. Cost-effective applications of photovoltaics for electric utilities: An overview

    SciTech Connect

    Bigger, J.E.

    1993-12-31

    Cost targets for the large-scale entry of photovoltaic (PV) systems keep moving, subject to the vagaries of global oil prices and the economic health of the world. Over the last four decades since a practical PV device was announced, costs have come down by a factor of 20 or more and this downward trend is expected to continue, albeit at a slower pace. Simultaneously, conversion efficiencies have nearly tripled. There are many applications today for which PV is cost-effective. In recognition of this, utility interest in PV is increasing and this is manifested by projects such as PVUSA and Central and South West`s renewable resource development effort. While no major technical barriers for the entry of PV systems have been uncovered, several key issues such as power quality, system reliability, ramp rates, spinning reserve requirements, and misoperation of protection schemes will have to be dealt with as the penetration of this technology increases. PV is still in the evolutionary phase and is expected to grow for several decades to come. Fueled by environmental considerations, interest in PV is showing a healthy rise both in the minds of the public and in the planning realms of the electric power community. In recognition of this, the Energy Development Subcommittee of the IEEE Energy Development and Power Generation Committee organized a Panel Session on photovoltaics applications at the 1993 International Joint Power Generation Conference held in Kansas City, Missouri. Summaries of the four presentations are assembled here for the benefit of the readers of this Review.

  19. Reliability and cost evaluation of small isolated power systems containing photovoltaic and wind energy

    NASA Astrophysics Data System (ADS)

    Karki, Rajesh

    Renewable energy application in electric power systems is growing rapidly worldwide due to enhanced public concerns for adverse environmental impacts and escalation in energy costs associated with the use of conventional energy sources. Photovoltaics and wind energy sources are being increasingly recognized as cost effective generation sources. A comprehensive evaluation of reliability and cost is required to analyze the actual benefits of utilizing these energy sources. The reliability aspects of utilizing renewable energy sources have largely been ignored in the past due the relatively insignificant contribution of these sources in major power systems, and consequently due to the lack of appropriate techniques. Renewable energy sources have the potential to play a significant role in the electrical energy requirements of small isolated power systems which are primarily supplied by costly diesel fuel. A relatively high renewable energy penetration can significantly reduce the system fuel costs but can also have considerable impact on the system reliability. Small isolated systems routinely plan their generating facilities using deterministic adequacy methods that cannot incorporate the highly erratic behavior of renewable energy sources. The utilization of a single probabilistic risk index has not been generally accepted in small isolated system evaluation despite its utilization in most large power utilities. Deterministic and probabilistic techniques are combined in this thesis using a system well-being approach to provide useful adequacy indices for small isolated systems that include renewable energy. This thesis presents an evaluation model for small isolated systems containing renewable energy sources by integrating simulation models that generate appropriate atmospheric data, evaluate chronological renewable power outputs and combine total available energy and load to provide useful system indices. A software tool SIPSREL+ has been developed which generates

  20. Design and modeling of a cost-effective achromatic Fresnel lens for concentrating photovoltaics.

    PubMed

    Vallerotto, Guido; Victoria, Marta; Askins, Stephen; Herrero, Rebeca; Domínguez, César; Antón, Ignacio; Sala, Gabriel

    2016-09-01

    This paper presents a novel Fresnel lens capable of significantly reducing chromatic aberration in solar applications. The optical performance of this achromatic lens has been analyzed through ray-tracing simulations, showing a concentration factor three times higher than that attained by a classic silicone on glass (SOG) Fresnel lens while maintaining the same acceptance angle. This should avoid the need for a secondary optical element, reducing the cost associated with its manufacturing and assembly and increasing the module reliability. The achromatic lens is made of inexpensive plastic and elastomer which allows a highly scalable and cost-competitive manufacturing process similar to the one currently used for the fabrication of SOG Fresnel lenses. PMID:27607727

  1. A photovoltaic industry overview - The results of a survey on photovoltaic technology industrialization

    NASA Technical Reports Server (NTRS)

    Ferber, R. R.; Costogue, E. N.; Thornhill, J. W.; Shimada, K.

    1981-01-01

    The National Photovoltaics Program of the United States Department of Energy has the objective of bringing photovoltaic power systems to a point where they can supply a significant portion of the United States energy requirements by the year 2000. This is planned to be accomplished through substantial research and technology development activities aimed at achieving major cost reductions and market penetration. This paper presents information derived from a limited survey performed to obtain photovoltaic industry attitudes concerning industrialization, and to determine current industry plans to meet the DOE program goals. Silicon material production, a key photovoltaic manufacturing industry, is highlighted with regards to implementation of technology improvement and silicon material supply outlook.

  2. Manufacturing costs for planar solid oxide fuel cells

    SciTech Connect

    Krist, K.; Wright, J.D.; Romero, C.

    1995-12-31

    In this paper the authors calculate how much one can afford to pay for a fuel cell, and set quantitative performance and cost targets that if met, will result in SOFC technology where the performance is high enough and the cost is low enough to generate commercial interest. To do this, the authors first calculate how much one can afford to pay for a fuel cell stack in two important applications: small scale cogeneration (200 kW{sub e}) and large scale power generation (50 MW{sub e}). They then compare the cost of the materials needed to fabricate the fuel cell with the allowable cost. Finally, they use a mathematical model of fuel cell performance to quantify some of the improvements that will be needed if planar fuel cells are to operate efficiently at 800 C or below.

  3. Cost and surface optimization of a remote photovoltaic system for two kinds of panels' technologies

    NASA Astrophysics Data System (ADS)

    Avril, S.; Arnaud, G.; Colin, H.; Montignac, F.; Mansilla, C.; Vinard, M.

    2011-10-01

    Stand alone photovoltaic (PV) systems comprise one of the promising electrification solutions to cover the demand of remote consumers, especially when it is coupled with a storage solution that would both increase the productivity of power plants and reduce the areas dedicated to energy production. This short communication presents a multi-objective design of a remote PV system coupled to battery and hydrogen storages systems simultaneously minimizing the total levelized cost and the occupied area, while fulfilling a constraint of consumer satisfaction. For this task, a multi-objective code based on particle swarm optimization has been used to find the best combination of different energy devices. Both short and mid terms based on forecasts assumptions have been investigated. An application for the site of La Nouvelle in the French overseas island of La Réunion is proposed. It points up a strong cost advantage by using Heterojunction with Intrinsic Thin layer (HIT) rather than crystalline silicon (c-Si) cells for the short term. However, the discrimination between these two PV cell technologies is less obvious for the mid term: a strong constraint on the occupied area will promote HIT, whereas a strong constraint on the cost will promote c-Si.

  4. Photovoltaics: Reviewing the European Feed-in-Tariffs and Changing PV Efficiencies and Costs

    PubMed Central

    Zhang, H. L.; Van Gerven, T.; Baeyens, J.; Degrève, J.

    2014-01-01

    Feed-in-Tariff (FiT) mechanisms have been important in boosting renewable energy, by providing a long-term guaranteed subsidy of the kWh-price, thus mitigating investment risks and enhancing the contribution of sustainable electricity. By ongoing PV development, the contribution of solar power increases exponentially. Within this significant potential, it is important for investors, operators, and scientists alike to provide answers to different questions related to subsidies, PV efficiencies and costs. The present paper therefore (i) briefly reviews the mechanisms, advantages, and evolution of FiT; (ii) describes the developments of PV, (iii) applies a comprehensive literature-based model for the solar irradiation to predict the PV solar energy potential in some target European countries, whilst comparing output predictions with the monthly measured electricity generation of a 57 m² photovoltaic system (Belgium); and finally (iv) predicts the levelized cost of energy (LCOE) in terms of investment and efficiency, providing LCOE values between 0.149 and 0.313 €/kWh, as function of the overall process efficiency and cost. The findings clearly demonstrate the potential of PV energy in Europe, where FiT can be considerably reduced or even be eliminated in the near future. PMID:24959614

  5. Photovoltaics: reviewing the European Feed-in-Tariffs and changing PV efficiencies and costs.

    PubMed

    Zhang, H L; Van Gerven, T; Baeyens, J; Degrève, J

    2014-01-01

    Feed-in-Tariff (FiT) mechanisms have been important in boosting renewable energy, by providing a long-term guaranteed subsidy of the kWh-price, thus mitigating investment risks and enhancing the contribution of sustainable electricity. By ongoing PV development, the contribution of solar power increases exponentially. Within this significant potential, it is important for investors, operators, and scientists alike to provide answers to different questions related to subsidies, PV efficiencies and costs. The present paper therefore (i) briefly reviews the mechanisms, advantages, and evolution of FiT; (ii) describes the developments of PV, (iii) applies a comprehensive literature-based model for the solar irradiation to predict the PV solar energy potential in some target European countries, whilst comparing output predictions with the monthly measured electricity generation of a 57 m² photovoltaic system (Belgium); and finally (iv) predicts the levelized cost of energy (LCOE) in terms of investment and efficiency, providing LCOE values between 0.149 and 0.313 €/kWh, as function of the overall process efficiency and cost. The findings clearly demonstrate the potential of PV energy in Europe, where FiT can be considerably reduced or even be eliminated in the near future. PMID:24959614

  6. Analysis of the influence of advanced materials for aerospace products R&D and manufacturing cost

    NASA Astrophysics Data System (ADS)

    Shen, A. W.; Guo, J. L.; Wang, Z. J.

    2015-12-01

    In this paper, we pointed out the deficiency of traditional cost estimation model about aerospace products Research & Development (R&D) and manufacturing based on analyzing the widely use of advanced materials in aviation products. Then we put up with the estimating formulas of cost factor, which representing the influences of advanced materials on the labor cost rate and manufacturing materials cost rate. The values ranges of the common advanced materials such as composite materials, titanium alloy are present in the labor and materials two aspects. Finally, we estimate the R&D and manufacturing cost of F/A-18, F/A- 22, B-1B and B-2 aircraft based on the common DAPCA IV model and the modified model proposed by this paper. The calculation results show that the calculation precision improved greatly by the proposed method which considering advanced materials. So we can know the proposed method is scientific and reasonable.

  7. Cost savings for manufacturing lithium batteries in a flexible plant

    NASA Astrophysics Data System (ADS)

    Nelson, Paul A.; Ahmed, Shabbir; Gallagher, Kevin G.; Dees, Dennis W.

    2015-06-01

    The flexible plant postulated in this study would produce four types of batteries for electric-drive vehicles - a hybrid (HEV), 10-mile range and 40-mile range plug-in hybrids (PHEV), and a 150-mile range battery-electric (EV). The annual production rate of the plant is 235,000 battery packs (HEV: 100,000; PHEV10: 60,000; PHEV40: 45,000; EV: 30,000). The cost savings per battery pack calculated with the Argonne BatPaC model for this flex plant vs. dedicated plants range from 9% for the EV battery packs to 21% for the HEV packs including the battery management systems (BMS). The investment cost savings are even larger, ranging from 21% for EVs to 43% for HEVs. The costs of the 1.0-kWh HEV batteries are projected to approach 714 per unit and that of the EV batteries to approach 188 per kWh with the most favorable cell chemistries. The best single indicator of the cost of producing lithium-manganate spinel/graphite batteries in a flex plant is the total cell area of the battery. For the four batteries studied, the price range is 20-24 per m2 of cell area, averaging 21 per m2 for the entire flex plant.

  8. Manufacturing and cost analyses of heliostats based on the second-generation heliostat-development study

    NASA Astrophysics Data System (ADS)

    Norris, H. F., Jr.; White, S. S.

    1982-12-01

    The manufacturing processes and users' costs were analyzed for the second generation heliostats. Mass production scenarios are examined by comparison and manufacturing analysis, including facility site selection and design, operations, equipment and tooling, and labor. Different transportation scenarios are compared, as are the site assembly and installation procedures. Users' costs are allocated to the central manufacturing facility, to transportation from the central manufacturing facility to the field, and to the field sites. Costs are compared for the major components: reflective assembly, drive mechanism, controls and field wiring, foundation/pedestal, and support structure. Breakdowns are given for direct materials, direct labor, and other expenses including an estimate of the gross profit. A contractor estimated capital price to the utility for each heliostat design and estimated operations and maintenance expenses are shown.

  9. In situ optical diagnostic for monitoring or control of sodium diffusion in photovoltaics manufacturing

    SciTech Connect

    Li, Jian; Levi, Dean; Contreras, Miguel; Glynn, Stephen

    2015-09-15

    A method of fabricating a photovoltaic device 100, includes the steps of providing a glass substrate 102, depositing a molybdenum layer 104 on a surface of the glass substrate, directing light through the glass substrate to the near-substrate region of the molybdenum layer 206, detecting an optical property of the near-substrate region of the molybdenum layer after interaction with the incident light 208 and determining a density of the near-substrate region of the molybdenum layer from the detected optical property 210. A molybdenum deposition parameter may be controlled based upon the determined density of the near-substrate region of the molybdenum layer 218. A non-contact method measures a density of the near-substrate region of a molybdenum layer and a deposition chamber 300.

  10. Space system production cost benefits from contemporary philosophies in management and manufacturing

    NASA Technical Reports Server (NTRS)

    Rosmait, Russell L.

    1991-01-01

    The cost of manufacturing space system hardware has always been expensive. The Engineering Cost Group of the Program Planning office at Marshall is attempting to account for cost savings that result from new technologies in manufacturing and management. The objective is to identify and define contemporary philosophies in manufacturing and management. The seven broad categories that make up the areas where technological advances can assist in reducing space system costs are illustrated. Included within these broad categories is a list of the processes or techniques that specifically provide the cost savings within todays design, test, production and operations environments. The processes and techniques listed achieve savings in the following manner: increased productivity; reduced down time; reduced scrap; reduced rework; reduced man hours; and reduced material costs. In addition, it should be noted that cost savings from production and processing improvements effect 20 to 40 pct. of production costs whereas savings from management improvements effects 60 to 80 of production cost. This is important because most efforts in reducing costs are spent trying to reduce cost in the production.

  11. DEVELOPMENT AND MANUFACTURE OF COST EFFECTIVE COMPOSITE DRILL PIPE

    SciTech Connect

    Dr. James C. Leslie; Mr. Jeffrey R. Jean; Hans Neubert; Lee Truong

    2000-10-30

    This annual, technical report will discuss the engineering research and data accomplishments that have transpired in support of the development of Cost Effective Composite Drill Pipe (CDP). The report discusses and illustrates the first iteration design of the tube and the tool joint interface. The report discusses standards and specifications to which the CDP design will be tailored and tested, and discusses conclusions of the first iteration design for future design enhancements.

  12. Development and Manufacture of Cost Effective Composite Drill Pipe

    SciTech Connect

    James C. Leslie; James C. Leslie, II; Lee Truong; James T. Heard

    2006-09-29

    This technical report presents the engineering research, process development and data accomplishments that have transpired to date in support of the development of Cost Effective Composite Drill Pipe (CDP). The report presents progress made from October 1, 2005 through September 30, 2006 and contains the following discussions: Qualification Testing; Prototype Development and Testing of ''Smart Design'' Configuration; Field Test Demonstration; Development of Ultra-Short Radius Composite Drill Pipe (USR-CDP); and Development of Smart USR-CDP.

  13. Validated Feasibility Study of Integrally Stiffened Metallic Fuselage Panels for Reducing Manufacturing Costs

    NASA Technical Reports Server (NTRS)

    Pettit, R. G.; Wang, J. J.; Toh, C.

    2000-01-01

    The continual need to reduce airframe cost and the emergence of high speed machining and other manufacturing technologies has brought about a renewed interest in large-scale integral structures for aircraft applications. Applications have been inhibited, however, because of the need to demonstrate damage tolerance, and by cost and manufacturing risks associated with the size and complexity of the parts. The Integral Airframe Structures (IAS) Program identified a feasible integrally stiffened fuselage concept and evaluated performance and manufacturing cost compared to conventional designs. An integral skin/stiffener concept was produced both by plate hog-out and near-net extrusion. Alloys evaluated included 7050-T7451 plate, 7050-T74511 extrusion, 6013-T6511 extrusion, and 7475-T7351 plate. Mechanical properties, structural details, and joint performance were evaluated as well as repair, static compression, and two-bay crack residual strength panels. Crack turning behavior was characterized through panel tests and improved methods for predicting crack turning were developed. Manufacturing cost was evaluated using COSTRAN. A hybrid design, made from high-speed machined extruded frames that are mechanically fastened to high-speed machined plate skin/stringer panels, was identified as the most cost-effective manufacturing solution. Recurring labor and material costs of the hybrid design are up to 61 percent less than the current technology baseline.

  14. Development and Manufacture of Cost Effective Composite Drill Pipe

    SciTech Connect

    James C. Leslie; James C. Leslie II; Lee Truong; James T. Heard; Steve Loya

    2006-02-20

    This technical report presents the engineering research, process development and data accomplishments that have transpired to date in support of the development of Cost Effective Composite Drill Pipe (CDP). The report presents progress made from October 1, 2004 through September 30, 2005 and contains the following discussions: (1) Qualification Testing; (2) Prototype Development and Testing of ''Smart Design'' Configuration; (3) Field Test Demonstration; and (4) Commercial order for SR-CDP from Torch International. The objective of this contract is to develop and demonstrate ''cost effective'' Composite Drill Pipe. It is projected that this drill pipe will weigh less than half of its steel counter part. The resultant weight reduction will provide enabling technology that will increase the lateral distance that can be reached from an offshore drilling platform and the depth of water in which drilling and production operations can be carried out. Further, composite drill pipe has the capability to carry real time signal and power transmission within the pipe walls. CDP can also accommodate much shorter drilling radius than is possible with metal drill pipe. As secondary benefits, the lighter weight drill pipe can increase the storage capability of floating off shore drilling platforms and provide substantial operational cost savings.

  15. Silicon-Film{trademark} photovoltaic manufacturing technology. Annual subcontract report, 15 November 1992--15 October 1993

    SciTech Connect

    Collins, S.R.; Hall, R.B.

    1994-06-01

    The goal of this project is to develop an advanced, low-cost manufacturing process for a new utility-scale, flat-plate module. The program has three main components: development of a Silicon-Film{trademark} (S-F) wafer machine that is capable of manufacturing wafers that are 225 cm{sup 2} in size with a total product cost reduction of 70%; development of an advanced solar cell manufacturing process that is capable of turning the wafer into a 14% efficient solar cell; and development of an advanced module design based on these large area, efficient silicon solar cells with an average power of 170 watts for 56 solar cells and 113 watts for 36 solar cells. During Phase 2, AstroPower made significant advances in improving S-F material quality and device performance. Advances were made in developing the prototype machines and processes toward reliable manufacturing counterparts. The following key achievements in Phase 2 are detailed: demonstration of a truly continuous production mode S-F machine; demonstration of a 2.5 watt, 15 cm by 15 cm solar cell; and demonstration of a 78 watt module fabricated from 36, 15 cm by 15 cm S-F solar cells.

  16. Utilization of UV Curing Technology to Significantly Reduce the Manufacturing Cost of LIB Electrodes

    SciTech Connect

    Voelker, Gary; Arnold, John

    2015-11-30

    Previously identified novel binders and associated UV curing technology have been shown to reduce the time required to apply and finish electrode coatings from tens of minutes to less than one second. This revolutionary approach can result in dramatic increases in process speeds, significantly reduced capital (a factor of 10 to 20) and operating costs, reduced energy requirements, and reduced environmental concerns and costs due to the virtual elimination of harmful volatile organic solvents and associated solvent dryers and recovery systems. The accumulated advantages of higher speed, lower capital and operating costs, reduced footprint, lack of VOC recovery, and reduced energy cost is a reduction of 90% in the manufacturing cost of cathodes. When commercialized, the resulting cost reduction in Lithium batteries will allow storage device manufacturers to expand their sales in the market and thereby accrue the energy savings of broader utilization of HEVs, PHEVs and EVs in the U.S., and a broad technology export market is also envisioned.

  17. DEVELOPMENT AND MANUFACTURE OF COST EFFECTIVE COMPOSITE DRILL PIPE

    SciTech Connect

    James C. Leslie; James C. Leslie II; Lee Truong; James T. Heard; Peter Manekas

    2005-03-18

    This technical report presents the engineering research, process development and data accomplishments that have transpired to date in support of the development of Cost Effective Composite Drill Pipe (CDP). The report presents progress made from October 1, 2003 through September 30, 2004 and contains the following discussions: (1) Direct Electrical Connection for Rotary Shoulder Tool Joints; (2) Conductors for inclusion in the pipe wall (ER/DW-CDP); (3) Qualify fibers from Zoltek; (4) Qualify resin from Bakelite; (5) First commercial order for SR-CDP from Integrated Directional Resources (SR-CDP); and (6) Preparation of papers for publication and conference presentations.

  18. Design, development and manufacture of high-efficiency low-cost solar modules based on CIGS PVICs

    NASA Astrophysics Data System (ADS)

    Eldada, Louay

    2010-02-01

    We describe the design, development and manufacture of solar power panels based on photovoltaic integrated circuits (PVICs) with high-quality high-uniformity Copper Indium Gallium Selenide (CIGS) thin films produced with the unique combination of low-cost ink-based and physical vapor deposition (PVD) based nanoengineered precursor thin films and a reactive transfer printing method. Reactive transfer is a two-stage process relying on chemical reaction between two separate precursor films to form CIGS, one deposited on the substrate and the other on a printing plate in the first stage. In the second stage, these precursors are brought into intimate contact and rapidly reacted under pressure in the presence of an electrostatic field while heat is applied. The use of two independent thin films provides the benefits of independent composition and flexible deposition technique optimization, and eliminates pre-reaction prior to the synthesis of CIGS. High quality CIGS with large grains on the order of several microns, and of preferred crystallographic orientation, are formed in just several minutes based on compositional and structural analysis by XRF, SIMS, SEM and XRD. Cell efficiencies of 14% and module efficiencies of 12% have been achieved using this method. When atmospheric pressure deposition of inks is utilized for the precursor films, the approach additionally provides lower energy consumption, higher throughput, and further reduced capital equipment cost with higher uptime.

  19. Spectroscopic ellipsometry as a process control tool for manufacturing cadmium telluride thin film photovoltaic devices

    NASA Astrophysics Data System (ADS)

    Smith, Westcott P.

    In recent decades, there has been concern regarding the sustainability of fossil fuels. One of the more promising alternatives is Cadmium Telluride (CdTe) thin-film photovoltaic (PV) devices. Improved quality measurement techniques may aid in improving this existing technology. Spectroscopic ellipsometry (SE) is a common, non-destructive technique for measuring thin films in the silicon wafer industry. SE results have also been tied to properties believed to play a role in CdTe PV device efficiency. A study assessing the potential of SE for use as a quality measurement tool had not been previously reported. Samples of CdTe devices produced by both laboratory and industrial scale processes were measured by SE and Scanning Electron Microscopy (SEM). Mathematical models of the optical characteristics of the devices were developed and fit to SE data from multiple angles and locations on each sample. Basic statistical analysis was performed on results from the automated fits to provide an initial evaluation of SE as a quantitative quality measurement process. In all cases studied, automated SE models produced average stack thickness values within 10% of the values produced by SEM, and standard deviations for the top bulk layer thickness were less than 1% of the average values.

  20. MANUFACTURING AND COST EVALUATION OF SECOND GENERATION HELIOSTATS VOLUME I - ANALYSIS AND RESULTS

    SciTech Connect

    Drumheller, K.; Bondurant, P. D.; Brown, D. R.; Williams, T. A.

    1981-09-01

    The Second Generation Heliostat Program involved five contractors who provided designs, manufacturing plans, and cost estimates for heliostats. The program was sponsored by the Department of Energy and managed by Sandia National Laboratories, Livermore. As part of the program, Pacific Northwest Laboratory (PNL) evaluated and compared the contractors' costs and production plans, and compared the actual costs of the Solar One (Barstow, California) pilot-plant heliostats to estimated mass production costs. One purpose of this review was to adjust contractor estimates to provide a common basis for cost comparisons. The five contractors were: Boeing Engineering and Construction, Martin Marietta Corporation, McDonnell Douglas Astronautics Company, Northrup Incorporated, and Westinghouse Electric Corporation. PNL evaluated the components and assembly of the five heliostats in terms of material, direct labor, production equipment, production building requirements, and overheads. Two adjustments were made to the costs estimated by the manufacturers. The first, producing "Adjusted Costs," was primarily to add items that appeared to have been omitted from the contractors' estimates or delete items that were not required. The second, called "Uniform Assumptions Costs," used common ground rules for major materials, building, labor, and overhead costs. The review of the contractors' production plans and cost estimates did not reveal any errors or omissions that would change the costs by more than 30%, when compared using uniform assumptions. This range is adequate for policy planning, and costs of $100/m{sup 2} appear achievable.

  1. DEVELOPMENT AND MANUFACTURE OF COST EFFECTIVE COMPOSITE DRILL PIPE

    SciTech Connect

    James C. Leslie; James C. Leslie II; Lee Truong; James T. Heard

    2003-03-30

    This technical report presents the engineering research and data accomplishments that have transpired to date in support of the development of Cost Effective Composite Drill Pipe (CDP). The report presents accomplishments made from October 1, 2002 through September 30, 2003. The following have been accomplished and are reported in detail herein: Metal-to-Composite Interface (MCI) redesign and testing; Successful demonstration of MCI connection for both SR and ER/DW CDP; Specifications for a 127mm (5 inch) ID by 152.4 mm (6 inch) OD composite drill pipe have been finalized for Extended Reach/Deep Water applications (ER/DW); Field testing of Short Radius CDP (SR); Sealing composite laminate to contain high pressure; Amendments; Amendment for ''Smart'' feature added to ER/DW development along with time and funding to complete battery of qualification tests with option for field demonstration; and Preparation of papers for publication and conference presentations.

  2. Aluminium alloyed iron-silicide/silicon solar cells: A simple approach for low cost environmental-friendly photovoltaic technology

    NASA Astrophysics Data System (ADS)

    Kumar Dalapati, Goutam; Masudy-Panah, Saeid; Kumar, Avishek; Cheh Tan, Cheng; Ru Tan, Hui; Chi, Dongzhi

    2015-12-01

    This work demonstrates the fabrication of silicide/silicon based solar cell towards the development of low cost and environmental friendly photovoltaic technology. A heterostructure solar cells using metallic alpha phase (α-phase) aluminum alloyed iron silicide (FeSi(Al)) on n-type silicon is fabricated with an efficiency of 0.8%. The fabricated device has an open circuit voltage and fill-factor of 240 mV and 60%, respectively. Performance of the device was improved by about 7 fold to 5.1% through the interface engineering. The α-phase FeSi(Al)/silicon solar cell devices have promising photovoltaic characteristic with an open circuit voltage, short-circuit current and a fill factor (FF) of 425 mV, 18.5 mA/cm2, and 64%, respectively. The significant improvement of α-phase FeSi(Al)/n-Si solar cells is due to the formation p+-n homojunction through the formation of re-grown crystalline silicon layer (~5-10 nm) at the silicide/silicon interface. Thickness of the regrown silicon layer is crucial for the silicide/silicon based photovoltaic devices. Performance of the α-FeSi(Al)/n-Si solar cells significantly depends on the thickness of α-FeSi(Al) layer and process temperature during the device fabrication. This study will open up new opportunities for the Si based photovoltaic technology using a simple, sustainable, and los cost method.

  3. Low-cost photovoltaics: Luminescent solar concentrators and colloidal quantum dot solar cells

    NASA Astrophysics Data System (ADS)

    Leow, Shin Woei

    Solar energy has long been lauded as an inexhaustible fuel source with more energy reaching the earth's surface in one hour than the global consumption for a year. Although capable of satisfying the world's energy requirements, solar energy remains an expensive technology that has yet to attain grid parity. Another drawback is that existing solar farms require large quantities of land in order to generate power at useful rates. In this work, we look to luminescent solar concentrator systems and quantum dot technology as viable solutions to lowering the cost of solar electricity production with the flexibility to integrate such technologies into buildings to achieve dual land use. Luminescent solar concentrator (LSC) windows with front-facing photovoltaic (PV) cells were built and their gain and power efficiency were investigated. Conventional LSCs employ a photovoltaic (PV) cell that is placed on the edge of the LSC, facing inward. This work describes a new design with the PV cells on the front-face allowing them to receive both direct solar irradiation and wave-guided photons emitted from a dye embedded in an acrylic sheet, which is optically coupled to the PV cells. Parameters investigated include the thickness of the waveguide, edge treatment of the window, cell width, and cell placement. The data allowed us to make projections that aided in designing windows for maximized overall efficiency. A gain in power of 2.2x over the PV cells alone was obtained with PV cell coverage of 5%, and a power conversion efficiency as high as 6.8% was obtained with a PV cell coverage of 31%. Balancing the trade-offs between gain and efficiency, the design with the lowest cost per watt attained a power efficiency of 3.8% and a gain of 1.6x. With the viability of the LSC demonstrated, a weighted Monte-Carlo Ray Tracing program was developed to study the transport of photons and loss mechanisms in the LSC to aid in design optimization. The program imports measured absorption

  4. The high intensity solar cell - Key to low cost photovoltaic power

    NASA Technical Reports Server (NTRS)

    Sater, B. L.; Goradia, C.

    1975-01-01

    This paper discusses the problems associated with conventional solar cells at high intensities and presents the design considerations and performance characteristics of the 'high intensity' (HI) solar cell which appears to eliminate the major problems. Test data obtained at greater than 250 AM1 suns gave a peak output power density of 2 W per sq cm at an efficiency exceeding 6% with an unoptimized cell operating at over 100 C. It appears that operation at 1000 AM1 suns at efficiencies greater than 10% is possible. At 1000 AM1 suns and 10% efficiency, the HI cell manufacturing cost is estimated to be $0.25/watt, with multi-megawatt annual production capability already existing within the industrial sector. A high intensity solar system was also analyzed to determine its cost effectiveness and to assess the benefits of further improving HI cell efficiency.

  5. Progress in phases 2 and 3 of the Photovoltaic Manufacturing Technology Project (PVMaT)

    SciTech Connect

    Witt, C E; Mitchell, R L; Mooney, G D; Herwig, L O; Hasti, D; Sellers, R

    1993-10-01

    This first year of the process-specific activities of the Photo- voltaic Manufacturing Technology (PVMaT) project has been completed, and the first subcontracts for teamed efforts on R&D of a general nature have been awarded. A second solicitation for process-specific research and development (R&D) is in the evaluation stage for award of subcontracts. This paper describes the technical accomplishments of the first process-specific subcontracts (Phase 2A), the status of the teamed research (Phase 3A), and the status of the solicitation for the second process-specific solicitation (Phases 2B).

  6. Colloidal CuInSe2 nanocrystals and thin films for low-cost photovoltaics

    NASA Astrophysics Data System (ADS)

    Ghali, M.; Elnimr, M.; Ali, Gh. F.; Yousif, B.

    2016-05-01

    We report on the synthesis of colloidal CuInSe2 nanocrystals (NCs) using simple solution-based method and its vacuum thermally evaporated films. The tetragonal phase CuInSe2 NCs grow in the shape of nanoparticles with diameter varies between 30 and 40 nm according to high resolution transmission electron microscopy and electron diffraction measurements. The deposited films have been annealed for different times (up to 45 min) in vacuum and at different temperatures (150-346 °C). Optical characterization of the CuInSe2 NCs films using UV-Vis-NIR absorption, transmittance, excitation and photoluminescence measurements were performed. Optical properties of the deposited CuInSe2 films were quantified using developed theoretical model based on transmission and reflectance data. We found a strong dependence of the structural, morphologies and optical absorption coefficient of the prepared films on both annealing temperatures and annealing times. A remarkable enhancement of the optical absorption coefficient (α ∼ 3 × 105 cm-1) of the formed CuInSe2 NCs films with annealing was demonstrated and suggested the potential use of colloidal CuInSe2 for low cost photovoltaics.

  7. Towards cost effective metal precursor sources for future photovoltaic material synthesis: CTS nanoparticles

    NASA Astrophysics Data System (ADS)

    Lokhande, A. C.; Gurav, K. V.; Jo, Eunjin; He, Mingrui; Lokhande, C. D.; Kim, Jin Hyeok

    2016-04-01

    Copper tin sulfide (CTS) is an emerging candidate for solar application due to its favorable band gap and higher optical absorption coefficient. Kuramite-Tetragonal Cu3SnS4 (CTS) monodisperse nanoparticles are prepared by hot injection technique involving cost effective sulfate metal precursor source. A protocol for controlled crystal structure has been demonstrated by variation of cationic Cu:Sn ratio. The crystal structure, size, phase purity, atomic composition, oxidation state and optical properties of the nanoparticles are confirmed from X-ray diffraction (XRD), transmission electron microscopy (TEM), Raman, energy dispersive X-ray spectroscopy (EDX), X-ray photoelectron spectroscopy (XPS) and UV-visible spectroscopy, respectively. Hexagonal shaped particles within the size distribution of 7-9 nm with an optimal band gap of 1.28 eV are obtained. XPS study shows the Cu1+, Sn4+ and S2- oxidation states. The effects of influential factors such as metal precursor ratio, metal precursor source, reaction time, heating rate and solvents have been demonstrated systematically on the synthesis of CTS nanoparticles. The plausible mechanism of the formation of CTS nanoparticles has been proposed. The obtained results provide new insight for applying CTS nanoparticles in photovoltaic applications.

  8. Solar PV Manufacturing Cost Model Group: Installed Solar PV System Prices (Presentation)

    SciTech Connect

    Goodrich, A. C.; Woodhouse, M.; James, T.

    2011-02-01

    EERE's Solar Energy Technologies Program is charged with leading the Secretary's SunShot Initiative to reduce the cost of electricity from solar by 75% to be cost competitive with conventional energy sources without subsidy by the end of the decade. As part of this Initiative, the program has funded the National Renewable Energy Laboratory (NREL) to develop module manufacturing and solar PV system installation cost models to ensure that the program's cost reduction targets are carefully aligned with current and near term industry costs. The NREL cost analysis team has leveraged the laboratories' extensive experience in the areas of project finance and deployment, as well as industry partnerships, to develop cost models that mirror the project cost analysis tools used by project managers at leading U.S. installers. The cost models are constructed through a "bottoms-up" assessment of each major cost element, beginning with the system's bill of materials, labor requirements (type and hours) by component, site-specific charges, and soft costs. In addition to the relevant engineering, procurement, and construction costs, the models also consider all relevant costs to an installer, including labor burdens and overhead rates, supply chain costs, and overhead and materials inventory costs, and assume market-specific profits.

  9. Development of hybrid lifecycle cost estimating tool (HLCET) for manufacturing influenced design tradeoff

    NASA Astrophysics Data System (ADS)

    Sirirojvisuth, Apinut

    In complex aerospace system design, making an effective design decision requires multidisciplinary knowledge from both product and process perspectives. Integrating manufacturing considerations into the design process is most valuable during the early design stages since designers have more freedom to integrate new ideas when changes are relatively inexpensive in terms of time and effort. Several metrics related to manufacturability are cost, time, and manufacturing readiness level (MRL). Yet, there is a lack of structured methodology that quantifies how changes in the design decisions impact these metrics. As a result, a new set of integrated cost analysis tools are proposed in this study to quantify the impacts. Equally important is the capability to integrate this new cost tool into the existing design methodologies without sacrificing agility and flexibility required during the early design phases. To demonstrate the applicability of this concept, a ModelCenter environment is used to develop software architecture that represents Integrated Product and Process Development (IPPD) methodology used in several aerospace systems designs. The environment seamlessly integrates product and process analysis tools and makes effective transition from one design phase to the other while retaining knowledge gained a priori. Then, an advanced cost estimating tool called Hybrid Lifecycle Cost Estimating Tool (HLCET), a hybrid combination of weight-, process-, and activity-based estimating techniques, is integrated with the design framework. A new weight-based lifecycle cost model is created based on Tailored Cost Model (TCM) equations [3]. This lifecycle cost tool estimates the program cost based on vehicle component weights and programmatic assumptions. Additional high fidelity cost tools like process-based and activity-based cost analysis methods can be used to modify the baseline TCM result as more knowledge is accumulated over design iterations. Therefore, with this

  10. Low-cost, flexible, and self-cleaning 3D nanocone anti-reflection films for high-efficiency photovoltaics.

    PubMed

    Tsui, Kwong-Hoi; Lin, Qingfeng; Chou, Hungtao; Zhang, Qianpeng; Fu, Huiying; Qi, Pengfei; Fan, Zhiyong

    2014-05-01

    Low-cost engineered nanotemplates are used to mold flexible nanocone anti-reflection (AR) films. Both optical reflectance measurements and photovoltaics characterizations demonstrate that the flexible nanocone AR films can considerably suppress device front-side reflectance and thus improve the power conversion efficiency of high-efficiency thin-film CdTe solar cells. Additionally, these nanocone AR films are found to be superhydrophobic and thus possess self-cleaning capability. PMID:24448979