Science.gov

Sample records for photovoltaic manufacturing cost

  1. 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.

  2. 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.

  3. 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.

  4. 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.

  5. 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.

  6. 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.

  7. Photovoltaic subsystem production cost model (SAMIS)

    NASA Astrophysics Data System (ADS)

    1982-07-01

    A complete introduction to the SAMIS model is provided. The purpose of the model is to estimate the costs of manufacturing photovoltaic solar energy products. The model procedure for estimating the long run or steady-state manufacturing cost is divided into four submodels: manufacturing process submodel, factory construction and staffing algorithm, capital requirements submodel, and the financial model of the firm. The model has been applied by Sandia National Laboratories for DOE's National Photovoltaics Program to assess the commercial viability of new solar energy manufacturing processes. However, given the proper input data, the model structure is flexible enough to support the design and analysis of any manufacturing industry. This document explains what the model can and cannot do, and what data is required. An example for a photovoltaic power conditioning unit demonstrates the application of the model.

  8. 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.

  9. 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.

  10. 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.

  11. 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.

  12. 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.

  13. 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.

  14. 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.

  15. 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.

  16. Paths to future growth in photovoltaics manufacturing

    SciTech Connect

    Basore, Paul A.

    2016-03-01

    The past decade has seen rapid growth in the photovoltaics industry, followed in the past few years by a period of much slower growth. A simple model that is consistent with this historical record can be used to predict the future evolution of the industry. Two key parameters are identified that determine the outcome. 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 modest improvement in CapIR to ensure future growth in photovoltaics. Several approaches are presented that can enable the required improvement in CapIR. If, in addition, there is an accompanying improvement in CapDR, the rate of growth can be substantially accelerated.

  17. 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.

  18. 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.

  19. 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.

  20. 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.

  1. Photovoltaic manufacturing technology (PVMAT) improvements for ENTECH's concentrator module

    SciTech Connect

    O'Neill, M.J. , Dallas/Fort Worth Airport, Texas 75261-2246 )

    1994-06-30

    With significant assistance from the U. S. Department of Energy (DOE), Sandia National Labs (Sandia), and the National Renewable Energy Laboratory (NREL), our technical team has been developing, field-testing, refining, and commercializing linear Fresnel lens photovoltaic concentrator technology for the past 15 years (Table I). In 1991 we completed Phase 1 of a DOE-sponsored Photovoltaic Manufacturing Technology (PVMaT) project. We are now performing Phase 2A of our PVMaT project. The key objective of our PVMaT project is to design, develop, and implement improved manufacturing processes for our fourth-generation concentrator module. The improved processes are being engineered to simultaneously achieve enhanced product quality (i.e., improved module efficiency, reliability, and field lifetime), higher production volume (10 MV/year initial rate), and lower production costs ($1.25/W[sub peak] goal). Under our PVMaT project, we have made significant improvements in manufacturing technology for our fourth-generation concentrator module, and the key results to date are summarized in the following paragraphs.

  2. 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.

  3. 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.

  4. Source-circuit design with multiple photovoltaic manufacturers

    NASA Technical Reports Server (NTRS)

    Spencer, R.

    1983-01-01

    The problems associated with source circuit design for use in photovoltaic (PV) hardware of different manufacturers or processes are discussed. The varying performance of dissimilar materials is examined and the need for standardization of equipment and performance output is investigated.

  5. 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.

  6. 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.

  7. 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…

  8. 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.

  9. 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.

  10. 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.

  11. 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.

  12. 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.

  13. 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.

  14. 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.

  15. 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.

  16. 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.

  17. 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.

  18. Amorphous silicon photovoltaic manufacturing technology, phase 2A

    NASA Astrophysics Data System (ADS)

    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.

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

    DOE PAGES

    Powell, Douglas M.; Fu, Ran; Horowitz, Kelsey; ...

    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.

  20. 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.

  1. 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.

  2. 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.

  3. 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.

  4. Manufacturing technology development of the Powergrid{trademark} linear focus photovoltaic concentrator system

    SciTech Connect

    Kaminar, N.; Alexander, T.; Amaya, J.; Bottenberg, W.; Carrie, P.; Chen, K.; Gilbert, D.; Guzman, P.; Hobden, P.; Ross, J.; Sahagian, J.; Rodrigues, D.; Zimmermann, J.

    1999-03-01

    This article reports manufacturing technology improvements developed for the production of the PVI Powergrid{trademark} linear focus photovoltaic concentrator as part of a PVMaT project. The improvements include the development of an advanced, acrylic plastic extrusion system for Fresnel lenses, an automated receiver station, an EVA encapsulation process, an improved collector fabrication method and a lower cost panel frame. These project improvements have prepared PVI for entrance into large-scale production of PV power generation systems. {copyright} {ital 1999 American Institute of Physics.}

  5. 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.

  6. 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.

  7. Organic photovoltaic cells: from performance improvement to manufacturing processes.

    PubMed

    Youn, Hongseok; Park, Hui Joon; Guo, L Jay

    2015-05-20

    Organic photovoltaics (OPVs) have been pursued as a next generation power source due to their light weight, thin, flexible, and simple fabrication advantages. Improvements in OPV efficiency have attracted great attention in the past decade. Because the functional layers in OPVs can be dissolved in common solvents, they can be manufactured by eco-friendly and scalable printing or coating technologies. In this review article, the focus is on recent efforts to control nanomorphologies of photoactive layer and discussion of various solution-processed charge transport and extraction materials, to maximize the performance of OPV cells. Next, recent works on printing and coating technologies for OPVs to realize solution processing are reviewed. The review concludes with a discussion of recent advances in the development of non-traditional lamination and transfer method towards highly efficient and fully solution-processed OPV.

  8. 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.

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

    NASA Astrophysics Data System (ADS)

    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.

  10. 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.

  11. 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.

  12. Using adhesives as a means to reduce costs and increase performance in the production of photovoltaic electricity.

    PubMed

    Thorey, Claire

    2013-01-01

    Although adhesives have been used for many years to manufacture cars in more efficient ways, their potential has not yet been fully exploited by the renewable energy industry. We argue in this article that photovoltaic module manufacturers can save costs and differentiate from competition by careful selection and use of their bonding systems. Clever adhesives can enable new, more effective product designs and can play a major role in the longevity of the complete product.

  13. 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.

  14. Efficiency enhancement in two-cell CIGS photovoltaic system with low-cost optical spectral splitter.

    PubMed

    Maragliano, Carlo; Apostoleris, Harry; Bronzoni, Matteo; Rampino, Stefano; Stefancich, Marco; Chiesa, Matteo

    2016-01-25

    Spectrum splitting represents a valid alternative to multi-junction solar cells for broadband light-to-electricity conversion. While this concept has existed for decades, its adoption at the industrial scale is still stifled by high manufacturing costs and inability to scale to large areas. Here we report the experimental validation of a novel design that could allow the widespread adoption of spectrum splitting as a low-cost approach to high efficiency photovoltaic conversion. Our system consists of a prismatic lens that can be manufactured using the same methods employed for conventional CPV optic production, and two inexpensive CuInGaSe(2) (CIGS) solar cells having different composition and, thus, band gaps. We demonstrate a large improvement in cell efficiency under the splitter and show how this can lead to substantial increases in system output at competitive cost using existing technologies.

  15. 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.

  16. 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.

  17. 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.

  18. 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.

  19. 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.

  20. 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.

  1. 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.

  2. 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.

  3. 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.

  4. ICAM Manufacturing Cost/Design Guide. Volume 3. Computerization.

    DTIC Science & Technology

    1980-09-01

    for the aluminum 2024 beaded panel manufactured with rubber press process require no other 43 manufacturing complexities, such as joggles , flanges...lineal aluminum part 2B, length= 24 inches, to compare the BPCOST and JOGGLES cost (cost of the base part plus joggles ) as a function of the cost...base part, plus joggles for the three manufacturing methods, shows that the minimum cost (by the rubber press method) is about 0.3 man-hours per part

  5. 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

  6. 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.

  7. 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.

  8. 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.

  9. 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.

  10. 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.

  11. 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.

  12. 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.

  13. 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.

  14. 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.

  15. Residential photovoltaic flywheel storage system performance and cost

    SciTech Connect

    Hay, R.D.; Millner, A.R.; Jarvinen, P.O.

    1980-01-01

    A subscale prototype of a flywheel energy storage and conversion system for use with photovoltaic power systems of residential and intermediate load-center size has been designed, built and tested by MIT Lincoln Laboratory. System design, including details of such key components as magnetic bearings, motor generator, and power-conditioning electronics, are described. Performance results of prototype testing are given and indicate that this system is the equal of or superior to battery and inverter systems for the same application. Results of cost and user-worth analysis show that residential systems are economically feasible in stand-alone and in utility-interactive applications.

  16. 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.

  17. 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.

  18. 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.

  19. Cost Accounting in the Automated Manufacturing Environment

    DTIC Science & Technology

    1988-06-01

    current cost accounting systems...Bennett et al., 1987]. First, users of cost accounting information express different levels of satisfaction with the 65 effectiveness of current cost accounting systems...Bennett et al., 1987). For example, it was found that, ආ percent of the users are unhappy with current cost accounting

  20. 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.

  1. 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.

  2. A review of manufacturing metrology for improved reliability of silicon photovoltaic modules

    NASA Astrophysics Data System (ADS)

    Davis, Kristopher O.; Walters, Joseph; Schneller, Eric; Seigneur, Hubert; Brooker, R. Paul; Scardera, Giuseppe; Rodgers, Marianne P.; Mohajeri, Nahid; Shiradkar, Narendra; Dhere, Neelkanth G.; Wohlgemuth, John; Rudack, Andrew C.; Schoenfeld, Winston V.

    2014-10-01

    In this work, the use of manufacturing metrology across the supply chain to improve crystalline silicon (c-Si) photovoltaic (PV) module reliability and durability is addressed. Additionally, an overview and summary of a recent extensive literature survey of relevant measurement techniques aimed at reducing or eliminating the probability of field failures is presented. An assessment of potential gaps is also given, wherein the PV community could benefit from new research and demonstration efforts. This review is divided into three primary areas representing different parts of the c-Si PV supply chain: (1) feedstock production, crystallization and wafering; (2) cell manufacturing; and (3) module manufacturing.

  3. 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.

  4. 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.

  5. An analysis of glass–glass CIGS manufacturing costs

    SciTech Connect

    Horowitz, Kelsey A. W.; Fu, Ran; Woodhouse, Michael

    2016-09-01

    This article examines current cost drivers and potential avenues to reduced cost for monolithic, glass-glass Cu(In,Ga)(Se,S)2 (CIGS) modules by constructing a comprehensive bottom-up cost model. For a reference case where sputtering plus batch sulfurization after selenization (SAS) is employed, we compute a manufacturing cost of $69/m2 if the modules are made in the United States at a 1 GW/year production volume. At 14% module efficiency, this corresponds to a manufacturing cost of $0.49/WDC and a minimum sustainable price (MSP) of $0.67/WDC. We estimate that MSP could vary within +/-20% of this value given the range of quoted input prices, and existing variations in module design, manufacturing processes, and manufacturing location. Potential for reduction in manufacturing costs to below $0.40/WDC may be possible if average production module efficiencies can be increased above 17% without increasing $/m2 costs; even lower costs could be achieved if $/m2 costs could be reduced, particularly via innovations in the CIGS deposition process or balance-of-module elements. We present the impact on cost of regional factors, CIGS deposition method, device design, and price fluctuations. One metric of competitiveness-levelized cost of energy (LCOE) -- is also assessed for several U.S. locations and compared to that of standard multi-crystalline silicon (m(c-Si)) and cadmium telluride (CdTe).

  6. 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

  7. 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

  8. 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.

  9. 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.

  10. III-Vs at Scale: A PV Manufacturing Cost Analysis of the Thin Film Vapor-Liquid-Solid Growth Mode

    SciTech Connect

    Zheng, Maxwell; Horowitz, Kelsey; Woodhouse, Michael; Battaglia, Corsin; Kapadia, Rehan; Javey, Ali

    2016-06-01

    The authors present a manufacturing cost analysis for producing thin-film indium phosphide modules by combining a novel thin-film vapor-liquid-solid (TF-VLS) growth process with a standard monolithic module platform. The example cell structure is ITO/n-TiO2/p-InP/Mo. For a benchmark scenario of 12% efficient modules, the module cost is estimated to be $0.66/W(DC) and the module cost is calculated to be around $0.36/W(DC) at a long-term potential efficiency of 24%. The manufacturing cost for the TF-VLS growth portion is estimated to be ~$23/m2, a significant reduction compared with traditional metalorganic chemical vapor deposition. The analysis here suggests the TF-VLS growth mode could enable lower-cost, high-efficiency III-V photovoltaics compared with manufacturing methods used today and open up possibilities for other optoelectronic applications as well.

  11. Photovoltaic concentrators

    NASA Astrophysics Data System (ADS)

    Boes, E. C.

    1980-01-01

    A status report on photovoltaic (PV) concentrators technology is presented. The major topics covered are as follows: (1) current PV concentrator arrays; designs, performances, and costs; (2) current PV concentrator array components; cells and cell assemblies, optical concentrators, support structures, tracking, and drive; (3) design of PV concentrator arrays; and (4) array manufacturing technology.

  12. 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

  13. 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.

  14. 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

  15. 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.

  16. 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.

  17. 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)

  18. 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.

  19. 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.

  20. Increase Productivity and Cost Optimization in CNC Manufacturing

    NASA Astrophysics Data System (ADS)

    Musca, Gavril; Mihalache, Andrei; Tabacaru, Lucian

    2016-11-01

    The advantage of the technological assisted design consists in easy modification of the machining technologies for obtaining machine alternation, tool changing, working parameters variation or the modification of loads to which the tools are subjected. By determining tool movement inside machining and by using tool related moving speeds needed for both positioning and manufacturing we are able to compute the required machining time for each component of the machining operation in progress. The present study describes a cost optimization model for machining operations which uses the following components: machine and its operator related cost, set-up and adjustment, unproductive costs (idle state), direct and indirect costs. By using manufacturing technologies assisted design procedures we may obtain various variants for the technological model by modifying the machining strategy, tooling, working regimes or the machine-tool that are used. Simulating those variants allows us to compare and establish the optimal manufacturing variant as well as the most productive one.

  1. 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.

  2. 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.

  3. 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.

  4. The economic impact of state ordered avoided cost rates for photovoltaic generated electricity

    NASA Astrophysics Data System (ADS)

    Bottaro, D.; Wheatley, N. J.

    Various methods the states have devised to implement federal policy regarding the Public Utility Regulatory Policies Act (PURPA) of 1978, which requires that utilities pay their full 'avoided costs' to small power producers for the energy and capacity provided, are examined. The actions of several states are compared with rates estimated using utility expansion and rate-setting models, and the potential break-even capital costs of a photovoltaic system are estimated using models which calculate photovoltaic worth. The potential for the development of photovoltaics has been increased by the PURPA regulations more from the guarantee of utility purchase of photovoltaic power than from the high buy-back rates paid. The buy-back rate is high partly because of the surprisingly high effective capacity of photovoltaic systems in some locations.

  5. 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.

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

    NASA Astrophysics Data System (ADS)

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

    1980-07-01

    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.

  7. 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.

  8. 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.

  9. 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

  10. Evaluating the causes of photovoltaics cost reduction: Why is PV different?

    SciTech Connect

    Trancik, Jessika; McNerney, James; Kavlak, Goksin

    2016-12-29

    The goals of this project were to quantify sources of cost reduction in photovoltaics (PV), improve theories of technological evolution, develop new analytical methods, and formu- late guidelines for continued cost reduction in photovoltaics. A number of explanations have been suggested for why photovoltaics have come down in cost rapidly over time, including increased production rates, significant R&D expenditures, heavy patenting ac- tivity, decreasing material and input costs, scale economies, reduced plant construction costs, and higher conversion efficiencies. We classified these proposed causes into low- level factors and high-level drivers. Low-level factors include technical characteristics, such as module efficiency or wafer area, which are easily posed in terms of variables of a cost equation. High-level factors include scale economies, research and development (R&D), and learning-by-doing.

  11. 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].

  12. 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.

  13. 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.

  14. 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.

  15. 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.

  16. 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.

  17. 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

  18. 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

  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. 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.

  1. U.S. Solar Photovoltaic System Cost Benchmark: Q1 2016

    SciTech Connect

    Fu, Ran; Chung, Donald; Lowder, Travis; Feldman, David; Ardani, Kristen; Margolis, Robert

    2016-09-01

    NREL has been modeling U.S. photovoltaic (PV) system costs since 2009. This report benchmarks costs of U.S. solar PV for residential, commercial, and utility-scale systems built in the first quarter of 2016 (Q1 2016). Our methodology includes bottom-up accounting for all system and project-development costs incurred when installing residential, commercial, and utility-scale systems, and it models the capital costs for such systems.

  2. U.S. Solar Photovoltaic System Cost Benchmark: Q1 2016

    SciTech Connect

    Fu, Ran; Chung, Donald; Lowder, Travis; Feldman, David; Ardani, Kristen; Margolis, Robert

    2016-07-19

    NREL has been modeling U.S. photovoltaic (PV) system costs since 2009. This report benchmarks costs of U.S. solar PV for residential, commercial, and utility-scale systems built in the first quarter of 2016 (Q1 2016). Our methodology includes bottom-up accounting for all system and project-development costs incurred when installing residential, commercial, and utility-scale systems, and it models the capital costs for such systems.

  3. Additively Manufactured Low Cost Upper Stage Combustion Chamber

    NASA Technical Reports Server (NTRS)

    Protz, Christopher; Cooper, Ken; Ellis, David; Fikes, John; Jones, Zachary; Kim, Tony; Medina, Cory; Taminger, Karen; Willingham, Derek

    2016-01-01

    Over the past two years NASA's Low Cost Upper Stage Propulsion (LCUSP) project has developed Additive Manufacturing (AM) technologies and design tools aimed at reducing the costs and manufacturing time of regeneratively cooled rocket engine components. High pressure/high temperature combustion chambers and nozzles must be regeneratively cooled to survive their operating environment, causing their design fabrication to be costly and time consuming due to the number of individual steps and different processes required. Under LCUSP, AM technologies in Sintered Laser Melting (SLM) GRCop-84 and Electron Beam Freeform Fabrication (EBF3) Inconel 625 have been significantly advanced, allowing the team to successfully fabricate a 25k-class regenerative chamber. Estimates of the costs and schedule of future builds indicate cost reductions and significant schedule reductions will be enabled by this technology. Characterization of the microstructural and mechanical properties of the SLM-produced GRCop-84, EBF3 Inconel 625 and the interface layer between the two has been performed and indicates the properties will meet the design requirements. The LCUSP chamber is to be tested with a previously demonstrated SLM injector in order to advance the Technology Readiness Level (TRL) and demonstrate the capability of the application of these processes. NASA is advancing these technologies to reduce cost and schedule for future engine applications and commercial needs.

  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-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)

  6. 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.

  7. 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.

  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 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.

  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 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.

  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 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.

  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)

    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.

  12. 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.

  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. Thin film CIGS photovoltaic modules: monolithic integration and advanced packaging for high performance, high reliability and low cost

    NASA Astrophysics Data System (ADS)

    Eldada, Louay

    2011-01-01

    In recent years, thin-film photovoltaic companies started realizing their low manufacturing cost potential, and have been grabbing an increasingly larger market share. Copper Indium Gallium Selenide (CIGS) is the most promising thin-film PV material, having demonstrated the highest energy conversion efficiency in both cells and modules. However, most CIGS manufacturers still face the challenge of delivering a reliable and rapid manufacturing process that can scale effectively and deliver on the promise of this material system. HelioVolt has developed a reactive transfer process for CIGS absorber formation that has the benefits of good compositional control, and a fast high-quality CIGS reaction. The reactive transfer process is a two stage CIGS fabrication method. Precursor films are deposited onto substrates and reusable cover plates in the first stage, while in the second stage the CIGS layer is formed by rapid heating with Se confinement. HelioVolt also developed best-in-class packaging technologies that provide unparalleled environmental stability. High quality CIGS films with large grains were fabricated on the production line, and high-performance highreliability monolithic modules with a form factor of 120 cm × 60 cm are being produced at high yield and low cost. With conversion efficiency levels around 14% for cells and 12% for modules, HelioVolt is commercializing the process on its first production line with 20 MW capacity, and is planning its next GW-scale factory.

  15. 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.

  16. Study of photovoltaic cost elements. Volume 1: Executive report. Volume 2: Project background

    NASA Astrophysics Data System (ADS)

    Ayers, J. B.

    1981-07-01

    Two models used for estimating installation costs for residential and intermediate photovoltaic energy systems are summarized. The modeling rationale is reviewed, and the results obtained when the models were applied to 10 residential and 10 intermediate PV systems are listed. Output reports for each of the test cases are appended.

  17. Concentrated photovoltaics system costs and learning curve analysis

    NASA Astrophysics Data System (ADS)

    Haysom, Joan E.; Jafarieh, Omid; Anis, Hanan; Hinzer, Karin

    2013-09-01

    An extensive set of costs in /W for the installed costs of CPV systems has been amassed from a range of public sources, including both individual company prices and market reports. Cost reductions over time are very evident, with current prices for 2012 in the range of 3.0 ± 0.7 /W and a predicted cost of 1.5 /W for 2020. Cost data is combined with deployment volumes in a learning curve analysis, providing a fitted learning rate of either 18.5% or 22.3% depending on the methodology. This learning rate is compared to that of PV modules and PV installed systems, and the influence of soft costs is discussed. Finally, if an annual growth rate of 39% is assumed for deployed volumes, then, using the learning rate of 20%, this would predict the achievement of a cost point of 1.5 /W by 2016.

  18. Cost Savings Analysis Guidelines for Manufacturing Technology Projects.

    DTIC Science & Technology

    1985-06-28

    Corporation .’-"- 2828 Pennsylvania Ave, N.W. ’- Washington, D.C. 20007 _ DTIC "" 28 June 1985 EECTE Final Report for 1985 MAY I .- Contract Number N00024...wae"ITI CLAMSP IgeTbm of Vg.S ph" PE.. * . *,. _d % I I- COST SAVINGS ANALYSIS GUIDELINES FOR MANUFACTURING TECHNOLOGY PROJECTS SYSCON Corporation I...Burlington. NA 01003 Candidate applications: 0 GaAs is in high dmnd for use in advanced electronic commnication . countermasure. and high speed computer

  19. 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

  20. 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.

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

    DOEpatents

    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.

  3. 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.

  4. The Department of the Navy Spent Recovery Act Funds on Photovoltaic Projects That Were Not Cost-Effective

    DTIC Science & Technology

    2011-09-22

    Report No. D-2011-106 September 22, 2011 The Department of the Navy Spent Recovery Act Funds on Photovoltaic Projects...Spent Recovery Act Funds on Photovoltaic Projects That Were Not Cost-Effective 5a. CONTRACT NUMBER 5b. GRANT NUMBER 5c. PROGRAM ELEMENT NUMBER 6...Command NFESC Naval Facilities Engineering Service Center MILCON Military Construction O&M Operations and Maintenance PV Photovoltaic

  5. 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.

  6. 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.

  7. 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.

  8. New Method for Analytical Photovoltaic Parameters Identification: Meeting Manufacturer’s Datasheet for Different Ambient Conditions

    NASA Astrophysics Data System (ADS)

    Cubas, Javier; Pindado, Santiago; de Manuel, Carlos

    At present, photovoltaic energy is one of the most important renewable energy sources. The demand for solar panels has been continuously growing, both in the industrial electric sector and in the private sector. In both cases the analysis of the solar panel efficiency is extremely important in order to maximize the energy production. In order to have a more efficient photovoltaic system, the most accurate understanding of this system is required. However, in most of the cases the only information available in this matter is reduced, the experimental testing of the photovoltaic device being out of consideration, normally for budget reasons. Several methods, normally based on an equivalent circuit model, have been developed to extract the I-V curve of a photovoltaic device from the small amount of data provided by the manufacturer. The aim of this paper is to present a fast, easy, and accurate analytical method, developed to calculate the equivalent circuit parameters of a solar panel from the only data that manufacturers usually provide. The calculated circuit accurately reproduces the solar panel behavior, that is, the I-V curve. This fact being extremely important for practical reasons such as selecting the best solar panel in the market for a particular purpose, or maximize the energy extraction with MPPT (Maximum Peak Power Tracking) methods.

  9. 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.

  10. Computer-based manufacturing cost analysis for the fabrication of thermoplastic composite structures

    NASA Astrophysics Data System (ADS)

    Foley, Michael; Bernardon, Edward

    1990-01-01

    Advanced composite structures are very expensive to manufacture. Cost estimation techniques are useful as tools for increasing cost effectiveness in part design, in selecting materials, and in the design of automated systems and manufacturing processes. A computer-based cost estimation model has been developed for analyzing the manufacturing costs involved in the fabrication of thermoplastic composite structures. The model, described in detail in this paper, evaluates existing manual and automated techniques for manufacturing a thermoplastic composite skin. Cost analysis results and their relevance to increasing cost effectiveness are discussed.

  11. 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

  12. 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.

  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

    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.

  15. 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... 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:...

  16. 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:...

  17. 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:...

  18. 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:...

  19. Modular Exhaust Design and Manufacturing Techniques for Low Cost Mid Volume Rapid Buidl to Order Systems

    DTIC Science & Technology

    2014-08-06

    technical data package will contain the following pieces of information: • Manufacturing Drawings • Code for running CNC machinery • Documentation...MODULAR EXHAUST DESIGN AND MANUFACTURING TECHNIQUES FOR LOW COST MID VOLUME RAPID BUILD TO ORDER SYSTEMS Kevin Nelson Project Engineer...customizable mufflers, as well as modular manufacturing techniques targeted at mid volume manufacturing quantities. A successful solution would reduce

  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. 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.

  3. 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.

  4. 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.

  5. 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.

  6. Solar Glitter: Low Cost, Solar Energy Harvesting with Microsystems Enabled Photovoltaics

    NASA Astrophysics Data System (ADS)

    Nelson, Jeffrey

    2012-03-01

    The sun covers our environment with energy harvesting opportunities throughout the day. Although great progress has been made in developing low-cost, solar photovoltaic technologies to harvest the suns energy, the traditional silicon-based PV module format has remained unchanged for almost 40 years, thereby limiting energy harvesting to rooftops and large open spaces. Thin-film and building-integrated photovoltaics have increased the opportunity for energy harvesting, but suffer from low-efficiency. We have developed, based on micro-electro-mechanical systems (MEMs) and other microsystems technology, a new approach to solar photovoltaics applicable in a wide range of environments -- Microsystems Enabled Photovoltaics (MEPV). MEPV solar cells made from crystalline silicon or III-V compound semiconductors (for example, GaAs) are 5-20 microns thick and with lateral dimensions of 250 microns to 1 mm. These solar cells minimize the amount of expensive semiconductor used, but retain the high efficiency of crystalline materials, and allow novel module and system designs not possible with traditional approaches. This talk will outline the science and engineering of MEPV technology, and highlight several novel applications.

  7. 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.

  8. 48 CFR 31.205-25 - Manufacturing and production engineering costs.

    Code of Federal Regulations, 2010 CFR

    2010-10-01

    ... production engineering costs. 31.205-25 Section 31.205-25 Federal Acquisition Regulations System FEDERAL... 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:...

  9. 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

  10. 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.

  11. 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.

  12. Study of installed and life-cycle costs for batteries in photovoltaic power systems

    NASA Astrophysics Data System (ADS)

    1982-10-01

    The overall objective was to estimate the installed and life-cycle costs of 9 battery technologies in a range of photovoltaic application types and sizes. For each battery type is given is a description of the battery technology, the battery factory price analysis, and the installed and life-cycle cost estimates for the battery in each of the applications evaluated. Battery types include: conventional lead-acid; sealed lead-acid; redox; zinc-bromine batteries of two types; zinc chloride; iron redox; lithium-metal sulfide; and sodium-sulfur. Applications include: shopping center; high school; multiple residence; hotel-motel; remote residence; and single residence.

  13. 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.

  14. 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.

  15. 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.

  16. 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

  17. 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.

  18. 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.

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

    NASA Astrophysics Data System (ADS)

    Osullivan, George A.; Osullivan, Joseph 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 1 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 2. 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.

  20. 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.

  1. 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)

  2. 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

  3. Automotive Lithium-ion Cell Manufacturing: Regional Cost Structures and Supply Chain Considerations

    SciTech Connect

    Chung, Donald; Elgqvist, Emma; Santhanagopalan, Shriram

    2016-04-01

    Manufacturing capacity for lithium-ion batteries (LIBs) — which power many consumer electronics and are increasingly used to power electric vehicles — is heavily concentrated in East Asia. To illuminate the factors that drive regional competitiveness in automotive LIB cell production, this study models cell manufacturing cost and minimum sustainable price, and examines development of LIB supply chains and current LIB market conditions. The study shows that factors driving the cost competitiveness of LIB manufacturing locations are mostly built—supply chain developments and competition, access to materials, and production expertise. Some regional costs — including cost of capital, labor, and materials — are significant and should be considered.

  4. Manufacturing metrology for c-Si photovoltaic module reliability and durability, Part I: Feedstock, crystallization and wafering

    SciTech Connect

    Seigneur, Hubert; Mohajeri, Nahid; Brooker, R. Paul; Davis, Kristopher O.; Schneller, Eric J.; Dhere, Neelkanth G.; Rodgers, Marianne P.; Wohlgemuth, John; Shiradkar, Narendra S.; Scardera, Giuseppe; Rudack, Andrew C.; Schoenfeld, Winston V.

    2016-06-01

    This article is the first in a three-part series of manufacturing metrology for c-Si photovoltaic (PV) module reliability and durability. Here in Part 1 we focus on the three primary process steps for making silicon substrates for PV cells: (1) feedstock production; (2) ingot and brick production; and (3) wafer production. Each of these steps can affect the final reliability/durability of PV modules in the field with manufacturing metrology potentially playing a significant role. This article provides a comprehensive overview of historical and current processes in each of these three steps, followed by a discussion of associated reliability challenges and metrology strategies that can be employed for increased reliability and durability in resultant modules. Gaps in the current state of understanding in connective metrology data during processing to reliability/durability in the field are then identified along with suggested improvements that should be considered by the PV community.

  5. Modeling Photovoltaic and Concentrating Solar Power Trough Performance, Cost, and Financing with Solar Advisor Model

    SciTech Connect

    Blair, N.; Mehos, M.; Christensen, C.; Cameron, C.

    2008-01-01

    A comprehensive solar technology systems analysis model, the Solar Advisor Model (SAM), has been developed to support the federal R&D community and the solar industry by staff at the National Renewable Energy Laboratory (NREL) and Sandia National Laboratory. This model is able to model the finances, incentives, and performance of flat-plate photovoltaic (PV), concentrating PV, and concentrating solar power (specifically, parabolic troughs). The primary function of the model is to allow users to investigate the impact of variations in performance, cost, and financial parameters to better understand their impact on key figures of merit. Figures of merit related to the cost and performance of these systems include, but aren't limited to, system output, system efficiencies, levelized cost of energy, return on investment, and system capital and O&M costs. SAM allows users to do complex system modeling with an intuitive graphical user interface (GUI). In fact, all tables and graphics for this paper are taken directly from the model GUI. This model has the capability to compare different solar technologies within the same interface, making use of similar cost and finance assumptions. Additionally, the ability to do parametric and sensitivity analysis is central to this model. There are several models within SAM to model the performance of photovoltaic modules and inverters. This paper presents an overview of each PV and inverter model, introduces a new generic model, and briefly discusses the concentrating solar power (CSP) parabolic trough model. A comparison of results using the different PV and inverter models is also presented.

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

    NASA Astrophysics Data System (ADS)

    1981-12-01

    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.

  7. 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.

  8. 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.

  9. Methods for improving the lifetime performance of organic photovoltaics with low-costing encapsulation.

    PubMed

    Giannouli, Myrsini; Drakonakis, Vasileios M; Savva, Achilleas; Eleftheriou, Polyvios; Florides, Georgios; Choulis, Stelios A

    2015-04-27

    Recent years have seen considerable advances in organic photovoltaics (OPVs), most notably a significant increase in their efficiency, from around 4 % to over 10 %. The stability of these devices, however, continues to remain an issue that needs to be resolved to enable their commercialization. This review discusses the main degradation processes of OPVs and recent methods that help to increase device stability and lifetime. One of the most effective steps that can be taken to increase the lifetime of OPVs is their encapsulation, which protects them from atmospheric degradation. Efficient encapsulation is essential for long-term device performance, but it is equally important for the commercialization of OPVs to strike a balance between achieving the maximum device protection possible and using low-cost processing for their encapsulation. Various encapsulation techniques are discussed herein, with emphasis on their cost effectiveness and their overall suitability for commercial applications.

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

    DOEpatents

    Stoddard, Nathan G [Gettysburg, PA

    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.

  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. 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.

  13. 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

  14. Additive Manufacturing for Superalloys - Producibility and Cost Validation (Preprint)

    DTIC Science & Technology

    2011-03-01

    cell located at Advanced Manufacturing Research Centre (AMRC) Sheffield . The rationale was to implement development in production standard conditions...inspections were completed, a rough dimensional inspection was performed with a surface plate and manual gages to verify that the level of distortion

  15. 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.

  16. 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.

  17. Installed Cost Benchmarks and Deployment Barriers for Residential Solar Photovoltaics with Energy Storage: Q1 2016

    SciTech Connect

    Ardani, Kristen; O'Shaughnessy, Eric; Fu, Ran; McClurg, Chris; Huneycutt, Joshua; Margolis, Robert

    2016-12-01

    In this report, we fill a gap in the existing knowledge about PV-plus-storage system costs and value by providing detailed component- and system-level installed cost benchmarks for residential systems. We also examine other barriers to increased deployment of PV-plus-storage systems in the residential sector. The results are meant to help technology manufacturers, installers, and other stakeholders identify cost-reduction opportunities and inform decision makers about regulatory, policy, and market characteristics that impede solar plus storage deployment. In addition, our periodic cost benchmarks will document progress in cost reductions over time. To analyze costs for PV-plus-storage systems deployed in the first quarter of 2016, we adapt the National Renewable Energy Laboratory's component- and system-level cost-modeling methods for standalone PV. In general, we attempt to model best-in-class installation techniques and business operations from an installed-cost perspective. In addition to our original analysis, model development, and review of published literature, we derive inputs for our model and validate our draft results via interviews with industry and subject-matter experts. One challenge to analyzing the costs of PV-plus-storage systems is choosing an appropriate cost metric. Unlike standalone PV, energy storage lacks universally accepted cost metrics, such as dollars per watt of installed capacity and lifetime levelized cost of energy. We explain the difficulty of arriving at a standard approach for reporting storage costs and then provide the rationale for using the total installed costs of a standard PV-plus-storage system as our primary metric, rather than using a system-size-normalized metric.

  18. Three-dimensional nanopillar-array photovoltaics on low-cost and flexible substrates.

    PubMed

    Fan, Zhiyong; Razavi, Haleh; Do, Jae-won; Moriwaki, Aimee; Ergen, Onur; Chueh, Yu-Lun; Leu, Paul W; Ho, Johnny C; Takahashi, Toshitake; Reichertz, Lothar A; Neale, Steven; Yu, Kyoungsik; Wu, Ming; Ager, Joel W; Javey, Ali

    2009-08-01

    Solar energy represents one of the most abundant and yet least harvested sources of renewable energy. In recent years, tremendous progress has been made in developing photovoltaics that can be potentially mass deployed. Of particular interest to cost-effective solar cells is to use novel device structures and materials processing for enabling acceptable efficiencies. In this regard, here, we report the direct growth of highly regular, single-crystalline nanopillar arrays of optically active semiconductors on aluminium substrates that are then configured as solar-cell modules. As an example, we demonstrate a photovoltaic structure that incorporates three-dimensional, single-crystalline n-CdS nanopillars, embedded in polycrystalline thin films of p-CdTe, to enable high absorption of light and efficient collection of the carriers. Through experiments and modelling, we demonstrate the potency of this approach for enabling highly versatile solar modules on both rigid and flexible substrates with enhanced carrier collection efficiency arising from the geometric configuration of the nanopillars.

  19. Present and Future Silver Cost Component in Crystalline Silicon PV Module Manufacturing

    SciTech Connect

    Redlinger, Michael; Eggert, Roderick G.; Woodhouse, Michael

    2016-03-01

    The purpose of this paper is to determine how increased c-Si PV module production might affect future silver demand and prices, as well as the impacts on total c-Si module manufacturing costs. To evaluate how PV's changing demand for silver might affect future silver prices, and the impact in terms of manufacturing costs, some scenarios of silver's contribution to c-Si PV cell manufacturing costs are compiled on the basis of projected changes in demand and price as a result of changes in material intensity. The analysis indicates that an expansion of c-Si production from 55GW/year to 250GW/year results in a 0.05-0.7 cent/W increase in manufacturing costs because of higher silver prices.

  20. Establishment of reference costs for occupational health services and implementation of cost management in Japanese manufacturing companies

    PubMed Central

    Nagata, Tomohisa; Mori, Koji; Aratake, Yutaka; Ide, Hiroshi; Nobori, Junichiro; Kojima, Reiko; Odagami, Kiminori; Kato, Anna; Hiraoka, Mika; Shiota, Naoki; Kobayashi, Yuichi; Ito, Masato; Tsutsumi, Akizumi; Matsuda, Shinya

    2016-01-01

    Objectives: We developed a standardized cost estimation method for occupational health (OH) services. The purpose of this study was to set reference OH services costs and to conduct OH services cost management assessments in two workplaces by comparing actual OH services costs with the reference costs. Methods: Data were obtained from retrospective analyses of OH services costs regarding 15 OH activities over a 1-year period in three manufacturing workplaces. We set the reference OH services costs in one of the three locations and compared OH services costs of each of the two other workplaces with the reference costs. Results: The total reference OH services cost was 176,654 Japanese yen (JPY) per employee. The personnel cost for OH staff to conduct OH services was JPY 47,993, and the personnel cost for non-OH staff was JPY 38,699. The personnel cost for receipt of OH services-opportunity cost-was JPY 19,747, expense was JPY 25,512, depreciation expense was 34,849, and outsourcing cost was JPY 9,854. We compared actual OH services costs from two workplaces (the total OH services costs were JPY 182,151 and JPY 238,023) with the reference costs according to OH activity. The actual costs were different from the reference costs, especially in the case of personnel cost for non-OH staff, expense, and depreciation expense. Conclusions: Using our cost estimation tool, it is helpful to compare actual OH services cost data with reference cost data. The outcomes help employers make informed decisions regarding investment in OH services. PMID:27170449

  1. 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.

  2. 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

    2016-09-05

    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.

  3. 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.

  4. Assessing the costs of photovoltaic and wind power in six developing countries

    NASA Astrophysics Data System (ADS)

    Schmidt, Tobias S.; Born, Robin; Schneider, Malte

    2012-07-01

    To support developing countries in greenhouse-gas emission abatement the 2010 Cancún Agreement established various institutions, among others a financial mechanism administered by the Green Climate Fund. However, the instruments for delivering the support and the magnitude of different countries' financial needs are strongly debated. Both debates are predominantly underpinned by rather aggregate and strongly varying top-down cost estimates. To complement these numbers, we provide a more fine-grained bottom-up approach, comparing the cost of the renewable-energy technologies photovoltaics and wind in six developing countries with those of conventional technologies. Our results unveil large cost variations across specific technology-country combinations and show to what extent fossil-fuel subsidies can negatively affect the competitiveness of renewable-energy technologies. Regarding the instrument debate, our results indicate that to foster transformative changes, nationally appropriate mitigation actions are often more suited than a reformed clean development mechanism. Regarding the debate on financial needs, our results highlight the need for a decision on a fair baseline calculation methodology. To this end, we propose a new methodology that incentivizes changes in the baseline through subsidy phase-out. Finally, we contribute to the debate on domestic versus international support for these measures.

  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.

  6. 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

  7. 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.

  8. 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.

  9. 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.

  10. 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.

  11. 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.

  12. 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.

  13. 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.

  14. 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.

  15. Solution-deposited CIGS thin films for ultra-low-cost photovoltaics

    NASA Astrophysics Data System (ADS)

    Eldada, Louay A.; Hersh, Peter; Stanbery, Billy J.

    2010-09-01

    We describe the production of photovoltaic modules with high-quality large-grain copper indium gallium selenide (CIGS) thin films obtained with the unique combination of low-cost ink-based precursors and a reactive transfer printing method. The proprietary metal-organic inks contain a variety of soluble Cu-, In- and Ga- multinary selenide materials; they are called metal-organic decomposition (MOD) precursors, as they are designed to decompose into the desired precursors. Reactive transfer is a two-stage process that produces CIGS through the chemical reaction between two separate precursor films, one deposited on the substrate and the other on a printing plate in the first stage. In the second stage, these precursors are rapidly reacted together under pressure in the presence of heat. 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. In a few minutes, the process produces high quality CIGS films, with large grains on the order of several microns, and preferred crystallographic orientation, as confirmed by compositional and structural analysis by XRF, SIMS, SEM and XRD. Cell efficiencies of 14% and module efficiencies of 12% were achieved using this method. The atmospheric deposition processes include slot die extrusion coating, ultrasonic atomization spraying, pneumatic atomization spraying, inkjet printing, direct writing, and screen printing, and provide low capital equipment cost, low thermal budget, and high throughput.

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

    DOEpatents

    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.

  17. 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.

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

    PubMed

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

    2015-12-03

    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/cm(2), 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.

  19. 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

  20. 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.

  1. 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.

  2. Low-cost manufacturing of the point focus concentrating module and its key component, the Fresnel lens

    SciTech Connect

    Saifee, T.; Konnerth, A. III )

    1991-11-01

    Solar Kinetics, Inc. (SKI) has been developing point-focus concentrating PV modules since 1986. SKI is currently in position to manufacture between 200 to 600 kilowatts annually of the current design by a combination of manual and semi-automated methods. This report reviews the current status of module manufacture and specifies the required approach to achieve a high-volume manufacturing capability and low cost. The approach taken will include process development concurrent with module design for automated manufacturing. The current effort reviews the major manufacturing costs and identifies components and processes whose improvements would produce the greatest effect on manufacturability and cost reduction. The Fresnel lens is one such key component. Investigating specific alternative manufacturing methods and sources has substantially reduced the lens costs and has exceeded the DOE cost-reduction goals. 15 refs.

  3. 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.

  4. Reducing the manufacturing cost of tubular solid oxide fuel cell technology

    NASA Astrophysics Data System (ADS)

    George, Raymond A.; F. Bessette, Norman

    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 (˜63% net AC/LHV CH4), (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 US 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.

  5. 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.

  6. 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.

  7. 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).

  8. An analysis of the benefits of photovoltaic-coated glazing on owning and operating costs of high rise commercial buildings

    NASA Astrophysics Data System (ADS)

    Sylvester, Keith Everette

    Energy efficient glazing is necessary to reduce heat gains or losses that contribute to the high-energy use of buildings. However, high-rise commercial buildings that use energy efficient glazing are still consumptive. To reduce their energy use further, recent studies have integrated photovoltaic glazed window systems into the building shell. With limited light transmittance due to their required production of electricity, photovoltaic glazed windows can be developed with thermal properties similar to Low-E coatings. Consequently, these window systems can reduce operating costs of buildings without reducing the human satisfaction of the built environment. To understand the relationship between photovoltaic windows, energy use and human satisfaction, this study investigates the effects of photovoltaic glazed windows on energy use of large commercial buildings and includes an assessment of the overall human satisfaction of the workers within photovoltaic glazed office spaces. This study targets high-rise commercial buildings and their occupants in urban centers of the four census regions---North, Northeast, South, and Midwest. A prototypical building was used to develop the base case simulations for the DOE-2 energy simulation program and the PV F-Chart photovoltaic analysis program. By substituting the appropriate variable in the base case simulation for each site, building was simulated to evaluate the impact of the PV glazing on the building's heat loss/gaining as well as the amount of electricity that could be expected from the PV. To test for human satisfaction, a survey was performed to assess the overall preference of the subjects to the office spaces using the photovoltaic glazed windows. An analysis of the variance was also conducted to test for significantly different treatment means. Overall, the findings of this study show that photovoltaic windows significantly decrease the energy used by high-rise commercial buildings. Payback periods 11 to 20 years

  9. Cost model relationships between textile manufacturing processes and design details for transport fuselage elements

    NASA Technical Reports Server (NTRS)

    Metschan, Stephen L.; Wilden, Kurtis S.; Sharpless, Garrett C.; Andelman, Rich M.

    1993-01-01

    Textile manufacturing processes offer potential cost and weight advantages over traditional composite materials and processes for transport fuselage elements. In the current study, design cost modeling relationships between textile processes and element design details were developed. Such relationships are expected to help future aircraft designers to make timely decisions on the effect of design details and overall configurations on textile fabrication costs. The fundamental advantage of a design cost model is to insure that the element design is cost effective for the intended process. Trade studies on the effects of processing parameters also help to optimize the manufacturing steps for a particular structural element. Two methods of analyzing design detail/process cost relationships developed for the design cost model were pursued in the current study. The first makes use of existing databases and alternative cost modeling methods (e.g. detailed estimating). The second compares design cost model predictions with data collected during the fabrication of seven foot circumferential frames for ATCAS crown test panels. The process used in this case involves 2D dry braiding and resin transfer molding of curved 'J' cross section frame members having design details characteristic of the baseline ATCAS crown design.

  10. Powder Injection Molding (PIM) for Low Cost Manufacturing of Intricate Parts to Net-Shape

    DTIC Science & Technology

    2006-05-01

    Molding (PIM) for Low Cost Manufacturing of Intricate Parts to Net-Shape 7 - 6 RTO-MP-AVT-139 high temperature materials find applications in...offers significant cost savings, increased design and materials flexibility, increased possibility of miniaturization, high mechanical properties, good...surface finish and high speed production. The activities and expertise in powder metallurgy as well as in process numerical modeling related to

  11. Automated packaging platform for low-cost high-performance optical components manufacturing

    NASA Astrophysics Data System (ADS)

    Ku, Robert T.

    2004-05-01

    Delivering high performance integrated optical components at low cost is critical to the continuing recovery and growth of the optical communications industry. In today's market, network equipment vendors need to provide their customers with new solutions that reduce operating expenses and enable new revenue generating IP services. They must depend on the availability of highly integrated optical modules exhibiting high performance, small package size, low power consumption, and most importantly, low cost. The cost of typical optical system hardware is dominated by linecards that are in turn cost-dominated by transmitters and receivers or transceivers and transponders. Cost effective packaging of optical components in these small size modules is becoming the biggest challenge to be addressed. For many traditional component suppliers in our industry, the combination of small size, high performance, and low cost appears to be in conflict and not feasible with conventional product design concepts and labor intensive manual assembly and test. With the advent of photonic integration, there are a variety of materials, optics, substrates, active/passive devices, and mechanical/RF piece parts to manage in manufacturing to achieve high performance at low cost. The use of automation has been demonstrated to surpass manual operation in cost (even with very low labor cost) as well as product uniformity and quality. In this paper, we will discuss the value of using an automated packaging platform.for the assembly and test of high performance active components, such as 2.5Gb/s and 10 Gb/s sources and receivers. Low cost, high performance manufacturing can best be achieved by leveraging a flexible packaging platform to address a multitude of laser and detector devices, integration of electronics and handle various package bodies and fiber configurations. This paper describes the operation and results of working robotic assemblers in the manufacture of a Laser Optical Subassembly

  12. Transport phenomena in the close-spaced sublimation deposition process for manufacture of large-area cadmium telluride photovoltaic panels: Modeling and optimization

    NASA Astrophysics Data System (ADS)

    Malhotra, C. P.

    With increasing national and global demand for energy and concerns about the effect of fossil fuels on global climate change, there is an increasing emphasis on the development and use of renewable sources of energy. Solar cells or photovoltaics constitute an important renewable energy technology but the major impediment to their widespread adoption has been their high initial cost. Although thin-film photovoltaic semiconductors such as cadmium sulfide-cadmium telluride (CdS/CdTe) can potentially be inexpensively manufactured using large area deposition techniques such as close-spaced sublimation (CSS), their low stability has prevented them from becoming an alternative to traditional polycrystalline silicon solar cells. A key factor affecting the stability of CdS/CdTe cells is the uniformity of deposition of the thin films. Currently no models exist that can relate the processing parameters in a CSS setup with the film deposition uniformity. Central to the development of these models is a fundamental understanding of the complex transport phenomena which constitute the deposition process which include coupled conduction and radiation as well as transition regime rarefied gas flow. This thesis is aimed at filling these knowledge gaps and thereby leading to the development of the relevant models. The specific process under consideration is the CSS setup developed by the Materials Engineering Group at the Colorado State University (CSU). Initially, a 3-D radiation-conduction model of a single processing station was developed using the commercial finite-element software ABAQUS and validated against data from steady-state experiments carried out at CSU. A simplified model was then optimized for maximizing the steady-state thermal uniformity within the substrate. It was inferred that contrary to traditional top and bottom infrared lamp heating, a lamp configuration that directs heat from the periphery of the sources towards the center results in the minimum temperature

  13. Cost comparisons for the use of nonterrestrial materials in space manufacturing of large structures

    NASA Technical Reports Server (NTRS)

    Bock, E. H.; Risley, R. C.

    1979-01-01

    This paper presents results of a study sponsored by NASA to evaluate the relative merits of constructing solar power satellites (SPS) using resources obtained from the earth and from the moon. Three representative lunar resources utilization (LRU) concepts are developed and compared with a previously defined earth baseline concept. Economic assessment of the alternatives includes cost determination, economic threshold sensitivity to manufacturing cost variations, cost uncertainties, program funding schedule, and present value of costs. Results indicate that LRU for space construction is competitive with the earth baseline approach for a program requiring 100,000 metric tons per year of completed satellites. LRU can reduce earth-launched cargo requirements to less than 10% of that needed to build satellites exclusively from earth materials. LRU is potentially more cost-effective than earth-derived material utilization, due to significant reductions in both transportation and manufacturing costs. Because of uncertainties, cost-effectiveness cannot be ascertained with great confidence. The probability of LRU attaining a lower total program cost within the 30-year program appears to range from 57 to 93%.

  14. 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 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.

  15. Advanced, Cost-Based Indices for Forecasting the Generation of Photovoltaic Power

    NASA Astrophysics Data System (ADS)

    Bracale, Antonio; Carpinelli, Guido; Di Fazio, Annarita; Khormali, Shahab

    2014-01-01

    Distribution systems are undergoing significant changes as they evolve toward the grids of the future, which are known as smart grids (SGs). The perspective of SGs is to facilitate large-scale penetration of distributed generation using renewable energy sources (RESs), encourage the efficient use of energy, reduce systems' losses, and improve the quality of power. Photovoltaic (PV) systems have become one of the most promising RESs due to the expected cost reduction and the increased efficiency of PV panels and interfacing converters. The ability to forecast power-production information accurately and reliably is of primary importance for the appropriate management of an SG and for making decisions relative to the energy market. Several forecasting methods have been proposed, and many indices have been used to quantify the accuracy of the forecasts of PV power production. Unfortunately, the indices that have been used have deficiencies and usually do not directly account for the economic consequences of forecasting errors in the framework of liberalized electricity markets. In this paper, advanced, more accurate indices are proposed that account directly for the economic consequences of forecasting errors. The proposed indices also were compared to the most frequently used indices in order to demonstrate their different, improved capability. The comparisons were based on the results obtained using a forecasting method based on an artificial neural network. This method was chosen because it was deemed to be one of the most promising methods available due to its capability for forecasting PV power. Numerical applications also are presented that considered an actual PV plant to provide evidence of the forecasting performances of all of the indices that were considered.

  16. 38 CFR 36.4251 - Loans to finance the purchase of manufactured homes and the cost of necessary site preparation.

    Code of Federal Regulations, 2012 CFR

    2012-07-01

    ... 38 Pensions, Bonuses, and Veterans' Relief 2 2012-07-01 2012-07-01 false Loans to finance the... Manufactured Home Lot Loans § 36.4251 Loans to finance the purchase of manufactured homes and the cost of necessary site preparation. (a) A loan to finance the purchase of a manufactured home may include funds...

  17. 38 CFR 36.4251 - Loans to finance the purchase of manufactured homes and the cost of necessary site preparation.

    Code of Federal Regulations, 2013 CFR

    2013-07-01

    ... 38 Pensions, Bonuses, and Veterans' Relief 2 2013-07-01 2013-07-01 false Loans to finance the... Manufactured Home Lot Loans § 36.4251 Loans to finance the purchase of manufactured homes and the cost of necessary site preparation. (a) A loan to finance the purchase of a manufactured home may include funds...

  18. 38 CFR 36.4251 - Loans to finance the purchase of manufactured homes and the cost of necessary site preparation.

    Code of Federal Regulations, 2014 CFR

    2014-07-01

    ... 38 Pensions, Bonuses, and Veterans' Relief 2 2014-07-01 2014-07-01 false Loans to finance the... Manufactured Home Lot Loans § 36.4251 Loans to finance the purchase of manufactured homes and the cost of necessary site preparation. (a) A loan to finance the purchase of a manufactured home may include funds...

  19. DEVELOPMENT OF LOW-COST MANUFACTURING PROCESSES FOR PLANAR, MULTILAYER SOLID OXIDE FUEL CELL ELEMENTS

    SciTech Connect

    Scott Swartz; Matthew Seabaugh; William Dawson; Harlan Anderson; Tim Armstrong; Michael Cobb; Kirby Meacham; James Stephan; Russell Bennett; Bob Remick; Chuck Sishtla; Scott Barnett; John Lannutti

    2004-06-12

    This report summarizes the results of a four-year project, entitled, ''Low-Cost Manufacturing Of Multilayer Ceramic Fuel Cells'', jointly funded by the U.S. Department of Energy, the State of Ohio, and by project participants. The project was led by NexTech Materials, Ltd., with subcontracting support provided by University of Missouri-Rolla, Michael A. Cobb & Co., Advanced Materials Technologies, Inc., Edison Materials Technology Center, Gas Technology Institute, Northwestern University, and The Ohio State University. Oak Ridge National Laboratory, though not formally a subcontractor on the program, supported the effort with separate DOE funding. The objective of the program was to develop advanced manufacturing technologies for making solid oxide fuel cell components that are more economical and reliable for a variety of applications. The program was carried out in three phases. In the Phase I effort, several manufacturing approaches were considered and subjected to detailed assessments of manufacturability and development risk. Estimated manufacturing costs for 5-kW stacks were in the range of $139/kW to $179/kW. The risk assessment identified a number of technical issues that would need to be considered during development. Phase II development work focused on development of planar solid oxide fuel cell elements, using a number of ceramic manufacturing methods, including tape casting, colloidal-spray deposition, screen printing, spin-coating, and sintering. Several processes were successfully established for fabrication of anode-supported, thin-film electrolyte cells, with performance levels at or near the state-of-the-art. The work in Phase III involved scale-up of cell manufacturing methods, development of non-destructive evaluation methods, and comprehensive electrical and electrochemical testing of solid oxide fuel cell materials and components.

  20. Materials Testing and Cost Modeling for Composite Parts Through Additive Manufacturing

    DTIC Science & Technology

    2016-04-30

    êÅÜ=mêçÖê~ãW= `êÉ~íáåÖ=póåÉêÖó=Ñçê=fåÑçêãÉÇ=`Ü~åÖÉ= - 246 - Panel 17. Reducing Life- Cycle Costs: Adopting Emerging Manufacturing Technologies...chain. Introduction Modern manufacturing processes tend to reflect globalization, a concentration on core activities, shorter product life- cycles ... cycle perspective, a number of organizations recognize that environmental benefits and performance improvements can be achieved (Horn & Harrysson, 2012

  1. ICAM ’Manufacturing Cost/Design Guide’ (MC/DG). Volume 1. Demonstration Sections

    DTIC Science & Technology

    1980-09-01

    The base part is an element in its simplest form and with designer-influenced cost elements (DICE) such as, in the case of sheet metal, joggles , cut...introducing manufacturing complexities. This is shown below: * Added standard manufacturing operations - Joggles Flanged holes - Special lineal trim...Percentage Brake Form 71.4 Hydro Form 17.1 Die Form 6.0 Stretch Form 1.7 Roll Form 1.3 Hammer Form 1.1 Joggle Form 1.0 Other Methods 0.4 Distribution by

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

    PubMed Central

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

    2015-01-01

    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. PMID:26632759

  3. Modeling Photovoltaic and Concentrating Solar Power Trough Performance, Cost, and Financing with the Solar Advisor Model: Preprint

    SciTech Connect

    Blair, N.; Mehos, M.; Christensen, C.; Cameron, C.

    2008-05-01

    A comprehensive solar technology systems analysis model, the Solar Advisor Model (SAM), has been developed to support the federal R&D community and the solar industry by staff at the National Renewable Energy Laboratory (NREL) and Sandia National Laboratory. This model is able to model the finances, incentives, and performance of flat-plate photovoltaic (PV), concentrating PV, and concentrating solar power (specifically, parabolic troughs). The primary function of the model is to allow users to investigate the impact of variations in performance, cost, and financial parameters to better understand their impact on key figures of merit. Figures of merit related to the cost and performance of these systems include, but aren't limited to, system output, system efficiencies, levelized cost of energy, return on investment, and system capital and O&M costs. There are several models within SAM to model the performance of photovoltaic modules and inverters. This paper presents an overview of each PV and inverter model, introduces a new generic model, and briefly discusses the concentrating solar power (CSP) parabolic trough model. A comparison of results using the different PV and inverter models is also presented.

  4. Manufacturing of high performance, low cost dual mirror lamp reflector modules

    NASA Astrophysics Data System (ADS)

    Shen, Li

    The Lamp Reflector Module (LRM) is a key component in every micro display projection system, which has played a dominant role in the large-screen display market today. The goal of this research is to (1) improve the Dual Mirror prototype's light output performance, (2) investigate the underlying principles of its slow output deterioration so as to help develop effective and efficient LRM thermal management for maximized lifetime performance, and (3) improve/enable low cost mass LRM manufacturing for the projection display market. The first part of this research addresses the prototype's low output problem. More sophisticated 3D Optical Ray Tracing (ORT) models were generated to provide the output prediction depending on the arc gap, system collection etendue, etc. It was concluded that upgrading the manufacturing processes, particularly the reflector shape, surface and cold mirror coating, could effectively improve the output performance. Additionally, these theoretical models are shown to be used to design a LRM with 16% output gain for the consumer Rear Projection display market. The second part of this research focuses on the issue of lifetime performance. The electrode, arc attachment and envelope evolution were monitored by camera systems. The upgraded ORT models confirmed the arc length insensitivity property of the Dual Mirror LRM being one of the major reasons for its longer native lifetime. The third part of this research focuses on issues related to the entire LRM manufacturing. A series of quality control tools were developed to help implement manufacturing process optimization. LRMs made with the upgraded manufacturing processes showed about 25% output gain over the previous prototypes. Based on the imaging property of the Dual Mirror LRM, a lower cost lamp reflector alignment method, called cold alignment, was developed. In this method, the etendue efficiency is maintained and a slower degrading and more stable lifetime output performance are achieved

  5. Photovoltaic module reliability workshop

    NASA Astrophysics Data System (ADS)

    Mrig, L.

    The paper and presentations compiled in this volume form the Proceedings of the fourth in a series of Workshops sponsored by Solar Energy Research Institute (SERI/DOE) under the general theme of photovoltaic module reliability during the period 1986 to 1990. The reliability photovoltaic (PV) modules/systems is exceedingly important along with the initial cost and efficiency of modules if the PV technology has to make a major impact in the power generation market, and for it to compete with the conventional electricity producing technologies. The reliability of photovoltaic modules has progressed significantly in the last few years as evidenced by warrantees available on commercial modules of as long as 12 years. However, there is still need for substantial research and testing required to improve module field reliability to levels of 30 years or more. Several small groups of researchers are involved in this research, development, and monitoring activity around the world. In the U.S., PV manufacturers, DOE laboratories, electric utilities and others are engaged in the photovoltaic reliability research and testing. This group of researchers and others interested in this field were brought together under SERI/DOE sponsorship to exchange the technical knowledge and field experience as related to current information in this important field. The papers presented here reflect this effort.

  6. Disk drive flat optics:design factors affecting manufacturing and cost in volume.

    PubMed

    Westney, R P; Swaby, B L

    1988-02-15

    Polarizers and beam splitters for optical drives are small but expensive. Crystalline, prismatic, or cemented optics can often be replaced with coated flats of comparable performance- Cost drivers are examined, and spectral comparison is made between a plate and cube polarizer. Moisture stability of thin film coatings is discussed, and related applications examined, especially those involving control of the relative phase shift between S and P polarization on reflection. Processes now exist enabling the volume manufacture of these optics.

  7. On the Path to SunShot. The Role of Advancements in Solar Photovoltaic Efficiency, Reliability, and Costs

    SciTech Connect

    Woodhouse, Michael; Jones-Albertus, Rebecca; Feldman, David; Fu, Ran; Horowitz, Kelsey; Chung, Donald; Jordan, Dirk; Kurtz, Sarah

    2016-05-01

    This report examines the remaining challenges to achieving the competitive photovoltaic (PV) costs and large-scale deployment envisioned under the U.S. Department of Energy's SunShot Initiative. Solar-energy cost reductions can be realized through lower PV module and balance-of-system (BOS) costs as well as improved system efficiency and reliability. Numerous combinations of PV improvements could help achieve the levelized cost of electricity (LCOE) goals because of the tradeoffs among key metrics like module price, efficiency, and degradation rate as well as system price and lifetime. Using LCOE modeling based on bottom-up cost analysis, two specific pathways are mapped to exemplify the many possible approaches to module cost reductions of 29%-38% between 2015 and 2020. BOS hardware and soft cost reductions, ranging from 54%-77% of total cost reductions, are also modeled. The residential sector's high supply-chain costs, labor requirements, and customer-acquisition costs give it the greatest BOS cost-reduction opportunities, followed by the commercial sector, although opportunities are available to the utility-scale sector as well. Finally, a future scenario is considered in which very high PV penetration requires additional costs to facilitate grid integration and increased power-system flexibility--which might necessitate even lower solar LCOEs. The analysis of a pathway to 3-5 cents/kWh PV systems underscores the importance of combining robust improvements in PV module and BOS costs as well as PV system efficiency and reliability if such aggressive long-term targets are to be achieved.

  8. Photovoltaics, the solar electric solution

    NASA Astrophysics Data System (ADS)

    Beach, C. D.; Litka, A. H.

    Direct conversion of solar energy to electricity by photovoltaic devices (solar cells) may be the most promising solution to the current energy problem. Photovoltaic energy systems provide a clean, simple method of energy conversion, and are reliable, safe, and flexible with respect to size (modular). The federal government is trying to commercialize photovoltaics by funding research on new materials and manufacturing processes. Earliest commercialization will be in residential systems, where the power grid back-up provides for a reliable electrical system without storage costs. The Florida Solar Energy Center has been operating a 5 kW experimental residential facility since 1980. The facility showed an average solar irradiance in the 62.5 sq m panels of 264 kw-hours/day from December 1980 through February 1981. The overall system efficiency was 7%, and the inverter operated with an ac output/dc input efficiency of 85-90%, depending on input levels.

  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. Affordable Design: A Methodolgy to Implement Process-Based Manufacturing Cost into the Traditional Performance-Focused Multidisciplinary Design Optimization

    NASA Technical Reports Server (NTRS)

    Bao, Han P.; Samareh, J. A.

    2000-01-01

    The primary objective of this paper is to demonstrate the use of process-based manufacturing and assembly cost models in a traditional performance-focused multidisciplinary design and optimization process. The use of automated cost-performance analysis is an enabling technology that could bring realistic processbased manufacturing and assembly cost into multidisciplinary design and optimization. In this paper, we present a new methodology for incorporating process costing into a standard multidisciplinary design optimization process. Material, manufacturing processes, and assembly processes costs then could be used as the objective function for the optimization method. A case study involving forty-six different configurations of a simple wing is presented, indicating that a design based on performance criteria alone may not necessarily be the most affordable as far as manufacturing and assembly cost is concerned.

  11. Low cost Czochralski crystal growing technology. Near implementation of the flat plate photovoltaic cost reduction of the low cost solar array project

    NASA Technical Reports Server (NTRS)

    Roberts, E. G.

    1980-01-01

    Equipment developed for the manufacture of over 100 kg of silicon ingot from one crucible by rechanging from another crucible is described. Attempts were made to eliminate the cost of raising the furnace temperature to 250 C above the melting point of silicon by using an RF coil to melt polycrystalline silicon rod as a means of rechanging the crucible. Microprocessor control of the straight growth process was developed and domonstrated for both 4 inch and 6 inch diameter. Both meltdown and melt stabilization processes were achieved using operator prompting through the microprocessor. The use of the RF work coil in poly rod melting as a heat sink in the accelerated growth process was unsuccessful. The total design concept for fabrication and interfacing of the total cold crucible system was completed.

  12. Benchmarking Non-Hardware Balance of System (Soft) Costs for U.S. Photovoltaic Systems Using a Data-Driven Analysis from PV Installer Survey Results

    SciTech Connect

    Ardani, K.; Barbose, G.; Margolis, R.; Wiser, R.; Feldman, D.; Ong, S.

    2012-11-01

    This report presents results from the first U.S. Department of Energy (DOE) sponsored, bottom-up data-collection and analysis of non-hardware balance-of-system costs--often referred to as 'business process' or 'soft' costs--for residential and commercial photovoltaic (PV) systems.

  13. Retrospective Benefit-Cost Evaluation of DOE Investment in Photovoltaic Energy Systems

    SciTech Connect

    O'Connor, Alan C.; Loomis, Ross J.; Braun, Fern M.

    2010-08-01

    This study is a retrospective analysis of net benefits accruing from DOE's investment in photovoltaic (PV) technology development. The study employed a technology cluster approach. That is, benefits measured for a subset of technologies in a meaningful cluster, or portfolio, of technologies were compared to the total investment in the cluster to provide a lower bound measure of return for the entire cluster.

  14. A discounted-cost continuous-time flexible manufacturing and operator scheduling model solved by deconvexification over time

    SciTech Connect

    Eaves, B.C.; Rothblum, U.G.

    1990-08-01

    A discounted-cost, continuous-time, infinite-horizon version of a flexible manufacturing and operator scheduling model is solved. The solution procedure is to convexify the discrete operator-assignment constraints to obtain a linear program, and then to regain the discreteness and obtain an approximate manufacturing schedule by deconvexification of the solution of the linear program over time. The strong features of the model are the accommodation of linear inequality relations among the manufacturing activities and the discrete manufacturing scheduling, whereas the weak features are intra-period relaxation of inventory availability constraints, and the absence of inventory costs, setup times, and setup charges.

  15. Low Cost Injection Mold Creation via Hybrid Additive and Conventional Manufacturing

    SciTech Connect

    Dehoff, Ryan R.; Watkins, Thomas R.; List, III, Frederick Alyious; Carver, Keith; England, Roger

    2015-12-01

    The purpose of the proposed project between Cummins and ORNL is to significantly reduce the cost of the tooling (machining and materials) required to create injection molds to make plastic components. Presently, the high cost of this tooling forces the design decision to make cast aluminum parts because Cummins typical production volumes are too low to allow injection molded plastic parts to be cost effective with the amortized cost of the injection molding tooling. In addition to reducing the weight of components, polymer injection molding allows the opportunity for the alternative cooling methods, via nitrogen gas. Nitrogen gas cooling offers an environmentally and economically attractive cooling option, if the mold can be manufactured economically. In this project, a current injection molding design was optimized for cooling using nitrogen gas. The various components of the injection mold tooling were fabricated using the Renishaw powder bed laser additive manufacturing technology. Subsequent machining was performed on the as deposited components to form a working assembly. The injection mold is scheduled to be tested in a projection setting at a commercial vendor selected by Cummins.

  16. Battery compatibility with photovoltaic charge controllers

    NASA Astrophysics Data System (ADS)

    Harrington, S. R.; Bower, W. I.

    Photovoltaic (PV) systems offer a cost-effective solution to provide electrical power for a wide variety of applications, with battery performance playing a major role in their success. Some of the results of an industry meeting regarding battery specifications and ratings that photovoltaic system designers require, but do not typically have available to them are presented. Communications between the PV industry and the battery industry regarding appropriate specifications were uncoordinated and poor in the past. The effort under way involving the PV industry and battery manufacturers is discussed and a working draft of specifications to develop and outline the information sorely needed on batteries is provided. The development of this information is referred to as 'Application Notes for Batteries in Photovoltaic Systems.' The content of these 'notes' was compiled from various sources, including the input from the results of a survey on battery use in the photovoltaic industry. Only lead-acid batteries are discussed.

  17. Cost Study for Manufacturing of Solid Oxide Fuel Cell Power Systems

    SciTech Connect

    Weimar, Mark R.; Chick, Lawrence A.; Gotthold, David W.; Whyatt, Greg A.

    2013-09-30

    Solid oxide fuel cell (SOFC) power systems can be designed to produce electricity from fossil fuels at extremely high net efficiencies, approaching 70%. However, in order to penetrate commercial markets to an extent that significantly impacts world fuel consumption, their cost will need to be competitive with alternative generating systems, such as gas turbines. This report discusses a cost model developed at PNNL to estimate the manufacturing cost of SOFC power systems sized for ground-based distributed generation. The power system design was developed at PNNL in a study on the feasibility of using SOFC power systems on more electric aircraft to replace the main engine-mounted electrical generators [Whyatt and Chick, 2012]. We chose to study that design because the projected efficiency was high (70%) and the generating capacity was suitable for ground-based distributed generation (270 kW).

  18. Technology Needs for Reduced Design and Manufacturing Cost of Commercial Transport Engines

    NASA Technical Reports Server (NTRS)

    Rohn, Douglas A.

    1997-01-01

    The objective of the study was to assess the needs in the design and manufacturing processes and identify areas where technology could impact in cost and cycle-time reduction. At the highest level, the team first identified the goals that were in line with long-range needs of the aeropropulsion industry, and to which technology and process improvements would be required to contribute. These goals are to reduce the time and costs in the development cycle of aircraft engines by a factor of two, reduce production cycle time by a factor of four, and to reduce production costs by 25%. Also, it was the intent of the team to identify the highest impact technologies that could be developed and demonstrated in five years.

  19. Automotive Lithium-ion Cell Manufacturing: Regional Cost Structures and Supply Chain Considerations

    SciTech Connect

    Chung, Donald; Elgqvist, Emma; Santhanagopalan, Shriram

    2016-04-08

    Manufacturing capacity for lithium-ion batteries (LIBs)--which power many consumer electronics and are increasingly used to power electric vehicles--is heavily concentrated in east Asia. Currently, China, Japan, and Korea collectively host 88% of all LIB cell and 79% of automotive LIB cell manufacturing capacity. Mature supply chains and strong cumulative production experience suggest that most LIB cell production will remain concentrated in Asia. However, other regions--including North America--could be competitive in the growing automotive LIB cell market under certain conditions. To illuminate the factors that drive regional competitiveness in automotive LIB cell production, this study models cell manufacturing cost and minimum sustainable price, and examines development of LIB supply chains and current LIB market conditions. Modeled costs are for large format, 20-Ah stacked pouch cells with lithium-nickel-manganese-cobalt-oxide (NMC) cathodes and graphite anodes suitable for automotive application. Production volume is assumed to be at commercial scale, 600 MWh per year.

  20. Low-cost and high-throughput realization of metasurface-based absorber/emitter for thermal-photovoltaic cells

    NASA Astrophysics Data System (ADS)

    Bonakdar, Alireza; Rezaei, Mohsen; Dexheimer, Eric; Mohseni, Hooman

    2015-08-01

    A thermal photovoltaic cell (TPV) is an optical heat engine that can extract energy from an emitter with elevated temperature. In theory, the efficiency of a TPV can reach to 80% by wavelength conversion, yet in practice, only 3.2% efficiency has been achieved. The main physical drawback is to maintain the device operation at very high temperature while managing total solar spectrum absorption and efficient coupling of the narrow-band thermal radiation into the photovoltaic cell. In this vein, utilizing of a nanophotonic structure to undergo the wavelength conversion of solar energy is inevitable. Furthermore, low cost, large area and high throughput realization of such a structure brings TPV beyond the research lab. Simultaneous tailoring of UV/visible and mid-infrared spectrums requires sub-100-nm feature size, which is challenging with conventional photolithography if it is not impossible. We have developed a microsphere deep-UV lithography that can produce minimum feature size of ~ 50 nm at extremely low cost and high throughput. In this work, we demonstrate a metasurface platform fabricated with this lithography technique which has omni-polarization and -angle absorption in visible spectrum and efficient emission at mid-infrared as confirmed both by FDTD simulation and Fourier transform infrared spectroscopy (FTIR) measurement. The developed technique is promising technology to expedite TPV in real-life energy harvesting applications.

  1. Development of advanced manufacturing technologies for low cost hydrogen storage vessels

    SciTech Connect

    Leavitt, Mark; Lam, Patrick

    2014-12-29

    The U.S. Department of Energy (DOE) defined a need for low-cost gaseous hydrogen storage vessels at 700 bar to support cost goals aimed at 500,000 units per year. Existing filament winding processes produce a pressure vessel that is structurally inefficient, requiring more carbon fiber for manufacturing reasons, than would otherwise be necessary. Carbon fiber is the greatest cost driver in building a hydrogen pressure vessel. The objective of this project is to develop new methods for manufacturing Type IV pressure vessels for hydrogen storage with the purpose of lowering the overall product cost through an innovative hybrid process of optimizing composite usage by combining traditional filament winding (FW) and advanced fiber placement (AFP) techniques. A numbers of vessels were manufactured in this project. The latest vessel design passed all the critical tests on the hybrid design per European Commission (EC) 79-2009 standard except the extreme temperature cycle test. The tests passed include burst test, cycle test, accelerated stress rupture test and drop test. It was discovered the location where AFP and FW overlap for load transfer could be weakened during hydraulic cycling at 85°C. To design a vessel that passed these tests, the in-house modeling software was updated to add capability to start and stop fiber layers to simulate the AFP process. The original in-house software was developed for filament winding only. Alternative fiber was also investigated in this project, but the added mass impacted the vessel cost negatively due to the lower performance from the alternative fiber. Overall the project was a success to show the hybrid design is a viable solution to reduce fiber usage, thus driving down the cost of fuel storage vessels. Based on DOE’s baseline vessel size of 147.3L and 91kg, the 129L vessel (scaled to DOE baseline) in this project shows a 32% composite savings and 20% cost savings when comparing Vessel 15 hybrid design and the Quantum

  2. Tandem Microwire Solar Cells for Flexible High Efficiency Low Cost Photovoltaics

    SciTech Connect

    Atwater, Harry A.

    2015-03-10

    This project has developed components of a waferless, flexible, low-cost tandem multijunction III-V/Si microwire array solar cell technology which combines the efficiency of wafered III-V photovoltaic technologies with the process designed to meet the Sunshot object. The project focused on design of lattice-matched GaAsP/SiGe two junction cell design and lattice-mismatched GaInP/Si tandem cell design. Combined electromagnetic simulation/device physics models using realistic microwire tandem structures were developed that predict >22% conversion efficiency for known material parameters, such as tunnel junction structure, window layer structure, absorber lifetimes and optical absorption and these model indicate a clear path to 30% efficiency for high quality III-V heterostructures. SiGe microwire arrays were synthesized via Cu-catalyzed vapor-liquid-solid (VLS) growth with inexpensive chlorosilane and chlorogermance precursors in an atmospheric pressure reactor. SiGe alloy composition in microwires was found to be limited to a maximum of 12% Ge incorporation during chlorogermane growth, due to the melting of the alloy near the solidus composition. Lattice mismatched InGaP double heterostructures were grown by selective epitaxy with a thermal oxide mask on Si microwire substrates using metallorganic vapor phase epitaxy. Transmission electron microscopy (TEM) analysis confirms the growth of individual step graded layers and a high density of defects near the wire/III-V interface. Selective epitaxy was initiated with a low temperature nucleation scheme under “atomic layer epitaxy” or “flow mediated epitaxy” conditions whereby the Ga and P containing precursors are alternately introduced into the reactor to promote layer-bylayer growth. In parallel to our efforts on conformal GaInP heteroepitaxy on selectively masked Si microwires, we explored direct, axial growth of GaAs on Si wire arrays as another route to a tandem junction architecture. We proposed axial

  3. Design and high-volume manufacture of low-cost molded IR aspheres for personal thermal imaging devices

    NASA Astrophysics Data System (ADS)

    Zelazny, A. L.; Walsh, K. F.; Deegan, J. P.; Bundschuh, B.; Patton, E. K.

    2015-05-01

    The demand for infrared optical elements, particularly those made of chalcogenide materials, is rapidly increasing as thermal imaging becomes affordable to the consumer. The use of these materials in conjunction with established lens manufacturing techniques presents unique challenges relative to the cost sensitive nature of this new market. We explore the process from design to manufacture, and discuss the technical challenges involved. Additionally, facets of the development process including manufacturing logistics, packaging, supply chain management, and qualification are discussed.

  4. Advanced Materials and Manufacturing for Low-Cost, High-Performance Liquid Rocket Combustion Chambers

    NASA Technical Reports Server (NTRS)

    Williams, Brian E.; Arrieta, Victor M.

    2013-01-01

    A document describes the low-cost manufacturing of C103 niobium alloy combustion chambers, and the use of a high-temperature, oxidation-resistant coating that is superior to the standard silicide coating. The manufacturing process involved low-temperature spray deposition of C103 on removable plastic mandrels produced by rapid prototyping. Thin, vapor-deposited platinum-indium coatings were shown to substantially improve oxidation resistance relative to the standard silicide coating. Development of different low-cost plastic thrust chamber mandrel materials and prototyping processes (selective laser sintering and stereolithography) yielded mandrels with good dimensional accuracy (within a couple of mils) for this stage of development. The feasibility of using the kinetic metallization cold-spray process for fabrication of free-standing C1O3 thrusters on removable plastic mandrels was also demonstrated. The ambient and elevated temperature mechanical properties of the material were shown to be reasonably good relative to conventionally processed C103, but the greatest potential benefit is that coldsprayed chambers require minimal post-process machining, resulting in substantially lower machining and material costs. The platinum-iridium coating was shown to provide greatly increased oxidation resistance over the silicide when evaluated through oxyacetylene torch testing to as high as 300 F (= 150 C). The iridium component minimizes reaction with the niobium alloy chamber at high temperatures, and provides the high-temperature oxidation resistance needed at the throat.

  5. Editorial: Photovoltaic Materials and Devices 2014

    SciTech Connect

    Sopori, Bhushan; Rupnowski, Peter; Shet, Sudhakar; Basnyat, Prakash

    2014-12-22

    An ever increasing demand on energy has fostered many new generation technologies, which include photovoltaics. In recent years, photovoltaic industry has grown very rapidly. The installed capacity of PV for 2013 was about 37 GW and 2014 sales are expected to be around 45 GW. However, there has been excess production for last several years, which is responsible in part for the low prices (about 60 c/W). To lower the PV energy costs further, a major strategy appears to be going to high efficiency solar cells. This approach is favored (over lower cost/lower efficiency) because cell efficiency has a very large influence on the acceptable manufacturing cost of a PV module. Hence, the PV industry is moving toward developing processes and equipment to manufacture solar cells that can yield efficiencies >20%. Therefore, further research is needed within existing technologies to accomplish these objectives. Likewise, research will continue to seek new materials and devices.

  6. 38 CFR 36.4251 - Loans to finance the purchase of manufactured homes and the cost of necessary site preparation.

    Code of Federal Regulations, 2010 CFR

    2010-07-01

    ... to Veterans to Purchase Manufactured Homes and Lots, Including Site Preparation Combination and... necessary site preparation. (a) A loan to finance the purchase of a manufactured home may include funds (or be augmented by a separate loan) to pay all or a part of the cost of the necessary site...

  7. 38 CFR 36.4251 - Loans to finance the purchase of manufactured homes and the cost of necessary site preparation.

    Code of Federal Regulations, 2011 CFR

    2011-07-01

    ... to Veterans to Purchase Manufactured Homes and Lots, Including Site Preparation Combination and... necessary site preparation. (a) A loan to finance the purchase of a manufactured home may include funds (or be augmented by a separate loan) to pay all or a part of the cost of the necessary site...

  8. PEM fuel cell cost minimization using ``Design For Manufacture and Assembly`` techniques

    SciTech Connect

    Lomax, F.D. Jr.; James, B.D.; Mooradian, R.P.

    1997-12-31

    Polymer Electrolyte Membrane (PEM) fuel cells fueled with direct hydrogen have demonstrated substantial technical potential to replace Internal Combustion Engines (ICE`s) in light duty vehicles. Such a transition to a hydrogen economy offers the potential of substantial benefits from reduced criteria and greenhouse emissions as well as reduced foreign fuel dependence. Research conducted for the Ford Motor Co. under a US Department of Energy contract suggests that hydrogen fuel, when used in a fuel cell vehicle (FCV), can achieve a cost per vehicle mile less than or equal to the gasoline cost per mile when used in an ICE vehicle. However, fuel cost parity is not sufficient to ensure overall economic success: the PEM fuel cell power system itself must be of comparable cost to the ICE. To ascertain if low cost production of PEM fuel cells is feasible, a powerful set of mechanical engineering tools collectively referred to as Design for Manufacture and Assembly (DFMA) has been applied to several representative PEM fuel cell designs. The preliminary results of this work are encouraging, as presented.

  9. Additive Manufacturing for Cost Efficient Production of Compact Ceramic Heat Exchangers and Recuperators

    SciTech Connect

    Shulman, Holly; Ross, Nicole

    2015-10-30

    An additive manufacture technique known as laminated object manufacturing (LOM) was used to fabricate compact ceramic heat exchanger prototypes. LOM uses precision CO2 laser cutting of ceramic green tapes, which are then precision stacked to build a 3D object with fine internal features. Modeling was used to develop prototype designs and predict the thermal response, stress, and efficiency in the ceramic heat exchangers. Build testing and materials analyses were used to provide feedback for the design selection. During this development process, laminated object manufacturing protocols were established. This included laser optimization, strategies for fine feature integrity, lamination fluid control, green handling, and firing profile. Three full size prototypes were fabricated using two different designs. One prototype was selected for performance testing. During testing, cross talk leakage prevented the application of a high pressure differential, however, the prototype was successful at withstanding the high temperature operating conditions (1300 °F). In addition, analysis showed that the bulk of the part did not have cracks or leakage issues. This led to the development of a module method for next generation LOM heat exchangers. A scale-up cost analysis showed that given a purpose built LOM system, these ceramic heat exchangers would be affordable for the applications.

  10. Low-cost small scale parabolic trough collector design for manufacturing and deployment in Africa

    NASA Astrophysics Data System (ADS)

    Orosz, Matthew; Mathaha, Paul; Tsiu, Anadola; Taele, B. M.; Mabea, Lengeta; Ntee, Marcel; Khakanyo, Makoanyane; Teker, Tamer; Stephens, Jordan; Mueller, Amy

    2016-05-01

    Concentrating Solar Power is expanding its deployment on the African subcontinent, highlighting the importance of efforts to indigenize manufacturing of this technology to increase local content and therefore local economic benefits of these projects. In this study a design for manufacturing (DFM) exercise was conducted to create a locally produced parabolic trough collector (the G4 PTC). All parts were sourced or fabricated at a production facility in Lesotho, and several examples of the design were prototyped and tested with collaborators in the Government of Lesotho's Appropriate Technology Services division and the National University of Lesotho. Optical and thermal performance was simulated and experimentally validated, and pedagogical pre-commercial versions of the PTC have been distributed to higher education partners in Lesotho and Europe. The cost to produce the PTC is 180 USD/m2 for a locally manufactured heat collection element (HCE) capable of sustaining 250C operation at ~65% efficiency. A version with an imported evacuated HCE can operate at 300°C with 70% efficiency. Economically relevant applications for this locally produced PTC include industrial process heat and distributed generation scenarios where cogeneration is required.

  11. Methods and apparatuses for manufacturing geometric multicrystalline cast silicon and geometric multicrystalline cast silicon bodies for photovoltaics

    DOEpatents

    Stoddard, Nathan G

    2015-02-10

    Methods and apparatuses are provided for casting silicon for photovoltaic cells and other applications. With such methods and apparatuses, a cast body of geometrically ordered multi-crystalline silicon may be formed that is free or substantially free of radially-distributed impurities and defects and having at least two dimensions that are each at least about 10 cm is provided.

  12. High throughput manufacturing of thin-film CdTe photovoltaic modules. Annual subcontract report, 16 November 1993--15 November 1994

    SciTech Connect

    Sandwisch, D W

    1995-11-01

    This report describes work performed by Solar Cells, Inc. (SCI), under a 3-year subcontract to advance SCI`s PV manufacturing technologies, reduce module production costs, increase module performance, and provide the groundwork for SCI to expand its commercial production capacities. SCI will meet these objectives in three phases by designing, debugging, and operating a 20-MW/year, automated, continuous PV manufacturing line that produces 60-cm {times} 120-cm thin-film CdTe PV modules. This report describes tasks completed under Phase 1 of the US Department of Energy`s PV Manufacturing Technology program.

  13. U.S. Photovoltaic Prices and Cost Breakdowns. Q1 2015 Benchmarks for Residential, Commercial, and Utility-Scale Systems

    SciTech Connect

    Chung, Donald; Davidson, Carolyn; Fu, Ran; Ardani, Kristen; Margolis, Robert

    2015-09-01

    The price of photovoltaic (PV) systems in the United States (i.e., the cost to the system owner) has continued to decline across all major market sectors. This report provides a Q1 2015 update regarding the prices of residential, commercial, and utility scale PV systems, based on an objective methodology that closely approximates the book value of a PV system. Several cases are benchmarked to represent common variations in business models, labor rates, and system architecture choice. We estimate a weighted-average cash purchase price of $3.09/W for residential scale rooftop systems, $2.15/W for commercial scale rooftop systems, $1.77/W for utility scale systems with fixed mounting structures, and $1.91/W for utility scale systems using single-axis trackers. All systems are modeled assuming standard-efficiency, polycrystalline-silicon PV modules, and further assume installation within the United States.

  14. Photovoltaic module reliability workshop

    SciTech Connect

    Mrig, L.

    1990-01-01

    The paper and presentations compiled in this volume form the Proceedings of the fourth in a series of Workshops sponsored by Solar Energy Research Institute (SERI/DOE) under the general theme of photovoltaic module reliability during the period 1986--1990. The reliability Photo Voltaic (PV) modules/systems is exceedingly important along with the initial cost and efficiency of modules if the PV technology has to make a major impact in the power generation market, and for it to compete with the conventional electricity producing technologies. The reliability of photovoltaic modules has progressed significantly in the last few years as evidenced by warranties available on commercial modules of as long as 12 years. However, there is still need for substantial research and testing required to improve module field reliability to levels of 30 years or more. Several small groups of researchers are involved in this research, development, and monitoring activity around the world. In the US, PV manufacturers, DOE laboratories, electric utilities and others are engaged in the photovoltaic reliability research and testing. This group of researchers and others interested in this field were brought together under SERI/DOE sponsorship to exchange the technical knowledge and field experience as related to current information in this important field. The papers presented here reflect this effort.

  15. Quo Vadis photovoltaics 2011

    NASA Astrophysics Data System (ADS)

    Jäger-Waldau, A.

    2011-10-01

    Since more than 10 years photovoltaics is one of the most dynamic industries with growth rates well beyond 40% per annum. This growth is driven not only by the progress in materials knowledge and processing technology, but also by market introduction programmes in many countries around the world. Despite the negative impacts on the economy by the financial crisis since 2009, photovoltaics is still growing at an extraordinary pace and had in 2010 an extraordinary success, as both production and markets doubled. The open question is what will happen in 2011 and the years after as the situation is dominated by huge manufacturing overcapacities and an increasing unpredictability of policy support. How can the PV industry continue their cost reduction to ensure another 10 to 20 years of sustained and strong growth necessary to make PV to one of the main pillars of a sustainable energy supply in 2030. Despite the fact, that globally the share of electricity from photovoltaic systems is still small, at local level it can be already now above 30% of the demand at certain times of the year. Future research in PV has to provide intelligent solutions not only on the solar cell alone, but also on the module and the system integration level in order to permit a 5 to 10% share of electricity in 2020.

  16. Manufacturing technologies for photovoltaics and possible means of their development in Russia (Review). Part 1: General approach to the development of photoelectric converters and basic silicon technologies

    NASA Astrophysics Data System (ADS)

    Tarasenko, A. B.; Popel', O. S.

    2015-11-01

    The state and key tendencies of the development of basic technologies for manufacture of photoelectric converters (PECs) in the world are considered, and their advantages and disadvantages are discussed. The first part of the review gives short information on the development of photovoltaics in the world and planes of the development of solar power plants in Russia. Total power of photoelectric plants operating in various countries in 2015 exceeded 150 GW and increased in the last ten years with a rate of approximately 50% per year. Russia made important state decisions on the support of the development of renewable power engineering and developed mechanisms, which were attractive for business, on the stimulation of building of the network of solar power plants with a total power to 1.5 GW in the country to 2020. At the same time, the rigid demands are made with respect to the localization of the production of components of these plants that opens new abilities for the development of the domestic production of photovoltaics manufacture. Data on the efficiency of PECs of various types that are attained in the leading laboratories of the world are given. Particular emphasis has been placed on the consideration of basic silicon technologies of PEC manufacture, which had the widest commercial application. The basic methods for production of polycrystalline silicon and making single-crystal and multicrystal silicon are described. Fundamentals of making techniques for plates, PECs, and photoelectric modules based on single-crystal and polycrystalline silicon are considered. The second part will be devoted to modifications of manufacturing techniques for photoelectric converters, enhancement methods for contact structures, and recommendations of authors with respect to the choice of prospective technologies for the expansion of PEC production in Russia. It will involve formulations and substantiations of the most promising lines of the development of photoelectric

  17. Concentrating photovoltaic technology

    SciTech Connect

    Edenburn, M.W.

    1984-01-01

    This paper will summarize the status and discuss likely future directions of photovoltaic concentrator technology. A current commercial Si cell module has a peak efficiency of 15.5%, and 17% has been reached with an experimental module. Advanced cells and module design improvements offer still higher efficiencies. Concentrator Fresnel lens array fields installed several years ago have all demonstrated very good electrical performance with little performance degradation. Fresnel lens arrays were commercially available and prices of $7/watt for installed one megawatt systems have been quoted. Cost projections predict that current technology concentrating PV arrays can be installed for less than $2/watt if they are manufactured in large, steady quantities. More advanced designs may cost even less.

  18. Photovoltaics industry profile

    SciTech Connect

    1980-10-01

    A description of the status of the US photovoltaics industry is given. Principal end-user industries are identified, domestic and foreign market trends are discussed, and industry-organized and US government-organized trade promotion events are listed. Trade associations and trade journals are listed, and a photovoltaic product manufacturers list is included. (WHK)

  19. Low Cost and Energy Efficient Methods for the Manufacture of Semi-Solid (SSM) Feedstock

    SciTech Connect

    Diran Apelian; Qingyue Pan; Makhlouf Makhlouf

    2005-11-07

    The SSM Consortium (now ACRC) at WPI has been carrying out fundamental, pre-competitive research in SSM for several years. Current and past research (at WPI) has generated many results of fundamental and applied nature, which are available to the SSM community. These include materials characterization, yield stress effects, alloy development, rheological properties, process modeling/simulation, semi-solid slurry formation, etc. Alternative method to produce SSM slurries at lower processing costs and with reduced energy consumption is a critical need. The production of low cost SSM feedstock will certainly lead to a dramatic increase in the tonnage of castings produced by SSM, and will provide end users such as the transportation industry, with lighter, cheaper and high performance materials. In this program, the research team has addressed three critical issues in semi-solid processing. They are: (1) Development of low cost, reliable slurry-on-demand approaches for semi-solid processing; (2) Application of the novel permanent grain refining technology-SiBloy for the manufacture of high-quality SSM feedstock, and (3) Development of computational and modeling tools for semi-solid processing to enhance SSM process control. Salient results from these studies are summarized and detailed in our final technical report.

  20. Photovoltaic technology assessment

    SciTech Connect

    Backus, C.E.

    1981-01-01

    After a brief review of the history of photovoltaic devices and a discussion of the cost goals set for photovoltaic modules, the status of photovoltaic technology is assessed. Included are discussions of: current applications, present industrial production, low-cost silicon production techniques, energy payback periods for solar cells, advanced materials research and development, concentrator systems, balance-of-system components. Also discussed are some nontechnical aspects, including foreign markets, US government program approach, and industry attitudes and approaches. (LEW)

  1. Photovoltaic manufacturing technology (PVMaT) improvements for ENTECH's concentrator module. Final subcontract report, 17 February 1992--14 June 1995

    SciTech Connect

    O'Neill, M.J.; McDanal, A.J.

    1995-11-01

    Since 1978, the ENTECH technical team has been developing, field testing, refining, and commercializing photovoltaic concentrator systems based on a patented arched Fresnel lens optical concentrator, which provides maximum optical efficiency coupled with exceptional real-world error tolerance. First- through third-generation systems were deployed from the early 1980s to the early 1990s. In 1991, ENTECH was awarded a contract by Sandia National Laboratories to develop a fourth-generation concentrator module. In 1992, ENTECH was funded by NREL under the PVMaT Phase 2A procurement to develop and implement the manufacturing process for the new module. This report documents the work performed by ENTECH, Inc. under this PVMAT Phase 2A program.

  2. Development of a fixed abrasive slicing technique (FAST) for reducing the cost of photovoltaic wafers. Final subcontract report, 9 January 1991--14 April 1991

    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.

  3. Low cost method for manufacturing a data acquisition system with USB connectivity

    NASA Astrophysics Data System (ADS)

    Niculescu, V.; Dobre, R. A.; Popovici, E.

    2016-06-01

    In the process of designing and manufacturing an electronic system the digital oscilloscope plays an essential role but it also represents one of the most expensive equipment present on the typical workbench. In order to make electronic design more accessible to students and hobbyists, an affordable data acquisition system was imagined. The paper extensively presents the development and testing of a low cost, medium speed, data acquisition system which can be used in a wide range of electronic measurement and debugging applications, assuring also great portability due to the small physical dimensions. Each hardware functional block and is thoroughly described, highlighting the challenges that occurred as well as the solutions to overcome them. The entire system was successfully manufactured using high quality components to assure increased reliability, and high frequency PCB materials and techniques were preferred. The measured values determined based on test signals were compared to the ones obtained using a digital oscilloscope available on the market and differences less than 1% were observed.

  4. Cost-Effective Additive Manufacturing in Space: HELIOS Technology Challenge Guide

    NASA Technical Reports Server (NTRS)

    DeVieneni, Alayna; Velez, Carlos Andres; Benjamin, David; Hollenbeck, Jay

    2012-01-01

    Welcome to the HELIOS Technology Challenge Guide. This document is intended to serve as a general road map for participants of the HELIOS Technology Challenge [HTC] Program and the associated inaugural challenge: HTC-01: Cost-Effective Additive Manufacturing in Space. Please note that this guide is not a rule book and is not meant to hinder the development of innovative ideas. Its primary goal is to highlight the objectives of the HTC-01 Challenge and to describe possible solution routes and pitfalls that such technology may encounter in space. Please also note that participants wishing to demonstrate any hardware developed under this program during any future HELIOS Technology Challenge showcase event(s) may be subject to event regulations to be published separately at a later date.

  5. Sustainable chemical manufacturing: a matter of resources, wastes, hazards, and costs.

    PubMed

    Lange, Jean-Paul

    2009-01-01

    Sustainable development is gaining importance in the chemical industry. It encompasses social, environmental, and economical aspects. Herein, sustainable development is translated into four basic dimensions, called "sustainability stresses": resources, wastes, hazards, and costs. These sustainability stresses are discussed in some detail and their usefulness is illustrated by applying them to three manufacturing processes applied commercially by Shell, namely Shell's OMEGA, SMPO, and "low monol" technologies for producing ethene diol, styrene/propene oxide, and polyether polyols, respectively. These examples show that large reductions in sustainable stresses have been achieved in a few decades. They also show that the economical, environmental, and social issues are not in conflict when tackled at their roots: they can be all addressed simultaneously.

  6. 78 FR 58559 - Notice Pursuant to the National Cooperative Research and Production Act of 1993-U.S. Photovoltaic...

    Federal Register 2010, 2011, 2012, 2013, 2014

    2013-09-24

    .... Photovoltaic Manufacturing Consortium, Inc. Notice is hereby given that, on August 20, 2013, pursuant to.... (``the Act''), U.S. Photovoltaic Manufacturing Consortium, Inc. (``USPVMC'') has filed...

  7. 78 FR 9939 - Notice Pursuant to the National Cooperative Research and Production Act of 1993-U.S. Photovoltaic...

    Federal Register 2010, 2011, 2012, 2013, 2014

    2013-02-12

    .... Photovoltaic Manufacturing Consortium, Inc. Notice is hereby given that, on January 15, 2013, pursuant to.... (``the Act''), U.S. Photovoltaic Manufacturing Consortium, Inc. (``USPVMC'') has filed ]...

  8. Low Cost Production of Thin-Film Photovoltaic Cells Final Report

    SciTech Connect

    McCamy, James; Hung, Cheng-Hung; Ma, Zhixun

    2015-06-04

    The objective of this project was to determine the feasibility of online deposition of the active layer for thin-film PV modules. The envisioned PV online manufacturing process has a number of discrete unit operations integrated into a single process. Demonstration of feasibility would be deemed successful with the individual demonstration of each of these unit operations and development of the integrated process was not within the scope of this phase.

  9. Economic Evaluation of Munitions Manufacturing Pink Wastewater Treatment Alternatives Using a Present Value-Unit Cost Methodology

    DTIC Science & Technology

    1982-02-01

    present value- unit cost (PVUC) methodology and compares seven state -of-the- art processes: activated granular carbon adsorption with and without...The United States Army controls seventeen Army Ammunition Plants (AAP) engaged in explosive or propellant manufacture. Seven AAP’s engage only in mar...Army manufactures all explosives (except nitroglycerin) employed by the United States Air Force and the Army LAP facilities process Air Force munitions

  10. Photovoltaic system criteria documents. Volume 2: Quality assurance criteria for photovoltaic applications

    NASA Technical Reports Server (NTRS)

    Koenig, John C.; Billitti, Joseph W.; Tallon, John M.

    1979-01-01

    Quality assurance criteria are described for manufacturers and installers of solar photovoltaic tests and applications. Quality oriented activities are outlined to be pursued by the contractor/subcontractor to assure the physical and operational quality of equipment produced is included. In the broad sense, guidelines are provided for establishing a QA organization if none exists. Mainly, criteria is provided to be considered in any PV quality assurance plan selected as appropriate by the responsible Field Center. A framework is established for a systematic approach to ensure that photovoltaic tests and applications are constructed in a timely and cost effective manner.

  11. Assessment of the cost-effectiveness of photovoltaic systems for telecommunications in Nigeria

    NASA Astrophysics Data System (ADS)

    Oparaku, O. U.

    2002-03-01

    Developing countries seeking relevance in the international community have to adopt programmes in order to achieve cost-effective economic growth. Telecommunications is one area where emphasis must be laid because of its impact on development. Since the power supply forms an essential part of any communication system it is important to chose the power supply option that has the lowest life-cycle cost. The life-cycle costs of several power supply alternatives to some telecommunication systems in Nigeria have been evaluated. A hybrid (Solar/Gen. Set) power supply option is shown to be cost-effective when compared with diesel generating systems powering telecommunication equipment and airconditioning loads. The cost of PV power supply option used for a celluphone system is about 10% of the cost of the alternative of daily battery replacement and haulage. The low teledensity in the country creates a need for bold initiatives to incorporate solar power in telecommunications network, particularly in the remote rural communities where conventional electricity is not only unavailable, but is unreliable and very costly to maintain.

  12. Evaluations of candidate encapsulation designs and materials for low-cost silicon photovoltaic arrays

    NASA Technical Reports Server (NTRS)

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

    1978-01-01

    Three encapsulation designs for silicon photovoltaic arrays based on cells with silk-screened Ag metallization have been evaluated: transparent polymeric coatings over cells laminated between two films or sheets of polymeric materials; cells adhesively bonded to a glass cover with a polymer pottant and a glass or other substrate component. Silicone and acrylic coatings were assessed, together with acrylic sheet, 0.635 mm fiberglass-reinforced polyester sheet, 0.102 mm polycarbonate/acrylic dual-layer film, 0.127 mm fluorocarbon film, soda-lime glass, borosilicate glass, low-iron glass, and several adhesives. The encapsulation materials were characterized by light transmittance measurements, determination of moisture barrier properties and bond strengths, and by the performance of cells before and after encapsulation. Silicon and acrylic coatings provided inadequate protection. Acrylic and fluorocarbon films displayed good weatherability and acceptable optical transmittance. Borosilicate, low-iron and soda-lime-float glasses were found to be acceptable candidate encapsulants for most environments.

  13. Photovoltaics program plan, FY 1991--FY 1995

    SciTech Connect

    Not Available

    1991-10-01

    This program plan describes the goals and philosophy of DOE National Photovoltaics Program and its major research and development activities for fiscal years (FY) 1991 through 1995. The plan represents a consensus among researchers and manufacturers, as well as current and potential users of photovoltaics (PV). It defines the activites that we believe are necessary to continue the rapid progress toward acceptance of photovoltaics as a serious candidate for cost-competitive electric power generation by the utility, transportation, buildings, and industrial sectors. A succesful National Photovoltaics Program will help achieve many of our national priorities. The mission of the National Photovoltaics Program is to help US industry to develop photovoltaic technology for large-scale generation of economically competitive electric power in the United States, making PV a significant part of our national energy mix. To fully achieve this, we must continue to work toward the long-term goals established in our previous program plan: reducing the price of delivered electricity to 5 to 6 cents per kilowatt-hour (kWh), increasing lifetimes to 30 years, and increasing module efficiencies to 15% for flat-plate and 25% for concentrator technologies. If progress continues at its current pace, we expect that the PV industry will have installed at least 1000 megawatts (MW) of capacity in the United States and 500 MW internationally by the year 2000.

  14. Photovoltaic subsystem marketing and distribution model: programming manual. Final report

    SciTech Connect

    Not Available

    1982-07-01

    Complete documentation of the marketing and distribution (M and D) computer model is provided. The purpose is to estimate the costs of selling and transporting photovoltaic solar energy products from the manufacturer to the final customer. The model adjusts for the inflation and regional differences in marketing and distribution costs. The model consists of three major components: the marketing submodel, the distribution submodel, and the financial submodel. The computer program is explained including the input requirements, output reports, subprograms and operating environment. The program specifications discuss maintaining the validity of the data and potential improvements. An example for a photovoltaic concentrator collector demonstrates the application of the model.

  15. Low-cost manufacturing of the point focus concentrating module and its key component, the Fresnel lens. Final subcontract report, 31 January 1991--6 May 1991

    SciTech Connect

    Saifee, T.; Konnerth, A. III

    1991-11-01

    Solar Kinetics, Inc. (SKI) has been developing point-focus concentrating PV modules since 1986. SKI is currently in position to manufacture between 200 to 600 kilowatts annually of the current design by a combination of manual and semi-automated methods. This report reviews the current status of module manufacture and specifies the required approach to achieve a high-volume manufacturing capability and low cost. The approach taken will include process development concurrent with module design for automated manufacturing. The current effort reviews the major manufacturing costs and identifies components and processes whose improvements would produce the greatest effect on manufacturability and cost reduction. The Fresnel lens is one such key component. Investigating specific alternative manufacturing methods and sources has substantially reduced the lens costs and has exceeded the DOE cost-reduction goals. 15 refs.

  16. Photovoltaic performance and reliability workshop

    SciTech Connect

    Mrig, L.

    1993-12-01

    This workshop was the sixth in a series of workshops sponsored by NREL/DOE under the general subject of photovoltaic testing and reliability during the period 1986--1993. PV performance and PV reliability are at least as important as PV cost, if not more. In the US, PV manufacturers, DOE laboratories, electric utilities, and others are engaged in the photovoltaic reliability research and testing. This group of researchers and others interested in the field were brought together to exchange the technical knowledge and field experience as related to current information in this evolving field of PV reliability. The papers presented here reflect this effort since the last workshop held in September, 1992. The topics covered include: cell and module characterization, module and system testing, durability and reliability, system field experience, and standards and codes.

  17. Financing, Overhead, and Profit: An In-Depth Discussion of Costs Associated with Third-Party Financing of Residential and Commercial Photovoltaic Systems

    SciTech Connect

    Feldman, D.; Friedman, B.; Margolis, R.

    2013-10-01

    Previous work quantifying the non-hardware balance-of-system costs -- or soft costs -- associated with building a residential or commercial photovoltaic (PV) system has left a significant portion unsegmented in an 'other soft costs' category. This report attempts to better quantify the 'other soft costs' by focusing on the financing, overhead, and profit of residential and commercial PV installations for a specific business model. This report presents results from a bottom-up data-collection and analysis of the upfront costs associated with developing, constructing, and arranging third-party-financed residential and commercial PV systems. It quantifies the indirect corporate costs required to install distributed PV systems as well as the transactional costs associated with arranging third-party financing.

  18. Photovoltaic Subcontract Program, FY 1990

    SciTech Connect

    Summers, K.A.

    1991-03-01

    This report summarizes the progress of the subcontracted photovoltaic (PV) research and development (R D) performed under the Photovoltaics Program at the Solar Energy Research Institute (SERI). The SERI subcontracted PV research and development represents most of the subcontracted R D that is funded by the US Department of Energy (DOE) National Photovoltaics Program. This report covers fiscal year (FY) 1990: October 1, 1989 through September 30, 1990. During FY 1990, the SERI PV program started to implement a new DOE subcontract initiative, entitled the Photovoltaic Manufacturing Technology (PVMaT) Project.'' Excluding (PVMaT) because it was in a start-up phase, in FY 1990 there were 54 subcontracts with a total annualized funding of approximately $11.9 million. Approximately two-thirds of those subcontracts were with universities, at a total funding of over $3.3 million. Cost sharing by industry added another $4.3 million to that $11.9 million of SERI PV subcontracted R D. The six technical sections of this report cover the previously ongoing areas of the subcontracted program: the Amorphous Silicon Research Project, Polycrystalline Thin Films, Crystalline Silicon Materials Research, High-Efficiency Concepts, the New Ideas Program, and the University Participation Program. Technical summaries of each of the subcontracted programs discuss approaches, major accomplishments in FY 1990, and future research directions. Another section introduces the PVMaT project and reports the progress since its inception in FY 1990. Highlights of technology transfer activities are also reported.

  19. Development of a low-cost extrusion-embossing process for a linear Fresnel lens photovoltaic concentration

    SciTech Connect

    Not Available

    1984-09-01

    Results of efforts to fabricate linear Fresnel lens using a low-cost extrusion-embossing process indicated that the extrusion-embossing process will be difficult to adapt to the manufacture of efficient lenses. Lenses produced in pilot runs acheived only 72% optical efficiency at 25X geometric concentration ratio, compared to 87% for lenses made by casting or Lensfilm processes. A highly accurate, yet simple, outdoor focal plane flux profile test apparatus was developed that can be used to qualify new lenses and to check the quality of production lenses.

  20. Warranty optimisation based on the prediction of costs to the manufacturer using neural network model and Monte Carlo simulation

    NASA Astrophysics Data System (ADS)

    Stamenkovic, Dragan D.; Popovic, Vladimir M.

    2015-02-01

    Warranty is a powerful marketing tool, but it always involves additional costs to the manufacturer. In order to reduce these costs and make use of warranty's marketing potential, the manufacturer needs to master the techniques for warranty cost prediction according to the reliability characteristics of the product. In this paper a combination free replacement and pro rata warranty policy is analysed as warranty model for one type of light bulbs. Since operating conditions have a great impact on product reliability, they need to be considered in such analysis. A neural network model is used to predict light bulb reliability characteristics based on the data from the tests of light bulbs in various operating conditions. Compared with a linear regression model used in the literature for similar tasks, the neural network model proved to be a more accurate method for such prediction. Reliability parameters obtained in this way are later used in Monte Carlo simulation for the prediction of times to failure needed for warranty cost calculation. The results of the analysis make possible for the manufacturer to choose the optimal warranty policy based on expected product operating conditions. In such a way, the manufacturer can lower the costs and increase the profit.

  1. Cost-Effective Silicon Wafers for Solar Cells: Direct Wafer Enabling Terawatt Photovoltaics

    SciTech Connect

    2010-01-15

    Broad Funding Opportunity Announcement Project: 1366 is developing a process to reduce the cost of solar electricity by up to 50% by 2020—from $0.15 per kilowatt hour to less than $0.07. 1366’s process avoids the costly step of slicing a large block of silicon crystal into wafers, which turns half the silicon to dust. Instead, the company is producing thin wafers directly from molten silicon at industry-standard sizes, and with efficiencies that compare favorably with today’s state-of-the-art technologies. 1366’s wafers could directly replace wafers currently on the market, so there would be no interruptions to the delivery of these products to market. As a result of 1366’s technology, the cost of silicon wafers could be reduced by 80%.

  2. Tracking the Sun III; The Installed Cost of Photovoltaics in the United States from 1998-2009

    SciTech Connect

    Barbose, Galen; Darghouth, Naim; Wiser, Ryan

    2010-12-13

    Installations of solar photovoltaic (PV) systems have been growing at a rapid pace in recent years. In 2009, approximately 7,500 megawatts (MW) of PV were installed globally, up from approximately 6,000 MW in 2008, consisting primarily of grid-connected applications. With 335 MW of grid-connected PV capacity added in 2009, the United States was the world's fourth largest PV market in 2009, behind Germany, Italy, and Japan. The market for PV in the United States is driven by national, state, and local government incentives, including up-front cash rebates, production-based incentives, requirements that electricity suppliers purchase a certain amount of solar energy, and federal and state tax benefits. These programs are, in part, motivated by the popular appeal of solar energy, and by the positive attributes of PV - modest environmental impacts, avoidance of fuel price risks, coincidence with peak electrical demand, and the possible deployment of PV at the point of use. Given the relatively high cost of PV, however, a key goal of these policies is to encourage cost reductions over time. Therefore, as policy incentives have become more significant and as PV deployment has accelerated, so too has the desire to track the installed cost of PV systems over time, by system characteristics, by system location, and by component. Despite the significant year-on-year growth, however, the share of global and U.S. electricity supply met with PV remains small, and annual PV additions are currently modest in the context of the overall electric system. To address this need, Lawrence Berkeley National Laboratory initiated a report series focused on describing trends in the installed cost of grid-connected PV systems in the United States. The present report, the third in the series, describes installed cost trends from 1998 through 2009, and provides preliminary cost data for systems installed in 2010. The analysis is based on project-level cost data from approximately 78

  3. Benchmarking Non-Hardware Balance-of-System (Soft) Costs for U.S. Photovoltaic Systems, Using a Bottom-Up Approach and Installer Survey - Second Edition

    SciTech Connect

    Friedman, B.; Ardani, K.; Feldman, D.; Citron, R.; Margolis, R.; Zuboy, J.

    2013-10-01

    This report presents results from the second U.S. Department of Energy (DOE) sponsored, bottom-up data-collection and analysis of non-hardware balance-of-system costs -- often referred to as 'business process' or 'soft' costs -- for U.S. residential and commercial photovoltaic (PV) systems. In service to DOE's SunShot Initiative, annual expenditure and labor-hour-productivity data are analyzed to benchmark 2012 soft costs related to (1) customer acquisition and system design (2) permitting, inspection, and interconnection (PII). We also include an in-depth analysis of costs related to financing, overhead, and profit. Soft costs are both a major challenge and a major opportunity for reducing PV system prices and stimulating SunShot-level PV deployment in the United States. The data and analysis in this series of benchmarking reports are a step toward the more detailed understanding of PV soft costs required to track and accelerate these price reductions.

  4. Low-cost, high-efficiency organic/inorganic hetero-junction hybrid solar cells for next generation photovoltaic device

    NASA Astrophysics Data System (ADS)

    Pudasaini, P. R.; Ayon, A. A.

    2013-12-01

    Organic/inorganic hybrid structures are considered innovative alternatives for the next generation of low-cost photovoltaic devices because they combine advantages of the purely organic and inorganic versions. Here, we report an efficient hybrid solar cell based on sub-wavelength silicon nanotexturization in combination with the spin-coating of poly (3,4-ethylene-dioxythiophene):polystyrenesulfonate (PEDOT:PSS). The described devices were analyzed by collecting current-voltage and capacitance-voltage measurements in order to explore the organic/inorganic heterojunction properties. ALD deposited ultrathin aluminium oxide was used as a junction passivation layer between the nanotextured silicon surface and the organic polymer. The measured interface defect density of the device was observed to decrease with the inclusion of an ultrathin Al2O3 passivation layer leading to an improved electrical performance. This effect is thought to be ascribed to the suppression of charge recombination at the organic/inorganic interface. A maximum power conversion efficiency in excess of 10% has been achieved for the optimized geometry of the device, in spite of lacking an antireflection layer or back surface field enhancement schemes.

  5. The Relationship between National Heart, Lung, and Blood Institute Weight Guidelines and Concurrent Medical Costs in a Manufacturing Population.

    ERIC Educational Resources Information Center

    Wang, Feifei; Schultz, Alyssa B.; Musich, Shirley; McDonald, Tim; Hirschland, David; Edington, Dee W.

    2003-01-01

    Explored the relationship between the 1998 National Heart, Lung, and Blood Institute (NHLBI) weight guidelines and concurrent medical costs among 177,971 employees, retirees, and adult dependents from a nationwide manufacturing corporation. Results indicated that the six weight groups defined by the NHLBI guidelines were consistent with concurrent…

  6. Development of Low-Cost Manufacturing Processes for Planar, Multilayer Solid Oxide Fuel Cell Elements

    SciTech Connect

    Scott Swartz; Matthew Seabaugh; William Dawson; Tim Armstrong; Harlan Anderson; John Lannutti

    2001-09-30

    This report summarizes the results of Phase II of this program, 'Low-Cost Manufacturing Of Multilayer Ceramic Fuel Cells'. The objective of the program is to develop advanced ceramic manufacturing technologies for making planar solid oxide fuel cell (SOFC) components that are more economical and reliable for a variety of applications. Phase II development work focused on three distinct manufacturing approaches (or tracks) for planar solid oxide fuel cell elements. Two development tracks, led by NexTech Materials and Oak Ridge National Laboratory, involved co-sintering of planar SOFC elements of cathode-supported and anode-supported variations. A third development track, led by the University of Missouri-Rolla, focused on a revolutionary approach for reducing operating temperature of SOFCs by using spin-coating to deposit ultra-thin, nano-crystalline YSZ electrolyte films. The work in Phase II was supported by characterization work at Ohio State University. The primary technical accomplishments within each of the three development tracks are summarized. Track 1--NexTech's targeted manufacturing process for planar SOFC elements involves tape casting of porous electrode substrates, colloidal-spray deposition of YSZ electrolyte films, co-sintering of bi-layer elements, and screen printing of opposite electrode coatings. The bulk of NexTech's work focused on making cathode-supported elements, although the processes developed at NexTech also were applied to the fabrication of anode-supported cells. Primary accomplishments within this track are summarized below: (1) Scale up of lanthanum strontium manganite (LSM) cathode powder production process; (2) Development and scale-up of tape casting methods for cathode and anode substrates; (3) Development of automated ultrasonic-spray process for depositing YSZ films; (4) Successful co-sintering of flat bi-layer elements (both cathode and anode supported); (5) Development of anode and cathode screen-printing processes; and (6

  7. LOW-COST COMPOSITES IN VEHICLE MANUFACTURE - Natural-fiber-reinforced polymer composites in automotive applications.

    SciTech Connect

    Holbery, Jim; Houston, Dan

    2006-11-01

    In the last decade, natural fiber composites have experienced rapid growth in the European automotive market, and this trend appears to be global in scale, provided the cost and performance is justified against competing technologies. However, mass reduction, recyclability, and performance requirements can be met today by competing systems such as injection-molded unreinforced thermoplastics; natural fiber composites will continue to expand their role in automotive applications only if such technical challenges as moisture stability, fiber-polymer interface compatibility, and consistent, repeatable fiber sources are available to supply automotive manufacturers. Efforts underway by Tier I and II automotive suppliers to explore hybrid glass-natural fiber systems, as well as applications that exploit such capabilities as natural fiber sound dampening characteristics, could very well have far-reaching effects. In addition, the current development underway of bio-based resins such as Polyhydroxyalkanoate (PHA) biodegradable polyesters and bio-based polyols could provide fully bio-based composite options to future automotive designers. In short, the development of the natural fiber composite market would make a positive impact on farmers and small business owners on a global scale, reduce US reliance on foreign oil, improve environmental quality through the development of a sustainable resource supply chain, and achieve a better CO2 balance over the vehicle?s lifetime with near-zero net greenhouse gas emissions.

  8. High Temperature Thermoplastic Additive Manufacturing Using Low-Cost, Open-Source Hardware

    NASA Technical Reports Server (NTRS)

    Gardner, John M.; Stelter, Christopher J.; Yashin, Edward A.; Siochi, Emilie J.

    2016-01-01

    Additive manufacturing (or 3D printing) via Fused Filament Fabrication (FFF), also known as Fused Deposition Modeling (FDM), is a process where material is placed in specific locations layer-by-layer to create a complete part. Printers designed for FFF build parts by extruding a thermoplastic filament from a nozzle in a predetermined path. Originally developed for commercial printers, 3D printing via FFF has become accessible to a much larger community of users since the introduction of Reprap printers. These low-cost, desktop machines are typically used to print prototype parts or novelty items. As the adoption of desktop sized 3D printers broadens, there is increased demand for these machines to produce functional parts that can withstand harsher conditions such as high temperature and mechanical loads. Materials meeting these requirements tend to possess better mechanical properties and higher glass transition temperatures (Tg), thus requiring printers with high temperature printing capability. This report outlines the problems and solutions, and includes a detailed description of the machine design, printing parameters, and processes specific to high temperature thermoplastic 3D printing.

  9. Electron Beam Freeform Fabrication (EBF3) for Cost Effective Near-Net Shape Manufacturing

    NASA Technical Reports Server (NTRS)

    Taminger, Karen M.; Hafley, Robert A.

    2006-01-01

    Manufacturing of structural metal parts directly from computer aided design (CAD) data has been investigated by numerous researchers over the past decade. Researchers at NASA Langley Research Center are developing a new solid freeform fabrication process, electron beam freeform fabrication (EBF3), as a rapid metal deposition process that works efficiently with a variety of weldable alloys. EBF3 deposits of 2219 aluminium and Ti-6Al-4V have exhibited a range of grain morphologies depending upon the deposition parameters. These materials have exhibited excellent tensile properties comparable to typical handbook data for wrought plate product after post-processing heat treatments. The EBF3 process is capable of bulk metal deposition at deposition rates in excess of 2500 cubic centimeters per hour (150 in3/hr) or finer detail at lower deposition rates, depending upon the desired application. This process offers the potential for rapidly adding structural details to simpler cast or forged structures rather than the conventional approach of machining large volumes of chips to produce a monolithic metallic structure. Selective addition of metal onto simpler blanks of material can have a significant effect on lead time reduction and lower material and machining costs.

  10. Electron Beam Freeform Fabrication for Cost Effective Near-Net Shape Manufacturing

    NASA Technical Reports Server (NTRS)

    Taminger, Karen M.; Hafley, Robert A.

    2006-01-01

    Manufacturing of structural metal parts directly from computer aided design (CAD) data has been investigated by numerous researchers over the past decade. Researchers at NASA Langley Research Center are developing a new solid freeform fabrication process, electron beam freeform fabrication (EBF3), as a rapid metal deposition process that works efficiently with a variety of weldable alloys. EBF3 deposits of 2219 aluminium and Ti-6Al-4V have exhibited a range of grain morphologies depending upon the deposition parameters. These materials have exhibited excellent tensile properties comparable to typical handbook data for wrought plate product after post-processing heat treatments. The EBF3 process is capable of bulk metal deposition at deposition rates in excess of 2500 cm3/hr (150 in3/hr) or finer detail at lower deposition rates, depending upon the desired application. This process offers the potential for rapidly adding structural details to simpler cast or forged structures rather than the conventional approach of machining large volumes of chips to produce a monolithic metallic structure. Selective addition of metal onto simpler blanks of material can have a significant effect on lead time reduction and lower material and machining costs.

  11. Manufacturing Cost Analysis for YSZ-Based FlexCells at Pilot and Full Scale Production Scales

    SciTech Connect

    Scott Swartz; Lora Thrun; Robin Kimbrell; Kellie Chenault

    2011-05-01

    Significant reductions in cell costs must be achieved in order to realize the full commercial potential of megawatt-scale SOFC power systems. The FlexCell designed by NexTech Materials is a scalable SOFC technology that offers particular advantages over competitive technologies. In this updated topical report, NexTech analyzes its FlexCell design and fabrication process to establish manufacturing costs at both pilot scale (10 MW/year) and full-scale (250 MW/year) production levels and benchmarks this against estimated anode supported cell costs at the 250 MW scale. This analysis will show that even with conservative assumptions for yield, materials usage, and cell power density, a cost of $35 per kilowatt can be achieved at high volume. Through advancements in cell size and membrane thickness, NexTech has identified paths for achieving cell manufacturing costs as low as $27 per kilowatt for its FlexCell technology. Also in this report, NexTech analyzes the impact of raw material costs on cell cost, showing the significant increases that result if target raw material costs cannot be achieved at this volume.

  12. Photovoltaics Fact Sheet

    SciTech Connect

    2016-02-01

    This fact sheet is an overview of the Photovoltaics (PV) subprogram at the U.S. Department of Energy SunShot Initiative. The U.S. Department of Energy (DOE)’s Solar Energy Technologies Office works with industry, academia, national laboratories, and other government agencies to advance solar PV, which is the direct conversion of sunlight into electricity by a semiconductor, in support of the goals of the SunShot Initiative. SunShot supports research and development to aggressively advance PV technology by improving efficiency and reliability and lowering manufacturing costs. SunShot’s PV portfolio spans work from early-stage solar cell research through technology commercialization, including work on materials, processes, and device structure and characterization techniques.

  13. Photovoltaic Materials

    SciTech Connect

    Duty, C.; Angelini, J.; Armstrong, B.; Bennett, C.; Evans, B.; Jellison, G. E.; Joshi, P.; List, F.; Paranthaman, P.; Parish, C.; Wereszczak, A.

    2012-10-15

    The goal of the current project was to help make the US solar industry a world leader in the manufacture of thin film photovoltaics. The overall approach was to leverage ORNL’s unique characterization and processing technologies to gain a better understanding of the fundamental challenges for solar cell processing and apply that knowledge to targeted projects with industry members. ORNL has the capabilities in place and the expertise required to understand how basic material properties including defects, impurities, and grain boundaries affect the solar cell performance. ORNL also has unique processing capabilities to optimize the manufacturing process for fabrication of high efficiency and low cost solar cells. ORNL recently established the Center for Advanced Thin-film Systems (CATS), which contains a suite of optical and electrical characterization equipment specifically focused on solar cell research. Under this project, ORNL made these facilities available to industrial partners who were interested in pursuing collaborative research toward the improvement of their product or manufacturing process. Four specific projects were pursued with industrial partners: Global Solar Energy is a solar industry leader in full scale production manufacturing highly-efficient Copper Indium Gallium diSelenide (CIGS) thin film solar material, cells and products. ORNL worked with GSE to develop a scalable, non-vacuum, solution technique to deposit amorphous or nanocrystalline conducting barrier layers on untextured stainless steel substrates for fabricating high efficiency flexible CIGS PV. Ferro Corporation’s Electronic, Color and Glass Materials (“ECGM”) business unit is currently the world’s largest supplier of metallic contact materials in the crystalline solar cell marketplace. Ferro’s ECGM business unit has been the world's leading supplier of thick film metal pastes to the crystalline silicon PV industry for more than 30 years, and has had operational cells and

  14. Photovoltaics: The endless spring

    NASA Technical Reports Server (NTRS)

    Brandhorst, H. W., Jr.

    1984-01-01

    An overview of the developments in the photovoltaic field over the past decade or two is presented. Accomplishments in the terrestrial field are reviewed along with projections and challenges toward meeting cost goals. The contrasts and commonality of space and terrestrial photovoltaics are presented. Finally, a strategic philosophy of photovoltaics research highlighting critical factors, appropriate directions, emerging opportunities, and challenges of the future is given.

  15. Large area low cost processing for CIS photovoltaics. Final technical report

    SciTech Connect

    B. Basol; G. Norsworthy; C. Leidholm; A. Halani; R. Roe; V. Kapur

    1999-07-22

    An ink coating method was developed for CIS absorber deposition. The technique involves four processing steps: (1) preparation of a Cu-In alloy powder, (2) preparation of an ink using this powder, (3) deposition of the ink on a substrate in the form of a precursor layer, and (4) selenization to convert the Cu-In precursor into a fused CIS film. Absorbers grown by this low-cost, large-area method were used in the fabrication of 10.5% efficient solar cells.

  16. Cost goals for a residential photovoltaic/thermal liquid collector system set in three northern locations

    NASA Astrophysics Data System (ADS)

    Dinwoodie, T. L.; Kavanaugh, J. P.

    1980-10-01

    The allowable costs for a residential PV/T liquid collector system are compared with those of both PV only and side-by-side PV and thermal collector systems. Four typs of conventional energy systems provide backup: all oil, all gas, all electric resistance, and electric resistance hot water with space heating by parallel heat pump. Electric space cooling is modeled, and the electric utility serves as backup for all electrical needs. The analysis is separated into two parts: (1) a base case study using conservative market and financial parameters for comparing PV/T economics in three northern locations; and (2) the sensitivity of PV/T economics to pertinent physical, market, and financial variables is examined. The difference in economic outlook for PV/T in retrofit applications is also estimated. It is indicated that, it for northern locations modeled, is less than that of separate (side-by-side) collector systems, at total array areas between 40-80 sq m. Below this range, allowable costs diverge, benefiting optimally sized separate collector systems.

  17. Preliminary estimate of the manufacturing cost for lithium/metal sulfide cells for stationary and mobile applications

    SciTech Connect

    Chilenskas, A. A.; Schaefer, J. C.; Towle, W. L.; Barney, D. L.

    1980-01-01

    A preliminary estimate has been made of the manufacturing cost for lithium/iron sulfide cells for stationary energy-storage and electric-vehicle applications. This preliminary cost analysis indicated that the manufacturing cost (in 1979 dollars) is $24 to 41/kW-h for stationary energy-storage cells and $31 to 55/kW-h for electric-vehicle cells. The materials cost was found to contribute between 52 and 65% of this manufacturing cost. The most expensive materials and components were lithium (metal and compounds), $4.61 to $14.26/kW-h; BN felt, $4.00 to 8.50/kW-h; feed-through components, $2.40/kW-h; positive current collectors, $1.48 to 2.20/kW-h; and aluminum, $1.43 to 1.66/kW-h. The projected lithium requirements were determined for use in lithium/iron sulfide batteries and conventional uses to the year 2006. The results showed that the lithium requirements were about 275,000 short tons by 2006, which is equivalent to about 51% of presently known US resources. Of this amount, about 33% would be used in battery production and 67% consumed in conventional uses. It is expected that the lithium used in battery production would be recycled.

  18. Photovoltaic Roofs

    NASA Technical Reports Server (NTRS)

    Drummond, R. W., Jr.; Shepard, N. F., Jr.

    1984-01-01

    Solar cells perform two functions: waterproofing roof and generating electricity. Sections through horizontal and slanting joints show overlapping modules sealed by L-section rubber strips and side-by-side modules sealed by P-section strips. Water seeping through seals of slanting joints drains along channels. Rooftop photovoltaic array used watertight south facing roof, replacing shingles, tar, and gravel. Concept reduces cost of residential solar-cell array.

  19. A learning curve approach to projecting cost and performance for photovoltaic technologies

    NASA Astrophysics Data System (ADS)

    Cody, George D.; Tiedje, Thomas

    1997-04-01

    The current cost of electricity generated by PV power is still extremely high with respect to power supplied by the utility grid, and there remain questions as to whether PV power can ever be competitive with electricity generated by fossil fuels. An objective approach to this important question was given in a previous paper by the authors which introduced analytical tools to define and project the technical/economic status of PV power from 1988 through the year 2010. In this paper, we apply these same tools to update the conclusions of our earlier study in the context of recent announcements by Amoco/Enron-Solarex of projected sales of PV power at rates significantly less than the US utility average.

  20. Learning curve approach to projecting cost and performance for photovoltaic technologies

    NASA Astrophysics Data System (ADS)

    Cody, George D.; Tiedje, Thomas

    1997-10-01

    The current cost of electricity generated by PV power is still extremely high with respect to power supplied by the utility grid, and there remain questions as to whether PV power can ever be competitive with electricity generated by fossil fuels. An objective approach to this important question was given in a previous paper by the authors which introduced analytical tools to define and project the technical/economic status of PV power from 1988 through the year 2010. In this paper, we apply these same tools to update the conclusions of our earlier study in the context of recent announcements by Amoco/Enron-Solar of projected sales of PV power at rates significantly less than the U.S. utility average.

  1. The Effect of Adopting New Storage Methods for Extending Product Validity Periods on Manufacturers Expected Inventory Costs

    PubMed Central

    Chen, Po-Yu

    2014-01-01

    The validness of the expiration dates (validity period) that manufacturers provide on food product labels is a crucial food safety problem. Governments must study how to use their authority by implementing fair awards and punishments to prompt manufacturers into adopting rigorous considerations, such as the effect of adopting new storage methods for extending product validity periods on expected costs. Assuming that a manufacturer sells fresh food or drugs, this manufacturer must respond to current stochastic demands at each unit of time to determine the purchase amount of products for sale. If this decision maker is capable and an opportunity arises, new packaging methods (e.g., aluminum foil packaging, vacuum packaging, high-temperature sterilization after glass packaging, or packaging with various degrees of dryness) or storage methods (i.e., adding desiccants or various antioxidants) can be chosen to extend the validity periods of products. To minimize expected costs, this decision maker must be aware of the processing costs of new storage methods, inventory standards, inventory cycle lengths, and changes in relationships between factors such as stochastic demand functions in a cycle. Based on these changes in relationships, this study established a mathematical model as a basis for discussing the aforementioned topics. PMID:25302332

  2. 76 FR 79218 - Notice Pursuant to the National Cooperative Research and Production Act of 1993-U.S. Photovoltaic...

    Federal Register 2010, 2011, 2012, 2013, 2014

    2011-12-21

    .... Photovoltaic Manufacturing Consortium, Inc. Notice is hereby given that, on November 14, 2011, pursuant to.... (``the Act''), U.S. Photovoltaic Manufacturing Consortium, Inc. (``USPVMC'') has filed written... the commercialization of next generation photovoltaic systems. Patricia A. Brink, Director of...

  3. Photovoltaic power conditioning subsystem: State of the art and development opportunities

    NASA Technical Reports Server (NTRS)

    Krauthamer, S.; Bahrami, K.; Das, R.; Macie, T.; Rippel, W.

    1984-01-01

    Photovoltaic systems, the state of the art of power conditioning subsystem components, and the design and operational interaction between photovoltaic systems and host utilities are detailed in this document. Major technical issues relating to the design and development of power conditioning systems for photovoltaic application are considered; these include: (1) standards, guidelines, and specifications; (2) cost effective hardware design; (3) impact of advanced components on power conditioning development; (4) protection and safety; (5) quality of power; (6) system efficiency; and (7) system integration with the host utility. Theories of harmonic distortion and reactive power flow are discussed, and information about power conditioner hardware and manufacturers is provided.

  4. Photovoltaic power conditioning subsystem: state of the art and development opportunities

    SciTech Connect

    Krauthamer, S.; Bahrami, K.; Das, R.; Macie, T.; Rippel, W.

    1984-01-15

    Photovoltaic sytems, the state of the art of power conditioning subsystem components, and the design and operational interaction between photovoltaic systems and hot utilities are detailed in this document. Major technical issues relating to the design and development of power conditioning systems for photovoltaic application are also considered, including: (1) standards, guidelines, and specifications; (2) cost-effective hardware design; (3) impact of advanced components on power conditioning development; (4) protection and safety; (5) quality of power; (6) system efficiency; and (7) system integration with the host utility. In addition, theories of harmonic distortion and reactive power flow are discussed, and information about power conditioner hardware and manufacturers is provided.

  5. Defect Engineering, Cell Processing, and Modeling for High-Performance, Low-Cost Crystalline Silicon Photovoltaics

    SciTech Connect

    Buonassisi, Tonio

    2013-02-26

    The objective of this project is to close the efficiency gap between industrial multicrystalline silicon (mc-Si) and monocrystalline silicon solar cells, while preserving the economic advantage of low-cost, high-volume substrates inherent to mc-Si. Over the course of this project, we made significant progress toward this goal, as evidenced by the evolution in solar-cell efficiencies. While most of the benefits of university projects are diffuse in nature, several unique contributions can be traced to this project, including the development of novel characterization methods, defect-simulation tools, and novel solar-cell processing approaches mitigate the effects of iron impurities ("Impurities to Efficiency" simulator) and dislocations. In collaboration with our industrial partners, this project contributed to the development of cell processing recipes, specialty materials, and equipment that increased cell efficiencies overall (not just multicrystalline silicon). Additionally, several students and postdocs who were either partially or fully engaged in this project (as evidenced by the publication record) are currently in the PV industry, with others to follow.

  6. Photovoltaic systems perspective

    NASA Technical Reports Server (NTRS)

    Sutton, P. D.; Jones, G. J.

    1979-01-01

    This paper summarizes the elements of photovoltaic power system and clarifies the terminology currently used. The relationship of system efficiency and cost is described particularly for the Balance of Photovoltaic System (BOPS) area. The current status of the BOPS development activity is described. The photovoltaic systems terminology is found to be on the road to standardization. Power conditioning, energy storage, and support structure are found to be BOPS cost and/or efficiency drivers. Although the current BOPS activity has identified low-cost/high-efficiency components, further development work is necessary.

  7. Low-cost Design and Manufacturing of Surgical Guides for Mandibular Reconstruction Using a Fibula

    PubMed Central

    Nakamura, Hiroko; Sowa, Yoshihiro; Nishino, Kenichi

    2016-01-01

    Background: Surgical cutting guides are used in mandibular reconstruction involving osteotomy of the mandible and fibula. Cutting guides produced using computer-aided design (CAD) and computer-aided manufacturing (CAM) technologies have been reported recently. These guides aim to increase the benefits to patients by improving the accuracy, shortening the operating time, and correcting occlusion. However, the availability of these advanced technologies is limited in some regions of the world. To test whether we could produce low-cost surgical cutting guides, we made surgical guides and investigated their accuracy. Methods: Using free CAD software, we designed surgical cutting guides for the mandible and fibula and used these to perform virtual mandibular segmental osteotomies and fibula transplants in 12 model surgeries. The cutting guides were printed on a 3-dimensional (3D) printer. The model surgeries were performed using 3D mandibular models and cutting guides to check their accuracy. Deviations between the virtually simulated plan and the actual model surgery were investigated. Results: CAD and CAM technologies were used to design and 3D print the cutting guides and models. The guided surgeries were performed. The deviations were about 1.3 mm for mandibular osteotomy, less than 1 mm for fibular osteotomy, and within 2.4 mm for reconstructions of the mandible. Conclusions: Without using expensive software or products, we were able to design surgical cutting guides for the mandible and fibula and used these to perform virtual simulation of mandibular segmental osteotomy and fibular reconstruction. Model surgeries using 3D-printed surgical guides showed that the accuracy of reconstruction was within a 3-mm deviation. In circumstances where commercial CAD/CAM guides are not available, it may be possible to use CAD/CAM surgical guides in the clinic if doctors are willing to volunteer their time for the design and printing. PMID:27536484

  8. Microsystems Enabled Photovoltaics

    ScienceCinema

    Gupta, Vipin; Nielson, Greg; Okandan, Murat, Granata, Jennifer; Nelson, Jeff; Haney, Mike; Cruz-Campa, Jose Luiz

    2016-07-12

    Sandia's microsystems enabled photovoltaic advances combine mature technology and tools currently used in microsystem production with groundbreaking advances in photovoltaics cell design, decreasing production and system costs while improving energy conversion efficiency. The technology has potential applications in buildings, houses, clothing, portable electronics, vehicles, and other contoured structures.

  9. Challenges to Scaling CIGS Photovoltaics

    NASA Astrophysics Data System (ADS)

    Stanbery, B. J.

    2011-03-01

    The challenges of scaling any photovoltaic technology to terawatts of global capacity are arguably more economic than technological or resource constraints. All commercial thin-film PV technologies are based on direct bandgap semiconductors whose absorption coefficient and bandgap alignment with the solar spectrum enable micron-thick coatings in lieu to hundreds of microns required using indirect-bandgap c-Si. Although thin-film PV reduces semiconductor materials cost, its manufacture is more capital intensive than c-Si production, and proportional to deposition rate. Only when combined with sufficient efficiency and cost of capital does this tradeoff yield lower manufacturing cost. CIGS has the potential to become the first thin film technology to achieve the terawatt benchmark because of its superior conversion efficiency, making it the only commercial thin film technology which demonstrably delivers performance comparable to the dominant incumbent, c-Si. Since module performance leverages total systems cost, this competitive advantage bears directly on CIGS' potential to displace c-Si and attract the requisite capital to finance the tens of gigawatts of annual production capacity needed to manufacture terawatts of PV modules apace with global demand growth.

  10. Make or Buy: Cost Impacts of Additive Manufacturing, 3D Laser Scanning Technology, and Collaborative Product Lifecycle Management on Ship Maintenance and Modernization

    DTIC Science & Technology

    2015-05-01

    1 Make or Buy: Cost Impacts of Additive Manufacturing , 3D Laser Scanning Technology, and Collaborative Product Lifecycle Management on Ship...DATES COVERED 00-00-2015 to 00-00-2015 4. TITLE AND SUBTITLE Make or Buy: Cost Impacts of Additive Manufacturing , 3D Laser Scanning Technology...management during operations 4 Potential Technology 3: Additive Manufacturing (“3D Printing”) 5 • 3D design/image (e.g. from 3D LS) of final part

  11. Negative resistance phenomenon in dual-frequency capacitively coupled plasma-enhanced chemical vapor deposition system for photovoltaic manufacturing process

    NASA Astrophysics Data System (ADS)

    Kwon, H. C.; Aman-ur-Rehman, Won, I. H.; Park, W. T.; Lee, J. K.

    2012-01-01

    The validity of effective frequency concept is investigated for dual-frequency (DF) capacitively coupled plasma (CCP) discharges by using particle-in-cell/Monte Carlo collision simulations. This concept helps in analyzing DF CCP discharges in a fashion similar to single-frequency (SF) CCP discharges with effective parameters. Unlike the driving frequency of SF CCP discharges, the effective frequency in DF CCP is dependent on the ratio of the two driving currents (or voltages) and this characteristic makes it possible to control the ion flux and the ion bombardment energy independently. This separate control principally allows to increase the ion flux and plasma density for high deposition rates, while keeping the ion mean energy constant at low values to prevent the bombardment of highly energetic ions at the substrate surface to avoid unwanted damage in the solar cell manufacturing. The abrupt transition of the effective frequency leads to the phenomenon of negative resistance which is one of the several physical phenomena associated uniquely with DF CCP discharges. Using effective frequency concept, the plasma characteristics have been investigated in the negative resistance regime for solar cell manufacturing.

  12. PVMaT improvements in the Solarex photovoltaic module manufacturing technology: Annual subcontract report: May 5, 1998 -- April 30, 1999

    SciTech Connect

    Wohlgemuth, J.

    2000-01-10

    This report describes work done by Solarex during the first year of this subcontract. The objective of this three-year PVMaT program is to continue the advancement of Solarex PV manufacturing technologies to design and implement a process that produces polycrystalline silicon PV modules that can be sold profitably for $2.00 per peak watt or less and that will increase the production capacity of the Frederick plant to at least 25 megawatts per year. Accomplishments during the first year of the program include: (1) Verification of the process to produce SiF{sub 4}, the precursor to silicon feedstock. (2) Design of a silicon feedstock pilot facility using the SiNaF process. (3) Development of and transfer to manufacturing of a process to use thinner wire in the wire saw. (4) Completion of a production trial with recycled SiC. (5) Laboratory development of a selective emitter process using rapid thermal processing. (6) Fabrication of high-efficiency polycrystalline cells using silicon nitride from three different sources. (7) Development of a new encapsulation formulation and laboratory demonstration of a 6-minute lamination cycle. (8) Implementation of an automated laminator. (9) Laboratory demonstration of automated handling of ceramics.

  13. Polymer Hybrid Photovoltaics for Inexpensive Electricity Generation: Final Technical Report, 1 September 2001--30 April 2006

    SciTech Connect

    Carter, S. A.

    2006-07-01

    The project goal is to understand the operating mechanisms underlying the performance of polymer hybrid photovoltaics to enable the development of a photovoltaic with a maximum power conversion efficiency over cost ratio that is significantly greater than current PV technologies. Plastic or polymer-based photovoltaics can have significant cost advantages over conventional technologies in that they are compatible with liquid-based plastic processing and can be assembled onto plastic under atmospheric conditions (ambient temperature and pressure) using standard printing technologies, such as reel-to-reel and screen printing. Moreover, polymer-based PVs are lightweight, flexible, and largely unbreakable, which make shipping, installation, and maintenance simpler. Furthermore, a numerical simulation program was developed (in collaboration with IBM) to fully simulate the performance of multicomponent polymer photovoltaic devices, and a manufacturing method was developed (in collaboration with Add-vision) to inexpensively manufacture larger-area devices.

  14. Do photovoltaics have a future

    NASA Technical Reports Server (NTRS)

    Williams, B. F.

    1979-01-01

    There is major concern as to the economic practicality of widespread terrestrial use because of the high cost of the photovoltaic arrays themselves. Based on their high efficiency, photovoltaic collectors should be one of the cheapest forms of energy generators known. Present photovoltaic panels are violating the trend of lower costs with increasing efficiency due to their reliance on expensive materials. A medium technology solution should provide electricity competitive with the existing medium to high technology energy generators such as oil, coal, gas, and nuclear fission thermal plants. Programs to reduce the cost of silicon and develop reliable thin film materials have a realistic chance of producing cost effective photovoltaic panels.

  15. Residential, Commercial, and Utility-Scale Photovoltaic (PV) System Prices in the United States: Current Drivers and Cost-Reduction Opportunities

    SciTech Connect

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

    2012-02-01

    The price of photovoltaic (PV) systems in the United States (i.e., the cost to the system owner) has dropped precipitously in recent years, led by substantial reductions in global PV module prices. However, system cost reductions are not necessarily realized or realized in a timely manner by many customers. Many reasons exist for the apparent disconnects between installation costs, component prices, and system prices; most notable is the impact of fair market value considerations on system prices. To guide policy and research and development strategy decisions, it is necessary to develop a granular perspective on the factors that underlie PV system prices and to eliminate subjective pricing parameters. This report's analysis of the overnight capital costs (cash purchase) paid for PV systems attempts to establish an objective methodology that most closely approximates the book value of PV system assets.

  16. Value and manufacturing costs of planar solid oxide fuel cell stacks. Topical report, January 1994-July 1996

    SciTech Connect

    Romero, C.A.; Wright, J.D.

    1996-07-01

    In the first part of this report, the authors analyze the economics of three different fuel cell applications, 200 kW cogeneration, 50 MW stand alone power generation, and a central power plant application of a fuel cell integrated into a 225 MW gas turbine/combined cycle power plant. In the second part of this report, the authors estimated the cost of fabricating a planar SOFC stack using a variety of manufacturing techniques. For a facility producing 200 MW/year of fuel cell systems, the authors obtained vendor equipment quotations, material cost estimates, utility requirements, and projected labor and overhead costs. The authors used a minimum after tax rate of return requirement of 20% to estimate SOFC stack costs.

  17. Plasmonic nanostructures for electronic designs of photovoltaic devices: plasmonic hot-carrier photovoltaic architectures and plasmonic electrode structures

    NASA Astrophysics Data System (ADS)

    Zhang, Tong; Su, Dan; Li, Ruo-Zhou; Wang, Shan-Jiang; Shan, Feng; Xu, Jia-Jia; Zhang, Xiao-Yang

    2016-10-01

    The tunable and amazing properties of plasmonic nanostructures have received significant attentions in the fields of solar energy conversion. Plasmonic nanostructures provide pathways to directly convert solar energy into electric energy by hot-carrier generation. They can also serve as economical electrodes for high-efficient carrier collection. Both have promising potential for manufacturing new generation solar cells. Here, we review recent advances in plasmonic nanostructures for electronic designs of photovoltaic devices and specially focus on plasmonic hot-carrier photovoltaic architectures and plasmonic electrode structures. Technical challenges toward low-cost and high-performance plasmonics-based solar cells are also discussed.

  18. Determination of the optimal time and cost of manufacturing flow of an assembly using the Taguchi method

    NASA Astrophysics Data System (ADS)

    Petrila, S.; Brabie, G.; Chirita, B.

    2016-08-01

    The optimization of the parts and assembly manufacturing operation was carried out in order to minimize both the time and cost of production as appropriate. The optimization was made by using the Taguchi method. The Taguchi method is based on the plans of experiences that vary the input and outputs factors. The application of the Taguchi method in order to optimize the flow of the analyzed assembly production is made in the following: to find the optimal combination between the manufacturing operations; to choose the variant involving the use of equipment performance; to delivery operations based on automation. The final aim of the Taguchi method application is that the entire assembly to be achieved at minimum cost and in a short time. Philosophy Taguchi method of optimizing product quality is synthesized from three basic concepts: quality must be designed into the product and not he product inspected after it has been manufactured; the higher quality is obtained when the deviation from the proposed target is low or when uncontrollable factors action has no influence on it, which translates robustness; costs entailed quality are expressed as a function of deviation from the nominal value [1]. When determining the number of experiments involving the study of a phenomenon by this method, follow more restrictive conditions [2].

  19. Department of Energy: Photovoltaics program - FY 1996

    SciTech Connect

    1996-12-31

    The National Photovoltaic Program supports efforts to make PV an important part of the US economy through three main program elements: Research and Development, Technology Development, and Systems Engineering and Applications. (1) Research and Development activities generate new ideas, test the latest scientific theories, and push the limits of PV efficiencies in laboratory and prototype materials and devices. (2) Technology Development activities apply laboratory innovations to products to improve PV technology and the manufacturing techniques used to produce PV systems for the market. (3) Systems Engineering and Applications activities help improve PV systems and validate these improvements through tests, measurements, and deployment of prototypes. In addition, applications research validates, sales, maintenance, and financing mechanisms worldwide. (4) Environmental, Health, Safety and Resource Characterization activities help to define environmental, health and safety issues for those facilities engaged in the manufacture of PV products and organizations engaged in PV research and development. All PV Program activities are planned and executed in close collaboration and partnership with the U.S. PV industry. The overall PV Program is planned to be a balanced effort of research, manufacturing development, and market development. Critical to the success of this strategy is the National Photovoltaic Program`s effort to reduce the cost of electricity generated by photovoltaic. The program is doing this in three primary ways: by making devices more efficient, by making PV systems less expensive, and by validating the technology through measurements, tests, and prototypes.

  20. Photovoltaic energy: Program overview, fiscal year 1990

    SciTech Connect

    Not Available

    1991-07-01

    This summary is prepared each year to provide an overview of the government-funded activities within the National Photovoltaics Program. The 1990 PV Program Achievements are listed. Launched the PV Manufacturing Technology initiative, designed to systematically lower PV module costs. Inaugurated the PV Concentrator Technologies Initiative by signing eight multiyear, cost-shared technology development subcontracts with concentrator companies. Established the PV Polycrystalline Thin-Film Initiative by signing six multiyear, cost-shared technology development subcontracts with six polycrystalline thin-film companies. Continued the Amorphous Silicon Project by awarding three new research and development contracts. Focused the resources of three program laboratories on finding solutions to industry's manufacturing problems: the Photovoltaic Device Fabrication Laboratory at Sandia National Laboratories and the Module Failure Analysis Laboratory and the Encapsulant Research Laboratory at SERI. Established an ongoing program to assist utilities in using PV for cost-effective, high-value applications. Completed nearly all of the construction planned for the first phase of PVUSA at Davis, California. Worked with the crystalline silicon PV industry on novel, low-cost cell fabrication processes and on resolving encapsulant problems. Took part in the development of qualification procedures tests for thin- and thick-film flat-plate modules and concentrator modules.

  1. Solar photovoltaic systems

    NASA Technical Reports Server (NTRS)

    Forney, R. G.

    1978-01-01

    The Department of Energy's photovoltaic program is outlined. The main objective of the program is the development of low cost reliable terrestrial photovoltaic systems. A second objective is to foster widespread use of the system in residential, industrial and commercial application. The system is reviewed by examining each component; silicon solar cell, silicon solar cell modules, advanced development modules and power systems. Cost and applications of the system are discussed.

  2. Quarterly Report: Microchannel-Assisted Nanomaterial Deposition Technology for Photovoltaic Material Production

    SciTech Connect

    Palo, Daniel R.

    2011-04-26

    Quarterly report to ITP for Nanomanufacturing program. Report covers FY11 Q2. The primary objective of this project is to develop a nanomanufacturing process which will reduce the manufacturing energy, environmental discharge, and production cost associated with current nano-scale thin-film photovoltaic (PV) manufacturing approaches. The secondary objective is to use a derivative of this nanomanufacturing process to enable greener, more efficient manufacturing of higher efficiency quantum dot-based photovoltaic cells now under development. The work is to develop and demonstrate a scalable (pilot) microreactor-assisted nanomaterial processing platform for the production, purification, functionalization, and solution deposition of nanomaterials for photovoltaic applications. The high level task duration is shown. Phase I consists of a pilot platform for Gen II PV films along with parallel efforts aimed at Gen III PV quantum dot materials. Status of each task is described.

  3. Costs incurred by applying computer-aided design/computer-aided manufacturing techniques for the reconstruction of maxillofacial defects.

    PubMed

    Rustemeyer, Jan; Melenberg, Alex; Sari-Rieger, Aynur

    2014-12-01

    This study aims to evaluate the additional costs incurred by using a computer-aided design/computer-aided manufacturing (CAD/CAM) technique for reconstructing maxillofacial defects by analyzing typical cases. The medical charts of 11 consecutive patients who were subjected to the CAD/CAM technique were considered, and invoices from the companies providing the CAD/CAM devices were reviewed for every case. The number of devices used was significantly correlated with cost (r = 0.880; p < 0.001). Significant differences in mean costs were found between cases in which prebent reconstruction plates were used (€3346.00 ± €29.00) and cases in which they were not (€2534.22 ± €264.48; p < 0.001). Significant differences were also obtained between the costs of two, three and four devices, even when ignoring the cost of reconstruction plates. Additional fees provided by statutory health insurance covered a mean of 171.5% ± 25.6% of the cost of the CAD/CAM devices. Since the additional fees provide financial compensation, we believe that the CAD/CAM technique is suited for wide application and not restricted to complex cases. Where additional fees/funds are not available, the CAD/CAM technique might be unprofitable, so the decision whether or not to use it remains a case-to-case decision with respect to cost versus benefit.

  4. Multilayer-Grown Ultrathin Nanostructured GaAs Solar Cells as a Cost-Competitive Materials Platform for III-V Photovoltaics.

    PubMed

    Gai, Boju; Sun, Yukun; Lim, Haneol; Chen, Huandong; Faucher, Joseph; Lee, Minjoo L; Yoon, Jongseung

    2017-01-24

    Large-scale deployment of GaAs solar cells in terrestrial photovoltaics demands significant cost reduction for preparing device-quality epitaxial materials. Although multilayer epitaxial growth in conjunction with printing-based materials assemblies has been proposed as a promising route to achieve this goal, their practical implementation remains challenging owing to the degradation of materials properties and resulting nonuniform device performance between solar cells grown in different sequences. Here we report an alternative approach to circumvent these limitations and enable multilayer-grown GaAs solar cells with uniform photovoltaic performance. Ultrathin single-junction GaAs solar cells having a 300-nm-thick absorber (i.e., emitter and base) are epitaxially grown in triple-stack releasable multilayer assemblies by molecular beam epitaxy using beryllium as a p-type impurity. Microscale (∼500 × 500 μm(2)) GaAs solar cells fabricated from respective device layers exhibit excellent uniformity (<3% relative) of photovoltaic performance and contact properties owing to the suppressed diffusion of p-type dopant as well as substantially reduced time of epitaxial growth associated with ultrathin device configuration. Bifacial photon management employing hexagonally periodic TiO2 nanoposts and a vertical p-type metal contact serving as a metallic back-surface reflector together with specialized epitaxial design to minimize parasitic optical losses for efficient light trapping synergistically enable significantly enhanced photovoltaic performance of such ultrathin absorbers, where ∼17.2% solar-to-electric power conversion efficiency under simulated AM1.5G illumination is demonstrated from 420-nm-thick single-junction GaAs solar cells grown in triple-stack epitaxial assemblies.

  5. Final Technical Progress Report: High-Efficiency Low-Cost Thin-Film GaAs Photovoltaic Module Development Program; July 14, 2010 - January 13, 2012

    SciTech Connect

    Mattos, L.

    2012-03-01

    This is the final technical progress report of the High-Efficiency Low-Cost Thin-Film GaAs Photovoltaic Module Development Program. Alta Devices has successfully completed all milestones and deliverables established as part of the NREL PV incubator program. During the 18 months of this program, Alta has proven all key processes required to commercialize its solar module product. The incubator focus was on back end process steps directed at conversion of Alta's high quality solar film into high efficiency 1-sun PV modules. This report describes all program deliverables and the work behind each accomplishment.

  6. Alpha Solarco`s Photovoltaic Concentrator Development program

    SciTech Connect

    Anderson, A.; Bailor, B.; Carroll, D.

    1995-10-01

    This report details the work done under Sandia`s Photovoltaic Concentrator Development contract, funded jointly by Alpha Solarco and the US Department of Energy. It discusses improvements made to the cell assembly and module design of Alpha Solarco`s point-focus, high-concentration photovoltaic module. The goals of this effort were to increase the module efficiency, reduce the manufacturing cost of the cell assembly, and increase product reliability. Redesign of the secondary optical element achieved a 4 percent increase in efficiency due to better cell fill factors and offtrack performance. New, lower cost materials were identified for the secondary optical element, the optical couple between the secondary optical element and the cell, and the cell assembly electrical insulator. Manufacturing process improvements and test equipment are also discussed.

  7. Flexible polycrystalline thin-film photovoltaics for space applications

    NASA Technical Reports Server (NTRS)

    Armstrong, J. H.; Lanning, B. R.; Misra, M. S.; Kapur, V. K.; Basol, B. M.

    1993-01-01

    Polycrystalline thin-film photovoltaics (PV), such as CIS and CdTe, have received considerable attention recently with respect to space power applications. Their combination of stability, efficiency, and economy from large-scale monolithic-integration of modules can have significant impact on cost and weight of PV arrays for spacecraft and planetary experiments. An added advantage, due to their minimal thickness (approximately 6 microns sans substrate), is the ability to manufacture lightweight, flexible devices (approximately 2000 W/kg) using large-volume manufacturing techniques. The photovoltaic effort at Martin Marietta and ISET is discussed, including large-area, large-volume thin-film deposition techniques such as electrodeposition and rotating cylindrical magnetron sputtering. Progress in the development of flexible polycrystalline thin-film PV is presented, including evaluation of flexible CIS cells. In addition, progress on flexible CdTe cells is presented. Finally, examples of lightweight, flexible arrays and their potential cost and weight impact is discussed.

  8. Laser-assisted manufacturing of micro-optical volume elements for enhancing the amount of light absorbed by solar cells in photovoltaic modules

    NASA Astrophysics Data System (ADS)

    Peharz, Gerhard; Kuna, Ladislav; Leiner, Claude

    2015-03-01

    The laser-generation of micro-optical volume elements is a promising approach to decrease the optical shadowing of front side metal contacts of solar cells. Focusing a femtosecond laser beam into the volume of the encapsulation material causes a local modification its optical constants. Suchlike fabricated micro-optical elements can be used to decrease the optical shadowing of the front side metallization of c-Si solar cells. Test samples comprising of a sandwich structure of a glass sheet with metallic grid-lines, an Ethylene-vinyl acetate (EVA) encapsulant and another glass sheet were manufactured in order to investigate the optical performance of the volume optics. Transmission measurements show that the shadowing of the metalling grid-lines is substantially decreased by the micro-optical volume elements created in the EVA bulk right above the grid-fingers. A detailed investigation of the optical properties of these volume elements was performed: (i) experimentally on the basis of goniometric measurements, as well as (ii) theoretically by applying optical modelling and optimization procedures. This resulted in a better understanding of the effectiveness of the optical volume elements in decreasing the optical shadowing of metal grid lines on the active cell surfaces. Moreover, results of photovoltaic mini-modules with incorporated micro-optical volume elements are presented. Results of optical simulation and Laser Beam Induced Current (LBIC) experiments show that the losses due to the grid fingers can be reduced by about 50%, when using this fs-laser structuring approach for the fabrication of micro-optical volume elements in the EVA material.

  9. Low-cost Electromagnetic Heating Technology for Polymer Extrusion-based Additive Manufacturing

    SciTech Connect

    Carter, William G.; Rios, Orlando; Akers, Ronald R.; Morrison, William A.

    2016-01-07

    To improve the flow of materials used in in polymer additive manufacturing, ORNL and Ajax Tocco created an induction system for heating fused deposition modeling (FDM) nozzles used in polymer additive manufacturing. The system is capable of reaching a temperature of 230 C, a typical nozzle temperature for extruding ABS polymers, in 17 seconds. A prototype system was built at ORNL and sent to Ajax Tocco who analyzed the system and created a finalized power supply. The induction system was mounted to a PrintSpace Altair desktop printer and used to create several test parts similar in quality to those created using a resistive heated nozzle.

  10. Mass manufactured secondary optics for CPV

    NASA Astrophysics Data System (ADS)

    Schmid, Tobias; Wiesenfarth, Maike; Hornung, Thorsten; Gremmelspacher, Matthias; Manns, Peter; Nitz, Peter

    2014-09-01

    The Fraunhofer Institutes for Solar Energy Systems ISE and for Mechanics of Materials IWM in cooperation with industrial partners have explored routes for highly cost effective mass manufacturing of dome lens shaped glass secondary optical elements (SOEs) for concentrating photovoltaics (CPV). This included optical design studies, design optimizations and outdoor measurements on prototypes by Fraunhofer ISE. Fraunhofer IWM has explored a short cycle molding process suitable for low-cost high volume production. SOEs of spherical shape can be a possible option for a cost-effective production.

  11. Towards low-cost high-efficiency GaAs photovoltaics and photoelectrodes grown via vapor transport from a solid source

    SciTech Connect

    Boucher, Jason; Ritenour, Andrew; Boettcher, Shannon W.

    2013-04-29

    Towards low-cost high-efficiency GaAs photovoltaics and photoelectrodes grown via vapor transport from a solid source GaAs is an attractive material for thin-film photovoltaic applications, but is not widely used for terrestrial power generation due to the high cost of metal-organic chemical vapor deposition (MOCVD) techniques typically used for growth. Close space vapor transport is an alternative that allows for rapid growth rates of III-V materials, and does not rely on the toxic and pyrophoric precursors used in MOCVD. We characterize CSVT films of GaAs using photoelectrochemical current-voltage and quantum efficiency measurements. Hole diffusion lengths which exceed 1.5 um are extracted from internal quantum efficiency measurements using the Gartner model. Device physics simulations suggest that solar cells based on these films could reach efficiencies exceeding 24 %. To reach this goal, a more complete understanding of the electrical properties and characterization of defects will be necessary, including measurements on complete solid-state devices. Doping of films is achieved by using source material containing the desired impurity (e.g., Te or Zn). We discuss strategies for growing III-V materials on inexpensive substrates that are not lattice-matched to GaAs.

  12. A probabilistic analysis of silicon cost

    NASA Technical Reports Server (NTRS)

    Reiter, L. J.

    1983-01-01

    Silicon materials costs represent both a cost driver and an area where improvement can be made in the manufacture of photovoltaic modules. The cost from three processes for the production of low-cost silicon being developed under the U.S. Department of Energy's (DOE) National Photovoltaic Program is analyzed. The approach is based on probabilistic inputs and makes use of two models developed at the Jet Propulsion Laboratory: SIMRAND (SIMulation of Research ANd Development) and IPEG (Improved Price Estimating Guidelines). The approach, assumptions, and limitations are detailed along with a verification of the cost analyses methodology. Results, presented in the form of cumulative probability distributions for silicon cost, indicate that there is a 55% chance of reaching the DOE target of $16/kg for silicon material. This is a technically achievable cost based on expert forecasts of the results of ongoing research and development and do not imply any market prices for a given year.

  13. Exploring the market for third-party-owned residential photovoltaic systems: insights from lease and power-purchase agreement contract structures and costs in California

    NASA Astrophysics Data System (ADS)

    Davidson, Carolyn; Steinberg, Daniel; Margolis, Robert

    2015-02-01

    Over the past several years, third-party-ownership (TPO) structures for residential photovoltaic (PV) systems have become the predominant ownership model in the US residential market. Under a TPO contract, the PV system host typically makes payments to the third-party owner of the system. Anecdotal evidence suggests that the total TPO contract payments made by the customer can differ significantly from payments in which the system host directly purchases the system. Furthermore, payments can vary depending on TPO contract structure. To date, a paucity of data on TPO contracts has precluded studies evaluating trends in TPO contract cost. This study relies on a sample of 1113 contracts for residential PV systems installed in 2010-2012 under the California Solar Initiative to evaluate how the timing of payments under a TPO contract impacts the ultimate cost of the system to the customer. Furthermore, we evaluate how the total cost of TPO systems to customers has changed through time, and the degree to which contract costs have tracked trends in the installed costs of a PV system. We find that the structure of the contract and the timing of the payments have financial implications for the customer: (1) power-purchase contracts, on average, cost more than leases, (2) no-money-down contracts are more costly than prepaid contracts, assuming a customer’s discount rate is lower than 17% and (3) contracts that include escalator clauses cost more, for both power-purchase agreements and leases, at most plausible discount rates. In addition, all contract costs exhibit a wide range, and do not parallel trends in installed costs over time.

  14. Low-Cost Nanocellulose-Reinforced High-Temperature Polymer Composites for Additive Manufacturing

    SciTech Connect

    Ozcan, Soydan; Tekinalp, Halil L.; Love, Lonnie J.; Kunc, Vlastimil; Nelson, Kim

    2016-07-13

    ORNL worked with American Process Inc. to demonstrate the potential use of bio-based BioPlus® lignin-coated cellulose nanofibrils (L-CNF) as a reinforcing agent in the development of polymer feedstock suitable for additive manufacturing. L-CNF-reinforced polylactic acid (PLA) testing coupons were prepared and up to 69% increase in tensile strength and 133% increase in elastic modulus were demonstrated.

  15. ULTRA BARRIER TOPSHEET (UBT) FOR FLEXIBLE PHOTOVOLTAICS

    SciTech Connect

    DeScioli, Derek

    2013-06-01

    This slide-show presents 3M photovoltaic-related products, particularly flexible components. Emphasis is on the 3M Ultra Barrier Solar Films. Topics covered include reliability and qualification testing and flexible photovoltaic encapsulation costs.

  16. High Throughput, Continuous, Mass Production of Photovoltaic Modules

    SciTech Connect

    Kurt Barth

    2008-02-06

    AVA Solar has developed a very low cost solar photovoltaic (PV) manufacturing process and has demonstrated the significant economic and commercial potential of this technology. This I & I Category 3 project provided significant assistance toward accomplishing these milestones. The original goals of this project were to design, construct and test a production prototype system, fabricate PV modules and test the module performance. The original module manufacturing costs in the proposal were estimated at $2/Watt. The objectives of this project have been exceeded. An advanced processing line was designed, fabricated and installed. Using this automated, high throughput system, high efficiency devices and fully encapsulated modules were manufactured. AVA Solar has obtained 2 rounds of private equity funding, expand to 50 people and initiated the development of a large scale factory for 100+ megawatts of annual production. Modules will be manufactured at an industry leading cost which will enable AVA Solar's modules to produce power that is cost-competitive with traditional energy resources. With low manufacturing costs and the ability to scale manufacturing, AVA Solar has been contacted by some of the largest customers in the PV industry to negotiate long-term supply contracts. The current market for PV has continued to grow at 40%+ per year for nearly a decade and is projected to reach $40-$60 Billion by 2012. Currently, a crystalline silicon raw material supply shortage is limiting growth and raising costs. Our process does not use silicon, eliminating these limitations.

  17. Handbook of estimating data, factors, and procedures. [for manufacturing cost studies

    NASA Technical Reports Server (NTRS)

    Freeman, L. M.

    1977-01-01

    Elements to be considered in estimating production costs are discussed in this manual. Guidelines, objectives, and methods for analyzing requirements and work structure are given. Time standards for specific specfic operations are listed for machining, sheet metal working, electroplating and metal treating; painting; silk screening, etching and encapsulating; coil winding; wire preparation and wiring; soldering; and the fabrication of etched circuits and terminal boards. The relation of the various elements of cost to the total cost as proposed for various programs by various contractors is compared with government estimates.

  18. SAMICS support study. Volume 1: Cost account catalog

    NASA Technical Reports Server (NTRS)

    1977-01-01

    The Jet Propulsion Laboratory (JPL) is examining the feasibility of a new industry to produce photovoltaic solar energy collectors similar to those used on spacecraft. To do this, a standardized costing procedure was developed. The Solar Array Manufacturing Industry Costing Standards (SAMICS) support study supplies the following information: (1) SAMICS critique; (2) Standard data base--cost account structure, expense item costs, inflation rates, indirect requirements relationships, and standard financial parameter values; (3) Facilities capital cost estimating relationships; (4) Conceptual plant designs; (5) Construction lead times; (6) Production start-up times; (7) Manufacturing price estimates.

  19. PV Inverter Products Manufacturing and Design Improvements for Cost Reduction and Performance Enhancements: Final Subcontract Report, November 2003 (Revised)

    SciTech Connect

    West, R.

    2004-04-01

    The specific objectives of this subcontracted development work by Xantrex Technology Inc. were to: (1) Capture the newest digital signal processor (DSP) technology to create high-impact,''next generation'' power conversion equipment for the PV industry; (2) Create a common resource base for three PV product lines. This standardized approach to both hardware and software control platforms will provide significant market advantage over foreign competition; (3) Achieve cost reductions through increased volume of common components, reduced assembly labor, and the higher efficiency of producing more products with fewer design, manufacturing, and production test variations; (4) Increase PV inverter product reliability. Reduce inverter size, weight and conversion losses. The contract goals were to achieve an overall cost reduction of 10% to 20% for the three inverters and with no compromise in performance. The cost of the 10-kW inverter was reduced by 56%, and the cost of the 25-kW inverter was reduced by 53%. The 2.5-kW inverter has no basis for comparison, but should benefit equally from this design approach. Not only were the contract cost reduction goals exceeded by a wide margin, but the performance and reliability of the products were also enhanced. The conversion efficiency improvement, as reflected in the 50% conversion loss reduction, adds significant value in renewable energy applications. The size and weight reductions also add value by providing less cumbersome product solutions for system designers.

  20. Manufacturing Cost Analysis of Novel Steel/Concrete Composite Vessel for Stationary Storage of High-Pressure Hydrogen

    SciTech Connect

    Feng, Zhili; Zhang, Wei; Wang, Jy-An John; Ren, Fei

    2012-09-01

    A novel, low-cost, high-pressure, steel/concrete composite vessel (SCCV) technology for stationary storage of compressed gaseous hydrogen (CGH2) is currently under development at Oak Ridge National Laboratory (ORNL) sponsored by DOE s Fuel Cell Technologies (FCT) Program. The SCCV technology uses commodity materials including structural steels and concretes for achieving cost, durability and safety requirements. In particular, the hydrogen embrittlement of high-strength low-alloy steels, a major safety and durability issue for current industry-standard pressure vessel technology, is mitigated through the use of a unique layered steel shell structure. This report presents the cost analysis results of the novel SCCV technology. A high-fidelity cost analysis tool is developed, based on a detailed, bottom-up approach which takes into account the material and labor costs involved in each of the vessel manufacturing steps. A thorough cost study is performed to understand the SCCV cost as a function of the key vessel design parameters, including hydrogen pressure, vessel dimensions, and load-carrying ratio. The major conclusions include: The SCCV technology can meet the technical/cost targets set forth by DOE s FCT Program for FY2015 and FY2020 for all three pressure levels (i.e., 160, 430 and 860 bar) relevant to the hydrogen production and delivery infrastructure. Further vessel cost reduction can benefit from the development of advanced vessel fabrication technologies such as the highly automated friction stir welding (FSW). The ORNL-patented multi-layer, multi-pass FSW can not only reduce the amount of labor needed for assembling and welding the layered steel vessel, but also make it possible to use even higher strength steels for further cost reductions and improvement of vessel structural integrity. It is noted the cost analysis results demonstrate the significant cost advantage attainable by the SCCV technology for different pressure levels when compared to the

  1. Real Cost Of He-Ne Lasers For The Original Equipment Manufacturer (OEM) User

    NASA Astrophysics Data System (ADS)

    Crane, Dale E.

    1982-07-01

    The real cost of He-Ne Lasers in systems is made up of many factors, only one of which is the actual purchase price of the laser itself. It behooves the system designer to thoroughly understand both the requirements of his system and the capabilities and limitations of the various lasers available in the market. Only in this way can the designer minimize the overall cost of his system and provide the best possible value to his customer.

  2. Next generation grinding spindle for cost-effective manufacture of advanced ceramic components

    SciTech Connect

    Kovach, J.A.; Laurich, M.A.

    2000-01-01

    Finish grinding of advanced structural ceramics has generally been considered an extremely slow and costly process. Recently, however, results from the High-Speed, Low-Damage (HSLD) program have clearly demonstrated that numerous finish-process performance benefits can be realized by grinding silicon nitride at high wheel speeds. A new, single-step, roughing-process capable of producing high-quality silicon nitride parts at high material removal rates while dramatically reducing finishing costs has been developed.

  3. Silicon nanowires for photovoltaic solar energy conversion.

    PubMed

    Peng, Kui-Qing; Lee, Shuit-Tong

    2011-01-11

    Semiconductor nanowires are attracting intense interest as a promising material for solar energy conversion for the new-generation photovoltaic (PV) technology. In particular, silicon nanowires (SiNWs) are under active investigation for PV applications because they offer novel approaches for solar-to-electric energy conversion leading to high-efficiency devices via simple manufacturing. This article reviews the recent developments in the utilization of SiNWs for PV applications, the relationship between SiNW-based PV device structure and performance, and the challenges to obtaining high-performance cost-effective solar cells.

  4. Photovoltaic cells and photodetectors made with semiconductor polymers: recent progress

    NASA Astrophysics Data System (ADS)

    Yu, Gang; Srdanov, Gordana; Wang, Hailiang; Cao, Yong; Heeger, Alan J.

    2000-05-01

    In this presentation, we discuss recent progress on polymer photovoltaic cells and polymer photodetectors. By improving the fill-factor of polymer photovoltaic cells, the energy conversion efficiency was improved significantly to over 4 percent. Such high efficiency polymer photovoltaic cells are promising for many applications including e-papers, e-books and smart-windows. Polymer photodetectors with similar device configuration show high photosensitivity, low dark current, large dynamic range, linear intensity dependence, low noise level and fast response time. These parameters are comparable to or even better than their inorganic counterparts. The advantages of low manufacturing cost, large detection area, and easy hybridization and integration with other electronic or optical components make them promising for a variety of applications including chemical/biomedical analysis, full-color digital image sensing and high energy radiation detection.

  5. Reducing metal alloy powder costs for use in powder bed fusion additive manufacturing: Improving the economics for production

    NASA Astrophysics Data System (ADS)

    Medina, Fransisco

    Titanium and its associated alloys have been used in industry for over 50 years and have become more popular in the recent decades. Titanium has been most successful in areas where the high strength to weight ratio provides an advantage over aluminum and steels. Other advantages of titanium include biocompatibility and corrosion resistance. Electron Beam Melting (EBM) is an additive manufacturing (AM) technology that has been successfully applied in the manufacturing of titanium components for the aerospace and medical industry with equivalent or better mechanical properties as parts fabricated via more traditional casting and machining methods. As the demand for titanium powder continues to increase, the price also increases. Titanium spheroidized powder from different vendors has a price range from 260/kg-450/kg, other spheroidized alloys such as Niobium can cost as high as $1,200/kg. Alternative titanium powders produced from methods such as the Titanium Hydride-Dehydride (HDH) process and the Armstrong Commercially Pure Titanium (CPTi) process can be fabricated at a fraction of the cost of powders fabricated via gas atomization. The alternative powders can be spheroidized and blended. Current sectors in additive manufacturing such as the medical industry are concerned that there will not be enough spherical powder for production and are seeking other powder options. It is believed the EBM technology can use a blend of spherical and angular powder to build fully dense parts with equal mechanical properties to those produced using traditional powders. Some of the challenges with angular and irregular powders are overcoming the poor flow characteristics and the attainment of the same or better packing densities as spherical powders. The goal of this research is to demonstrate the feasibility of utilizing alternative and lower cost powders in the EBM process. As a result, reducing the cost of the raw material to reduce the overall cost of the product produced with

  6. Compensation of the impact of low-cost manufacturing techniques in the design of E-plane multiport waveguide junctions

    NASA Astrophysics Data System (ADS)

    San-Blas, A. A.; Roca, J. M.; Cogollos, S.; Morro, J. V.; Boria, V. E.; Gimeno, B.

    2016-06-01

    In this work, a full-wave tool for the accurate analysis and design of compensated E-plane multiport junctions is proposed. The implemented tool is capable of evaluating the undesired effects related to the use of low-cost manufacturing techniques, which are mostly due to the introduction of rounded corners in the cross section of the rectangular waveguides of the device. The obtained results show that, although stringent mechanical effects are imposed, it is possible to compensate for the impact of the cited low-cost manufacturing techniques by redesigning the matching elements considered in the original device. Several new designs concerning a great variety of E-plane components (such as right-angled bends, T-junctions and magic-Ts) are presented, and useful design guidelines are provided. The implemented tool, which is mainly based on the boundary integral-resonant mode expansion technique, has been successfully validated by comparing the obtained results to simulated data provided by a commercial software based on the finite element method.

  7. Energy conversion approaches and materials for high-efficiency photovoltaics

    NASA Astrophysics Data System (ADS)

    Green, Martin A.; Bremner, Stephen P.

    2017-01-01

    The past five years have seen significant cost reductions in photovoltaics and a correspondingly strong increase in uptake, with photovoltaics now positioned to provide one of the lowest-cost options for future electricity generation. What is becoming clear as the industry develops is that area-related costs, such as costs of encapsulation and field-installation, are increasingly important components of the total costs of photovoltaic electricity generation, with this trend expected to continue. Improved energy-conversion efficiency directly reduces such costs, with increased manufacturing volume likely to drive down the additional costs associated with implementing higher efficiencies. This suggests the industry will evolve beyond the standard single-junction solar cells that currently dominate commercial production, where energy-conversion efficiencies are fundamentally constrained by Shockley-Queisser limits to practical values below 30%. This Review assesses the overall prospects for a range of approaches that can potentially exceed these limits, based on ultimate efficiency prospects, material requirements and developmental outlook.

  8. Energy conversion approaches and materials for high-efficiency photovoltaics.

    PubMed

    Green, Martin A; Bremner, Stephen P

    2016-12-20

    The past five years have seen significant cost reductions in photovoltaics and a correspondingly strong increase in uptake, with photovoltaics now positioned to provide one of the lowest-cost options for future electricity generation. What is becoming clear as the industry develops is that area-related costs, such as costs of encapsulation and field-installation, are increasingly important components of the total costs of photovoltaic electricity generation, with this trend expected to continue. Improved energy-conversion efficiency directly reduces such costs, with increased manufacturing volume likely to drive down the additional costs associated with implementing higher efficiencies. This suggests the industry will evolve beyond the standard single-junction solar cells that currently dominate commercial production, where energy-conversion efficiencies are fundamentally constrained by Shockley-Queisser limits to practical values below 30%. This Review assesses the overall prospects for a range of approaches that can potentially exceed these limits, based on ultimate efficiency prospects, material requirements and developmental outlook.

  9. Low-cost high-manufacturability and thermal stability optical front-end for 10-Gb ethernet applications

    NASA Astrophysics Data System (ADS)

    Lee, Shin-Ge; Lee, Chun-Hsing; Liao, Li-Chun; Tsai, Cheng-Hung; Chen, Chih-Li; Huang, Min-Fa; Hsu, Chih-Hao; Cheng, Fu-Yi; Kao, Min-Sheng; Wang, Chiung-Hung

    2004-05-01

    With the drastic expansion of internet usage, the demand of 10Gb/s transmission optoelectronic devices for local-area-network (LAN) and storage-area-network (SAN) are increasing. The key issues of these applications are to improve cost, manufacturability and reliability of optoelectronic devices in high speed transmission. The authors have demonstrated extremely low cost, high manufacturability and thermal stability optical fron-end for 10Gb/s Ethernet applications in this paper. High performance and high sensitivity of 10Gb/s transmitter optical sub-assembly (TOSA) and receiver optical sub-assembly (ROSA) with TO-Can packages are discussed and demonstrated to overcome the critical points in high speed applications, respectively. Moreover, 10km interconnection of 10Gb/s optical front-end without isolated elements inside are also proved to be error free at 10.3125Gb/s. In order to improve the signal integrity and manufacturability of 10Gb/s OSA in small form factor transceiver modules assembly, the authors also integrate high speed flex board and OSA package to extend the signal path, and to minimize the effect of crosstalk in modules. Furthermore, the integration of flex board and OSA package more release the difficulties in conjuunction OSA and electrical sub-assembly (ESA) in module to fulfill the request of 10Gb/s transeivers' Multi-Source Agreement (MSA). The performance of temperature stabilized TOSA over wide case temperature range is also experimented. The optical eye diagram of 10Gb/s TOSA developed in this study showing excellent eye quality passing 10Gb/s Ethernet mask test between 0°C to 85°C.

  10. Nanostructured photovoltaics

    NASA Astrophysics Data System (ADS)

    Fu, Lan; Tan, H. Hoe; Jagadish, Chennupati

    2013-01-01

    Energy and the environment are two of the most important global issues that we currently face. The development of clean and sustainable energy resources is essential to reduce greenhouse gas emission and meet our ever-increasing demand for energy. Over the last decade photovoltaics, as one of the leading technologies to meet these challenges, has seen a continuous increase in research, development and investment. Meanwhile, nanotechnology, which is considered to be the technology of the future, is gradually revolutionizing our everyday life through adaptation and incorporation into many traditional technologies, particularly energy-related technologies, such as photovoltaics. While the record for the highest efficiency is firmly held by multijunction III-V solar cells, there has never been a shortage of new research effort put into improving the efficiencies of all types of solar cells and making them more cost effective. In particular, there have been extensive and exciting developments in employing nanostructures; features with different low dimensionalities, such as quantum wells, nanowires, nanotubes, nanoparticles and quantum dots, have been incorporated into existing photovoltaic technologies to enhance their performance and/or reduce their cost. Investigations into light trapping using plasmonic nanostructures to effectively increase light absorption in various solar cells are also being rigorously pursued. In addition, nanotechnology provides researchers with great opportunities to explore the new ideas and physics offered by nanostructures to implement advanced solar cell concepts such as hot carrier, multi-exciton and intermediate band solar cells. This special issue of Journal of Physics D: Applied Physics contains selected papers on nanostructured photovoltaics written by researchers in their respective fields of expertise. These papers capture the current excitement, as well as addressing some open questions in the field, covering topics including the

  11. Phase 2 of the Array Automated Assembly Task for the Low Cost Silicon Solar Array Project

    NASA Technical Reports Server (NTRS)

    Wihl, M.; Torro, J.; Scheinine, A.; Anderson, J.

    1978-01-01

    An automated process sequence, to manufacture photovoltaic modules at a capacity of approximately 500 MW per year at a cost of approximately $0.50 per peak watt is described. Verification tests were performed and are reported along with cost predictions.

  12. Editorial: Photovoltaic Materials and Devices 2014

    DOE PAGES

    Sopori, Bhushan; Rupnowski, Peter; Shet, Sudhakar; ...

    2014-12-22

    An ever increasing demand on energy has fostered many new generation technologies, which include photovoltaics. In recent years, photovoltaic industry has grown very rapidly. The installed capacity of PV for 2013 was about 37 GW and 2014 sales are expected to be around 45 GW. However, there has been excess production for last several years, which is responsible in part for the low prices (about 60 c/W). To lower the PV energy costs further, a major strategy appears to be going to high efficiency solar cells. This approach is favored (over lower cost/lower efficiency) because cell efficiency has a verymore » large influence on the acceptable manufacturing cost of a PV module. Hence, the PV industry is moving toward developing processes and equipment to manufacture solar cells that can yield efficiencies >20%. Therefore, further research is needed within existing technologies to accomplish these objectives. Likewise, research will continue to seek new materials and devices.« less

  13. A photovoltaic array simulator

    NASA Astrophysics Data System (ADS)

    Vachtsevanos, G. J.; Grimbas, E. J.

    A system simulating the output voltage-current characteristics of a photovoltaic array is described. The simulator may be used to test the performance of PV arrays and associated power conditioning equipment necessary for the autonomous or interconnected operation of photovoltaic energy sources. The simulator's main features include simplicity of construction, wide parametric variability and low cost. It is capable of reproducing the output characteristics of commercially available arrays at varying solar irradiation levels with sufficient accuracy. The design ensures the lowest possible power dissipation and minimal thermal drift. It is estimated that the cost of the simulator is an insignificant fraction of the actual array cost in the kilowatt power range.

  14. Manufacturing Cost/Design Guide (MC/DG) for Aerospace Applications.

    DTIC Science & Technology

    1988-05-02

    prevent removal without distortion if driven into the impression while the metal was hot. Underfill : The portion of a forging which does not have its...monitoring) - Laminate (quality/ voids /porosity). 3.4 Diffusion bonding e Complexity e Size -Available equipment capacity -Support tooling * Equipment costs a

  15. Photovoltaics: The next ten years

    SciTech Connect

    Yerkes, J.W.

    1984-08-01

    By 1984 companies manufacturing photovoltaics had been doing serious business making low cost solar arrays for twelve years. Grid connected systems of megawatt size are operating in California, and more are on the drawing board. At least six companies in the USA have produced thin film cells of over ten percent and more are working in the field. New short term goals for thin film efficiency in the twelve to fifteen percent range promise to challenge the single crystal silicon cell which has dominated the business since 1972. ARCO Solar believes that a new class of ULTRA GENERATORS twenty percent efficient and selling for two dollars per peak watt can be deployed by utilities in the 1990's.

  16. ICAM Manufacturing Cost/Design Guide. Volume 2. Appendices to Demonstration Sections.

    DTIC Science & Technology

    1980-09-01

    case of sheet metal, joggles , cut-outs, and heat treatment, a discrete part is defined. Typical DICE analyzed for mechanically fastened assemblies are...Discrete Parts (1) Drawings of the sheet-metal aerospace discrete parts showing configurations, dimensions, joggles , holes, trim, heat treatment, etc...elements (DICE) which might include joggles , holes, bends, lightening holes, and special tolerances, that add cost to the base part con- figuration. These

  17. Manufacturing Cost/Design Guide (MC/DG) for Conceptual Design. Supplement

    DTIC Science & Technology

    1989-08-01

    ELEMENTS DESIGNER FUNCTION *(COMPLEXITIES i~e. JOGGLES , LIGHTENING HOLES. tc) L D F IJ FIGURE 2.1-8 tIANUFACTURII1G COST/DESIGN GUIDE AND DESIGN PROCESS...1 6+ 0 1 4.10 0 1+ + ++ - .-.I.+ JOGGLE -I 1 Ii 2 PL.ACES/ + + + + + + 4+ 4 4 + + + 8 SECTION B-B DOUBLER 14.0" x 16.0" x 0.060" - 2024 - T81 SECTION

  18. Manufacture of patient-specific vascular replicas for endovascular simulation using fast, low-cost method

    NASA Astrophysics Data System (ADS)

    Kaneko, Naoki; Mashiko, Toshihiro; Ohnishi, Taihei; Ohta, Makoto; Namba, Katsunari; Watanabe, Eiju; Kawai, Kensuke

    2016-12-01

    Patient-specific vascular replicas are essential to the simulation of endovascular treatment or for vascular research. The inside of silicone replica is required to be smooth for manipulating interventional devices without resistance. In this report, we demonstrate the fabrication of patient-specific silicone vessels with a low-cost desktop 3D printer. We show that the surface of an acrylonitrile butadiene styrene (ABS) model printed by the 3D printer can be smoothed by a single dipping in ABS solvent in a time-dependent manner, where a short dip has less effect on the shape of the model. The vascular mold is coated with transparent silicone and then the ABS mold is dissolved after the silicone is cured. Interventional devices can pass through the inside of the smoothed silicone vessel with lower pushing force compared to the vessel without smoothing. The material cost and time required to fabricate the silicone vessel is about USD $2 and 24 h, which is much lower than the current fabrication methods. This fast and low-cost method offers the possibility of testing strategies before attempting particularly difficult cases, while improving the training of endovascular therapy, enabling the trialing of new devices, and broadening the scope of vascular research.

  19. Manufacture of patient-specific vascular replicas for endovascular simulation using fast, low-cost method

    PubMed Central

    Kaneko, Naoki; Mashiko, Toshihiro; Ohnishi, Taihei; Ohta, Makoto; Namba, Katsunari; Watanabe, Eiju; Kawai, Kensuke

    2016-01-01

    Patient-specific vascular replicas are essential to the simulation of endovascular treatment or for vascular research. The inside of silicone replica is required to be smooth for manipulating interventional devices without resistance. In this report, we demonstrate the fabrication of patient-specific silicone vessels with a low-cost desktop 3D printer. We show that the surface of an acrylonitrile butadiene styrene (ABS) model printed by the 3D printer can be smoothed by a single dipping in ABS solvent in a time-dependent manner, where a short dip has less effect on the shape of the model. The vascular mold is coated with transparent silicone and then the ABS mold is dissolved after the silicone is cured. Interventional devices can pass through the inside of the smoothed silicone vessel with lower pushing force compared to the vessel without smoothing. The material cost and time required to fabricate the silicone vessel is about USD $2 and 24 h, which is much lower than the current fabrication methods. This fast and low-cost method offers the possibility of testing strategies before attempting particularly difficult cases, while improving the training of endovascular therapy, enabling the trialing of new devices, and broadening the scope of vascular research. PMID:27976687

  20. Manufacture of patient-specific vascular replicas for endovascular simulation using fast, low-cost method.

    PubMed

    Kaneko, Naoki; Mashiko, Toshihiro; Ohnishi, Taihei; Ohta, Makoto; Namba, Katsunari; Watanabe, Eiju; Kawai, Kensuke

    2016-12-15

    Patient-specific vascular replicas are essential to the simulation of endovascular treatment or for vascular research. The inside of silicone replica is required to be smooth for manipulating interventional devices without resistance. In this report, we demonstrate the fabrication of patient-specific silicone vessels with a low-cost desktop 3D printer. We show that the surface of an acrylonitrile butadiene styrene (ABS) model printed by the 3D printer can be smoothed by a single dipping in ABS solvent in a time-dependent manner, where a short dip has less effect on the shape of the model. The vascular mold is coated with transparent silicone and then the ABS mold is dissolved after the silicone is cured. Interventional devices can pass through the inside of the smoothed silicone vessel with lower pushing force compared to the vessel without smoothing. The material cost and time required to fabricate the silicone vessel is about USD $2 and 24 h, which is much lower than the current fabrication methods. This fast and low-cost method offers the possibility of testing strategies before attempting particularly difficult cases, while improving the training of endovascular therapy, enabling the trialing of new devices, and broadening the scope of vascular research.

  1. A direct thin-film path towards low-cost large-area III-V photovoltaics.

    PubMed

    Kapadia, Rehan; Yu, Zhibin; Wang, Hsin-Hua H; Zheng, Maxwell; Battaglia, Corsin; Hettick, Mark; Kiriya, Daisuke; Takei, Kuniharu; Lobaccaro, Peter; Beeman, Jeffrey W; Ager, Joel W; Maboudian, Roya; Chrzan, Daryl C; Javey, Ali

    2013-01-01

    III-V photovoltaics (PVs) have demonstrated the highest power conversion efficiencies for both single- and multi-junction cells. However, expensive epitaxial growth substrates, low precursor utilization rates, long growth times, and large equipment investments restrict applications to concentrated and space photovoltaics (PVs). Here, we demonstrate the first vapor-liquid-solid (VLS) growth of high-quality III-V thin-films on metal foils as a promising platform for large-area terrestrial PVs overcoming the above obstacles. We demonstrate 1-3 μm thick InP thin-films on Mo foils with ultra-large grain size up to 100 μm, which is ~100 times larger than those obtained by conventional growth processes. The films exhibit electron mobilities as high as 500 cm²/V-s and minority carrier lifetimes as long as 2.5 ns. Furthermore, under 1-sun equivalent illumination, photoluminescence efficiency measurements indicate that an open circuit voltage of up to 930 mV can be achieved, only 40 mV lower than measured on a single crystal reference wafer.

  2. A direct thin-film path towards low-cost large-area III-V photovoltaics

    PubMed Central

    Kapadia, Rehan; Yu, Zhibin; Wang, Hsin-Hua H.; Zheng, Maxwell; Battaglia, Corsin; Hettick, Mark; Kiriya, Daisuke; Takei, Kuniharu; Lobaccaro, Peter; Beeman, Jeffrey W.; Ager, Joel W.; Maboudian, Roya; Chrzan, Daryl C.; Javey, Ali

    2013-01-01

    III-V photovoltaics (PVs) have demonstrated the highest power conversion efficiencies for both single- and multi-junction cells. However, expensive epitaxial growth substrates, low precursor utilization rates, long growth times, and large equipment investments restrict applications to concentrated and space photovoltaics (PVs). Here, we demonstrate the first vapor-liquid-solid (VLS) growth of high-quality III-V thin-films on metal foils as a promising platform for large-area terrestrial PVs overcoming the above obstacles. We demonstrate 1–3 μm thick InP thin-films on Mo foils with ultra-large grain size up to 100 μm, which is ~100 times larger than those obtained by conventional growth processes. The films exhibit electron mobilities as high as 500 cm2/V-s and minority carrier lifetimes as long as 2.5 ns. Furthermore, under 1-sun equivalent illumination, photoluminescence efficiency measurements indicate that an open circuit voltage of up to 930 mV can be achieved, only 40 mV lower than measured on a single crystal reference wafer. PMID:23881474

  3. Photovoltaic technology and applications: Overview for the workshop on photochemistry research opportunities

    SciTech Connect

    Benner, J.P.

    1996-09-01

    The business surrounding photovoltaic energy conversion for terrestrial applications has changed dramatically in the last several years. It is now a business that makes money. Industry is responding. with manufacturing capacity expansions, and planned expansions, that will triple U.S. annual output within the next eighteen months. The majority of this product is exported (70%) where it is proven to be a cost competitive alternative. This industry provides experience in manufacturing and reliability in fielded systems that will serve as the basis for extrapolating growth to larger-scale installations and utility systems. The largest part of the National Photovoltaic Program budget supports assisting industry in advancing manufacturing technology and stimulating applications to reduce cost and expand the evolving industry. A growing segment of society looks to photovoltaics as an alternative that may be needed to replace conventional electric generating capacity. The grand challenge for photovoltaics is to make the technology economically competitive for large scale electric power generation before real or perceived evidence of environmental damage from conventional sources dictates its use at economically disruptive costs.

  4. Engineering and economic evaluation of central-station photovoltaic power plants

    SciTech Connect

    Stolte, W.J. )

    1992-12-01

    This report describes the conceptual design, design optimization, and estimated cost and performance of three 50 MW photovoltaic power plants. The first design uses Fresnel lens/glass silo modules mounted on two-axis tracking arrays. The second design has all of the cells mounted on a central receiver on top of a single tower, with heliostats concentrating sunlight onto the receiver. Both designs are based on a similar advanced back-contact silicon concentrator cell developed under EPRI sponsorship. The third design uses thin-film copper indium diselenide flat-plate modules mounted on fixed-tilt array structures. The design and manufacture of the photovoltaic cells and modules are described, along with selection of the photovoltaic technologies, generating and cell manufacturing plant sites. Power system simulation and revenue requirement analyses are included for all of the plant designs.

  5. Engineering and economic evaluation of central-station photovoltaic power plants. Final report

    SciTech Connect

    Stolte, W.J.

    1992-12-01

    This report describes the conceptual design, design optimization, and estimated cost and performance of three 50 MW photovoltaic power plants. The first design uses Fresnel lens/glass silo modules mounted on two-axis tracking arrays. The second design has all of the cells mounted on a central receiver on top of a single tower, with heliostats concentrating sunlight onto the receiver. Both designs are based on a similar advanced back-contact silicon concentrator cell developed under EPRI sponsorship. The third design uses thin-film copper indium diselenide flat-plate modules mounted on fixed-tilt array structures. The design and manufacture of the photovoltaic cells and modules are described, along with selection of the photovoltaic technologies, generating and cell manufacturing plant sites. Power system simulation and revenue requirement analyses are included for all of the plant designs.

  6. Feasibility Study of Solar Dome Encapsulation of Photovoltaic Arrays

    NASA Technical Reports Server (NTRS)

    1978-01-01

    The technical and economic advantages of using air-supported plastic enclosures to protect flat plate photovoltaic arrays are described. Conceptual designs for a fixed, latitude-tilt array and a fully tracking array were defined. Detailed wind loads and strength analyses were performed for the fixed array. Detailed thermal and power output analyses provided array performance for typical seasonal and extreme temperature conditions. Costs of each design as used in a 200 MWe central power station were defined from manufacturing and material cost estimates. The capital cost and cost of energy for the enclosed fixed-tilt array were lower than for the enclosed tracking array. The enclosed fixed-tilt array capital investment was 38% less, and the levelized bus bar energy cost was 26% less than costs for a conventional, glass-encapsulated array design. The predicted energy cost for the enclosed fixed array was 79 mills/kW-h for direct current delivered to the power conditioning units.

  7. Integral Airframe Structures (IAS): Validated Feasibility Study of Integrally Stiffened Metallic Fuselage Panels for Reducing Manufacturing Costs

    NASA Technical Reports Server (NTRS)

    Munroe, J.; Wilkins, K.; Gruber, M.; Domack, Marcia S. (Technical Monitor)

    2000-01-01

    The Integral Airframe Structures (IAS) program investigated the feasibility of using "integrally stiffened" construction for commercial transport fuselage structure. The objective of the program was to demonstrate structural performance and weight equal to current "built-up" structure with lower manufacturing cost. Testing evaluated mechanical properties, structural details, joint performance, repair, static compression, and two-bay crack residual strength panels. Alloys evaluated included 7050-T7451 plate, 7050-T74511 extrusion, 6013-T6511x extrusion, and 7475-T7351 plate. Structural performance was evaluated with a large 7475-T7351 pressure test that included the arrest of a two-bay longitudinal crack, and a measure of residual strength for a two-bay crack centered on a broken frame. Analysis predictions for the two-bay longitudinal crack panel correlated well with the test results. Analysis activity conducted by the IAS team strongly indicates that current analysis tools predict integral structural behavior as accurately as built-up structure. The cost study results indicated that, compared to built-up fabrication methods, high-speed machining structure from aluminum plate would yield a recurring cost savings of 61%. Part count dropped from 78 individual parts on a baseline panel to just 7 parts for machined IAS structure.

  8. Make or buy analysis model based on tolerance allocation to minimize manufacturing cost and fuzzy quality loss

    NASA Astrophysics Data System (ADS)

    Rosyidi, C. N.; Puspitoingrum, W.; Jauhari, W. A.; Suhardi, B.; Hamada, K.

    2016-02-01

    The specification of tolerances has a significant impact on the quality of product and final production cost. The company should carefully pay attention to the component or product tolerance so they can produce a good quality product at the lowest cost. Tolerance allocation has been widely used to solve problem in selecting particular process or supplier. But before merely getting into the selection process, the company must first make a plan to analyse whether the component must be made in house (make), to be purchased from a supplier (buy), or used the combination of both. This paper discusses an optimization model of process and supplier selection in order to minimize the manufacturing costs and the fuzzy quality loss. This model can also be used to determine the allocation of components to the selected processes or suppliers. Tolerance, process capability and production capacity are three important constraints that affect the decision. Fuzzy quality loss function is used in this paper to describe the semantic of the quality, in which the product quality level is divided into several grades. The implementation of the proposed model has been demonstrated by solving a numerical example problem that used a simple assembly product which consists of three components. The metaheuristic approach were implemented to OptQuest software from Oracle Crystal Ball in order to obtain the optimal solution of the numerical example.

  9. ICAM Manufacturing Cost/Design Guide. Volume 3. Airframes. User’s Manual.

    DTIC Science & Technology

    1983-01-01

    PER MATERIAL CUBIC INCH POUND ALUMINUM 705F -T6 -T652 r-T7352 TITANIUM 0.16 $30Ti6AI-4V LOW ALLOY STEEL 0.28 $3 4340 PH CRES $0.28 $7 15 - 5PH FIGURE...DG ...... ................ ... 3-3 3.3 Utilization of Learning Curve . . . . . . . . . 3-6 3.4 Cost Worksheet for Airframe Designers ...... 3-9 3.4.1...for Airframe Assemblies . 4.2- 15 4.2.5 Ground Rules for Mechanically Fastened Assembly Section .............. 4.2-27 4.2.5.1 General Ground Rules

  10. A low-cost technique to manufacture a container to process meiofauna for scanning electron microscopy.

    PubMed

    Abolafia, J

    2015-09-01

    An easy and low-cost method to elaborate a container to dehydrate nematodes and other meiofauna in order to process them for scanning electron microscopy (SEM) is presented. Illustrations of its elaboration, step by step, are included. In addition, a brief methodology to process meiofauna, especially nematodes and kinorhynchs, and illustrations are provided. With this methodology it is possible to easily introduce the specimens, to lock them in a closed chamber allowing the infiltration of fluids and gases (ethanol, acetone, carbon dioxide) but avoiding losing the specimens. After using this meiofauna basket for SEM the results are efficient. Examples of nematode and kinorhynch SEM pictures obtained using this methodology are also included.

  11. Manufacturing technologies for photovoltaics and possible means of their development in Russia (Review): Part 2. Modification of production technologies for photoelectric converters, development of contact structures, and choice of promising technologies for expansion of FEC production in Russia

    NASA Astrophysics Data System (ADS)

    Tarasenko, A. B.; Popel', O. S.

    2015-12-01

    As the development of the first part of the review of modern industrial technologies for manufacture of photoelectric converters (PECs) of solar power, the present paper considers modifications of technologies for manufacture of PECs, including various thin-film techniques. Main tendencies in the advancement of contact structures of PECs are described. Formulation and substantiation are made for promising, in the authors' opinion, lines of the development of industry of PECs in Russia based on the upcoming implementation of 1.5 GW network photovoltaic power plants to 2020, which are developed with the national support under conditions of the fulfillment of rigid requirements to manufacture localization. As the most prospective technology for development of the competitive manufacture of photoelectric converters subject to the Russian scientific and engineering groundwork, the authors recommend the technology based on single-crystal silicon of the n type with the passivation of the frontal and rear sides and symmetrical contacts ( n-PASHa), which provides the possibility to produce double-faced solar modules also.

  12. Non-Hardware ("Soft") Cost-Reduction Roadmap for Residential and Small Commercial Solar Photovoltaics, 2013-2020

    SciTech Connect

    Ardani, K.; Seif, D.; Margolis, R.; Morris, J.; Davidson, C.; Truitt, S.; Torbert, R.

    2013-08-01

    The objective of this analysis is to roadmap the cost reductions and innovations necessary to achieve the U.S. Department of Energy (DOE) SunShot Initiative's total soft-cost targets by 2020. The roadmap focuses on advances in four soft-cost areas: (1) customer acquisition; (2) permitting, inspection, and interconnection (PII); (3) installation labor; and (4) financing. Financing cost reductions are in terms of the weighted average cost of capital (WACC) for financing PV system installations, with real-percent targets of 3.0% (residential) and 3.4% (commercial).

  13. Organic photovoltaics

    NASA Astrophysics Data System (ADS)

    Leo, Karl

    2016-08-01

    Organic photovoltaics are on the verge of revolutionizing building-integrated photovoltaics. For other applications, however, several basic open scientific questions need answering to, in particular, further improve energy-conversion efficiency and lifetime.

  14. High Efficiency, Low Cost Solar Cells Manufactured Using 'Silicon Ink' on Thin Crystalline Silicon Wafers

    SciTech Connect

    Antoniadis, H.

    2011-03-01

    Reported are the development and demonstration of a 17% efficient 25mm x 25mm crystalline Silicon solar cell and a 16% efficient 125mm x 125mm crystalline Silicon solar cell, both produced by Ink-jet printing Silicon Ink on a thin crystalline Silicon wafer. To achieve these objectives, processing approaches were developed to print the Silicon Ink in a predetermined pattern to form a high efficiency selective emitter, remove the solvents in the Silicon Ink and fuse the deposited particle Silicon films. Additionally, standard solar cell manufacturing equipment with slightly modified processes were used to complete the fabrication of the Silicon Ink high efficiency solar cells. Also reported are the development and demonstration of a 18.5% efficient 125mm x 125mm monocrystalline Silicon cell, and a 17% efficient 125mm x 125mm multicrystalline Silicon cell, by utilizing high throughput Ink-jet and screen printing technologies. To achieve these objectives, Innovalight developed new high throughput processing tools to print and fuse both p and n type particle Silicon Inks in a predetermined pat-tern applied either on the front or the back of the cell. Additionally, a customized Ink-jet and screen printing systems, coupled with customized substrate handling solution, customized printing algorithms, and a customized ink drying process, in combination with a purchased turn-key line, were used to complete the high efficiency solar cells. This development work delivered a process capable of high volume producing 18.5% efficient crystalline Silicon solar cells and enabled the Innovalight to commercialize its technology by the summer of 2010.

  15. PVMaT Improvements in the BP Solar Photovoltaic Module Manufacturing Technology: Final Subcontract Report, 4 May 1998 - 30 November 2001

    SciTech Connect

    Wohlgemuth, J.; Shea, S.

    2002-04-01

    This report describes the advancement of BP Solar PV manufacturing technologies in order to design and implement a process that produces polycrystalline silicon PV modules that can be sold profitably for $2.00 per peak watt or less and that increases the production capacity of the Frederick plant to at least 25 megawatts per year. Achieving these major objectives was based on meeting the following specific task goals: (1) Develop a process to produce silicon feedstock from Na2SiF6 that can be sold profitably for less than $15/kilogram in large quantities. Demonstrate the process in a pilot facility. (2) Optimize and improve control of the casting process to increase the process yield by 7% and to improve material quality such that average cell efficiency increases by 4%. (3) Reduce the center-to-center cut distance on the wire saw to less than 450?mm in production, and develop a wire saw process that reduces the consumable costs by at least $0.05/wafer, that does not require organic cleaners, nor result in generation of hazardous waste material. (4) Develop, demonstrate, and implement a cost-effective cell process that produces a minimum average cell efficiency of 15% and improves the cell line electrical yield by 5% when applied to BP Solar cast polycrystalline silicon wafers. (5) Develop and qualify an encapsulation system that meets all technical and reliability requirements and can be laminated and cured in less than 6 minutes. (6) Improve BP Solar's product and materials handling to increase line yield by 3% and reduce handling labor to save $0.05/watt. (6) Improve process measurement and control in the production line to improve yield by 3% and reduce rework by 50%.

  16. Comparing Photovoltaic (PV) Costs and Deployment Drivers in the Japanese and U.S. Residential and Commercial Markets

    SciTech Connect

    Friedman, B.; Margolis, R.; Seel, J.

    2016-04-19

    Japan has re-emerged in 2013 as one of the world's fastest-growing and largest photovoltaic (PV) markets (Renewable Energy World 2013). Year-over-year growth in Japanese installed capacity in the first half of 2013 was about 270%. Japan's PV market was on pace to triple in 2013 compared with 2012, with approximately 2.7 GW installed during the first half of 2013 (compared to about 1.6 GW in the United States). This places Japan's market among the world's largest PV markets, along with China, Germany, and the United States. This report explores details of the rapidly changing Japanese market, and similarities and differences between the Japanese and U.S. markets. We collected data from a diverse group of Japanese PV installers, and we gathered additional Japanese and U.S. data from published sources as well as internal analyses.

  17. Photovoltaic device

    DOEpatents

    Reese, Jason A; Keenihan, James R; Gaston, Ryan S; Kauffmann, Keith L; Langmaid, Joseph A; Lopez, Leonardo; Maak, Kevin D; Mills, Michael E; Ramesh, Narayan; Teli, Samar R

    2017-03-21

    The present invention is premised upon an improved photovoltaic device ("PV device"), more particularly to an improved photovoltaic device with a multilayered photovoltaic cell assembly and a body portion joined at an interface region and including an intermediate layer, at least one interconnecting structural member, relieving feature, unique component geometry, or any combination thereof.

  18. Photovoltaic device

    DOEpatents

    Reese, Jason A.; Keenihan, James R.; Gaston, Ryan S.; Kauffmann, Keith L.; Langmaid, Joseph A.; Lopez, Leonardo C.; Maak, Kevin D.; Mills, Michael E.; Ramesh, Narayan; Teli, Samar R.

    2015-06-02

    The present invention is premised upon an improved photovoltaic device ("PV device"), more particularly to an improved photovoltaic device with a multilayered photovoltaic cell assembly and a body portion joined at an interface region and including an intermediate layer, at least one interconnecting structural member, relieving feature, unique component geometry, or any combination thereof.

  19. Photovoltaic device

    DOEpatents

    Reese, Jason A.; Keenihan, James R.; Gaston, Ryan S.; Kauffmann, Keith L.; Langmaid, Joseph A.; Lopez, Leonardo C.; Maak, Kevin D.; Mills, Michael E.; Ramesh, Narayan; Teli, Samar R.

    2015-09-01

    The present invention is premised upon an improved photovoltaic device ("PV device"), more particularly to an improved photovoltaic device (10) with a multilayered photovoltaic cell assembly (100) and a body portion (200) joined at an interface region (410) and including an intermediate layer (500), at least one interconnecting structural member (1500), relieving feature (2500), unique component geometry, or any combination thereof.

  20. System-Cost-Optimized Smart EVSE for Residential Application: Final Technical Report including Manufacturing Plan

    SciTech Connect

    Zhu, Charles

    2015-05-15

    In the 2nd quarter of 2012, a program was formally initiated at Delta Products to develop smart-grid-enabled Electric Vehicle Supply Equipment (EVSE) product for residential use. The project was funded in part by the U.S. Department of Energy (DOE), under award DE-OE0000590. Delta products was the prime contractor to DOE during the three year duration of the project. In addition to Delta Products, several additional supplier-partners were engaged in this research and development (R&D) program, including Detroit Edison DTE, Mercedes Benz Research and Development North America, and kVA. This report summarizes the program and describes the key research outcomes of the program. A technical history of the project activities is provided, which describes the key steps taken in the research and the findings made at successive stages in the multi-stage work. The evolution of an EVSE prototype system is described in detail, culminating in prototypes shipped to Department of Energy Laboratories for final qualification. After the program history is reviewed, the key attributes of the resulting EVSE are described in terms of functionality, performance, and cost. The results clearly demonstrate the ability of this EVSE to meet or exceed DOE's targets for this program, including: construction of a working product-intent prototype of a smart-grid-enabled EVSE, with suitable connectivity to grid management and home-energy management systems, revenue-grade metering, and related technical functions; and cost reduction of 50% or more compared to typical market priced EVSEs at the time of DOE's funding opportunity announcement (FOA), which was released in mid 2011. In addition to meeting all the program goals, the program was completed within the original budget and timeline established at the time of the award. The summary program budget and timeline, comparing plan versus actual values, is provided for reference, along with several supporting explanatory notes. Technical information

  1. Silicon solar photovoltaic power stations

    NASA Technical Reports Server (NTRS)

    Chowaniec, C. R.; Ferber, R. R.; Pittman, P. F.; Marshall, B. W.

    1977-01-01

    Modular design of components and arrays, cost estimates for modules and support structures, and cost/performance analysis of a central solar photovoltaic power plant are discussed. Costs of collector/reflector arrays are judged the dominant element in the total capital investment. High-concentration solar tracking arrays are recommended as the most economic means for producing solar photovoltaic energy when solar cells costs are high ($500 per kW generated). Capital costs for power conditioning subsystem components are itemized and system busbar energy costs are discussed at length.

  2. The costs and benefits of getting the ISO 9000 certification in the manufacturing sector in Saudi Arabia.

    PubMed

    Mezher, T; Ramadan, H

    1998-01-01

    Many Saudi companies, in their journey to improve quality, efficiency and competitiveness, are pursuing and obtaining the ISO 9000 certificate. Many studies have evaluated how to implement ISO 9000 in different sectors, but none have analyzed the effectiveness of ISO 9000 certification (costs and benefits) on improving the overall quality and on meeting expectations. This study addressed these issues by investigating manufacturing organizations in Saudi Arabia that have the ISO 9000 certification. A survey questionnaire was distributed to firms throughout the kingdom. Thirty-two firms participated in the study. Results indicate that increased consistency of operations, improved service, and product quality are among the top motivators for pursuing the ISO certificate. The benefits most often experienced were improved awareness of procedural problems, better management control, keeping existing customers, increased customer satisfaction, and improved customer service. Difficulties experienced during the certification process involved time and cost, but these were not considered to be major problems. A high volume of paperwork was the main problem experienced following initial certification. Respondents in general said that the ISO 9000 certification met their expectations and that their level of satisfaction regarding the impact of ISO 9000 was high. Most recommended that other organizations pursue the certificate.

  3. Laser generated microstructures in tape cast electrodes for rapid electrolyte wetting: new technical approach for cost efficient battery manufacturing

    NASA Astrophysics Data System (ADS)

    Pfleging, W.; Kohler, R.; Pröll, J.

    2014-03-01

    Three-dimensional (3D) battery architectures are under current scientific investigation since they can achieve large areal energy capacities while maintaining high power densities. A main objective of surface patterning is the enhancement of lithium-ion diffusion which is often a limiting factor in lithium-ion cells. By using a rather new approach, laser material processing of thick-film electrodes has been investigated for the precise adjustment of 3D surface topography. Besides lithium-ion diffusion in electrode materials as an electrochemically limited process, a critical step in lithium-ion pouch cell manufacturing is the homogeneous electrolyte wetting of stacked electrodes and separators. This process requires cost expensive and time-consuming vacuum and storage processes at elevated temperatures. A new and cost efficient laser process has been successfully applied in order to significantly improve the electrode wetting and the battery operation. Preliminary investigations for testing the process on pouch cell geometry revealed higher capacities and increased cell life-time compared to standard cells without storage processes at elevated temperatures. The laser structuring process can be applied to commercial electrode materials and integrated into existing production lines.

  4. Benchmarking concentrating photovoltaic systems

    NASA Astrophysics Data System (ADS)

    Duerr, Fabian; Muthirayan, Buvaneshwari; Meuret, Youri; Thienpont, Hugo

    2010-08-01

    Integral to photovoltaics is the need to provide improved economic viability. To achieve this goal, photovoltaic technology has to be able to harness more light at less cost. A large variety of concentrating photovoltaic concepts has provided cause for pursuit. To obtain a detailed profitability analysis, a flexible evaluation is crucial for benchmarking the cost-performance of this variety of concentrating photovoltaic concepts. To save time and capital, a way to estimate the cost-performance of a complete solar energy system is to use computer aided modeling. In this work a benchmark tool is introduced based on a modular programming concept. The overall implementation is done in MATLAB whereas Advanced Systems Analysis Program (ASAP) is used for ray tracing calculations. This allows for a flexible and extendable structuring of all important modules, namely an advanced source modeling including time and local dependence, and an advanced optical system analysis of various optical designs to obtain an evaluation of the figure of merit. An important figure of merit: the energy yield for a given photovoltaic system at a geographical position over a specific period, can be calculated.

  5. Photovoltaic Subcontract Program

    SciTech Connect

    Surek, Thomas; Catalano, Anthony

    1993-03-01

    This report summarizes the fiscal year (FY) 1992 progress of the subcontracted photovoltaic (PV) research and development (R D) performed under the Photovoltaic Advanced Research and Development Project at the National Renewable Energy Laboratory (NREL)-formerly the Solar Energy Research Institute (SERI). The mission of the national PV program is to develop PV technology for large-scale generation of economically competitive electric power in the United States. The technical sections of the report cover the main areas of the subcontract program: the Crystalline Materials and Advanced Concepts project, the Polycrystalline Thin Films project, Amorphous Silicon Research project, the Photovoltaic Manufacturing Technology (PVMaT) project, PV Module and System Performance and Engineering project, and the PV Analysis and Applications Development project. Technical summaries of each of the subcontracted programs provide a discussion of approaches, major accomplishments in FY 1992, and future research directions.

  6. Cable manufacture

    NASA Technical Reports Server (NTRS)

    Gamble, P.

    1972-01-01

    A survey is presented of flat electrical cable manufacturing, with particular reference to patented processes. The economics of manufacture based on an analysis of material and operating costs is considered for the various methods. Attention is given to the competitive advantages of the several processes and their resulting products. The historical area of flat cable manufacture is presented to give a frame of reference for the survey.

  7. Manufacturing cost analysis of a parabolic dish concentrator (General Electric design) for solar thermal electric power systems in selected production volumes

    NASA Technical Reports Server (NTRS)

    1981-01-01

    The manufacturing cost of a General Electric 12 meter diameter concentrator was estimated. This parabolic dish concentrator for solar thermal system was costed in annual production volumes of 100 - 1,000 - 5,000 - 10,000 - 50,000 100,000 - 400,000 and 1,000,000 units. Presented for each volume are the costs of direct labor, material, burden, tooling, capital equipment and buildings. Also presented is the direct labor personnel and factory space requirements. All costs are based on early 1981 economics.

  8. Benchmarking Non-Hardware Balance-of-System (Soft) Costs for U.S. Photovoltaic Systems Using a Bottom-Up Approach and Installer Survey

    SciTech Connect

    Ardani, Kristen; Margolis, Robert; Feldman, David; Ong, Sean; Barbose, Galen; Wiser, Ryan

    2012-11-01

    This report presents results from the first U.S. Department of Energy (DOE) sponsored, bottom-up data-collection and analysis of non-hardware balance-of-system costs—often referred to as “business process” or “soft” costs—for residential and commercial photovoltaic (PV) systems. Annual expenditure and labor-hour-productivity data are analyzed to benchmark 2010 soft costs related to the DOE priority areas of (1) customer acquisition; (2) permitting, inspection, and interconnection; (3) installation labor; and (4) installer labor for arranging third-party financing. Annual expenditure and labor-hour data were collected from 87 PV installers. After eliminating outliers, the survey sample consists of 75 installers, representing approximately 13% of all residential PV installations and 4% of all commercial installations added in 2010. Including assumed permitting fees, in 2010 the average soft costs benchmarked in this analysis total $1.50/W for residential systems (ranging from $0.66/W to $1.66/W between the 20th and 80th percentiles). For commercial systems, the median 2010 benchmarked soft costs (including assumed permitting fees) are $0.99/W for systems smaller than 250 kW (ranging from $0.51/W to $1.45/W between the 20th and 80th percentiles) and $0.25/W for systems larger than 250 kW (ranging from $0.17/W to $0.78/W between the 20th and 80th percentiles). Additional soft costs not benchmarked in the present analysis (e.g., installer profit, overhead, financing, and contracting) are significant and would add to these figures. The survey results provide a benchmark for measuring—and helping to accelerate—progress over the next decade toward achieving the DOE SunShot Initiative’s soft-cost-reduction targets. We conclude that the selected non-hardware business processes add considerable cost to U.S. PV systems, constituting 23% of residential PV system price, 17% of small commercial system price, and 5% of large commercial system price (in 2010

  9. Resolving Inadequacies of the Navy Industrial Fund Cost Accounting System to Enable Its Use in the RAMP SMP (Rapid Acquisition of Manufactured Parts Small Manufactured Parts) Facility

    DTIC Science & Technology

    1988-12-01

    development is drawn from current cost accounting practices, and theoretical cost accounting principles in the commercial workplace. A detailed...production or service output. These definitions are sound in the man-paced environment. However, current cost accounting practices create the

  10. 78 FR 37572 - Notice Pursuant to the National Cooperative Research and Production Act of 1993-U.S. Photovoltaic...

    Federal Register 2010, 2011, 2012, 2013, 2014

    2013-06-21

    .... Photovoltaic Manufacturing Consortium, Inc. Notice is hereby given that, on May 21, 2013, pursuant to Section 6... Act''), U.S. Photovoltaic Manufacturing Consortium, Inc. (``USPVMC'') has filed written...

  11. Photovoltaic Energy Program Overview Fiscal Year 1996

    SciTech Connect

    1997-05-01

    Significant activities in the National Photovoltaic Program are reported for each of the three main program elements. In Research and Development, advances in thin-film materials and crystalline silicon materials are described. The Technology Development report describes activities in photovoltaic manufacturing technology, industrial expansion, module and array development, and testing photovoltaic system components. Systems Engineering and Applications projects described include projects with government agencies, projects with utilities, documentation of performance for international applications, and product certification.

  12. Analysis of Garment Production Methods. Part 2: Comparison of Cost and Production between a Traditional Bundle System and Modular Manufacturing

    DTIC Science & Technology

    1992-02-01

    also saw this project as an opportunity for our manufacturing management students to see first hand how companies respond to changes in their economic...Modular Manufacturing . We wanted to see if it was just a fad or a new business strategy that could be added to a manufacturer’s arsenal in the master...Fashion Industries 227 West 27 Street 000301 New York, NY 10001 Defense Logistics Agency DLA Manufacturing Engineering Branch Cameron Station (DLA

  13. Photovoltaic power systems for rural areas of developing countries

    NASA Technical Reports Server (NTRS)

    Rosenblum, L.; Bifano, W. J.; Hein, G. F.; Ratajczak, A. F.

    1979-01-01

    Systems technology, reliability, and present and projected costs of photovoltaic systems are discussed using data derived from NASA, Lewis Research Center experience with photovoltaic systems deployed with a variety of users. Operating systems in two villages, one in Upper Volta and the other in southwestern Arizona are described. Energy cost comparisons are presented for photovoltaic systems versus alternative energy sources. Based on present system technology, reliability, and costs, photovoltaics provides a realistic energy option for developing nations.

  14. Organic photovoltaics

    NASA Astrophysics Data System (ADS)

    Demming, Anna; Krebs, Frederik C.; Chen, Hongzheng

    2013-12-01

    Energy inflation, the constant encouragement to economize on energy consumption and the huge investments in developing alternative energy resources might seem to suggest that there is a global shortage of energy. Far from it, the energy the Sun beams on the Earth each hour is equivalent to a year's supply, even at our increasingly ravenous rate of global energy consumption [1]. But it's not what you have got it's what you do with it. Hence the intense focus on photovoltaic research to find more efficient ways to harness energy from the Sun. Recently much of this research has centred on organic solar cells since they offer simple, low-cost, light-weight and large-area flexible photovoltaic structures. This issue with guest editors Frederik C Krebs and Hongzheng Chen focuses on some of the developments at the frontier of organic photovoltaic technology. Improving the power conversion efficiency of organic photovoltaic systems, while maintaining the inherent material, economic and fabrication benefits, has absorbed a great deal of research attention in recent years. Here significant progress has been made with reports now of organic photovoltaic devices with efficiencies of around 10%. Yet operating effectively across the electromagnetic spectrum remains a challenge. 'The trend is towards engineering low bandgap polymers with a wide optical absorption range and efficient hole/electron transport materials, so that light harvesting in the red and infrared region is enhanced and as much light of the solar spectrum as possible can be converted into an electrical current', explains Mukundan Thelakkat and colleagues in Germany, the US and UK. In this special issue they report on how charge carrier mobility and morphology of the active blend layer in thin film organic solar cells correlate with device parameters [2]. The work contributes to a better understanding of the solar-cell characteristics of polymer:fullerene blends, which form the material basis for some of the most

  15. Methods for Analyzing the Benefits and Costs of Distributed Photovoltaic Generation to the U.S. Electric Utility System

    SciTech Connect

    Denholm, P.; Margolis, R.; Palmintier, B.; Barrows, C.; Ibanez, E.; Bird, L.; Zuboy, J.

    2014-09-01

    This report outlines the methods, data, and tools that could be used at different levels of sophistication and effort to estimate the benefits and costs of DGPV. In so doing, we identify the gaps in current benefit-cost-analysis methods, which we hope will inform the ongoing research agenda in this area. The focus of this report is primarily on benefits and costs from the utility or electricity generation system perspective. It is intended to provide useful background information to utility and regulatory decision makers and their staff, who are often being asked to use or evaluate estimates of the benefits and cost of DGPV in regulatory proceedings. Understanding the technical rigor of the range of methods and how they might need to evolve as DGPV becomes a more significant contributor of energy to the electricity system will help them be better consumers of this type of information. This report is also intended to provide information to utilities, policy makers, PV technology developers, and other stakeholders, which might help them maximize the benefits and minimize the costs of integrating DGPV into a changing electricity system.

  16. A sensitivity analysis of central flat-plate photovoltaic systems and implications for national photovoltaics program planning

    NASA Technical Reports Server (NTRS)

    Crosetti, M. R.

    1985-01-01

    The sensitivity of the National Photovoltaic Research Program goals to changes in individual photovoltaic system parameters is explored. Using the relationship between lifetime cost and system performance parameters, tests were made to see how overall photovoltaic system energy costs are affected by changes in the goals set for module cost and efficiency, system component costs and efficiencies, operation and maintenance costs, and indirect costs. The results are presented in tables and figures for easy reference.

  17. Reflection-type single long-pulse solar simulator for high-efficiency crystalline silicon photovoltaic modules.

    PubMed

    Hu, Binxin; Li, Buyin; Zhao, Rixin; Yang, Tiechen

    2011-06-01

    Photovoltaic module measurements are predominantly taken by using pulsed solar simulators. However, significant errors can be generated when the existing simulators are applied to current high-efficiency crystalline silicon photovoltaic modules. This paper presents the design and implementation of a novel solar simulator featuring reflection-type light source and single long-pulse flash. The analysis and experimental study of the capacitance effect and the technical details of the simulator including reflection-type lamp house, xenon flash lamp power supply, and source-measure unit are introduced. The results show that the complete system achieves Class AAA performance in accordance with the international standard. The proposed simulator outperforms other similar products on the market and has been adopted by some well-known photovoltaic module manufacturers. The practical application demonstrates that this high-performance and cost-effective simulator is quite suitable for photovoltaic module production line.

  18. Advanced Manufacturing Technologies

    NASA Technical Reports Server (NTRS)

    Fikes, John

    2016-01-01

    Advanced Manufacturing Technologies (AMT) is developing and maturing innovative and advanced manufacturing technologies that will enable more capable and lower-cost spacecraft, launch vehicles and infrastructure to enable exploration missions. The technologies will utilize cutting edge materials and emerging capabilities including metallic processes, additive manufacturing, composites, and digital manufacturing. The AMT project supports the National Manufacturing Initiative involving collaboration with other government agencies.

  19. Development of a low-cost integrated 20-kW ac solar tracking sub- array for grid-connected PV power system applications. Phase 1, Annual technical report, 11 July 1995--31 July 1996

    SciTech Connect

    Stern, M.; West, R.; Fourer, G.; Whalen, W.; Van Loo, M.; Duran, G.

    1997-06-01

    The overall goal of this effort is to reduce the installed cost of utility scale grid connected photovoltaic power systems. The focus of the effort is on ``BOS`` (Balance-Of-System) component manufacturing technology, which essentially involves all PV power system engineering, manufacturing, assembly and construction tasks from the receipt of a PV module to the deliver of grid connected electricity.

  20. National Center for Photovoltaics at NREL

    ScienceCinema

    VanSant, Kaitlyn; Wilson, Greg; Berry, Joseph; Al-Jassim, Mowafak; Kurtz, Sarah

    2016-07-12

    The National Center for Photovoltaics at the National Renewable Energy Laboratory (NREL) focuses on technology innovations that drive industry growth in U.S. photovoltaic (PV) manufacturing. The NCPV is a central resource for our nation's capabilities in PV research, development, deployment, and outreach.

  1. Semiconductors: In Situ Processing of Photovoltaic Devices

    NASA Technical Reports Server (NTRS)

    Curreri, Peter A.

    1998-01-01

    The possible processing of semiconductor photovoltaic devices is discussed. The requirements for lunar PV cells is reviewed, and the key challenges involved in their manufacturing are investigated. A schematic diagram of a passivated emitter and rear cell (PERC) is presented. The possible fabrication of large photovoltaic arrays in space from lunar materials is also discussed.

  2. A Low-Cost Computer-Controlled Arduino-Based Educational Laboratory System for Teaching the Fundamentals of Photovoltaic Cells

    ERIC Educational Resources Information Center

    Zachariadou, K.; Yiasemides, K.; Trougkakos, N.

    2012-01-01

    We present a low-cost, fully computer-controlled, Arduino-based, educational laboratory (SolarInsight) to be used in undergraduate university courses concerned with electrical engineering and physics. The major goal of the system is to provide students with the necessary instrumentation, software tools and methodology in order to learn fundamental…

  3. Fundamental understanding and development of low-cost, high-efficiency silicon solar cells

    SciTech Connect

    ROHATGI,A.; NARASIMHA,S.; MOSCHER,J.; EBONG,A.; KAMRA,S.; KRYGOWSKI,T.; DOSHI,P.; RISTOW,A.; YELUNDUR,V.; RUBY,DOUGLAS S.

    2000-05-01

    The overall objectives of this program are (1) to develop rapid and low-cost processes for manufacturing that can improve yield, throughput, and performance of silicon photovoltaic devices, (2) to design and fabricate high-efficiency solar cells on promising low-cost materials, and (3) to improve the fundamental understanding of advanced photovoltaic devices. Several rapid and potentially low-cost technologies are described in this report that were developed and applied toward the fabrication of high-efficiency silicon solar cells.

  4. Economically sustainable scaling of photovoltaics to meet climate targets

    DOE PAGES

    Needleman, David Berney; Poindexter, Jeremy R.; Kurchin, Rachel C.; ...

    2016-04-21

    To meet climate targets, power generation capacity from photovoltaics (PV) in 2030 will have to be much greater than is predicted from either steady state growth using today's manufacturing capacity or industry roadmaps. Analysis of whether current technology can scale, in an economically sustainable way, to sufficient levels to meet these targets has not yet been undertaken, nor have tools to perform this analysis been presented. Here, we use bottom-up cost modeling to predict cumulative capacity as a function of technological and economic variables. We find that today's technology falls short in two ways: profits are too small relative tomore » upfront factory costs to grow manufacturing capacity rapidly enough to meet climate targets, and costs are too high to generate enough demand to meet climate targets. We show that decreasing the capital intensity (capex) of PV manufacturing to increase manufacturing capacity and effectively reducing cost (e.g., through higher efficiency) to increase demand are the most effective and least risky ways to address these barriers to scale. We also assess the effects of variations in demand due to hard-to-predict factors, like public policy, on the necessary reductions in cost.Lastly, we review examples of redundant technology pathways for crystalline silicon PV to achieve the necessary innovations in capex, performance, and price.« less

  5. Economically sustainable scaling of photovoltaics to meet climate targets

    SciTech Connect

    Needleman, David Berney; Poindexter, Jeremy R.; Kurchin, Rachel C.; Peters, I. Marius; Wilson, Gregory; Buonassisi, Tonio

    2016-04-21

    To meet climate targets, power generation capacity from photovoltaics (PV) in 2030 will have to be much greater than is predicted from either steady state growth using today's manufacturing capacity or industry roadmaps. Analysis of whether current technology can scale, in an economically sustainable way, to sufficient levels to meet these targets has not yet been undertaken, nor have tools to perform this analysis been presented. Here, we use bottom-up cost modeling to predict cumulative capacity as a function of technological and economic variables. We find that today's technology falls short in two ways: profits are too small relative to upfront factory costs to grow manufacturing capacity rapidly enough to meet climate targets, and costs are too high to generate enough demand to meet climate targets. We show that decreasing the capital intensity (capex) of PV manufacturing to increase manufacturing capacity and effectively reducing cost (e.g., through higher efficiency) to increase demand are the most effective and least risky ways to address these barriers to scale. We also assess the effects of variations in demand due to hard-to-predict factors, like public policy, on the necessary reductions in cost.Lastly, we review examples of redundant technology pathways for crystalline silicon PV to achieve the necessary innovations in capex, performance, and price.

  6. Photovoltaic power systems workshop

    NASA Technical Reports Server (NTRS)

    Killian, H. J.; Given, R. W.

    1978-01-01

    Discussions are presented on apparent deficiencies in NASA planning and technology development relating to a standard power module (25-35 kW) and to future photovoltaic power systems in general. Topics of discussion consider the following: (1) adequate studies on power systems; (2) whether a standard power system module should be developed from a standard spacecraft; (3) identification of proper approaches to cost reduction; (4) energy storage avoidance; (5) attitude control; (6) thermal effects of heat rejection on solar array configuration stability; (7) assembly of large power systems in space; and (8) factoring terrestrial photovoltaic work into space power systems for possible payoff.

  7. On the Path to SunShot - The Role of Advancements in Solar Photovoltaic Efficiency, Reliability, and Costs

    SciTech Connect

    Woodhouse, Michael; Jones-Albertus, Rebecca; Feldman, David; Fu, Ran; Horowitz, Kelsey; Chung, Donald; Jordan, Dirk; Kurtz, Sarah

    2016-05-01

    Although tremendous progress has been made in reducing the cost of PV systems, additional LCOE reductions of 40%–50% between 2015 and 2020 will be required to reach the SunShot Initiative’s targets (see Woodhouse et al. 2016). Understanding the tradeoffs between installed prices and other PV system characteristics—such as module efficiency, module degradation rate, and system lifetime—are vital. For example, with 29%-efficient modules and high reliability (a 50-year lifetime and a 0.2%/year module degradation rate), a residential PV system could achieve the SunShot LCOE goal with modules priced at almost $1.20/W. But change the lifetime to 10 years and the degradation rate to 2%/year, and the system would need those very high-efficiency modules at zero cost to achieve the same LCOE. Although these examples are extreme, they serve to illustrate the wide range of technological combinations that could help drive PV toward the LCOE goals. SunShot’s PV roadmaps illustrate specific potential pathways to the target cost reductions.

  8. Data base on batteries, power-conditioning equipment, and photovoltaic arrays. Final report

    SciTech Connect

    Podder, A; Kapner, M; Morse, T

    1981-02-01

    The objective of this study was to compile an up-to-date comprehensive data base for research, design, and development of photovoltaic systems, primarily in the areas of applications and battery technology, and secondarily in the area of power conditioning and photovoltaic array technology. This volume contains the data base used to develop the end-use scenarios and identify the R and D needed for batteries to be used in photovoltaic power systems. In addition to its specific application to the present study, this data base is intended to provide state-of-the-art information to manufacturers of the various components of photovoltaic power systems, system designers, and researchers in this field. An extensive literature search was conducted to obtain technical data on batteries, power conditioners, and photovoltaic arrays. The data obtained from published technical literature and direct communication with manufacturers and developers are compiled. Principles of operation, types of systems, performance characteristics, test data, and cost data are included for each of the components. (WHK)

  9. Reducing the efficiency-stability-cost gap of organic photovoltaics with highly efficient and stable small molecule acceptor ternary solar cells.

    PubMed

    Baran, Derya; Ashraf, Raja Shahid; Hanifi, David A; Abdelsamie, Maged; Gasparini, Nicola; Röhr, Jason A; Holliday, Sarah; Wadsworth, Andrew; Lockett, Sarah; Neophytou, Marios; Emmott, Christopher J M; Nelson, Jenny; Brabec, Christoph J; Amassian, Aram; Salleo, Alberto; Kirchartz, Thomas; Durrant, James R; McCulloch, Iain

    2017-03-01

    Technological deployment of organic photovoltaic modules requires improvements in device light-conversion efficiency and stability while keeping material costs low. Here we demonstrate highly efficient and stable solar cells using a ternary approach, wherein two non-fullerene acceptors are combined with both a scalable and affordable donor polymer, poly(3-hexylthiophene) (P3HT), and a high-efficiency, low-bandgap polymer in a single-layer bulk-heterojunction device. The addition of a strongly absorbing small molecule acceptor into a P3HT-based non-fullerene blend increases the device efficiency up to 7.7 ± 0.1% without any solvent additives. The improvement is assigned to changes in microstructure that reduce charge recombination and increase the photovoltage, and to improved light harvesting across the visible region. The stability of P3HT-based devices in ambient conditions is also significantly improved relative to polymer:fullerene devices. Combined with a low-bandgap donor polymer (PBDTTT-EFT, also known as PCE10), the two mixed acceptors also lead to solar cells with 11.0 ± 0.4% efficiency and a high open-circuit voltage of 1.03 ± 0.01 V.

  10. Towards low-cost high-efficiency GaAs photovoltaics and photoelectrodes grown via vapor transport from a solid source

    NASA Astrophysics Data System (ADS)

    Boucher, Jason W.; Ritenour, Andrew J.; Boettcher, Shannon W.

    2013-05-01

    GaAs is an attractive material for thin-film photovoltaic applications, but is not widely used for terrestrial power generation due to the high cost of metal-organic chemical vapor deposition (MOCVD) techniques typically used for growth. Close space vapor transport is an alternative that allows for rapid growth rates of III-V materials, and does not rely on the toxic and pyrophoric precursors used in MOCVD. We characterize CSVT films of GaAs using photoelectrochemical current-voltage and quantum efficiency measurements. Hole diffusion lengths which exceed 1.5 μm are extracted from internal quantum efficiency measurements using the Gärtner model. Device physics simulations suggest that solar cells based on these films could reach efficiencies exceeding 24%. To reach this goal, a more complete understanding of the electrical properties and characterization of defects will be necessary, including measurements on complete solid-state devices. Doping of films is achieved by using source material containing the desired impurity (e.g., Te or Zn). We discuss strategies for growing III-V materials on inexpensive substrates that are not lattice-matched to GaAs.

  11. Reducing the efficiency-stability-cost gap of organic photovoltaics with highly efficient and stable small molecule acceptor ternary solar cells

    NASA Astrophysics Data System (ADS)

    Baran, Derya; Ashraf, Raja Shahid; Hanifi, David A.; Abdelsamie, Maged; Gasparini, Nicola; Röhr, Jason A.; Holliday, Sarah; Wadsworth, Andrew; Lockett, Sarah; Neophytou, Marios; Emmott, Christopher J. M.; Nelson, Jenny; Brabec, Christoph J.; Amassian, Aram; Salleo, Alberto; Kirchartz, Thomas; Durrant, James R.; McCulloch, Iain

    2016-11-01

    Technological deployment of organic photovoltaic modules requires improvements in device light-conversion efficiency and stability while keeping material costs low. Here we demonstrate highly efficient and stable solar cells using a ternary approach, wherein two non-fullerene acceptors are combined with both a scalable and affordable donor polymer, poly(3-hexylthiophene) (P3HT), and a high-efficiency, low-bandgap polymer in a single-layer bulk-heterojunction device. The addition of a strongly absorbing small molecule acceptor into a P3HT-based non-fullerene blend increases the device efficiency up to 7.7 +/- 0.1% without any solvent additives. The improvement is assigned to changes in microstructure that reduce charge recombination and increase the photovoltage, and to improved light harvesting across the visible region. The stability of P3HT-based devices in ambient conditions is also significantly improved relative to polymer:fullerene devices. Combined with a low-bandgap donor polymer (PBDTTT-EFT, also known as PCE10), the two mixed acceptors also lead to solar cells with 11.0 +/- 0.4% efficiency and a high open-circuit voltage of 1.03 +/- 0.01 V.

  12. Photovoltaic Power Station with Ultracapacitors for Storage

    NASA Technical Reports Server (NTRS)

    Eichenberg, Dennis J.; Kolacz, John S.; Soltis, Richard F.; Tavernelli, Paul F.

    2003-01-01

    A solar photovoltaic power station in which ultracapacitors, rather than batteries, are used to store energy is discussed. Developments in the semiconductor industry have reduced the cost and increased the attainable efficiency of commercially available photovoltaic panels; as a result, photovoltaic generation of power for diverse applications has become practical. Photovoltaic generation can provide electric power in remote locations where electric power would otherwise not be available. Photovoltaic generation can also afford independence from utility systems. Applications include supplying power to scientific instruments and medical equipment in isolated geographical regions.

  13. Process-Based Cost Modeling of Photonics Manufacture: The Cost Competitiveness of Monolithic Integration of a 1550-nm DFB Laser and an Electroabsorptive Modulator on an InP Platform

    NASA Astrophysics Data System (ADS)

    Fuchs, Erica R. H.; Bruce, E. J.; Ram, R. J.; Kirchain, Randolph E.

    2006-08-01

    The monolithic integration of components holds promise to increase network functionality and reduce packaging expense. Integration also drives down yield due to manufacturing complexity and the compounding of failures across devices. Consensus is lacking on the economically preferred extent of integration. Previous studies on the cost feasibility of integration have used high-level estimation methods. This study instead focuses on accurate-to-industry detail, basing a process-based cost model of device manufacture on data collected from 20 firms across the optoelectronics supply chain. The model presented allows for the definition of process organization, including testing, as well as processing conditions, operational characteristics, and level of automation at each step. This study focuses on the cost implications of integration of a 1550-nm DFB laser with an electroabsorptive modulator on an InP platform. Results show the monolithically integrated design to be more cost competitive over discrete component options regardless of production scale. Dominant cost drivers are packaging, testing, and assembly. Leveraging the technical detail underlying model projections, component alignment, bonding, and metal-organic chemical vapor deposition (MOCVD) are identified as processes where technical improvements are most critical to lowering costs. Such results should encourage exploration of the cost advantages of further integration and focus cost-driven technology development.

  14. Economically Sustainable Scaling of Photovoltaics to Meet Climate Targets

    SciTech Connect

    Needleman, David Berney; Poindexter, Jeremy R.; Kurchin, Rachel C.; Peters, Marius I.; Wilson, Gregory; Buonassisi, Tonio

    2016-11-21

    To meet climate goals, photovoltaics (PV) deployment will have to grow rapidly over the next fifteen years. We identify two barriers to this growth: scale-up of manufacturing capacity and the cost of PV module production. We explore several technoeconomic approaches to overcoming these barriers and identify deep reductions in the capital intensity (capex) of PV module manufacturing and large increases in module efficiency as the most promising routes to rapid deployment. Given the lag inherent in rolling out new technology, we explore an approach where growth is fueled by debt or subsidies in the short-term and technological advances in the medium term. Finally, we analyze the current capex structure of crystalline silicon PV module manufacturing to identify potential savings.

  15. Photovoltaic cell

    DOEpatents

    Gordon, Roy G.; Kurtz, Sarah

    1984-11-27

    In a photovoltaic cell structure containing a visibly transparent, electrically conductive first layer of metal oxide, and a light-absorbing semiconductive photovoltaic second layer, the improvement comprising a thin layer of transition metal nitride, carbide or boride interposed between said first and second layers.

  16. Designing future photovoltaic systems

    SciTech Connect

    Jones, G.J.

    1984-01-01

    The large scale use of photovoltaic systems to generate our electricity is a dream for the future; but if this dream is to be realized, we must understand these systems today. As a result, there has been extensive research into the design and economic tradeoffs of utility interconnected photovoltaic applications. The understanding gained in this process has shown that photovoltaic system design can be a very simple and straight-forward endeavor. This paper reviews those past studies and shows how we have reached the present state of system design evolution. The concept of the utility interactive PV system with energy value determined by the utility's avoided cost will be explored. This concept simplifies the screening of potential applications for economic viability, and we will present several rules-of-thumb for this purpose.

  17. Enhancement of photovoltaic response in multilayer MoS2 induced by plasma doping.

    PubMed

    Wi, Sungjin; Kim, Hyunsoo; Chen, Mikai; Nam, Hongsuk; Guo, L Jay; Meyhofer, Edgar; Liang, Xiaogan

    2014-05-27

    Layered transition-metal dichalcogenides hold promise for making ultrathin-film photovoltaic devices with a combination of excellent photovoltaic performance, superior flexibility, long lifetime, and low manufacturing cost. Engineering the proper band structures of such layered materials is essential to realize such potential. Here, we present a plasma-assisted doping approach for significantly improving the photovoltaic response in multilayer MoS2. In this work, we fabricated and characterized photovoltaic devices with a vertically stacked indium tin oxide electrode/multilayer MoS2/metal electrode structure. Utilizing a plasma-induced p-doping approach, we are able to form p-n junctions in MoS2 layers that facilitate the collection of photogenerated carriers, enhance the photovoltages, and decrease reverse dark currents. Using plasma-assisted doping processes, we have demonstrated MoS2-based photovoltaic devices exhibiting very high short-circuit photocurrent density values up to 20.9 mA/cm(2) and reasonably good power-conversion efficiencies up to 2.8% under AM1.5G illumination, as well as high external quantum efficiencies. We believe that this work provides important scientific insights for leveraging the optoelectronic properties of emerging atomically layered two-dimensional materials for photovoltaic and other optoelectronic applications.

  18. Space and Terrestrial Photovoltaics: Synergy and Diversity

    NASA Astrophysics Data System (ADS)

    Bailey, Sheila; Raffaelle, Ryne; Emery, Keith

    2002-10-01

    A historical view of the research and development in photovoltaics from the perspective of both the terrestrial and the space communities is presented from the early days through the '70s and '80s and the '90s and beyond. The synergy of both communities in the beginning and once again in the present and hopefully future are highlighted, with examples of the important features in each program. The space community which was impressed by the light-weight and reliability of photovoltaics drove much of the early development. Even up to today, nearly every satellites and other scientific space probe that has been launched has included some solar power. However, since the cost of these power systems were only a small fraction of the satellite and launch cost, the use of much of this technology for the terrestrial marketplace was not feasible. It was clear that the focus of the terrestrial community would be best served by reducing costs. This would include addressing a variety of manufacturing issues and raising the rate of production. Success in these programs and a resulting globalization of effort resulted in major strides in the reduction of PV module costs and increased production. Although, the space community derived benefit from some of these advancements, its focus was on pushing the envelope with regard to cell efficiency. The gap between theoretical efficiencies and experimental efficiencies for silicon, gallium arsenide and indium phosphide became almost non-existent. Recent work by both communities have focused on the development thin film cells of amorphous silicon, CuInSe2 and CdTe. These cells hold the promise of lower costs for the terrestrial community as well as possible flexible substrates, better radiation resistance, and higher specific power for the space community. It is predicted that future trends in both communities will be directed toward advances through the application of nanotechnology. A picture is emerging in which the space and

  19. Space and Terrestrial Photovoltaics: Synergy and Diversity

    NASA Technical Reports Server (NTRS)

    Bailey, Sheila; Raffaelle, Ryne; Emery, Keith

    2002-01-01

    A historical view of the research and development in photovoltaics from the perspective of both the terrestrial and the space communities is presented from the early days through the '70s and '80s and the '90s and beyond. The synergy of both communities in the beginning and once again in the present and hopefully future are highlighted, with examples of the important features in each program. The space community which was impressed by the light-weight and reliability of photovoltaics drove much of the early development. Even up to today, nearly every satellites and other scientific space probe that has been launched has included some solar power. However, since the cost of these power systems were only a small fraction of the satellite and launch cost, the use of much of this technology for the terrestrial marketplace was not feasible. It was clear that the focus of the terrestrial community would be best served by reducing costs. This would include addressing a variety of manufacturing issues and raising the rate of production. Success in these programs and a resulting globalization of effort resulted in major strides in the reduction of PV module costs and increased production. Although, the space community derived benefit from some of these advancements, its focus was on pushing the envelope with regard to cell efficiency. The gap between theoretical efficiencies and experimental efficiencies for silicon, gallium arsenide and indium phosphide became almost non-existent. Recent work by both communities have focused on the development thin film cells of amorphous silicon, CuInSe2 and CdTe. These cells hold the promise of lower costs for the terrestrial community as well as possible flexible substrates, better radiation resistance, and higher specific power for the space community. It is predicted that future trends in both communities will be directed toward advances through the application of nanotechnology. A picture is emerging in which the space and

  20. The future of amorphous silicon photovoltaic technology

    SciTech Connect

    Crandall, R; Luft, W

    1995-06-01

    Amorphous silicon modules are commercially available. They are the first truly commercial thin-film photovoltaic (PV) devices. Well-defined production processes over very large areas (>1 m{sup 2}) have been implemented. There are few environmental issues during manufacturing, deployment in the field, or with the eventual disposal of the modules. Manufacturing safety issues are well characterized and controllable. The highest measured initial efficiency to date is 13.7% for a small triple-stacked cell and the highest stabilized module efficiency is 10%. There is a consensus among researchers, that in order to achieve a 15% stabilized efficiency, a triple-junction amorphous silicon structure is required. Fundamental improvements in alloys are needed for higher efficiencies. This is being pursued through the DOE/NREL Thin-Film Partnership Program. Cost reductions through improved manufacturing processes are being pursued under the National Renewable Energy Laboratory/US Department of Energy (NREL/DOE)-sponsored research in manufacturing technology (PVMaT). Much of the work in designing a-Si devices is a result of trying to compensate for the Staebler-Wronski effect. Some new deposition techniques hold promise because they have produced materials with lower stabilized defect densities. However, none has yet produced a high efficiency device and shown it to be more stable than those from standard glow discharge deposited material.

  1. Silicon material technology status. [assessment for electronic and photovoltaic applications

    NASA Technical Reports Server (NTRS)

    Lutwack, R.

    1983-01-01

    Silicon has been the basic element for the electronic and photovoltaic industries. The use of silicon as the primary element for terrestrial photovoltaic solar arrays is projected to continue. The reasons for this projection are related to the maturity of silicon technology, the ready availability of extremely pure silicon, the performance of silicon solar cells, and the considerable present investment in technology and manufacturing facilities. The technologies for producing semiconductor grade silicon and, to a lesser extent, refined metallurgical grade silicon are considered. It is pointed out that nearly all of the semiconductor grade silicon is produced by processes based on the Siemens deposition reactor, a technology developed 26 years ago. The state-of-the-art for producing silicon by this process is discussed. It is expected that efforts to reduce polysilicon process costs will continue.

  2. Photovoltaic prospects in Europe

    NASA Astrophysics Data System (ADS)

    Starr, M. R.

    The economics of solar cells is reviewed with an eye to potential cost reductions in processing, and potential markets are explored. Current solar cell systems costs are noted to be on the road to achieving the U.S. DoE goals of $0.40/kWp by 1990. Continued progress will depend on technical developments in cheaper materials and processes, scaling up production, and the success of sales programs. Various consumer and professional markets are outlined, with a prediction that a 12 MWp deman will be reached as a steady state by 1995. Photovoltaic panels may conceivably replace conventional roofing materials, resulting in the projection that, if grid-supplied power continues to inflate in price, then all new European homes would be equipped with photovoltaics by the year 2000. Further, accomplishment of the cost goals could generate a 1 GWp/yr industrial market at the same time.

  3. Byproduct mineral commodities used for the production of photovoltaic cells

    USGS Publications Warehouse

    Bleiwas, Donald I.

    2010-01-01

    Rising fossil fuel costs, environmental concerns relating to global climate change, and Government policy to signifcantly increase our Nation's energy independence have placed greater emphasis on the generation of electricity from renewable sources, such as the Sun (light and heat), water, and wind, which for all intents and purposes are inexhaustible resources. Although the total amount of electricity generated from the direct conversion of sunlight through photovoltaic cells is relatively small compared with that from other forms of renewable energy, the rate of growth in the sector is signifcant. The total value of energy of photovoltaic cells produced worldwide increased to nearly 7 gigawatts (GW) in 2008 from 45 megawatts (MW) in 1990, a compound annual growth rate of about 30 percent. In the United States, manufacturing of photovoltaic cells has grown exponentially to about 480 MW in 2008, accounting for 6 percent of world production, from less than 10 MW of photovoltaic capacity in 1990 (Benner, 2007; U.S. Department of Energy, Energy Information Administration, 2010), a compound annual growth rate of approxi-mately 23 percent. A production capacity of 1 GW of electricity [or 8,760 gigawatthours1 (GWh)] is equivalent to the annual electricity requirements for roughly 800,000 average households in the United States (U.S. Department of Energy, Energy Information Administration, 2010). This estimate does not include losses of electricity, such as during transmission through power lines.

  4. Increased photovoltaic power output via diffractive spectrum separation.

    PubMed

    Kim, Ganghun; Dominguez-Caballero, Jose A; Lee, Howard; Friedman, Daniel J; Menon, Rajesh

    2013-03-22

    In this Letter, we report the preliminary demonstration of a new paradigm for photovoltaic power generation that utilizes a broadband diffractive-optical element (BDOE) to efficiently separate sunlight into laterally spaced spectral bands. These bands are then absorbed by single-junction photovoltaic cells, whose band gaps correspond to the incident spectral bands. We designed such BDOEs by utilizing a modified version of the direct-binary-search algorithm. Gray scale lithography was used to fabricate these multilevel optics. They were experimentally characterized with an overall optical efficiency of 70% over a wavelength range of 350-1100 nm, which was in excellent agreement with simulation predictions. Finally, two prototype devices were assembled: one with a pair of copper indium gallium selenide based photovoltaic devices, and another with GaAs and c-Si photovoltaic devices. These devices demonstrated an increase in output peak electrical power of ∼ 42% and ∼ 22%, respectively, under white-light illumination. Because of the optical versatility and manufacturability of the proposed BDOEs, the reported spectrum-splitting approach provides a new approach toward low-cost solar power.

  5. A users evaluation of SAMIS. [Solar Array Manufacturing Industry Simulation

    NASA Technical Reports Server (NTRS)

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

    1981-01-01

    SAMIS, the Solar Array Manufacturing Industry Simulation computer program was developed by Jet Propulsion Laboratories (JPL) to provide a method whereby manufacturers or potential manufacturers of photovoltaics could simulate a solar industry using their own particular approach. This paper analyzes the usefulness of SAMIS to a growing photovoltaic industry and clearly illustrates its limitations as viewed by an industrial user.

  6. Organic photovoltaics: key photophysical, device and design aspects

    NASA Astrophysics Data System (ADS)

    Joshi, Dhruv; Shivanna, Ravichandran; Narayan, K. S.

    2014-12-01

    Key aspects of Organic Photovoltaics (OPVs) have been reviewed in this tutorial. Issues pertaining to the choice of materials, fabrication processes, photophysical mechanisms, device characterization, morphology of active layers and manufacturing are discussed. Special emphasis has been given to recent developments in large-area modules. Current strategies in enhancing the performance using external optical engineering approaches have also been highlighted. OPVs as a technology combine low weight, flexibility, low cost, good form factor and high-throughput processing; making them a promising PV technology for the future.

  7. Why silicon is and will remain the dominant photovoltaic material

    NASA Astrophysics Data System (ADS)

    Singh, Rajendra

    2009-07-01

    Rising demands of energy in emerging economies, coupled with the green house gas emissions related problems around the globe have provided a unique opportunity of exploiting the advantages offered by photovoltaic (PV) systems for green energy electricity generation. Similar to cell phones, power generated by PV systems can reach over two billion people worldwide who have no access to clean energy. Only silicon based PV devices meet the low-cost manufacturing criterion of clean energy conversion (abundance of raw material and no environmental health and safety issues). The use of larger size glass substrates and manufacturing techniques similar to the ones used by the liquid crystal display industry and the large scale manufacturing of amorphous silicon thin films based modules (~ GW per year manufacturing at a single location) can lead to installed PV system cost of $3/Wp. This will open a huge market for grid connected PV systems and related markets. With further research and development, this approach can provide $2/Wp installed PV system costs in the next few years. At this cost level, PV electricity generation is competitive with any other technology, and PV power generation can be a dominant electricity generation technology in the 21st century.

  8. Development of the SEA Corporation Powergrid{trademark} photovoltaic concentrator

    SciTech Connect

    Kaminar, N.; Curchod, D.; Daroczi, S.; Walpert, M.; Sahagian, J.; Pepper, J.

    1998-03-01

    This report covers the three phase effort to bring the SEA Corporation`s Powergrid{trademark} from the concept stage to pilot production. The three phases of this contract covered component development, prototype module development, and pilot line production. The Powergrid is a photovoltaic concentrator that generates direct current electricity directly from sunlight using a linear Fresnel lens. Analysis has shown that the Powergrid has the potential to be very low cost in volume production. Before the start of the project, only proof of concept demonstrations of the components had been completed. During the project, SEA Corporation developed a low cost extruded Fresnel lens, a low cost receiver assembly using one sun type cells, a low cost plastic module housing, a single axis tracking system and frame structure, and pilot production equipment and techniques. In addition, an 800 kW/yr pilot production rate was demonstrated and two 40 kW systems were manufactured and installed.

  9. A low-cost computer-controlled Arduino-based educational laboratory system for teaching the fundamentals of photovoltaic cells

    NASA Astrophysics Data System (ADS)

    Zachariadou, K.; Yiasemides, K.; Trougkakos, N.

    2012-11-01

    We present a low-cost, fully computer-controlled, Arduino-based, educational laboratory (SolarInsight) to be used in undergraduate university courses concerned with electrical engineering and physics. The major goal of the system is to provide students with the necessary instrumentation, software tools and methodology in order to learn fundamental concepts of semiconductor physics by exploring the process of an experimental physics inquiry. The system runs under the Windows operating system and is composed of a data acquisition/control board, a power supply and processing boards, sensing elements, a graphical user interface and data analysis software. The data acquisition/control board is based on the Arduino open source electronics prototyping platform. The graphical user interface and communication with the Arduino are developed in C# and C++ programming languages respectively, by using IDE Microsoft Visual Studio 2010 Professional, which is freely available to students. Finally, the data analysis is performed by using the open source, object-oriented framework ROOT. Currently the system supports five teaching activities, each one corresponding to an independent tab in the user interface. SolarInsight has been partially developed in the context of a diploma thesis conducted within the Technological Educational Institute of Piraeus under the co-supervision of the Physics and Electronic Computer Systems departments’ academic staff.

  10. Photovoltaic industry progress through 1984

    SciTech Connect

    Watts, R.L.; Smith, S.A.; Dirks, J.A.

    1985-04-01

    The growth of the US photovoltaics (PV) industry over the past decade has been impressive. First designed to provide power for satellites using high-cost production techniques, PV is now the economical choice in many remote terrestrial applications. The remarkable growth of PV in terms of quality of cells and modules, production techniques, and system design, was initiated by a cooperative effort of the US Government and the domestic PV manufacturers. European and Japanese firms entered the PV industry later, but are also growing rapidy. The Europeans continue to supply PV systems for village electrification and water pumping to many Third World countries. The Japanese have been developing the amorphous silicon (A-Si) technology by expanding its use in consumer goods. The world PV industry saw dramatic changes in industry ownership and in the emphasis on developing new and improved technology during 1984. The objective of this report is to present information on the developments of the world PV industry and focuses on developments occurring in 1984. Information is presented on a regional basis (US, Europe, Japan, other) to avoid disclosing company-confidential data. All information was gleaned from several sources, including a review of the technical literature and direct contacts with PV manufacturers. Prior to publishing the regional totals, all numbers were compared with those of other sources. The information contained in this report is prepared for use by the Department of Energy for their use in long-term R and D planning. However, this information should also be of interest by PV manufacturers and to those who may be contemplating entering the PV market. PV shipments for 1984, government supports for PV, and various PV market sectors are discussed.

  11. US photovoltaic patents: 1991--1993

    SciTech Connect

    Pohle, L

    1995-03-01

    This document contains US patents on terrestrial photovoltaic (PV) power applications, including systems, components, and materials as well as manufacturing and support functions. The patent entries in this document were issued from 1991 to 1993. The entries were located by searching USPA, the database of the US Patent Office. The final search retrieved all patents under the class ``Batteries, Thermoelectric and Photoelectric`` and the subclasses ``Photoelectric,`` ``Testing,`` and ``Applications.`` The search also located patents that contained the words ``photovoltaic(s)`` or ``solar cell(s)`` and their derivatives. After the initial list was compiled, most of the patents on the following subjects were excluded: space photovoltaic technology, use of the photovoltaic effect for detectors, and subjects only peripherally concerned with photovoltaic. Some patents on these three subjects were included when ft appeared that those inventions might be of use in terrestrial PV power technologies.

  12. Technology advances needed for photovoltaics to achieve widespread grid price parity: Widespread grid price parity for photovoltaics

    SciTech Connect

    Jones-Albertus, Rebecca; Feldman, David; Fu, Ran; Horowitz, Kelsey; Woodhouse, Michael

    2016-04-20

    To quantify the potential value of technological advances to the photovoltaics (PV) sector, this paper examines the impact of changes to key PV module and system parameters on the levelized cost of energy (LCOE). The parameters selected include module manufacturing cost, efficiency, degradation rate, and service lifetime. NREL's System Advisor Model (SAM) is used to calculate the lifecycle cost per kilowatt-hour (kWh) for residential, commercial, and utility scale PV systems within the contiguous United States, with a focus on utility scale. Different technological pathways are illustrated that may achieve the Department of Energy's SunShot goal of PV electricity that is at grid price parity with conventional electricity sources. In addition, the impacts on the 2015 baseline LCOE due to changes to each parameter are shown. These results may be used to identify research directions with the greatest potential to impact the cost of PV electricity.

  13. Optimization of low cost, non toxic, earth abundant p-type Cu2SnS3 thin film for Photovoltaic application

    NASA Astrophysics Data System (ADS)

    Chaudhari, J. J.; Patel, S.; Joshi, U. S.

    2016-09-01

    Cu2SnS3 (CTS) is one of promising candidate as an absorber material for thin film solar cell. Because of relatively higher prize of Indium and hazardous environmental impact of processing of Gallium, CTS is suitable alternative candidate to Cu2SnS3 (CIGS) based solar cell as its constituent elements such as copper, tin and sulphur are abundantly available in earth's crust. CTS is ternary semiconductor and its energy band gap is 1.5eV, which is perfectly matched with solar energy spectrum for maximum transfer of solar energy into electrical energy through photovoltaic action. The primary methods for the synthesis of CTS are Thermal evaporation, electrochemical, sputtering and wet chemical methods. Here in this paper we have optimized a low cost non-vacuum solution process method for the synthesis of CTS without any external sulfurization. The X-ray diffraction studies showed the formation of phase with the peaks corresponding to (112), (220) and (312) planes. Chemical Solution Deposition (CSD) for the synthesis of CTS is suitable for large area deposition and it includes several routes like solvothermal methods, direct liquid coating and nano ink based technique. The metal Chloride salts and thiourea is used as a source of sulphur to synthesize CTS solution and homogeneous thin films of CTS deposited on glass substrate using spin coating method. Use of abrasive solvent like hydrazine and hydrogen sulphide gas which are used to synthesize CTS thin film have detrimental effect on environment, we report eco friendly solvent based approach to synthesize CTS at low temperature 200 °C.

  14. Environmentally benign silicon solar cell manufacturing

    SciTech Connect

    Tsuo, Y.S.; Gee, J.M.; Menna, P.; Strebkov, D.S.; Pinov, A.; Zadde, V.

    1998-09-01

    The manufacturing of silicon devices--from polysilicon production, crystal growth, ingot slicing, wafer cleaning, device processing, to encapsulation--requires many steps that are energy intensive and use large amounts of water and toxic chemicals. In the past two years, the silicon integrated-circuit (IC) industry has initiated several programs to promote environmentally benign manufacturing, i.e., manufacturing practices that recover, recycle, and reuse materials resources with a minimal consumption of energy. Crystalline-silicon solar photovoltaic (PV) modules, which accounted for 87% of the worldwide module shipments in 1997, are large-area devices with many manufacturing steps similar to those used in the IC industry. Obviously, there are significant opportunities for the PV industry to implement more environmentally benign manufacturing approaches. Such approaches often have the potential for significant cost reduction by reducing energy use and/or the purchase volume of new chemicals and by cutting the amount of used chemicals that must be discarded. This paper will review recent accomplishments of the IC industry initiatives and discuss new processes for environmentally benign silicon solar-cell manufacturing.

  15. PHOTOVOLTAICS AND THE ENVIRONMENT 1998. REPORT ON THE WORKSHOP PHOTOVOLTAICS AND THE ENVIRONMENT 1999

    SciTech Connect

    FTHENAKIS,V.; ZWEIBEL,K.; MOSKOWITZ,P.

    1999-02-01

    The objective of the workshop ``Photovoltaics and the Environment'' was to bring together PV manufacturers and industry analysts to define EH and S issues related to the large-scale commercialization of PV technologies.

  16. Terrestrial Photovoltaic System Analysis.

    DTIC Science & Technology

    1980-07-01

    tanks is cost Iv (P3 per Watt) bet’aulse ofanll-t distri bution svsteri and uise if exit ic heat. 01latgr 1 C 01:1 li:-iorn. ItIe r e1o0re iS t i a1t...install an array size ot at least 300i kW. The estimated initial instal led cost oi th., cmibiiid phit,)voltaic!tLier- mal system is $28 per watt. The use...conclusion, theretore, is that ;al electric - only photovoltaic system is more cost effective. The daily average power requirement of the

  17. Solar Glitter -- Microsystems Enabled Photovoltaics

    NASA Astrophysics Data System (ADS)

    Nielson, Gregory N.

    2012-02-01

    Many products have significantly benefitted from, or been enabled by, the ability to manufacture structures at an ever decreasing length scale. Obvious examples of this include integrated circuits, flat panel displays, micro-scale sensors, and LED lighting. These industries have benefited from length scale effects in terms of improved performance, reduced cost, or new functionality (or a combination of these). In a similar manner, we are working to take advantage of length scale effects that exist within solar photovoltaic (PV) systems. While this is a significant step away from traditional approaches to solar power systems, the benefits in terms of new functionality, improved performance, and reduced cost for solar power are compelling. We are exploring scale effects that result from the size of the solar cells within the system. We have developed unique cells of both crystalline silicon and III-V materials that are very thin (5-20 microns thick) and have very small lateral dimensions (on the order of hundreds of microns across). These cells minimize the amount of expensive semiconductor material required for the system, allow improved cell performance, and provide an expanded design space for both module and system concepts allowing optimized power output and reduced module and balance of system costs. Furthermore, the small size of the cells allows for unique high-efficiency, high-flexibility PV panels and new building-integrated PV options that are currently unavailable. These benefits provide a pathway for PV power to become cost competitive with grid power and allow unique power solutions independent of grid power.

  18. Nanoplasmonics: a frontier of photovoltaic solar cells

    NASA Astrophysics Data System (ADS)

    Gu, Min; Ouyang, Zi; Jia, Baohua; Stokes, Nicholas; Chen, Xi; Fahim, Narges; Li, Xiangping; Ventura, Michael James; Shi, Zhengrong

    2012-12-01

    Nanoplasmonics recently has emerged as a new frontier of photovoltaic research. Noble metal nanostructures that can concentrate and guide light have demonstrated great capability for dramatically improving the energy conversion efficiency of both laboratory and industrial solar cells, providing an innovative pathway potentially transforming the solar industry. However, to make the nanoplasmonic technology fully appreciated by the solar industry, key challenges need to be addressed; including the detrimental absorption of metals, broadband light trapping mechanisms, cost of plasmonic nanomaterials, simple and inexpensive fabrication and integration methods of the plasmonic nanostructures, which are scalable for full size manufacture. This article reviews the recent progress of plasmonic solar cells including the fundamental mechanisms, material fabrication, theoretical modelling and emerging directions with a distinct emphasis on solutions tackling the above-mentioned challenges for industrial relevant applications.

  19. Inverted organic photovoltaic cells.

    PubMed

    Wang, Kai; Liu, Chang; Meng, Tianyu; Yi, Chao; Gong, Xiong

    2016-05-21

    The advance in lifestyle, modern industrialization and future technological revolution are always at high expense of energy consumption. Unfortunately, there exist serious issues such as limited storage, high cost and toxic contamination in conventional fossil fuel energy sources. Instead, solar energy represents a renewable, economic and green alternative in the future energy market. Among the photovoltaic technologies, organic photovoltaics (OPVs) demonstrate a cheap, flexible, clean and easy-processing way to convert solar energy into electricity. However, OPVs with a conventional device structure are still far away from industrialization mainly because of their short lifetime and the energy-intensive deposition of top metal electrode. To address the stability and cost issue simultaneously, an inverted device structure has been introduced into OPVs, bridging laboratory research with practical application. In this review, recent progress in device structures, working mechanisms, functions and advances of each component layer as well their correlations with the efficiency and stability of inverted OPVs are reviewed and illustrated.

  20. Additive manufacturing of liquid/gas diffusion layers for low-cost and high-efficiency hydrogen production

    SciTech Connect

    Mo, Jingke; Zhang, Feng -Yuan; Dehoff, Ryan R.; Peter, William H.; Toops, Todd J.; Green, Jr., Johney Boyd

    2016-01-14

    The electron beam melting (EBM) additive manufacturing technology was used to fabricate titanium liquid/gas diffusion media with high-corrosion resistances and well-controllable multifunctional parameters, including two-phase transport and excellent electric/thermal conductivities, has been first demonstrated. Their applications in proton exchange membrane eletrolyzer cells have been explored in-situ in a cell and characterized ex-situ with SEM and XRD. Compared with the conventional woven liquid/gas diffusion layers (LGDLs), much better performance with EBM fabricated LGDLs is obtained due to their significant reduction of ohmic loss. The EBM technology components exhibited several distinguished advantages in fabricating gas diffusion layer: well-controllable pore morphology and structure, rapid prototyping, fast manufacturing, highly customizing and economic. In addition, by taking advantage of additive manufacturing, it possible to fabricate complicated three-dimensional designs of virtually any shape from a digital model into one single solid object faster, cheaper and easier, especially for titanium. More importantly, this development will provide LGDLs with control of pore size, pore shape, pore distribution, and therefore porosity and permeability, which will be very valuable to develop modeling and to validate simulations of electrolyzers with optimal and repeatable performance. Further, it will lead to a manufacturing solution to greatly simplify the PEMEC/fuel cell components and to couple the LGDLs with other parts, since they can be easily integrated together with this advanced manufacturing process

  1. Additive manufacturing of liquid/gas diffusion layers for low-cost and high-efficiency hydrogen production

    DOE PAGES

    Mo, Jingke; Zhang, Feng -Yuan; Dehoff, Ryan R.; ...

    2016-01-14

    The electron beam melting (EBM) additive manufacturing technology was used to fabricate titanium liquid/gas diffusion media with high-corrosion resistances and well-controllable multifunctional parameters, including two-phase transport and excellent electric/thermal conductivities, has been first demonstrated. Their applications in proton exchange membrane eletrolyzer cells have been explored in-situ in a cell and characterized ex-situ with SEM and XRD. Compared with the conventional woven liquid/gas diffusion layers (LGDLs), much better performance with EBM fabricated LGDLs is obtained due to their significant reduction of ohmic loss. The EBM technology components exhibited several distinguished advantages in fabricating gas diffusion layer: well-controllable pore morphology and structure,more » rapid prototyping, fast manufacturing, highly customizing and economic. In addition, by taking advantage of additive manufacturing, it possible to fabricate complicated three-dimensional designs of virtually any shape from a digital model into one single solid object faster, cheaper and easier, especially for titanium. More importantly, this development will provide LGDLs with control of pore size, pore shape, pore distribution, and therefore porosity and permeability, which will be very valuable to develop modeling and to validate simulations of electrolyzers with optimal and repeatable performance. Further, it will lead to a manufacturing solution to greatly simplify the PEMEC/fuel cell components and to couple the LGDLs with other parts, since they can be easily integrated together with this advanced manufacturing process« less

  2. Smart Manufacturing.

    PubMed

    Davis, Jim; Edgar, Thomas; Graybill, Robert; Korambath, Prakashan; Schott, Brian; Swink, Denise; Wang, Jianwu; Wetzel, Jim

    2015-01-01

    Historic manufacturing enterprises based on vertically optimized companies, practices, market share, and competitiveness are giving way to enterprises that are responsive across an entire value chain to demand dynamic markets and customized product value adds; increased expectations for environmental sustainability, reduced energy usage, and zero incidents; and faster technology and product adoption. Agile innovation and manufacturing combined with radically increased productivity become engines for competitiveness and reinvestment, not simply for decreased cost. A focus on agility, productivity, energy, and environmental sustainability produces opportunities that are far beyond reducing market volatility. Agility directly impacts innovation, time-to-market, and faster, broader exploration of the trade space. These changes, the forces driving them, and new network-based information technologies offering unprecedented insights and analysis are motivating the advent of smart manufacturing and new information technology infrastructure for manufacturing.

  3. Recycling Of Cis Photovoltaic Waste

    DOEpatents

    Drinkard, Jr., William F.; Long, Mark O.; Goozner; Robert E.

    1998-07-14

    A method for extracting and reclaiming metals from scrap CIS photovoltaic cells and associated photovoltaic manufacturing waste by leaching the waste with dilute nitric acid, skimming any plastic material from the top of the leaching solution, separating glass substrate from the leachate, electrolyzing the leachate to plate a copper and selenium metal mixture onto a first cathode, replacing the cathode with a second cathode, re-electrolyzing the leachate to plate cadmium onto the second cathode, separating the copper from selenium, and evaporating the depleted leachate to yield a zinc and indium containing solid.

  4. Photovoltaic cell and production thereof

    DOEpatents

    Narayanan, Srinivasamohan; Kumar, Bikash

    2008-07-22

    An efficient photovoltaic cell, and its process of manufacture, is disclosed wherein the back surface p-n junction is removed from a doped substrate having an oppositely doped emitter layer. A front surface and edges and optionally the back surface periphery are masked and a back surface etch is performed. The mask is not removed and acts as an anti-reflective coating, a passivating agent, or both. The photovoltaic cell retains an untextured back surface whether or not the front is textured and the dopant layer on the back surface is removed to enhance the cell efficiency. Optionally, a back surface field is formed.

  5. Recovering valuable metals from recycled photovoltaic modules.

    PubMed

    Yi, Youn Kyu; Kim, Hyun Soo; Tran, Tam; Hong, Sung Kil; Kim, Myong Jun

    2014-07-01

    Recovering valuable metals such as Si, Ag, Cu, and Al has become a pressing issue as end-of-life photovoltaic modules need to be recycled in the near future to meet legislative requirements in most countries. Of major interest is the recovery and recycling of high-purity silicon (> 99.9%) for the production of wafers and semiconductors. The value of Si in crystalline-type photovoltaic modules is estimated to be -$95/kW at the 2012 metal price. At the current installed capacity of 30 GW/yr, the metal value in the PV modules represents valuable resources that should be recovered in the future. The recycling of end-of-life photovoltaic modules would supply > 88,000 and 207,000 tpa Si by 2040 and 2050, respectively. This represents more than 50% of the required Si for module fabrication. Experimental testwork on crystalline Si modules could recover a > 99.98%-grade Si product by HNO3/NaOH leaching to remove Al, Ag, and Ti and other metal ions from the doped Si. A further pyrometallurgical smelting at 1520 degrees C using CaO-CaF2-SiO2 slag mixture to scavenge the residual metals after acid leaching could finally produce > 99.998%-grade Si. A process based on HNO3/NaOH leaching and subsequent smelting is proposed for recycling Si from rejected or recycled photovoltaic modules. Implications: The photovoltaic industry is considering options of recycling PV modules to recover metals such as Si, Ag, Cu, Al, and others used in the manufacturing of the PV cells. This is to retain its "green" image and to comply with current legislations in several countries. An evaluation of potential resources made available from PV wastes and the technologies used for processing these materials is therefore of significant importance to the industry. Of interest are the costs of processing and the potential revenues gained from recycling, which should determine the viability of economic recycling of PV modules in the future.

  6. Photovoltaics: A Solar Technology for Powering Tomorrow.

    ERIC Educational Resources Information Center

    Flavin, Christopher

    1983-01-01

    Photovoltaics, the technology that converts sunlight directly into electricity, may soon be a reliable power source for the world's poor. The one major challenge is cost reduction. Many topics are discussed, including solar powering the Third World, designing the solar building, investing in the sun, and the future of photovoltaics. (NW)

  7. Solar photovoltaic reflective trough collection structure

    DOEpatents

    Anderson, Benjamin J.; Sweatt, William C.; Okandan, Murat; Nielson, Gregory N.

    2015-11-19

    A photovoltaic (PV) solar concentration structure having at least two troughs encapsulated in a rectangular parallelepiped optical plastic structure, with the troughs filled with an optical plastic material, the troughs each having a reflective internal surface and approximately parabolic geometry, and the troughs each including photovoltaic cells situated so that light impinging on the optical plastic material will be concentrated onto the photovoltaic cells. Multiple structures can be connected to provide a solar photovoltaic collection system that provides portable, efficient, low-cost electrical power.

  8. Manufacture of ammonium sulfate fertilizer from gypsum-rich byproduct of flue gas desulfurization - A prefeasibility cost estimate

    USGS Publications Warehouse

    Chou, I.-Ming; Rostam-Abadi, M.; Lytle, J.M.; Achorn, F.P.

    1996-01-01

    Costs for constructing and operating a conceptual plant based on a proposed process that converts flue gas desulfurization (FGD)-gypsum to ammonium sulfate fertilizer has been calculated and used to estimate a market price for the product. The average market price of granular ammonium sulfate ($138/ton) exceeds the rough estimated cost of ammonium sulfate from the proposed process ($111/ ton), by 25 percent, if granular size ammonium sulfate crystals of 1.2 to 3.3 millimeters in diameters can be produced by the proposed process. However, there was at least ??30% margin in the cost estimate calculations. The additional costs for compaction, if needed to create granules of the required size, would make the process uneconomical unless considerable efficiency gains are achieved to balance the additional costs. This study suggests the need both to refine the crystallization process and to find potential markets for the calcium carbonate produced by the process.

  9. Photovoltaics: Energy for the New Millenium

    NASA Astrophysics Data System (ADS)

    Surek, Thomas

    2000-04-01

    Photovoltaics (PV) is a semiconductor-based technology that directly converts sunlight to electricity. The stimulus for terrestrial PV started more than 25 years ago in response to the oil crises of the 1970s, which resulted in major government programs in the United States, Europe, Japan, and elsewhere. Ongoing concerns with the global environment, as well as the worldwide efforts to seek alternate, indigenous sources of energy, continue to drive the investment in PV research and deployment. Today, the manufacture, sale, and use of PV has become a billion-dollar industry worldwide, with nearly 200 megawatts (MW) of PV modules shipped in 1999. The twenty five years of research and development led to the discovery of new PV materials, devices, and fabrication approaches; continuing improvements in the efficiency and reliability of solar cells and modules; and lower PV module and system costs. This talk reviews the rapid progress that has occurred in PV technology from the laboratory to the marketplace, including reviews of the leading technology options, status and issues, and key industry players. New processes for fabricating PV materials and devices, and innovative PV approaches with low-cost potential are elements of an ongoing research program aimed at future advancements in PV cost and performance While major market opportunities continue to exist in the developing countries, where sizable populations are without any electricity, today's manufacturing expansions are fueled by market initiatives for grid-connected PV in residential and commercial buildings. The combinations of increased production capacities, with the attendant cost reductions as a result of economies of scale, are expected to lead to sustainable markets. A key to achieving the ultimate potential of PV is to continue to increase the sunlight-to-electricity conversion efficiencies and translate the laboratory successes to cost-competitive products. Building a robust technology base is essential

  10. Photovoltaic Engineering

    NASA Technical Reports Server (NTRS)

    2005-01-01

    The Ohio Aerospace Institute through David Scheiman and Phillip Jenkins provided the Photovoltaics Branch at the NASA Glenn Research Center (GRC) with expertise in photovoltaic (PV) research, flight experiments and solar cell calibration. NASA GRC maintains the only world-class solar cell calibration and measurement facility within NASA. GRC also has a leadership role within the solar cell calibration community, and is leading the effort to develop ISO standards for solar cell calibration. OAI scientists working under this grant provided much of the expertise and leadership in this area.

  11. Advanced manufacturing technologies for reduced cost and weight in portable ruggedized VIS-IR and multi-mode optical systems for land, sea, and air

    NASA Astrophysics Data System (ADS)

    Sweeney, Michael; Spinazzola, Robert; Morrison, Donald; Macklin, Dennis; Marion, Jared

    2011-06-01

    Homeland security systems, special forces, unmanned aerial vehicles (UAV), and marine patrols require low cost, high performance, multi-mode visible through infrared (VIS-IR) wavelength optical systems to identify and neutralize potential threats that often arise at long ranges and under poor visibility conditions. Long range and wide spectral performance requirements favor reflective optical system design solutions. The limited field of view of such designs can be significantly enhanced by the use of catadioptric optical solutions that utilize molded or diamond point machined VIS-IR lenses downstream from reflective objective optics. A common optical aperture that services multiple modes of field-of-view, operating wavelength, and includes laser ranging and spotting, provides the highest utility and is most ideal for size and weight. Such a design also often requires fast, highly aspheric, reflective, refractive, and sometimes diffractive surfaces using high performance and aggressively light-weighted materials that demand the finest of manufacturing technologies. Visible wavelength performance sets the bar for component optical surface irregularity on the order of 20 nm RMS and surface finishes less than 3.0 nm RMS. Aluminum mirrors and structures can also be precision machined to yield "snap together alignment" or limited compensation assembly approaches to reduce cost and enhance interchangeability. Diamond point turning, die cast and investment cast mirror substrates and structures, computerized optical polishing, mirror replication, lens molding and other advanced manufacturing technologies can all be used to minimize the cost of this type of optical equipment. This paper discusses the tradeoffs among materials and process selection for catadioptric, multi-mode systems that are under development for a variety of DoD and Homeland Security applications. Several examples are profiled to illuminate the confluence of applicable design and manufacturing

  12. The new alchemy of photovoltaics

    SciTech Connect

    Jeffries, J.P.

    1983-01-01

    The work is a review. The expanding field of use of photovoltaic electric power plants includes single family homes. Solar batteries with a surface area of less than 90 square meters mounted on a roof totally or partially satisfy their daily requirement for electric power. The cost of a single family, approximately 220 square meter home built near Sante Fe and equipped with a passive solar system with a photovoltaic power plant with a power production of 6,500 kilovolthours per year is 190,000 dollars. The cost of a solar battery has been reduced to 7 to 15 dollars per watt of peak power, which is totally insufficient for buy back even over forth years. The threshold of cost, when the solar battery is competitive is 3 dollars per watt. Nevertheless, approximately 6,000 single family dwelling passive solar systems with a photovoltaic power plant are in operation in the United States. The previous opponents of the photovoltaic method, the oil companies, have become suporters of the development and production of solar energy. After the decline in 1982 as a result of the five fold reduction of government financing in works in the field of renewable energy sources, the photovoltaic industry enjoyed a new rise in popularity.

  13. Photovoltaic Subcontract Program, FY 1991

    SciTech Connect

    Not Available

    1992-03-01

    This report summarizes the fiscal year (FY) 1991 (October 1, 1990, through September 30, 1991) progress of the subcontracted photovoltaic (PV) research and development (R D) performed under the Photovoltaic Advanced Research and Development Project at the National Renewable Energy Laboratory (NREL) -- formerly the Solar Energy Research Institute (SERI). The mission of the national PV program is to develop PV technology for large-scale generation of economically competitive electric power in the United States. The technical sections of the report cover the main areas of the subcontract program: the Amorphous Silicon Research Project, Polycrystalline Thin Films, Crystalline Silicon Materials Research, High-Efficiency Concepts, the New Ideas Program, the University Participation Program, and the Photovoltaic Manufacturing Technology (PVMaT) project. Technical summaries of each of the subcontracted programs provide a discussion of approaches, major accomplishments in FY 1991, and future research directions.

  14. Advanced Manufacturing Process for Lower Cost Rechargeable Lithium-ion Batteries for DOD Including the BB2590

    DTIC Science & Technology

    2013-11-30

    Nickelate in 18650 Cell 24 8. Installation of Resistance Welder 25 9. Bi-Cell Vacuum Dryer and with Activation Box 26 10. Semi...DOD lithium-ion rechargeable cells/batteries are composed of combinations using Asian 18650 cells including the BB2590. This dependence is due to the...much lower cost of the Asian and particularly the Chinese 18650 cells which are made on very large scale and also with lower labor costs. LithChem

  15. Creating Cost Growth Models for the Engineering and Manufacturing Development Phase of Acquisition Using Logistic and Multiple Regression

    DTIC Science & Technology

    2004-03-01

    actual costs method extrapolates the data gathered over the course of the program to produce a cost estimate. While this technique creates very...significantly revised over the past two years , this instruction still shapes acquisition structure, policy, and the processes for making war fighting...AFIT Theses (Gordon, 1996:2-3) Author ( Year ) Findings Sensitivity Factors Nystrom (1996) Complex non-linear EAC methods not superior to simpler

  16. Characteristic features of determining the labor input and estimated cost of the development and manufacture of equipment

    NASA Technical Reports Server (NTRS)

    Kurmanaliyev, T. I.; Breslavets, A. V.

    1974-01-01

    The difficulties in obtaining exact calculation data for the labor input and estimated cost are noted. The method of calculating the labor cost of the design work using the provisional normative indexes with respect to individual forms of operations is proposed. Values of certain coefficients recommended for use in the practical calculations of the labor input for the development of new scientific equipment for space research are presented.

  17. Photovoltaics information user study

    SciTech Connect

    Belew, W.W.; Wood, B.L.; Marie, T.L.; Reinhardt, C.L.

    1980-10-01

    The results of a series of telephone interviews with groups of users of information on photovoltaics (PV) are described. These results, part of a larger study on many different solar technologies, identify types of information each group needed and the best ways to get information to each group. The report is 1 of 10 discussing study results. The overall study provides baseline data about information needs in the solar community. It covers these technological areas: photovoltaics, passive solar heating and cooling, active solar heating and cooling, biomass energy, solar thermal electric power, solar industrial and agricultural process heat, wind energy, ocean energy, and advanced energy storage. An earlier study identified the information user groups in the solar community and the priority (to accelerate solar energy commercialization) of getting information to each group. In the current study only high-priority groups were examined. Results from seven PV groups respondents are analyzed in this report: DOE-Funded Researchers, Non-DOE-Funded Researchers, Researchers Working for Manufacturers, Representatives of Other Manufacturers, Representatives of Utilities, Electric Power Engineers, and Educators.

  18. Analysis and evalaution in the production process and equipment area of the low-cost solar array project. [including modifying gaseous diffusion and using ion implantation

    NASA Technical Reports Server (NTRS)

    Goldman, H.; Wolf, M.

    1979-01-01

    The manufacturing methods for photovoltaic solar energy utilization are assessed. Economic and technical data on the current front junction formation processes of gaseous diffusion and ion implantation are presented. Future proposals, including modifying gaseous diffusion and using ion implantation, to decrease the cost of junction formation are studied. Technology developments in current processes and an economic evaluation of the processes are included.

  19. Evaluation of the technical feasibility and effective cost of various wafer thicknesses for the manufacture of solar cells. Final report, July 15, 1978-July 15, 1979

    SciTech Connect

    Not Available

    1980-03-20

    The principal activities in the performance of this contract effort include practical evaluation of the Yasunaga YQ-100 saw in a production environment. The wafering system is a free-abrasive multiple-loop single wire machine where the number of wafers/cm is determined by the wire pitch. In addition, the effects of wire diameter and abrasive size were studied. Solar cells were manufactured from each saw run to analyze surface damage and effects varying thickness on efficiency. It was determined that surface damage was much reduced compared to fixed abrasive saws, and as little as 5 to 10 micrometers of surface removal from each side of the wafer was sufficient to obtain optimum efficiency for the particular process which was used. Since thin wafers were produced, an analysis of panel manufacture using thin cells was made with special concern for flexibility of the panels and breakage. The saw was found to be much more labor intensive than expected, and wafering system modifications are recommended which can result in effective cost reduction for the manufacture of solar cells.

  20. High-performance polymer photovoltaic cells and photodetectors

    NASA Astrophysics Data System (ADS)

    Yu, Gang; Srdanov, Gordana; Wang, Hailiang; Cao, Yong; Heeger, Alan J.

    2001-02-01

    Polymer photovoltaic cells and photodetectors have passed their infancy and become mature technologies. The energy conversion efficiency of polymer photovoltaic cells have been improved to over 4.1% (500 nm, 10 mW/cm2). Such high efficiency polymer photovoltaic cells are promising for many applications including e-papers, e-books and smart- windows. The development of polymer photodetectors is even faster. The performance parameters have been improved to the level meeting all specifications for practical applications. The polymer photodetectors are of high photosensitivity (approximately 0.2 - 0.3 A/Watt in visible and UV), low dark current (0.1 - 1 nA/cm2), large dynamic range (> 8 orders of magnitude), linear intensity dependence, low noise level and fast response time (to nanosecond time domain). These devices show long shelf and operation lives. The advantages of low manufacturing cost, large detection area, and easy hybridization and integration with other electronic or optical components make the polymer photodetectors promising for a variety of applications including chemical/biomedical analysis, full-color digital image sensing and high energy radiation detection.

  1. Designing using manufacturing features

    NASA Astrophysics Data System (ADS)

    Szecsi, T.; Hoque, A. S. M.

    2012-04-01

    This paper presents a design system that enables the composition of a part using manufacturing features. Features are selected from feature libraries. Upon insertion, the system ensures that the feature does not contradict the design-for-manufacture rules. This helps eliminating costly manufacturing problems. The system is developed as an extension to a commercial CAD/CAM system Pro/Engineer.

  2. Workforce Development for Manufacturing

    ERIC Educational Resources Information Center

    Bernard, Rosalie

    2007-01-01

    In a recent skills gap report, the National Association of Manufacturers (NAM) noted some disturbing trends in the gap between the demand for highly skilled manufacturing workers and the potential supply. The NAM report notes that smaller manufacturers rank finding qualified workers ahead of energy costs, taxes and government regulations on the…

  3. PV Manufacturing R&D Project -- Trends in the U.S. PV Industry

    SciTech Connect

    Brown, K. E.; Mitchell, R. L.; Bower, W. I.; King, R.

    2005-01-01

    To foster continued growth in the U.S. photovoltaic (PV) industry, the U.S. Department of Energy initiated the PV Manufacturing R&D (PVMR&D) Project--a partnership with U.S. PV industry participants to perform cost-shared manufacturing research and development. Throughout FY 2004, PVMR&D managed fourteen subcontracts across the industry. The impact of PVMR&D is quantified by reductions in direct module manufacturing costs, scale-up of existing PV production capacity, and accrual of cost savings to the public and industry. An analysis of public and industry investment shows that both recaptured funds by mid-1998 based on estimated manufacturing cost savings from PVMR&D participation. Since project inception, total PV manufacturing capacity has increased from 14 MW to 201 MW at the close of 2003, while direct manufacturing costs declined from $5.55/W to $2.49/W. These results demonstrate continued progress toward the overriding goals of the PVMR&D project.

  4. Human pluripotent stem cell-derived products: Advances towards robust, scalable and cost-effective manufacturing strategies

    PubMed Central

    Jenkins, Michael J; Farid, Suzanne S

    2015-01-01

    The ability to develop cost-effective, scalable and robust bioprocesses for human pluripotent stem cells (hPSCs) will be key to their commercial success as cell therapies and tools for use in drug screening and disease modelling studies. This review outlines key process economic drivers for hPSCs and progress made on improving the economic and operational feasibility of hPSC bioprocesses. Factors influencing key cost metrics, namely capital investment and cost of goods, for hPSCs are discussed. Step efficiencies particularly for differentiation, media requirements and technology choice are amongst the key process economic drivers identified for hPSCs. Progress made to address these cost drivers in hPSC bioprocessing strategies is discussed. These include improving expansion and differentiation yields in planar and bioreactor technologies, the development of xeno-free media and microcarrier coatings, identification of optimal bioprocess operating conditions to control cell fate and the development of directed differentiation protocols that reduce reliance on expensive morphogens such as growth factors and small molecules. These approaches offer methods to further optimise hPSC bioprocessing in terms of its commercial feasibility. PMID:25524780

  5. Photovoltaic-module encapsulation design and materials selection: Volume 1

    SciTech Connect

    Cuddihy, E.; Carroll, W.; Coulbert, C.; Gupta, A.; Liang, R.

    1982-06-01

    Encapsulation-material system requirements, material-selection criteria, and the status and properties of encapsulation materials and processes available to the module manufacturer are presented in detail. Technical and economic goals established for photovoltaic modules and encapsulation systems and their status are described for material suppliers to assist them in assessing the suitability of materials in their product lines and the potential of new-material products. A comprehensive discussion of available encapsulation technology and data is presented to facilitate design and material selection for silicon flat-plate photovoltaic modules, using the best materials available and processes optimized for specific power applications and geographic sites. A basis is provided for specifying the operational and environmental loads that encapsulation material systems must resist. Potential deployment sites for which cost effectiveness may be achieved at a module price much greater than $0.70/W/sub p/, are also considered; data on higher-cost encapsulant materials and processes that may be in use and other material candidates that may be justified for special application are discussed. Described are encapsulation-system functional requirements and candidate design concepts and materials that have been identified and analyzed as having the best potential to meet the cost and performance goals for the Flat-Plate Solar Array Project. The available data on encapsulant material properties, fabrication processing, and module life and durability characteristics are presented.

  6. Silicon wafer-based tandem cells: The ultimate photovoltaic solution?

    NASA Astrophysics Data System (ADS)

    Green, Martin A.

    2014-03-01

    Recent large price reductions with wafer-based cells have increased the difficulty of dislodging silicon solar cell technology from its dominant market position. With market leaders expected to be manufacturing modules above 16% efficiency at 0.36/Watt by 2017, even the cost per unit area (60-70/m2) will be difficult for any thin-film photovoltaic technology to significantly undercut. This may make dislodgement likely only by appreciably higher energy conversion efficiency approaches. A silicon wafer-based cell able to capitalize on on-going cost reductions within the mainstream industry, but with an appreciably higher than present efficiency, might therefore provide the ultimate PV solution. With average selling prices of 156 mm quasi-square monocrystalline Si photovoltaic wafers recently approaching 1 (per wafer), wafers now provide clean, low cost templates for overgrowth of thin, wider bandgap high performance cells, nearly doubling silicon's ultimate efficiency potential. The range of possible Si-based tandem approaches is reviewed together with recent results and ultimate prospects.

  7. Photovoltaic concentrators: performance and reliability data and future design directions

    SciTech Connect

    Edenburn, M.W.; Boes, E.C.

    1984-05-01

    This paper will summarize the status and discuss likely future directions of photovoltaic concentrator technology. A current commercial Si cell module has a peak efficiency of 15.5%, and 17% has been reached for an experimental module. Advanced cells and module design improvements offer still higher efficiencies. Concentrator Fresnel lens array fields installed several years ago have all demonstrated very good electrical performance with little performance degradation. Fresnel lens arrays are commercially available and prices of $7/watt for installed one megawatt systems have been quoted. Cost projections predict that current technology concentrating PV arrays can be installed for less than $2/watt if they are manufactured in large, steady quantities. More advanced designs may cost even less.

  8. Photovoltaic concentrators: Performance and reliability data and future design directions

    SciTech Connect

    Edenbrum, M.

    1984-05-01

    This paper will summarize the status and discuss likely future directions of photovoltaic concentrator technology. A current commercial Si cell module has a peak efficiency of 15.5%, and 17% has been reached for an experimental module. Advanced cells and module design improvements offer still higher efficiencies. Concentrator Fresnel lens array fields installed several years ago have all demonstrated very good electrical performance with little performance degradation. Fresnel lens arrays are commercially available and prices of $7/watt for installed one megawatt systems have been quoted. Cost projections predict that current technology concentrating PV arrays can be installed for less than $2/watt if they are manufactured in large, steady quantities. More advanced designs may cost even less.

  9. Real time PV manufacturing diagnostic system

    SciTech Connect

    Kochergin, Vladimir; Crawford, Michael A.

    2015-09-01

    The main obstacle Photovoltaic (PV) industry is facing at present is the higher cost of PV energy compared to that of fossil energy. While solar cell efficiencies continue to make incremental gains these improvements are so far insufficient to drive PV costs down to match that of fossil energy. Improved in-line diagnostics however, has the potential to significantly increase the productivity and reduce cost by improving the yield of the process. On this Phase I/Phase II SBIR project MicroXact developed and demonstrated at CIGS pilot manufacturing line a high-throughput in-line PV manufacturing diagnostic system, which was verified to provide fast and accurate data on the spatial uniformity of thickness, an composition of the thin films comprising the solar cell as the solar cell is processed reel-to-reel. In Phase II project MicroXact developed a stand-alone system prototype and demonstrated the following technical characteristics: 1) ability of real time defect/composition inconsistency detection over 60cm wide web at web speeds up to 3m/minute; 2) Better than 1mm spatial resolution on 60cm wide web; 3) an average better than 20nm spectral resolution resulting in more than sufficient sensitivity to composition imperfections (copper-rich and copper-poor regions were detected). The system was verified to be high vacuum compatible. Phase II results completely validated both technical and economic feasibility of the proposed concept. MicroXact’s solution is an enabling technique for in-line PV manufacturing diagnostics to increase the productivity of PV manufacturing lines and reduce the cost of solar energy, thus reducing the US dependency on foreign oil while simultaneously reducing emission of greenhouse gasses.

  10. Manufacturing technology

    SciTech Connect

    Leonard, J.A.; Floyd, H.L.; Goetsch, B.; Doran, L.

    1993-08-01

    This bulletin depicts current research on manufacturing technology at Sandia laboratories. An automated, adaptive process removes grit overspray from jet engine turbine blades. Advanced electronic ceramics are chemically prepared from solution for use in high- voltage varistors. Selective laser sintering automates wax casting pattern fabrication. Numerical modeling improves performance of photoresist stripper (simulation on Cray supercomputer reveals path to uniform plasma). And mathematical models help make dream of low- cost ceramic composites come true.

  11. Photovoltaic Cz silicon module improvements. Annual technical progress report, November 9, 1995--November 8, 1996

    SciTech Connect

    King, R.R.; Mitchell, K.W.; Jester, T.L.

    1998-02-01

    Work focused on reducing the cost per watt of Cz silicon photovoltaic modules under Phase I of Siemens Solar Industries` DOE/NREL PVMaT 4A subcontract is described. Module cost components are analyzed and solutions to high-cost items are discussed in terms of specific module designs. The approaches of using larger cells and modulus to reduce per-part processing cost, and of minimizing yield loss are particularly leveraging. Yield components for various parts of the fabrication process and various types of defects are shown, and measurements of the force required to break wafers throughout the cell fabrication sequence are given. The most significant type of yield loss is mechanical breakage. The implementation of statistical process control on key manufacturing processes at Siemens Solar Industries is described. Module configurations prototyped during Phase I of this project and scheduled to begin production in Phase II have a projected cost per watt reduction of 19%.

  12. Photovoltaic Power Systems: A Tour Through the Alternatives

    ERIC Educational Resources Information Center

    Kelly, Henry

    1978-01-01

    Photovoltaic systems are examined as potentially major energy sources, along with the economic factors that will affect their future use. Cell design, power efficiency, and manufacturing problems are also considered. (MA)

  13. Photovoltaic Degradation Risk: Preprint

    SciTech Connect

    Jordan, D. C.; Kurtz, S. R.

    2012-04-01

    The ability to accurately predict power delivery over the course of time is of vital importance to the growth of the photovoltaic (PV) industry. Important cost drivers include the efficiency with which sunlight is converted into power, how this relationship changes over time, and the uncertainty in this prediction. An accurate quantification of power decline over time, also known as degradation rate, is essential to all stakeholders - utility companies, integrators, investors, and researchers alike. In this paper we use a statistical approach based on historical data to quantify degradation rates, discern trends and quantify risks related to measurement uncertainties, number of measurements and methodologies.

  14. Fuel cycle cost, reactor physics and fuel manufacturing considerations for Erbia-bearing PWR fuel with > 5 wt% U-235 content

    SciTech Connect

    Franceschini, F.; Lahoda, E. J.; Kucukboyaci, V. N.

    2012-07-01

    The efforts to reduce fuel cycle cost have driven LWR fuel close to the licensed limit in fuel fissile content, 5.0 wt% U-235 enrichment, and the acceptable duty on current Zr-based cladding. An increase in the fuel enrichment beyond the 5 wt% limit, while certainly possible, entails costly investment in infrastructure and licensing. As a possible way to offset some of these costs, the addition of small amounts of Erbia to the UO{sub 2} powder with >5 wt% U-235 has been proposed, so that its initial reactivity is reduced to that of licensed fuel and most modifications to the existing facilities and equipment could be avoided. This paper discusses the potentialities of such a fuel on the US market from a vendor's perspective. An analysis of the in-core behavior and fuel cycle performance of a typical 4-loop PWR with 18 and 24-month operating cycles has been conducted, with the aim of quantifying the potential economic advantage and other operational benefits of this concept. Subsequently, the implications on fuel manufacturing and storage are discussed. While this concept has certainly good potential, a compelling case for its short-term introduction as PWR fuel for the US market could not be determined. (authors)

  15. A Photovoltaic System Payback Calculator

    SciTech Connect

    Riley, Daniel M.; Fleming, Jeffrey E.; Gallegos, Gerald R.

    2016-06-01

    The Roof Asset Management Program (RAMP) is a DOE NNSA initiative to manage roof repairs and replacement at NNSA facilities. In some cases, installation of a photovoltaic system on new roofs may be possible and desired for financial reasons and to meet federal renewable energy goals. One method to quantify the financial benefits of PV systems is the payback period, or the length of time required for a PV system to generate energy value equivalent to the system's cost. Sandia Laboratories created a simple spreadsheet-based solar energy valuation tool for use by RAMP personnel to quickly evaluate the estimated payback period of prospective or installed photovoltaic systems.

  16. Voltage Regulators for Photovoltaic Systems

    NASA Technical Reports Server (NTRS)

    Delombard, R.

    1986-01-01

    Two simple circuits developed to provide voltage regulation for highvoltage (i.e., is greater than 75 volts) and low-voltage (i.e., is less than 36 volts) photovoltaic/battery power systems. Use of these circuits results in voltage regulator small, low-cost, and reliable, with very low power dissipation. Simple oscillator circuit controls photovoltaic-array current to regulate system voltage and control battery charging. Circuit senses battery (and system) voltage and adjusts array current to keep battery voltage from exceeding maximum voltage.

  17. Battery testing for photovoltaic applications

    SciTech Connect

    Hund, T.

    1996-11-01

    Battery testing for photovoltaic (PV) applications is funded at Sandia under the Department of Energy`s (DOE) Photovoltaic Balance of Systems (BOS) Program. The goal of the PV BOS program is to improve PV system component design, operation, reliability, and to reduce overall life-cycle costs. The Sandia battery testing program consists of: (1) PV battery and charge controller market survey, (2) battery performance and life-cycle testing, (3) PV charge controller development, and (4) system field testing. Test results from this work have identified market size and trends, PV battery test procedures, application guidelines, and needed hardware improvements.

  18. Life‐cycle and cost of goods assessment of fed‐batch and perfusion‐based manufacturing processes for mAbs

    PubMed Central

    Bunnak, Phumthep; Allmendinger, Richard; Ramasamy, Sri V.; Lettieri, Paola

    2016-01-01

    Life‐cycle assessment (LCA) is an environmental assessment tool that quantifies the environmental impact associated with a product or a process (e.g., water consumption, energy requirements, and solid waste generation). While LCA is a standard approach in many commercial industries, its application has not been exploited widely in the bioprocessing sector. To contribute toward the design of more cost‐efficient, robust and environmentally‐friendly manufacturing process for monoclonal antibodies (mAbs), a framework consisting of an LCA and economic analysis combined with a sensitivity analysis of manufacturing process parameters and a production scale‐up study is presented. The efficiency of the framework is demonstrated using a comparative study of the two most commonly used upstream configurations for mAb manufacture, namely fed‐batch (FB) and perfusion‐based processes. Results obtained by the framework are presented using a range of visualization tools, and indicate that a standard perfusion process (with a pooling duration of 4 days) has similar cost of goods than a FB process but a larger environmental footprint because it consumed 35% more water, demanded 17% more energy, and emitted 17% more CO2 than the FB process. Water consumption was the most important impact category, especially when scaling‐up the processes, as energy was required to produce process water and water‐for‐injection, while CO2 was emitted from energy generation. The sensitivity analysis revealed that the perfusion process can be made more environmentally‐friendly than the FB process if the pooling duration is extended to 8 days. © 2016 American Institute of Chemical Engineers Biotechnol. Prog., 32:1324–1335, 2016 PMID:27390260

  19. Active and passive cooling for concentrating photovoltaic arrays

    SciTech Connect

    Edenburn, M.W.

    1981-10-01

    Optimization, based on minimum energy cost, of active and passive cooling designs for point-focus Fresnel lens photovoltaic arrays and line-focus, parabolic-trough photovoltaic arrays is discussed, and the two types of cooling are compared. Passive cooling is more cost-effective for Fresnel lens arrays while the reverse is true for parabolic-trough arrays.

  20. Design and fabrication of a rectenna system to be coupled to photovoltaic solar cells

    NASA Astrophysics Data System (ADS)

    Mossavat, Mazda

    Inkjet-printed metamaterials and nanotechnology enabled flexible antennas fabricated on glass or polyester substrates help in further absorption of transmitted radiation through photovoltaic solar cells. Using metamaterials processed by inkjet printing and diffusing it, for a rectenna system coupled with photovoltaic solar cells, as rectifying antenna, an antenna in system in tandem is created. Metamaterials are artificial materials engineered to have properties that may not be found in nature (negative refractive index). When used in an antenna, they increase gain. For efficient solar cell use, nanophotonics on the incident surface or metamaterials under it as a rectenna, can enhance voltage gain in cloudy or rainy condition, which in turn increases the overall efficiency and reduces the amount of material required, thereby cutting costs. Photovoltaic is a field of technology and research related to practical application of photovoltaic cells in producing electricity from light. Cells are described as photovoltaic cells when the light source is not necessarily sunlight but can be lamplight, artificial light, or any other source used for detecting light or other electromagnetic radiation at different light intensity and producing voltage. These can be, for example, infrared detectors, or detectors for measurement of light intensity. Conventional solar cell films are typically manufactured using expensive and slow manufacturing methods, which rely on high-temperature fabrication and finicky `vacuum deposition' processes for depositing solar materials onto substrates (III-V elements). The resultant products are simply too thick to allow for transparency. An important consideration in the development of a commercially viable solar powered cell is the glass substrate. The learning process and skills involved in developing the antenna below a solar cell is a great experience in theory and practice. My main effort will be to design and check performance of different