Science.gov

Sample records for photovoltaic manufacturing cost

  1. Manufacturing cost analysis for photovoltaic concentrator tracking structures

    NASA Astrophysics Data System (ADS)

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

    1983-11-01

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

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

    NASA Technical Reports Server (NTRS)

    Chamberlain, R. G.

    1979-01-01

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

  3. 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.

  4. Photovoltaic Manufacturing Technology Phase 1

    SciTech Connect

    Stern, M.J. )

    1991-11-01

    This report documents Utility Power Group's (UPG) contract under Phase 1 of the Photovoltaic Manufacturing Technology (PVMaT) project. Specifically, the report contains the results of a manufacturing technology cost analysis based on an existing PV module production facility. It also projects the cost analysis of a future production facility based on a larger module area, a larger production rate, and the elimination of several technical obstacles. With a coordinated 18-month engineering effort, the technical obstacles could be overcome. Therefore, if solutions to the financial obstacles concerning production expansion were found, UPG would be able to manufacture PV modules at a cost of under $1.25 per watt by 1994.

  5. Cost analysis methodology: Photovoltaic Manufacturing Technology Project. Annual subcontract report, 11 March 1991--11 November 1991

    SciTech Connect

    Whisnant, R.A.

    1992-09-01

    This report describes work done under Phase 1 of the Photovoltaic Manufacturing Technology (PVMaT) Project. PVMaT is a five-year project to support the translation of research and development in PV technology into the marketplace. PVMaT, conceived as a DOE/industry partnership, seeks to advanced PV manufacturing technologies, reduce PV module production costs, increase module performance, and expand US commercial production capacities. Under PVMaT, manufacturers will propose specific manufacturing process improvements that may contribute to the goals of the project, which is to lessen the cost, thus hastening entry into the larger scale, grid-connected applications. Phase 1 of the PVMaT project is to identify obstacles and problems associated with manufacturing processes. This report describes the cost analysis methodology required under Phase 1 that will allow subcontractors to be ranked and evaluated during Phase 2.

  6. 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.

  7. Photovoltaic manufacturing cost analysis: a required-price approach. Volume 2. Appendixes. Final report

    SciTech Connect

    Wright, S.R.; Champagne, P.T.; Brookshire, K.L.

    1986-09-01

    These appendices contain supporting information to aid in interpreting a comparative assessment of the required module price drivers for five different processes of producing photovoltaic modules. They include: definition of the IMCAP model, base case simulation results, cost catalog, and definition of the dendritic web process, the Czochralski process, single-junction amorphous silicon process, tandem-junction amorphous silicon process, and 500X concentrator process. (LEW)

  8. Photovoltaic manufacturing technology, Phase 1

    SciTech Connect

    Izu, M. )

    1992-03-01

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

  9. Photovoltaic Cz silicon manufacturing technology improvements

    SciTech Connect

    Jester, T.L. )

    1994-06-30

    Siemens Solar Industries (SSI) began a three-year, three-phase cost shared contract in March 1992 to demonstrate significant cost reductions and improvements in manufacturing technology. The work has focused on near-term projects for implementation in the SSI Czochralski (Cz) manufacturing facility in Camarillo, California. The work has been undertaken to increase the commercial viability and volume of photovoltaic manufacturing by evaluating the most significant cost categories and then lowering the cost of each item through experimentation, materials refinement, and better industrial engineering. The initial phase of the program has concentrated in the areas of crystal growth, wafer technology, module development, and environmental, safety, and health issues.

  10. Photovoltaic Cz silicon manufacturing technology improvements

    NASA Astrophysics Data System (ADS)

    Jester, Theresa L.

    1996-01-01

    Siemens Solar Industries (SSI) began a three-year, three-phase cost shared contract in March 1992 to demonstrate significant cost reductions and improvements in manufacturing technology. The work has focused on near-term projects for implementation in the SSI Czochralski (Cz) manufacturing facility in Camarillo, California. The work has been undertaken to increase the commercial viability and volume of photovoltaic manufacturing by evaluating the most significant cost categories and then lowering the cost of each item through experimentation, materials refinement, and better industrial engineering. The program has concentrated in the areas of crystal growth, wafer technology, module development and environmental, safety and health issues.

  11. Research on advanced photovoltaic manufacturing technology

    SciTech Connect

    Jester, T.; Eberspacher, C. )

    1991-11-01

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

  12. 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.

  13. 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.

  14. 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.

  15. 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.

  16. 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.

  17. 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.

  18. Photovoltaic manufacturing technology, Phase 1

    SciTech Connect

    Somberg, H. )

    1991-11-01

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

  19. 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.

  20. 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.

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

    SciTech Connect

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

    1999-11-16

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

  2. Photovoltaic 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.

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

    SciTech Connect

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

    1991-12-01

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

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

    SciTech Connect

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

    1991-12-01

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

  5. 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.

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

    SciTech Connect

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

    1993-08-01

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

  7. 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.

  8. 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 dollar/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 dollar/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. Here, 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.

  9. Paths to future growth in photovoltaics manufacturing

    DOE PAGES

    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 dollar/W). The other is how much capital investment is required for each watt of annual manufacturing capacity, normalized to the service lifemore » of the assets (capacity-normalized capital demand rate, CapDR, units dollar/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. Here, 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.« less

  10. 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.

  11. 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.

  12. 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.

  13. 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.

  14. Surrogate Final Technical Report for "Solar: A Photovoltaic Manufacturing Development Facility"

    SciTech Connect

    Farrar, Paul

    2014-06-27

    The project goal to create a first-of-a-kind crystalline Silicon (c-Si) photovoltaic (PV) Manufacturing & Technology Development Facility (MDF) that will support the growth and maturation of a strong domestic PV manufacturing industry, based on innovative and differentiated technology, by ensuring industry participants can, in a timely and cost-effective manner, access cutting-edge manufacturing equipment and production expertise needed to accelerate the transition of innovative technologies from R&D into manufacturing.

  15. The Photovoltaic Manufacturing Technology Project: Phase 1 subcontractors

    SciTech Connect

    Not Available

    1992-07-01

    The Phase I portion of the Photovoltaic Manufacturing Technology (PVMaT) Project, the problem identification phase, was completed in mid-1991. This work involved competitive bidding that was open to any US firm with existing manufacturing capabilities, regardless of material or module design. In early 1991, subcontracts were awarded to 22 of approximately 40 bidders. Each subcontract was funded at a level of up to $50,000 and a duration of three months. The problems identified by the research in this phase of the program represent opportunities for industrial participants to improve their manufacturing processes, reduce manufacturing costs, increase product performance, or develop a foundation for scaling up US-based manufacturing plant capacities. Many of these opportunities have since been detailed in the approaches that these organizations suggested for Phase 2 (the problem solution phase) research and development (R D). It is not. anticipated that any additional Phase I solicitation will be issued because Phase I was intended to help the US Department of Energy (DOE) characterize the status and needs of the US photovoltaic (PV) industry and encourage the industry to examine and prioritize required manufacturing line improvements. Phase I subcontracted research included five subcontractors working on flat-plate crystalline silicon technology, eleven working on flat-plate thin-film modules (one in thin-film crystalline silicon, six in amorphous silicon. and four in polycrystalline thin films), six working on concentrator systems, and two working on general equipment/production options. (Two of the participants each worked in two areas).

  16. The Photovoltaic Manufacturing Technology Project: Phase 1 subcontractors

    SciTech Connect

    Not Available

    1992-07-01

    The Phase I portion of the Photovoltaic Manufacturing Technology (PVMaT) Project, the problem identification phase, was completed in mid-1991. This work involved competitive bidding that was open to any US firm with existing manufacturing capabilities, regardless of material or module design. In early 1991, subcontracts were awarded to 22 of approximately 40 bidders. Each subcontract was funded at a level of up to $50,000 and a duration of three months. The problems identified by the research in this phase of the program represent opportunities for industrial participants to improve their manufacturing processes, reduce manufacturing costs, increase product performance, or develop a foundation for scaling up US-based manufacturing plant capacities. Many of these opportunities have since been detailed in the approaches that these organizations suggested for Phase 2 (the problem solution phase) research and development (R&D). It is not. anticipated that any additional Phase I solicitation will be issued because Phase I was intended to help the US Department of Energy (DOE) characterize the status and needs of the US photovoltaic (PV) industry and encourage the industry to examine and prioritize required manufacturing line improvements. Phase I subcontracted research included five subcontractors working on flat-plate crystalline silicon technology, eleven working on flat-plate thin-film modules (one in thin-film crystalline silicon, six in amorphous silicon. and four in polycrystalline thin films), six working on concentrator systems, and two working on general equipment/production options. (Two of the participants each worked in two areas).

  17. Cost and performance projections for SPS photovoltaic blankets

    NASA Technical Reports Server (NTRS)

    Scott-Monck, J. A.

    1981-01-01

    An estimate, based on optimistic projections of current technology, is given for the specific power of photovoltaic blankets which might be achieved if the SPS concept was to be implemented. A simultaneous consideration of cost and technical requirements is used to identify key blanket technologies which must be developed for this reference system. The terrestrial photovoltaic experience coupled with new technology is used to develop cost estimates for the blanket, assuming an annual demand of 5 GW and a manufacturing industry dedicated to blanket production. The results indicate that blanket specific power goals may be exceeded, but there is little prospect that the cost goals can be met. This argues for a reconsideration of the photovoltaic option based on more expensive but higher performance blankets.

  18. 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.

  19. 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.

  20. 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.

  1. 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.

  2. 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.

  3. 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.

  4. 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…

  5. 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.

  6. 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.

  7. 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.

  8. 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.

  9. 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.

  10. 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.

  11. 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.

  12. 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.

  13. Thin film photovoltaic device and process of manufacture

    SciTech Connect

    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.

  14. 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.

  15. 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.

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

    SciTech Connect

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

    1994-12-09

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

  17. 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.

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

    SciTech Connect

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

    2015-09-07

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

  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 system costs using local labor and materials in developing countries

    NASA Astrophysics Data System (ADS)

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

    1980-05-01

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

  2. 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.

  3. 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.

  4. 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.

  5. Novel approaches for low-cost photovoltaic concentrators

    NASA Astrophysics Data System (ADS)

    Muller, T.; Maraschin, R.

    1982-11-01

    The feasibility of producing a low cost photovoltaic concentrator that uses sealed beam headlight technology was investigated. The photovoltaic cell is placed at the focus of the headlamp reflector. A prototype 60 W array was built. The array efficiency was approximately 6%.

  6. 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.

  7. 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.}

  8. 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.

  9. 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.

  10. 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.

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

    SciTech Connect

    Izu, M. )

    1993-04-01

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

  12. 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.

  13. 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.

  14. 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.

  15. Assessing Reliability of Cold Spray Sputter Targets in Photovoltaic Manufacturing

    NASA Astrophysics Data System (ADS)

    Hardikar, Kedar; Vlcek, Johannes; Bheemreddy, Venkata; Juliano, Daniel

    2017-06-01

    Cold spray has been used to manufacture more than 800 Cu-In-Ga (CIG) sputter targets for deposition of high-efficiency photovoltaic thin films. It is a preferred technique since it enables high deposit purity and transfer of non-equilibrium alloy states to the target material. In this work, an integrated approach to reliability assessment of such targets with deposit weight in excess of 50 lb. is undertaken, involving thermal-mechanical characterization of the material in as-deposited condition, characterization of the interface adhesion on cylindrical substrate in as-deposited condition, and developing means to assess target integrity under thermal-mechanical loads during the physical vapor deposition (PVD) sputtering process. Mechanical characterization of cold spray deposited CIG alloy is accomplished through the use of indentation testing and adaptation of Brazilian disk test. A custom lever test was developed to characterize adhesion along the cylindrical interface between the CIG deposit and cylindrical substrate, overcoming limitations of current standards. A cohesive zone model for crack initiation and propagation at the deposit interface is developed and validated using the lever test and later used to simulate the potential catastrophic target failure in the PVD process. It is shown that this approach enables reliability assessment of sputter targets and improves robustness.

  16. Assessing Reliability of Cold Spray Sputter Targets in Photovoltaic Manufacturing

    NASA Astrophysics Data System (ADS)

    Hardikar, Kedar; Vlcek, Johannes; Bheemreddy, Venkata; Juliano, Daniel

    2017-10-01

    Cold spray has been used to manufacture more than 800 Cu-In-Ga (CIG) sputter targets for deposition of high-efficiency photovoltaic thin films. It is a preferred technique since it enables high deposit purity and transfer of non-equilibrium alloy states to the target material. In this work, an integrated approach to reliability assessment of such targets with deposit weight in excess of 50 lb. is undertaken, involving thermal-mechanical characterization of the material in as-deposited condition, characterization of the interface adhesion on cylindrical substrate in as-deposited condition, and developing means to assess target integrity under thermal-mechanical loads during the physical vapor deposition (PVD) sputtering process. Mechanical characterization of cold spray deposited CIG alloy is accomplished through the use of indentation testing and adaptation of Brazilian disk test. A custom lever test was developed to characterize adhesion along the cylindrical interface between the CIG deposit and cylindrical substrate, overcoming limitations of current standards. A cohesive zone model for crack initiation and propagation at the deposit interface is developed and validated using the lever test and later used to simulate the potential catastrophic target failure in the PVD process. It is shown that this approach enables reliability assessment of sputter targets and improves robustness.

  17. 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.

  18. Cost Estimates Of Concentrated Photovoltaic Heat Sink Production

    DTIC Science & Technology

    2016-06-01

    generation. As the CPV market has matured, production costs have come down to near flat-panel photovoltaic (PV) production costs. CPV units...sink designs to increase efficiency. Modern heat sink design can achieve greater overall efficiencies of electricity generation. As the CPV market ...capital costs and intermittency (DASN, 2012). While the price per kWh of solar is falling as the solar market continues to mature, solar installation

  19. 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.

  20. 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.

  1. 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.

  2. 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.

  3. 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.

  4. 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.

  5. 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.

  6. 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.

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

    SciTech Connect

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

    2011-12-02

    The College of Nanoscale Science and Engineering (CNSE) at the University at Albany received funding from the Department of Energy for its proposal Prototyping and Development of Commercial Nanocrystalline and Thin Film Si for Photovoltaic Manufacturing. This project was created to identify growth rate, texture uniformity, process window, economics, composition and thickness uniformity solutions related to fabricating large area, high efficiency thin film silicon based solar cells. This document serves as a final report for the closure of this program and details the deliverables from CNSE against its original scope of work. Thin-film silicon solar cells are a promising candidate for electricity generation applications because of a combination of advantages. Nanocrystalline and poly-Si based thin films, reduces the use of expensive semiconductor material content, can be deposited onto a foreign substrate (e.g. glass or flexible stainless steel) and enables use of the cells in wide variety of applications. In addition, nano and poly-Si films have higher carrier mobility as well as reduce recombination effects, relative to traditional amorphous-silicon films. They can be mass-produced at low cost, and expected to have a strong position in the international photovoltaic industry, which is experiencing a compounded annual growth of 25%. The objectives included: Demonstration of high rate VHF (Very High Frequency) growth of nc-Si over large areas with uniform thickness. Demonstration of single chamber device growth that allows mass production processing. Demonstration of uniform segmented electrodes. Development of computer models to accelerate efforts. Demonstration of large grain thin film polycrystalline silicon films fabrication. Utilizing the AIC (Aluminum Induced Crystallization) process for large grain silicon film fabrication. Demonstration of 12% efficient nanocrystalline and polycrystalline thin film devices. The end result expected was the production of high

  8. 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.

  9. 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.

  10. 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.

  11. 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.

  12. 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.

  13. 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.

  14. 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.

  15. Cost Models for MMC Manufacturing Processes

    NASA Technical Reports Server (NTRS)

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

    1996-01-01

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

  16. 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.

  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. 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.

  19. 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.

  20. 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

  1. 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.

  2. Detailed cost estimate of reference residential photovoltaic designs

    SciTech Connect

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

    1983-04-01

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

  3. 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.

  4. 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.

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

    NASA Astrophysics Data System (ADS)

    Ayers, J. B.

    1981-07-01

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

  6. 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.

  7. 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.

  8. 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.

  9. Low Cost Manufacturing of Composite Cryotanks

    NASA Technical Reports Server (NTRS)

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

    2002-01-01

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

  10. 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.

  11. 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.

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

    NASA Astrophysics Data System (ADS)

    Rosenblum, L.

    1985-08-01

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

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

    NASA Technical Reports Server (NTRS)

    1977-01-01

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

  14. 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.

  15. 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.

  16. 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

  17. 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.

  18. 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

  19. Product costing program for wood component manufacturers

    Treesearch

    Adrienn Andersch; Urs Buehlmann; Jeff Palmer; Janice K Wiedenbeck; Steve. Lawser

    2013-01-01

    Accurate and timely product costing information is critically important for companies in planning the optimal utilization of company resources. While an overestimation of product costs can lead to loss of potential business and market share, underestimation of product costs can result in financial losses to the company. This article introduces a product costing program...

  20. 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.

  1. 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.

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

    NASA Astrophysics Data System (ADS)

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

    1984-12-01

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

  3. 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).

  4. 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.

  5. 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

  6. 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

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

    NASA Astrophysics Data System (ADS)

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

    2011-03-01

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

  8. 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.

  9. 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)

  10. 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

  11. 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.

  12. 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.

  13. 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

  14. High Throughput Manufacturing of Thin-Film CdTe Photovoltaic Materials; Final Subcontract Report, 16 November 1993-31 December 1998

    SciTech Connect

    Sandwisch, D. W.

    1999-09-02

    This report describes work performed by Solar Cells, Inc. (SCI), during this Photovoltaic Manufacturing Technology (PVMaT) subcontract. Cadmium telluride (CdTe) is recognized as one of the leading materials for low-cost photovoltaic modules. SCI has developed this technology and is preparing to scale its pilot production capabilities to a multi-megawatt level. This four-phase PVMaT subcontract supports these efforts. The work was related to product definition, process definition, equipment engineering, and support programs development. In the area of product definition and demonstration, two products were specified and demonstrated-a grid-connected, frameless, high-voltage product that incorporates a pigtail potting design and a remote low-voltage product that may be framed and may incorporate a junction box. SCI produced a 60.3-W thin-film CdTe module with total-area efficiency of 8.4%; SCI also improved module pass rate on the interim qualification test protocol from less than 20% to 100% as a result of work related to the subcontract. In the manufacturing process definition area, the multi-megawatt manufacturing process was defined, several of the key processes were demonstrated, and the process was refined and proven on a 100-kW pilot line that now operates as a 250-kW line. In the area of multi-megawatt manufacturing-line conceptual design review, SCI completed a conceptual layout of the multi-megawatt lines. The layout models the manufacturing line and predicts manufacturing costs. SCI projected an optimized capacity, two-shift/day operation of greater than 25 MW at a manufacturing cost of below $1.00/W.

  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. 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.

  17. 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.

  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. Modeling of Performance, Cost, and Financing of Concentrating Solar, Photovoltaic, and Solar Heat Systems (Poster)

    SciTech Connect

    Blair, N.; Mehos, M.; Christiansen, C.

    2006-10-03

    This poster, submitted for the CU Energy Initiative/NREL Symposium on October 3, 2006 in Boulder, Colorado, discusses the modeling, performance, cost, and financing of concentrating solar, photovoltaic, and solar heat systems.

  20. The complexity and cost of vaccine manufacturing - An overview.

    PubMed

    Plotkin, Stanley; Robinson, James M; Cunningham, Gerard; Iqbal, Robyn; Larsen, Shannon

    2017-07-24

    As companies, countries, and governments consider investments in vaccine production for routine immunization and outbreak response, understanding the complexity and cost drivers associated with vaccine production will help to inform business decisions. Leading multinational corporations have good understanding of the complex manufacturing processes, high technological and R&D barriers to entry, and the costs associated with vaccine production. However, decision makers in developing countries, donors and investors may not be aware of the factors that continue to limit the number of new manufacturers and have caused attrition and consolidation among existing manufacturers. This paper describes the processes and cost drivers in acquiring and maintaining licensure of childhood vaccines. In addition, when export is the goal, we describe the requirements to supply those vaccines at affordable prices to low-resource markets, including the process of World Health Organization (WHO) prequalification and supporting policy recommendation. By providing a generalized and consolidated view of these requirements we seek to build awareness in the global community of the benefits and costs associated with vaccine manufacturing and the challenges associated with maintaining consistent supply. We show that while vaccine manufacture may prima facie seem an economic growth opportunity, the complexity and high fixed costs of vaccine manufacturing limit potential profit. Further, for most lower and middle income countries a large majority of the equipment, personnel and consumables will need to be imported for years, further limiting benefits to the local economy. Copyright © 2017 The Authors. Published by Elsevier Ltd.. All rights reserved.

  1. 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.

  2. 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.

  3. 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.

  4. 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.

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

    SciTech Connect

    Fernandez, S.

    1999-07-01

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

  6. 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.

  7. 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.

  8. 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.

  9. 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.

  10. 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.

  11. 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.

  12. 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].

  13. LOW-COST COMPOSITES IN VEHICLE MANUFACTURE - Low-Cost Composites in Automotive and Heavy Vehicle Manufacture

    SciTech Connect

    Grant, Glenn J.

    2006-11-01

    The automotive and heavy vehicle manufacturing markets are extremely sensitive to costs. Margins are not high in these markets and differences in fixed costs and national infrastructure between different companies and countries creates a highly competitive environment. Composites can offer tremendous competitive advantages in this industry to help differentiate between products by offering increased safety, strength, fuel efficiency, and recyclability. However, composites are by definition more complex than the largely monolithic materials they replace. This leads to a situation where the composite solution to a structural problem is often a higher-cost solution. To successfully implement a composite material into an engineering system there is a need to drive down the costs of the composite materials. This can be done through the use of low-cost raw material precursors, low-cost manufacturing methods, or by using composites of high specific stiffness so that less material is needed in the structure. In this issue we have gathered five papers describing some of the recent advances in the application of low-cost composites to automotive and heavy vehicle manufacturing. These papers cover metal-matrix composites (MMCs), carbon fiber and natural fiber polymer-based composites, and a unique reaction-processed cermet. The papers included here are by no means exhaustive of the increasing new composite applications in transportation manufacturing, but give a flavor of some of the current research directions.

  14. 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

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

    SciTech Connect

    Wohlgemuth, J

    1997-01-01

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

  16. 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

  17. Manufacturing costs of HPV vaccines for developing countries.

    PubMed

    Clendinen, Chaevia; Zhang, Yapei; Warburton, Rebecca N; Light, Donald W

    2016-11-21

    Nearly all of the 500,000 new cases of cervical cancer and 270,000 deaths occur in middle or lower income countries. Yet the two most prevalent HPV vaccines are unaffordable to most. Even prices to Gavi, the Vaccine Alliance, are unaffordable to graduating countries, once they lose Gavi subsidies. Merck and Glaxosmithkline (GSK) claim their prices to Gavi equal their manufacturing costs; but these costs remain undisclosed. We undertook this investigation to estimate those costs. Searches in published and commercial literature for information about the manufacturing of these vaccines. Interviews with experts in vaccine manufacturing. This detailed sensitivity analysis, based on the best available evidence, finds that after a first set of batches for affluent markets, manufacturing costs of Gardasil for developing countries range between $0.48 and $0.59 a dose, a fraction of its alleged costs of $4.50. Because volume of Cervarix is low, its per unit costs are much higher, though at comparable volumes, its costs would be similar. Given the recovery of fixed and annual costs from sales in affluent markets, Merck's break-even price to Gavi could be $0.50-$0.60, not $4.50. These savings could support Gavi programs to strengthen delivery and increase coverage. Outside Gavi, prices to lower- and middle-income countries, with profit, could also be lowered and made available to millions more adolescents at risk. These estimates and their policy implications deserve further discussion. Copyright © 2016 The Authors. Published by Elsevier Ltd.. All rights reserved.

  18. 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

  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 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.

  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. 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.

  4. 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.

  5. 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.

  6. 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.

  7. 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.

  8. 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.

  9. 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

  10. 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

  11. Cost Savings Analysis Guidelines for Manufacturing Technology Projects.

    DTIC Science & Technology

    1985-06-28

    84-C- 7078 Modification PO0002, CLIN 002AB Approved for Public Release; Distribution is Unlimited Prepared for MANUFACTURING TECHNOLOGY OFFICE Applied...8217 2828 Pennsylvania Ave, N.W. Washington, D.C. 20007 28 June 1985 Final Report for 1985 -. Contract Number N00024-84-C- 7078 - FrJUIUModification P00002...osecription of Items quantity Cost of Handling Cost per" nr far USED P r -) cost (+ O- Year I + or - -014: 0tilities. Templates"" 0 0 0 Rnumal Roster Cutters

  12. 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)

  13. 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.

  14. 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.

  15. 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.

  16. 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.

  17. 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.

  18. Unneeded electric plant's cost draws manufacturer shutdown threat

    SciTech Connect

    Efron, S.

    1984-11-05

    If the Big Rivers Electric Corp. succeeds in raising its rates to cover the cost of surplus capacity resulting from new constrcution, an aluminum smelter threatens to stop manufacturing, which would raise rates even higher for the remaining consumers. Efforts to sell power out of state and to generate financial assistance from the Rural Electrification Administration are underway. The comment period for rate intervenors ends in mid November.

  19. 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.

  20. 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.

  1. 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.

  2. Continuous roll-to-roll a-Si photovoltaic manufacturing technology. Semiannual technical progress report, 1 April 1992--30 September 1992

    SciTech Connect

    Izu, M.

    1993-04-01

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

  3. 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.

  4. 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.

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

    SciTech Connect

    Jeffrey, F

    1997-02-01

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

  6. 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.

  7. 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.

  8. 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.

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

    SciTech Connect

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

    1994-04-01

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

  11. 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.

  12. 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.

  13. 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.

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

    NASA Technical Reports Server (NTRS)

    Sutter, James K.

    1998-01-01

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

  15. 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.

  16. 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.

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

    SciTech Connect

    Wohlgemuth, J

    1996-06-01

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

  18. 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.

  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. Photovoltaics: New opportunities for utilities

    SciTech Connect

    Not Available

    1991-07-01

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

  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. 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.

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

    NASA Technical Reports Server (NTRS)

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

    1978-01-01

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

  4. 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

  5. Plywood manufacturing cost trends, excluding wood, in Western U.S. mills: 1975-1988

    Treesearch

    Henry Spelter

    1989-01-01

    Plywood manufacturing costs have increased over the years with inflation. In recent years, new technologies that improve productivity and reduce costs have become available. Cost data published by the American Plywood Association (APA) show moderating rates of increase by 1983. New data from a sample of western U.S. mills show that nonwood manufacturing costs have...

  6. 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.

  7. 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.

  8. 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.

  9. 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.

  10. 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

  11. 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:...

  12. 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:...

  13. 48 CFR 31.205-25 - Manufacturing and production engineering costs.

    Code of Federal Regulations, 2010 CFR

    2010-10-01

    ... 48 Federal Acquisition Regulations System 1 2010-10-01 2010-10-01 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:...

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

    Code of Federal Regulations, 2011 CFR

    2011-10-01

    ... 48 Federal Acquisition Regulations System 1 2011-10-01 2011-10-01 false Manufacturing and... 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:...

  15. 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:...

  16. 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.

  17. 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.

  18. 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.

  19. 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.

  20. Reliability Research for Photovoltaic Modules

    NASA Technical Reports Server (NTRS)

    Ross, Ronald J., Jr.

    1986-01-01

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

  1. Impact of photovoltaic-array conversion efficiency on system energy cost

    NASA Astrophysics Data System (ADS)

    Jones, G. J.; Post, H. N.

    The relationship between photovoltaic collector efficiency and total system cost is analyzed using the most recent data on subsystem costs. Results are compared with competitive system prices to determine minimum array efficiency requirements. Central power station results show a requirement for arrays with a 10 percent minimum efficiency even for inexpensive collectors. For intermediate applications, this required minimum drops to 6 to 7 percent for the same collectors. Residential systems would seem to allow much lower efficiencies but are probably constrained by the available roof area.

  2. 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.

  3. 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.

  4. 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.

  5. 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.

  6. 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.

  7. 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.

  8. 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.

  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. 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.

  11. 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.

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

    SciTech Connect

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

    1995-01-01

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

  13. 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.

  14. 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.

  15. 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.

  16. Good Manufacturing Practices (GMP) manufacturing of advanced therapy medicinal products: a novel tailored model for optimizing performance and estimating costs.

    PubMed

    Abou-El-Enein, Mohamed; Römhild, Andy; Kaiser, Daniel; Beier, Carola; Bauer, Gerhard; Volk, Hans-Dieter; Reinke, Petra

    2013-03-01

    Advanced therapy medicinal products (ATMP) have gained considerable attention in academia due to their therapeutic potential. Good Manufacturing Practice (GMP) principles ensure the quality and sterility of manufacturing these products. We developed a model for estimating the manufacturing costs of cell therapy products and optimizing the performance of academic GMP-facilities. The "Clean-Room Technology Assessment Technique" (CTAT) was tested prospectively in the GMP facility of BCRT, Berlin, Germany, then retrospectively in the GMP facility of the University of California-Davis, California, USA. CTAT is a two-level model: level one identifies operational (core) processes and measures their fixed costs; level two identifies production (supporting) processes and measures their variable costs. The model comprises several tools to measure and optimize performance of these processes. Manufacturing costs were itemized using adjusted micro-costing system. CTAT identified GMP activities with strong correlation to the manufacturing process of cell-based products. Building best practice standards allowed for performance improvement and elimination of human errors. The model also demonstrated the unidirectional dependencies that may exist among the core GMP activities. When compared to traditional business models, the CTAT assessment resulted in a more accurate allocation of annual expenses. The estimated expenses were used to set a fee structure for both GMP facilities. A mathematical equation was also developed to provide the final product cost. CTAT can be a useful tool in estimating accurate costs for the ATMPs manufactured in an optimized GMP process. These estimates are useful when analyzing the cost-effectiveness of these novel interventions. Copyright © 2013 International Society for Cellular Therapy. Published by Elsevier Inc. All rights reserved.

  17. 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)

  18. Advanced Drying Process for Lower Manufacturing Cost of Electrodes

    SciTech Connect

    Ahmad, Iftikhar; Zhang, Pu

    2016-11-30

    electrode materials. For the existing electrode materials, the material analysis and cell characterization data from ADP dried electrodes showed equivalent (or slightly better) performance. However, for high loading and thicker electrode materials (for high energy densities) the ADP advantages are more prominent. There was less binder migration, the resistance was lower hence the current capacities and retention of the battery cells were higher. The success of the project has enabled credible communications with commercial end users as well as battery coating line integrators. Goal is to scale ADP up for high volume manufacturing of Li-ion battery electrodes. The implementation of ADP in high volume manufacturing will reduce a high cost production step to bring the overall price of Li-ion batteries down. This will ultimately have a positive impact on the public by making electric and hybrid vehicles more affordable.

  19. Low-cost modular array-field designs for flat-panel and concentrator photovoltaic systems

    SciTech Connect

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

    1982-09-01

    This paper describes the design and development of low-cost, modular array fields for flatpanel and concentrator photovoltaic (PV) systems. The objective of the work was to reduce substantially the cost of the array-field balance-of-system (BOS) subsystems and site-specific design costs as compared to previous PV installations. These subsystems include site preparation, foundations, support structures, electrical wiring, grounding, lightning protection, electromagnetic interference considerations, and controls. To reduce these BOS and design costs, standardized modular (building-block) designs for flat-panel and concentrator array fields have been developed that are fully integrated and optimized for lowest life-cycle costs. Using drawings and specifications now available, these building-block designs can be used in multiples to install various size array fields. The developed designs are immediately applicable and reduce the array-field BOS costs to a small fraction of previous costs. Prototype array fields are currently being installed using each of the two alternative building-block designs developed for flat-panel PV array fields.

  20. 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.

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

    NASA Technical Reports Server (NTRS)

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

    1981-01-01

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

  2. 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.

  3. 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

  4. 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.

  5. 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.

  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. Costs, Benefits, and Adoption of Additive Manufacturing: A Supply Chain Perspective.

    PubMed

    Thomas, Douglas

    2016-07-01

    There are three primary aspects to the economics of additive manufacturing: measuring the value of goods produced, measuring the costs and benefits of using the technology, and estimating the adoption and diffusion of the technology. This paper provides an updated estimate of the value of goods produced. It then reviews the literature on additive manufacturing costs and identifies those instances in the literature where this technology is cost effective. The paper then goes on to propose an approach for examining and understanding the societal costs and benefits of this technology both from a monetary viewpoint and a resource consumption viewpoint. The final section discusses the trends in the adoption of additive manufacturing. Globally, there is an estimated $667 million in value added produced using additive manufacturing, which equates to 0.01 % of total global manufacturing value added. US value added is estimated as $241 million. Current research on additive manufacturing costs reveals that it is cost effective for manufacturing small batches with continued centralized production; however, with increased automation distributed production may become cost effective. Due to the complexities of measuring additive manufacturing costs and data limitations, current studies are limited in their scope. Many of the current studies examine the production of single parts and those that examine assemblies tend not to examine supply chain effects such as inventory and transportation costs along with decreased risk to supply disruption. The additive manufacturing system and the material costs constitute a significant portion of an additive manufactured product; however, these costs are declining over time. The current trends in costs and benefits have resulted in this technology representing 0.02 % of the relevant manufacturing industries in the US; however, as the costs of additive manufacturing systems decrease, this technology may become widely adopted and change the

  8. Costs, Benefits, and Adoption of Additive Manufacturing: A Supply Chain Perspective

    PubMed Central

    Thomas, Douglas

    2017-01-01

    There are three primary aspects to the economics of additive manufacturing: measuring the value of goods produced, measuring the costs and benefits of using the technology, and estimating the adoption and diffusion of the technology. This paper provides an updated estimate of the value of goods produced. It then reviews the literature on additive manufacturing costs and identifies those instances in the literature where this technology is cost effective. The paper then goes on to propose an approach for examining and understanding the societal costs and benefits of this technology both from a monetary viewpoint and a resource consumption viewpoint. The final section discusses the trends in the adoption of additive manufacturing. Globally, there is an estimated $667 million in value added produced using additive manufacturing, which equates to 0.01 % of total global manufacturing value added. US value added is estimated as $241 million. Current research on additive manufacturing costs reveals that it is cost effective for manufacturing small batches with continued centralized production; however, with increased automation distributed production may become cost effective. Due to the complexities of measuring additive manufacturing costs and data limitations, current studies are limited in their scope. Many of the current studies examine the production of single parts and those that examine assemblies tend not to examine supply chain effects such as inventory and transportation costs along with decreased risk to supply disruption. The additive manufacturing system and the material costs constitute a significant portion of an additive manufactured product; however, these costs are declining over time. The current trends in costs and benefits have resulted in this technology representing 0.02 % of the relevant manufacturing industries in the US; however, as the costs of additive manufacturing systems decrease, this technology may become widely adopted and change the

  9. 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.

  10. 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.

  11. 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.

  12. 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

  13. Activity-Based Costing for Agile Manufacturing Control

    DTIC Science & Technology

    1998-08-01

    Agile Manufacturing Control PE 63570E 6. AUTHOR( S ) PR A934 David R. Arnsdorf, Robert A. Erickson, Monica J. Fox TA 00 wU 03 7. PERFORMING ORGANIZATION...NAME( S ) AND ADDRESS(ES) 8. PERFORMING ORGANIZATION Industrial Technology Institute REPORT NUMBER P.O. Box 1485 94-31-42 Ann Arbor, MI 48106 9...SPONSORING MONITORING AGENCY NAME( S ) AND ADDRESS(ES) 10. SPONSORING/MONITORING Materials & Manufacturing Directorate AGENCY REP NUMBER Air Force Research

  14. 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.

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

    SciTech Connect

    Bigger, J.E.

    1993-12-31

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

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

    SciTech Connect

    MOORE,LARRY M.

    2000-04-11

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

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

    NASA Astrophysics Data System (ADS)

    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.

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

    NASA Astrophysics Data System (ADS)

    Karki, Rajesh

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

  20. 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.

  1. 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

  2. Cost Analysis of Utilizing Electric Vehicles and Photovoltaic Solar Energy in the United States Marine Corps Commercial Vehicle Fleet

    DTIC Science & Technology

    2009-12-01

    The purpose of this MBA project is to examine the upfront cost associated with purchasing electric vehicles and installing photovoltaic (PV) solar...analysis for implementing Low Speed Vehicle (LSV), Pure Electric Vehicles (PEV), and PV solar electric energy in the United States Marine Corps commercial vehicle fleet at Marine Corps Logistics Base Barstow.

  3. Product costing guide for wood dimension and component manufacturers

    Treesearch

    Adrienn Andersch; Urs Buehlmann; Jeff Palmer; Janice K. Wiedenbeck; Steve. Lawser

    2014-01-01

    The North American hardwood dimension and components industry plays a critical role in the hardwood forest products industry as the industry is a user of high-value hardwood lumber. Customer expectations, global markets, and international competition, however, require hardwood dimension and components manufacturers to continuously improve their ability to manage their...

  4. 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

  5. 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.

  6. Nanostructured Materials for High Efficiency Low Cost Solution-Processed Photovoltaics

    SciTech Connect

    Salleo, Alberto

    2012-10-31

    The goal of the project was to develop a suite of materials coupled with processing technologies aimed at the fabrication of entirely solution-processed photovoltaic devices. Most of the emphasis in terms of innovation was placed on the transparent electrodes, widely considered a critical component of the solar cell in terms of cost and performance. The active layer technologies proposed hinged on the fabrication and deposition of semiconducting nanoparticles. The electrode development hit all the milestones proposed: by the end of the grant we were able to fabricate transparent and flexible electrodes with transmission over the solar spectrum higher than 85% and sheet resistance lower than 10 Ω/square. To the best of our knowledge, this is the highest-performance transparent electrode reported. Furthermore these electrodes were deposited by spray-coating, a large-area, low-cost deposition techniques. Hence the first main goal of the proposal, which was to find an alternative to ITO was successfully achieved. Organic photovoltaic devices were made with these electrodes having a performance indistinguishable from that of devices made on ITO (the industry standard), e.g. ~5% for P3HT:PCBM cells. We also innovated in the active-area part of the device where semiconducting inks were designed rather than nanoparticle suspensions. The process we selected, called air-stable ink rolling (AIR) allowed to deposit well-controlled films of ternary and quaternary II-VI semiconductors. Developing a new technology from scratch proved to be more challenging than anticipated and therefore we were not able to demonstrate a fully integrated device using our nanostructured high-performance transparent electrodes as well as AIR active layers. As a result, we did not achieve the second main goal of the proposal, which was to fabricate an entire cell using nanostructured materials. We were able to develop the components separately but did not integrate them in a device.

  7. 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.

  8. Silicon Film{trademark} photovoltaic manufacturing technology. Semiannual technical progress report, 15 January 1992--15 July 1992

    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.

  9. 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.

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

    NASA Astrophysics Data System (ADS)

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

    2011-10-01

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

  11. 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.

  12. 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.

  13. 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

  14. 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

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

    PubMed

    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

    2016-07-22

    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. 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. 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. 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.

  16. 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.

  17. 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.

  18. 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.

  19. Manufacturing Readiness and Cost Impacts for PEM Stack and Balance of Plant

    SciTech Connect

    Wheeler, Douglas; Ulsh, Michael

    2014-10-05

    The results of two Manufacturing Readiness Assessments of PEM fuel cell stacks and material handling equipment (MHE) and backup power (BUP) PEM fuel cell systems are given. Design modifications of fuel cell systems were made because the initial, 2008 designs did not fully meet the operational requirements of the markets. This situation indicates the 2008 risk elements were overstated.For 2010 BUP and MHE fuel cell systems, manufacturers had not reached the Low Rate Initial Production (LRIP) defined in the 2008 MRA Report at 1,000 units per year per manufacturer.For fuel cell stacks, LRIP was demonstrated by more than one manufacturer.The federal tax incentive program has compensated for the initial high cost of fuel cell systems.The Balance-of-Plant (BOP) has not evolved as rapidly as the PEM fuel cell stack manufacturing readiness.The BOP in 2014 is as costly as the fuel cell stack for MHE applications.

  20. Cost Savings for Manufacturing Lithium Batteries in a Flexible Plant

    SciTech Connect

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

    2015-06-01

    The flexible plant postulated in this study would produces types of batteries for electric-drive vehicles of the types hybrid (HEV), 10-mile range and 40-mile range plug-in hybrids (PHEV) and a 150-mile range battery-electric (EV). The annual production rate of the plant is 235,000 per year (30,000 EV batteries and 100,000 HEV batteries). The unit cost savings as calculated with the Argonne BatPaC model for this flex plant vs. dedicated plants range from 8% for the EV battery packs to 23% for the HEV packs including the battery management systems (BMS). The investment cost savings are even larger, ranging from 21% for EVs to 43% for HEVs. The costs of the 1.0-kWh HEV batteries are projected to approach $710 per unit and that of the EV batteries $228 per kWh with the most favorable cell chemistries and including the BMS. The best single indicator of the cost of producing lithium-manganate spinel/graphite batteries in a flex plant is the total cell area of the battery. For the four batteries studied, the price range is $20-24 per m2 of cell area including the cost of the BMS, averaging $21 per m2 for the entire flex plant.

  1. 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.

  2. 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.

  3. 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).

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

    NASA Astrophysics Data System (ADS)

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

    2015-06-01

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

  5. 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.

  6. 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.

  7. 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.

  8. PCS: a pallet costing system for wood pallet manufacturers (version 1.0 for Windows®)

    Treesearch

    A. Jefferson, Jr. Palmer; Cynthia D. West; Bruce G. Hansen; Marshall S. White; Hal L. Mitchell

    2002-01-01

    The Pallet Costing System (PCS) is a computer-based, Microsoft Windows® application that computes the total and per-unit cost of manufacturing an order of wood pallets. Information about the manufacturing facility, along with the pallet-order requirements provided by the customer, is used in determining production cost. The major cost factors addressed by PCS...

  9. Silicon-Film{trademark} photovoltaic manufacturing technology. Semiannual subcontract report, 15 October 1993--15 April 1994

    SciTech Connect

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

    1994-09-01

    This report describes work to develop an advanced, low-cost manufacturing process for a now utility-scale, flat-plate module. This process starts with the production of continuous sheets of thin-film, polycrystalline silicon using the Silicon-Film{trademark} process. Sheets are cut into wafers that are nominally 15 cm on a side. Fifty-six of these wafers are then fabricated into solar cells that are strung together into a 170-W module. Twelve of these modules form a 2-kW array. The program has three main components: (1) development of a Silicon-Film{trademark} wafer machine that is capable of manufacturing waters that are 225 cm{sup 2} in size at a rate of 3.0 MW/yr, with a total product cost reduction of 70%; (2) development of an advanced solar cell manufacturing process that is capable of turning the Silicon-Film{trademark} wafer into a 3.25-W solar cell; and (3) development of an advanced module design based on these large-area silicon solar cells with an average power of 170 W for 56 solar cells and 113 W for 36 solar cells.

  10. Estimating Fixed and Variable Costs of Airframe Manufacturers

    DTIC Science & Technology

    1991-03-01

    York: John Wiley and Sons, 1964, p. 243. [B-2] Pindyck , Robert S., and Daniel L. Rubinfeld. Econometric Models and Economic Forecasts. New York...the estimating techniques in use at IDA and several Department of Defense offices. 19 REFERENCES [1] Dickey, Robert I., ed. Accountants’ Cost Handbook...November 1973. [14] Kaplan, Robert S. Advanced Management Accounting. Englewood Cliffs: Prentice-Hall Inc., 1982, pp. 90-92. [15] Womer, Norman K

  11. DEVELOPMENT AND MANUFACTURE OF COST EFFECTIVE COMPOSITE DRILL PIPE

    SciTech Connect

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

    2000-10-30

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

  12. Development and Manufacture of Cost Effective Composite Drill Pipe

    SciTech Connect

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

    2006-09-29

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

  13. 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.

  14. 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.

  15. 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

  16. Current topics in photovoltaics

    SciTech Connect

    Coutts, T.J. ); Meakin, J.D. . Inst. of Energy Conversion)

    1990-01-01

    This book contains papers on current research in photovoltaics. Areas include: outdoor spectral odor radiation variations and their relationship to photovoltaic device performance, numerical modeling for analysis and design of solar cells, radiation damage mechanisms in GaAs and Si solar cells, and health and safety issues in the manufacturing of photovoltaic cells.

  17. 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

  18. Novel approaches for low-cost photovoltaic concentrator. Final report, January 1978-July 1980

    SciTech Connect

    Muller, T.; Maraschin, R.

    1982-11-01

    A concept has been developed for a photovoltaic concentrator that uses sealed beam headlight technology. The photovoltaic cell is placed at the focus of the headlamp reflector. A prototype 60 W array was designed, built, and tested. Array efficiency was approximately 6%.

  19. 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.

  20. 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.

  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, 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.

  3. 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.

  4. 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

  5. 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.

  6. Amorphous silicon photovoltaic manufacturing technology - phase 2A. Semiannual subcontract report, May 1, 1994--October 31, 1994

    SciTech Connect

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

    1995-10-01

    The objectives for this task are to integrate and test the automated encapsulation system designed in the second year of this effort. Once the system is fully integrated, UPG will collect and analyze data from continuous production runs employing the advanced encapsulation materials and processes utilized in the manufacture of POWERGLASS modules. Representative modules encapsulated utilizing the automated station will then be submitted for qualification (NREL/TR-213-3624) testing. This task is anticipated to result in a 98% yield and a cost reduction of 60% (cumulative) in the UPG encapsulation process.

  7. 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.

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

    SciTech Connect

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

    2011-02-01

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

  9. Leveraging costs and reducing risk in the development of optics manufacturing technological thrusts

    NASA Astrophysics Data System (ADS)

    Potts, Joe

    1992-01-01

    The Army Manufacturing Technology (MANTECH) program has exerted a strong and lasting influence on the U.S. defense industrial base for more than 25 years. The defense industrial base can be described as the aggregate ability to provide the manufacturing technology, research, development, and resources necessary to produce defense material. The Army's MANTECH program is designed to develop manufacturing thrusts (such as optics) that will result in the development of new and improved manufacturing processes. The Joint Logistics Commanders' assessment of the precision optics industrial base emphasized the need to modernize optics fabrication techniques and equipment. As a result of the study, the American Precision Optics Manufacturers Association (APOMA), the Department of the Army, and several academic institutions have collaborated to establish and support the Center for Optics Manufacturing (COM) at the University of Rochester. Through this successful collaboration of knowledge and resources, participants are able to leverage and reduce the cost, risk, and difficulty of developing new automated optics manufacturing systems and supporting technologies. The optics manufacturing thrust is now in its second year and support from industrial, academic, and government participants continues to increase.

  10. 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.

  11. Reliability Evaluation of Concentrator Photovoltaic Modules per IEC Qualification Specifications

    SciTech Connect

    Tamizhmani, Govindasamy

    2012-12-05

    This project is related to the qualification testing of new generation CPV (concentrator photovoltaics) modules at lower testing costs and lower turnaround time. In this project, the first testing program was completed for two CPV manufacturers, the second testing program was completed for two manufacturers at 65% of the actual testing cost and at less than 3 months of testing turnaround time and the third testing program was completed for two manufacturers at 65% of the actual testing cost and at less than 3 months of testing turnaround time. Due to their financial situation and restructuring, Amonix (one of the CPV manufacturers) intermittently terminated the test programs.

  12. Systematic review of drug administration costs and implications for biopharmaceutical manufacturing.

    PubMed

    Tetteh, Ebenezer; Morris, Stephen

    2013-10-01

    The acquisition costs of biologic drugs are often considered to be relatively high compared with those of nonbiologics. However, the total costs of delivering these drugs also depend on the cost of administration. Ignoring drug administration costs may distort resource allocation decisions because these affect cost effectiveness. The objectives of this systematic review were to develop a framework of drug administration costs that considers both the costs of physical administration and the associated proximal costs; and, as a case example, to use this framework to evaluate administration costs for biologics within the UK National Health Service (NHS). We reviewed literature that reported estimates of administration costs for biologics within the UK NHS to identify how these costs were quantified and to examine how differences in dosage forms and regimens influenced administration costs. The literature reviewed were identified by searching the Centre for Review and Dissemination Databases (DARE, NHS EED and HTA); EMBASE (The Excerpta Medica Database); MEDLINE (using the OVID interface); Econlit (EBSCO); Tufts Medical Center Cost Effectiveness Analysis (CEA) Registry; and Google Scholar. We identified 4,344 potentially relevant studies, of which 43 studies were selected for this systematic review. We extracted estimates of the administration costs of biologics from these studies. We found evidence of variation in the way that administration costs were measured, and that this affected the magnitude of costs reported, which could then influence cost effectiveness. Our findings suggested that manufacturers of biologic medicines should pay attention to formulation issues and their impact on administration costs, because these affect the total costs of healthcare delivery and cost effectiveness.

  13. 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.

  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. 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.

  16. 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

  17. 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.

  18. Photovoltaic materials.

    PubMed

    Perez-Albuerne, E A; Tyan, Y S

    1980-05-23

    Solid-state photovoltaic cells are feasible devices for converting solar energy directly to electricity. Recent cost reductions have spurred an incipient industry, but further advances in materials science and technology are needed before photovoltaic cells can compete with other sources for the supply of large amounts of energy. In this article energy loss mechanisms in solid-state photovoltaic cells are examined and related to materials properties. Various systems under development are reviewed which illustrate some key concepts, opportunities, and problems of this most promising emerging technology. Areas where contributions from innovative materials research would have a significant effect are also indicated.

  19. 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.

  20. 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

  1. 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

  2. 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%.

  3. 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%.

  4. Fundamental understanding and integration of rapid thermal processing, PECVD, and screen printing for cost-effective, high-efficiency silicon photovoltaic devices

    NASA Astrophysics Data System (ADS)

    Doshi, Parag Mahendra

    of emitter profiles, and engineering of a high-quality rapid thermal oxide (RTO) for surface passivation, eliminated short wavelength losses. Identical performance to conventional furnace-processed cells was achieved in half the processing time. Record-high RTP efficiencies >19% were achieved using photolithography. Screen-printed contacts on RTP cells reduced processing time by another factor of >four and resulted in >16%-efficient manufacturable cells. These results have brought photovoltaics one step closer to cost-effective commercialization.

  5. 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.

  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

    ... 38 Pensions, Bonuses, and Veterans' Relief 2 2010-07-01 2010-07-01 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 (or...

  7. 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...

  8. 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...

  9. 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...

  10. 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.

  11. 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.

  12. Strategic research on the sustainable development cost of manufacturing industry under the background of carbon allowance and trade policy

    NASA Astrophysics Data System (ADS)

    Ma, Zhongmin; Cheng, Mengting; Wang, Mei

    2017-08-01

    The important subjects of energy consumption and carbon emission are manufacturing enterprises, with the deepening of international cooperation, and the implementation of carbon limit and trade policy, costs of manufacturing industry will rise sharply. How can the manufacturing industry survive in this reform, and it has to be a problem that the managers of the manufacturing industry need to solve. This paper analyses sustainable development cost connotation and value basis on the basis of sustainable development concept, discusses the influence of carbon allowance and trade policy for cost strategy of manufacturing industry, thinks that manufacturing industry should highlight social responsibility and realize maximization of social value, implement cost strategy the sustainable development, and pointed out the implementation way.

  13. 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.

  14. 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.

  15. Metal and Glass Manufactures Reduce Costs by Increasing Energy Efficiency in Process Heating Systems

    SciTech Connect

    2004-05-01

    Process heating plays a key role in producing steel, aluminum, and glass and in manufacturing products made from these materials. Faced with regulatory and competitive pressures to control emissions and reduce operating costs, metal and glass manufacturers are considering a variety of options for reducing overall energy consumption. As 38% of the energy used in U.S. industrial plants is consumed for process heating applications, metal and glass manufacturers are discovering that process heating technologies provide significant opportunities for improving industrial productivity, energy efficiency, and global competitiveness. This fact sheet is the first in a series to describe such opportunities that can be realized in industrial systems by conducting plant-wide assessments (PWA).

  16. 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.

  17. Recent advances in photovoltaics

    SciTech Connect

    Carlson, D.E.

    1995-12-31

    Photovoltaic energy conversion has been widely used for over three decades in the space program to power satellites and in the last two decades has also found widespread use in remote applications such as powering microwave communication repeaters, providing cathodic protection for wells and pipelines, pumping water in remote locations, etc. With continued improvements in performance and ongoing reductions in manufacturing costs, PV systems are expected to become cost effective for grid-connected applications in the next few years. While crystalline silicon technology accounts for the majority of the present PV business, new thin film PV technologies such as multifunction amorphous silicon, copper-indium-diselenide and cadmium telluride have progressed to a point where several companies are building multi-megawatt production facilities. High efficiency concentrator arrays may also prove to be cost effective for grid-connected applications in regions of the world with significant direct sunlight.

  18. 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

  19. 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.

  20. Energy conserved and costs saved by small and medium-size manufacturers, 1988--1989

    SciTech Connect

    Kirsch, F.W.

    1991-05-01

    Energy Analysis and Diagnostic Centers (EADCs) provided energy-conserving and cost saving assistance in 339 small and medium-size manufacturing plants nationwide during 1988-89. This report presents the results of what was recommended to those manufacturers, the record of what was implemented by them, and an analysis of the financial rewards gained by them. It also includes an accounting of the financial returns to the federal government, derived from taxes upon the cost savings, or incremental income, of the manufacturers who implement the EADCs` recommendations. EADCs collect implementation data within a year of the energy audit, and for these results that time period extended through 1990. The EADCs are located at accredited engineering departments of universities and staffed by faculty and students. At present there are 18 EADCs serving manufacturers in 37 states; of these, two were established as a result of the 1989 competition, and five more were chosen competitively in 1990. Most of the results in this report were generated by 11 EADCs (named in the Appendix); two others withdrew voluntarily after completing only 10 energy audits during 1988-89. Primary responsibility for selecting, training, evaluating, and managing the EADCs belongs to the Industrial Technology and Energy Management (ITEM) division of University City Science Center (UCSC). The Department of Energy`s Office of Industrial Technologies sponsors the EADC program through an agreement with UCSC.

  1. Enhancing absorption in a thin film photovoltaic system with periodic nanostructures obtained by low-cost techniques

    NASA Astrophysics Data System (ADS)

    Le Bris, Arthur; Brudieu, Barbara; Gacoin, Thierry; Teisseire, Jérémie; Sorin, Fabien

    2013-03-01

    Light trapping structures are a promising approach to increase light absorption in ultrathin absorbers of interest for photovoltaic applications. To be integrated within real systems, their fabrication approach need to be simple and scalable, insuring that the gain in efficiency is worth the extra manufacturing steps. Here, we optimize through simulation using a RCWA code, a variety of 1D and 2D structures that can be fabricated with such simple and scalable techniques. In particular, we investigate the effect 1D and 2D gratings fabricated by Nanoimprint Lithography, onto Bragg mirrors that could be made using simple liquid process approaches. The optimized structures exhibit a significant gain in absorption with almost twice as much absorption in the wavelength range 0.5 to 1 micron, compared to a bare absorbing film of GaAs chosen as our reference. We also identify the various phenomena behind the absorption peaks observed and study the angular dependency of absorption with these structures.

  2. 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.

  3. Broadcasting photonic lab on a chip concept through a low cost manufacturing approach.

    PubMed

    Rodríguez-Ruiz, Isaac; Teychené, Sébastien; Van Pham, Nhat; Radajewski, Dimitri; Lamadie, Fabrice; Llobera, Andreu; Charton, Sophie

    2017-08-01

    A low cost fabrication process for photonic lab on a chip systems is here proposed. For the implementation of the masters suitable for cast molding fabrication, an inexpensive dry film photoresist, patternable using standard laboratory equipment, is benchmarked against standardized SU-8 masters obtained using UV lithography and systems manufacture in clean room facilities. Results show adequate system fabrication and a comparable performance of the photonic structures for absorbance/extinction measurements. Copyright © 2017 Elsevier B.V. All rights reserved.

  4. 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.

  5. 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

  6. Toward Cost-effective Manufacturing of Si Solar Cells: Electrodeposition of High Quality Si Films in a CaCl2-based Molten Salt.

    PubMed

    Yang, Xiao; Ji, Li; Zou, Xingli; Lim, Taeho; Zhao, Ji; Yu, Edward T; Bard, Allen J

    2017-09-13

    Electrodeposition of Si films from a Si-containing electrolyte is a cost-effective approach for the manufacturing of solar cells. Proposals relying on molten salts have suffered from low product quality due to difficulties in impurity control. Here we demonstrate a novel approach to electrodeposit high quality Si films from a CaCl2-based molten salt. Soluble SiIV-O anions generated from solid SiO2 are electrodeposited onto a graphite substrate to form a uniform layer of crystalline Si. Impurities in the deposited Si film are controlled at low concentrations (both B and P are less than 1 ppm). In the photoelectrochemical measurements, the Si film shows p-type semiconductor character and large photocurrent. A p-n junction fabricated from the deposited Si film exhibits clear photovoltaic effects. This study represents a first step to the ultimate goal of developing a cost-effective manufacturing process for Si solar cells based on electrodeposition. © 2017 WILEY-VCH Verlag GmbH & Co. KGaA, Weinheim.

  7. 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.

  8. 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.

  9. 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.

  10. 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.

  11. 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

  12. 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.

  13. 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.

  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. 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.

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

    DTIC Science & Technology

    2016-04-30

    qÜáêíÉÉåíÜ=^ååì~ä= ^Åèìáëáíáçå=oÉëÉ~êÅÜ= póãéçëáìã= qÜìêëÇ~ó=pÉëëáçåë= sçäìãÉ=ff= = Materials Testing and Cost Modeling for Composite Parts Through Additive...Research Associate, NPS Jonathan Mun, Research Professor, NPS Materials Testing and Cost Modeling for Composite Parts Through Additive...Materials Testing and Cost Modeling for Composite Parts Through Additive Manufacturing Eric S. Holm—recently graduated from the Air Force Institute of

  20. 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.

  1. 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)

  2. 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

  3. Cost benefit of investment on quality in pharmaceutical manufacturing: WHO GMP pre- and post-certification of a Nigerian pharmaceutical manufacturer.

    PubMed

    Anyakora, Chimezie; Ekwunife, Obinna; Alozie, Faith; Esuga, Mopa; Ukwuru, Jonathan; Onya, Steve; Nwokike, Jude

    2017-09-18

    Pharmaceutical companies in Africa need to invest in both facilities and quality management systems to achieve good manufacturing practice (GMP) compliance. Compliance to international GMP standards is important to the attainment of World Health Organization (WHO) prequalification. However, most of the local pharmaceutical manufacturing companies may be deterred from investing in quality because of many reasons, ranging from financial constraints to technical capacity. This paper primarily evaluates benefits against the cost of investing in GMP, using a Nigerian pharmaceutical company, Chi Pharmaceuticals Limited, as a case study. This paper also discusses how to drive more local manufacturers to invest in quality to attain GMP compliance; and proffers practical recommendations for local manufacturers who would want to invest in quality to meet ethical and regulatory obligations. The cost benefit of improving the quality of Chi Pharmaceuticals Limited's facilities and system to attain WHO GMP certification for the production of zinc sulfate 20-mg dispersible tablets was calculated by dividing the annual benefits derived from quality improvement interventions by the annual costs of implementing quality improvement interventions, referred to as a benefit-cost ratio (BCR). Cost benefit of obtaining WHO GMP certification for the production of zinc sulfate 20-mg dispersible tablets was 5.3 (95% confidence interval of 5.0-5.5). Investment in quality improvement intervention is cost-beneficial for local manufacturing companies. Governments and regulators in African countries should support pharmaceutical companies striving to invest in quality. Collaboration of local manufacturing companies with global companies will further improve quality. Local pharmaceutical companies should be encouraged to key into development opportunities available for pharmaceutical companies in Africa.

  4. 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

  5. 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.

  6. 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.

  7. Energy conserved and costs saved by small and medium-size manufacturers. 1983-84 EADC Program period

    SciTech Connect

    Kirsch, F.W.; Perrotti, G.M.

    1986-02-01

    Almost 300 small and medium-size manufacturers were able to benefit during 1983-84 from the services provided in their plants by 12 Energy Analysis and diagnostic Centers (EADCs) managed by University City Science Center under an agreement with the US Department of Energy, Office of Industrial Programs. This report describes and analyzes what the EADCs recommended, reviews and assesses what the manufacturers implemented, and evaluates how cost-effective the manufacturers found the EADCs' recommendations to be.

  8. 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)

  9. 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.

  10. Reducing workers' compensation costs for latex allergy and litigation against glove manufacturing companies.

    PubMed

    Edlich, Richard F; Mason, Shelley S; Swainston, Erin; Dahlstrom, Jill J; Gubler, K; Long, William B

    2009-01-01

    It has been well documented in the medical literature that powdered medical gloves can have serious consequences to patients and health-care workers. Adverse reactions to natural latex gloves, such as contact dermatitis and urticaria, occupational asthma, and anaphylaxis, have been documented as a significant cause of Workers' Compensation claims among health-care workers. While the cost of examination and surgical gloves is significant, this factor must be considered with the total cost of Workers' Compensation claims and possible litigation bestowed upon hospitals and glove manufacturing companies. In the United States, Canada, Belgium, and Germany, medical leaders have documented the dangers of powdered latex gloves and have implemented transition programs that are reducing Workers' Compensation claims filed by health-care workers. While attorneys view litigation against powdered glove manufacturers as the "next big tort", the authors of this article were not able to document all compensation costs to disabled workers because many settlements do not allow the claimant to disclose this information.

  11. 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...

  12. 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.

  13. 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 ]...

  14. 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...

  15. 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.

  16. 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.

  17. The costs of work-related musculoskeletal disorders in automotive manufacturing.

    PubMed

    Punnett, L

    1999-01-01

    Inadequate application of ergonomic principles to the design of workplaces and individual jobs has adverse consequences for worker health and safety, especially in terms of strains, sprains, and other musculoskeletal disorders. In addition to the human pain and suffering, other losses are externalized to workers, with adverse financial and psychosocial impacts. There are also costs to employers through workers' compensation claims, scrap, and decreased production quality, medical insurance premiums, labor turnover, and adverse impacts on labor relations, although many of these are not linked by traditional accounting methods to ergonomic problems per se. Data collected in five plants of two major U.S. automotive manufacturing companies in the last decade have been used to estimate some of the costs associated with work-related musculoskeletal disorders (MSDs), only some of which resulted in workers compensation claims. In one plant in 1984-85, the payroll cost of all back and shoulder disorders was at least $320 per year per worker, not including workers' compensation premiums or claims paid. A large proportion of these costs were accrued by "unreported" cases, that is, cases that either had never been reported to the plant clinic or had been reported in the past and were considered administratively to have recovered. In the other four plants, annual costs associated with in-plant medical visits for MSDs in 1989-93 were almost as high as those resulting from compensation claims. At least one-half of these disorders were estimated to be attributable to physical ergonomic exposures in the workplace and thus preventable. These data are consistent with estimates by others that the real costs to employers are at least two to three times the amount paid in workers' compensation cases, and that at least 50 percent of all work-related musculoskeletal disorders among the working population could be prevented by appropriate ergonomic job design. Furthermore, recent

  18. 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.

  19. 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.

  20. 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.

  1. 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.

  2. 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.

  3. 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.

  4. 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.

  5. Energy conserved and costs saved by small and medium-size manufacturers: 1986-1987 EADC program period

    SciTech Connect

    Kirsch, F.W.

    1989-03-01

    The Energy Analysis and Diagnostic Center (EADC) program provides energy-conserving and cost-saving assistance to small and medium-size manufacturers in 36 states. Engineering faculty from 13 universities, assisted by graduate and undergraduate students, analyze energy usage and manufacturing operations in each plant and then prepare an individualized report that recommends specific actions and estimates their costs and their benefits. Manufacturing plants are eligible if they meet the size criteria and are not more than 150 miles from an EADC. The US Department of Energy, Office of Industrial Programs, sponsors the EADC program, which is managed by University City Science Center, through its Industrial Technology and Energy Management (ITEM) Division. This and similar reports are prepared from data which ITEM staff members extract as they review every energy audit report prepared by the EADCs. Eventually these data also include the results of manufacturers' implementation of EADCs' recommendations, together with costs and savings. 14 tabs.

  6. Dickten & Masch Manufacturing Company: Industrial Energy Assessment Achieves $35,000 in Cost Savings for Plastics Manufacturer

    SciTech Connect

    Not Available

    2005-09-01

    Industrial Technologies Program's BestPractices case study based on a comprehensive plant assessment conducted at the Dickten & Masch Manufacturing Company by ITP's Industrial Assessment Center in conjunction with The Society of the Plastics Industry, Inc.

  7. Photovoltaic manufacturing technology monolithic amorphous silicon modules on continuous polymer substrates. Annual technical progress report, July 5, 1996--December 31, 1997

    SciTech Connect

    Jeffrey, F.

    1998-08-01

    Iowa Thin Film Technologies, Inc.`s (ITF) goal is to develop the most cost effective PV manufacturing process possible. To this end the authors have chosen a roll based manufacturing process with continuous deposition and monolithic integration. Work under this program is designed to meet this goal by improving manufacturing throughput and performance of the manufactured devices. Significant progress was made during Phase 2 of this program on a number of fronts. A new single pass tandem deposition machine was brought on line which allows greatly increased and improved throughput for rolls of tandem material. The TCO deposition process was improved resulting in an increase in throughput by 20%. A new alignment method was implemented on the printing process which improves throughput six fold while improving alignment from 100 {micro}m to 10 {micro}m. A roll based lamination procedure was developed and implemented on selected products which improves throughput from 20 sq. ft./hr. to 240 sq. ft./hr. A wide range of lower cost encapsulants were evaluated. A promising material was selected initially to be introduced in 5 year lifetime type products. The sum of these improvements bring the overall cost reduction resulting from this program to 49%.

  8. 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.

  9. Photovoltaics: electricity from sunlight

    SciTech Connect

    Not Available

    1984-09-01

    The role of photovoltaic power in the world's energy mix is discussed. The role of the US federal government in the research and development of photovoltaic technology is described as one of undertaking long-range, high-risk research and development in areas that industry is not likely to pursue because of the costs and risks involved. The commercial growth of photovoltaic technology is alluded to briefly, and the basic operating theory of photovoltaic conversion is introduced. Numerous applications of photovoltaic technology are described, including uses in communications, rural electrification, waer pumping, corrosion protectio, navigational aids, and railroads, as well as utility network power. The economics of photovoltaic power are discussed, and the products and technology of the US photovoltaic industry are described. (LEW)

  10. Photovoltaic Cz Silicon Module Improvements; Final Subcontract Report, 9 November 1995 - 8 November 1998

    SciTech Connect

    T. L. Jester.

    1999-06-17

    This report describes work that focused on reducing the cost per watt of Cz silicon photovoltaic modules under Siemens Solar Industries' (SSI) DOE/NREL Photovoltaic Manufacturing Technology (PVMaT) 4A subcontract. SSI researchers deployed new module designs, realized improvements in yield of more than 25%, and implemented statistical process control (SPC). They have described yield improvements in detail and reported on the deployment of SPC in critical process steps. The sum of all improvements resulted in a greater than 17% cost per watt reduction in manufacturing.

  11. 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.

  12. 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.

  13. 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.

  14. 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.

  15. Depleted-heterojunction colloidal quantum dot photovoltaics employing low-cost electrical contacts

    NASA Astrophysics Data System (ADS)

    Debnath, Ratan; Greiner, Mark T.; Kramer, Illan J.; Fischer, Armin; Tang, Jiang; Barkhouse, D. Aaron R.; Wang, Xihua; Levina, Larissa; Lu, Zheng-Hong; Sargent, Edward H.

    2010-07-01

    With an aim to reduce the cost of depleted-heterojunction colloidal quantum dot solar cells, we describe herein a strategy that replaces costly Au with a low-cost Ni-based Ohmic contact. The resultant devices achieve 3.5% Air Mass 1.5 power conversion efficiency. Only by incorporating a 1.2-nm-thick LiF layer between the PbS quantum dot film and Ni, we were able to prevent undesired reactions and degradation at the metal-semiconductor interface.

  16. 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

  17. 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.

  18. 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.

  19. 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.

  20. 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.

  1. 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.

  2. 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.

  3. 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.

  4. Basic photovoltaics

    SciTech Connect

    Zweibel, K.

    1984-01-01

    Here is a photovoltaics guide that converts highly technical information into language that can be understood by both scientists and non-scientists. It provides an introduction to solar cell technology, explaining how PV cells work, how they are manufactured, and how they are put together into effective energy-producing systems. The authors investigate a new PV technology based on an altered form of silicon capable of producing conversion efficiencies of 10% to 15%. They explain the PV effect, loss mechanisms, and advances in fabrication methods.

  5. Cost-performance tradeoff between design and manufacturing: DfM or MfD?

    NASA Astrophysics Data System (ADS)

    Balasinski, A.; Cetin, J.; Karklin, L.

    2007-03-01

    Design, CAD, and manufacturing are focused on optimizing translation methodology from electrical design to physical layout, and finally to mask data. The general goal is to improve integrated circuit (IC) functionality, reliability, manufacturability, testability, etc., using Design-for-X-ability (DfX) rules. Among those, the key role is played by DfM which is most directly related to the yield and therefore, the profit. A lot of pressure is being put on design to improve their understanding of all technology implementation issues, such that the mask pattern generated out of design layout would be "correct by construction" and comply with all of them. One can expect that such DfM-compliant layout should require significant effort to create, and its salient features would include: Manhattan geometries, and restricted grid for critical geometries, such as poly gates, large enclosures of the active area in the corners of implant layers, complete symmetry and proximity of the matched devices on all masking levels, minimal amount of jogs even for the complex features, neat alignment of source and drain contacts, line ends of gates and interconnects, doubled contacts and vias, etc. The question is if the cost of following all these practices at design time is not higher than that of other design improvement options. One alternative approach is to automatically adjust the "draft" layout using CAD post-processing such that all geometries would be optimized to conform to the DfM rules. Another approach to the DfM methodology is to improve the manufacturing capabilities such that the process tools would be able to achieve high yield for a layout which conforms only to some basic set of rules. This approach becomes even more relevant when the product line tries to address only selected DfM issues to improve die performance where it is most needed. We discussed the layout flow charts to determine the best approach, depending on the direct cost of the solution, the wafer volume

  6. 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.

  7. 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%.

  8. A low-cost photovoltaic cell process based on thick film techniques

    NASA Technical Reports Server (NTRS)

    Mardesich, N.; Pepe, A.; Bunyan, S.; Edwards, B.; Olson, C.

    1980-01-01

    The low-cost, easily automated processing for solar cell fabrication being developed at Spectrolab for the DOE LSA program is described. These processes include plasma-etching, spray-on diffusion sources and antireflective coating, thick film metallization, aluminum back contacts, laser scribing and ultrasonic soldering. The process sequence has been shown to produce solar cells having 15% conversion efficiency at AM1 which meet the cell fabrication budget required for the DOE 1986 cost goal of $0.70 per peak watt in 1980.

  9. 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.

  10. 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...

  11. 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

  12. 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.

  13. Microsystems Enabled Photovoltaics

    SciTech Connect

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

    2012-07-02

    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.

  14. 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.

  15. Was it worthwhile? Where have the benefits of rooftop solar photovoltaic generation exceeded the cost?

    NASA Astrophysics Data System (ADS)

    Vaishnav, Parth; Horner, Nathaniel; Azevedo, Inês L.

    2017-09-01

    We estimate the lifetime magnitude and distribution of the private and public benefits and costs of currently installed distributed solar PV systems in the United States. Using data for recently-installed systems, we estimate the balance of benefits and costs associated with installing a non-utility solar PV system today. We also study the geographical distribution of the various subsidies that are made available to owners of rooftop solar PV systems, and compare it to distributions of population and income. We find that, after accounting for federal subsidies and local rebates and assuming a discount rate of 7%, the private benefits of new installations will exceed private costs only in seven of the 19 states for which we have data and only if customers can sell excess power to the electric grid at the retail price. These states are characterized by abundant sunshine (California, Texas and Nevada) or by high electricity prices (New York). Public benefits from reduced air pollution and climate change impact exceed the costs of the various subsidies offered system owners for less than 10% of the systems installed, even assuming a 2% discount rate. Subsidies flowed disproportionately to counties with higher median incomes in 2006. In 2014, the distribution of subsidies was closer to that of population income, but subsidies still flowed disproportionately to the better-off. The total, upfront, subsidy per kilowatt of installed capacity has fallen from 5200 in 2006 to 1400 in 2014, but the absolute magnitude of subsidy has soared as installed capacity has grown explosively. We see considerable differences in the balance of costs and benefits even within states, indicating that local factors such as system price and solar resource are important, and that policies (e.g. net metering) could be made more efficient by taking local conditions into account.

  16. 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.

  17. 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.

  18. 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.

  19. The prevalence and workplace costs of adult attention deficit hyperactivity disorder in a large manufacturing firm.

    PubMed

    Kessler, R C; Lane, M; Stang, P E; Van Brunt, D L

    2009-01-01

    Little is known about the effects of adult attention deficit hyperactivity disorder (ADHD) on work performance or accidents-injuries.MethodA survey was administered in 2005 and 2006 to employees of a large manufacturing firm to assess the prevalence and correlates of adult ADHD. Respondents (4,140 in 2005, 4,423 in 2006, including 2,656 in both surveys) represented 35-38% of the workforce. ADHD was assessed with the World Health Organization (WHO) Adult ADHD Self-Report Scale (ASRS), a validated screening scale for DSM-IV adult ADHD. Sickness absence, work performance and workplace accidents-injuries were assessed with the WHO Health and Work Performance Questionnaire (HPQ). The estimated current prevalence (standard error) of DSM-IV ADHD was 1.9% (0.4). ADHD was associated with a 4-5% reduction in work performance (chi12=9.1, p=0.001), a 2.1 relative-odds of sickness absence (chi12=6.2, p=0.013), and a 2.0 relative-odds of workplace accidents-injuries (chi12=5.1, p=0.024). The human capital value (standard error) of the lost work performance associated with ADHD totaled USD 4,336 (676) per worker with ADHD in the year before interview. No data were available to monetize other workplace costs of accidents-injuries (e.g. destruction of equipment). Only a small minority of workers with ADHD were in treatment. Adult ADHD is a significantly impairing condition among workers. Given the low rate of treatment and high human capital costs, in conjunction with evidence from controlled trials that treatment can reduce ADHD-related impairments, ADHD would seem to be a good candidate for workplace trials that evaluate treatment cost-effectiveness from the employer's perspective.

  20. 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.

  1. 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.

  2. 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.

  3. 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.

  4. 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.

  5. 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.

  6. 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.

  7. 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.

  8. 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.

  9. 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…

  10. 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…

  11. 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.

  12. 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.

  13. Low Cost, Epitaxial Growth of II-VI Materials for Multijunction Photovoltaic Cells

    SciTech Connect

    Hardin, Brian E.; Peters, Craig H.

    2014-04-30

    Multijunction solar cells have theoretical power conversion efficiencies in excess of 29% under one sun illumination and could become a highly disruptive technology if fabricated using low cost processing techniques to epitaxially grow defect tolerant, thin films on silicon. The PLANT PV/Molecular Foundry team studied the feasibility of using cadmium selenide (CdSe) as the wide band-gap, top cell and Si as the bottom cell in monolithically integrated tandem architecture. The greatest challenge in developing tandem solar cells is depositing wide band gap semiconductors that are both highly doped and have minority carrier lifetimes greater than 1 ns. The proposed research was to determine whether it is possible to rapidly grow CdSe films with sufficient minority carrier lifetimes and doping levels required to produce an open-circuit voltage (Voc) greater than 1.1V using close-space sublimation (CSS).

  14. 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.

  15. 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.

  16. 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

  17. Cost-efficient manufacturing process of switchable glazing based on twisted nematic LC cells

    NASA Astrophysics Data System (ADS)

    Kurz, Eberhard; Rau, Lothar; Frühauf, Norbert; Haase, Walter; Prskalo, Marijo; Sobek, Werner

    2011-10-01

    Large-area glass facades are widely spread in contemporary architecture. They meet demands for natural light illumination of rooms and satisfy esthetic requirements of modern architecture. However, larger glass facades increase transfer of energy into the building. Since this has to be compensated by the intense use of air conditioning, modulation of the energy passing through the glazing is essential. The authors have been developing a corresponding system. It consists of a modified twisted nematic (TN) liquid crystal (LC) cell which is embedded in a double glazing. Since a conventional outside film polarizer is susceptible to heat, the authors substituted this component for an inside coatable polarizer. Long term outdoor weathering tests demonstrated that the concept is viable. Part of the current research is the integration of the TN LC cell into double-glazing. A further demand for such a system is a cost-efficient manufacturing process. It has been investigated to use the coatable polarizer at the same time as an alignment layer for the liquid crystal. Aluminum zinc oxide (AZO) is to be used for the electrode material substituting conventionally used indium tin oxide (ITO) which is expensive. Currently the authors are looking into the coating process for the inside polarizer.

  18. 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.

  19. 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.

  20. 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.

  1. 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.

  2. 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.

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

    DTIC Science & Technology

    2011-09-22

    rooftops of various facilities at Naval Station Pearl Harbor in Oahu, Hawaii , and at the Pacific Missile Range Facility in Kauai , Hawaii . To execute...Photovoltaic Systems at Navy Installations in Hawaii 40 Project P856-M, Photovoltaic System at Marine Corps Base Camp Pendleton, California 40 C...reviewed Project P856-M at Marine Corps Base Camp Pendleton (Camp Pendleton), Project RM09-1363 at Navy installations in Hawaii , and Project RM09-1440 at

  4. Silicon-film{trademark} photovoltaic manufacturing technology. Annual subcontract report, 15 January 1992--15 November 1992

    SciTech Connect

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

    1994-02-01

    This report describes work under a subcontract to upgrade AstroPower, Inc.`s facility to produce 1.22-m{sup 2} Silicon-Film{trademark} PV modules with an output of 170 W{sub p}. The focus for the first year of the PVMaT Phase 2A project is to establish the baseline process capability and optimize the performance of the present machine. This first year`s activities accelerated the advance of Silicon-Film{trademark} manufacturing technology in several ways. First, the project led directly to plans to make an early introduction of a large solar cell product. The successful fabrication of 646-cm{sup 2} wafers and solar cells paved the way for dramatically increasing the power output per solar cell. Second was the establishment of a basis for the design and construction of a 2.4-MW/yr wafer machine. Another important contribution was the determination of the importance of H{sup +} implantation processes for polycrystalline silicon technologies.

  5. 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.

  6. 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.

  7. Fabrication of Semi-Transparent Photovoltaic Cell by a Cost-Effective Technique

    NASA Astrophysics Data System (ADS)

    Nithyayini, K. N.; Ramasesha, Sheela K.

    2015-09-01

    Semi-transparent inorganic thin film PV cells have been fabricated using n-type (CdS) and p-type (CdTe) semiconductors. Large area devices which can be used as windows and skylights in buildings can be fabricated using cost effective solution processes. The device structure is Glass/TCO/CdTe/CdS/TCO. Chemically stable CdS and CdTe layers are deposited at temperatures 353 K to 373 K (80 °C to 100 °C) under controlled pH. The CdCl2 activation is carried out followed by air annealing. The p-n junction is formed by sintering the device at 673 K to 723 K (400 °C to 450 °C). The characterization of cells is carried out using XRD, SEM, AFM, and UV-Visible spectroscopy. The thickness of the cell is ~600 nm. The band gap values are 2.40 eV for CdS and 1.36 eV for CdTe with transmittance of about 70 pct in the visible region. Under 1.5 AM solar spectrum, V oc, and I sc of the initial device are 3.56e-01 V and 6.20e-04 A, respectively.

  8. 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.

  9. 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.

  10. 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

  11. The effect of adopting new storage methods for extending product validity periods on manufacturers expected inventory costs.

    PubMed

    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.

  12. 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.

  13. 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.

  14. 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.

  15. 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.

  16. 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.

  17. 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

  18. Low cost and manufacturable complete microTAS for detecting bacteria.

    PubMed

    Sauer-Budge, Alexis F; Mirer, Paul; Chatterjee, Anirban; Klapperich, Catherine M; Chargin, David; Sharon, Andre

    2009-10-07

    In this paper, we present a fully integrated lab-on-a-chip and associated instrument for the detection of bacteria from liquid samples. The system conducts bacterial lysis, nucleic acid isolation and concentration, polymerase chain reaction (PCR), and end-point fluorescent detection. To enable truly low-cost manufacture of the single-use disposable chip, we designed the plastic chip in a planar format without any active components to be amenable to injection molding and utilized a novel porous polymer monolith (PPM) embedded with silica that has been shown to lyse bacteria and isolate the nucleic acids from clinical samples (M. D. Kulinski, M. Mahalanabis, S. Gillers, J. Y. Zhang, S. Singh and C. M. Klapperich, Biomed. Microdevices, 2009, 11, 671-678).(1) The chip is made of Zeonex(R), a thermoplastic with a high melting temperature to allow PCR, good UV transmissibility for UV-curing of the PPM, and low auto-fluorescence for fluorescence detection of the amplicon. We have built a prototype instrument to automate control of the fluids, temperature cycling, and optical detection with the capability of accommodating various chip designs. To enable fluid control without including valves or pumps on the chip, we utilized a remote valve switching technique. To allow fluid flow rate changes on the valveless chip, we incorporated speed changing fluid reservoirs. The PCR thermal cycling was achieved with a ceramic heater and air cooling, while end-point fluorescence detection was accomplished with an optical spectrometer; all integrated in the instrument. The chip seamlessly and automatically is mated to the instrument through an interface block that presses against the chip. The interface block aligns and ensures good contact of the chip to the temperature controlled region and the optics. The integrated functionality of the chip was demonstrated using Bacillus subtilis as a model bacterial target. A Taqman assay was employed on-chip to detect the isolated bacterial DNA.

  19. 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

  20. Low-Cost Opportunity for Small-Scale Manufacture of Hardwood Blanks

    Treesearch

    Bruce G. Hansen; Philip A. Araman

    1985-01-01

    We analyzed the manufacture of standard-size hardwood blanks from lumber on a relatively small scale by conventional processing. Requiring an investment of just over $200,000, the conventional mill can process 500 M bf (thousand board feet) of kiln-dried lumber annually. The study focused on the economics associated with manufacture of blanks from four species -...

  1. Photovoltaic Power Plants

    NASA Astrophysics Data System (ADS)

    Berman, Elliot

    1986-11-01

    To demonstrate technical viability of photovoltaic modules in central, grid connected energy systems, ARCO Solar, Inc. has designed, installed and is operating two photovoltaic power plants on the megawatt scale. These systems use two-axis tracking. The first generation plant in Lugo (Hesperia), California, with a nominal rating of one MWpk (DC)" was installed in 1982 in the Southern California Edison Company grid. The second system, rated at 6.4 MWDk (DC), is located in the Carrisa Plain in California and connected to the Pacific Gas and Electric Company grid. Based on the cost and performance data from these installations, an assessment of the current status and future needs of large scale photovoltaic energy systems is made. With each new system, improved techniques of design, installation and system integration have been developed. Expectations have been confirmed as to the performance and adaptability of solar cells, especially the ease of incremental increases in capacity when needed. Modular photovoltaic systems have been found to be easy to build and operate, and to be highly reliable. Prologue: Technological advancement usually requires good science and logical engineering. In the main, faith, persistence and feel are also required. Rule: The balance-of-system costs for photovoltaic energy systems equal photovoltaic module costs. Photovoltaic systems have progressed to their current stage of high promise because of faith, persistence, feel and belief in this rule.

  2. 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.

  3. 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.

  4. 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.

  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. 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.

  7. 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].

  8. 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.

  9. Life cycle cost study for coated conductor manufacture by metal organic chemical vapor deposition

    SciTech Connect

    Chapman, J.N.

    1999-07-13

    The purpose of this report is to calculate the cost of producing high temperature superconducting wire by the Metal Organic Chemical Vapor Deposition (MOCVD) process. The technology status is reviewed from the literature and a plant conceptual design is assumed for the cost calculation. The critical issues discussed are the high cost of the metal organic precursors, the material utilization efficiency and the capability of the final product as measured by the critical current density achieved. Capital, operating and material costs are estimated and summed as the basis for calculating the cost per unit length of wire. Sensitivity analyses of key assumptions are examined to determine their effects on the final wire cost. Additionally, the cost of wire on the basis of cost per kiloampere per meter is calculated for operation at lower temperatures than the liquid nitrogen boiling temperature. It is concluded that this process should not be ruled out on the basis of high cost of precursors alone.

  10. 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.

  11. 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.

  12. The practice of quality-associated costing: application to transfusion manufacturing processes.

    PubMed

    Trenchard, P M; Dixon, R

    1997-01-01

    This article applies the new method of quality-associated costing (QAC) to the mixture of processes that create red cell and plasma products from whole blood donations. The article compares QAC with two commonly encountered but arbitrary models and illustrates the invalidity of clinical cost-benefit analysis based on these models. The first, an "isolated" cost model, seeks to allocate each whole process cost to only one product class. The other is a "shared" cost model, and it seeks to allocate an approximately equal share of all process costs to all associated products.

  13. 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

  14. PV Cz silicon manufacturing technology improvements. Annual subcontract report, 1 April 1992--31 March 1993

    SciTech Connect

    Jester, T.

    1994-01-01

    This report describes work performed under a 3-year contract to demonstrate significant cost reductions and improvements in manufacturing technology. The work focused on near-term projects for implementation in the Siemens Solar Industries Czochralski (Cz) manufacturing facility in Camarillo, California. The work was undertaken to increase the commercial viability and volume of photovoltaic manufacturing by evaluating the most significant cost categories and then lowering the cost of each item through experimentation, materials refinement, and better industrial engineering. The initial phase of the program concentrated on the areas of crystal growth; wafer technology; and environmental, safety, and health issues.

  15. Status and opportunities associated with product costing strategies in wood component manufacturing

    Treesearch

    Adrienn Andersch; Urs Buehlmann; Jan Wiedenbeck; Steve. Lawser

    2013-01-01

    Product costing systems are critically important for businesses because they help reduce costs, price products at competitive prices, and enable strategic decisionmaking. This article reports the results of a survey designed to collect information about practices used by the North American hardwood dimension and components industry to calculate the cost of their...

  16. 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.

  17. 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.

  18. 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.

  19. 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

  20. 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.

  1. 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.

  2. 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.

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

    DOE PAGES

    Davidson, Carolyn; Steinberg, Daniel; Margolis, Robert

    2015-02-04

    We report that 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. Thismore » 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. Additionally, all contract costs exhibit a wide range, and do not parallel trends in installed costs over time.« less

  4. 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.

  5. 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.

  6. 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.

  7. 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.

  8. 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.

  9. 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.

  10. 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.

  11. 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.

  12. 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.

  13. 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.

  14. 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.

  15. 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.

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

    DTIC Science & Technology

    1980-09-01

    stringers, doublers, frames, ribs, webs , skins, fairings, and brackets each produced by a number of manufacturing processes, such as brake forming...equipment (for laminated structure, sinewave formed webs , etc.) 30 * Lack of scandardization of clips, etc. * Designs requiring "close fit-up" or nesting...integration of the panels and lineal shapes into structural assemblies, such as lifting surfaces, fuselages, and internal webs , is shown in Figure 19

  17. 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.

  18. 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.

  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. 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.