PowerGuard(R) Advanced Manufacturing: PVMaT Final Report, 1 July 1998 - 30 September 2001

This final report describes the PVMaT results of manufacturing improvements directed toward innovative, low-cost, high-return, high-impact PV products. PowerLight's focus for this subcontract was manufacturing improvements for its patented PowerGuard? building-integrated PV roofing tile. These manufacturing improvements were selected to reduce PowerGuard? system costs, increase PowerGuard? tilefabrication capability to 16 MW/year, and stimulate an increase in manufacturing of PV laminates, within the United States, by 2 MW/year. Production rates rose from 200 tiles per 8-hour shift to more than 500 tiles per 8-hour shift. The overall system cost of PowerGuard? was reduced by 38%. The original goal of a 46% reduction was not met, due to unexpectedly high global demand for PV laminatesand limitations on supply. PowerLight has successfully reduced balance-of-system costs, including the cost of installation. At the end of this subcontract, BOS costs had been reduced by 68%. Project goals included: Implementation of an automated tile manufacturing facility, in Berkeley, California, exceeding 16-MW/year capacity; improved quality of finished goods due to improved tooling andprocesses in PowerGuard? manufacturing, which also simultaneously improved throughput and lowered costs; completion of wind tunnel testing of all design refinements; testing of PowerGuard? installations on mechanically attached roof membranes; creation of an installation manual and training program for installing PowerGuard? systems; certification and listing of PowerGuard? products withUnderwriters Laboratories and international certification organizations, and application for listing with the International Conference of Building Officials (ICBO).