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

    Research output: NRELSubcontract Report


    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).
    Original languageAmerican English
    PublisherNational Renewable Energy Laboratory (NREL)
    Number of pages44
    StatePublished - 2002

    Bibliographical note

    Work performed by PowerLight Corporation, Berkeley, California

    NREL Publication Number

    • NREL/SR-520-32064


    • adhesive priming
    • amorphous silicon
    • balance of systems (BOS)
    • building-integrated PV roofing tiles
    • capacitor bank
    • DC/AC inverter
    • electrical quick connects
    • extruded polystyrene processing
    • flat plate
    • installations
    • laminates
    • PV
    • roofing tile fabrication
    • single-ply membrane system
    • solar electric array
    • thin film
    • wind tunnels


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