PVMaT Improvements in the Manufacturing of the PVI Powergrid(TM): Phase I Annual Technical Report, 26 October 1995 - 25 October 1996

Photovoltaics International, LLC (PVI), is improving the manufacturing of the Powergrid(TM) under the Photovoltaics Manufacturing Technology (PVMaT) program by development in five basic areas: an advanced, state-of the-art lens extrusion system; an advanced, state-of the-art module side extrusion system; a second-generation, automated receiver assembly station; low-cost, roll- formed steelpanel-frame members; a low volatile organic compound (VOC) and Hazmat automated module assembly process. Phase 1 of the PVI PVMaT program is a design phase, Phase 2 is an implementation phase, and Phase 3 is a demonstration phase. Under Phase 1, PVI researchers accomplished the following: designed and specified an advanced extrusion system; completed proof-of-concept tests on elements of theextrusion system; built and tested an advanced die for lens extrusion; built and tested a unique die concept for module side extrusion; designed the second-generation, automated receiver assembly system; completed proof-of-concept tests on elements of the receiver assembly station; designed a panel frame using roll-formed members and built prototypes; designed a low-VOC module and builtprototypes; developed a process for encapsulating a concentrator receiver with ethylene vinyl acetate (EVA); built two EVA encapsulation vacuum ovens. The Powergrid(TM) has the potential to be very low cost in the short term. The PVI PVMaT program should allow PVI to reach the cost goals set by the company. This, in turn, will allow PVI to become a substantial player in the PV market and willallow the DOE goals of increased application of PV to become a reality.