PVMaT Cost Reductions in the EFG High Volume PV Manufacturing Line: Final Subcontract Report, 5 August 1998 -- 4 February 2001

Technical Report · Fri Mar 01 00:00:00 EST 2002

DOI:https://doi.org/10.2172/15000365· OSTI ID:15000365

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

This report describes the three major task areas: manufacturing systems development, low-cost processing technology, and flexible manufacturing methods. In Manufacturing Systems, we have worked on implementing and utilizing SPC on a larger scale by developing support systems for computer-aided data bases and equipment and process-tracking methodology; developing and implementing new diagnostic techniques; reducing acid use and waste products by introducing a new dry-etch process; and formalizing documentation and training procedures for manufacturing processes (ISO 9000) and for waste product and safety management (ISO 14000) to assist in handling the larger manufacturing organization. Low-Cost Processes, we report on progress in demonstrating low-damage, high-throughput laser technology; studies on Rapid Thermal Processing approaches to improving cell efficiency; evaluating new thin-wafer technology using EFG cylinders; and developing a large EFG octagon and laser-cutting technology for producing 12.5 cm x 12.5 cm wafers. For Flexible Manufacturing, we completed introduction of manufacturing data bases for wafer and cell manufacturing; process modifications to accommodate manufacture of 10 cm x 15 cm wafers; and module field-performance studies and defect tracking to be used to improve manufacturing processes, new encapsulant qualification and introduction into manufacturing, and progress in developing designs for low-cost modules.

• Research Organization: National Renewable Energy Lab. (NREL), Golden, CO (United States)
• Sponsoring Organization: US Department of Energy (US)
• DOE Contract Number: AC36-99-GO10337
• OSTI ID: 15000365
• Report Number(s): NREL/SR-520-31722; ZAX-8-17647-10; TRN: US200325%%250
• Resource Relation: Other Information: PBD: 1 Mar 2002; Related Information: Work performed by ASE Americas, Billerica, Massachusetts
• Country of Publication: United States
• Language: English

Related Subjects

14 SOLAR ENERGY
DEFECTS
DIAGNOSTIC TECHNIQUES
DOCUMENTATION
EFFICIENCY
LASERS
MANAGEMENT
MANUFACTURING
MODIFICATIONS
PROCESSING
SAFETY
TRAINING
WASTES
SOLAR ENERGY
PV
MANUFACTURING LINE
EFG PV MODULE
SOLAR CELL EFFICIENCIES
DRY-ETCH PROCESS
OCTAGON AND LASER-CUTTING TECHNOLOGY
LOW-COST MODULES
LAMINATION STRUCTURE
MULTICRYSTALLINE SI SOLAR CELLS
SILICON NITRIDE ANTIREFLECTION COATING
PLASMA FLAME CONFIGURATION
EFG WAFER
SOLAR ENERGY - PHOTOVOLTAICS