Cast polycrystalline silicon photovoltaic module manufacturing technology improvements. Semiannual subcontract report, January 1--June 30, 1995
- Solarex Corp., Frederick, MD (United States)
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. To achieve these objectives, Solarex is working in the following technical areas: casting, wire saws, cell process, module assembly, frameless module development, and automated cell handling. Accomplishments reported include: Cast first successful larger ingot producing 73% larger volume of usable Si; Increased the size of the ingot even further and cast an ingot yielding nine 11.4 {times} 11.4 cm bricks, representing a 125% increase in usable Si from a single casting; Operated the wire-saw in a semi-operational mode, producing 459,000 wafers at 94.1% overall yield; Reduced the cost of wire-saw consumables, spare parts, and waste disposal; Developed a cost-effective back surface field process that increases cell efficiency by 5% and began production trials; Developed a plan for increasing the capacity in the module assembly area; Completed qualification testing of modules built using Spire`s automated tabbing and stringing machine; Selected, tested, and qualified a low-cost electrical termination system; Completed long-term UV testing of experimental back sheets; Qualified the structure and adhesive-tape system for mounting frameless modules; and ARRI completed a study of the fracture properties of cast polycrystalline Si wafers and provided the information necessary to calculate the maximum stresses allowable during wafer handling.
- Research Organization:
- National Renewable Energy Lab. (NREL), Golden, CO (United States); Solarex Corp., Frederick, MD (United States)
- Sponsoring Organization:
- USDOE, Washington, DC (United States)
- DOE Contract Number:
- AC36-83CH10093
- OSTI ID:
- 195684
- Report Number(s):
- NREL/TP-411-20589; ON: DE96000527; TRN: AHC29605%%60
- Resource Relation:
- Other Information: PBD: Feb 1996
- Country of Publication:
- United States
- Language:
- English
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