Innovative Approaches to Low Cost Module Manufacturing of String Ribbon Si PV Modules: Phase II, Annual Technical Progress Report, 1 April 2003--31 May 2004

Technical Report · Fri Oct 01 00:00:00 EDT 2004

DOI:https://doi.org/10.2172/15009940· OSTI ID:15009940

Hanoka, J I

This subcontract resulted in a number of important advances for Evergreen Solar Inc. Foremost amongst these is the production implementation of dual ribbon growth from a single crucible (Gemini) using the String Ribbon continuous ribbon technology. This project has resulted in the flattest ribbon and the highest yields and machine uptime ever seen at Evergreen Solar. This then has resulted in significantly lowered consumables costs and lower overall direct manufacturing costs. In addition, methods to control the as-grown surface of Gemini ribbon have permitted the usage of the so-called no-etch process that allows for direct transfer of as-grown ribbon to diffusion without any intermediate etching step. In-line diagnostics for Gemini were further developed--these included more accurate methods for measuring and controlling melt depth and more accurate means to measure and control ribbon thickness. Earlier in the project, the focus was on monolithic module development. With the Gemini advances described above, monolithic module work was brought to a close during this second year of the overall three year project. A significant advance in this technology was the development of a conductive adhesive in combination with Evergreen's proprietary backskin and encapsulant. 25-W size experimental monolithic modules have been tested and found to be able to withstand up to 1400 thermal cycles.

• 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: 15009940
• Report Number(s): NREL/SR-520-36908; ZDO-2-30628-09; TRN: US200430%%1907
• Resource Relation: Other Information: PBD: 1 Oct 2004; Related Information: Work performed by Evergreen Solar, Inc., Marlboro, Massachusetts
• Country of Publication: United States
• Language: English

Related Subjects

14 SOLAR ENERGY
36 MATERIALS SCIENCE
42 ENGINEERING
ADHESIVES
CRUCIBLES
DIFFUSION
ETCHING
IMPLEMENTATION
MANUFACTURING
PRODUCTION
PROGRESS REPORT
THICKNESS
PV MODULE
MANUFACTURER
STRING RIBBON
GEMINI-DUAL RIBBON GROWTH
NO-ETCH PROCESS
MONOLITHIC
CONDUCTIVE ADHESIVE
BACKSKIN
ENCAPSULANT
COEFFICIENT OF THERMAL EXPANSION (CTE)
OXIDE THICKNESS
IN-SITU DIAGNOSTICS
THERMAL CYCLES
SOLAR ENERGY - PHOTOVOLTAICS