skip to main content
OSTI.GOV title logo U.S. Department of Energy
Office of Scientific and Technical Information

Title: Cast polycrystalline silicon photovoltaic module manufacturing technology improvements. Semiannual subcontract report, January 1--June 30, 1995

Abstract

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,more » 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.« less

Authors:
 [1]
  1. Solarex Corp., Frederick, MD (United States)
Publication Date:
Research Org.:
National Renewable Energy Lab., Golden, CO (United States); Solarex Corp., Frederick, MD (United States)
Sponsoring Org.:
USDOE, Washington, DC (United States)
OSTI Identifier:
195684
Report Number(s):
NREL/TP-411-20589
ON: DE96000527; TRN: AHC29605%%60
DOE Contract Number:  
AC36-83CH10093
Resource Type:
Technical Report
Resource Relation:
Other Information: PBD: Feb 1996
Country of Publication:
United States
Language:
English
Subject:
14 SOLAR ENERGY; 36 MATERIALS SCIENCE; SILICON SOLAR CELLS; MANUFACTURING; SILICON; CASTING; PROGRESS REPORT; SIZE; COST; MECHANICAL PROPERTIES; MATERIALS HANDLING; POLYCRYSTALS; NUMERICAL DATA

Citation Formats

Wohlgemuth, J. Cast polycrystalline silicon photovoltaic module manufacturing technology improvements. Semiannual subcontract report, January 1--June 30, 1995. United States: N. p., 1996. Web. doi:10.2172/195684.
Wohlgemuth, J. Cast polycrystalline silicon photovoltaic module manufacturing technology improvements. Semiannual subcontract report, January 1--June 30, 1995. United States. doi:10.2172/195684.
Wohlgemuth, J. Thu . "Cast polycrystalline silicon photovoltaic module manufacturing technology improvements. Semiannual subcontract report, January 1--June 30, 1995". United States. doi:10.2172/195684. https://www.osti.gov/servlets/purl/195684.
@article{osti_195684,
title = {Cast polycrystalline silicon photovoltaic module manufacturing technology improvements. Semiannual subcontract report, January 1--June 30, 1995},
author = {Wohlgemuth, J},
abstractNote = {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.},
doi = {10.2172/195684},
journal = {},
number = ,
volume = ,
place = {United States},
year = {1996},
month = {2}
}