Large-Scale PV Module Manufacturing Using Ultra-Thin Polycrystalline Silicon Solar Cells: Annual Subcontract Report, 1 April 2002--30 September 2003 (Revised)

Abstract

NOTICE This report was prepared as an account of work sponsored by an agency of the United States government. Neither the United States government nor any agency thereof, nor any of their employees, makes any warranty, express or implied, or assumes any legal liability or responsibility for the accuracy, completeness, or usefulness of any information, apparatus, product, or process disclosed, or represents that its use would not infringe privately owned rights. Reference herein to any specific commercial product, process, or service by trade name, trademark, manufacturer, or otherwise does not necessarily constitute or imply its endorsement, recommendation, or favoring by the United States government or any agency thereof. The views and opinions of authors expressed herein do not necessarily state or reflect those of the United States government or any agency thereof. The following personnel at BP Solar have contributed to the technical efforts covered in this report. The major objectives of this program are to continue the advancement of BP Solar polycrystalline silicon manufacturing technology. The Program includes work in the following areas. • Efforts in the casting area to increase ingot size, improve ingot material quality, and improve handling of silicon feedstock as it is loaded into the casting stations. • Developing wire saws to slice 100 µm thick silicon wafers on 200 µm centers. • Developing equipment for demounting and subsequent handling of very thin silicon wafers. • Developing cell processes using 100 µm thick silicon wafers that produce encapsulated cells with efficiencies of at least 15.4% at an overall yield exceeding 95%. • Expanding existing in-line manufacturing data reporting systems to provide active process control. • Establishing a 50 MW (annual nominal capacity) green-field Mega-plant factory model template based on this new thin polycrystalline silicon technology. • Facilitating an increase in the silicon feedstock industry's production capacity for lower-cost solar grade silicon feedstock. ACCOMPLISHMENTS During the first year of the program there were significant accomplishments in each of the task areas. As part of the feedstock task a review of materials requirements and a ranking of material types were completed. Materials were ranked for use in casting based on minority carrier lifetime, factory yield and the distribution of cell efficiencies. A factory cost module was utilized to rank the types of silicon feedstock based on their cost to produce a watt of finished solar cells. Finally, developmental relationships were established with several feedstock vendors to provide …

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@inproceedings{Shea2002LargeScalePM, title={Large-Scale PV Module Manufacturing Using Ultra-Thin Polycrystalline Silicon Solar Cells: Annual Subcontract Report, 1 April 2002--30 September 2003 (Revised)}, author={Stephen P. Shea and Dinesh Amin and Fiore Artigliere and James Cliber and Roger Clark and Mark Conway and Joseph Creager and Danny Cunningham and Paul Garvison and George Kelly and Shaun Kendle and Bonnie Kinsey and Timothy Koval and M. Narayanan and Andy Nguyen and Jean Posbic and William Poulin and Paul Schneider and Jay Shaner and George Winstead and John H. Wohlgemuth and Murray Bennett and Haibin Yu and Jim Newton}, year={2002} }