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

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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 ... continued below

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30 p.

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Wohlgemuth, J. February 1, 1996.

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Description

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.

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30 p.

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OSTI as DE96000527

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  • Other Information: PBD: Feb 1996

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  • Other: DE96000527
  • Report No.: NREL/TP--411-20589
  • Grant Number: AC36-83CH10093
  • DOI: 10.2172/195684 | External Link
  • Office of Scientific & Technical Information Report Number: 195684
  • Archival Resource Key: ark:/67531/metadc670205

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  • February 1, 1996

Added to The UNT Digital Library

  • June 29, 2015, 9:42 p.m.

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  • March 31, 2016, 8:41 p.m.

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Wohlgemuth, J. Cast polycrystalline silicon photovoltaic module manufacturing technology improvements. Semiannual subcontract report, January 1--June 30, 1995, report, February 1, 1996; Golden, Colorado. (digital.library.unt.edu/ark:/67531/metadc670205/: accessed June 18, 2018), University of North Texas Libraries, Digital Library, digital.library.unt.edu; crediting UNT Libraries Government Documents Department.