PVMaT Improvements in the BP Solar Photovoltaic Module Manufacturing Technology: Final Subcontract Report, 4 May 1998 - 30 November 2001

Wohlgemuth, J. ; Shea, S.

National Renewable Energy Laboratory (U.S.)

关键词: Pv;    36 Materials Science;    Casting;    Efficiency;    Anti-Reflection Coating;   

DOI  :  10.2172/15000440
RP-ID  :  NREL/SR-520-32066
RP-ID  :  AC36-99-GO10337
RP-ID  :  15000440

美国|英语

来源: UNT Digital Library

【 摘 要 】

This report describes the advancement of BP Solar PV manufacturing technologies in order to design and implement a process that produces polycrystalline silicon PV modules that can be sold profitably for $2.00 per peak watt or less and that increases the production capacity of the Frederick plant to at least 25 megawatts per year. Achieving these major objectives was based on meeting the following specific task goals: (1) Develop a process to produce silicon feedstock from Na2SiF6 that can be sold profitably for less than $15/kilogram in large quantities. Demonstrate the process in a pilot facility. (2) Optimize and improve control of the casting process to increase the process yield by 7% and to improve material quality such that average cell efficiency increases by 4%. (3) Reduce the center-to-center cut distance on the wire saw to less than 450?mm in production, and develop a wire saw process that reduces the consumable costs by at least $0.05/wafer, that does not require organic cleaners, nor result in generation of hazardous waste material. (4) Develop, demonstrate, and implement a cost-effective cell process that produces a minimum average cell efficiency of 15% and improves the cell line electrical yield by 5% when applied to BP Solar cast polycrystalline silicon wafers. (5) Develop and qualify an encapsulation system that meets all technical and reliability requirements and can be laminated and cured in less than 6 minutes. (6) Improve BP Solar's product and materials handling to increase line yield by 3% and reduce handling labor to save $0.05/watt. (6) Improve process measurement and control in the production line to improve yield by 3% and reduce rework by 50%.