PVMaT Improvements in the Solarex Photovoltaic Module Manufacturing Technology: Annual Subcontract Report, 5 May 1998-30 April 1999

This report describes work done by Solarex during the first year of this subcontract. The objective of this three-year PVMaT program is to continue the advancement of Solarex PV manufacturing technologies 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 will increase the production capacity ofthe Frederick plant to at least 25 megawatts per year. ; Accomplishments during the first year of the program include:; 1? Verification of the process to produce SiF4, the precursor to silicon feedstock.; 2? Design of a silicon feedstock pilot facility using the SiNaF process.; 3? Development of and transfer to manufacturing of a process to use thinner wire in the wire saw.; 4? Completion of aproduction trial with recycled SiC.; 5? Laboratory development of a selective emitter process using rapid thermal processing.; 6? Fabrication of high-efficiency polycrystalline cells using silicon nitride from three different sources.; 7? Development of a new encapsulation formulation and laboratory demonstration of a 6-minute lamination cycle.; 8? Implementation of an automated laminator.; 9?Laboratory demonstration of automated handling of ceramics.;