Silicon-Film(TM) Photovoltaic Manufacturing Technology: Annual Subcontract Report, 1 January 1994 - 31 December 1994

This report describes work performed by AstroPower to develop an advanced, low-cost manufacturing process for a new utility-scale, flat-plate module. This process starts with the production of continuous sheets of thin-film, polycrystalline silicon using the Silicon-Film(TM) process. The main product focus is a 240-cm2 solar cell. Continuous sheets of silicon are produced and cut into wafers thatare 15.5 cm on a side. Both standard modules (36 solar cells) and a new 56-cell module were produced. The targeted high-power module design is a 170-W module, used in a 12-module array to generate 2 kW. The project relies on the parallel development of three technologies: (1) a growth technique that produces high quality, polycrystalline sheets at high generation rates, (2) a solar cellfabrication technique that captures the material's potential while qualifying as low cost manufacturing, and (3) a module fabrication process that efficiently integrates the solar cells into a utility-scale power source. Accordingly, project results are presented in three sections that discuss basic development: (1) the Silicon-Film(TM) sheet fabrication process, (2) solar cell fabrication, and(3) module assembly.