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Innovative Approaches to Low-Cost Module Manufacturing of String Ribbon Si PV Modules

机译：弦带si光伏组件低成本模块制造的创新方法

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A three year PV Manufacturing Research and Development subcontract has resulted in major gains for Evergreen Solar. As a result of this work, Evergreen is now poised to take String Ribbon technology to new heights. In the ribbon growth area, project Gemini - the growth of dual ribbons from a single crucible-has reached or exceeded all the manufacturing goals set for it. This project grew from an R&D concept to a production pilot phase and finally to a full production phase, all within the span of this subcontract. A major aspect of the overall effort was the introduction of controls and instrumentation as in-line diagnostic tools. In the ribbon production area, the result has been a 12% increase in yields, a 10% increase in machine uptime, and the flattest ribbon ever grown at Evergreen. In the cell area, advances in process development and robotic handling of Gemini wafers have contributed, along with the advances in crystal growth, to a yield improvement of 6%. Particularly noteworthy in the cell area was the refinement of the no-etch process whereby the as-grown ribbon surface could be controlled sufficiently to allow this process to succeed as well as it has. This process obviates any need for wet chemistry or etching between ribbon growth and diffusion. Evergreen's factory in Marlboro, MA, has expanded to a maximal capacity of about 15 MW/yr. The net result of all of this has been a reduction of 33% in direct manufacturing costs, a very notable achievement. Earlier in the project, the focus was on monolithic module development. With the Gemini advances described above, the focus of the entire project changed and the monolithic module work was brought to a close during this second year of the overall three year project. A significant advance in this technology was the development of a conductive adhesive in combination with Evergreen's proprietary backskin and encapsulant. 25 W size experimental monolithic modules have been tested and found to able to withstand up to 1600 thermal cycles.

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