Cast polycrystalline silicon photovoltaic cell and module manufacturing technology improvements

The objectives of this NREL sponsored Phase 2B Photovoltaic Manufacturing Technology (PVMaT) Program were to advance Solarex's cast polycrystalline silicon manufacturing technology, reduce module production cost in half, increase module performance and expand Solarex's commercial production capacity by a factor of three. To meet these objectives Solarex: I) Modified the casting process and stations and is now casting larger ingots in production; 2) Developed wire saw technology to cut wafers with less kerf loss and is now using wire saws for more than 80% of wafering production; 3) Developed an aluminum paste back surface field (BSF) process to increase cell efficiency by 5% and has transferred this process to production using a fully automated printing system; 4) Completed modifications to the module assembly area to reduce labor and to increase capacity by a factor of three; and 5) Developed a frameless module with a lower cost backsheet and a simple, low cost electrical termination system.