3 - Solar cell manufacture and module packaging

Abstract

This chapter focuses on the silicon manufacturing process and the production of silicon solar cells. In the beginning, the process of converting sand to silicon and afterward, the production of solar cells from silicon wafers are reviewed. Then, the latest silicon cell technologies including the interdigitated back contact cells, and passivated emitter and rear contact cells are introduced which can achieve a nominal average efficiency of ∼25%. Later, the different steps in solar module production are discussed starting from the interconnection materials, stringing and tabbing, encapsulation, backsheet, and lamination. Finally, quality control in the solar module manufacturing and common issues in the manufacturing are explained toward higher quality solar panels. The case studies at the end of the chapter include the building integrated photovoltaic (BIPV) system at the Water and Life museum in California and the solar ring at Metlife stadium in New Jersey, which show the applications of large scale BIPV systems in commercial structures.