Automated array assembly. Final report

Abstract

Three main sections are included which describe a general technology assessment and manufacturing cost analysis; a near-term (1982) factory design; and the results of an experimental production study for the large-scale production of flat-panel silicon solar-cell arrays. The results of an extensive study and detailed analysis of technologies which could be related to array module manufacturing are presented. From this study, several manufacturing sequences emerge as candidates for satisfying the ERDA/JPL cost goal of $0.50/W selling price in 1986. A minimum manufacturing cost was found in a highly automated line of $0.30/W assuming the silicon is free. The panels are of a double-glass construction and are based on round wafers. Screen-printed silver has been used as the metallization with a spray-coated antireflection (AR) layer. The least expensive junction-formation technology appears to be ion implantation;however, several other technologies also may be used with very little cost penalty as described. An interim 1982 factory is described for the large-scale production of silicon solar-cell array modules. The boundary conditions for this design are the use of Czochralski silicon crystals and $25/kg polycrystalline silicon. The objective is a large-scale production facility to meet an intermediate ERDA cost goal of $2.00/W in 1982. A 6-month experimental production study of the elements of low-cost solar-cell manufacturing sequences is described as an outgrowth of the cost and manufacturing studies. This program consisted of three parts: an experimental production line study of the major variables associated with the fabrication of 3-in.-diameter silicon solar cells; a study of thick-film screen-printed silver metallization; and panel design and assembly development. (WHK)