EFG Technology and Diagnostic R&D for Large-Scale PV Manufacturing; Final Subcontract Report, 1 March 2002 - 31 March 2005

Abstract

The objective of this subcontract was to carry out R&D to advance the technology, processes, and performance of RWE Schott-Solar's wafer, cell, and module manufacturing lines, and help configure these lines for scaling up of edge-defined, film-fed growth (EFG) ribbon technology to the 50-100 MW PV factory level. EFG ribbon manufacturing continued to expand during this subcontract period and now has reached a capacity of 40 MW. EFG wafer products were diversified over this time period. In addition to 10 cm x 10 cm and 10 cm x 15 cm wafer areas, which were the standard products at the beginning of this program, R&D has focused on new EFG technology to extend production to 12.5 cm x 12.5 cm EFG wafers. Cell and module production also has continued to expand in Billerica. A new 12-MW cell line was installed and brought on line in 2003. R&D on this subcontract improved cell yield and throughput, and optimized the cell performance, with special emphasis on work to speed up wafer transfer, hence enhancing throughput. Improvements of wafer transfer processes during this program have raised cell line capacity from 12 MW to over 18 MW. Optimization of module manufacturing processes was carried out on new equipment installed during a manufacturing upgrade in Billerica to a 12-MW capacity to improve yield and reliability of products.