Large-scale PV module manufacturing using ultra-thin polycrystalline silicon solar cells

This paper will report on the work performed by BP Solar during the first two years of NREL PVMaT subcontract #ZDO-2-30628-03. The major objectives of this program are to continue the advancement of BP Solar´s multicrystalline silicon manufacturing technology to: increase ingot size; improve ingot material quality; develop wire saws to slice 100 μm thick silicon wafers; develop equipment for demounting and handling of ultra-thin wafers; develop cell processes that produce cells with efficiencies of at least 15.4% at an overall yield exceeding 95%; expand existing in-line manufacturing data reporting systems; establish a 50 MW factory model; and facilitate an increase in the silicon feedstock industry´s production capacity for lower-cost solar grade feedstock.