Electricity from photovoltaic solar cells: Flat-Plate Solar Array Project final Report. Volume III: Silicon sheet: wafers and ribbons

Abstract

The Flat-Plate Solar Array (FSA) Project, funded by the U.S. Government and managed by the Jet Propulsion Laboratory, was formed in 1975 to develop the module/array technology needed to attain widespread terrestrial use of photovoltaics by 1985. To accomplish this, the FSA Project established and managed an Industry, University, and Federal Government Team to perform the needed research and development. The primary objective of the Silicon Sheet Task of the FSA Project was the development of one or more low-cost technologies for producing silicon sheet suitable for processing into cost-eompetitive solar cells. Silicon sheet refers to high-purity crystalline silicon of size and thickness for fabrication into solar cells. The Task effort began with state-of-the-art sheet technologies and then solicited and supported any new silicon sheet alternatives that had the potential to achieve the Project goals. A total of 48 contracts were awarded that covered work in the areas of ingot growth and casting, wafering, ribbon growth, other sheet technologies, and programs of supportive research. Periodic reviews of each sheet technology were held, assessing the technical progress and the long-range potential. Technologies that failed to achieve their promise, or seemed to have lower probabilities for success in comparison with others, were dropped. A series of workshops was initiated to assess the state of the art, to provide insights into problems remaining to be addressed, and to support technology transfer. The Task made and fostered significant improvements in silicon sheet including processing of both ingot and ribbon technologies. An additional important outcome was the vastly improved understanding of the characteristics associated with high-quality sheet, and the control of the parameters required for higher efficiency solar cells. Although significant sheet cost reductions were made, the technology advancements required to meet the Task cost goals were not achieved. This FSA Final Report (JPL Publication 86-31, 5101-289, DOE/JPL 1012-125, October 1986) is composed of eight volumes, consisting of an Executive Summary and seven technology reports: Volume I: Executive Summary. Volume II: Silicon Material. Volume III: Silicon Sheet: Wafers and Ribbons Volume IV: High-Efficiency Solar Celis. Volume V: Process Development. Volume VI: Engineering Sciences and Reliability. Volume VII: Module Encapsulation. Volume VIII: Project Analysis and Integration. Two supplemental reports included in the final report package are: FSA Project: 10 Years of Progress, JPL Document 400-279. 5101-279, October 1985. Summary of FSA Project Documentation: Abstracts of Published Documents, 1975 to 1986, JPL Publication 82-79 (Revision 1),5101-221, DOE/JPL-1 012-76, September 1986.

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