19th Project Integration Meeting Handout...5101-192 Department of Energy Flat-Plate Solar Array Project 19th Project Integration Meeting Handout Pasadena Center November 11, 1981 Jet

5101-192

Department of Energy

Flat-Plate Solar Array Project

19th Project Integration Meeting

Handout

Pasadena Center November 11, 1981

Jet Propulsion Laboratory

California Institute of Technology

Pasadena, California

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Prepared by the Je t Propulsion Labora tory, California Inst itute of Technology, for the Department of Energy through an agreement with the National

Aeronautics a nd Space Administration .

The J PL r-Iat-Platc Solar Array Project is spo nsored by the Department of Energy (DOE) and forms part of the Photovol taic Energy Systems Program to init iate a major effort toward the development of cost-competit ive solar arrays.

This report was prepared as an account of work sponsored by the United States Government . Neither the United States no r the United States Department of Energy, nor any of their employees, nor any of their contractors, subcontractor s, or their employees, makes any warranty, express or implied , or assumes any legal liability or responsibility for the accuracy, completeness or usefu lness of a ny information, apparatus, prod uct or process disclosed, or represents that its use would not infringe privately owned rights.

Reference herein to any specific commercial product, process, or service by trade name, trademark , manufacturer , o r otherwise, does not necessarily constitu te or imply its endorsement, recommendations, or favor ing by the Uni ted States Government or any agency thereof. The views and opinions of authors expressed herein do not necessa rily state or reflec t th ose of the Uni ted States Government

or any agency the reof.

REMINDER: Please bring this Handout

with you to the PIM

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5101-192

Department of Energy

Flat-Plate Solar Array Project

19th Project Integration Meeting

Handout

Pasadena Center November 11, 1981


California Institute of Technology


I TECHNOLOGY

DEVELOPMENT AREA

K.M. KOLIWAD, MGR M. LEIPOLD, DEP. MGR

-

-

-

SILICON MATERIAL TASK

R. LUTWACK, MGR

LARGE-AREA SI LICON SHEET TASK

J. K. LIU, MGR

ENCAPSULATION TASK

C. COULBERT I MGR

FLAT-PLATE SOLAR ARRAY PROJECT

STAFF

E. CHRISTENSEN D.G. TUSTIN

I PROCESS

DEVELOPMENT AREA

D. B. BICKLER, MGR

- PROCESS AUTOMATION

- NEWLY DEVELOPED PROCESSES

- TECHNOLOGY TRANSFER

- TECHNOLOGY ASSESSMENT

- NEAR-TERM COST REDUCTION

PROJECT MANAGER W. T. CALLAGHAN

DEPUTY MANAGER R.R. McDONALD

SECY: M. J. PHILLIPS

ANALYSIS AND INTEGRATION

AREA

P.K. HENRY, MGR

- PROJECT INTEGRATION

- ARRAY TECHNOLOGY COSTS

- ECONOMICS AND INDUSTRIALIZATION

FINANCIAL B. S. LENCK, MGR

PROCUREMENT P.S. RYKEN

QUALITY ASSURANCE R.L. MORCK

I ENGINEERING

AREA

R.G. ROSS, MGR

- ARRAY DESIGN REQUIREMENTS

- ARRAY SUBSYSTEM ENGINEERING

- ARRAY COMPONENT ENGINEERING

- RELIABILITY ENGINEERING

- PERFORMANCE CRITERIA AND TEST METHODS

I OPERATIONS

AREA

L. D. RUNKLE, MGR

- MODULE DEVELOPMENT

- PROBLEM-FAILURE REPORTING AND ANALYSIS

- ENVIRONMENT AL TESTS

..,_ PERFORMANCE MEASUREMENTS

-MODULE CONTROL

Fl. !

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CONTENTS

INTRODUCTION •••••••• . . . . . •. . . . . . . . MAP: Meeting Locations . . . . . . . AGENDA • • • • • • • . . . . . . . . . . . . .

1

2

3

9

9

TECHNICAL SUMMARIES

Silicon Material

Large-Area Silicon Sheet. . . . . . . . . . . . . . . . 15

27

35

43

57

71

15

Encapsulation . . . . . . Process Development Area ••

Engineering

Operations •

. . . . . . . . . . . . . .

. . . .. . . LSA PROJECT ACTIVE CONTRACTS ••

LSA PROJECT PUBLISHED DOCUMENTS . . . . . . . . . . MAPS: Pasadena Area and Pasadena Center ••

For Your Information

. . . .

Inside Back

Cover

Check-in: Please check in at the registration desk on the lower level of the conference building before the start of the meeting on Wednesday morning.

Telephone Messages: Incoming calls will be received at JPL on (213) 577-9520. Constant coverage of this phone will be provided and messages will be transmitted.

BADGES: We will appreciate your returning your badges at the end of the meeting. You will find deposit boxes at the lower-level exits.

iii

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INTRODUCTION

The 19th Project Integration Meeting (PIM) for the Flat-plate Solar Array (FSA) Project (formerly Low-cost Solar Array Project) will be held at the Pasadena Center on November 11, 1981. It will be conducted differently from previous PIMS in that it will be only a one-day meeting, consisting primarily of parallel technology sessions for an assessment of recent Project progress since the last PIM in July. The usual plenary sessions with emphasis on a theme or themes, special topic sessions, and displays will be omitted. Late in the afternoon, brief summaries of the Critical Technology Workshops and of FSA progress will be presented.

On Tilursday and Friday, a number of PIM participants will attend the SAMICS short course held at the Pasadena Center. It is hoped that they will find it timely and useful.

All of us have felt the pinch of DOE's reduced photovoltaic budget. It is difficult to reduce and/or eliminate efforts that we believe contribute to the advancement of the national photovoltaic effort; nonetheless, that must be done. We believe, however, that significant, worthwhile activities will continue during FY82 based on the still-substantial budget for the year.

1

EXIT

MEETING LOCATIONS

C 314 C 304 C 306

C305 0307

C312 I

OPEN AREA To ~ III LOWER LEVEL

Ill II L..J-9-, ffl ~~ L =:J C 326 C 324 n- EI.EVIQOIIS n C 316

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CONFERENCE BUILDING PLAZA LEVEL

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C 101 C 102 C 103 C 104 C 105

ell IY IUl lb

I JI D EXHIBIT AREA D I[

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C 112 LITTLE llEATAE

l=EJ _L FREIGHTDOOA

CONFERENCE BUILDING LOWER LEVEL

2

LOADING DOCK

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FLAT-PLATE SOLAR ARRAY

PROJECT INTEGRATION MEETING

AGENDA

Wednesday November 11, 1981

Pasadena Center

7: 30 Registration EXHIBIT AREA (Lower Lobby)

Room

8 : 30 Announcements C124 W. Callaghan 45 minutes

DOE PV Pol icy & Guidelines DOE

FSA Plans fo r 1982 W. Callaghan

Coffee a v a i l a b l e i n EXHIBIT AREA dur ing morning t o coinc ide with indiv idual s e s s i o n chairmen's schedule.

9: 25 Technology Sessions 3 hours

S i l i c o n Material C312 R. Lutwack S i l i con Sheet C316 J. L ~ U

~ n c a p s u l a t i o n C301 C. Coulbert Process Development C324 D. ~ i c k l e r ~ngineering/Operations/~~&~ C124 R. Ross/D. Runkle/P. Henry

12:25 Lunch

Coffee a v a i l a b l e i n EXHIBIT AREA dur ing a£ ternoon t o coincide with indiv idual s e s s i o n chairmen's schedule.

1:30 Technology Sessions (continued - rooms a s above) 3 hours

5:00 Summaries

5 : 4 5 Socia l Hour

ClZ4

EXHIBIT AREA

45 minutes

9:45

10:30

11: 15

11:30

12:15

1:45

2:00

2:30


CHAIRMAN: Ralph Lutwack


Room C312

Silane/Silicon Process

Hydrochlorination Process

Coffee Available

Dichlorosilane CVD Process

Lunch

Process Analysis

Effects of Impurities on Solar Cell Performance

In-house Silicon Program

4

Union.Carbide Corp.

Solarelectronics

Hemlock Semiconductor

Texas Res. & Eng. Inst.

C. T. Sah Associates

JPL

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9:25

10:05

10:45

11: 20

12:00

1:30

2:10

2:50

3:30

LARGE AREA SILICON SHEET TASK

CHAIRMAN: Jim Liu


Room C316

Internal Diameter Wafering (ID)

Fixed Abrasive Slicing Technique (FAST)

Multiple Blade Slurry Sawing (MBS)

Ubiquitous Crystallization Process (UCP)

Lunch

Advanced Czochralski Ingot Growth (Adv. CZ)

Dendritic Web Ribbon (Web)

Edge Defined Film Fed (EFG)

Cell Fabrication

4:10 Discussion

5

Silicon Tech. Corp.

Crystal Systems, Inc.

Norlin Indus try

SEMIX, Inc.

Kayex Corporation

Westinghouse

Mobil-Tyco

Applied Solar Energy Corporation

ENCAPSULATION TASK

CHAIRMAN: Cliff Coulbert


Room C301/302

TOPICS: Encapsulation Engineering

9:25

9:45

10:30

10:50

11: 05

11:25

12:25

Encapsulation Technology Transfer

Materials Development

Advanced Encapsulant Test Results

Ion-plating

Primer Technology

Encapsulant Design Analysis and Test Verification

Lunch

TOPICS: Material Durability and Life Testing

1:30

1:45

2:00

2:30

3:00

3:30

Module Life Assessment Status

Encapsulation Material Stability

Photodegradation Modeling

Development of Polymer Stabilizers

Interface Degradation and Corrosion

Photothermal Characterization of Polymers

6

c. Coulbert

Springborn Labs

P.Frickland

Illinois Tool Works

E. Pluddemann

Spectrolab/Hughes

C. Coulbert

A. Gupta

Univ. of Toronto

Univ. of Massachusetts

Science Center

R. Liang

r I

b

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9:25

9:35

10:20

ll:05

11: 35

12:00

12:25

1 :45

2: 15

2:45

3: 15

3:45

4: 15

LJ

Introduction

Process Sequence

Process Sequence

PROCESS DEVELOPMENT AREA

CHAIRMAN: Don Bickler


Room C324

Junction Formation

Ion Implantation

Automation

Lunch

Metallization

Assembly

Coffee Break

Process Sequence

Assessment

End of Meeting

7

Don Bickler

Westinghouse

Solarex

Spire

Dennis Fitzgerald

Robotics

Bernd Ross Associates

Tracor MB Associates

Photowatt

Univ. of Pennsylvania

9:25

10:00

10:25

10:45

11 :OS

11:25

11:45

12:25

1:30

2:10

2:30

2:50

3:10

3:30

3:50

4: 10

ENGINEERING/OPERATIONS/PA&!

CHAIRMEN: Dan Runkle and Ron Ross


Room Cl24

Module Development Task Update

Qualification Test Results on MIT/RES Modules

Residential Module Fire Testing

Block V Hot Spot Test Experience

MIT/LL Residential and Field Test Results

Module Reliability and PV Homeowner Economics

Advanced Residential Array Development ? /7,,f/Jl---:S Pote ,::;. ri! xS j /L,f~~u, c.!J 1 kf ~W -bA>".S ,.c~,e. s;-~~,J (

Lunch

Advanced Residential Array Development

Array Grounding and Electrical Safety

Power Conditioner Array Interface Considerations

Bypass Diode Integration into Modules

Module Cooling Under Field Wind Conditions

Interconnect Fatigue Update

Interpretation of Laser Scan Data

Voltage Breakdown Testing Status

8

D. Runkle

J. Griffith

D. Otth

J. Griffith

Mass. Inst. of Tech.

P. Henry

AIA/RC

General Electric

Underwriters Lab

C. Gonzalez

General Electric

L. Wen

G. Mon

A. Shumka

G. Mon

r L

J 7,..C. r/:.e' ,1/l j~c.1~/?c,.-g

//J a /o · 2 S - J' / TECHNICAL SUMMARIES

l/cJo &l r J./~,t 17"t rJ .J .:SO C.,0-.f e.7l. C r C /t /°.,

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In-House Program


Jet Propulsion Laboratory Pasadena, California

The objective of this effort is to provide support to the Silicon Material Task in selected critical areas.

A six-inch-diameter fluidized-bed reactor (FBR) for making silicon (Si) by pyrolysis of silane was designed on the basis of test results of a two-inch-diameter FBR, and fabrication was completed. The six-inch size was selected as being appropriate for obtaining data that would be applicable to the design of production-size units as well as being the same diameter as the FBR in Union Carbide Corporation's R & D program. Construction of the test system was also completed. Experiments are expected to start around the middle of January 1982.

An installation for cold-flow testing of distributors, employing a transparent, six-inch-diameter FBR, was designed and constructed. Distributors employing a variety of silane gas inletting features will be studied in this facility.

The silane-to-silicon converter was operated over a range of silane flow rates and hydrogen diluent concentrations. Early tests exhibited considerable plugging of the silane inlet orifice, but in subsequent tests, plugging was eliminated by changing the design and position of the inlet orifice. The longest test to-date lasted 20 minutes. At 1600 to 1750uC, the first-produced Si reacts with the carbon reactor and rapidly converts it to silicon carbide,and the reactor pores then fill with Si. It is anticipated that longer operation will result in coating of the wall with Si and the production of high-purity product. The reactor has demonstrated repeated heating and cooling without cracking. Since the present reactor appears too short for obtaining complete conversion of silane to molten Si at moderate flow rates, a longer reactor is being designed.

In the task for the analysis of impurities using thermally stimulated capacitance (TSCAP) measurements, effort was spent in improving the automation of the experiments and measuring known impurities in Si using samples from the Yestinghouse impurity program.

In the task for the analysis of impurities by Zeeman atomic absorption spectroscopy, the spectrometer was calibrated for iron, chromium and copper and used to analyze Si powder from the Union Carbide Corporation process. Six samples of the powder were analyzed for Fe, giving 2.6, 5.6, 6.7, 8.0, 8.5 and 9.0 micrograms of Fe per gram of Si. The values obtained for Cr and Cu were about an order of magnitude lower. The spread in values indicates that the powder is not uniform in Fe content.

(Jc/ik ~ l9J/ I

Date

9

Task I- Silicon Materials Task

Hemlock Semiconductor Corporation

Hemlock, Michigan 48626

Contract Title: Development of a Polysilicon Process Based on Chemical Vapor Deposition (Phase 2)

Contract No.: 955533

The objective of this program is to demonstrate the feasibility of a chlorosilane based chemical vapor deposition process for the production of a low cost-high purity polysilicon. Efforts are currently being expended in the following technical areas:

Operating an intermediate sized dichloro.silane decomposition reactor Operating a process develop~ent unit that produces dichlorosilane Modifying and integrating a Model 11D decomposition reactor to decompose dichlorosilane Evaluating key variables (sensitivity analysis) impact on polysilicon cost for the 1000 MT/Year plant

The integrated PDU - Model SD reactor system was successfully started up in June, 1981. More than twenty-seven reactor runs have been completed at four different operating conditions and analyzed for purity (boron, donor, carbon, and trace heavy elements) decomposition characteristics, and vent gas composition.

The evaluation of the 3" diameter redistribution reactor is complete. The 5" diameter redistribution reactor has been installed and is now operating routinely.

Site selection has been approved for dichlorosilane mixed feed evaluation in a Model 11 D reactor. Critic al long lead items have been identified and have been ordered.

Process flow diagrams for the 1000 MT/Year plant have been updated to reflect current information obtained from the PDU. In addition the 1000 MT/Year plant has been modeled by computer using Advanced System for Process Engineering (ASPEN). Design alternatives can be evaluated and economic evaluations can be performed promptly using this system.

10/6/81 Date

10

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Contract Title:

Contract No. :

SILICON MATERIALS TASK

C. T. SAH ASSOCIATES

Urbana, Illinois

STUDY OF THE EFFECTS OF IMPURITIES ON THE PROPERTIES OF

SILICON MATERIALS AND PERFORMANCE OF SILICON SOLAR CELL

954685

The purpose of this study is to determine the effects of impurities and defects on the performance and permanence of silicon solar cells. It includes theoretical (computer-aided-design) and experimental studies of the effects of impurities on the electrical properties of silicon materials intentionally doped with specific impurity elements, and the effects of these impurities on the impurity related energy level positions, the concentration of these energy levels and the recombination-generation-trapping rates of electrons and holes at these energy levels.

The fifth annual and final technical report is completed and submitted for approval.

During the last quarter, additional analyses and calculations have been carried out on the degradation of the open-circuit voltage due to defects and impurities which short circuit the back-surfacefield junction of high-efficiency silicon solar cells. A two-region developed peJlimeteJt model is used to model the edge defects around the perimeter of the cell and a three-region developed peJlimeteJt model is used to model the bulk defects which are distributed across the backsurface-field junction area.

Measurements of thermal capture rates of holes at the lower and second donor level of Ti in Si have been made from 77 to 144K which are consistent with earlier results. The data are obtained using the capacitance transient method with multiple trap filling (by holes) pulses. These low temperature data join the higher temperature data of Chen-Milnes-Rohatgi (SSE 22, 801, 1979) only moderately well. A comparison of the experimental capture-emission cross section ratio with theory shows that both Ti levels (E,;1+305 and E -231 mV) have donor-like impurity potentials and are electron hon~ states. These results are consistent with the valence bond model in which the two outer shell 4s electrons of Ti [(Ar)3d 24s 2 ] are loosely bound since the 4s radii are 1.477A compared with half of the inter-silicon spacing of 1.18A. The very large capture-emission cross section ratio, 78, at the first donor level (E -231) and the very small ratio, 1/167, at the second donor level (~+305) suggest large lattice relaxation and strong electron-phonon interaction during the electron and hole thermal capture and emission transitions. The configuration entropy is roughly 4k.

C. T. Sah October 9, 1981

Approval Signature Date

11

TASK I SILICON WiATERIAL

SOLARELECTRONICS, INC. Bellingham, Massachusetts.

Contract Title: Investigation of the Hydrochlorination of SiCl4

Contract No.: 9 56 061

A program was initiated in July of this year to study the hydrochlorination of silicon tetrachloride and metallurgical grade (m.g.) silicon to trichlorosilane,

3 Sic14 + 2 H2 + Si ~ ~ 4 SiHC13

This one-year contract is conducted as a complementary research and development program to supplement the engineering process development activities under the JPL/Union Carbide Contract No. 954334 and the JPL/Hemlock Semiconductor Contract No. 955533. Both the Union Carbide silane-to-silicon process and the Hemlock polysilicon process based on chemical vapor deposition utilize the hydrochlorination reaction as the first step to produce the starting material SiHC1

3. Trichloro

silane is also the starting material used in the Siemens process currently practised by the electronics industry for the production of polycrystalline silicon metal. The hydrochlorination reaction is unique in a way that it not only produces the starting SiHC1

3, but

also, it consumes the by-product SiC14 generated in the Siemens process. A summary of the experimental results previously obtained on the hydrochlorination studies is presented. The significance of the hydrochlorination reaction to these three different processes for the production of semiconductor grade silicon is discussed.

While experimental work on the hydrochlorination of Sic14 and m.g. silicon metal has been carried out at Union Carbide and, subsequently, at the Massachusetts Institute of Technology (JPL Contract ~o. 955382), the research and development contract to Solarelectronics is primarily designed to refine specific engineering design criteria and to evaluate new concepts with the ultimate goal of improving efficiency and to reduce cost. This may include a comprehensive corrosion study to select the most suitable material of construction for the hydrochlorination reactor, a fluidization mechanism study to evaluate the merits of the fluidized-bed versus the fixed-bed reactor design and a new concept to recycle chloride waste. An out-line on these research and development efforts is presented.

A 2 inch-diameter and a 4 inch-diameter hydrochlorination reactor will be used for these studies. Design of the hydrochlorination reactor has been completed. Construction and installation of the hydrochlorination apparatus are in progress.

~~~ ~Signature

October 7, 1981. Date

12

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Contract Title:

Contract No. :


TEXAS RESEARCH AND ENGINEERING INSTITUTE

Groves, Texas 77619

SILICON PRODUCTION PROCESS EVALUATIONS

956045

The goals of this program are to perform chemical engineering studies and analyses of the preliminary process design activities for the processes under consideration for production of silicon. The program also includes provisions for performing economic and cost analyses of the polysilicon production processes being evaluated by the Silicon Material Task.

During this reporting period, chemical engineering analysis was continued for the HSC process (Hemlock Semiconductor Corporation) for producing silicon from dichlorosilane. Major efforts in the chemical engineering analysis of the HSC process were devoted to the preliminary process design of a plant to produce 1,000 MT/yr of silicon using the technology.

Progress and status for the chemical engineering analysis are summarized below for the primary process design engineering activities:

Prior Current ---1. Base Case Conditions 40% 80%

2. Reaction Chemistry 40% 80%

3. Process Flow Diagram 30% 50%

4. Material Balance 20% 50%

5. Energy Balance 5% 20%

6. Property Data 5% 20%

7. Equipment Design 0% 15%

8. Major Equipment List 0% 5%

e~~.~~ Approval~ature

} o ,~, ra' Date

13


UNION CARBIDE CORPORATION Tonawanda, New York 14150

Contract Title: Silane-to-Silicon EPSDU

Contract No. : 954334

A series of funding recisions in FY 1981 made it necessary to suspend all activities except those relating to the silane-to-silicon EPSDU construction. The most noticeable activity which was postponed was the development of fluid bed pyrolysis of silane.

The EPSDU project status as of September 15, 1981, is as follows:

• Over 90% of equipment has been delivered to the EPSDU site in East Chicago;

• Each piece of equipment received was inspected and was found to be satisfactory in the majority of cases;

• Some equipment has been installed in place;

• Both the mechanical and electrical installation drawing packages have been completed, sent out for bids, and bids were received. The bid prices were in line with our own estimates, however these contracts have not been awarded to date.

It became apparent that DOE/JPL does not have sufficient funds to complete EPSDU construction. Union Carbide is currently in discussion with DOE/JPL on ways and means of completing an EPSDU program.

A small R&D program on fluid bed silane pyrolysis was revived October 1, 1981. Our plan is to perform a series of tests with the existing PDU throughout the first 6 months of 1982. A process design package for our fluid bed pyrolysis system suitable for EPSDU will be developed in the subsequent 3 months.

K /1,l. ~- '1 for H· Morihara Approval Signature

14

October 6, 1981

Date

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In-House Program

Wafering




a) Tensile strength tests and scanning electron microscopy examinations were performed on eight mil nominal diameter Laser Technology 11 Super \lire", a candidate for FAST saw. The 11 Super Wire 11 consists of a high tensile core material and an electrolyte copper sheath for holding 45 r.iicron diamonds. There was very little scatter in the load value at failure, indicating the uniform strength of the wire. The tensile strength of the core material is about 427 KPSI. b) Due to difficulties in maintaining SiC abrasive suspension in water soluble oil solutions, efforts to identify suitable suspension agents have been initiated.

Materials and Cell Characterization

a) Preliminary results, from strength tests on Semix polycrystalline silicon square wafers using the four-point twisting technique, indicate that Semix wafers have considerably lower strength than Cz single crystalline wafers. b) Experiments on the photoresponse of Semix wafers and solar cells using EBIC and infrared light spot scanning are in progress. The objective is to characterize effects of structural defects on cell performance and to search for better cell fabrication processes. c) Experiments using the grooving-and-staining technique and crosssection EBIC show that the diffused n-type region at grain boundaries in Wacker polycrystalline wafers extends further into the p-type base material than that in the grains. The observation can be attributed to enhanced diffusion of phosphorous atoms along grain boundaries. However, further investigations are needed to make a positive conclusion.

Date

15

Contract Title:

Contract No. :


Applied Solar Energy Corporation City of Industry, California 91746

Silicon Solar Cell Process Development, Fabrication and Analysis

955089

The objective of this program is to investigate, develop, and utilize technologies appropriate and necessary for improving the efficiency of solar cells made from various unconventional silicon sheets. Silicon sheets processed included UCP (SEMIX) and LASS (Energy Material).

A UCP ingot (4 11 x 411 x 4.5 11) was sectioned and sliced to prepare sub

strates. Baseline process solar cells (2x2cm) were fabricated and the cell performance was mapped as a function of location within the ingots.

In addition, high efficiency processes such as shallow junction, back surface field, or back surface reflector, and multilayer AR coating were applied to selected areas of the ingot and to other UCP wafers supplied by JPL. Sometimes a gettering process was used with both the baseline and high efficiency processes.

The results for both process sequences will be summarized and presented.

For the LASS material, high efficiency processes were used on blanks from two ribbons and the results will be presented.

Other measurements (cell spectral response, minority diffusion length) were made on selected cells for both UCP and LASS samples. Some of these results will be presented, to backup the cell results.

1fJ-r-trt Date

16

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Contract Tit I e :

Contract No. :


CORNELL UNIVERSITY

ITIIACA, NY

Characterization of Structural, Electrical Chemical Properties of Silicon Sheet Material.

954852

In the period 6/1/81 to 9/8/81 the following work was carried out:

(a) EBIC and TEM investigation of processed EFG.

and

Cross-sectional EBIC of processed EFG shows that the depth of the p-n junction varies along the ribbon. The variations are compatible with a model which considers enhanced diffusion along planar defects. (Similar variations in junction depth have been observed by Biegelson et al in laser annealed silicon which is similar to EFG in that it also contains planar defects intersecting the surface from which the diffusion is carried out). TEM of the base material of processed EFG shows the presence of small (10 to 50 nm) coherent precipitates at dislocation nodes. The chemical nature of these precipitates has not been identified. The planar density of the defects is about· !ES/sq.cm, since the dislocation compr1s1ng the network are about 1000 nm apart. Formation of the precipitates is process related since they are not found in unprocessed EFG. An un-symetric_distribution of debris along the margins of well defined dislocation networks such as small angle tilt grain boundaries indicates that dislocation networks move laterally during processing. (Similar effects have been observed by Gleiter in GaAs). TEM of the emitter region of EFG material shows coiled dislocations, indicative of the absorption of process induced point defects. (Similar effects have been observed by Strunk et al.). In addition, the dislocation appear to be very weakly decorated.

(b) EBIC investigation of HEM. The bulk of HEM material is featureless in EBIC. However,the material contained in the corners appears to contain not only coherent twins, but also the same kind of higher order (111)(115) twins observed earlier in EFG material. To establish the presence or absence of these higher order twins more firmly TEM is being carried out.

/). /. ~-Approval Signature

D.G.Ast 17

8-8-1981

Date


Crystal Systems, Inc.

Salem, MA 01970

Contract Title: Multi-Wire Wafering Technology Development

by the Fixed Abrasive Slicing Technique (FAST)


A new contract on the development of Fixed Abrasive Slicing Technique started on July 15, 1981. The goal of this program is to study parameters which would lead to effective slicing of 10 cm diameter and 10 cm x 10 cm cross-section silicon ingots at 25 wafers/cm and 15 cm diameter ingots at 19 wafers/cm.

During the current period emphasis has been placed on blade development and testing has been carried out by slicing 10 cm diameter ingots at 25 wafers/cm. It has been found that the wire blade performance is strongly correlated with the diamond concentration. SEM examination of wires which have shown good cutting performance indicates no significant decrease in diamond concentration; however, testing gave lower cutting rates and poorer yields with each subsequent ingot sliced. High magnification SEM examination showed that some diamonds may have been fractured at the surface or just below the surface of nickel plating. Therefore, besides diamond concentration the nickel buildup may also be important. A series of t·ests were carried out using wirepacks with varying plating time. No significant correlation could be arrived at because of variation in diamond concentration. Efforts are being made to improve the diamond concentration and uniformity of the wires.

A slicing test using a wirepack fabricated by an outside vendor has been tested. This wirepack with 19 wires/cm spacing has been used to slice a 10 cm diameter ingot. SEM examination has shown that the diamond plating was restricted to one side of the wires; however, the concentration was low and nickel buildup was more than optimum. Cutting rates of 1.6 mils/min, 0.041 mm/min and a 73% yield were achieved.

It has been experienced that high feed forces give higher cutting rates; however, wire wander is also increased. Correlation of feed forces and slicing rates was sought but misalignment in the slicer caused poor yields. This led to inconclusive results.

The first test with an electroformed wirepack spaced at 25 wires/cm has been carried out. The diamonds and plating were constrained to a 30 degree segment. Good performance has been demonstrated and higher cutting rates have been achieved.

Addition of a counterbalance, replacing the gear box and incorporating a shock absorber between the drive system and bladehead of the

T slicer has dam "brations at higher reciprocating speeds.

18

October 7, 1981

Dote

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P.R. Hoffman Division of Norlin Industries, Inc.

Carlisle, PA 17013

Contract Title: Multiple Blade Sawing (MBS) of Silicon Ingot Into Sheet: Testing and Development


The objective of this program is to provide optimization of the saw design and the MBS wafering process via prototype research of the process and investigation of several potential means of cost reduction. This research and development program is intented to result in technological improvements which will provide definition of an MBS silicon sheet production process compatible with the goals of the Flat Plate Solar Array Project (FSA).

The technical progress report to be presented at this Project Integration Meeting will include discussion of work performed in the areas of wafer lift-off mechanism, vehicle and abrasive reclamation, improvements in cutting rates, investigation of alternative consumables, and process/equipment design optimization.

Sensitivity studies have resulted in identification of those cost areas having significant impact on over-all process costs. Results of these studies will be presented in support of a revised !PEG cost analysis and process cost projections.

11-11-81

/) Approval Signature Date

19


Kayex Corporation

Rochester, New York

Contract Title: Development of an Advanced Czochralski Growth Process to

produce low cost 150 kg silicon ingots from a single crucible.


The contract was extended five months to March, 1982, all material was placed on hold and direct labor on the contract was reduced by approximately half to minimize FY '81 expenditures.

The goals of the contract remained the same and are sununarized as follows:

1. To design and construct a crystal grower capable of producing 150 kilograms of ingot from one crucible (5 x 30 kg ingots);

2. Accelerated recharge and growth rate; 3. Microprocessor controls; 4. After growth yields of 90%; 5. Throughput of 2.5 kg/hr.

Because of the slowdown in the program, the emphasis was placed upon the microprocessor controls and sensors. Melt temperature sensing and control for seeding was investigated. It was established that melt temperature can be controlled reproducibly for repeatable seeding of the melt. This allows for a simpler program for automatic control of the neck and shoulder. The bulk of this work was done on a standard CG2000 using 12-inch crucible and 18 kilogram melts.

The microprocessor has now been interfaced with the JPL grower and experiments are underway to evaluate the autmoatic melt temperature control for 35 kilogram melts and to program the automation for 150 nun diameter ingots.

One 150 kilogram run has been performed on the new growth facility.

A Technical Direction Memorandum was received from JPL which placed emphasis on (1) improvement of growth rates using radiation shielding, and (2) investigation of the crucible-·melt interaction for improved yields. A revised experimental plan is being developed to respond to the TOM.

10/9/81 Approval Signature Date

20

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LARGE .,AREA SILICON SHEET TASK

MATERIALS RESEARCH, INC:

CENTERVILLE, UTAH'

Contract Title: Analysis of Defect Structure in Silicon


The analyses of one hundred and ninety-three ( 193 ) silicon sheet samples for twin boundary density, dislocation pit density, precipitate density, and grain boundary length has been accomplished in the past contract period. One hundred and fifteen ( 115 ) of these samples were manufactured by Crystal Systems, Inc.

using their Heat Exchanger Mehtod ( HEM ) , thirty-eight ( 38 ) by Mobil Tyco using Edge - defined Film - fed Growth ( EFG ), twenty-three ( 23 ) by Honeywell using the Silicon-On-Ceramic ( SOC ) process, and ten ( 10 ) by Westinghouse using the Dendritic Web process. Seven ( 7 ) solar cells were also step-etched to determine the internal defect distribution on these samples.

Procedures have been developed for the quantitative characterization of structural defects such as dislocation pits, precipitates, and twin boundaries using a QTM 720 Quantitative Image Analyzing System interfaced with a PDP l l /03 mini - computer. These procedures were routinely applied to all the samples. Charac-terization of the grain boundary length per unit area for polycrystalline samples was done by using the II intercept method 11

on an Olympus HBM Microscope •

Individual reports on each sample type and the draft of a Final Report on the entire work has been submitted to JPL for review. These reports describe the results obtained and discussion of data for various types of silicon materials analyzed.


21


Mobil Tyco Solar Energy Corporation

Waltham, Massachusetts 02254

Contract Title: LARGE AREA SILICON SHEET BY EFG

Contract No.: 9 54 355

The program plan for the remainder of 1981 has been reduced in scope to concentrate on studies of factors affecting ribbon non-flatness and stress, and its electronic quality. This work will be done with 10 cm wide ribbon in the single-cartridge furnaces 17 and 18. The stress-related goal is to reduce stress and non-flatness in 200 µm ~~ick ribbon grown at 4 cm/minute to levels where high yields in cutting and processing can be achieved. The quality goal is to demonstrate large area (50 cm2 } cells of 12% efficiency on this ribbon. No further experiments with multiple ribbon furnaces are to be done on the LSA program, as this phase of technology development is now incorporated into the Mobil Tyco in-house program.

Optimization of growth conditions in the 10 cm cartridge has resulted in the achievement of good growth stability, and allowed growth for periods of over one hour without freezes at 4 cm/minute. Progress has been made in identifying factors contributing to ribbon non-flatness and stressinduced buckling of thin (200 µmin thickness) ribbon grown at this target speed. Improvements in growth system alignment and studies of ribbon guidance have contributed to minimizing perturbations during growth and improving the ribbon flatness. At the same time, changes in the ribbon post-growth cooling profile have led to changes in the buckle pattern and a reduction in ribbon stresses and buckle severity.

A review will be presented of progress in multiple ribbon furnace technology development that is culminating now in the construction of a unit for growth of four 10 cm wide ribbons. This unit is considered to be the prototype on which will be based technology for producing silicon ribbon substrates by EFG at a cost sufficiently low to achieve $0.70 pW solar cells.

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Contract No. :

Semix Incorporated

Gaithersburg, MD

Semicrystalline Casting Process Development and Verification

DE-FC01-80ET 23197

The overall goal of this Cooperative Agreement between Semix Incorporated and the United States· Department of Energy is to demonstrate the Technical Feasioility of the Semix UCP approach producing 70¢ per peak watt photovoltaics. Specific goals during this second contractual year are as follows:

1. Crystallization of 42 kg. silicon bricks.

2, Evaluation and incorporation of critical elements and materials for high throughput UCP systems.

3. Advancement of techniques for controlling and evaluating UCP processes and results.

4. Evaluation and improvement of wafering techniques,

5. Demonstration of 14% AMl efficiency for 100 cm2 solar cells.

Work to be presented at this Project Integration Meeting will concentrate on the following areas:

1. UCP performance and resulting solar cell characteristics.

2, Multi-blade and ID wafering evaluations for sem:i:crys-talline -~ silicon.

3. Progress in UCP control systems,

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Contract Title:

Contract No. :


SILICON TECHNOLOGY CORPORATION

Oakland, NJ

ADVANCED ID WAFERING TECHNOLOGY

956053

Purpose of this contract is to engage in research and development aimed at developing technology to produce large areas of silicon sheet at reduced cost using ID wafering technology.

The scope of the contract entails development of equipment and tools and new ID blade design to study ID wafering. Our initial work has involved vibrational analysis and the effect of vibration on wafering. Initial results are encouraging. Reduction of vibration by a factor of two has resulted in 50 percent to 25 percent increased cutting speeds and improved yields.

We have modified the basic feed mechanism to improve the stability of the saw to reduce vibration and improve dimensional accuracy. Most of our work has been on 6 inch diameter circular CZ ingots. We have achieved 3 inches per minute cutting rates on the 6 inch diameter ingots. Kerf losses have been about 13 mils. During the next quarter, we plan to experiment with new blade materials which will reduce kerf to about 10 mils for 6 inch diameter ingots.

Peter Aharonyan 10/09./81

Approval Signature Dote

24

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Large Area Silicon Sheet

University of Illinois Circle Campus

Chicago, Illinois 60680

Contract Title: STUDY OF ABRASIVE WEAR· RATE OF SILICON USING n-ALCOHOLS


The goals of the contract are to investigate the fundamental mechanisms of abrasive wear of silicon in the presence of n-alcohols. An experiment was designed to simulate the currently used wafering methods. A single crystal (100) p-type silicon wafer is abraded by a pyramid diamond in three fluids and the abrasion rate is recorded as a function of fluid, normal force on an abrading diamond, depth of damage and type of debris generated in the abrasion process. The abraded surfaces are studied by scanning electron microscopy and analysis of acoustic signals generated during abrasion.

The results of measuring groove depth as a function of normal force on the diamond and varying the fluids, all other experimental conditions being held constant are that the groove depth rates (depth of groove/s) are in the ratio of 1:2:3 for water, absolute ethanol and acetone respectively, for a constant normal force. The groove depth is lower when the normal force is decreased. In addition, at a constant normal force, the silicon abraded in the presence of water was chipped as expected for a classical brittle material while the surfaces abraded in the other two fluids showed ductile ploughing as the main mechanism for silicon removal.

Acoustic signals generated during the abrasion showed a marked difference in both the transient and steady state frequency spectra when the fluid was changed.

No major problems or uncertainties in achieving the goals are foreseen at present.

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Approval Signature. Date

25

LARGE AREA SILICON SHEET

Westinghouse Research and Development Center

Pittsburgh, PA 15235

Contract Title: ADVANCED DENDRITIC WEB GROWTH DEVELOPMENT


Computer models necessary for the attainment of greater crystal width and area throughput rate have been completed and verified. The three models necessary for this purpose 1) predict the critical buckling stress (the stress value at which buckling will occur) within a silicon ribbon of specific width and thickness, 2) relate the thermally generated stress and temperature profile for a silicon ribbon, and 3) predict the silicon ribbon temperature profile which will be generated by a specific thermal system geometry and dimensions. These models have been verified and refined by comparison with measured results from a series of experimental web growth runs and growth system temperature measurements. The models will be used to define approximate system configurations to provide reduced stress and, consequently, increased non-buckled width of growth. More precise thermal systems dimensions will be determined experimentally with actual web growth and thermal system temperature measurements.

In order to accommodate the wider crystals that should result from the improved thermal design, a longer crucible has been installed in the web growth system. To do so it was necessary to perform a series of experimental web growth runs for adjusting the thermal conditions to provide the required temperature profiles within the susceptor, crucible and melt. It was also necessary to trim the system so as to prevent harmful accumulation of oxide. These procedures have been completed and the system is now suitable for evaluation and optimization of new geometry determined by application of the models and web growth.

A new experimental silicon web growth machine has been completed and will be used for implementation of the wider growth experiments described above. This machine incorporates for the first time all of the web growth features developed during this program and necessary for long term growth at high throughput. A critical feature is the melt level control system which, by way of controlled melt replenishment, maintains a fixed silicon melt level during web growth. A fixed melt level is necessary in order to obtain and maintain optimized growth conditions. Fully detailed design drawings of the growth and control systems have been prepared. A complete description of the machine was covered in a final design review presented October 6.

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ENCAPSULATION TASK


Photothermal Characterization of Encapsulation Materials.

Photothermal characterization of EVA (Springborn 9918), EMA (Gulf) and PVB (Monsanto) have been completed for up to 800 hours of testing. A detailed description of these tests will be incorporated into a JPL report. Results have been used to rank candidate pottants and outer covers materials and also obtain data to validate/refine degradation mechanism of EVA (Springborn 9918) being developed by the University of Toronto.

Testing of polymerizable U.V. absorbers and UV absorbing acrylic copolymers has resulted in understanding of degradation mechanism of 2[(2-hydroxy 5-vinylphenyl) 2H-benzotriazole] -co-mma, supplied by the University of Massachusetts and also the Acrylar R films obtained from 3M Corp.

Controlled environment reactor (CER) testing of these materials as well as Tedlar UTB 300 (DuPont) is in pr.ogress.

Construction of the full scale UV gradient tester is nearly complete. Components have been procured and received. Design of the chamber has been completed. The effect of photothermal stresses in 2' X 4' modules in presence of water vapor as well as liquid water will be investigated in this chamber. These tests will be used ·to refine/validate the photohygrothermal interface degradation and corrosian model proposed by the Rockwell Science Center.

10/13/81 Date

27

ENCAPSULATION TASK

CASE WESTERN RESERVE UNIVERSITY CLEVELAND, OHIO 44106

Contract Title: Systems Studies of Basic Aging and Diffusion


The objective of this study is to establish the kinetics and mechanism of thermal and photo-oxidative degradation of candidate encapsulation materials for the FSA Project. That information is to be used to develop accelerated testing and life performance prediction methods and to guide the continuing selection of optimum performance encapsulation material systems. The study is being carried out in cooperation with related studies at JPL.

The present work is aimed towards establishing the modes of degradation of poly(n-butylacrylate)(PNBA) and their effects on selected chemical and physical properties. It has been found that for PNBA: 1. The photo-oxidation of PNBA is apparently a first order reaction with an initial rate (up to 2000 hours exposure in the QUV apparatus) that is higher than the subsequent rate. Reaction rate constants for loss of ester groups and for formation of crosslinks, CO groups, and COOH groups have been established. 2. Reaction products in the residual polymer after 2000 hours of exposure in the QUV include carboxyl, carbonyl, aldehyde, hydroxyl, and crosslinks attributed to keto linkages. These groups have been detected using FTIR, UV, swelling ratio measurements, and chemical methods specific for certain functional groups. 3. Analysis of the data has been made to relate the loss of ester groups to the formation of the reaction products observed in terms of the reaction mechanisms proposed and the quantum efficiencies of the reactions. 4. The study of the dynamic mechanical properties and other relevant physical properties related to crosslink formation and other degradation modes indicates that changes observed after long term exposure (> 2000 hours) are relatively minor. The crosslinks/initial polymer chain is estimated to be of the order of ten after 2000 hours exposure.

Continuing studies will include the analysis of the degradation mechanism to establish the overall process in terms of exposure conditions. The validity of predictions of long term exposure performance based on short term testing will be assessed.

~~ ApprovaTinature

1 Oct 81

Date

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Encapsulation Task

Illinois Tool Works, Inc., Venture Group

Elgin, IL

Contract Title: Ion Plating of Solar Cell Arrays


The ITW contract was initiated in December 1979 to investigate, develop and demonstrate the capability to produce operational solar cells having metallizations and AR coatings deposited by gasless ion plating, which will separately and/or in combination with a low cost encapsulation system meet the LSA project life, cost and performance goals.

Metallization of 100mm diameter 5mm thick P/N wafers has resulted in producing cells with an average efficiency of 12.49% (AMI). These cells were fabricated using contact masks cut from .008" thick steel shim stock to delineate a front electrode pattern having .011" wide collector fingers and two bus bars (~10% area of coverage on the front of the cell). The ion plated metallizations consisted of a nickelcopper front electrode pattern and a titanium-copper back contact, which were then solder dipped.

Efforts to metallize N/P type wafers have concentrated on improving the ohmic contact made to the back surface of the wafer (base wafer with boron impurity ~2Gcm). A 65Ti/35Al alloy has been shown to produce good ohmic contacts of <160m0cm2 when deposited on nondegenerate P type silicon, but not consistantly enough yet to allow production of cells from N/P wafers.

Results from a SAMIS analysis based on the production of 50 MW/year of 100mm diameter round cells (P/N wafers) with nickel-copper front and titanium-copper back metallizations plus a SiOx AR coating indicate a cost of .056 ($1980)/peak-watt for the metallization and AR coating •

10-6- 51 / Date

29

ENCAPSULATION TASK

ROCKWELL INTERNATIONAL SCIENCE CENTER

Thousand Oaks, CA.

Contract Title: Study Program for Encapsulation Materials for Low Cost

Solar Arrays.


The major objectives of this study are to conduct a physical/chemical study of surface and interface degradation in solar cell encapsulant systems induced by environmental factors such as moisture, temperature and UV radiation.

A.C. impedance has been used to characterize the changes in the electrical properties of modules exposed to simulated environments. Corrosive attack or moisture induced mechanical failure of current carrying components effectively places additional resistances in series with the module and leads to high 12R power loss. The a.c. impedances of a number of modules undergoing the Battelle accelerated test have been analyzed. The results showed that an equivalent resistor and capacitor representing failed interconnects lie in series with the cells.

Experiments designed to study the influence of moisture diffusion on solar cell performance have shown that conducting paths develop at cracks, within the encapsulant, or at the encapsulant/substrate interface. By decreasing the shunt resistance, Rsh' these additional paths may dissipate the photo-excited state and limit the power of the cell. A fiber-board backed, EVA-encapsulated and fluorocarbon-covered two cell module was subjected to a controlled cyclic hydrothermal stress. Analyses of the module at intervals during the treatment showed irreversible decrements in Rsh correlating with the hydrothermal cycle. Introduction of an artificially produced crack also decreased Rsh·

Additional work has demonstrated the specific influence of corrosion on delamination of an encapsulant from a metal surface. Results of experiments initiated during this period suggest that the loss of adhesion at metal encapsulant interfaces gives rise to a particular set of problems not encountered for non-conducting interfaces. Specifically, the separability of the anodic and cathodic half reactions of corrosion can cause non-uniform interfacial chemistry, or electrochemical potential over the surface of the substrate. These variations influence adhesion to varying degrees and by different mechanisms. A simple test to assess the significance of the separate anodic or cathodic processes has been applied to primed (A11861-1) and unprimed EVA-encapsulated metal surfaces.

Approv 1flp-1

Date

30

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ENCAPSULATION TASK

Spectrolab, Inc.

Sylmar, California

Contract Title: The Design, Analysis, and Test Verification

of Advanced Encapsulation Systems


The objective of this program is to develop analytical methodology for advanced encapsulation systems which will aid in the determination of optimum systems for meeting the Flat-Plate Solar Array Project goals.

During this period, testing of the thermal, thermal structural, and structural deflection models has been completed. Workup of the raw data has not yet been completed. Analyses of optical and electrical data obtained from optical and electrical verification testing show good correlation with the models.

Fabrication of qualification modules should begin in November •

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Approval Signature

31

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Contract Title: ·

Contract No. :

ENCAPSULATION TASK

SPRINGBORN LABORATORIES, INC.

Enfield, Connecticut

INVESTIGATION OF TEST METHODS, MATERIAL PROPERTIES AND PROCESSES FOR SOLAR CELL ENCAPSULANTS

954527

This program involves the evaluation of materials and processes for the encapsulation of .solar cells. Material selections are being investigated consistent with the DOE objectives of achieving a photovoltaic flatplate module or concentrator array at a manufactured cost of $0.70 per peak watt ($70/sq.M) (1980 dollars).

During this quarter development efforts on pottants for solar modules were continued. Development of an industrially ready butyl acrylate casting syrup was completed. The formulation is UV stabilized and may be cured with a non-hazardous inititator. The cata1yzed syrup is stable at room temperature and cures in 18 minutes at 60°C. The investigation of aliphatic polyurethane syrups was also continued and prototype formulations are available that exhibit rapid cure, low modulus, low mixed viscosity and good optical transmission.

A series of anti-soiling treatments on glass and plastic cover films were deployed outdoors to determine the efficiency of soil resistance. Based on stand.ard cell measurements, fluorosilane coatings were found to give significant improvement over control after five months exposure.

Continuing studies of adhesion chemistry for bonding pottants to other module components- resulted in primers for EVA, butyl acrylate and urethane to glass, Tedlar and Mylar cover materials.

Experiments to evaluate outdoor prote~tive coatings for hardboard and mild steel substrate candidates were started and test specimens were put into field exposure.

Evaluation of materials under RS/4 radiation is continuing. After 9,000 hours exposure the new EMA formulation shows no change in optical or mechanical properties. The outer cover candidates, ·x-22417 acrylic film and Tedlar lOOBG have also survived unchanged. The butyl acrylate and aliphatic urethane pottants are also undamaged after·4,000 hours exposure. Outdoor photothermal aging racks are being constructed for studying the heat accelerated degradation of polymers in natural sunlight.

~£~ Approval Signature

32

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Contract No. :

ENCAPSULATION TASK

J. E. Guillet University of Toronto

Toronto, Canada Modeling of Polymer Photooxidation

955591

This research program is intended to model the photodegradation of polymers used as pottants and/ or cover sheets in FSA applications. An efficient com -puter program has been constructed which utilises a choice set of elementary reactions and rate data to generate concentration vs. time profiles of all chemical species. Our modified GEAR routine has now been verified with a smaller set of reactions obtained from the literature for the caesium flare. Identical results were obtained in this model case.

The degradation of EV A at ambient temperatures is essentially that of the ethylene segments. The mechanistic model for photooxidation consists of 31 or 32 elementary reactions which include photochemical decomposition of ketone and hydroperoxide since these are early culprits in degradation. No allowance has yet been made for (i) the different reactivities of secondary and tertiary C-H groups, (ii) the restricted diffusion of polymeric radicals in the solid state, (iii) temperature cycling in an outdoor environment, (iv) light and dark perio1s in a daily cycle, (v) the effect of additives and residues or (vi) the crosslinking of EVA prior to application. However, results from the simulation to date (using the best available rate data) show the following.

1. The photooxidation process has a long induction period of up to several years, followed by a rapid deterioration.

2. The chemical changes that result lead to: (i) The formation of polar alcohols and acids which could affect wettability

and electrical resistance of the polymers; (ii) The formation of ketones which could become conjugated, leading to

discoloration and further molecular scission which also affects physical properties; and

(iii) Possible crosslinking through alkoxy radicals coupling in a cage to form peroxide linkages which could cause the polymer to shrink and hence tear or pull away from connections and supports in a module failure mode.

~~ Approval Signature Date

33

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Process Developnent Area

In-House Program Non-Mass Analyzed Ion Irrplant

An experirnent was performed to determine the effects of starting material preconditioning on the performance of ion implanted solar cells. There is some speculation that the standard PO:la diffusion process acts as a getter to tie up potential recombination sites {impurities, disloactions, rnicrocracks, etc.) and thus improve solar cell performance. The experiment utilized 7-14 ohm-cm material from the sarre ingot. Sane of the material was POC1 3 diffused in the standard fashion. Part of the diffused samples were etched on the back to renove the diffused layer and the remainder were etched on both sides. A second group of material was exposed to a thermal cycle in a reducing gas and subsequently etched on both sides. The thermal cycle was identical to that seen during the diffusion process. A third group of material was not preconditioned in any way. The samples with diffused fronts were made into cells as a reference. The rest of the material was ion implanted with non-mass-analyzed phosphorous at 15KeV and 6 x 10 1 5 atorns/crn2 • The ion implanted cells were thermal annealed and were metallized with the diffused reference samples. The results of this experiment will be documented.

Approval Signature

35

9 October 1981

Dote

Process Developm2nt Area

In-House Program Robotic Effort

An advanced robot system for attachment of electrical power- out connectors to sol ar arrays will be described and demons trated. The automated connector attachments t echnolO:JY demonstration consists of solder i ng a power buss t ab to the modul e backsi de , laying down a glue bead and placing a connector housing over the t ab. The syst em uses visual feedback t o determine the location of the power- out buss stri ps to which the power tab must be soldered. The robot then removes a tab f rom a dis)?=nser , dips it into a solder bath and sol ders the tab t o the modul e. During tab CCX)ling the vision system ins)?=cts the resul t while the robot s imul taneousl y obtains a connector housing from the parts presenter. The robot then lays down a gl ue bead around the vertical tab . After the gl ue bead is finished , the vis ion system ins)?=cts for breaks, pro)?=r width and positioning . If the bead i s correct , the syst em pl aces the housing on the tab and seats it in the glue . To avold damaging the fragile tab , the system uses a force/torque sensor to "feel " the tab as the connector housing i s pushed over i t. The system inspect s each step after it i s per form2d to verify r esults and if errors are detected it will reject the part and/or alert the s u)?=rvi s ing OJ?=rator .

Approval Signature

36

9 Cx::tober 1981 Date

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Contract Title:

Contract No. :


BERND ROSS ASSOCIATES

SAN DIEGO, CA 92109

DEVELOPMENT OF AN ALL-METAL THICK FILM COST

EFFECTIVE METALLIZATION SYSTEM FOR SOLAR CELLS

955688

This summary covers work done from June 1981 to October 1981. The objective of this investigation is the study of economical thick film solar cell electrodes based upon screenable base metal compositions.

Several copper pastes employing a fritless thick film system using fluorocarbon powder as well as silver fluoride as an oxide scavenger have shown promising results, passing adhesion tape tests.

Preliminary electrical tests were obtained on 2x2 cells (without AR coating) giving moderate efficiencies. The cells had been provided with a back contact of screened copper-fluorocarbon paste or copper-silver fluoride paste.

Reproducibility and fill factor require further improvement.

Reaction analyses as well as DTA and TGA tests are continuing to provide a better understanding of the processes.

10-81


37


PHOTOWATT INTERNATIONAL, INC. TEMPE, AZ 85281

Contract Title: DEVELOPMENT OF TECHNIQUE FOR AR COATING AND NICKEL AND COPPER METALLIZATION OF SOLAR CELLS

Contract No.: JPL Contract 955986

Thi s contract , i n i ti ate d on May 1 5 , l 9 81 , has as major goal s the development and testing of a novel nickel copper metallization system. It consists of printing a specially formulated nickel paste onto the silicon nitride over the active area of i.he eel 1. This paste, when fired, wi 11 make ohmic contact to the silicon. The conductivity of the contact is improved by electroplating copper on front and back.

An innovative, yet high throughput, brush plating system to e l e c t r o p l at e c o p p e r w i 1 l b e i n v e s t f'g at e d . R e l i a b i l i t y s t u d i e s on the metallization system will be performed in weatherometric chambers and wi 11 be greater than l 0%. Preliminary cost analysis using SAMICS shows the metallization cost to be less than 4¢/watt.

During this reporting period an initial group of nickel pastes were formulated and utilized to contact N-type silicon. These units were used to evaluate ohmic contact and adherence levels.Appropriate paste formulations and fire cycles were selected for usage with the complete nickel/copper metallization system to evaluate completed solar cell characteristics. These initial pastes with appropriate fire cycles and brush copper plating have yielded solar cells with open-circuit voltages of .570 to .580 volts and curve fill factors of .60 to .65.

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38

October l O, 1981 Date

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PROCESS DEVELOPMENT

Solarex Corporation

Rockville, Maryland 20850

Contract Tit I e : A MODULE EXPERIMENTAL PROCESS SYSTEM DEVELOPMENT UNIT (MEPSDU)


The purpose of this program is to demonstrate the technical readiness of a cost-effective process sequence that has the potential for the production of flat plate photovoltaic modules which meet the cost goal in 1986 of 70¢ or less per peak Watt.

The program efforts have been in the following areas:

• Cell fabrication using the proposed process sequence;

• Optimization of cell processes;

• Identification and testing of insulator tapes and edge seal material;

• Optimization of a lamination procedure;

• Evaluation of encapsulation materials;

• Identification, discussions, demonstrations, and visits with candidate equipment vendors;

• Updating the drawing package and QA plan;

• Collecting data for preliminary Samics cost analysis;

• Termination of all module process efforts;

• Rescheduling of the program in light of the reduced scope and budget with emphasis on cell process development.

39

October 8 2 1981 Date


Spire Corporation

Bedford, Massachusetts 01730

Contract Title: DEVELOPMENT AND FABRICATION OF A

SOLAR CELL JUNCTION PROCESSING SYSTEM

Contract No.: DOE/ JPL 955640

9 June 1981 - 7 October 1981

The objectives of this program are to design and build equipment capable of ion implanting and pulse annealing junctions for 4-inch-diameter solar cells.

Since the last report, the full energy storage capacity of the machine has been realized. Eleven capacitors and a high current, high voltage power supply capable of charging the system in less than 3 seconds have been installed. Preliminary results with 4-inch-diameter electron beam anneals have yielded sheet p of 30 ohms/square versus approximately 60 ohms/square for furnace annealed controls. Preliminary cell data on 2 x 2 cm cells taken from various spots on the 4-inch-diameter wafer have yielded some 13% (AMl) efficiency cells versus 15% from the furnace anneal control group (no BSF). Improving the uniformity of this anneal is now being done by fine tuning the numerous electrical parameters on the annealer.

The wafer handling system, including the linear transport, vacuum locks, and cassette elevators, have been completed and are now being debugged. The entire system is now working except for some minor adjustments that are needed in timing and indexing of the cassette elevators.

The non-mass analyzed ion implanter portion of the machine is now being designed. Some data obtained on wafers implanted by JPL have indicated some loss of efficiency due to the lack of mass analysis. This effect is now being investigated further with a recently constructed test apparatus at Spire which will provide a non-mass analyzed phosphorus beam for beam focusing and trial wafer implants. This ion source has been operated and some good results have been obtained in electrostatically bending and shaping the beam into a configuration needed in the solar ion implanter. The overall design of the ion implanter must await the completion of these beam handling experiments and these non-mass analyzed solar cell results.

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7 October 1981 Date

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University of Pennsylvania

Philadelphia, PA

Contract Title: Analysis and Evaluation of MEPSDU Processes


Process cost reduction has lately found more attention than module efficiency, although the latter is as important.

One of the aspects of large area cell design is the front metallization. However, the grid pattern design depends on the front layer sheet resistance. In turn, particularly where the front layer design has been optimized in an empirical process with a given front metal design, the front layer itself may yield higher performance after redesign for the improved metal pattern. This leads to the second question: do the presently used front layer formation processes really yield best cell performance? It is now generally recognized that these processes - using diffusion or ion implantation -yield impuritity concentrations above 1019 cm-3, where the "heavy doping effects" (Auger recombination, bandgap narrowing) exert a substantial performance-degrading influence. Lower diffusion temperatures are not necessarily the sole answer to this problem.

Then there are the questions of the influence of hightemperature processes on the electronic parameters in the various layers of the device. What diffusion length does really exist in the front layer, in consequence of the applied process? Is there a pile-up of recombination centers in the depletion region, or adjacent to it in the base? Some experiments have shown such occurences, but are they really experienced in solar cells, and how do they depend on the process used? How is diffusion length in the base influenced by the front layer and the so-called "BSF" formation processes? If diffusion length improvements (gettering?) or degradation occur, how do they depend on the original silicon material and the wafer processing?

What are the results of application of the various "BSF" formation processes? To what degree do they lead to structures and material properties in the base region which should yield high performance according to the design calculations?

Answers to these questions will be needed, if solar cell process design is to move from an art to an engineering method. The required, substantial research will utilize many of the existing but will also need the development of some new approaches. The next efforts under this project will concentrate on defining appropriate methods for obtaining answers to the above questions.

10·- g- >ii ., Approval Signalure Date

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PROCESS DEVELOPMENT

WESTINGHOUSE ADVANCED ENERGY SYSTEMS DIVISION

PITTSBURGH, PENNSYLVANIA 15236

Contract Tit I e : A MODULE EXPERI'IBNTAL PROCESS SYSTEM DEVELOPMENT UNIT (WESTINGHOUSE)


Work was initiated on the Westinghouse MEPSDU contract on November 26, 1980. The objective of the contract is to determine technical feasibility of the production of photovoltaic modules designed to meet all environment specifications contained in JPL Document 5101-138 at an FOB price of 70¢ or less per watt (peak) in 1980 dollars.

Since the last P.I.M., a series of tests has been conducted on simulated modules to demonstrate that all JPL environmental specifications (wind loading, hailstone impact, thermal cycling, and humidity cycling) are satisfied by the Westinghouse design. All tests, except hailstone impact, have been successfully completed. Hailstone impact simulation tests are currently underway.

Although the baseline process sequence remained unchanged from that which was presented at previous PIM's, investigations of four alternate process steps continued. These investigations have been performed to identify potential improvement to the cost effectiveness of the baseline Westinghouse MEPSDU process sequence.

An in-depth economic analysis of the baseline Westinghouse MEPSDU orocess sequence has been initiated. Using the SAMICS computer code, photovoltaic module production costs were projected for the 1 "t'M/yr capacity MEPSDU line and a 25 Wil/yr capacity production line. The value added was determined for each process step at both levels of production. This analysis has verified that the current baseline process sequence can meet the DOE/JPL cost goals for 1986.

Design work at Kulicke and Soffa on the automated cell interconnect station proceeded as scheduled during the past quarter. An ultrasonic rolling spot bonding technique has been selected for use in the machine to perform the aluminum interconnect to cell metallization electrical joints required in the Westinghouse MEPSDU module configuration. This selection was based on extensive experimental tests and economic analyses. Work on machine concepts for the remainder of the cell interconnect station is proceeding, and an Equipment Specification (E-Spec) has been prepared.

Equipment procurement for the MEPSDU test facility was initiated during this quarter. A combination cell test/module test/data acquisition system and an automated laser scribe were placed on order. These are longlead items which will not be affected by experimental process sequence design ~ark cur~ntly underway.

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In-House Program

ARRAY REQUIREMENTS

ENGINEERING AREA


The Array Requirements activity addresses the identification and development of detailed design requirements and test methods at the array level. Continuing areas of activity that addressed improved definition of array requirements include (1) the establishment of module and array electrical safety criteria, (2) the generation of intermediate-load-center building codes as applied to array design and (3) the development of array-to-power conditioner electrical interfaces (coordinated with Sandia and MIT/LL).

Safety Requirements

Personnel from the FSA Engineering Area participated in the fourth meeting of the National Electrical Code (NEC) Ad Hoc Subcommittee Meeting on Photovoltaics. The meeting was held August 11-13, 1981 in Northbrook, Il. The outcome of the meeting was a tentative agreement on a new article for consideration by the NEC Correlating Committee for the 1984 Edition of the National Electrical Code. Formal balloting by Subconmittee members occurred during September 1981 and results were forwarded to the NEC Correlations Committee for d ispos it ion.

In support of residential roof mounted array safety a series of exploratory fire tests were observed by Engineering Area personnel at Underwriters Laboratories, Inc. (UL), Northbrook, Il on August 14, 1981. Shingle and integrally mounted glass superstrate modules were subjected to spread-of-flame and burning brand tests. The shingle module proved to be highly flame resistant to the 10 minute spread of flame test and withstood both Class A and Class B burning brands up to 45 minutes. The EVA based integral-mount module was resistive to Class C burning brands test, however, the Class B brand easily failed the glass cover and ignited the encapsulant which led to a rain of fire droplets into the attic within 5 minutes.

Approval Signature

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Comnercial/Industrial Building Codes

In support of intermediate-load array design guidelines Burt Hill Kosar Rittlemann Associates completed their assessment of intermediate load center building codes and regulations (initial results were presented at the 17th PIM). An executive sumnary and clarifying points are being added to the final report now scheduled for release in December, 1981.

Power Conditioning Interface

Work on the array-power conditioner task focused on (1) comparisons of degraded array and virgin array results and how the interface between array and power conditioner is effected and (2) the determination of the array power output characteristics for a degraded array. A draft of the interim task report is in preparation; a December '81 release is planned.

Updated tables were forwarded to the Photovoltaic Lead Center for the Power Conditioning Task coordinated with Sandia National Laboratories. These inputs provide the optimum power-conditioner voltage, current, and power levels vs array requirements for residential and intermediate-load applications.

ARRAY SUBSYSTEM DEVELOPMENT

The Array Subsystem Development activity focused on the development of conceptual designs for integrated flat-plate array module/support structures as a key approach to minimizing total array costs. An important output of array conceptual designs is the definition of specific design requirements addressed to functional performance, interface and maintainability (at the array level).

JPL in-house and contractor work continued in the development of cost effective support structures. Preliminary design reviews were held at JPL August 25, 1981 with AIA/RC and with GE on July 17, 1981 on the Integrated Residential PV Array Development contracts. A detailed review of their concepts are presented in the contractor sunmaries (following this JPL in-house sunmary). JPL Engineering Area in-house efforts are developing a prototype residential array design which eliminates the need of a 100% watertight interface between the PV module and the support structure. Low-cost, non-metallic extrusions that include leakage or drainage channels are on order to complete a 5' x 9' prototype for verification.

Additional JPL in-house efforts included the determination of the edge vulnerability of 1/8 inch tempered glass sheets to hail impact using a variety of edge support conditions. Results showed that 1/8 inch tempered glass panels can survive JPL 5101-161 Block V hail-impact test without edge protection. However, tempering techniques do vary with manufacturer and designers are advised to perform similar ice-ball tests on tempered glass panels they intend to use.

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A Viewgraph Presentation entitled 11 Photovoltaics--Electricity from the Sun 11 was given to the Kansas Society of Architects at the 1981 AIA Kansas State Convention in Topeka, Kansas, on September 4, 1981. The seminar overview of photovoltaics, presented jointly by FSA Engineering Area and AIA Research Corporation personnel was consistant with the convention theme "Energy Naturally" and was intended to stimulate interest in photovoltaics.

MODULE ENGINEERING

Module engineering addresses the development of design methods, analysis tools and design concepts necessary to support significant cost and performance improvements at the array element level. Activities are conducted to clarify design tradeoffs, develop analysis tools and test methods and provide generalized design solutions for the PV conununity. Specific activities durin9 this reporting period included (1) Cell Reliability Testing; (2) Module Voltage Isolation, (3) Interconnect Fatigue (4) Hot-Spot Endurance, (5) Cell Fracture Mechanics, (6) Module Soiling, and (7) Module Environmental Endurance.

Cell Reliability Testing

A joint in-house/contractor-supported R & D test program to stress test and evaluate encapsulated cells was initiated in cooperation with the Encapsulation Task and Process Development Area. The test program includes cells made with different cell metalization systems and encapsulation systems. A key aspect of this effort is an expanded joint failure analysis followup phase which is to be supported by various technical disciplines. It is planned that the actual testing will take place at Clemson University.

Module Voltage Isolation

The voltage isolation task addresses the source and magnitude of leakage currents to ground caused by initial insulation flaws or material aging. The development effort is directed toward predictions of module life and providing for human safety. The electrical insulation environmental test chamber for accelerated aging under voltage of mini-modules and test coupons (with experimental encapsulants) is nearing completion with installation of data collection circuitry and instrumentation. The procurement of 100 mini-modules, earmarked for the above electrical insulation tests, was completed and representative Block IV, PROA and conunercial designs were obtained. The test coupons are being supplied by the encapsulation group and PP & E in a joint testing program for voltage and environmental testing.

The central station module field exposure insulation studies continues with data collection on two experimental modules featuring RTV and EVA encapsulants installed on the new 3000 VDC test stand. The results will give the responses of these encapsulants to exposures of temperature and humidity variations while under 3000 volt electrification.

45

Characterization of voltage breakdown levels of various contractor and JPL in-house polyester films and multilayer composites using the low-voltage breakdown apparatus is continuing. The data reduction software is being developed for rapid analysis of test results.

Interconnect Fatigue

Examination of the mechanical-fatigue life of cell interconnects is continuing in an effort to obtain a 20 year life predictive model. Computer code is being generated to fit interconnect failure data to a Weibull probabalistic function for predicting interconnect failures. The interconnect fatigue report "Solar Cell Interconnect Design for Terrestrial Photovoltaic Modules" was completed and forwarded for review by the organizing cornnittee of the ASME April '82 meeting in Albuquerque, N.M.

Fatigue testing of 5-mil thick clad laminates was initiated with samples received from Texas Instruments (Attleboro, Mass.); stainless steel/copper interconnects, on the basis of preliminary testing, appear to exhibit improved fatigue resistance over pure copper.

Hot Spot Endurance

Development of suitable laboratory test procedures for evaluation of the hot-spot endurance of a module under severe hot-spot field conditions is this activities' objective. Development activities included the revision of the hot-spot endurance studies thermal analysis model to include a family of plots that provide a simple graphic solution for users. The task report on hot-spot heating design guidelines is under revision and was rescheduled for release in February 1982.

A paper entitled 11 Uses of Infrared Thermography in the Low Cost Solar Array Program," was presented at the Annual Meeting of the Society of Photo-optical Instrumentation Engineers in Ottawa, Canada on 9/1-4/81. The paper dealt with the use of the IR Camera in the FSA Operation Area in connection with photovoltaic array field sites (including Mt. Laguna), and with FSA Engineering Area work in connection with hot-spot test development.

Cell Fracture Mechanics

The fracture mechanics study on the mechanical strength of the silicon solar cells continued with the examination of loading rates for silicon testing. The measured strength of silicon cells is dependent on the loading rate, and results with Cz wafers from twist and biaxial stress tests have indicated a decrease in strength with increasing loading rates. A final report, documenting the test and decreasing the effect of loading rates, is being prepared for review.

Module Soiling

Engineering Area personnel gave a presentation on "Low-Cost Methods for Cleaning Photovoltaic Arrays" at the Soiling and Cleaning Conference for Solar Materials at Sandia, Livermore on July 21-22.

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Module Environmental Endurance

Several environmental endurance development efforts are addressed to provide the technical base required to achieve reliable modules with 20-year lifetimes. !ITRI is continuing its work in compiling reliability data on all module design technologies versus how each design technology has performed in both field use and field tests. A major input to the !ITRI work was made when the U.S. Coast Guard Research and Development Center agreed to provide FSA with reliability data obtained from different module designs they have tested, refer to the contractors progress summary.

JPL in-house efforts included the development of a humidity degradation rate curve based on comparisons of humidity testing cycles and humidity temperature data from Solmet weather tapes. To obtain the required temperature-humidity acceleration factors a contract was initiated with Wyle Laboratories to subject Block I and Block III modules to a 6 month long humidity test with environments of 400c, 93% RH and 950c, 85% RH. Results derived from inspections at the end of 10 and 20 days of exposure have noted color changes in tedlar and epoxy substrate materials exposed in the 85/85 chamber, however, no degradation in electrical performance has occurred.

Final manuscripts submitted by Engineering Area personnel for publication in the upcoming issue of the IEEE Transactions on Reliability featuring solar energy devices and systems included:

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"Photovoltaic Array Reliability Optimization," R. Ross

"Investigating Reliability Attributes of Silicon Photovoltaic Cells--An Overview", E. Royal.

"Laboratory Testing of Flat-Plate Photovoltaic Modules", A. Hoffman, J. Griffith and R. Ross

11A Technique for Determining Solar Irradiance Deficits," C. Gonzalez and R. Ross

PERFORMANCE CRITERIA AND TEST STANDARDS

Active interfaces are maintained between the LSA Engineering activities and the SERI Performance Criteria/Test Standards (PC/TS) project to establish Interim Performance Criteria (IPC) and test standards covering both flat-plate and concentrator arrays. Final drafts of 21 test methods were delivered for inclusion in SERl's IPC document (Issue 2) scheduled for release in January, 1982. Two working subgroups in support of the SERI effort collated industry and testing laboratory comnents, revisions and final additions for the above IPC-2 input. The Photovoltaic Environmental Test Subgroup chaired by FSA Engineering personnel held their second meeting at the U.S. Coast Guard Research and Development Center at Groton, Conn. on September 23rd and 24th and reviewed environmental test methods and a visual inspection procedure. This subgroup's objective is to develop

47

for flat-plate and concentrator array elements a cost effective set of qualification test procedures that can provide reasonable assurance of reliable performance in a wide range of U.S. and Worldwide climates. An October 21, 22 meeting of the Electrical Performance Subgroup of the SERI Interim Performance Task Group (led by Arizona State University) was held at Acurex, Mountain View, CA to finalize test method draft for Off-Axis Performance of Concentrator Modules and Optical Element Evaluation Techniques.

Arizona State University was granted a 90 day no cost extension to their contract for developing electrical performance test methods for concentrating photovoltaics.

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AIA RESEARCH CORPORATION

WASHINGTON, DC

Contract Title: INTEGRATED RESIDENTIAL PHOTOVOLTAIC ARRAY DEVELOPMENT


The objective of this study is to develop optimal roof mounted arrays for residences that require the least life cycle energy cost. Optimal array development follows an integrated systems approach to consider detailed electrical, mechanical, thermal, safety and environmental requirements. The resulting array design concept was fabricated in a mock-up partial roof-section model to identify additional roof-array interface concerns. A second model is under development for inspection at the 19th Project Integration Meeting.

Sixteen design concepts were developed by eight teams. These concepts considered both panel and shingle module types, as well as integral, direct, standoff and rack mounting. Three concepts were selected from this group based on proof-of-concept status, significance of innovative features, mounting system reliability, and initial cost. This phase of the study is described in the first quarterly report (DOE/JPL 955893-1).

The three concepts were then evaluated to confirm design trade-offs through concept optimization in production, fabrication, design and specification practice, installation, operation and maintenance of the array. Key innovative features of the design concepts included: reduction in construction trade limitations; adaptability to different mounting types; use of connnonly available materials; use of quick connect/disconnects; and, wiring harness elimination. The single concept selected for further optimization allowed incorporation of the significant innovative features without restraining choice of module size and output or material selection to achieve acceptable system interface, structural support, thermal design, safety, electrical circuit design, reliability, and environmental endurance. This phase of the study is described in the second quarterly report (DOE/JPL 955893-2).

The selected design concept uses nominal 2 kWp, 12 FT. X 24 FT. roofmounting panels. Each panel contains two branch circuits consisting of nine modules that provide a Vno of 199 volts. The 2 Ft. X 8 FT. frameless, gasketless modules are adhesively bonded to cedar panel-rails. Branch-circuit wiring between modules through the prewired panel is accomplished using quick connect/disconnect while panel wiring is accomplished using end-unit busbars. Preformed flashing is provided with each "panel kit" supplied to the job site. The panels can be installed in an integral, direct, or standoff mounting. Array subsystem costs are projected to be less than $1.25/Wp (in 1980 dollars) for a mature 1986 market with annual module production volume of 50000 m2 • Development and optimization of this concept is sunnnarized in the third quarter y report (DOE/JPL 955893-3).

9/29/81

Date

49

Contract Title:

Contract No.:

ENGINEERING AREA

Clemson University Clemson, SC 29631

INVESTIGATION OF RELIABILITY ATTRIBUTES AND ACCELERATED STRESS FACTORS ON TERRESTRIAL SOLAR CELLS

954929

The objectives of this study are to develop accelerated test methods and specifications which can be used to determine the reliability attributes of terrestrial solar cells. The overall program approach involves comparing the response of various types of cells subjected to different stress conditions involving the accelerating factors of humidity, temperature, current, and rate of change of temperature with time.

Preliminary stress testing of encapsulated cells shows remarkable correlation with the unencapsulated results indicating that the encapsulation serves mainly as mechanical rather than environmental protection.

To further evaluate the reliability attributes of cells with advanced metallization systems a new round of unencapsulated cell testing has just gotten underway. In addition, a more thorough program to examine the response of encapsulated cells to accelerated stress testing is scheduled to begin in early 1982.

10/1 Ls, Date

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DSET LABORATORIES!' INC..

PHOENIX, ARIZONA 85029

Contract Title: SUNLIGHT AGING TESTS OF' SOLAR CELL MODULES

Contract No.: BQ-713131

The JPL contract for "Sunlight Aging of Solar Cell Modules" has been completed. The 2 1/2 year program included weathering of mini-modules on the Super-Maq Frensel concentrating accelerated weather machine, submini-modules on the standard EMMAQUA@ accelerated weathering machine, exposure of submini-modules on an equatorial tracking mount with water spray (EEKQUA) and conventional exposure of submini-modules on a 34° South direct exposure rack. Also included in the program were weekly visual inspections, monthly 35 mm slide photos and monthly 1-V measurements used for monitoring the physical and electrical characteristics of the modules.

Failure modes experienced during the program included cell cracking, delamination, carbonation, and contact corrosion, as well as noticeable max power losses, non-ohmic contact, and series resistance changes. Overall the program was successful. A quote from a paper, concerning this program, co-written by JPL and DSET that was presented by JPL at the 1980 Photovoltaic Solar Conference at Cannes, France in October of 1980 states the following, "B~sed on the results of this initial series of accelerated sunlight aging of photovoltaic modules it can be concluded that (1) field experienced failure modes have been duplicated, (2) acceleration factors of 6X to BX are readily attainable, and (3) the test method is feasible as a predictive tool for photovoltaic module lifetime durability. New module designs should be subjected to this test procedure as they become available for evaluation. 11 Also, certain design flaws that may lead to catastrophic failures have been detected quickly using the DSET accelerated exposure technique.

The advantage of a DSET accelerated test lies in its ability to complete the exposure period 8 times quicker than conventional exposure while maintaining near-natural environmental parameters. Therefore, the success of this contract stems from the fact that the program results verify the concept of natural sunlight accelerated weathering of photovoltaic modules to predict certain failure modes as well as lifetime durability. Super-Maq, EMMAQUA@, EEKQUA and Conventional exposure are now currently available at DSET for commercial clients.

~~L Approval Signature

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October 7, 1981 Date

ENGINEERING AREA

DSET LABORATORIES, INC. PHOENIX, ARIZONA 85029

Contract Title: NATURAL SUNLIGHT SPECTRAL MEASUREMENTS

Contract No.: BQ-713137

DSET' s So 1 a r Scanning Spec t roradi ometer ( SSSR) has been fi.e 1 d-checked and calibrated. Operational procedures have been developed, and are being documented. Formatting and computer ~oftware development required to interface the 16-bit BCD output of the rzdiometer with the Data General Nova 30 Computer (OSET's main frame) and a "transportable" Data General MicroNova MClOO (for field operations) have been completed.

All hardware and the rights to the desiyn and construction are the property of DSET Laboratories. In turn for computer software program support, a data subscription service has been arranged with JPL for delivery of routine solar spectral data obtained at the DSET New River site.

The spectrorad·iometer is based on the following components: (1) source optics comprising a 6-in integrating sphere and a detachable/coupled pyrheliometer with a 6° field of view, (2) a double quartz prism high resolution monochromator manufactured by Carl Leiss (Berlin), a Princeton Applied Research synchronous motor-chopper assembly, (3) thermo-electrically cooled lead sulfide infrared and UV-enhanced silicon photodiode UV-VIS detectors, and (4) associated calibration and control equipment.

The spectroradiometer is capable of making complete wavelength continuous solar spectral measurements in the 290- to 2500nm wavelength region for both the direct beam and global conditions--the latter at any· anyle of tilt from horizontal and 0° horizontal. The direct beam measurement subtends a cone having a planar field of view of approx.6°.

During the past twelve months, efforts have been directed to making the SSSR field operational and reliable. The facility is now completed. A field check to verify calibration and to ensure that optical misalignment does not occur during laboratory-to-field transportation has been completed.

The spectroradiometer is being employed to measure both the direct beam and global spectrum all day on approximately the 15th of each month for two years, and all day for a complete week at each of the two annual solstices and two annual equinoxes .

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ENGINEERING AREA General Electric Co.

Advanced Energy Programs Department Philadelphia, PA 19101

Contract Title: Integrated Residential Photovoltaic Array Development

Contract No.: JPL 955894

The objective of this contract i s to develop an optimized integrated residential photovoltaic array concept and to prepare detailed design definition which includes sufficient information to permit fabrication, assembly and installation by a competent third-party. A prototypical s imulated roof section of the optimized design concept will be constructed to demonstrate the fabrication and installation features of the photovoltaic array.

The detailed des ign of the selected integrated residential photovoltaic array has been completed and described in the Third Quarterly Report (DOE/JPL 955894-3) . A six module simul ated roof section , which incorporates all the design features of the selected array concept, is currently under construction and is schedul ed for display at the 19th FSA PIM.

An additional task activity, which addresses by-pass diode integration within a photovoltaic module, has been started since the last PIM. Available diode types and representative mounting configurations have been identified and thermal analyses performed to establish the range of forward current carrying capabil ity for each configuration.

-i.~ 1 SL«....J, S:. Approval Signature Date

53

ENGINEERING AREA

IIT Research Institute

Chi cago , Ill Contract Title: Deve lopment of Rel iability Engineering Techni ques for

Flat Plate Photovoltaic Modul es/Arrays

Contract No. : 9 5 5 720

The objective of the !ITRI support study is to deve l op research and development techniques for the re l iability engineering of terrestrial fl at plate photovoltaic modules/arrays. Meeting the objective involves accomp lishment of at l east the fol lowing sub-tasks:

o Develop methods appropriate to establi sh failu re rates for PV modules .

0 Devel op methods to determine degradation modifying factors which can be used during R&D as an analysis tool for assess ing the re li abi l ity/ life potential of photovoltaic modul es.

During this reporting period data was obtained from t he U.S. Coast Guard (USCG) on modules exposed to mar ine environment s both from field sites and laboratory exposure in pressure immersion and temperature (PIT) tests. The data is being used to develop reliability weighting facto r s as a f unction of differences in design, application, exposure etc . This study will generate a method t o properly allocate and predict the reli ability on any new photovo l taic module design prior to fie ld dep l oyment.

P. Milhalk anin/R. Anderson 10/09/81 Approval Signature Date

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Contract No. :

ENGINEERING AREA

Underwriters Laboratories Inc.

Melville, New York

Development of Photovoltaic Array and Module Safety Requirements

955392

The present objectives include the (1) development of system safety schemes, (2) characterizing arcing phenomena as to its propensity for ignition of materials, and (3) refinement of a draft Standard for Safety, Photovoltaic Modules and Panels .

With regard to the development of system safety schemes, a differential type de ground fault detector (100 ma sensitivity) has been constructed and installed in the MIT- Lincoln Laborato r y prototype at the Northeast Photovoltaic Residential Experimental Station. This installation is being monitored for false (unwanted) responses and for desired responses to known faults . The results of this work are expected to be available in early November , 1981, and any problems are expected to be uncovered at that time .

Arcing tests, attempting to cause ignition of various materials from arcs at sever a l current and voltage levels and between several different electrode materials, are being conducted. It is hoped that information relative to arc magnitude which might ignite materials will be gained, and that such can be used to describe the sensitivity of protective devices for incorporation in arrays. This is expected t o be a complex task because of the many variables involved.

The draft of the Proposed Standard for Safety , Photovoltaic Modules and Panels, has been completed to the degree that will allow its use in evaluating products. Such evaluations a r e now being undertaken. These evaluations are expected to show the viability and/or failings of the document .

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OPERATIONS AREA


Pasadena, CA

On the remaining Block IV design phase contracts, the Solarex intermediate-load and residential modules and the ARCO intermediate-load modules have passed qualification tests. Redesigned Photowatt modules have been delivered and are now in test. ARCO Solar residential modules have experienced some test problems, as a result of which the manufacturer has made some minor design and process changes and will supply another set of modules for test. Of the small Block IV production purchase orders ASEC, Spire and Solarex are in production, and the ARCO Solar intermediate-load purchase order has been issued.

A new program has been initiated to provide for purchasing modules (which are not involved in the Block programs) for test to Block V specifications. Following solicitation of price quotations, purchase orders have been issued, to date, to ASEC, Free Energy Systems, Motorola, Solar Power, and Solec International.

All Block V module design contracts have been issued. The contractors are ARCO Solar, Inc., General Electric Company, Mobil Tyco Solar Energy Corporation, RCA, Solarex Corporation, and Spire Corporation.

Environmental testing to Block IV specifications was carried out on a variety of modules, including process development samples, commercial units, MIT/LL Residential Experiment Station modules, and Block IV modules. In addition seven modules have been subjected to Block V qualification tests to assess the effect of these tests on existing module technology. On a few modules these tests revealed some problems which did not occur under Block IV tests. Examples of such problems are a few cell failures from hot spot tests, broken interconnects (on one module) from the 200-cycle thermal test, and some delamination and hardware corrosion from the humidity-freeze test.

The field test plan was restructured to reduce field test costs and to redirect the emphasis toward early detection of module failure modes. This plan has been implemented, as follows. The 12 continental remote sites have been decommissioned and the modules are being returned to JPL for final testing where appropriate. Some of these modules have been redeployed to the Goldstone site for continuation of endurance tests. A new 5-site network has been reconfigured to accommodate the Block IV modules that will be deployed. The JPL on-lab site field


57

In-House Program

OPERATIONS AREA (Continued)

wiring system was redesigned for the new modules that will be mounted both individually and in arrays. As the new modules are received and mounted the final wiring will take place. The new portable I-V logger is being constructed and should be ready for field use in late November or early December.

The failure analysis activity continues to perform analyses on Block II and III modules returned from Bryan, Ohio, Mead, Nebraska and Natural Bridges. The Bryan and Mead failures are as previously reported, fractured cell interconnects and opens due to cracked cells. The Natural Bridges failures relate to cell string shorts to ground caused by the interconnect foil coming in contact with the module frame and to broken glass caused by edge flaws and temperature stress.

Failure analysis of modules from residential applications has verified reported current leakage between the cell string and ground. The leakage is found between the back tedlar/metal laminate and the frame. Creating a hard short between the frame and the back tedlar laminate improves the high voltage withstanding capability of the laminate structure. Also, the change in leakage current with temperature between the frame, laminate and cell string is being investigated. It appears that the pottant, PVB, becomes more resistive with temperature.


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OPERATIONS AREA

Applied Solar Energy Corporation

City of Industry, CA

CONTRACT TITLE: Block IV Photovoltaic Solar Cell Production Module

CONTRACT NO.: FY-730101

Applied Solar Energy Corporation Block IV production module has over a 11 dimensions of 27. 38 11 x 47 .19 11 x 1. 54 11

• It consists of 3/16" thick tempered Sunadex glass, an aluminum frame, 136 solar cells, polyvinyl butyral for encapsulation, 11 Proglaze 11 for edge sealing, Tedlar film for moisture barrier, and the necessary electrical terminals. The solar cells are of 311 diameter and have proven Titanium-Palladium-Silver contacts and multilayer anti-reflection coating for high performance. The average efficiency of the cells is in excess of 13.5%. The 136 solar cells in the module are connected 4 in parallel and 34 in series which provides an average output power of 71.0 watts at a nominal operating voltage of 14.0 volts at NOCT of 54.5 degrees C.

Applied Solar Energy Corporation has delivered 35 modules with an average power of 73.4 watts. A procedure for the repair of defective modules has been developed. Some modules were repaired according to the procedure with JPL's consent. The completion of the modules has been rescheduled to allow for further investigation of the lamination and repair techniques.

59

ARCO Solar, Inc.

Chatsworth, CA

Contract Title: Design, Fabrication, Test, Qualification, and Price Analysis of "Third Generation" Design Solar Cell Modules


This contract involves two module designs, intermediate load and one for residential applications.

Intermediate Load Module Design

one for rooftop

The final review for the ILM design was held. The drawing package and inspection system plan were updated. The modules of this design have completed and passed all the qualification tests carried out at AS, Inc. and at JPL. The final report draft was approved and is now ready for distribution. The work in this part of the contract is complete.

Residential Module Design

Modules are presently under test at JPL and at AS, Inc. according to the qualification plan. During thermal cycling, the Tedlar {R) top layer shrinks and remains under tensional stress. In the inner radius where the pan edges are turned up, occasional delamination is observed. This phenomenon has had no effect on electrical performance and in actual use will be covered by overlap of adjoining roofing parts. Technical studies are under way to eliminate the phenomenon.

l[.J ' . .,.

60

cJ::t~ ~ 8"1

tThj Dote

Contract Tit I e :

Contract No.:

OPERATIONS AREA General Electric Co.

Advanced Energy Programs Department Philadelphia, PA 19101

Block V Module Design

JPL 956098

This contract activity, which was initiated on August 15, 1981, is directed toward the design of an advanced residential module meeting the requirements of JPL Document 5101-162. A rectangular, directmounted, shingle-type module has been designed to meet these requirements. This module mounts directly to the roof sheathing and, when assembled in an overlapped shingle fashion, provides a watertight exposed surface. The design features and performance characteristics of the module are surrmarized in the accompanying table.

The preliminary design review for this contract is scheduled for November 13, 1981.

Character; stic Value

Solar Cell Size lOOmn quasi-square

Electrical Circuit Configuration 36 series x 2 parallel

Total Solar Cell Area per Module 0.6996 m2

Module Area 0.7812 m2

Module Packing Factor 0.896

Glass Superstrate 5mm thick, Tempered Sunadex

Encapsulant EVA

Number of By-Pass Diodes 3

Diode Type and Mounting Chips integral with encapsulant laminate

Module Maximum Power Output at 90.0H Peak Power Conditions ( 100 mt-l/nun2 insolation and 2soc cell temperature)

Module Efficiency 11.5 percent

1v.~ + sL, __ J., JD. Oc~ C.. J I "llS'} Approval Signature Date

61

PHOTOWATT INTERNATIONAL, INC., (SENSOR TECHNOLOGY, INC.) TEMPE, AZ 85281

Contract Title: THIRD GENERATION SOLAR CELL MODULE

Contract No. : 955410 Date: January 5, 1981

This contract was initiated November 1, 1979 and has as major objectives the design, fabrication, performance qualification and price analysis of an intermediate load s~olar module that meets or exceeds the requirements of JPL 5101-16. Photowatt's objective is also to design into the intermediate load module, a significant degree of producibility and tolerance to normal production related defects.

During this reporting period, Photowatt fabricated a group of six modules per revised design/manufacturing criteria and supplied these modules to JPL for qualification testing and inspection. It is anticipated that a final design review will be scheduled during the next report period.

?p/t! ~--( Approval Signature

M. C. Keeling ( 62


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Contract Title:

Contract No.:

MODULE DEVELOPMENT

RCA CORPORATION

CAMDEN, NJ

DESIGN OF BLOCK V SOLAR CELL MODULES - 1981

. 956100

The contract has just begun at the time of sul:mission of this description.

The module under design is 4' x 4' in size; it is covered with glass sheets both in the front and in the back; and it is composed of closely packed rectangular cells encapsulated in EVA. It is configured to produce SV, and the design is fault tolerant. The application is aimed at a large Intennediate Load Center or a Small Central Station .

M. L. Levene 10/9/81


63

Solarex Corporation

Rockville, Maryland

Contract Title:

Contract No. :

Design, Fabrication, Test, Qualification, and Price Analysis of "Third Generation" Design Solar Cell Modules 955404

Solarex has built 36 modules, 18 for intermediate load center application and 18 for residential applications. Features include:

• Semicrystalline silicon as the basic cell material;

• Outside envelope dimensions of 63.5 cm x 120 cm;

• 72 9.5 cm x 9.5 cm cells arranged in a high density pattern;

• Fault tolerant cell-interconnect design which allows for some cell damage with little resulting performance degradation.

• 3/16 in tempered Sunadex Superstrate Ethylene Vinyl Acetate (EVA) Pottant, White Tedlar moisture barrier.

The modules have passed environmental tests and the only items still to be done are the final design report and the SAMICS analysis. These are in progress. Some technical data as verified by JPL includes:

NOCT - oc

Average Power at SOC -Watts

Maximum Module Power, 2aoc, Peak Power (Solarex measurement) - Watts

Residential

56

56

72.4

~ ~ ~ )" (-; \.::b~ s L-Approval Signature

64

Intermediate Load

56

56

7 J.. 8

October 8, 1981

Date

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Solarex Corporation

Rockville, Maryland

Contract Title: Design of Block V Solar Cell Modules


-=

The contract was initiated on August 7, 1981. Solarex plans several innovations in the Block V design. These include:

A larger cell - a 10 cm x 15 cm cell made from Semix semicrystalline material.

A fault tolerant cell design which incorporates multiple current path redundancy and integral feedthroughs.

A larger module - 37.8 in x 54.1 in, which contains 78 cells.

Cell design and fabrication studies, mechanical design, and the inspection system plan are in progress.

This contract has no hardware deliverables, but we plan to fabricate several mini-modules for demonstration at the final design review •

Approval Signature

65

October a, 1981 Date

Contract Title:

Solarex Corporation

Rockville, Maryland

Block IV Production Modules

Contract No. : Purchase Orders CB-730108, CB-730109

Solarex is building 75 intermediate load modules and 25 residential load modules in accordance with the design established and qualified as part of contract 955404.

Production is in progress. A JPL Qual~ty Assurance inspector is doing a 100 percent source inspection.

As of this date, approximately half the task has been completed.

_j~~s ~ \-Ws~ Approval Signature

66

October 8, 1981

Date

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Contract Title:

Contract No. :

OPERATIONS AREA

SOLENERGY CORPORATION

WOBURN, MASSACHUSETTS 01801

HEM-MATERIAL MODULE PURCHASE

JL-730114

Solenergy Corporation received a JPL purchase order for the design and fabrication of modules using HEM silicon, totaling 2kW of power. A high quality, high density module with a low iron tempered glass superstrate and annealed glass substrate, using silicone rubber encapsulation was designed to exceed the requirements of JPL document 5101-16/A. Drawings and Inspectio~ System Plan are submitted to JPL. The module features 44 -10 x 10cm cells, is appropriately protected against backward biasing and has a fault tolerant cell interconnect design to allow for cell breakage. The first modules are fabricated and will be delivered to JPL after inhouse inspection. Further production awaits delivery of more silicon material.

67


Contract Title:

Contract No. :

OPERATIONS AREA

Spire Corporation Bedford, Massachusetts 01730

DESIGN, FABRICATION, TEST, QUALIFICATION AND PRICE ANALYSIS OF THIRD GENERATION D~IGN SOLAR CELL MODULES LK-730100

The Block IV module has been revised to accommodate a larger solar cell. The new design uses 108 cells to obtain similar performance to that generated previously by 152 cells. The parallel crosstie frequency has been changed to reduce the maximum power dissipation per cell in the event of reverse bias operation.

The design is completed and module production has begun. Forty modules will be fabricated, producing a peak power of 2 kW. To date fourteen modules producing a total peak power of 718 watts at SOC have been delivered.

Individual module performance at SOC (NOCT = 560C) is given below:

P max ( watts) 50.9 49.7 49.0 49.5 52.3 53.2 52. 7 52.2 51.4 51.1 51.0 52.0 51.6 51.4 51.3 +1.2

~R~~~ Approva ignatu e

68

17(%) 10.2

9.9 9.8 9.9

10.5 10.6 10.5 10.4 10.3 10.2 10.2 10.4 10.3 10.3 10.3 +0.2

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OPERATIONS AREA

Spire Corporation Bedford, Massachusetts 01730

Contract Title: DESIGN OF BLOCK V SOLAR CELL MODULES


Under this 4 month program Spire Corporation will prepare the initial design of a Block V Module for residential applications. The design will be based upon Spire's successful Block IV module but will include improvements, simplifications and changes for residential applications. Features of the new design will include:

• Elimination of module frame • Incorporation of roof mounted array structure • Elimination of junction box • Internally laminated bypass diodes • Improved fault tolerance in cell design and circuitry • Larger size module • Improved high voltage isolation

c~££~~ Approval S~ure

69

CONTRACTS AND DOCUMENTS

.-,

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'--' LSA PROJECT ACTIVE CONTRACTS

,-,

-._j EXPECTED

START COMPLETION CONTRACT TASK NAME DATE DATE NUMBER DESCRIPTION

~

L....J SILICON MATERIAL TASK:

HEMLOCK SEMICONDUCTOR CORP. 10/79 05/82 955533 DEVELOPMENT OF A POLYSILICON -, HEMLOCK, MI PROCESS

...:..I C. T. SAH ASSOCIATES 02/77 10/61 954685 STUDY OF EFFECTS OF IMPURITIES URBANA, IL IN SILICON MATERIALS

,-""")

SOLARELECTRONICS 07/81 07/82 956061 INVESTIGATION OF ---".] CAMBRIDGE, MA HYDROCHLORINATION REACTOR

TEXAS RESEARCH & ENGINEERING 10/75 05/82 956045 SILICON PRODUCTION PROCESS -, PORT NECHES, TX EVALUATION

......:..J UNION CARBIDE CORPORATION 10/75 12/82 954334 SILANE TO SILICON EPSDU NEW YORK, NY

c-,,

WESTINGHOUSE R&D CENTER. 10/75 11/81 954331 SOLAR CELL GRADE SILICON '-' PITTSBURGH, PA DEFINITION

.-, LARGE-AREA SILICON SHEET:

·__J APPLIED SOLAR ENERGY CORP. 05178 09/81 955089 SOLAR CELL PROCESS DEVELOPMENT CITY OF INDUSTRY, CA

,-, CORNELL UNIVERSITY 03/78 05/82 956046 CHARACTERIZATION OF STRUCTURAL,

-........J' ITHACA, NY AND CHEMICAL PROPERTIES OF SILICON

~ CRYSTAL SYSTEMS 07/81 10/82 956073 MULTI-WIRE WAFERING TECHNOLOGY SALEM, MA DEVELOPMENT BY A FIXED ABRASIVE

._J SLICING TECHNIQUE (FAST)

--,,, KAYEX CORPORATION 09/80 05/82 955733 ADVANCED CZ GROWTH PROCESS ROCHESTER, NY

.. ..;) MATERIALS RESEARCH, INC. 06/80 11/81 955676 ANALYSIS OF DEFECTIVE STRUCTURE

CENTERVILLE, UT IN SILICON . ..,

MOBIL-TYCO SOLAR ENERGY CORP. 10/75 12/81 954355 EDGE-DEFINED FILM-FED GROWTH FOR ,_J WALTHAM, MA SILICON GROWTH DEVELOPMENT

.,.., NORLIN INDUSTRIES 03/81 05/82 955981 MULTIBLADE SAWING (MBS) OF CARLISLE, PA OF SILICON INGOT INTO SHEET

~

SILICON TECHNOLOGY CORP. 06/81 06/82 956043 ADVANCED ID WAFERING TECHNOLOGY --, OAKLAND, NJ

UNIVERSITY OF ILLINOIS 06/81 07/82 956053 STUDY OF THE ABRASIVE WEAR RATE ~ CHICAGO, IL OF SILICON

-..., WESTINGHOUSE ELECTRIC CORP. 10/80 09/82 955843 DENDRITIC WEB PROCESS DEVELOPMENT PITTSBURGH, PA

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EXPECTED START COMPLETION CONTRACT TASK

NAME DATE DATE NUMBER DESCRIPTION

ENCAPSULATION:

CASE WESTERN UNIVERSITY 03177 12/81 954738 SYSTEM STUDIES--BASIC AGING AND CLEVELAND, OH DIFFUSION

ILLINOIS TOOL WORKS 09179 11/81 955506 DEPOSIT OF ANTI-REFLECTIVE ELGIN, IL COATING BY ION PLATING

ROCKWELL SCIENCE CENTER 03177 12/81 954739 MATERIALS INTERFACE PROBLEM STUDY THOUSAND OAKS, CA

SPECTROLAB, INC. 11/79 11/81 955567 DESIGN, ANALYSIS, AND TEST SYLMAR, CA VERIFICATION OF ADVANCED

ENCAPSULATION SYSTEMS

SPRINGBORN LABORATORIES, INC. 05176 08/82 954527 METHODS AND MATERIAL PROPERTIES ENFIELD, CT EVALUATION

UNIVERSITY OF MASSACHUSETTS 08179 12/81 955531 DEVELOPMENT OF SYNTHETIC AMHERST, MA PROCEDURES FOR POLYMERIC

ULTRAVIOLET STABILIZERS AND ABSORBERS

UNIVERSITY OF TORONTO 01/80 04/82 955591 PHOTODEGRADATION MODELING TORONTO, ONTARIO, CANADA

PROCESS DEVELOPMENT:

APPLIED SOLAR ENERGY CORP. 03/79 11/81 955423 LABORATORY SERVICES CITY OF INDUSTRY, CA

BERND ROSS ASSOCIATES 05/80 11/81 955688 DEVELOPMENT OF AN ALL METAL SAN DIEGO, CA THICK FILM COST EFFECTIVE

METALLIZATION SYSTEM FOR SOLAR CELLS

PHOTOWATT INTERNATIONAL 05/81 05/82 955986 AR COATING AND Ni/Cu METALLIZATION TEMPE, AZ OF SOLAR CELLS

SOLAREX CORPORATION 11/80 03/83 955902 MODULE EXPERIMENTAL PROCESS SYSTEM ROCKVILLE, MD DEVELOPMENT UNIT {MEPSDU)

SPIRE CORPORATION 01/80 02/82 955640 DEVELOPMENT AND FABRICATION OF A BEDFORD, MA SOLAR CELL JUNCTION PROCESSING

SYSTEM

UNIVERSITY OF PENNSYLVANIA 05/81 05/82 956034 MODULE EXPERIMENTAL PROCESS SYSTEM PHILADELPHIA, PA DEVELOPMENT UNIT {MEPSDU)

ANALYSIS/EVALUATION

WESTINGHOUSE ELECTRIC CORP. 11/80 03/83 955909 MODULE EXPERIMENTAL PROCESS SYSTEM PITTSBURGH, PA DEVELOPMENT UNIT (MEPSDU)

72

--,

,.__J

.,--,

o__J

!__., EXPECTED

d START COMPLETION CONTRACT TASK NAME DATE DATE NUMBER DESCRIPTION

~

ENGINEERING: Lc.J

AIA RESEARCH CORPORATION 11/80 11/81 955893 INTEGRATED RESIDENTIAL PV r""1 WASHINGTON, D.C. DEVELOPMENT

t..::.J CLEMSON UNIVERSITY 12/77 09/82 954929 INVESTIGATION OF RELIABILITY AND CLEMSON, SC ACCELERATED STRESS FACTORS ON

TERRESTRIAL SOLAR CELLS ....,., GENERAL ELECTRIC CORP. 10/80 11/81 955894 INTEGRATED RESIDENTIAL

_:.) PHILADELPHIA, PA. PHOTOVOLTAIC ARRAY DEVELOPMENT

,-.. IIT RESEARCH INSTITUTE 03/80 12/81 955720 RELIABILITY ENGINEERING TECHNICAL

'-'"-.) CHICAGO, ILL SUPPORT

UNDERWRITERS LABORATORIES, INC. 05/79 11/81 955392 SOLAR ARRAY AND MODULE SAFETY ,-,, MELVILLE, NY REQUIREMENTS

"-'-' MODULE PRODUCTION:

-~ ARCO SOLAR, INC. 08/81 12/61 956097 DESIGN OF BLOCK V SOLAR CELL

l...'-'.J CHATSWORTH, CA MODULES - 1981

GENERAL ELECTRIC CO. 08/81 12/81 956098 DESIGN OF BLOCK V SOLAR CELL ,-, PHILADELPHIA, PA MODULES - 1981

L..J MOBIL-TYCO SOLAR ENERGY CORP. 08/81 12/61 956099 DESIGN OF BLOCK V SOLAR CELL WALTHAM, MA MODULES - 1981

,--. PHOTOWATT INTERNATIONAL 04/79 11/81 955410 DESIGN AND FABRICATION, BLOCK IV

''-"-' TEMPE, AZ MODULES

RCA CORPORATION 08/81 12/61 956100 DESIGN OF BLOCK V SOLAR CELL r, WALTHAM, MA MODULES - 1981

,_J SOLAREX CORPORATION 08/81 12/82 956102 DESIGN OF BLOCK V SOLAR CELL ROCKVILLE, IL MODULES

~ SPIRE CORPORATION 08/8 12/82 956103 DESIGN OF BLOCK V SOLAR CELL • ._J BEDFORD, MA MODULES

,....,

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.-, 73

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Document Number

5040-29 ERDA/JPL-1012-76/3

5101-2 ERDA/JPL-1012-76/1

5101-5 ERDA/JPL-1012-76/4

5101-7 ERDA/JPL-1012-76/6

5101-8 ERDA/JPL-1012-76/7

5101-10 ERDA/JPL-1012-77/1

5101-12

5101-13

5101-14

5101-15

FSA PROJECT PUBLISHED DOCUMENTS

Author/Date

Doane, J. w. June, 1976

PROJECT OFFICE January, 1976

PROJECT OFFICE April, 1976

PROJECT OFFICE October 8, 1976

PROJECT OFFICE July 30, 1976

PROJECT OFFICE

Zoutendyk, J. October 28, 1976

Gonzalez, C. C. February 14, 1977

Edelson, E. January 26, 1977

Chamberlain, R. G. September 1977

75

Document Title

The Cost of Energy From Utility-Owned Solar Electric Systems

Proceedings of the First Task Integration Meeting

Proceedings of the Second Project Integration Meeting

LSA First Quarterly Report - April 1976 to June 1976

Proceedings of the Third Project Integration Meeting

LSA Second Quarterly Report - July 1976 to September 1976

Progress in Silicon Crystal Technology for Terrestrial Photovoltaic Solar Energy Conversion

Availability of Ultraviolet Radiation Data (for Encapsulation System Design)

Preliminary Analysis of Industrial Growth and the Factors That Affect Growth Rate

SAMICS (Solar Array Manufacturing Costing Standards) Workbook

Document Number

5101-16 Rev. A DOE/JPL-1012-78/10

5101-19

5101-20

5101-21 Rev. B

5101-24 ERDA/JPL-1012-77/2

5101-31

5101-32 DOE/JPL-1012-77/3

5101-33

5101-36

5101-39

5101-40

5101-43

Author/Date

LSA. ENG. AREA November 1, 1978

Moore, D. February 28, 1977

Cantu, A.H. February 28, 1977

Bishop/Anhalt November 3, 1978

PROJECT OFFICE

Stultz/Wen July 29, 1977

PROJECT OFFICE

Chamberlain/Aster September 10, 1977

Smokler, M. October 15, 1977

Jaffe, P. August 3, 1978

Coulbert, C. D. June 8, 1977

Grippi, R. A. October 7, 1977

76

Document Title

Block IV Solar Cell Module Design and Test Specification for Intermediate Load Center Applications

Cyclic Pressure - Load Developmental Testing of Solar Panels

Test Program on Low-Cost Connector for Solar-Array Modules

Acceptance/Rejection Criteria for JPL/LSA Modules

Project Quarterly Report - 3 for the Period October 1976 to December 1976

Thermal Performance Testing and Analysis of Photovoltaic Modules in Natural Sunlight

Quarterly Report - 4 for the Period January 1977 to March 1977

Interim Price Estimation Guidelines: A Precursor and an Adjunct to SAMIS III, Version One

User Handbook for Block II Silicon Solar Cell Modules

LSA Field Test Activity System Description

Development & Validation of A Life-Prediction Methodology for LSA Encapsulated Modules

Module Efficiency Definitions, Characteristics and Examples

F1' kJ

F' ~

F' tw

C ,

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w

Document Number

5101-45

5101-46 DOE/JPL-1012-77/4 JPL Publ. /178-9

5101-51

5101-53 DOE/JPL-1012-77/6

5101-54 Vol. I DOE/JPL-1012-78/1

5101-54 Vol. II DOE/JPL-1012-78/1

5101-55 DOE/JPL-1012-78/2

5101-56 DOE/JPL-1012-78/3

5101-57 DOE/JPL-1012-78/7

5101-58

5101-59

Author/Date

Gonzalez, C. C. December 6, 1977

PROJECT OFFICE June, 1977

Praturi/Lutwack/ Hsu July 1 7, 1977

O'Donnell/Leipold/ Hagan March 1, 1978

Smith, J. L. April 1978

Smith, J. L. March 1, 1978

PROJECT OFFICE

Turner, G. B. March 1, 1978

Chen, C. P. February 22, 1978

Estey, R. S. March 15, 1978

Document Title

Environmental Hail Model for Assessing Risk to Solar Collectors

Project Quarterly Report-5 for the Period April - June 1977

Chemical Vapor Deposition of Silicon from Silane Pyrolysis

Compatability Studies of Various Refractory Materials in Contact with Molten Sil icon

Historical Evidence of Importance to the Industrialization of Flat-Plate Silicon Photovoltaic Systems: Executive SuIIDDary

Historical Evidence of Importance to the Industrialization of Flat-Plate Silicon Photovoltaic Systems

Project Quarterly Report-6 for the period July 1977 - September 1977

Structure of Deformed Silicon and Implications for Low Cost Solar Cells

Multi-Wire Slurry Wafering Demonstrations

Measurement of Solar and Simulator Ultraviolet Spectral Irradiance

Chamberlain, R. G. SAMICS Usage Update No. 1 February 1, 1978

77

Document Number

5101-60 Rev. B

5101-61

5101-62 DOE/JPL-1012-78/6

5101-65 D0E/JPL-10l2-78/7A

5101-68 Rev. A DOE/JPL-1012-47 JPL Puhl. //80-51

5101-69

5101-70 Rev. B

5101-71 Rev. B

5101-72

5101-73 DOE/JPL-1012-78/8

Author/Date

Met ca 1 f , M • S • April 21, 1980

Cuddihy, E. April 13, 1978

Moore/Wilson October 15, 1978

LSA ENGR. AREA March 24, 1978

Aster, R. W. January 15, 1980

Daud/Koliwad June 15, 1978

Document Title

Standard Assembly-Line Manufacturing Industry Simulation (SAMIS) Computer Program User's Guide, Release 3

Encapsulation Material Trends Reliability 1986 Cost Goals

Photovoltaic Solar Panel Resistance to Simulated Hail

Photovoltaic Module Design, Qualification and Testing Specification

Price Allocation Guidelines January 1980

Effect of Grain Boundary in Silicon Sheet on Minority Carrier Diffusion Length and Solar Cell Efficiency

Chamberlain/Firnett Standard Assembly-Line Manufacturing /Horton Industry Simulation SAMIS Design April 21, 1980 Document Release 3

Chamberlain, R. G. April 21, 1980

Maxwell, H. June 15, 1978

Von Roos, O. May 31, 1978

78

Standard Assembly-Line Manufacturing Industry Simulation (SAMIS) Computer Program Source Code, Release 3

Encapsulant Candidate Materials for 1982 Cost Goals

Determination of Bulk Diffusion Lengths for Angle-Lapped Semiconductor Material via the Scanning Electron Microscope -A Theoretical Analysis

F luu;

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I

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Document Number

5101-75

5101-76 DOE/JPL-1012-78/9

5101-77

5101-79

5101-81 DOE/JPL-1012-78/13

5101-82 DOE/JPL-1012-79/6

5101-83 DOE/JPL-1012-78/14

5101-84 DOE/JPL-1012-78/11

5101-85 DOE/JPL-1012-78/12

5101-88 DOE/JPL-1012-2 JPL Puhl. #79-14

5101-91, Vol. I DOE/JPL-1012-25,Vol.l JPL Puhl. #79-103,Vol.l

Author/Date

Smith, J. L. May 30, 1978

Stultz, J. W. July 31, 1978

Gupta, A August 10 , 197 8

Gupta, A. August 18, 1978

PROJECT OFFICE November 15, 1978

Smokler, M. I. February 1, 1979

LSA ENGR. AREA November 1, 1978

Hoffman/Miller October 15, 1978

Jaffe, Peter September 15, 1978

PROJECT OFFICE

Smith, J. H. January 15, 1980

79

Document Title

The Penetration of the International Market by Domestically Produced Photovoltaic Power Systems: A Survey of Recent Estimates

Thermal and Other Tests of Photovoltaic Modules Performed in Natural Sunlight

Photodegradation of Polymeric Encapsulants of Solar Cell Modules

Effect of Photodegradation on Chemical Structure and Surface Characteristics of Silicon Pottants Used in Solar Cell Modules

Project Quarterly Report 7 for the Period October 1977-December 1977

User Handbook for Block III Silicon Solar Cell Modules

Block IV Solar Cell Module Design and Test Specification for Residential Applications

Bias-Humidity Testing of Solar Cell Modules

LSA Field Test Annual Report August 1977-August 1978

Project Quarterly Report 8 for the Period January - March 1978

Handbook of Solar Energy Data for South-Facing Surfaces in the United States-Volume I: An Insolation, Array Shadowing, and Reflector Augmentation Model

Document Number

5101-91, Vol. II DOE/JPL-1012-25,Vol.2 JPL Puhl. #79-103,Vol.2

5101-91, Vol. III DOE/JPL-1012-25,Vol.3 JPL Puhl. #79-103,Vol.3

5101-93 DOE/JPL-1012-79/5

5101-94 DOE/JPL-1012-78/17

5101-96 DOE/JPL-1012-23

5101-98 DOE/JPL-1012-79/1

5101-99 Period April - June 1978

5101-100 DOE/JPL-1012-4 JPL Puhl. #79-16

5101-102

5101-103 D0E/JPL-1012-79/8A

Author/Date



Chamberlain, R. G. January 15, 1979

Aster, Robert December 1, 1978

Tsou/Schwartz March 1, 1979

Griffith, John S. January 1, 1979

PROJECT OFFICE DOE/ JPL-1012-3

PROJECT OFFICE

Slonski, M. L. February 15, 1979

Repar, John February 15, 1979

80

Document Title

Handbook of Solar Energy Data for South-Facing Surfaces in the United States-Volume II: Average Hourly and Total Daily Insolation Data for 235 Localities (Alaska-Montana)

Handbook of Solar Energy Data for South-Facing Surfaces in the United States-Volume III: Average Hourly and Total Daily Insolation Data for 235 Localities (North Carolina-Wyoming)

A Normative Price for a Manufactured Product: The SAMICS Methodology Volume I: Executive Summary/Volume II: Analysis

Economic Analysis of A Candidate 50¢/Wp Flat-Plate Photovoltaic Manufacturing Technology

Module Performance Assessment: Laboratory and Field Environment

Environmental Testing of Block II Solar Cell Modules.

Project Quarterly Report 9 for the Period April - June 1978

Project Quarterly Report 10 for the Period July - September 1978

Energy Systems Economics Analysis (ESEA) Methodology & User's Guide

Experience with Silicones in Photovoltaic Modules

Fl ~

F' ~

L...I

Document Number

5101-104 D0E/JPL-l012-79/7B

5101-105 DOE/JPL-1012-20

5101-106 DOE/JPL-1012-21

5101-107 DOE/JPL-1012-18

5101-108 DOE/JPL-1012-19

5101-109 DOE/JPL-1012-26

5101-112 DOE/JPL 1012-27

5101-131 DOE/JPL-1012-49 JPL Pub. f/80-87

5101-133 DOE/JPL-1012-29 JPL Puhl. #79-88

5101-134 DOE/JPL-1012-30 JPL Puhl. #79-96

5101-135 DOE/JPL-1012-31 JPL Publ. # 79-92

Author/Date

Goldsmith/Bickler August 30, 1978

Praturi, A.K. Apri 1 15, 1979

Praturi, A. K. April 1, 1979

Rhein, Robert A. April 15, 1979

Rhein, Robert A. April 15, 1979

PROJECT OFFICE

PROJECT OFFICE

Hoffman/Maag November 1, 1980

PROJECT OFFICE

Griffith, J. S. September 1, 1979

Laue/Gupta Septmber 21, 1979

81

Document Title

LSA Project Technology Development Update

Modeling of Silicon Particle Growth: A Progress Report

On the Modeling of Silane Pyrolysis in a Continuous Flow Reactor

Purification of Silicon by the Silicon Fluoride Transport Process - A Thermochemical Study

Silicon Preparation and Purity from the Reaction of Sodium with Silicon Tetrafluoride and Silicon Tetrachloride - A Thermochemical Study

11th Project Integration Meeting and Quarterly Report for 10/12/78

Progress Report 12 for the Period January to April 1979 and Proceedings of the 12th Project Integration Meeting

Photovoltaic Module Soiling Studies May 1978-0ctober 1980

Progress Report 13 for the Period April 1979 to August 1979 and Proceedings of the 13th Project Integration Meeting

Environmental Testing of Block III Solar Cell Modules, Part I: Qualification Testing of Standard Production Modules

Reactor for Simulation and Acceleration of Solar Ultraviolet Damage

Document Number

5101-137 DOE/JPL-1012-32 JPL Puhl. #79-102

5101-138 DOE/JPL-1012-36

5101-139 OOE/JPL-1012-34 JPL Puhl. #79-116

5101-141 DOE/JPL-1012-38 JPL Puhl. 1180-5

5101-142 DOE/JPL-1012-42 JPL Pub 1. f/80-21

5101-143

5101-144

5101-146 OOE/JPL-1012-37 JPL Pub. 1180-25

5101-147 DOE/JPL-1012-40 JPL Puhl. #80-12

5101-148 DOE/JPL-1012-41 JPL Puhl. #80-34

Author/Date

Chen, C. P. October 15, 1979

LSA ENGINEERING January 15, 1980

Salama, A. M. November 1, 1979

Jaffe, Peter December 15, 1979

PROJECT OFFICE

PROJECT OFFICE January 1980

Cuddihy,E. F. January 15, 1980

Document Title

Fracture Strength of Silicon Solar Cells

1982 Technical Readiness Module Design and Test Specification - Intermediate Load Applications

Characterization of Deliberately Nickel-Doped Silicon Wafers and Solar Cells

LSA Field Test Annual Report August 1978 - August 1979

Progress Report 14 for the Period August 1979 to December 1979 and Proceedings of the 14th Project Integration Meeting

Electricity from Photovoltaic Solar Cells: Status of Low-Cost Solar Array Project

Encapsulation Materials Status to December 1979

Leipold/Radics/ Cost of Czochralski Wafers as a Kachare Function of Diameter February 15, 1980

Bouquet, F. L. Glass for Low-Cost Photovoltaic Solar February 1, 1980 Arrays

Moore, D. M. March 1, 1980

82

Proposed Method for Determining the Thickness of Glass in Solar Collector Panels

F' ~

C

,..,.,,

w

Document Number

5101-150

5101-151 DOE/JPL-1012-44 JPL Pub 1. f/80-27

5101-154

5101-155

5101-156 Rev. A

5101-158 Rev. A.

5101-159 Rev. A.

5101-160 DOE/JPL-1012-51 JPL Pub. f/80-100

5101-165 DOE/JPL-1012-53 JPL Pub f/81-30

5101-166 DOE/JPL-1012-52 JPL Pub. f/81-12

Author/Date

Christensen, E.

JPL April 1980

Document Title

Electricity from Photovoltaic Solar Cells, LSA Project, as displayed at Congressional Hearings February 1980

Progress Report 15 for the period December 1979 to April 1980 and Proceedings of the 15th Project Intregration Meeting

Chamberlain/Aster/ SAMICS Cost Account Catalog/Version 4 Firnett April 21, 1980

Christensen, E. June 1980

Firnett, P. J. November 17, 1980

Aster/Chamberlain Miller/Firnett November 17, 1980

National Photovoltaic Progam/Electr.ical Power from Solar Cells

Improved Price Estimation Guidelines (!PEG) Computer Program User's Guide Release 2

Improved Price Estimation Guidelines (!PEG) Design Document Release 2

Chamberlain/Firnett Improved Price Estimation Guidelines Miller (!PEG) Computer Program Source Code November 17, 1980 Release 2

Project Office

WILSON, A.H. June 15, 1981

Jaffe, Peter December 30, 1980

83

Progress Report 16 for the Period April to September 1980 and Proceedings of the 16th Project Integration Meeting

Low-Cost Solar Array Structure Development

LSA Field Test Annual Report August 1979-August 1980

Document Number

5101-169 DOE/JPL-1012-50 JPL Pub. /181-1

5101-170

5101-171 DOE/JPL-1012-55 JPL Pub. {181-37

5101-172 DOE/JPL-1012-54 JPL Pub. /!81-35

5101-178C

5101-189 DOE/JPL-1012-57 JPL Pub. /181-76

Author/Date

Seaman, C.H. January 15, 1981

Engineering Area May 20, 1980

Mokashi/Kachare March 15, 1981

LSA Project

LSA Project July 1981

K. A. Yamakawa September 1, 1981

Document Title

The Correction for Spectral Mismatch Effects on the Calibration of a Solar Cell When Using a Solar Simulator

Flat-Plate Photovoltaic Module & Array Circuit Design Optimization Workshop Proceedings - May 19 & 20, 1980

Sensitivity Analysis of the Add-On Price Estimate for the Edge-Defined Film-Fed Growth Process

Progress Report 17 for the Period September 1980 to February 1981 and Proceedings of the 17th Project Integration Meeting

Electricity From Photovoltaic Solar Cells-Low Cost Solar Array Project As Displayed at the 15th Photovoltaic Specialist Conference-May 1981 Revised for Project Integration Meeting

The Effects of Impurities on the Performance of Silicon Solar Cells

Please contact the Solar Data Center for those documents which do not carry a DOE number. (213) 577-9519 or 577-9520

84

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I I I I I I I I I I I I I I I I I I I

NOTES

PASADENA CENTER

300 E. Green Street Pasadena, CA

1213) 577 -4343

HILTON HOTEL-PASADENA

150 South Los Robles Avenue

Pasadena, CA

12131 577-1000

HUNTINGTON-SHERATON HOTEL 1401 South Oak Knoll Avenue Pasadena, CA 12 131 792-0266

TRAVELOOGE PASADENA

2767 East Colorado Blvd. Pasadena, CA

12131795-7213

HOLIDAY INN

303 Cordova

Pasadena, CA

12131 4 49-4000

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19th Project Integration Meeting Handout...5101-192 Department of Energy Flat-Plate Solar Array Project 19th Project Integration Meeting Handout Pasadena Center November 11, 1981 Jet

Documents