Phase 2 of the automated array assembly task of the Low-Cost Silicon Solar Array Project. Annual report

This report presents the results of investigations and analyses of an advanced process sequence for manufacturing high efficiency solar cells and modules in a cost-effective manner. The entire process sequence is presented and discussed step by step. Emphasis is on process simplicity and minimizing consumed materials. The process sequence incorporates texture etching, plasma processes for damage removal and patterning, ion implantation, low pressure silicon nitride deposition, and plated metal. A reliable module design is presented. Specific process step developments are presnted. Further, a detailed cost analysis has been performed to indicate future areas of fruitful cost reduction effort. Finally, recommendations for advanced investigations are presented