PV Technology and Manufacturing

This book discusses the manufacturing processes of photovoltaic solar cells, from conventional silicon cells, to thin-film technologies and ending with the cutting-edge technologies of third-generation photovoltaics. The rapid advances in photovoltaic technologies are propelled by the discovery of new materials through innovative routes of synthesis and deposition. For example, the exponential enhancement in efficiencies of perovskite solar cells between years 2015 and 2020 is a direct result of the availability of new materials to capitalize on innovative manufacturing techniques. Currently, efficiencies of up to 25.5% are achieved by perovskite solar cells technologies. 

This book is intended for scientists and engineers who are keen on having a solid understanding of conventional manufacturing processes of bulk silicon for photovoltaic purposes, as well as advanced processes used to synthesize materials for emerging photovoltaic technologies such as thin-film and third-generation PV. The book is designed to be self-contained to allow the reader to develop knowledge and experience in materials selection as well as a good understanding of pertinent manufacturing process to arrive at best device performance. The technologies presented are also analyzed for its energy and environmental impacts. 

1.    Front matter

2.    Chapter 1: Introduction

a.      Current market trends: importance of solar photovoltaics

b.     Energy conversion and harvesting (theoretical consideration of the photovoltaic conversion: brief device physics, power and efficiency)

c.      Role of precursors, materials and device physics on device performance

3.    Chapter 2: First generation solar cells

a.      Introduction and proliferation

b.     History of manufacturing technology

c.      Available conventional manufacturing processes

4.    Chapter 3: Solar Grade Silicon Feedstock

a.      Harvesting and conventional processing of silicon material

b.     Energy and environmental impact

c.      Cost and lifecycle analysis of silicon solar panels

5.    Chapter 4: Silicon Manufacturing Techniques

a.      State of the art processing technologies (from sand to wafer)

b.     Enhancements to solar photovoltaic modules: optical, electrical and mechanical material properties

c.      Doping considerations: materials and processes

d.     Surface and bulk passivation

6.    Chapter 5: Monocrystalline and multicrystalline Silicon Solar Cells and Modules

a.      Monocrystalline vs. multicrystalline processing and application

b.     Market shares

c.      wafer making and testing

                                                    i.     Bulk silicon doping

                                                iii.     Bulk properties, passivation and surface texturing

                                                  v.     Front and back contact printing

                                              vii.     Co-firing

d.     Module making and testing

                                                    i.     Wafer connection welding (series/parallel)

                                                  ii.     Module framing, glazing and back surface field insulation (Tedlar)

7.    Chapter 6: Thin-film Solar cells

This chapter focuses on the shift from bulk silicon technologies into thin film technologies to reduce material waste, production time and consequently, unit cost. The manufacturing technologies, material and precursors considerations will be covered for the most commercially successful technologies.

a.      Materials and motivation for thin film device production

b.     Manufacturing technologies: chemical vapor deposition, physical vapor deposition (pulsed laser deposition, atomic layer deposition, sputtering, thermal evaporation) and slot-dye, doctor blading, drop casting and spin-coating techniques.

c.      Most common technologies: manufacturing techniques and performance (efficiency and power) for the following:

                                                    i.     Amorphous silicon solar cells manufacturing technologies

                                                  ii.     Cadmium-telluride (CdTe) solar cells manufacturing technologies