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Work on the add-on study of Phase 2 of the Array Automated Assembly Task was conducted during this reporting period. Three applications of the spray-on technique were investigated. The most effective spray-on boron back surface fields were produced at the drive-in temperature of 1000°C for the range of temperatures investigated. Of the three spray-on aluminum metallization techniques under consideration, two appear to be promising, and the third was shown to be unsuccessful. The smallest spray-on AR coating layer thickness available from our spray-on system at the present time was found to be 1000A. Work in the area of pulsed microwave heating for solar cell fabrication was initiated. A subcontractor was selected to develop an appropriate microwave system.
The LSA Automated Array Assembly Task has as its goal the manufacture of photovoltaic modules at a capacity of 500 MW per year at a cost of $0.50 per peak watt. Divided between ten solar cell manufacturers, each installation should produce 50 MW per year. This implies that automated machinery would continuously produce 120 solar cells per minute. The purpose of this report is to detail the processes and techniques which are believed to have great promise of accomplishing this task. The initial stages of the program were involved in studying the possibility of automated assembly. Phase 1 reviewed a large cross section of processes, conceptual designs, and innovative technologies in preparation for 1986. Through this documentation, a large amount of comprehensive data has been collected. It is these reports upon which the next phase of the program is based. The purpose of Phase 2 is to propose an automated sequence, verify it and present future cost projections. Utilizing the large amount of information available from Phase 1 and drawing from its own experience Solarex has proposed a process sequence which it is believed has great potential of achieving the LSA goals. This report describes the processes, details, the verification tests performed, and estimates the cost of such an automated array assembly.