Dave from DesignSpark
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We continue exploring the manufacturing process of solar cells by learning phases 3 and 4, which is to turn silicon wafer into solar cells, and then solar cells into solar panels.
Here is a summary of the entire manufacturing process of solar panels:
Phase 1: Purify Quartz in to Solar grade silicon | Carbothermic reduction | Reduce SiO2 into S |
---|---|---|
Siemens process | Purify metallurgical grade Si in to solar grade Si | |
Phase 2: Solar grade Si in to Si wafers | CZochralski process | To produce p-doped monocrstalline Si |
Bridgman process | To produce p-doped polycrystalline Si | |
Wire Saw | Slice Si ingots in to wafers | |
Phase 3: Si wafer in to Si cell | Water surface processing | Remove damaged surface and reduce reflectivity |
Quartz furnace | N-doped p wafer | |
Antireflective coating | ||
Screen printing | To produce top and bottom metal contacts, as well as back surface field | |
Firing | Allow diffusion of front and back contacts to contact with the emitter and absorber layer, respectively | |
Phase 4: Si solar cell in to solar panel | Tabbing | Electrically connect solar cells |
Lamination | To adhere the entire solar panel stack | |
Post-lamination | Al frame, Silicon gasket , junction box added |
Further reference materials that I highly recommend:
Other parts in this series:
- Chapter 1: Introduction
- Chapter 2.0: Semiconductor Physics (Band Diagram, Free Carriers)
- Chapter 3.0: PN Junction diode (Drift and Diffusion)
- Chapter 3.1: PN Junction diode (Forward & Reverse Bias, IV Curve)
- Chapter 4: Photons
- Chapter 5.0: How do Solar Cells Work? (Working Principle, IV Curve, Photovoltaic Parameters, Solar Cell Datasheet)
- Chapter 5.1: How do Solar Cells Work? (Typical Structure, Shockley-Queisser Limit)
- Chapter 6.0: How are solar panels made? (From quartz to silicon wafers)