Engineering topics
Publications and source records attributed to Sanchez, L. E..
Large-scale production model combines most modern manufacturing techniques to produce silicon-solar-cell panels of low costs by 1982. Model proposes facility capable of operating around the clock with annual production capacity of 20 W of solar cell panels.
The casting of silicon blanks for solar cells directly without slicing is an exciting concept. An experiment was performed to investigate the feasibility of developing a machine that casts wafers directly. A Czochralski furnace was modified to accept a graphite ingot-simulating fixture. Silicon was melted in the middle of the ingot simulator in a boron nitride mold. Sample castings showed reasonable crystal size. Solar cells were made from the cast blanks. The performance is reported.
The recent development of a shingle-type solar-cell module makes it possible to incorporate easily photovoltaic power generation into the sloping roofs of residential or commercial buildings. These modules, which use a closely packed array of nineteen 53-mm-diameter circular solar cells, are capable of producing 101 watts/sq m of module area under standard operating conditions. This module performance is achievable by the use of solar cells with an average efficiency of 13.3 percent at 1 kW/sq m air-mass-1.5 insolation and at a cell temperature of 28 C. When these modules are mounted on a sloping south-facing roof which is insulated on the rear surface, the annual energy generated at the maximum power operating point will vary from 255.6 to 137.3 kWh/sq m of module area depending on the site location, with Albuquerque, NM, and Seattle, WA, representing the highest and lowest values of the thirteen sites considered.
The development of a solar cell module, which is suitable for use in place of shingles on the sloping roofs of residental or commercial buildings, is reported. The design consists of nineteen series-connected 53 mm diameter solar cells arranged in a closely packed hexagon configuration. The shingle solar cell module consists of two basic functional parts: an exposed rigid portion which contains the solar cell assembly, and a semi-flexible portion which is overlapped by the higher courses of the roof installation. Consideration is given to the semi-flexible substrate configuration and solar cell and module-to-module interconnectors. The results of an electrical performance analysis are given and it is noted that high specific power output can be attributed to the efficient packing of the circular cells within the hexagon shape. The shingle should function for at least 15 years, with a specific power output of 98 W/sq w.
Manufacturing sequence for silicon solar cells using Czochralsky crystal growing techniques in order to produce at a rate of 20 MW per year on a 24-hour per day basis is discussed. Cost analysis of the manufacturing is presented and consideration is given to the following processing decision categories of the manufacturing of an unencapsulated solar cell from a silicon wafer: (1) treatment of the optical surface; (2) formation of the junction(s); and (3) metallization of electrical collectors. The manufacturing of encapsulated solar modules from solar cells, using two glass plates, a low iron front surface, and a standard float glass back plate, is described. Totaling the three major activities of wafer making, cell manufacturing, and module fabrication, the resulting contribution to module price will be 1.945 $/watt.