Process Development for Cigs-Based Thin-Film Photovoltaic Modules: Phase I Technical Report

This report describes work performed by Global Solar Energy (GSE) under Phase I of this subcontract. GSE has initiated an extensive and systematic plan to accelerate the commercialization of thin-film photovoltaics (PV) on copper indium gallium diselenide (CIGS). GSE is developing the technology to deposit and monolithically integrate CIGS photovoltaics on a flexible substrate. CIGS-deposited on flexible substrates can be fabricated into either flexible or rigid modules. Low-cost, rigid PV panels for remote power, bulk/utility, telecommunications, and rooftop applications will be produced by affixing the flexible CIGS to an expensive rigid panel by lamination or adhesive. In the GSE approach, long (up to 700 m) continuous rolls of substrate are processed, as opposed to individual small glass plates. In combination with roll-to-roll processing, GSE is developing evaporation deposition operations that enable low-cost and high-efficiency CIGS modules. Efforts are under way to transition the CIGS deposition process into manufacturing at GSE. CIGS process development is focused on synchronizing the operation of the effusion sources, the Se delivery profile, substrate temperature, and a host of other parameters. GSE has selected an interconnect scheme and procured, installed, and tested the equipment necessary to implement the cell interconnection for thin-film CIGS modules on a polyimide substrate.