CIGS P1, P2, P3 Scribing Processes using a Pulse Programmable Industrial Fiber Laser: Preprint

We describe a novel set of laser processes for the CIGS P1, P2 and P3 scribing steps, the development of which has been enabled by a unique pulse-programmable fiber laser. We find that the unique pulse control properties of this 1064 nm wavelength laser have significant effects on the material removal dynamics of the various film layers in the CIGS material system. In the case of the P2 and P3processes, the shaped pulses create new laser/material interaction effects that permit the material to be cleanly and precisely removed with zero Heat Affected Zone (HAZ) at the edges of the scribe. The new P2 and P3 processes we describe demonstrate the first use of infrared nanosecond laser pulses that eliminate the HAZ and the consequent localized compositional changes in the CIGS absorbermaterial that result in poor shunt resistance. SEM micrographs and EDX compositional scans are presented. For the P1 scribe, we process the bi-layer molybdenum from the film side as well as through the glass substrate. Microscopic inspection and compositional analysis of the scribe lines are not sufficient to determine electrical and optical performance in working PV modules. Therefore, todemonstrate the applicability of the infrared pulse-programmable laser to all three scribing processes for thin-film CIGS, we fabricate small-size multiple-cell monolithically interconnected mini-modules in partnership with the National Renewable Energy Laboratory (Golden, Colorado). A total of four mini-modules are produced, two utilizing all laser scribing, and two with the P2 and P3 stepsmechanically scribed (by a third party) for reference. Mini-module performance data measured at NREL is presented, and we also discuss the commercialization potential of the new single-laser CIGS scribing process. Finally we present a phenomenological model to describe this physics underlying this novel ablation process.