Continuous Roll-to-Roll a-Si Photovoltaic Manufacturing Technology: Final Subcontract Report, 1 April 1992 - 30 September 1995

This report describes work performed by Energy Conversion Devices, Inc. (ECD) to advance roll-to-roll, triple-junction photovoltaic (PV) manufacturing technologies, reduce module production costs, increase stabilized module performance, and expand commercial production capacity using such roll-to-roll technology. The specific goal of this subcontract is to develop advanced large-scalemanufacturing technology incorporating ECD's earlier research advances with the capability of producing modules with stable 10.2% efficiency at a cost of about $1.00 per peak watt. The activities reported in this report include: (1) optimization of the high-performance back-reflector system; (2) optimization of the Si-Ge narrow-band-gap solar cell; (3) optimization of the stable efficiency ofphotovoltaic modules; (4) demonstration of serpentine web continuous roll-to-roll deposition technology; (5) material cost reductions, and (6) improving the module assembly process. Accomplishments made toward these objectives are described.