Efficiency and Throughput Advances in Continuous Roll-to-Roll a-Si Alloy PV Manufacturing Technology: Annual Technical Progress Report, 22 June 1998 - 21 June 1999

This document reports on work performed by Energy Conversion Devices, Inc. (ECD) during Phase I of this subcontract. During this period, ECD researchers: 1) Completed design and construction of new, improved substrate heater; 2) Tested and verified improved performance of the new substrate heater in the pilot machine; 3) Verified improved performance of the new substrate heater in the productionmachine; 4) Designed and bench-tested a new infrared temperature sensor; 5) Installed a prototype new infrared temperature sensor in the production machine for evaluation; 6) Designed a new rolling thermocouple temperature sensor; 7) Designed and bench-tested a reflectometer for the backreflector deposition machine; 8) Designed and bench-tested in-line non-contacting cell diagnostic sensor andPV capacitive diagnostic system; 9) Installed the in-line cell diagnostic sensor in the 5-MW a-Si deposition machine for evaluation; 10) Demonstrated a new low-cost zinc metal process in the pilot backreflector machine; and 11) Fully tested a new cathode design for improved uniformity.