Implementation of a Comprehensive On-Line Closed-Loop Diagnostic System for Roll-to-Roll Amorphous Silicon Solar Cell Production: Annual Report, Year Two; 1 September 2003--31 August 2004

Energy Conversion Devices, Inc. (ECD) has developed and built 7 generations of roll-to-roll amorphous silicon PV production equipment. In the ECD/United Solar Ovonic production process, we deposit about a 1-mm-thick, 12-layer coating consisting of a metal/oxide backreflector, a - layer a-Si/a-SiGe alloy triple-junction solar cell, and a top transparent conductive oxide coating onto 125-mm-thick,35.5-cm-wide stainless steel webs in a series of three roll-to-roll deposition machines. ECD has now completed the Phase II work for this program. In the following report, we summarize the Phase II work in each of these tasks. We have involved United Solar production personnel in each of these Tasks. This is important for two reasons: Firstly, the collaboration of ECD and United Solar personnelkeeps the projects responsive to the developing needs at United Solar. Secondly, most of the tasks affect operations and consequently need the support of United Solar production and QA/QC managers. In the process, we have developed a good working relationship between the production personnel and good balance between optimizing production, while also 'adiabatically' improving the manufacturingequipment.