Lab to Large Scale Transition for Non-Vacuum Thin Film CIGS Solar Cells: Phase I Annual Technical Report, 1 August 2002-31 July 2003

The purpose of this subcontract is to (1) identify the challenges that ISET may face in the process of making a 'Lab to Large-Scale' transition for its ink-based non-vacuum process in production of thin-film CIGS solar cells and modules, and (2) develop workable solutions for these challenges such that they can readily be implemented in a large-scale processing line for CIGS modules. The primaryobjective of this research is to streamline ISET's ink-based non-vacuum process for fabricating efficient CIGS modules at a lower cost of module production of < $1.0/watt. To achieve this objective, ISET focuses R&D efforts on investigating topics that directly impact the ultimate cost of processing CIGS modules. These topics include (i) module output, and therefore, the solar cell and moduleefficiency, (ii) overall process yield, which requires developing a process that offers a very high degree of repeatability for every manufacturing step, and finally (iii) a process approach that maximizes the utilization of the materials used. In accordance with the above, this report will cover activity during Phase I in the investigation of methods for low-cost manufacturing and processdevelopment. Specific tasks cover four broad areas: (1) solar cell efficiency, (2) process control, (3) module integration, and (4) enhanced material utilization by recycling unused materials.