Lab to Large Scale Transition for Non-Vacuum Thin Film CIGS Solar Cells: Phase II--Annual Technical Report, August 2003-July 2004

The purpose of this subcontract, as part of the R&D Partners category is to: (i) identify the challenges that International Solar Electric Technology, Inc. (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 (ii) develop workable solutions for these challenges such that theycan readily be implemented in a large-scale processing line for CIGS modules. The primary objective of this research is to streamline ISET's ink-based non-vacuum process for fabricating efficient CIGS modules to lower the cost of module production << $1.0/watt. To achieve this objective, ISET has focused R&D efforts on investigating topics that directly impact the ultimate cost of processingCIGS modules. These topics of concern include (i) module output, and therefore, the solar cell and the module efficiency, (ii) overall process yield which requires developing a process that offers a very high degree of repeatability for every manufacturing step, and (iii) a process approach that maximizes the utilization of the materials used. In accordance with the above, this report will coveractivity during Phase II in the investigation of methods for low-cost manufacturing and process development. Specific tasks cover four broad areas: (1) solar cell efficiency, (2) process control, (3) module integration, and (4) enhanced material utilization by reduction of waste stream.