Advancements in flexible CIGS module manufacturing

Roll-to-roll (RTR) manufacturing of consistent photovoltaic (PV) material over 1000-ft long metal foil lots has been realized at Global Solar Energy (GSE). Development of robust sensors and in-situ, real-time process control strategies for all thin-film coating (TFC) steps has enabled Global Solar to achieve manufacturing yields above 90%. In turn, reliable processing conditions enable rapid progress using well-controlled experiments designed for device optimization. Average large-area cell efficiency now exceeds 10%. Efficiency and yield have also been increased at the module level through improved fabrication methods. Flexible modules attain a power-to-weight ratio of 40 W/kg and aperture area efficiencies exceeding 11%. Real-time and accelerated stress tests investigating product reliability are underway.