Photovoltaic Manufacturing Technology Monolithic Amorphous Silicon Modules on Continuous Polymer Substrates: Annual Technical Progress Report, 5 July 1995 - 4 June 1996

Iowa Thin Film Technologies' goal is to develop the most cost-effective photovoltaic manufacturing process possible. During the first year, they developed the capability of sputtering a high-quality Zn(Al)O; successfully implemented increased deposition rates for the ZnO top contact deposition; improved registration and ink-line width to reduce area loss due to interconnects; developed a newalignment process and sensor to improve the speed and accuracy of registration for the patterning processes; developed a new Silver ink composition that allows finer print lines and lower series resistance; demonstrated an 8% overall improvement in area utilization; evaluated water-based insulator inks for compatibility with their processes; investigated and tested the use of roll-basedlamination as a means to reduce the cost of assembly; developed straight roll lamination capability using pressure-sensitive adhesives and thermally activated bonding; and evaluated the use of the standard EVA/Tefzel encapsulant with a roll laminator.