Recent Improvements in Very Large Area a-Si PV Module Manufacturing

Abstract

Amorphous silicon based photovoltaic (PV) cells are at present the most promising technology for the future reduction in the cost of PV modules. Although progress in the laboratory on both single and multi-junction a-Si based devices has been very encouraging both in terms of initial and stabilized efficiencies few of these improvements have been successfully transferred to the market place in terms of low cost power modules. The problems associated with scaling up from the laboratory to a commercially viable product are discussed with emphasis being given to processing equipment design, cell-module efficiency losses and cost issues. A number of approaches which could be adopted for the volume manufacture of amorphous silicon modules are discussed, with the single chamber “batch” approach which has been successfully adopted by A.P.S. Inc. in its manufacturing line in Trenton, N.J., being examined in detail. Recent progress in the operational “Eureka” manufacturing facility, which will have a capacity of 10 MWp per annum of a-Si based power modules, is reported along with results on high efficiency 2 1/2′ × 5′ single junction modules.