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The European project FLEXCELLENCE: Roll to roll technology for the production of high efficiency low cost thin film solar cells

: Soppe, W.; Andreu, J.; Fahland, M.; Roth, K.; Topic, M.; Willford, T.

Poortmans, J. ; European Commission, Joint Research Centre -JRC-:
21st European Photovoltaic Solar Energy Conference 2006. Proceedings. CD-ROM : Proceedings of the international conference held in Dresden, Germany, 4 - 8 September 2006
München: WIP-Renewable Energies, 2006
ISBN: 3-936338-20-5
European Photovoltaic Solar Energy Conference <21, 2006, Dresden>
Conference Paper
Fraunhofer FEP ()
photovoltaic; Solar

The EU research project FLEXCELLENCE started on October 1st 2005 and is set to last during 3 years. FLEXCELLENCE aims at developing the equipment and the processes for cost-effective roll-to-roll production of high-efficiency thin-film modules, involving amorphous and microcrystalline silicon. Eight partners, with extended experience in complementary fields, are involved. Within the first year of the project, a hot wire chemical vapour deposition system (HW-CVD) has been built; and a roll-to-roll deposition system for microwave plasma enhanced chemical vapour deposition (MW-PECVD) has been further developed and put into operation. In the meantime, the very high frequency (VHF) PECVD pilot line at VHF-Technologies is being upgraded to allow higher throughput. Regarding the optimisation of the VHF-PECVD process, device grade quality microcrystalline silicon has been deposited on 30 cm x 30 cm at 2 nm/s and laboratory scale a-Si:H and microcrystalline-Si:H cells have been developed in a new double chamber system on plastic substrates. So far, these cells achieve a conversion efficiency of 6.2 % and 8.2 %, respectively. In addition, a 2D simulation program has shown that only 10 % total losses from a solar cell to a module are achievable on the flexible VHF-Technologies modules. Finally, a first cost calculation has demonstrated that production costs below 0.8 EUR/Wp should be reasonably achievable with single a-Si:H cells, and that an important part of this cost is for the encapsulation.