This report describes the project by Energy Conversion Devices, Inc. (ECD) and its American joint venture, United Solar Systems Corp. (United Solar), to develop and commercialize a roll-to-roll triple-junction amorphous silicon alloy PV manufacturing technology. This low material cost, roll-to-roll production technology has the economies of scale to meet the cost goals necessary for widespread use of PV. ECD developed and built the present 5-MW United Solar manufacturing plant in Troy, Michigan, and is now designing and building a new 25-MW facility, also in Michigan. United Solar holds the world's record for amorphous silicon PV conversion efficiency, and manufactures and markets a wide range of PV products including flexible portable modules, power modules, and innovative building-integrated PV (BIPV) shingle and metal-roofing modules that take advantage of this lightweight, rugged, and flexible PV technology. All of United Solar's power and BIPV products are approved by Underwriters Laboratories and carry a 10-year warranty. ECD and United Solar are addressing issues to reduce the cost and to improve the manufacturing technology for the ECD/United Solar PV module manufacturing process. ECD and United Solar identified five technology development tasks that would reduce the module manufacturing cost in the present 5-MW production facility and would also be applicable to future larger-scale manufacturing facilities. These development tasks are: Task 5: Improved substrate heating and monitoring systems; Task 6: The development of new on-line diagnostic systems; Task 7: Development of new back-reflector deposition technology; Task 8: Development of improved RF PECVD reactor cathode and gas distribution configurations; and Task 8A: Development of new pinch valve technology.
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