Roll-to-Roll Front Contact Patterning by Wire Shading

Abstract

ABSTRACTWire shading during thin film deposition is a promising approach to low-cost, high volume manufacturing of flexible thin film photovoltaic modules. This contribution demonstrates successful patterning of a transparent conducting oxide layer by wire shading during dynamic web coating. Continuous sputter deposition of Al-doped ZnO on a 30 cm wide polymer foil and simultaneous wire shading form 1 cm wide and 300 cm long front contact stripes for thin film photovoltaic modules. Analysing the distribution of lateral shunt resistances after separating the initial 28 stripes into 1323 pieces, yields a patterning success of 97.3 %. Thus the technique seems well suited for flexible modules from organic solar cells.