Solar cells based on polycrystalline Cu(In,Ga)Se(2) absorber layers have yielded the highest conversion efficiency among all thin-film technologies, and the use of flexible polymer films as substrates offers several advantages in lowering manufacturing costs. However, given that conversion efficiency is crucial for cost-competitiveness, it is necessary to develop devices on flexible substrates that perform as well as those obtained on rigid substrates. Such comparable performance has not previously been achieved, primarily because polymer films require much lower substrate temperatures during absorber deposition, generally resulting in much lower efficiencies. Here we identify a strong composition gradient in the absorber layer as the main reason for inferior performance and show that, by adjusting it appropriately, very high efficiencies can be obtained. This implies that future manufacturing of highly efficient flexible solar cells could lower the cost of solar electricity and thus become a significant branch of the photovoltaic industry.

Cu(In,Ga)Se 2 (CIGS) absorber layers for thin-film solar cells were grown without sodium. Na was diffused into some of the absorbers after growth, which led to strongly improved device performance compared with Na-free cells. Efficiencies of 13.3% and 14.4% were achieved at substrate temperatures as low as 400 and 450 °C, respectively. With the post-deposition treatment, the effects of Na on CIGS growth are excluded, and most of the Na is expected to reside at grain boundaries. The dominating cause for Na-induced device improvements might be passivation of grain boundaries.

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We report on the progress that we have made in the quality of our baseline process for the production of high efficiency soda lime glass/Mo/Cu(In,Ga)Se2 (CIGS)/CdS/i‐ZnO/ZnO:Al/MgF2 solar cells. The enhancement of the average performance level has enabled us to reach conversion efficiencies of up to 19·3% (internal measurement). The new quality initiative uses process control, optical and electrical modelling, and the critical revision of all process steps as tools for the attainment of the 19% efficiency level. Our experiments show that the compositional process window for CIGS solar cells that have an efficiency of η ≈ 19% is very wide. Accordingly, we suggest that an efficiency of 19·0–19·5% is achievable in the following compositional process windows: 0·69 ≤ Cu/(Ga + In) ≤ 0·98 and 0·21 ≤ Ga/(Ga + In) ≤ 0·38. In addition, our results show that large CIGS grains are not a necessary requirement for high efficiencies up to 19%. These findings and the partly lacking ability to correlate certain aspects of our progress with experimental parameters lead us to the conclusion that there are still some important process variables undiscovered. From this conclusion and from the evaluation of the available data we infer that there is a potential for the enhancement of CIGS solar cell efficiencies beyond 20%. Copyright © 2007 John Wiley & Sons, Ltd.