Apparatus and systems for intermixing cadmium sulfide layers and cadmium telluride layers for thin film photovoltaic devices

An apparatus for vapor deposition of a sublimated source material as a thin film on a photovoltaic module substrate, said apparatus comprising:

• a deposition head;
• a receptacle disposed in said deposition head, said receptacle configured for receipt of a granular source material;
• a heated distribution manifold disposed below said receptacle, said distribution manifold comprising a plurality of passages defined therethrough, said distribution manifold configured to indirectly heat said receptacle to a degree sufficient to sublimate source material within said receptacle;
• a distribution plate disposed below said distribution manifold and at a defined distance above a horizontal conveyance plane of an upper surface of a substrate conveyed through said apparatus, said distribution plate comprising a plurality of passages therethrough;
• a transversely extending seal at each longitudinal end of said deposition head, said seals defining an entry and exit slot for a substrate conveyed through said apparatus, said seals disposed at a distance above the surface of the substrate that is less than the distance between the surface of the substrate and said distribution plate;
• and,
• a gas tank connected to an exit port via a gas source line, wherein the exit port is positioned to supply a gas through the distribution plate to a deposition surface of the substrate conveyed through said apparatus.

An apparatus for vapor deposition of a sublimated source material as a thin film on a photovoltaic module substrate, said apparatus comprising:

• a deposition head;
• a receptacle disposed in said deposition head, said receptacle configured for receipt of a source material;
• a distribution plate disposed below said distribution manifold and at a defined distance above a horizontal conveyance plane of an upper surface of a substrate conveyed through said apparatus, said distribution plate comprising a pattern of passages therethrough that distribute sublimated source material upon heating the source material in the receptacle;
• a conveyor disposed below said deposition head, said conveyor comprising a continuous loop conveyor on which the substrates are supported below said distribution plate, said conveyor configured to convey the substrates at a constant linear speed through said apparatus between an entry slot and an exit slot such that leading and trailing sections of the substrates are exposed to generally the same vapor deposition conditions within said deposition head in a direction of conveyance of the substrates through said apparatus;
• and,
• a gas tank connected to an exit port via a gas source line, wherein the exit port is positioned to supply a gas through the distribution plate to a deposition surface of the substrate conveyed through said apparatus on said conveyor.