Roll-to-roll metallization of solar cells
AssigneeSunPower Corporation
InventorsRichard Hamilton Sewell, Gabriela Elena Bunea
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Abstract
Disclosed herein are approaches to fabricating solar cells, solar cell strings and solar modules using roll-to-roll foil-based metallization approaches. Methods disclosed herein can comprise the steps of providing at least one solar cell wafer on a first roll unit and conveying a metal foil to the first roll unit. The metal foil can be coupled to the solar cell wafer on the first roll unit to produce a unified pairing of the metal foil and the solar cell wafer. We disclose solar energy collection devices and manufacturing methods thereof enabling reduction of manufacturing costs due to simplification of the manufacturing process by a high throughput foil metallization process.
Claims20
A method of fabricating a solar cell, the method comprising:
- providing a solar cell on a first roll unit, the solar cell comprising a plurality of semiconductor regions;
- conveying a metal foil directly to the first roll unit without contacting the first roll unit, wherein the metal foil contacts the solar cell on the first roll unit;
- coupling the metal foil to the solar cell to provide a unified pairing of the metal foil and the solar cell;
- and
- patterning the metal foil coupled to the solar cell.
A method of manufacturing a solar cell string, the method comprising:
- providing plurality of solar cells on a first roll unit;
- conveying a metal foil directly to the first roll unit without contacting the first roll unit, wherein the metal foil contacts a solar cell of plurality of solar cells on the first roll unit;
- and
- coupling the metal foil to the solar cell of plurality of solar cells to form a solar cell string.
A method of manufacturing a solar module, the method comprising:
- providing plurality of solar cells on a first roll unit;
- conveying a metal foil directly to the first roll unit without contacting the first roll unit, wherein the metal foil contacts a solar cell of plurality of solar cells on the first roll unit;
- coupling the metal foil to the solar cell of plurality of solar cells to form a solar cell string;
- and
- encapsulating the cell string arrangement to form a photovoltaic laminate.
Dependencies are inferred from the claim text.