# US 10,872,992 B2 · Polymer conductor sheets, solar cells and methods for producing same > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 10,872,992 B2 - Document ID: US10872992B2 - Status: Granted - Kind: B2 - Application number: 15/773,953 - Filed: 2016-10-27 - Published: 2018-11-01 - Granted: 2020-12-22 - Earliest claimed: 2015-11-06 - Assignees: Meyer Burger (Switzerland) AG - Applicants: Meyer Burger (Switzerland) AG - Inventors: Maria Gragert; Thomas Soderstrom; Rainer Grischke; Yu Yao; Hengyu Li - Web page: https://patentgrep.com/patent/US10872992B2 ## CPC - H10F 19/906: {characterised by the materials of the structures} - B32B 3/08: characterised by added members at particular parts {(layer formed of separate pieces of material which are juxtaposed side-by-side B32B3/14, B32B3/18)} - B32B 5/142: {Variation across the area of the layer} - B32B 5/147: {by treatment of the layer} - B32B 17/00: Layered products essentially comprising sheet glass, or glass, slag, or like fibres - B32B 17/10: of synthetic resin - B32B 25/04: comprising rubber as the main or only constituent of a layer, {which is} next to another layer of {the same or of} a {different material (next to a layer of a particular substance B32B9/043; next to a bituminous or tarry layer B32B11/044; next to a water setting substance layer B32B13/042; next to a metal layer B32B15/06; next to a glass layer B32B17/063; next to a layer formed of natural mineral fibres or particles B32B19/043; next to a wood layer B32B21/045; next to a cellulosic plastic layer B32B23/046)} - B32B 25/042: {of natural rubber or synthetic rubber} - B32B 25/14: comprising {synthetic rubber copolymers (B32B25/18 and B32B25/20 take precedence)} - B32B 27/06: as the main or only constituent of a layer, {which is} next to another layer of {the same or of} a {different material (next to a layer of a particular substance B32B9/045; next to a bituminous or tarry layer B32B11/046; next to a water setting substance layer B32B13/12; next to a metal layer B32B15/08; next to a glass layer B32B17/10; next to a layer formed of natural mineral fibres or particles B32B19/045; next to a wood layer B32B21/08; next to a cellulosic plastic layer B32B23/08; next to a natural or synthetic rubber layer B32B25/08)} - B32B 27/08: of synthetic resin - B32B 27/16: specially treated, e.g. irradiated - B32B 27/20: using fillers, pigments, thixotroping agents - B32B 27/281: {comprising polyimides} - B32B 27/283: {comprising polysiloxanes} - B32B 27/304: {comprising vinyl halide (co)polymers, e.g. PVC, PVDC, PVF, PVDF} - B32B 27/306: {comprising vinyl acetate or vinyl alcohol (co)polymers} - B32B 27/308: {comprising acrylic (co)polymers} - B32B 27/32: comprising polyolefins {(comprising vinyl (co)polymers or acrylic (co)polymers B32B27/30)} - B32B 27/322: {comprising halogenated polyolefins, e.g. PTFE} - B32B 27/34: comprising polyamides - B32B 27/36: comprising polyesters - B32B 27/40: comprising polyurethanes - B32B 27/42: comprising condensation resins of aldehydes, e.g. with phenols, ureas or melamines - H10F 19/80: Encapsulations or containers for integrated devices, or assemblies of multiple devices, having photovoltaic cells - H10F 19/807: {Double-glass encapsulation, e.g. photovoltaic cells arranged between front and rear glass sheets} - B32B 2255/10: on synthetic resin layer or on natural or synthetic rubber layer - B32B 2255/205: Metallic coating - B32B 2270/00: Resin or rubber layer containing a blend of at least two different polymers - B32B 2307/202: Conductive - B32B 2307/412: Transparent - B32B 2457/12: Photovoltaic modules - Y02E 10/50: Photovoltaic [PV] energy - H10F: INORGANIC SEMICONDUCTOR DEVICES SENSITIVE TO INFRARED RADIATION, LIGHT, ELECTROMAGNETIC RADIATION OF SHORTER WAVELENGTH OR CORPUSCULAR RADIATION - B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM - Y02E: REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION ## Abstract The present invention relates to polymer conductor sheets comprising zones featuring different degrees of polymerization and/or crosslinking within the same polymer sheet, wherein the zones differ, for example, in mechanical stability, ductility and/or (thermo)adhesiveness. The present invention also teaches devices comprising these zoned polymer conductor sheets such as solar cell strings, matrices and modules, uses thereof and methods for producing these. ## Claims ### Claim 1 A polymer conductor sheet comprising (i) a polymer sheet comprising at least two adjacent zones within the same polymer sheet, which zones run in longitudinal direction of the polymer sheet, wherein (1) a first zone is sufficiently ductile and/or adhesive to fix the position of an elongated conductor on its surface facing the outside of the polymer sheet, and (2) a second zone adjacent to the first zone that has a different degree of polymerization and/or crosslinking than the first zone; and (ii) at least one elongated conductor positioned on the surface of the first zone facing the outside of the polymer sheet. ### Claim 2 (depends on 1) The polymer conductor sheet of claim 1, wherein the difference in the degree of polymerization and/or crosslinking in the first, second and/or third zone is the result of one or more of the following: 1. zone-specific irradiation, preferably electron, ion, atomic, neutron, heat or electro-magnetic irradiation, 2. zone-specific temperature treatment, 3. zone-specific chemical treatment within the same polymer sheet. ### Claim 3 (depends on 1) The polymer conductor sheet of claim 1, wherein the polymer is selected from the group consisting of thermoplasts, duroplasts, elastomers, and thermoplastic elastomers, preferably polyolefins, polyesters, polyamides, polyimides, polyacrylates, ionomers, polyvinylbutyral (PVB), silicones and polyurethanes (PU), more preferably thermoplastic polyolefins (TPO), polyolefinic elastomers (POE), thermoplastic polyurethanes (TPU), ethylene vinyl acetates (EVAs), polyethylenetetrafluoroethylene (ETFE), polyvinyl chlorides (PVCs), ionomers, polyethylene methacrylic acid (EMA) and polyethylene acrylic acid (EAA), polyethylene terephthalate (PET) and nylon, poly methyl methacrylate (PMMA), polymethacrylate (PMA), polyvinylsilanes or any combination thereof. ### Claim 4 (depends on 1) The polymer conductor sheet of claim 1, further comprising a third zone within the same polymer sheet that has a different degree of polymerization and/or crosslinking than the second zone, wherein the third zone is located adjacent to the second zone. ### Claim 5 (depends on 4) The polymer conductor sheet of claim 4, wherein the first zone within the same polymer sheet has a lower degree of polymerization and/or crosslinking than the second zone and the third zone within the same polymer sheet has a lower degree of polymerization and/or crosslinking than the first zone. ### Claim 6 (depends on 4) The polymer conductor sheet of claim 4, wherein the third zone within the same polymer sheet has a lower degree of polymerization and/or crosslinking than the second zone. ### Claim 7 (depends on 6) The polymer conductor sheet of claim 6, wherein the third zone within the same polymer sheet has a lower degree of polymerization and/or crosslinking than the second zone and the first zone. ### Claim 8 (depends on 4) The polymer conductor sheet of claim 4, wherein the first and/or third zone is/are thermoadhesive. ### Claim 9 (depends on 8) The polymer conductor sheet of claim 8, wherein the first zone is ductile and the third zone is thermoadhesive. ### Claim 10 (depends on 1) A device comprising a polymer conductor sheet of claim 1. ### Claim 11 (depends on 1, 10) The device according to claim 10, wherein the device is a tabbed solar cell, a solar cell string, matrix or module comprising current generating elements interconnected by a polymer conductor sheet of claim 1. ### Claim 12 (depends on 11) The device according to claim 11, wherein the solar cell module is (I) a solar cell module having a top and bottom side comprising: (a) at least two current generating elements, (b) at least two polymer conductor sheets, (c) optionally at least two encapsulant layers, and (d) at least two glass plates, wherein (i) at least two current generating elements (a) are conductively interconnected by the conductors of the at least two polymer conductor sheets (b) to form a solar cell string, and (iia) the glass plates (d) are connected to the polymer conductor sheets (b) on the top and bottom sides of the solar module, which glass plates form the outer surface of the solar cell module, or (iib) the optional encapsulant layers (c) connect the glass plates (d) to the polymer conductor sheets (b) on the top and/or bottom side of the solar module, which glass plates form the outer surface of the solar module; or (II) a solar cell module having a light source-facing and a light source-averted side comprising: (a) at least two current generating elements, (b) at least two polymer conductor sheets, (b2) optionally at least two encapsulant layers, (c) a back sheet, preferably an opaque back sheet, and (d) a glass plate, wherein (i) at least two current generating elements (a) are conductively interconnected by the conductors of the at least two polymer conductor sheets (b), (ii) the back sheet (c) is connected to the polymer conductor sheet (b) on the light source-averted side of the solar module, (iii) the glass plate (d) is connected to the polymer conductor sheet (b) on the light source-facing side of the solar module, and (iv) the optional encapsulant layers (b2) connect the glass plate (d) and/or the back sheet (c) to the polymer conductor sheets (b) on the top and bottom side of the solar module, respectively, which glass plate and back sheet form the outer surface of the solar module; or (III) a solar cell module according to (I) or (II) above, further comprising at least one encapsulant layer consisting of a polymer sheet comprising at least two adjacent zones within the same polymer sheet, which zones run in longitudinal direction of the polymer sheet, wherein (i) a first zone of the encapsulant layer is sufficiently ductile and/or adhesive to adhere to an outer layer of the solar module with its surface facing outside of the polymer sheet, and (ii) a second zone adjacent to the first zone of the encapsulant layer that has a different degree of polymerization and/or crosslinking than the first zone. ### Claim 13 (depends on 1) A method for producing a tabbed solar cell, a solar cell string, matrix or module, comprising the steps of: (i) providing a polymer conductor sheet of claim 1, and (ii) aligning and contacting the polymer conductor sheet of step (i) to at least one current generating element, and (iii) conductively connecting the polymer conductor sheet to the at least one current generating element, optionally under pressure and/or heat. ### Claim 14 (depends on 1, 13) The method according to claim 13, wherein at least one polymer conductor sheet of claim 1 is aligned, contacted and connected to each side of at least one current generating element. ### Claim 15 (depends on 1, 13) The method according to claim 13, wherein at least one polymer conductor sheet of claim 1 is aligned, contacted and connected to at least one side of at least two current generating element, thus mechanically and electrically interconnecting said elements. ### Claim 16 (depends on 1) A method for forming a polymer conductor sheet according to claim 1, comprising the steps of: a) providing a polymerizable and/or crosslinkable sheet that can be at least partially polymerized and/or crosslinked; b) polymerizing and/or crosslinking the polymerizable and/or crosslinkable sheet zone-specifically to generate a first, second and/or third zone within the same polymer sheet by one or more treatments selected from the group consisting of: zone-specific irradiation, preferably electron, ion, atomic, neutron, heat or electro-magnetic irradiation, zone-specific temperature treatment, and zone-specific chemical treatment within the same polymer sheet; c) providing an elongated conductor; and d) positioning, preferably temporarily attaching, the elongated conductor on the surface of the first zone facing the outside of the polymer sheet.