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US 2014/0213013 A1Published application
Photovoltaic interconnect systems, devices, and methods
AssigneesGlobal Solar Energy, Inc., Hanergy Hi-Tech Power (HK) Limited
InventorsJeffrey S. BRITT, Scott WIEDEMAN
Life of this patent
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Abstract
Photovoltaic modules may include multiple flexible thin film photovoltaic cells electrically connected in series by a substantially transparent top sheet having an embedded conductive wire grid pattern. Methods of manufacturing photovoltaic modules including integrated multi-cell interconnections are provided.
Claims20
A method of manufacturing a photovoltaic module, comprising:
- applying a photoactive composition to a conductive substrate to produce a continuous sheet of flexible photovoltaic material including first and second cell regions;
- scribing through the photoactive composition to electrically isolate one or more interconnection regions disposed on the top side of the conductive substrate from the photoactive composition surrounding the one or more interconnection regions;
- cutting the photovoltaic material into first and second discrete photovoltaic cells corresponding respectively to the first and second cell regions, each cell region including photoactive composition disposed on a top side of a conductive back sheet, wherein each conductive back sheet is a portion of the conductive substrate, and the first cell region includes a first interconnection region of the one or more interconnection regions;
- preparing interconnection tape including a conductive strip disposed on a dielectric strip;
- applying the interconnection tape to the first cell region such that the conductive strip contacts the first interconnection region;
- electrically connecting the conductive strip to the top side of the conductive back sheet of the first cell region through the first interconnection region;
- folding the interconnection tape to a folded position, the folded position corresponding to the conductive strip wrapped around the dielectric strip;
- preparing an optically transmissive front sheet including an embedded conductive wire pattern;
- and
- electrically interconnecting the first and second discrete cells by placing the conductive wire pattern in electrical contact with the photoactive composition of the second discrete cell and with the conductive strip that is electrically connected to the top side of the conductive back sheet of the first discrete cell.
7 more elements
A method of manufacturing a photovoltaic module, comprising:
- cutting a continuous sheet of flexible photovoltaic material including first and second cell regions into first and second discrete photovoltaic cells corresponding respectively to the first and second cell regions, each cell region including photoactive composition disposed on a top side of a conductive substrate;
- forming a first interconnection zone on the first cell region by removing photoactive composition from the top side of the conductive substrate of the first cell region to electrically isolate the first interconnection zone from the photoactive composition of the first cell region disposed outside of the first interconnection zone;
- preparing an interconnection strip including a conductive strip and a dielectric strip, the conductive strip having a top face and a bottom face, the dielectric strip being disposed on the top face of the conductive strip;
- applying a portion of the bottom face of the conductive strip to the first interconnection zone;
- electrically connecting the conductive strip to the top side of the conductive substrate of the first cell region through the first interconnection zone;
- penetrating the dielectric strip to expose a portion of the top face of the conductive strip;
- preparing an optically transmissive front sheet, the front sheet including an embedded conductive wire grid;
- and
- electrically interconnecting the first and second discrete cells in series by placing the embedded conductive wire grid in electrical contact with the portion of the top face of the conductive strip and with the photoactive composition of the second discrete cell.
6 more elements
A method of manufacturing a photovoltaic module, comprising:
- applying a photoactive composition to a conductive substrate to produce a continuous sheet of photovoltaic material including first and second cell regions;
- cutting the photovoltaic material into first and second discrete photovoltaic cells respectively corresponding to the first and second cell regions, each cell region including photoactive composition disposed on a top side of a portion of the conductive substrate;
- creating a first interconnection area on the first cell region by removing a portion of the photoactive composition from the top side of the portion of the conductive substrate of the first cell region to electrically isolate the first interconnection area from the photoactive composition of the first cell region disposed outside of the first interconnection area;
- disposing a first conductive strip on the first interconnection area;
- electrically connecting the first conductive strip to the portion of the conductive substrate of the first cell region;
- and
- electrically interconnecting the first and second discrete cells, after disposing the first conductive strip on the first interconnection area, by placing a first conductive wire grid embedded in a front sheet in electrical contact with the first conductive strip and with the photoactive composition of the second discrete cell.
4 more elements
Dependencies are inferred from the claim text.