Method for interconnecting photovoltaic devices

A method for interconnecting a plurality of photovoltaic devices using a laminate of dielectric material and of electrically conductive material, comprising the steps of:

• forming a plurality of patterns in the electrically conductive material, the patterns having an extended portion and a plurality of angled tabs;
• providing a void in the dielectric material proximate the extended portion;
• protruding the angled tabs through the dielectric material;
• bending the angled tabs upward so that photovoltaic devices can be placed on the dielectric material, the angled tabs positioned about the photovoltaic devices;
• placing photovoltaic devices on the dielectric material;
• pressing the angled tabs toward the photovoltaic devices so that a portion of the angled tabs comes in contact with a photovoltaic device;
• bonding the angled tabs to the photovoltaic devices;
• and
• bonding the extended portion to an adjacent photovoltaic device.

A method of interconnecting an array of photovoltaic devices which have a first and a second side, the method comprising:

• punching a plurality of angled tabs through a laminated sheet of electrically conductive material and of dielectric material, the plurality of angled tabs substantially forming a skeleton outline of a photovoltaic device;
• forming predetermined patterns in the sheet of electrically conductive material laminated to a sheet of dielectric material, the patterns substantially surrounding groups of angled tabs and providing two conductive paths for contacting the first and second sides;
• removing a portion of the dielectric material associated with each pattern to expose a portion of electrically conductive material;
• preparing the angled tabs and areas of electrically conductive material exposed by removing a portion of the dielectric material for attachment to one of the photovoltaic devices;
• placing a photovoltaic device in each outline formed by the angled tabs;
• making electrical connections between the prepared angled tabs and the first side of the photovoltaic devices and the prepared area of electrically conductive material and the second sides of the photovoltaic device wherein the angled tabs of a pattern and associated areas of electrically conductive material are connected respectively to first and second sides of adjacent photovoltaic devices.

A method of interconnecting an array of photovoltaic devices by using an electrical conductor/dielectric laminate wherein the photovoltaic devices have a first and a second side, the method comprising:

• punching groups of angled tabs from the conductor and dielectric laminate so that a portion of the angled tabs remain connected to the laminate, the angled tabs having an acute angle and the electrical conductor portion of the angled tabs extending through plane of the dielectric;
• etching patterns in the electrical conductor portion of the laminate so that the patterns incorporate groups of the angled tabs and form an extended portion associated with each group of angled tabs, the angled tabs and extended portion originally formed in a plane;
• removing an area of dielectric over the extended portion to expose an area of the electrical conductor;
• tinning the exposed area of electrical conductor and the angled tabs;
• positioning a photovoltaic device in each group of angled tabs so that at least a piece of the angled tab is on the first side of the photovoltaic device;
• and soldering the angled tabs to the first side of the photovoltaic device and soldering the second side of an adjacent photovoltaic device to the exposed area of electrical conductor so that the angled tabs of a group are connected to the first side of a photovoltaic device and the exposed area of the associated extended portion is connected to the second side of an adjacent photovoltaic device.