US 7,732,243 B2 · Substrate structures for integrated series connected photovoltaic arrays and process of manufacture of such arrays

Abstract

This invention comprises manufacture of photovoltaic cells by deposition of thin film photovoltaic junctions on metal foil substrates. The photovoltaic junctions may be heat treated if appropriate following deposition in a continuous fashion without deterioration of the metal support structure. In a separate operation, an interconnection substrate structure is provided, optionally in a continuous fashion. Multiple photovoltaic cells are then laminated to the interconnection substrate structure and conductive joining methods are employed to complete the array. In this way the interconnection substrate structure can be uniquely formulated from polymer-based materials employing optimal processing unique to polymeric materials. Furthermore, the photovoltaic junction and its metal foil support can be produced in bulk without the need to use the expensive and intricate material removal operations currently taught in the art to achieve series interconnections.

Claims22

Dependent claims

A method contributing to the facile manufacture of an array of photovoltaic cells, said method comprising the steps of,

production of photovoltaic cells having structure comprising semiconductor material supported on a first metal-based foil and having a top surface facing in an upward direction and a conductive bottom surface formed by said first metal-based foil and facing in a downward direction, said cell production employing at least one continuous processing step wherein said first metal-based foil is provided in a continuous form,
providing a unit of interconnecting substrate comprising materials in addition to those incorporated into said cells, said additional materials comprising both conductive and non-conductive materials forming respective conductive and non-conductive upper surface regions of said unit, said unit having a sheetlike structure,
combining said unit and a first of said cells such that a first portion of said additional conductive material is positioned under the metal based foil of the first cell and a second portion of the conductive material is positioned outside a terminal edge of the first cell to supply an upward facing surface to which electrical contact may be achieved.

Dependencies are inferred from the claim text.

Substrate structures for integrated series connected photovoltaic arrays and process of manufacture of such arrays

Life of this patent

Substrate structures for integrated series connected photovoltaic arrays and process of manufacture of such arrays

Life of this patent

Abstract

Claims22