US 8,802,479 B2Granted

Solar cell interconnection method using a flat metallic mesh

AssigneeNuvosun, Inc.

InventorsDavid B. Pearce, Bruce D. Hachtmann, Liguang Gong, Thomas M. Valeri, Dennis R. Hollars

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Abstract

An improved method for interconnecting thin film solar cells to form solar cell modules is provided, the method comprising using a flat metallic mesh formed from a thin metallic strip to provide a current collection grid over a thin film solar cell. The method is particularly useful for forming interconnections between thin film solar cells deposited on flexible substrates. The rectangular cross sectional shape of the mesh elements provides an increased area of electrical contact to the solar cell compared to the small tangential area provided by elements of circular cross section. Mesh elements can be made higher rather than wider to improve conductivity without proportionally increasing shading loss. Various coatings can be applied to the mesh to improve its performance, provide corrosion resistance, and improve its cosmetic appearance.

Claims23

Dependent claims

A method for interconnecting thin film solar cells, comprising:

(a) attaching a first surface of a thin flat metallic mesh to a first thin film solar cell material to form a current collection grid on the first thin film solar cell material, wherein a metal foil comprises a slit region forming the thin flat metallic mesh and a tab region that is contiguously formed with the slit region, wherein the first thin film solar cell material and the metal foil are provided in rolls;
(b) unrolling the roll of first thin film solar cell material and the roll of metal foil;
(c) heating a pair of rollers, wherein one of the rollers is dispersed adjacent to the unrolled first surface of the thin flat metallic mesh and the other roller is disposed adjacent to the unrolled first thin film solar cell material;
(d) connecting a second surface of the tab region directly to a backside of a second thin film solar cell material having a flat metallic mesh to form a serial electrical connection between the first and the second thin film solar cell materials, wherein the first surface of the thin flat metallic mesh and the second surface of the tab region are on opposing sides of the metal foil, wherein the second thin film solar cell material is provided in a roll;
(e) connecting successive thin film solar cell material to the first and second thin film solar cell material with the attached flat metallic meshes to form an electrically integrated roll of interconnected thin film solar cell material;
and
(f) cutting the electrically integrated roll of interconnected thin film solar cell material into an electrically integrated string of interconnected thin film solar cells;
(g) integrating the string of interconnected thin film solar cells into a solar cell module.

5 more elements

A method for interconnecting thin film solar cells, comprising:

(a) attaching a first surface of a thin flat metallic mesh to a first thin film solar cell material to form a current collection grid on the first thin film solar cell material, wherein the first thin film solar cell material comprises a dielectric at an edge portion of the first thin film solar cell material, wherein a metal foil comprises a slit region forming the thin flat metallic mesh and a tab region that is contiguously formed with the slit region, wherein the first thin film solar cell material and the metal foil are provided in rolls;
(b) unrolling the roll of first thin film solar cell material and the roll of metal foil;
(c) heating a pair of rollers, wherein one of the rollers is disposed adjacent to the unrolled first surface of the thin flat metallic mesh and the other roller is disposed adjacent to the unrolled first thin film solar cell material;
(d) connecting the first thin film solar cell material via a second surface of the tab region of the attached metal foil directly to a backside of a second thin film solar cell material having a flat metallic mesh to form a serial electrical connection between the first and the second thin film solar cell materials, such that the metal foil is disposed adjacent to the dielectric, wherein the first surface of the thin flat metallic mesh and the second surface of the tab region are on opposing sides of the metal foil, wherein the second thin film solar cell material is provided in a roll;
(e) connecting successive thin film solar cells to the first and second thin film solar cell materials with the attached flat metallic meshes to form an electrically integrated roll of interconnected thin film solar cell materials;
(f) cutting the electrically integrated roll of interconnected thin film solar cell materials into an electrically integrated string of interconnected thin film solar cells;
and
(g) integrating the string of interconnected thin film solar cells into a solar cell module.

5 more elements

Dependencies are inferred from the claim text.

Facts

Application: 12/793,617Filed 3 Jun 2010
Published: US 2011/0300661 A18 Dec 2011
Granted: 12 Aug 2014
Term ends: Not estimatedThe source records don’t support an estimate.

Classification8 codes

H10F 71/1375
Batch treatment of the devices: apparatus for automatic interconnection of photovoltaic cells in a module
H10F 19/35
Having multiple laterally adjacent thin-film photovoltaic cells deposited on the same substrate: structures for the connecting of adjacent…
H10F 19/80
Integrated devices, or assemblies of multiple devices, comprising at least one photovoltaic cell covered by group H10F10/00, e.g. photovoltaic…
H10F 19/904
For series or parallel connection of photovoltaic cells: characterised by the shapes of the structures