公开(公告)号：US20080216887A1

公开(公告)日：2008-09-11

申请号：US11963841

申请日：2007-12-23

申请人： Peter Hacke ,  David H. Meakin ,  James M. Gee ,  Sysavanh Southimath ,  Brian Murphy

发明人： Peter Hacke ,  David H. Meakin ,  James M. Gee ,  Sysavanh Southimath ,  Brian Murphy

IPC分类号： H01L31/05 ,  H01L31/18

CPC分类号： H01L31/022441 ,  H01L31/0516 ,  Y02E10/50 ,  Y10T29/49171

摘要： Methods and systems for interconnecting back contact solar cells. The solar cells preferably have reduced area busbars, or are entirely busbarless, and current is extracted from a variety of points on the interior of the cell surface. The interconnects preferably relieve stresses due to solder reflow and other thermal effects. The interconnects may be stamped and include external or internal structures which are bonded to the solder pads on the solar cell. These structures are designed to minimize thermal stresses between the interconnect and the solar cell. The interconnect may alternatively comprise porous metals such as wire mesh, wire cloth, or expanded metal, or corrugated or fingered strips. The interconnects are preferably electrically isolated from the solar cell by an insulator which is deposited on the cell, placed on the cell as a discrete layer, or laminated directly to desired areas of the interconnect.

摘要翻译： 用于互连背接触太阳能电池的方法和系统。 太阳能电池优选地具有减小的面积母线，或者完全无母线，并且电流从电池表面内部的各种点提取。 互连优选地减轻由于焊料回流和其它热效应引起的应力。 互连可以被冲压并且包括结合到太阳能电池上的焊盘的外部或内部结构。 这些结构被设计成使互连和太阳能电池之间的热应力最小化。 互连可以可选地包括多孔金属，例如金属丝网，金属丝布或多孔金属，或波纹状或指形条。 互连优选地通过绝缘体与太阳能电池电隔离，所述绝缘体沉积在电池上，作为离散层放置在电池上，或者直接层压到互连的期望区域。

公开(公告)号：US20120204938A1

公开(公告)日：2012-08-16

申请号：US13419264

申请日：2012-03-13

申请人： Peter HACKE ,  David H. Meakin ,  James M. Gee ,  Sysavanh Southimath ,  Brian Murphy

发明人： Peter HACKE ,  David H. Meakin ,  James M. Gee ,  Sysavanh Southimath ,  Brian Murphy

IPC分类号： H01L31/052 ,  H01L31/048 ,  H01L31/0203 ,  H01L31/0224 ,  H01L31/05

CPC分类号： H01L31/022441 ,  H01L31/0516 ,  Y02E10/50 ,  Y10T29/49171

摘要： Methods and systems for interconnecting back contact solar cells. The solar cells preferably have reduced area busbars, or are entirely busbarless, and current is extracted from a variety of points on the interior of the cell surface. The interconnects preferably relieve stresses due to solder reflow and other thermal effects. The interconnects may be stamped and include external or internal structures which are bonded to the solder pads on the solar cell. These structures are designed to minimize thermal stresses between the interconnect and the solar cell. The interconnect may alternatively comprise porous metals such as wire mesh, wire cloth, or expanded metal, or corrugated or fingered strips. The interconnects are preferably electrically isolated from the solar cell by an insulator which is deposited on the cell, placed on the cell as a discrete layer, or laminated directly to desired areas of the interconnect.

摘要翻译： 用于互连背接触太阳能电池的方法和系统。 太阳能电池优选地具有减小的面积母线，或者完全是无母线的，并且电流从电池表面内部的各种点提取。 互连优选地减轻由于焊料回流和其它热效应引起的应力。 互连可以被冲压并且包括结合到太阳能电池上的焊盘的外部或内部结构。 这些结构被设计成使互连和太阳能电池之间的热应力最小化。 互连可以可选地包括多孔金属，例如金属丝网，金属丝布或多孔金属，或波纹状或指形条。 互连优选地通过绝缘体与太阳能电池电隔离，所述绝缘体沉积在电池上，作为离散层放置在电池上，或者直接层压到互连的期望区域。

公开(公告)号：US20110126878A1

公开(公告)日：2011-06-02

申请号：US12952018

申请日：2010-11-22

申请人： Peter Hacke ,  David H. Meakin ,  James M. Gee ,  Sysavanh Southimath ,  Brian Murphy

发明人： Peter Hacke ,  David H. Meakin ,  James M. Gee ,  Sysavanh Southimath ,  Brian Murphy

IPC分类号： H01L31/05

CPC分类号： H01L31/022441 ,  H01L31/0516 ,  Y02E10/50 ,  Y10T29/49171

摘要： Methods and systems for interconnecting back contact solar cells. The solar cells preferably have reduced area busbars, or are entirely busbarless, and current is extracted from a variety of points on the interior of the cell surface. The interconnects preferably relieve stresses due to solder reflow and other thermal effects. The interconnects may be stamped and include external or internal structures which are bonded to the solder pads on the solar cell. These structures are designed to minimize thermal stresses between the interconnect and the solar cell. The interconnect may alternatively comprise porous metals such as wire mesh, wire cloth, or expanded metal, or corrugated or fingered strips. The interconnects are preferably electrically isolated from the solar cell by an insulator which is deposited on the cell, placed on the cell as a discrete layer, or laminated directly to desired areas of the interconnect.

摘要翻译： 用于互连背接触太阳能电池的方法和系统。 太阳能电池优选地具有减小的面积母线，或者完全无母线，并且电流从电池表面内部的各种点提取。 互连优选地减轻由于焊料回流和其它热效应引起的应力。 互连可以被冲压并且包括结合到太阳能电池上的焊盘的外部或内部结构。 这些结构被设计成使互连和太阳能电池之间的热应力最小化。 互连可以可选地包括多孔金属，例如金属丝网，金属丝布或多孔金属，或波纹状或指形条。 互连优选地通过绝缘体与太阳能电池电隔离，所述绝缘体沉积在电池上，作为离散层放置在电池上，或者直接层压到互连的期望区域。

公开(公告)号：US20110067751A1

公开(公告)日：2011-03-24

申请号：US12905921

申请日：2010-10-15

申请人： David H. Meakin ,  James M. Gee ,  Sysavanh Southimath ,  Brian Murphy ,  John Telle ,  Andrew Mark Mitchell

发明人： David H. Meakin ,  James M. Gee ,  Sysavanh Southimath ,  Brian Murphy ,  John Telle ,  Andrew Mark Mitchell

IPC分类号： H01L31/048

CPC分类号： H01L31/0201 ,  H01L31/02013 ,  H01L31/048 ,  H01L31/049 ,  H01L31/0516 ,  H02S40/34 ,  Y02E10/50

摘要： Photovoltaic modules comprising back-contact solar cells manufactured using monolithic module assembly techniques comprising a flexible circuit comprising a back sheet and a patterned metallization. The module may comprise busses in electrical contact with the patterned metallization to extract the current. The module may alternatively comprise multilevel metallizations. Interlayer dielectric comprising islands or dots relieves stresses due to thermal mismatch. The use of multiple cord plates enables flexible circuit layouts, thus optimizing the module. The modules preferably comprise a thermoplastic encapsulant and/or hybrid adhesive/solder materials. An ultrathin moisture barrier enables roll-to-roll processing.

摘要翻译： 包括使用整体模块组装技术制造的背接触式太阳能电池的光伏模块，该技术包括包含背板和图案化金属化的柔性电路。 模块可以包括与图案化的金属化物电接触以提取电流的母线。 该模块可以替代地包括多层金属化。 包含岛或点的层间电介质减轻了由于热失配引起的应力。 使用多个电缆板可实现灵活的电路布局，从而优化模块。 模块优选地包括热塑性密封剂和/或混合粘合剂/焊料材料。 超薄防潮屏障可实现卷对卷加工。

公开(公告)号：US20100012172A1

公开(公告)日：2010-01-21

申请号：US12432706

申请日：2009-04-29

申请人： David H. Meakin ,  James M. Gee ,  Sysavanh Southimath ,  Brian Murphy ,  John Telle ,  Andrew Mark Mitchell

发明人： David H. Meakin ,  James M. Gee ,  Sysavanh Southimath ,  Brian Murphy ,  John Telle ,  Andrew Mark Mitchell

IPC分类号： H01L31/048 ,  H01L31/042

CPC分类号： H01L31/0201 ,  H01L31/02013 ,  H01L31/048 ,  H01L31/049 ,  H01L31/0516 ,  H02S40/34 ,  Y02E10/50

摘要： Photovoltaic modules comprising back-contact solar cells manufactured using monolithic module assembly techniques comprising a flexible circuit comprising a back sheet and a patterned metallization. The module may comprise busses in electrical contact with the patterned metallization to extract the current. The module may alternatively comprise multilevel metallizations. Interlayer dielectric comprising islands or dots relieves stresses due to thermal mismatch. The use of multiple cord plates enables flexible circuit layouts, thus optimizing the module. The modules preferably comprise a thermoplastic encapsulant and/or hybrid adhesive/solder materials. An ultrathin moisture barrier enables roll-to-roll processing.

摘要翻译： 包括使用整体模块组装技术制造的背接触式太阳能电池的光伏模块，该技术包括包含背板和图案化金属化的柔性电路。 模块可以包括与图案化的金属化物电接触以提取电流的母线。 该模块可以替代地包括多层金属化。 包含岛或点的层间电介质减轻了由于热失配引起的应力。 使用多个电缆板可实现灵活的电路布局，从而优化模块。 模块优选地包括热塑性密封剂和/或混合粘合剂/焊料材料。 超薄防潮屏障可实现卷对卷加工。

公开(公告)号：US20100024881A1

公开(公告)日：2010-02-04

申请号：US12563040

申请日：2009-09-18

申请人： Peter Hacke ,  David H. Meakin ,  James M. Gee ,  Brian Murphy

发明人： Peter Hacke ,  David H. Meakin ,  James M. Gee ,  Brian Murphy

IPC分类号： H01L31/00

CPC分类号： H01L31/022441 ,  H01L31/0516 ,  Y02E10/50 ,  Y10T29/49171

摘要： Methods and systems for interconnecting back contact solar cells. The solar cells preferably have reduced area busbars, or are entirely busbarless, and current is extracted from a variety of points on the interior of the cell surface. The interconnects preferably relieve stresses due to solder reflow and other thermal effects. The interconnects may be stamped and include external or internal structures which are bonded to the solder pads on the solar cell. These structures are designed to minimize thermal stresses between the interconnect and the solar cell. The interconnect may alternatively comprise porous metals such as wire mesh, wire cloth, or expanded metal, or corrugated or fingered strips. The interconnects are preferably electrically isolated from the solar cell by an insulator which is deposited on the cell, placed on the cell as a discrete layer, or laminated directly to desired areas of the interconnect.

摘要翻译： 用于互连背接触太阳能电池的方法和系统。 太阳能电池优选地具有减小的面积母线，或者完全是无母线的，并且电流从电池表面内部的各种点提取。 互连优选地减轻由于焊料回流和其它热效应引起的应力。 互连可以被冲压并且包括结合到太阳能电池上的焊盘的外部或内部结构。 这些结构被设计成使互连和太阳能电池之间的热应力最小化。 互连可以可选地包括多孔金属，例如金属丝网，金属丝布或多孔金属，或波纹状或指形条。 互连优选地通过绝缘体与太阳能电池电隔离，所述绝缘体沉积在电池上，作为离散层放置在电池上，或者直接层压到互连的期望区域。

公开(公告)号：US20120234586A1

公开(公告)日：2012-09-20

申请号：US13419967

申请日：2012-03-14

申请人： JOHN TELLE ,  Brian J. Murphy ,  David H. Meakin

发明人： JOHN TELLE ,  Brian J. Murphy ,  David H. Meakin

IPC分类号： H05K1/09 ,  H05K3/10 ,  H05K1/02 ,  H05K1/03 ,  H05K1/00

CPC分类号： H05K3/202 ,  H05K1/0393 ,  H05K2203/033 ,  H05K2203/1545 ,  Y10T29/49155

摘要： Embodiments of the invention generally relate to methods of forming flexible substrates for use in photovoltaic modules. The methods include shaping a metal foil and adhering the metal foil to a flexible backsheet. An optional interlayer dielectric and anti-tarnish material may then be applied to the upper surface of the shaped metal foil disposed on the flexible backsheet. The metal foil may be shaped using die cutting, roller cutting, or laser cutting techniques. The die cutting, roller cutting, and laser cutting techniques simplify the flexible substrate formation processes by eliminating resist-printing and etching steps previously used to pattern metal foils. Additionally, the die cutting, roller cutting, and laser cutting techniques reduce the consumption of consumable materials previously used in the patterning of metal foils.

摘要翻译： 本发明的实施例一般涉及形成用于光伏模块的柔性基板的方法。 所述方法包括成形金属箔并将金属箔粘附到柔性底片上。 然后可以将任选的层间电介质和防晦暗材料施加到设置在柔性底片上的成形金属箔的上表面。 金属箔可以使用模切，辊切割或激光切割技术成形。 模切，辊切割和激光切割技术通过消除先前用于图案化金属箔的抗蚀印刷和蚀刻步骤来简化柔性基板形成工艺。 此外，模切，辊切割和激光切割技术减少了先前用于金属箔图案化的消耗材料的消耗。

公开(公告)号：US20120240971A1

公开(公告)日：2012-09-27

申请号：US13420178

申请日：2012-03-14

申请人： John Telle ,  William Bottenberg ,  Brian J. Murphy ,  David H. Meakin

发明人： John Telle ,  William Bottenberg ,  Brian J. Murphy ,  David H. Meakin

IPC分类号： H01L31/05 ,  H05K3/02

CPC分类号： H05K1/189 ,  H01L31/049 ,  H01L31/0516 ,  H05K3/244 ,  H05K2201/10143 ,  H05K2203/073 ,  Y02E10/50 ,  Y10T29/49156

摘要： Embodiments of the invention generally include a method of forming a low cost flexible substrate having one or more conductive elements that are used to form a low resistance current carrying path used to interconnect a plurality of solar cell devices disposed in a photovoltaic module. A surface of the one or more conductive elements will generally comprise a plurality of patterned electrical contact regions that are used to form part of the electrical circuit that interconnects the plurality of solar cell devices. The plurality of electrical contact points form an electrical circuit that has a lower series resistance versus conventional designs. Embodiments may also include a method and apparatus that form the electrical contact regions on an inexpensive conductive material before electrically connecting the anode or cathode regions of a formed solar cell to the conductive material.

摘要翻译： 本发明的实施例通常包括形成具有一个或多个导电元件的低成本柔性基板的方法，所述导电元件用于形成用于互连设置在光伏模块中的多个太阳能电池器件的低电阻载流路径。 一个或多个导电元件的表面通常将包括多个图案化的电接触区域，其被用于形成互连多个太阳能电池器件的电路的一部分。 多个电接触点形成与传统设计相比具有较低串联电阻的电路。 实施例还可以包括在将形成的太阳能电池的阳极或阴极区域电连接到导电材料之前在便宜的导电材料上形成电接触区域的方法和装置。

公开(公告)号：US20120103388A1

公开(公告)日：2012-05-03

申请号：US13284784

申请日：2011-10-28

申请人： David H. Meakin ,  Fares Bagh ,  James Gee ,  William Bottenberg

发明人： David H. Meakin ,  Fares Bagh ,  James Gee ,  William Bottenberg

IPC分类号： H01L31/05 ,  H01L31/048 ,  H01L31/18 ,  H01L31/0216

CPC分类号： H01L31/188 ,  B32B7/14 ,  B32B17/10018 ,  B32B17/10788 ,  B32B17/10807 ,  B32B17/10935 ,  B32B2307/202 ,  B32B2311/12 ,  B32B2311/24 ,  B32B2323/04 ,  B32B2327/12 ,  B32B2367/00 ,  H01L31/049 ,  H01L31/0516 ,  Y02E10/50 ,  Y10T156/1052 ,  Y10T156/1062 ,  Y10T156/1092 ,  Y10T156/1093

摘要： Embodiments of the invention contemplate the formation of a solar cell module comprising an array of interconnected solar cells that are formed using an automated processing sequence that is used to form a novel planar solar cell interconnect structure. In one embodiment, the module structure described herein includes a patterned adhesive layer that is disposed on a backsheet to receive and bond a plurality of conducting ribbons thereon. The substantially planar bonded conducting ribbons are then used to interconnect an array of solar cell devices to form a solar cell module that can be electrically connected to one or more external components, such as an electrical power grid, satellites, electronic devices or other similar power requiring units. Embodiments of the invention may further provide a roll-to-roll system that is configured to serially form a plurality of solar cell modules over different portions of a backsheet material received from a roll of backsheet material.

摘要翻译： 本发明的实施例考虑了太阳能电池模块的形成，该太阳能电池模块包括使用用于形成新的平面太阳能电池互连结构的自动化处理顺序形成的互连太阳能电池阵列。 在一个实施例中，本文所述的模块结构包括图案化的粘合剂层，其设置在底片上以在其上接收和粘合多个导电带。 然后使用基本上平面的接合的导电带来互连太阳能电池器件的阵列以形成太阳能电池模块，该太阳能电池模块可以电连接到一个或多个外部组件，例如电力电网，卫星，电子设备或其它类似功率 要求单位。 本发明的实施例还可以提供卷对卷系统，其被配置为在从底片材料卷接收的底片材料的不同部分上串联地形成多个太阳能电池模块。

公开(公告)号：US20120260973A1

公开(公告)日：2012-10-18

申请号：US13445741

申请日：2012-04-12

申请人： John Telle ,  Brian J. Murphy ,  David H. Meakin

发明人： John Telle ,  Brian J. Murphy ,  David H. Meakin

IPC分类号： H01L31/048 ,  H05K1/00 ,  H05K1/09 ,  H01L31/18

CPC分类号： H01L31/022441 ,  H01L31/049 ,  H01L31/0516 ,  Y02E10/50

摘要： Embodiments of the invention generally relate to a busing sub-assembly and methods of forming photovoltaic modules having busing sub-assemblies. The busing sub-assembly generally includes a carrier backsheet and a plurality of conductive ribbons coupled to the carrier backsheet. An electrically insulating cover is disposed over the conductive ribbons and the carrier backsheet. The ends of each conductive ribbon remain exposed for making an electrical connection to the conductive foil or a junction box. Methods of forming photovoltaic modules generally include positioning a flexible backsheet having an opening therethrough and a conductive foil thereon on a support. A busing sub-assembly is disposed on the flexible backsheet over the opening and in electrical contact with the conductive foil. The busing sub-assembly includes the components necessary to bus electrical current from a plurality of solar cells to a junction box, and can be applied to a photovoltaic module in a singe process step.

摘要翻译： 本发明的实施例一般涉及一种用于形成具有通气子组件的光伏模块的通气子组件和方法。 该通气子组件通常包括载体底片和耦合到载体底片的多个导电带。 电绝缘盖设置在导电带和载体底片之上。 每个导电带的端部保持暴露以与导电箔或接线盒形成电连接。 形成光伏模块的方法通常包括将具有开口的柔性底片和其上的导电箔定位在支撑件上。 一个通气子组件通过开口设置在柔性底片上并与导电箔电接触。 传声子组件包括将电流从多个太阳能电池传送到接线​​盒所需的部件，并且可以在单个工艺步骤中应用于光伏组件。