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Manufacturing processes for light concentrating solar module

  • US 20090032087A1
  • Filed: 09/26/2008
  • Published: 02/05/2009
  • Est. Priority Date: 02/06/2007
  • Status: Abandoned Application
First Claim
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1. A method of fabricating a light concentrating solar module having a plurality of photovoltaic cells, each photovoltaic cell having a plurality of conductive contacts located on a back surface of each photovoltaic cell, the method comprising:

  • feeding a flexible electrical backplane onto a planar surface, said flexible electrical backplane comprising a flexible substrate and a light concentrating layer disposed adjacent to a front surface of said flexible substrate, said flexible electrical backplane having preformed conductive interconnects in contact with interconnect pads exposed on a front surface of said flexible electrical backplane at predetermined locations;

    forming a plurality of interconnect attachments in electrical contact with said exposed interconnect pads based on applying an interconnect material onto said exposed interconnect pads;

    placing said conductive contacts of said photovoltaic cells in an alignment with said predetermined locations of said interconnect pads and in contact with said interconnect attachments, said predetermined locations determined to provide said alignment for said interconnect pads, said interconnect attachments, and said conductive contacts;

    providing an underlay encapsulant to fill a plurality of spaces formed between said back surfaces of said photovoltaic cells and said front surface of said flexible substrate; and

    applying a curing process to said underlay encapsulant solidifying said underlay encapsulant and to said interconnect attachments forming a conductive path from each conductive contact through a respective one of said interconnect attachments to a respective one of said interconnect pads.

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