Photovoltaic power modules and methods for making same
First Claim
1. A photovoltaic power module comprising in combination:
- an array of photovoltaic semiconductor crystal cells disposed in individual cell sites formed in a laminated substrate comprised of two electrically conductive sheets separated by an insulating sheet;
a light transmissive lens sheet having an array of lenses formed therein disposed at a distance from and relative to said laminated substrate whereby radiation incident on the lenses of said lens sheet is focused onto said photovoltaic cells in said substrate;
wherein the combined thickness of the lens sheet, laminated substrate and space therebetween is less than 2 inches.
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Accused Products
Abstract
A solar concentrator photovolataic power module of small scale wherein a plurality of pre-fabricated photovoltaic solar cells reside in a matrix array in a substrate comprised of a pair of thin sheet conductors separated by an insulator sheet. A lens sheet on which a multiplicity of lenses have been formed is disposed in a fixed spaced relation to the substrate and operates to focus radiation (sunlight) onto the photo active surfaces of the cells in order to generate electricity. The overall thickness of the module including the substrate, lens sheet and space between the two is less than two inches. The laminated substrate is formed by disposing a plurality of pre-fabricated solar cells in a matrix array onto a back conductor, overlaying onto the back conductor an insulator which surrounds each of the cells and overlaying onto the insulator a top conductor. After electrical and mechanical heat activated bonding materials are disposed between the elements of the substrate, the laminate is heated until the substrate is bonded into a single rigid module substrate.
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Citations
19 Claims
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1. A photovoltaic power module comprising in combination:
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an array of photovoltaic semiconductor crystal cells disposed in individual cell sites formed in a laminated substrate comprised of two electrically conductive sheets separated by an insulating sheet; a light transmissive lens sheet having an array of lenses formed therein disposed at a distance from and relative to said laminated substrate whereby radiation incident on the lenses of said lens sheet is focused onto said photovoltaic cells in said substrate; wherein the combined thickness of the lens sheet, laminated substrate and space therebetween is less than 2 inches. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9)
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10. A photovoltaic power module comprising in combination:
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a thin back conductor sheet of electrically conductive material; an array of photovoltaic semiconductor crystal cells attached both mechanically and electrically in a spaced array onto said back conductor; an insulator sheet of electrically insulating material substantially the same thickness as said cells and having an array of holes which are larger than said cells and arranged in a matrix which matches the matrix of cells on said back conductor, said insulator sheet overlayed and affixed to said back conductor such that each cell on said back conductor is within a hole of said insulator sheet; a thin top conductor sheet of electrically conductive material having an array of holes in a matrix which matches the matrix of cells on said back conductor, said top conductor overlayed and affixed to said insulator such that a small perimeter area of each cell is also overlayed by said top conductor which is electrically connected to said cell at such perimeter overlay; a thin lens sheet having a array of concentrating lenses arranged in a matrix which matches the matrix of cells on said back conductor, said lens sheet affixed at a spaced distance from said top conductor whereby radiation on said lenses is concentrated and directed to said lens; wherein the combined thickness of said back conductor, said insulator, said top conductor, said lens sheet and the space between said top conductor and said lens sheet is less than two inches. - View Dependent Claims (11, 12, 13, 14)
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15. A method of making a very thin photovoltaic (PV) module substrate comprising the steps of:
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locating a plurality of PV cells in a matrix array on a back conductor of electrically conductive material; overlaying an insulator of electrically non-conductive material having a matrix of holes matching the matrix of cells onto the back conductor whereby each of the cells is disposed in an insulator hole and is surrounded by insulator material; overlaying onto the insulator a top conductor of electrically conductive material having an array of holes in a matrix corresponding to the matrix of cells wherein the holes are smaller than the cells whereby the perimeters of the cells are overlayed by the top conductor; disposing heat activated bonding material between the top conductor and the insulator and between the back conductor and the insulator; disposing heat activated electrical bonding material between each cell and the top and back conductor; and heating the formed substrate at a temperature and for a duration which activates the bonding materials and forms a unified rigid substrate wherein the top conductor and the cells and the back conductor and cells are electrically contacted; wherein the combined thickness of the substrate is less than one inch. - View Dependent Claims (16, 17, 18, 19)
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Specification