Interconnect structure for solar cells and method of making same

• US 6,313,395 B1
• Filed: 04/24/2000
• Issued: 11/06/2001
• Est. Priority Date: 04/24/2000
• Status: Expired due to Term

• Current Assignee: Sunpower Corporation (Totalenergies Se)
• Original Assignee: Sunpower Corporation (Totalenergies Se)
• Inventors: Daroczi, Shandor G., Piper, Matthew B., Crane, Richard A.
• Primary Examiner(s): DIAMOND, ALAN D
• Application Number:
  US09/558,409
• Time in Patent Office: 561 Days
• Field of Search: 136/244, 136/261, 136/251, 136/291, 136/256, 136/293, 721/35, 721/36, 721/46, 298/25, 298/50, 439/32, 439/775, 439/816, 439/954
• US Class Current: 136/244
• CPC Class Codes: H01L 31/0201 comprising specially adapted module bus-bar structures
• CPC Class Codes: H01L 31/0508 the interconnection means having a particular shape
• CPC Class Codes: Y02E 10/50 Photovoltaic [PV] energy
• CPC Class Codes: Y10S 136/291 Applications
• CPC Class Codes: Y10S 136/293 Circuits
• CPC Class Codes: Y10S 439/954 Special orientation of electrical connector
• CPC Class Codes: Y10T 29/49117 Conductor or circuit manufacturing
• CPC Class Codes: Y10T 29/49162 by using wire as conductive path

Abstract

An interconnect structure for use with solar cells and like devices which are subject to compressive and/or expansive forces through packaging or in application comprises a flattened spiral of a metal strip. The interconnect is fabricated by first providing a length of metal strip, wrapping the metal strip around a cylindrical or flat mandrel or otherwise folded in a helical pattern, removing the mandrel, and then flattening the metal strip to reduce thickness of the interconnect.

Claims

1. A solar cell module comprising

(a) a plurality of silicon substrates with each substrate including solar cells and electrical contacts,

(b) a plurality of first interconnects connecting contacts of adjacent silicon substrates, and

(c) a flexible peripheral interconnect connected to at least one silicon substrate and comprising a flattened spiral of a metal strip which allows for contraction and expansion of the interconnect without significant buckling.

2. The solar cell module as defined by claim 1 wherein the metal strip comprises silver foil.

3. The solar cell module as defined by claim 2 wherein the metal strip comprises a silver foil having a width of about 0.150 inch and a thickness of about 0.002 inch.

4. The solar cell module as defined by claim 3 wherein the spiral prior to flattening has a diameter of about 0.090 inch and the flattened spiral is about 0.150 inch wide and 0.004 inch in thickness.

5. The solar cell module as defined by claim 3 wherein the first plurality of interconnects comprises a silver foil with a perforated through hole pattern therein to accommodate contraction and expansion of module components.

6. The solar cell module as defined by claim 5 and further including a laminate housing for the module.

7. The solar cell module as defined by claim 6 wherein the laminate housing comprises two layers of a fluoro-plastic film.

8. The solar cell module as defined by claim 1 wherein the first plurality of interconnects comprises a metal foil with a perforated through hole pattern therein to accommodate contraction and expansion.

9. The solar cell module as defined by claim 8 and further including a laminate housing for the module.

10. The solar cell module as defined by claim 9 wherein the laminate housing comprises two layers of fluoro-plastic film.

11. The solar cell module as defined by claim 1 and further including a laminate housing for the module.

12. The solar cell module as defined by claim 11 wherein the laminate housing comprises two layers of fluoro-plastic film.

13. A method of fabricating an electrical interconnect for use in an application which subjects the interconnect to contraction comprising the steps of:

(a) providing a metal strip,

(b) wrapping the metal strip around a cylindrical mandrel in a helical spiral pattern,

(c) removing the mandrel, and

(d) flattening the metal spiral to reduce thickness of the interconnect.