Affixing method and solar decal device using a thin film photovoltaic

• US 8,207,008 B1
• Filed: 03/18/2009
• Issued: 06/26/2012
• Est. Priority Date: 08/01/2008
• Status: Expired due to Fees

• Current Assignee: Stion Corporation
• Original Assignee: Stion Corporation
• Inventors: Farris, Chester A. III
• Primary Examiner(s): Michener, Jennifer
• Assistant Examiner(s): Martin, Matthew
• Application Number:
  US12/406,623
• Time in Patent Office: 1,196 Days
• Field of Search: 438/73, 438 15- 17, 438/30, 438 52- 57, 438/98, 136/249, 136/252, 136/256, 257/E21.415, 257/52, 257/111, 257/112, 257/529
• US Class Current: 438/73
• CPC Class Codes: H01L 31/0392 including thin films deposited on metallic or insulating substrates ; characterised by specific substrate materials or substrate features or by the presence of intermediate layers, e.g. barrier layers, on the substrate textured substrates H01L31/02366
• CPC Class Codes: H01L 31/03923 including AIBIIICVI compound materials, e.g. CIS, CIGS
• CPC Class Codes: H01L 31/03925 including AIIBVI compound materials, e.g. CdTe, CdS
• CPC Class Codes: H01L 31/1892 methods involving the use of temporary, removable substrates
• CPC Class Codes: Y02E 10/541 CuInSe2 material PV cells
• CPC Class Codes: Y02P 70/50 Manufacturing or production processes characterised by the final manufactured product

Abstract

A solar device is provided, comprising a substrate structure having a surface region, a flexible and conformal material comprising a polymer material affixing the surface region, and one or more solar cells spatially provided by one or more films of materials characterized by a thickness dimension of 25 microns and less and mechanically coupled to the flexible and conformal material. The one or more solar cells have a flexible characteristic. The flexible characteristic maintains each of the solar cells substantially free from any damage or breakage thereto when the one or more films of materials is subjected to bending.

Claims

1. A method for manufacturing a solar decal device affixable to a substrate structure, the method comprising:

providing a transparent substrate member having a surface region;

forming a flexible and conformal material overlying the surface region with a polymer material capable of detachment from the transparent substrate member;

forming an interface region within a vicinity between the surface region of the transparent substrate member and the polymer material;

forming one or more films of materials mechanically overlying the flexible and conformal material, the one or more films of materials including an absorber material having a grain size ranging from about 0.5 to about 4 microns;

forming one or more solar cells spatially provided by the one or more films of materials having a thickness dimension of 25 microns and less with a flexible characteristic, wherein the flexible characteristic maintains each of the solar cells substantially free from any damage or breakage thereto when the one or more films of materials is subjected to bending;

supporting at least the transparent substrate member, the flexible and conformal material, the interface region, and the one or more solar cells to expose a backside region of the transparent substrate member; and

irradiating the backside region with electromagnetic radiation to selectively release the flexible and conformal material from the surface region of the transparent substrate member to substantially free the one or more solar cells spatially provided by the one or more films of materials mechanically coupled to the flexible and conformal material.

2. The method of claim 1 wherein providing a transparent substrate member comprises using a substrate material selected from glass, quartz, metal, semiconductor or plastic.

3. The method of claim 2 wherein the substrate material is optically transparent to the electromagnetic radiation.

4. The method of claim 1 wherein the polymer material is configured to absorb thermal energy from the electromagnetic radiation.

5. The method of claim 1 wherein forming the flexible and conformal material comprises coating the surface region with the polymer material ranging from about 1 micron to about 10 microns.

6. The method of claim 1 wherein the flexible and conformal material acts as a carrier material to hold the one or more solar cells.

7. The method of claim 1 wherein the one or more solar cells is configured as a plurality of stripes arranged on and to be released from one portion of the transparent substrate member.

8. The method of claim 7 further comprises affixing the plurality of stripes onto the substrate structure pre-applied with a layer of flexible and conformal material.

9. The method of claim 8 wherein the substrate structure comprises a portion of an automobile, glass, window, laptop computer, handheld PDA device, clothing, table, housing tile, outdoor furniture, and or shaped object.

10. The method of claim 1 wherein one or more films of materials comprises a first electrode layer, an absorber layer overlying the electrode layer, a window layer overlying the absorber layer, and a second electrode layer overlying the window layer.

11. The method of claim 10 wherein the one or more films of materials comprises a thickness less than about 20 microns.

12. The method of claim 1 wherein the thickness of the absorber material is about the grain size thereof.

13. The method of claim 1 wherein one or more solar cells has a thin film absorber material.

14. The method of claim 1 wherein the interface region comprises a plurality of Van der Wal'"'"'s forces to bond the flexible and conformal material with the surface region, the plurality of Van der Wal'"'"'s forces being overcome during the detachment of the flexible and conformal material from the surface region.