Solar cell edge interconnects

• US 10,749,061 B1
• Filed: 02/27/2020
• Issued: 08/18/2020
• Est. Priority Date: 05/23/2019
• Status: Active Grant

• Current Assignee: Zhejiang Kaiying New Materials Co., Ltd.
• Original Assignee: Zhejiang Kaiying New Materials Co., Ltd.
• Inventors: Hilali, Mohamed M., Li, Zhiyong
• Primary Examiner(s): Mershon, Jayne L
• Application Number:
  US16/803,300
• Time in Patent Office: 173 Days
• CPC Class Codes: H01L 2021/60007 involving a soldering or an alloying process
• CPC Class Codes: H01L 2021/60277 involving the use of conductive adhesives
• CPC Class Codes: H01L 21/50 Assembly of semiconductor devices using processes or apparatus not provided for in a single one of the subgroups H01L21/06 - H01L21/326, e.g. sealing of a cap to a base of a container
• CPC Class Codes: H01L 31/022433 Particular geometry of the grid contacts
• CPC Class Codes: H01L 31/048 Encapsulation of modules
• CPC Class Codes: H01L 31/05 Electrical interconnection means between PV cells inside the PV module, e.g. series connection of PV cells electrodes H01L31/0224; electrical interconnection of thin film solar cells formed on a common substrate H01L31/046; particular structures for electrical interconnecting of adjacent thin film solar cells in the module H01L31/0465; electrical interconnection means specially adapted for electrically connecting two or more PV modules H02S40/36
• CPC Class Codes: H01L 31/0504 specially adapted for series or parallel connection of solar cells in a module
• CPC Class Codes: H01L 31/0508 the interconnection means having a particular shape
• CPC Class Codes: H01L 31/0512 made of a particular material or composition of materials
• CPC Class Codes: Y02E 10/50 Photovoltaic [PV] energy

Abstract

Edge interconnects for interconnecting solar cells are disclosed. The edge interconnects include a layer of an electrically conductive adhesive overlying an insulating dielectric layer applied to edge of a solar cell and electrically interconnected to a busbar. Solar cell modules include adjacent solar cells comprising edge interconnects interconnected using an interconnection element. An interconnection element can be a solder paste or a solder containing electrically conductive ribbon. Methods of forming solar cell edge interconnects include applying an insulating dielectric coating to edges of a solar cell, depositing a busbar in proximity to the insulated edges of the solar cell, depositing an electrically conductive adhesive over at least portion of the busbar an over at least a portion of the dielectric layer. Solar cell modules can be formed by interconnecting adjacent solar cells using an interconnection element.

Claims

1. A method of fabricating a solar cell edge interconnect, comprising:

depositing a dielectric layer overlying a peripheral side edge of a solar cell;

depositing a busbar metallization overlying a surface of the solar cell in proximity to the peripheral side edge of the solar cell; and

depositing an electrically conductive adhesive overlying at least a portion of the dielectric layer and overlying at least a portion of the busbar to provide a solar cell edge interconnect.

2. The method of claim 1, wherein the dielectric layer is configured to passivate the peripheral side edge.

3. The method of claim 1, wherein the electrically conductive adhesive covers the dielectric layer.

4. The method of claim 1, further comprising, after depositing the electrically conductive adhesive, curing the electrically conductive adhesive.

5. The method of claim 4, further comprising, after curing the electrically conductive adhesive, depositing a solder paste overlying at least a portion of the cured electrically conductive adhesive.

6. The method of claim 5, wherein depositing the solder paste comprises depositing using additive manufacturing.

7. The method of claim 1, wherein depositing the dielectric layer comprises depositing using chemical vapor deposition.

8. The method of claim 1, wherein depositing the electrically conductive adhesive comprises depositing using additive manufacturing.

9. The method of claim 1, further comprising applying a non-electrically conductive elastomeric component on a portion of the peripheral side edge of the solar cell.

10. A solar cell comprising an edge interconnect fabricated using the method of claim 1.

11. A photovoltaic module comprising the solar cell of claim 10.

12. A power system comprising a plurality of the photovoltaic modules of claim 11.