Collector grid and interconnect structures for photovoltaic arrays and modules

• US 20100224230A1
• Filed: 03/31/2010
• Published: 09/09/2010
• Est. Priority Date: 04/13/2006
• Status: Active Grant

• Current Assignee: Solannex Incorporated
• Original Assignee: Solannex Incorporated
• Inventors: Luch, Daniel Randolph, Luch, Daniel
• Granted Patent: US 8,076,568 B2
• Time in Patent Office: Days
• US Class Current: 136/244
• CPC Class Codes: H01L 31/02008 for solar cells or solar cell modules
• CPC Class Codes: H01L 31/022425 for solar cells
• CPC Class Codes: H01L 31/046 PV modules composed of a plurality of thin film solar cells deposited on the same substrate
• CPC Class Codes: H01L 31/0465 comprising particular structures for the electrical interconnection of adjacent PV cells in the module H01L31/0463 takes precedence
• CPC Class Codes: Y02E 10/50 Photovoltaic [PV] energy

Abstract

An interconnected arrangement of photovoltaic cells is achieved using laminating current collector electrodes. The electrodes comprise a pattern of conductive material extending over a first surface of sheetlike substrate material. The first surface comprises material having adhesive affinity for a selected conductive surface. Application of the electrode to the selected conductive surface brings the first surface of the sheetlike substrate into adhesive contact with the conductive surface and simultaneously brings the conductive surface into firm contact with the conductive material extending over first surface of the sheetlike substrate. Use of the laminating current collector electrodes allows facile and continuous production of expansive area interconnected photovoltaic arrays.

Claims

1. A device comprising two adjacent electrically interconnected photovoltaic cells,

said cells having a top light incident surface and a bottom surface,

said device including a unit of interconnecting structure functioning to secure said two cells in adjacent positioning,

said unit of interconnecting structure having upward and downward facing surfaces, a portion of said upward facing surface formed by a first adhesive material contacting the bottom surface of a first cell, and a electrical conductor in electrical contact with the bottom surface of said first cell, said conductor positioned between said first adhesive material and said first cell bottom surface, said first adhesive material being separate and disconnected from a second adhesive material contacting the bottom surface of a second of said cells.

2. The device of claim 1 wherein said conductor extends from below the first cell to above the top light incident surface of the second cell.

3. The device of claim 2 wherein said conductor comprises a monolithic form extending from below the first cell to above the top light incident surface of the second cell.

4. The device of claim 1 wherein a portion of said downward facing surface is formed by a third adhesive material in contact with the light incident surface of the first cell, and wherein said third adhesive material is separate and disconnected from adhesive material contacting the light incident surface of the second cell.

5. The device of claim 4 wherein at least a portion of the light incident surfaces of the first and second cells are further overlayed by polymer support layers, and wherein the polymer support layer overlaying the first of said cells is separate and disconnected from the polymer support layer overlaying the second of said cells.

6. The device of claim 1 wherein at least a portion of the bottom surfaces of the first and second cells are further covered by polymer support layers, and wherein the polymer support layer covering the bottom surface of the first of said cells is separate and disconnected from the polymer support layer covering the bottom surface of the second of said cells.

7. The device of claim 1 wherein the light incident surfaces of both first and second cells are overlayed by a common barrier layer.

8. The device of claim 7 wherein said common barrier layer comprises glass.

9. The device of claim 2 wherein said conductor forms a conductive pattern extending over a predominance of the light incident surface of the second cell.

10. The device of claim 9 wherein said conductive pattern comprises multiple substantially parallel conductive traces having ends distal from said first cell, and wherein the distal ends of two adjacent traces are electrically connected such that should a first of said two traces become impaired the performance of the cell remains substantially undiminished.

11. The device of claim 1 wherein said top light incident surfaces comprise a transparent conductive material.

12. The device of claim 1 wherein said cells comprise thin film semiconductor.

13. The device of claim 1 wherein said cells comprise a self supporting metal foil.

14. The device of claim 4 wherein said third adhesive material comprises a thermoplastic.

15. The device of claim 4 wherein said third adhesive material comprises material from the group olefinics, inomers, acrylics, and silicones.

16. The device of claim 5 wherein said polymer support layer comprises material from the group polypropylene, polyethylene terepthalate (PET), polyethylene naphthalate (PEN), acrylic or polycarbonate.

17. The device of claim 6 wherein said polymer support layer comprises material from the group polypropylene, polyethylene terepthalate (PET), polyethylene naphthalate (PEN), acrylic or polycarbonate.

18. The device of claim 5 wherein the polymer support layer underneath the first of said cells extends outward over a portion of the top surface of the second of said cells.

19. The device of claim 9 wherein the pattern is positioned between the top light incident surface of said second cell and the adhesive material overlaying said second cell.

20. The device of claim 1 wherein said conductor comprises a wire form.

21. The device of claim 1 wherein said conductor has a low profile.

22. The device of claim 4 wherein said third adhesive has a thickness of 250 micrometers or less.

23. In combination two electrically interconnected photovoltaic cells,

each of said cells having a top light incident surface,

each of said cells further having an adhesive material contacting at least a portion of said light incident surface and a polymer support layer overlaying at least a portion of said adhesive and said cell,

said polymer support layer overlaying the first of said cells being separate and disconnected from the polymer support layer overlaying the second of said cells.

24. The combination of claim 23 wherein the light incident surfaces of both first and second cells are overlayed by a common barrier layer.

25. The combination of claim 24 wherein said common barrier layer comprises a glass sheet.

26. In combination two electrically interconnected photovoltaic cells,

each of said cells having a bottom surface,

each of said cells further having an adhesive material contacting at least a portion of said bottom surface and a polymer support layer covering at least a portion of said adhesive and said cell,

said polymer support layer covering the first of said cells being separate and disconnected from the polymer support layer covering the second of said cells.

27. The combination of claim 26 wherein the light incident surfaces of both first and second cells are overlayed by a common barrier layer.