The Boeing Company

Eric Rehder

Dale H Waterman

John Steven Frost

Christopher M Fetzer

Daniel C Law

Xiaobo Zhang

John Suarez

Kristina I Kassem

Jonah C Huffman

Richard Roland King

Philip T Chiu

Xing-Quan Liu

Robyn L Woo

Tom Crocker

Joseph Charles Boisvert

Peichen Pien

Dale Waterman

A solar cell array comprised of one or more solar cells attached to a substrate. The substrate includes one or more electrical connections to the solar cells and one or more switches for changing a string length for one or more of the solar cells by altering a current flow path between the one or more of the solar cells and one or more of the electrical connections.

Solar cell array with changeable string length

An electrical connection is formed between first and second conductive elements, by inserting a nano-metal material between the first and second conductive elements; and heating the nano-metal material to a melting temperature to form the electrical connection between the first and second conductive elements. The nano-metal material may comprise a nano-metal paste or ink comprised of one or more of Gold (Au), Copper (Cu), Silver (Ag), and/or Aluminum (Al) nano-particles that melt or fuse into a solid to form the electrical connection, at a melting temperature of about 150-250 degrees C., and more preferably, about 175-225 degrees C. The electrical connection may be formed between a solar cell and a substrate by creating a via in the solar cell between a front and back side of the solar cell, wherein the via is connected to a contact on the front side of the solar cell and a trace on the substrate.

Nano-metal connections for a solar cell array

One or more solar cells are connected to a flex circuit, wherein: the flex circuit is comprised of a flexible substrate having one or more conducting layers for making electrical connections to the solar cells; the flex circuit is attached to a panel; and the solar cells are attached to the panel. The flex circuit can be attached to the panel so that the conducting layers are adjacent the solar cells, or the flex circuit can be attached to the panel so that the conducting layers run underneath the solar cells. The conducting layers can be deposited on the flexible substrate and/or the conducting layers can be embedded in the flex circuit, wherein the conducting layers are sandwiched between insulating layers of the flex circuit.

Wiring for a rigid panel solar array

The present disclosure is directed to a method of processing a solar cell device. The method comprises detecting at least one inconsistency at a surface of a semiconductor substrate having a solar cell active region formed therein. A deposition pattern is determined based on the location of the at least one inconsistency. A material is selectively deposited on the substrate according to the deposition pattern.

Method of processing inconsistencies in solar cell devices and devices formed thereby

At least one solar cell is mounted to a flexible substrate using an adhesive, wherein: the flexible substrate includes at least one insulating layer and at least one conductive layer patterned on the insulating layer as one or more traces for making electrical connections with the solar cell; the traces on the flexible substrate are unencapsulated and at least some of the traces remain exposed after the solar cell is mounted to the flexible substrate; the solar cell is positioned above the traces on the flexible substrate; and a backside metal layer of the solar cell does not make contact to the traces on the flexible substrate when the solar cell is mounted on the flexible substrate. The result is a rollable solar array or panel having a reduced stress energy and a reduced minimum rolling radius as compared to a baseline solar cell mounted to a baseline flexible substrate.

Lightweight flexible solar array

A solar cell for a solar cell array with one or more grid on a surface thereof, wherein electrical connections are made to the grids in a plurality of locations positioned around the solar cell; and the electrical connections extend to one or more conductors located under the solar cell. The conductors located under the solar cell are buried within a substrate, and each of the conductors comprises a low resistance conducting path that distributes current from the solar cell. The conductors are loops, U-shaped, or have only up or down pathways. The solar cell comprises a full cell that has four cropped corners and the locations are in the cropped corners.

Solar cells for a solar cell array

A solar array including at least one solar panel comprised of a substrate having one or more solar cells bonded thereto, and a frame for supporting the substrate and the solar cells, wherein the substrate is attached to the frame at a perimeter of the frame along one or more edges of the substrate, the frame has a cutout or opening in a center of the frame under the solar cells, and the cutout or opening enables direct cooling of the solar cells through the substrate by exposing a back side of the substrate for transferring or radiating heat directly through the cutout or opening of the frame.

Solar array attachment

One or more solar cells are connected to a flex circuit, wherein: the flex circuit is single sheet; the flex circuit is comprised of a flexible substrate having one or more conducting layers for making electrical connections to the solar cells; and the flex circuit includes one or more flat sections where the solar cells are attached to the flex circuit that remain flat when the flex circuit is folded and one or more folding sections between the flat sections where the flex circuit is folded.

Single sheet foldout solar array

A solar cell structure is disclosed. The solar cell structure comprises a carrier having a front side and a P-N junction, a solar cell electrically coupled to the front side of the carrier, and an adhesive layer. The adhesive layer bonds the front side of the carrier to the solar cell. The adhesive layer includes conductive particles that electrically couple the carrier to the solar cell.

Semiconductor device including an electrically conductive adhesive layer and a bypass diode in a carrier

Photovoltaic (PV) cell structures are disclosed. In one example embodiment, a PV cell includes an emitter layer, a base layer adjacent to the emitter layer, and a back surface field (BSF) layer adjacent to the base layer. The BSF layer includes a first layer, and a second layer adjacent to the first layer. The first layer includes a first material and the second layer includes a second material different than the first material.

Multi-layer back surface field layer in a solar cell structure

At least first and second solar panels are provided, wherein: each of the first and second solar panels is comprised of a substrate having one or more solar cells bonded thereto, and a frame for supporting the substrate and the solar cells; the frame has a cutout or opening in a center of the frame under the solar cells and, when deployed, the cutout or opening enables cooling of the solar cells through the substrate by exposing a back side of the substrate for transferring or radiating heat directly through the cutout or opening of the frame; and the frame of the first solar panel is configured to be nested inside the cutout or opening of the frame of the second solar panel when the first and second solar panels are stowed in a stacked configuration.

Growing community of inventors

Los Angeles, CA, United States of America

Eric Rehder