Photon Power, Inc.

Guy A Roderick

Curtis M Lampkin

Peter Locke

Robert B Nikodem

Methods and apparatus are provided for forming films of materials which are component layers of solar energy conversion devices, e.g. photovoltaic cells and heat collector panels. A selected substrate, generally glass, is heated while being sprayed with solutions which react on the heated surface to form a particular film. Films of SnO.sub.x and CdS are particularly produced. According to the present invention, a thermal energy input gradient is provided to approximate the energy loss gradient during the spray process. Radiative heaters provide a rapid resupply of energy to the substrate and, in some instances, directly to the film forming surface. Temperature detectors, such as thermocouples, monitor substrate temperature to provide the radiative energy input needed for substantial temperature uniformity.

Apparatus for quality film formation

Methods and apparatus are provided for forming films of materials which are component layers of solar energy conversion devices, e. g. photovoltaic cells and heat collector panels. A selected substrate is heated while being sprayed with solutions which react on the heated surface to form a particular film. Films of SnO.sub.x and CdS are particularly produced. According to the present invention, the spray is projected at an angle to control upstream flow and confine film formation to the substrate panel portions most suitable for forming the selected film. Various waste products are removed to minimize defects in the resulting film. Baffles are located to shield the substrate surface at selected areas and preclude the spray from impacting on the shielded areas.

Method for quality film formation

A solar panel module is provided, wherein a plurality of solar panel units are electrically interconnected and supported within a low cost frame assembly, which may conveniently be formed from wood products. Each solar panel unit is provided with extending conductors for electrical connections with adjacent solar panels. Each solar panel unit is formed in a back-wall configuration where solar radiation is incident on a transparent vitreous substrate. The panel surface opposite the substrate is sealed, preferably with a bituminous material, to minimize permeation of the solar panel by environmental elements. The sealing material cooperates with the frame to provide an insulated exposed surface. In one embodiment, the completed module is formed to external dimensions generally standard in the building industry for easy installation.

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El Paso, TX, United States of America

Guy A Roderick