The Standard Oil Company

Energy Conversion Devices, Inc.

Paul E Koch

Robert A Hartman

Thomas J Bond

Richard C Adams

Ronald C Cull

David A Dilts

Gary C Catella

A process and apparatus for continuously producing a relatively large-area, lightweight array of amorphous semiconductor alloy photovoltaic cells having no substrate includes depositing a semiconductor alloy film, such as amorphous silicon, on a travelling surrogate substrate, applying a support material to the traveling film to give it mechanical strength and separating the film and support material from the traveling surrogate substrate by exposing them to a thermal shock. The surrogate substrate is preferably an endless stainless steel band from which the deposited alloy film is repeatedly stripped and on which deposits are repeatedly made. The apparatus may include a cleaning station for cleaning the surrogate substrate after an alloy film is removed from the substrate and before another alloy film is deposited. The apparatus may provide for the deposition and patterning of a back electrode on the substrate before deposition of the alloy film to form one set of electrical interconnections for the array. The apparatus may also provide for the deposition and patterning of a transparent, electrically conducting layer on the alloy film, before application of the support material, in order to form a second set of electrical interconnections for the array. The apparatus may also apply a protective, support material to the rear of the alloy film.

Process and apparatus for continuous production of lightweight arrays of

A semirigid support member is provided for deploying flexible photovoltaic modules in a manner that imparts a degree of rigidity and permanence to the deployment. The semirigid support members provide lightweight economical means for lending structural support to flexible photovoltaic modules. The support members may be interconnected and additionally connected to a permanent base foundation.

Semirigid photovoltaic module assembly and structural support therefor

A photovoltaic array module incorporating a plurality of photovoltaic cell strips (11). Each cell strip (11) incorporates an electrically conductive substrate layer (22), a semiconductor body (23) deposited on the substrate layer (22), and a transparent electrically conductive layer (24) deposited on the semiconductor body (23). Electrically conductive filaments (20) are alternately connected to contact points (31) on the electrically conductive substrate layer (22) of one cell strip (11) and to contact points (32) on the transparent electrically conductive layer (24) of another cell strip (11). A first busbar (12) and a second busbar (13) are connected to the end cell strips (11) of the array to collect the electrical energy generated thereby.

Flexible, rollable photovoltaic cell module

The coextrusion device (20) of the present invention can be used with conventional extruders (24-26) and extrusion dies (90) for forming layered products (91) from at least two materials. It includes a manifold (21) for receiving a plurality of extruded feed materials (A, B, C) and a feedblock (22) receiving the feed materials from the manifold. The feedblock includes first and second faces (43, 52), entrance ports (40, 41, 42) in the first face corresponding to the number of feed materials, channel means (50, 60, 70) passing through the feedblock between the first and second faces directing each feed material into at least one separate profile, and exit ports (51, 61, 71) in the second face corresponding to the number of channel means, defining a first profile for each feed material. An adaptor (23) is provided for receiving the first profiles from the feedblock and includes first and second faces (82, 85), an entrance port (83) in the first face receiving said first profiles, an exit port (84) in the second face corresponding to the entrance of the extrusion die and, a transition zone (86) between the entrance and exit ports wherein the first profiles become contiguous and the overall configuration of the contiguous first profiles is adapted for receipt by the extrusion die. The device can further include a reverser plate (110) and alternate feedblocks (130 ) having different exit ports (139, 140, 152, 153). Lastly, a method is provided for reducing perturbation while coextruding, utilizing a device of the present invention.

Method of coextruding diverse materials

The coextrusion device (20) of the present invention can be used with conventional extruders (24-26) and extrusion dies (90) for forming layered products (91) from at least two materials. It includes a manifold (21) for receiving a plurality of extruded feed materials (A, B, C) and a feedblock (22) receiving the feed materials from the manifold. The feedblock includes first and second faces (43, 52), entrance ports (40, 41, 42) in the first face corresponding to the number of feed materials, channel means (50, 60, 70) passing through the feedblock between the first and second faces directing each feed material into at least one separate profile, and exit ports (51, 61, 71) in the second face corresponding to the number of channel means, defining a first profile for each feed material. An adaptor (23) is provided for receiving the first profiles from the feedblock and includes first and second faces (82, 85), an entrance port (83) in the first face receiving said first profiles, an exit port (84) in the second face corresponding to the entrance of the extrusion die and, a transition zone (86) between the entrance and exit ports wherein the first profiles become contiguous and the overall configuration of the contiguous first profiles is adapted for receipt by the extrusion die. The device can further include a reverser plate (110) and alternate feedblocks (130) having different exit ports (139, 140, 152, 153).

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Chagrin Falls, OH, United States of America

Paul E Koch