Tesla, Inc.

Solarcity Corporation

Peter P Nguyen

Bobby Yang

Piotr Zajac

Kaleb A Klauber

Jiunn Benjamin Heng

Pablo Gonzalez

Seth M Winger

Zheng Xu

Charles Bernardo Almy

Brian Edward Atchley

Christoph Georg Erben

Alex Christopher Mayer

Alex Mayer

Anand J Reddy

Andreas Meisel

Bhavananda R Nadimpally

Jennifer L Wang

Scott Tripp

Lilja Magnusdottir

Mykola O Pashkevych

Brian E Atchley

One embodiment can provide a photovoltaic roof tile module. The photovoltaic roof tile module can include a front cover, a back cover assembly, photovoltaic structures positioned between the front cover and back cover assembly, and an internal circuit component electrically coupled to the photovoltaic structures. The internal circuit component is positioned between the front cover and the back cover assembly. The back cover assembly can include at least one through hole and a metallic plug inserted inside the through hole. A first surface of the metallic plug can electrically couple to the internal circuit component, and a second opposite surface of the metallic plug can be exposed to surroundings external to the photovoltaic roof tile module, thereby facilitating electrical coupling between the photovoltaic roof tile module and another photovoltaic roof tile module.

External electrical contact for solar roof tiles

One embodiment described herein provides a photovoltaic roof module. The roof module can include at least a first photovoltaic roof tile, a second photovoltaic roof tile positioned adjacent to the first photovoltaic roof tile, and a spacer coupled to and positioned between the first and second photovoltaic roof tiles. The spacer is configured to facilitate a semi-rigid joint between the first and second photovoltaic roof tiles.

Inter-tile support for solar roof tiles

One embodiment can provide a photovoltaic roof tile module. The photovoltaic roof tile module can include a photovoltaic roof tile module. The photovoltaic roof tile module can include at least: a first photovoltaic roof tile and a second photovoltaic roof tile positioned adjacent to each other, and a spacer coupled to and positioned between the first and second photovoltaic roof tiles. A respective photovoltaic roof tile can include front and back glass covers, and multiple cascaded strings encapsulated between the front and back glass covers. A respective cascaded string can include a plurality of photovoltaic structures electrically coupled to each other in series, and the multiple cascaded strings can be electrically coupled to each other in parallel. The first and second photovoltaic roof tiles can be electrically coupled to each other in parallel.

Solar roof tile module

One embodiment can provide a photovoltaic roof tile module. The photovoltaic roof tile module can include a first photovoltaic roof tile and a second photovoltaic roof tile positioned adjacent to each other and a spacer coupled to and positioned between the first and second photovoltaic roof tiles. A respective photovoltaic roof tile can include a front glass cover and a back cover, which includes a glass substrate and a pre-laid circuit attached to the glass substrate. The pre-laid circuit is electrically coupled to the plurality of photovoltaic structures. The spacer can include a thermal plastic body and one or more metallic strips embedded within the thermal plastic body, and both ends of a respective metallic strip extend beyond edges of the thermal plastic body to facilitate electrical coupling between pre-laid circuits of the first and second photovoltaic roof tiles.

Solar roof tile spacer with embedded circuitry

One embodiment can provide a photovoltaic roof module. The photovoltaic roof module can include a plurality of photovoltaic roof tiles positioned side by side. A respective solar roof tile comprises a plurality of photovoltaic structures positioned between a front cover and a back cover, and the photovoltaic structures are electrically coupled to each other in series. The photovoltaic roof tiles are electrically coupled to each other in parallel.

Parallel-connected solar roof tile modules

One embodiment can provide a photovoltaic roof tile module. The photovoltaic roof tile module can include a front glass cover, a back glass cover, a plurality of photovoltaic structures positioned between the front and back glass covers, and an internal circuit component electrically coupled to the plurality of photovoltaic structures. The internal circuit component is positioned between the front and back glass covers. The back glass cover can include at least one through hole and a metallic plug inserted inside the through hole. A first surface of the metallic plug can electrically couple to the internal circuit component, and a second opposite surface of the metallic plug can be exposed to surroundings external to the photovoltaic roof tile module, thereby facilitating electrical coupling between the photovoltaic roof tile module and another photovoltaic roof tile module.

One embodiment provides a solar roof tile module. The module includes a plurality of solar roof tiles positioned side by side and one or more tile spacers. The tiles are electrically and mechanically coupled to each other. A tile spacer is positioned between two adjacent solar roof tiles, thereby preventing water leakage. A solar roof tile can include a front cover, a back cover, and a plurality of photovoltaic strips positioned between the front and back covers. Each photovoltaic strip includes a first edge busbar located on an edge of a first surface and a second edge busbar located on an opposite edge of a second surface, and the photovoltaic strips are arranged in such a way that the first edge busbar of a photovoltaic strip overlaps with a second edge busbar of an adjacent photovoltaic strip, thereby forming a serial connection among the photovoltaic strips.

Packaging for solar roof tiles

One embodiment can provide a photovoltaic roof module. The photovoltaic roof module can include a plurality photovoltaic roof tiles. A respective photovoltaic roof tile can include a glass front cover, a back cover that includes glass of photovoltaic backsheet, and a plurality of photovoltaic structures encapsulated between the glass front cover and the back cover by an encapsulant. The photovoltaic roof tile can be configured to function as a roof tile when placed on a rooftop of a building, thereby protecting the building from weather elements.

System and method for packaging photovoltaic roof tiles

One embodiment can provide a current-collecting mechanism of a photovoltaic structure. The current-collecting mechanism can include a top metallic grid positioned on a top surface of the photovoltaic structure and a bottom metallic grid positioned on the bottom surface of the photovoltaic structure. The top metallic grid can include a top busbar positioned near an edge of the photovoltaic structure, and the bottom metallic grid can include a bottom busbar positioned near an opposite edge. The top busbar and the bottom busbar can have complementary topology profiles such that, when the edge of the photovoltaic structure overlaps with an opposite edge of an adjacent photovoltaic structure, the top busbar of the photovoltaic structure and the bottom busbar of the adjacent photovoltaic structure interlock with each other.

Photovoltaic structures with interlocking busbars

One embodiment of the present invention provides a solar panel. The solar panel includes a plurality of subsets of solar cells. The solar cells in a subset are coupled in series, and the subsets of solar cells are coupled in parallel. The number of solar cells in a respective subset is sufficiently large such that the output voltage of the solar panel is substantially the same as an output voltage of a conventional solar panel with all of its substantially square shaped solar cells coupled in series.

High efficiency solar panel

A photovoltaic module can be constructed from one or more strings, with each of the strings being constructed from a plurality of cascaded solar cells. A connector can electrically connect the strings to one another. The connector can include strain relief connectors that extend between the connector and the strings to help reduce effects caused by thermal expansion.

Strain relief apparatus for solar modules

Systems and methods for manufacturing solar panels are disclosed. Solar cells are placed on a conveyor that transports the cells from a start point to an end point. A laser scribing module scribes the cells at a predetermined depth. A paste dispensing module deposits a predetermined amount of conductive paste on the surface of the solar cells. A cleaving apparatus divides the cells into smaller strips. A shingling module creates a string of cells by overlapping the strips. A targeted annealing module cures the paste, and a layup module places the strings on a backsheet. A glass cover is then added to one side of the strings.

Growing community of inventors

San Jose, CA, United States of America

Peter P Nguyen