Photon Energy Gmbh

Scot P Albright

Rhodes R Chamberlin

John F Jordan

David K Brown

Larry M Dugan

Roger A Thompson

Bruce Ackerman

John F Jordon

Provided is a thin film photovoltaic device and a method of manufacturing the device. The thin film photovoltaic device comprises a film layer having particles which are smaller than about 30 microns in size held in an electrically insulating matrix material to reduce the potential for electrical shorting through the film layer. The film layer may be provided by depositing preformed particles onto a surrogate substrate and binding the particles in a film-forming matrix material to form a flexible sheet with the film layer. The flexible sheet may be separated from the surrogate substrate and cut into flexible strips. A plurality of the flexible strips may be located adjacent to and supported by a common supporting substrate to form a photovoltaic module having a plurality of electrically interconnected photovoltaic cells.

Thin film photovoltaic device and process of manufacture

Provided is a method for controlling electrical properties and morphology of a p-type material of a photovoltaic device. The p-type material, such as p-type cadmium telluride, is first subjected to heat treatment in an oxidizing environment, followed by recrystallization in an environment substantially free of oxidants. In one embodiment, the heat treatment step comprises first subjecting the p-type material to an oxidizing atmosphere at a first temperature to getter impurities, followed by second subjecting the p-type material to an oxidizing atmosphere at a second temperature, higher than the first temperature, to develop a desired oxidation gradient through the p-type material.

Photovoltaic cell manufacturing process

A photovoltaic cell has an n-type polycrystalline layer and a p-type polycrystalline layer adjoining the n-type polycrystalline layer to form a photovoltaic junction. The p-type polycrystalline layer comprises a substantially planar layer portion having relatively large crystals adjoining the n-type polycrystalline layer. The planar layer portion includes oxidized impurities which contribute to obtainment of p-type electrical properties in the planar layer portion.

Photovoltaic cell having a p-type polycrystalline layer with large

The subject inventions concern various photovoltaic module designs to protect the module from horizontal and vertical impacts and degradation of solar cell efficiency caused by moisture. In one design, a plurality of panel supports that are positioned adjacent to the upper panel in a photovoltaic module absorb vertical forces exerted along an axis perpendicular to the upper panel. Other designs employ layers of glass and tempered glass, respectively, to protect the module from vertical impacts. A plurality of button-shaped channels is used around the edges of the photovoltaic module to absorb forces applied to the module along an axis parallel to the module and direct moisture away from the module that could otherwise penetrate the module and adversely affect the cells within the module. A spacer is employed between the upper and lower panels that has a coefficient of thermal expansion substantially equivalent to the coefficient of thermal expansion of at least one of the panels.

Apparatus for encapsulating a photovoltaic module

A novel photovoltaic module (10) and method for constructing the same are disclosed. The module (10) includes a plurality of photovoltaic cells (12) formed on a substrate (14) and laterally separated by interconnection regions (15). Each cell (12) includes a bottom electrode (16), a photoactive layer (18) and a top electrode layer (20). Adjacent cells (12) are connected in electrical series by way of a conductive-buffer line (22). The buffer line (22) is also useful in protecting the bottom electrode (16) against severing during downstream layer cutting processes.

Series interconnected photovoltaic cells and method for making same

An improved photovoltaic panel and method of forming a photovoltaic panel are disclosed for producing a high efficiency CdS/CdTe photovoltaic cell. The photovoltaic panel of the present invention is initially formed with a substantially thick Cds layer, and the effective thickness of the CdS layer is substantially reduced during regrowth to both form larger diameter CdTe crystals and substantially reduce the effective thickness of the C

Photovoltaic cell with thin CS layer

A thin film photovoltaic panel includes a backcap for protecting the active components of the photovoltaic cells from adverse environmental elements. A spacing between the backcap and a top electrode layer is preferably filled with a desiccant to further reduce water vapor contamination of the environment surrounding the photovoltaic cells. The contamination of the spacing between the backcap and the cells may be further reduced by passing a selected gas through the spacing subsequent to sealing the backcap to the base of the photovoltaic panels, and once purged this spacing may be filled with an inert gas. The techniques of the present invention are preferably applied to thin film photovoltaic panels each formed from a plurality of photovoltaic cells arranged on a vitreous substrate. The stability of photovoltaic conversion efficiency remains relatively high during the life of the photovoltaic panel, and the cost of manufacturing highly efficient panels with such improved stability is significantly reduced.

Thin film photovoltaic panel and method

Improved techniques are provided for forming a very thin polycrystalline layer of a semiconductor material on a glass substrate. The film material may be formed from a slurry of a semiconductor powder and a liquid carrier, and the slurry economically applied at room temperature by spraying techniques. Once dried, the film is compressed by the application of a substantial mechanical force. The compressed film is regrown in a heated atmosphere, forming a polycrystalline film comprised of large mean diameter crystals, with many crystals having a mean diameter in excess of the film thickness. A high quality cadmium sulfide polycrystalline film suitable for forming a photovoltaic cells may be inexpensively manufactured according to these techniques.

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El Paso, TX, United States of America

Scot P Albright