Nuvosun, Inc.

Dow Global Technolgoies LLC

Thomas M Valeri

Bruce Hachtmann

Dennis R Hollars

David B Pearce

Liguang Gong

Arthur C Wall

Christine Tsai

Herb Delarosa

Bruce D Hachtmann

An improved method for interconnecting thin film solar cells to form solar cell modules is provided, the method comprising using a flat metallic mesh formed from a thin metallic strip to provide a current collection grid over a thin film solar cell. The method is particularly useful for forming interconnections between thin film solar cells deposited on flexible substrates. The rectangular cross sectional shape of the mesh elements provides an increased area of electrical contact to the solar cell compared to the small tangential area provided by elements of circular cross section. Mesh elements can be made higher rather than wider to improve conductivity without proportionally increasing shading loss. Various coatings can be applied to the mesh to improve its performance, provide corrosion resistance, and improve its cosmetic appearance.

Solar cell interconnection method using a flat metallic mesh

A method for forming photovoltaic cells comprises providing a first roll of a photovoltaic material and a second roll of an expanded metallic mesh. The photovoltaic material comprises a photoactive material adjacent to a flexible substrate, and the expanded metallic mesh comprises a plurality of openings. Next, an electrically insulating material is provided adjacent to an edge portion of the photovoltaic material. The photovoltaic material from the first roll can then be brought in proximity to the expanded mesh from the second roll to form a nascent photovoltaic cell. The electrically insulating material can be disposed between the expanded metallic mesh and the photovoltaic material. Next, the nascent photovoltaic cell is cut into individual sections to form a plurality of photovoltaic cells.

Automated flexible solar cell fabrication and interconnection utilizing rolls expanded metallic mesh

Disclosed is a highly automated method of interconnecting flexible solar cells to form solar modules having a wide variety of sizes and electrical characteristics. The method is fast and economical, providing many attributes of a 'pseudo monolithic integration' scheme that has previously been attainable only on rigid substrates.

Flexible solar cell interconnection systems and methods

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Gilroy, CA, United States of America

Thomas M Valeri