Photovoltaic power modules and methods for making same

Abstract

A solar concentrator photovolataic power module of small scale wherein a plurality of pre-fabricated photovoltaic solar cells reside in a matrix array in a substrate comprised of a pair of thin sheet conductors separated by an insulator sheet. A lens sheet on which a multiplicity of lenses have been formed is disposed in a fixed spaced relation to the substrate and operates to focus radiation (sunlight) onto the photo active surfaces of the cells in order to generate electricity. The overall thickness of the module including the substrate, lens sheet and space between the two is less than two inches. The laminated substrate is formed by disposing a plurality of pre-fabricated solar cells in a matrix array onto a back conductor, overlaying onto the back conductor an insulator which surrounds each of the cells and overlaying onto the insulator a top conductor. After electrical and mechanical heat activated bonding materials are disposed between the elements of the substrate, the laminate is heated until the substrate is bonded into a single rigid module substrate.