Substrate and collector grid structures for integrated series connected photovoltaic arrays and process of manufacture of such arrays

Abstract

The invention teaches novel structure and methods for producing electrical current collectors and electrical interconnection structure. Such articles find particular use in facile production of modular arrays of photovoltaic cells. The current collector and interconnecting structures may be initially produced separately from the photovoltaic cells thereby allowing the use of unique materials and manufacture. Subsequent combination of the structures with photovoltaic cells allows facile and efficient completion of modular arrays. Methods for combining the collector and interconnection structures with cells and final interconnecting into modular arrays are taught.

1 . A method of manufacturing an intermediate article in the production of an interconnected array of photovoltaic cells, said intermediate article comprising current collector structure suitable for collecting current from a light incident surface of a photovoltaic cell, said method comprising the steps of,
 providing a flexible substrate having one or more regions which are transparent or translucent and having a length dimension characterized as continuous,   feeding said substrate continuously in said length dimension to a process wherein current collector structure comprising a pattern of electrically conductive material is formed over a portion of a first of said regions,   said pattern comprising multiple electrically conductive current collector traces arranged to be distributed over a preponderance of the light incident surface of a photovoltaic cell,   the product of said process being a continuous form of substrate having current collector structure positioned thereon,   said process being accomplished separately and distinctly from a said photovoltaic cell.   
   
   
       2 . The method of  claim 1  wherein said traces have a length dimension greater than about one centimeter. 
   
   
       3 . A method of manufacturing an intermediate article in the production of an interconnected array of photovoltaic cells, said cells having length and width dimensions defining a light incident surface, said intermediate article comprising current collector structure suitable for collecting current from a said light incident surface, said method comprising the steps of,
 providing a flexible substrate having a first surface and a length dimension characterized as continuous, and further having one or more regions which are transparent or translucent,   feeding said substrate to a process wherein current collector structure comprising multiple electrically conductive material traces is formed on a portion of a first of said regions, said traces positioned to achieve a substantially uniform distribution over a predominance of a said light incident surface,   said process being accomplished separately and distinctly from a said photovoltaic cell.   
   
   
       4 . The method of  claim 3  wherein at least a portion of said first surface is formed by a polymer based adhesive material 
   
   
       5 . The method of  claim 3  wherein the product of said process is a continuous form of substrate having said current collector structure positioned thereon. 
   
   
       6 . The method of  claim 5  wherein said continuous form of substrate is further accumulated onto a roll, thereby characterizing said process as a roll-to-roll process. 
   
   
       7 . The method of  claim 3  wherein said substrate comprises multiple polymer based layers. 
   
   
       8 . The method of  claim 3  wherein portions of exposed surfaces of said conductive material traces are formed by an electrically conductive adhesive. 
   
   
       9 . The method of  claim 3  wherein portions of exposed surfaces of said conductive material traces are formed by a low melting point metal based material. 
   
   
       10 . The method of  claim 9  wherein said low melting point metal based material comprises Indium. 
   
   
       11 . The method of  claim 3  wherein said current collector structure comprises multiple substantially parallel traces. 
   
   
       12 . The method of  claim 11  wherein said parallel traces are joined by a conductive buss structure. 
   
   
       13 . The method of  claim 12  wherein portions of both said traces and said buss structure are formed by a common monolithic material. 
   
   
       14 . The method of  claim 3  wherein portions of said traces are defined by printed material. 
   
   
       15 . The method of  claim 14  wherein said printed material comprises an electrically conductive ink. 
   
   
       16 . The method of  claim 14  wherein said printed material is characterized as having the ability to facilitate metal deposition. 
   
   
       17 . The method of  claim 3  wherein said process comprises chemical or electrochemical deposition of metal. 
   
   
       18 . The method of  claim 3  wherein said electrically conductive material comprises multiple layers. 
   
   
       19 . A method of manufacturing an intermediate article in the production of an interconnected array of photovoltaic cells, said intermediate article comprising current collector structure suitable for collecting current from light incident surfaces of photovoltaic cells, said method comprising the steps of,
 providing a flexible substrate having a continuous length dimension and one or more transparent or translucent portions, said substrate having a first surface,   feeding said substrate to a process wherein multiple electrically separated structures of electrically conductive material are positioned on a first of said transparent or translucent portions, each of said structures being elongate in said length dimension and having a width dimension perpendicular to said length dimension, said structures being repetitive in said width direction, said structures being distinctly separated from an adjacent structure by a region of substrate absent conductive material and wherein said region extends in said length dimension,   said process being accomplished absent the presence of a said photovoltaic cell.   
   
   
       20 . The method of  claim 19  wherein said substrate is fed to said process continuously in said length direction from a roll of substrate material, said method further characterized as resulting in said regions of substrate absent conductive material extending continuously in said length dimension.