Wire network for interconnecting photovoltaic cells

Abstract

Provided are novel interconnect wire network assemblies and methods of fabricating thereof. An assembly may include conductive portions/individual wires that, in certain embodiments, are substantially parallel to each other. The assembly also includes two or more carrier films (i.e., the front side and back side films) attached to opposite sides of the wires. The films are typically attached along the wire ends. The films are made from electrically insulating materials and at least the front side film is substantially transparent. The front side film is used to attach the wires to a photovoltaic surface of one cell, while the back side film is used for attachment to a substrate surface of another cell. These attachments electrically interconnect the two cells in series. In certain embodiments, one or both carrier films extend beyond two end wires and form insulated portions that allow much closer arrangements of the cells in a module.

1 . An interconnect wire network assembly comprising:
 a plurality of conductive portions extending substantially parallel to each other, the plurality of conductive portions having a first set of ends defining a first edge and a second set of ends defining a second edge, the plurality of conductive portions configured for current collection from a front side surface of a first photovoltaic cell and electrical connection with a back side surface of a second photovoltaic cell;   a first carrier film comprising a first substantially transparent electrically insulating layer, the first carrier film coupled to the plurality of conductive portions along the first edge and configured to attach the plurality of conductive portions to the front side surface of the first photovoltaic cell to form a first electrical connection between the front side surface and the plurality of conductive portions; and   a second carrier film comprising a second substantially transparent electrically insulating layer, the second carrier film coupled to the plurality of conductive portions along the second edge and configured to attach the plurality of conductive portions to the back side surface of the second photovoltaic cell to form a second electrical connection between the back side surface and the plurality of conductive portions.   
     
     
         2 . The interconnect wire network assembly of  claim 1 , wherein the first carrier film is positioned on another side of the plurality of conductive portions with respect to the second carrier film, and wherein the first carrier film and the second carrier film form an overlap. 
     
     
         3 . The interconnect wire network assembly of  claim 1 , wherein the first carrier film is positioned at a predetermined distance from the second carrier film. 
     
     
         4 . The interconnect wire network assembly of  claim 1 , wherein an outside edge of the first carrier film substantially coincides with the first edge of the plurality of conductive portions. 
     
     
         5 . The interconnect wire network assembly of  claim 1 , wherein the first carrier film extends past the first edge of the plurality of conductive portions. 
     
     
         6 . The interconnect wire network assembly of  claim 1 , wherein the plurality of conductive portions extends past two edges of the first carrier film. 
     
     
         7 . The interconnect wire network assembly of  claim 1 , wherein the first carrier film comprises one or more materials selected from the group consisting of: polyethylene terephthalate, polyethylene co-methacrylic acid, polyamide, and polyetheretherketone. 
     
     
         8 . The interconnect wire network assembly of  claim 1 , wherein the plurality of conductive portions comprises one or more materials selected from the group consisting of: copper, aluminum, nickel, and chrome. 
     
     
         9 . The interconnect wire network assembly of  claim 1 , wherein the plurality of conductive portions comprises multiple individual wires. 
     
     
         10 . The interconnect wire network assembly of  claim 9 , wherein the multiple individual wire are between 24 gauge and 56 gauge. 
     
     
         11 . The interconnect wire network assembly of  claim 9 , wherein the multiple individual wires are spaced apart by between about 2 millimeters and about 5 millimeters. 
     
     
         12 . The interconnect wire network assembly of  claim 9 , wherein each wire of the multiple individual wires is electrically insulated from other wires prior to attaching the interconnect wire network assembly to the first photovoltaic cell or the second photovoltaic cell. 
     
     
         13 . The interconnect wire network assembly of  claim 9 , wherein the multiple individual wires comprise a strip of foil attached to the second edge and electrically interconnecting the multiple individual wires. 
     
     
         14 . The interconnect wire network assembly of  claim 1 , wherein the first carrier film extends past two end wires of the plurality of conductive portions forming two side insulating regions. 
     
     
         15 . The interconnect wire network assembly of  claim 1 , wherein the first carrier film extends past and folds over two end conductive portions of the plurality of conductive portions, forming insulating shells around the two end conductive portions. 
     
     
         16 . A method of fabricating an interconnect wire network assembly comprising:
 unwinding multiple individual wires from corresponding multiple wire rolls;   extending the multiple individual wires along an unwinding direction substantially parallel to each other at a predetermined distance from each other, wherein the multiple individual wires form a first surface and a second surface, with the first surface and the second surface spaced apart by a cross-sectional dimension of the multiple individual wires;   applying a first carrier film onto the first surface of the multiple individual wires; and   applying a second carrier film onto the second surface of the multiple individual wires.   
     
     
         17 . The method of fabricating an interconnect wire network assembly of  claim 16 , wherein the first carrier film and the second carrier film are applied substantially perpendicular to the unwinding direction. 
     
     
         18 . The method of fabricating an interconnect wire network assembly of  claim 16 , further comprising:
 forming a roll of interconnect wire network subassemblies;   unwinding the roll of interconnect wire network subassemblies; and   cutting the multiple individual wires substantially perpendicular to the multiple individual wires to form the interconnect wire network assembly.   
     
     
         19 . The method of fabricating an interconnect wire network assembly of  claim 16 , further comprising cutting the multiple individual wires substantially perpendicular to the multiple individual wires to form the interconnect wire network assembly. 
     
     
         20 . The method of fabricating an interconnect wire network assembly of  claim 19 , wherein cutting the multiple individual wires comprises cutting the first carrier film or the second carrier film. 
     
     
         21 . The method of fabricating an interconnect wire network assembly of  claim 16 , wherein applying the first carrier film comprises passing an electric current through a portion of the multiple individual wires that is in contact with the first carrier film in order to heat this portion. 
     
     
         22 . A photovoltaic module comprising:
 a first photovoltaic cell comprising a front side surface;   a second photovoltaic cell comprising a back side surface; and   an interconnect wire network assembly comprising:
 a plurality of conductive portions extending substantially parallel to each other and in electrical communication with the front side of the first photovoltaic cell and the back side of the second photovoltaic cell, the conductive portions having a first set of ends defining a first edge and a second set of ends defining a second edge; 
 a first carrier film comprising a first substantially transparent electrically insulating layer, the first carrier film coupled to the plurality of conductive portions along the first edge and attaching the plurality of conductive portions to the front side surface of the first photovoltaic cell; and 
 a second carrier film comprising a second substantially transparent electrically insulating layer, the second carrier film coupled to the plurality of conductive portions along the second edge and attaching the plurality of conductive portions to the back side surface of the second photovoltaic cell.