Structures and fabrication methods for solar cells and modules

Abstract

Solar module structures and methods for assembling solar module structures. The solar module structures may be used in solar glass applications, building facade applications, rooftop installation applications as well as for centralized solar electricity generation.

What is claimed is: 
     
         1 . A solar module structure, comprising:
 a top encapsulant layer;   a plurality of pyramidal three-dimensional thin-film solar cells, each thin-film solar cell comprising:
 a pyramidal three-dimensional thin-film solar cell substrate comprising emitter junction regions and doped base regions; 
 emitter metallization regions; and 
 base metallization regions; 
 wherein said pyramidal three-dimensional thin-film solar cell substrate comprises a plurality of pyramid-shaped unit cells; 
   a printed circuit board;   a rear encapsulant layer; and   a protective back plate.   
     
     
         2 . The solar module structure of  claim 1 , further comprising a glass layer. 
     
     
         3 . The solar module structure of  claim 2 , wherein said glass layer comprises a separate glass cover. 
     
     
         4 . The solar module structure of  claim 2 , wherein said glass layer comprises a glass-like protective coating formed by a coating method. 
     
     
         5 . The solar module structure of  claim 1 , further comprising a top patterned cell interconnect layer. 
     
     
         6 . The solar module structure of  claim 1 , further comprising a rear patterned cell interconnect layer. 
     
     
         7 . The solar module structure of  claim 1 , wherein said protective back plate comprises a Tedlar protective back plate. 
     
     
         8 . The solar module structure of  claim 1 , wherein each pyramidal three-dimensional thin-film solar cell further comprises a rear mirror. 
     
     
         9 . The solar module structure of  claim 8 , wherein said rear mirror comprises an integrated rear mirror. 
     
     
         10 . The solar module structure of  claim 8 , wherein said rear mirror comprises a detached rear mirror. 
     
     
         11 . The solar module structure of  claim 1 , wherein each pyramidal three-dimensional thin-film solar cell further comprises a peripheral cell frame. 
     
     
         12 . The solar module structure of  claim 11 , wherein said peripheral cell frame may be used to produce wrap-through or wrap-around emitter metallization for making contacts to the cell emitter at the bottom of each three-dimensional thin-film solar cell. 
     
     
         13 . A method for assembling a solar module structure, comprising:
 patterning a frontside and a backside of a double-sided printed circuit board coated with metallic foils according to desired frontside and backside interconnect layouts;   applying a first coating layer to the rear side of a plurality of pyramidal three-dimensional thin-film solar cells, each pyramidal three-dimensional thin-film solar cell comprising:   a pyramidal three-dimensional thin-film solar cell substrate comprising emitter junction regions and doped base regions;
 emitter metallization regions; and 
 base metallization regions; 
 wherein said pyramidal three-dimensional thin-film solar cell substrate comprises a plurality of pyramid-shaped unit cells; 
   placing said plurality of pyramidal three-dimensional thin-film solar cells on the frontside of said double-sided printed circuit board;   preparing a solar module assembly, comprising:
 a glass layer; 
 a top encapsulant layer; 
 said plurality of pyramidal three-dimensional thin-film solar cells on the frontside of said double-sided printed circuit board; 
 a rear encapsulant layer; 
 a protective back plate; and 
   sealing and packaging said solar module assembly.   
     
     
         14 . The method for assembling a solar module structure of  claim 13 , wherein each pyramidal three-dimensional thin-film solar cell further comprises a rear mirror. 
     
     
         15 . The method for assembling a solar module structure of  claim 13 , further comprising arranging a plurality of said solar module assemblies in series. 
     
     
         16 . The method for assembling a solar module structure of  claim 13 , further comprising arranging a plurality of said solar module assemblies in parallel. 
     
     
         17 . The method for assembling a solar module structure of  claim 15 , further comprising connecting at least one pair of module power output electrical leads. 
     
     
         18 . The method for assembling a solar module structure of  claim 16 , further comprising connecting at least one pair of module power output electrical leads. 
     
     
         19 . A solar module structure, comprising:
 a top glass plate;   a plurality of pyramidal three-dimensional thin-film solar cells, each three-dimensional thin-film solar cell comprising:
 a pyramidal three-dimensional thin-film solar cell substrate comprising emitter junction regions and doped base regions; 
 emitter metallization regions; and 
 base metallization regions; 
 wherein said pyramidal three-dimensional thin-film solar cell substrate comprises a plurality of pyramid-shaped unit cells; 
   a rear patterned cell interconnect layer; and   a bottom glass plate.   
     
     
         20 . The solar module structure of  claim 19 , wherein each pyramidal three-dimensional thin-film solar cell further comprises a peripheral cell frame.