High-efficiency pv panel with conductive backsheet

Abstract

One embodiment of the invention can provide a solar panel, which can include a cover, a backsheet, and a plurality of solar cell strings. The backsheet can include a first insulation layer, a second insulation layer, and a conductive interlayer positioned between the first insulation layer and the second insulation layer. The solar cell strings can be positioned between the cover and the first insulation layer of the backsheet. The first insulation layer can include a plurality of vias, and the conductive interlayer can be patterned according to locations of the vias, thereby facilitating electrical interconnections among the solar cell strings.

What is claimed is: 
     
         1 . A solar panel, comprising:
 a cover;   a backsheet comprising a first insulation layer, a second insulation layer, and a conductive interlayer positioned between the first insulation layer and the second insulation layer; and   a plurality of solar cell strings positioned between the cover and the first insulation layer of the backsheet;   wherein the first insulation layer comprises a plurality of vias, and wherein the conductive interlayer is patterned according to locations of the vias, thereby facilitating electrical interconnections among the solar cell strings.   
     
     
         2 . The solar panel of  claim 1 , wherein the first insulation layer comprises polyethylene terephthalate (PET), fluoropolymer, polyvinyl fluoride (PVF), polyamide, or any combination thereof; and wherein the conductive interlayer comprises Al, Cu, graphite, conductive polymer, or any combination thereof. 
     
     
         3 . The solar panel of  claim 1 , wherein a respective via is filled with a conductive paste to facilitate:
 electrical coupling between a contact pad located on a corresponding solar cell string and the conductive interlayer; and/or   mechanical bonding between a contact pad located on a corresponding solar cell string and the conductive interlayer.   
     
     
         4 . The solar panel of  claim 1 , wherein a respective solar cell string comprises a plurality of cascaded photovoltaic structures. 
     
     
         5 . The solar panel of  claim 1 , further comprising a plurality of bypass diodes, wherein a respective bypass diode is coupled to a photovoltaic structure through the conductive interlayer. 
     
     
         6 . The solar panel of  claim 1 , wherein a conductive path between a first solar cell string and a second solar cell string comprises:
 a first contact pad of the first solar cell string;   a first set of vias within the first insulation layer, wherein the first set of vias are filled with a conductive paste and are positioned beneath the first contact pad;   a second contact pad of the second solar cell string;   a second set of vias within the first insulation layer, wherein the second set of vias are filled with the conductive paste and are positioned beneath the second contact pad; and   a continuous portion of the conductive interlayer that is in contact with both the first and second sets of vias.   
     
     
         7 . The solar panel of  claim 1 , wherein the second insulation layer comprises a plurality of vias filled with a conductive paste to electrically couple the interconnected solar cell strings to a junction box. 
     
     
         8 . A method for manufacturing a solar panel, comprising:
 obtaining a backsheet that comprises a first insulation layer, a second insulation layer, and a conductive interlayer positioned between the first insulation layer and the second insulation layer, wherein the first insulation layer comprises a plurality of vias, and wherein the conductive interlayer is patterned according to locations of the vias;   overlaying a plurality of solar cell strings on the backsheet, wherein the first insulation layer faces the solar cell strings, and wherein the solar cell strings are overlaid in such a way that selected contact pads of the solar cell strings are positioned above the vias, thereby facilitating electrical interconnections among the solar cell strings; and   laminating the solar cell strings between the backsheet and a glass cover.   
     
     
         9 . The method of  claim 8 , wherein the first insulation layer comprises polyethylene terephthalate (PET), fluoropolymer, polyvinyl fluoride (PVF), polyamide, or any combination thereof; and wherein the conductive interlayer comprises Al, Cu, graphite, conductive polymer, or any combination thereof. 
     
     
         10 . The method of  claim 8 , further comprising filling the vias with a conductive paste, wherein a respective via filled with the conductive paste is configured to facilitate:
 electrical coupling between a contact pad located on a corresponding solar cell string and the conductive interlayer; and/or   mechanical bonding between a contact pad located on a corresponding solar cell string and the conductive interlayer.   
     
     
         11 . The method of  claim 8 , wherein a respective solar cell string comprises a plurality of cascaded photovoltaic structures. 
     
     
         12 . The method of  claim 8 , further comprising coupling a plurality of bypass diodes to the interconnected solar cell strings, wherein a respective bypass diode is coupled to a photovoltaic structure through the conductive interlayer. 
     
     
         13 . The method of  claim 8 , further comprising establishing a conductive path between a first solar cell string and a second solar cell string by curing a conductive paste that fills the vias, wherein the conductive path comprises:
 a first contact pad of the first solar cell string;   a first set of vias within the first insulation layer, wherein the first set of vias are filled with the conductive paste and are positioned beneath the first contact pad;   a second contact pad of the second solar cell string;   a second set of vias within the first insulation layer, wherein the second set of vias are filled with the conductive paste and are positioned beneath the second contact pad; and   a continuous portion of the conductive interlayer that is in contact with both the first and second sets of vias.   
     
     
         14 . The method of  claim 8 , further comprising filling vias included in the second insulation layer with a conductive paste to electrically couple the interconnected solar cell strings to a junction box. 
     
     
         15 . A photovoltaic structure encapsulation mechanism, comprising:
 a transparent cover; and   a non-transparent cover comprising a first insulation layer, a second insulation layer, and a conductive interlayer positioned between the first insulation layer and the second insulation layer;   wherein the first insulation layer comprises a plurality of through holes, and wherein the conductive interlayer is patterned according to locations of the through holes, thereby facilitating electrical interconnections among solar cell strings sandwiched between the transparent cover and the non-transparent cover.   
     
     
         16 . The photovoltaic structure encapsulation mechanism of  claim 15 , wherein the first insulation layer comprises polyethylene terephthalate (PET), fluoropolymer, polyvinyl fluoride (PVF), polyamide, or any combination thereof; and wherein the conductive interlayer comprises Al, Cu, graphite, conductive polymer, or any combination thereof. 
     
     
         17 . The photovoltaic structure encapsulation mechanism of  claim 15 , wherein a respective through hole is filled with a conductive paste. 
     
     
         18 . The photovoltaic structure encapsulation mechanism of  claim 17 , wherein the conductive paste comprises:
 a conductive metallic core surrounded by a resin; and/or   a resin comprising a number of suspended conductive particles.   
     
     
         19 . The photovoltaic structure encapsulation mechanism of  claim 17 , wherein the through hole filled with the conductive paste facilitates:
 electrical coupling between a contact pad located on a corresponding solar cell string and the conductive interlayer; and/or   mechanical bonding between a contact pad located on a corresponding solar cell string and the conductive interlayer.   
     
     
         20 . The photovoltaic structure encapsulation mechanism of  claim 15 , wherein the second insulation layer comprises a plurality of through holes filled with a conductive paste to electrically couple the interconnected solar cell strings to a junction box.