Solar module structures and assembly methods for three-dimensional thin-film solar cells

Abstract

A method for assembling a solar module structure comprises 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 three-dimensional thin-film solar cells, each three-dimensional thin-film solar cell comprising: a three-dimensional thin-film solar cell substrate comprising emitter junction regions and doped base regions; emitter metallization and base metallization regions; the three-dimensional thin-film solar cell substrate comprising a plurality of single-aperture unit cells; placing the three-dimensional thin-film solar cells on the frontside of the double-sided printed circuit board; preparing a solar module assembly, comprising: a glass layer; a top encapsulant layer; the plurality of three-dimensional thin-film solar cells on the frontside of the double-sided printed circuit board; a rear encapsulant layer; a protective back plate; and sealing and packaging the solar module assembly.

1 . 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 three-dimensional thin-film solar cells, each three-dimensional thin-film solar cell comprising:
 a three-dimensional thin-film solar cell substrate comprising emitter junction regions and doped base regions; 
 emitter metallization regions; and 
 base metallization regions; 
 wherein said three-dimensional thin-film solar cell substrate comprises a plurality of single-aperture unit cells; 
   placing said plurality of 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 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.   
     
     
         2 . The method for assembling a solar module structure of  claim 1 , wherein each three-dimensional thin-film solar cell further comprises a rear mirror. 
     
     
         3 . The method for assembling a solar module structure of  claim 1 , further comprising arranging a plurality of said solar module assemblies in series. 
     
     
         4 . The method for assembling a solar module structure of  claim 1 , further comprising arranging a plurality of said solar module assemblies in parallel. 
     
     
         5 . The method for assembling a solar module structure of  claim 3 , further comprising connecting at least one pair of module power output electrical leads. 
     
     
         6 . The method for assembling a solar module structure of  claim 4 , further comprising connecting at least one pair of module power output electrical leads.