JP6642841B2 - Shingled solar cell module - Google Patents

Description

[Cross-reference of related applications]
This international patent application is disclosed in U.S. Patent Application No. 14 / 530,405 (the title of the invention is "Shingled Solar Cell Module", filed on October 31, 2014), and U.S. Patent Application No. 14 / 532,293 ( The title of the invention is "Shingled Solar Cell Module", the filing date is November 4, 2014), U.S. Patent Application No. 14 / 536,486 (the title of the invention is "Shingled Solar Cell Module, filing date 2014-11" , US Patent Application No. 14 / 539,546 (titled "Shingled Solar Cell Module", filed on November 12, 2014), U.S. Patent Application No. 14 / 543,580 (Invention) Is "Shingled Solar Cell Module" U.S. Patent Application No. 14 / 548,081 (title of "Singled Solar Cell Module", filing date November 19, 2014); U.S. Patent Application No. 14 / 548,081; No./550,676 (titled "Singled Solar Cell Module", filed on November 21, 2014), U.S. Patent Application No. 14 / 552,761 (titled "Shingled Solar Cell Module", U.S. Patent Application No. 14 / 560,577 (titled "Singled Solar Cell Module", filing date December 4, 2014), U.S. Patent Application No. 14 / 560,577. No. 566,278 (the title of the invention is "Singled Solar" US Patent Application No. 14 / 565,820, entitled "Shingled Solar Cell Module", filed on December 10, 2014, U.S. Pat. Application No. 14 / 572,206 (the title of the invention is "Shingled Solar Cell Module", filing date is December 16, 2014), U.S. Patent Application No. 14 / 577,593 (the title of the invention is "Shingled Solar Cell Module") "Module", filed on December 19, 2014), U.S. Patent Application No. 14 / 586,025 (titled "Singled Solar Cell Module", filed on December 30, 2014), U.S. Patent Application No. 14 / 585,917 (the title of the invention is "Sh singled Cell Cell Module, filing date December 30, 2014), U.S. Patent Application No. 14 / 594,439 (titled "Singled Solar Cell Module, filing date January 12, 2015), U.S. Patent Application No. 14 / 605,695, entitled "Shingled Solar Cell Module", filed January 26, 2015, U.S. Provisional Patent Application No. 62 / 003,223, entitled ""Singled Solar Cell Module", filed on May 27, 2014), and U.S. Provisional Patent Application No. 62 / 036,215 (titled "Singled Solar Cell Module", filed on August 12, 2014) U.S. Provisional Patent Application No. 62 / 042,615. (The title of the invention is "Shingled Solar Cell Module", the filing date is August 27, 2014), U.S. Provisional Patent Application No. 62 / 048,858 (the title of the invention is "Shingled Solar Cell Module, the filing date is 2014") U.S. Provisional Patent Application Ser. No. 834 (the title of the invention is "Shingled Solar Cell Module", the filing date is October 16, 2014); application , March 31, 2015), U.S. Provisional Patent Application No. 62 / 081,200 (titled "Solar Cell Panel Employing Hidden Taps", filed November 18, 2014) No. 62 / 113,250 (the title of the invention is "Singled Solar Cell Panel Employing Hidden Taps", filed on February 6, 2015), and U.S. Provisional Patent Application No. 62 / 082,904 (the title of the invention is "High"). "Voltage Solar Panel", filing date November 21, 2014), U.S. Provisional Patent Application No. 62 / 103,816 (the title of the invention is "High Voltage Solar Panel", filing date January 15, 2015), US Provisional Patent Application No. 62 / 111,75 No. (Invention title is "High Voltage Solar Panel", filing date: February 4, 2015), U.S. Provisional Patent Application No. 62 / 134,176 (Invention title is "Solar Cell Cleaning Tools and Methods", application) Dated March 17, 2015), U.S. Provisional Patent Application No. 62 / 150,426 (titled "Singled Solar Cell Panel Compiling Stencil-Printed Cell Metallization", filed April 21, 2015); U.S. Provisional Patent Application No. 62 / 035,624, entitled "Solar Cells with Reduced Edge Carrier Recombination," filed on August 11, 2014, United States Design Application No. 29 / 506,415 (filing date: October 15, 2014), US Design Application No. 29 / 506,755 (filing date: October 20, 2014), US Design Application No. 29/508 , 323 (filed on November 5, 2014), US Design Application No. 29 / 509,586 (filed on November 19, 2014), and US Design Application No. 29 / 509,588 (filed Claims the priority date of November 19, 2014). Each of the patent applications in the above list is hereby incorporated by reference in its entirety for all purposes.

  The present invention generally relates to a solar cell module in which solar cells are arranged in a shingle-like shape.

  Alternative energy sources are needed to meet the ever-increasing global energy demand. Solar energy sources are sufficient to meet such demands in many geographic regions, in part, by providing power generated by solar (eg, photo) cells.

  Disclosed herein is a highly efficient arrangement of solar cells within a solar cell module and a method of making such a solar module.

  In one aspect, the solar module includes a series connection string of N (≧ 25) rectangular or substantially rectangular solar cells having a breakdown voltage greater than about 10 volts on average. The plurality of solar cells are grouped into one or more supercells, and the supercells are in a state where the long sides of adjacent solar cells overlap and are conductively joined to each other by an electric and heat conductive adhesive. Have two or more of the solar cells arranged side by side. No single solar cell or group of less than N solar cells in the above string of solar cells are individually electrically connected in parallel with the bypass diode. Safe and reliable operation of solar modules effectively prevents or reduces the formation of hot spots in reverse-biased solar cells along supercells through the joining overlap of adjacent solar cells Easy heat conduction. The supercell may be encapsulated in a thermoplastic olefin polymer sandwiched between, for example, a front and back sheet of glass, which further enhances the module's robustness with respect to thermal damage. In some variations, N ≧ 30, ≧ 50, or ≧ 100.

  In another aspect, the supercell has a rectangular or substantially rectangular shape having a shape defined by opposed first and second parallel long sides and two oppositely located short sides. Includes a plurality of silicon solar cells each having a front side (sun side) and a back side. Each solar cell includes an electrically conductive front metallization pattern including at least one front contact pad positioned adjacent the first long side, and at least one rear surface positioned adjacent the second long side. An electrically conductive backside metallization pattern including contact pads. In the plurality of silicon solar cells, the first long side and the second long side of the adjacent silicon solar cells are overlapped, and the front and rear contact pads on the adjacent silicon solar cells are overlapped with each other. The adjacent silicon solar cells are electrically connected in series by a conductive adhesive bonding agent and are arranged side by side in a state of being electrically connected in series. The front metallization pattern of each silicon solar cell includes substantially applying the conductive adhesive to the at least one front contact pad prior to curing of the conductive adhesive during manufacture of the supercell. Including a barrier configured for containment.

  In another aspect, the supercell has a rectangular or substantially rectangular shape having a shape defined by opposed first and second parallel long sides and two oppositely located short sides. It includes a plurality of silicon solar cells, each including a front side (sun side) and a rear side. Each solar cell includes an electrically conductive front metallization pattern including at least one front contact pad positioned adjacent the first long side, and at least one rear surface positioned adjacent the second long side. An electrically conductive backside metallization pattern including contact pads. In the plurality of silicon solar cells, the first long side and the second long side of the adjacent silicon solar cells are overlapped, and the front and rear contact pads on the adjacent silicon solar cells are overlapped with each other. The adjacent silicon solar cells are electrically connected in series by a conductive adhesive bonding agent and are arranged side by side in a state of being electrically connected in series. The backside metallization pattern of each silicon solar cell may include applying the conductive adhesive to the at least one back contact pad prior to curing the conductive adhesive during fabrication of the supercell. Including a barrier configured for containment.

  In another aspect, a method of making a solar cell string comprises forming the one or more pseudo-square silicon wafers along a plurality of lines of the one or more pseudo-square silicon wafers that are parallel to a long edge of each pseudo-square silicon wafer. Dicing to form a plurality of rectangular silicon solar cells, each having substantially the same length along a major axis. The method also includes the step of arranging the plurality of rectangular silicon solar cells side by side with the adjacent solar cells overlapped and conductively connected to each other such that the adjacent solar cells are electrically connected in series. The plurality of rectangular silicon solar cells include: at least one rectangular solar cell including two chamfered corners corresponding to a plurality of corners of the pseudo-square wafer or a part of the plurality of corners; And one or more rectangular silicon solar cells, each having no. The distance between the plurality of parallel lines along which the dicing of the pseudo-square wafer is performed has a width perpendicular to the major axis of the rectangular silicon solar cell including the chamfered corner, and does not have the chamfered corner. A plurality of rectangular silicon solar cells are selected to compensate for the chamfered corners by making them larger than a width perpendicular to the long axis of the rectangular silicon solar cells, whereby each of the rectangular silicon solar cells in the solar cell string is And a front surface having substantially the same area exposed to light in operation of the solar cell string.

  In another embodiment, the supercell is a plurality of silicon solar cells arranged side by side with the ends of adjacent solar cells overlapping and conductively joined to each other to electrically connect the adjacent solar cells in series. Including. At least one of the plurality of silicon solar cells has a plurality of corners of the pseudo-square silicon wafer to be diced, or has a chamfered corner corresponding to a part of the plurality of corners, and At least one of the plurality of silicon solar cells does not have a chamfered corner, and each of the plurality of silicon solar cells has a front surface having substantially the same area exposed to light during operation of the solar cell string. Have.

In another aspect, a method of making two or more supercells comprises forming one or more of the one or more pseudo-square silicon wafers along a plurality of lines parallel to a long edge of each pseudo-square silicon wafer. Dicing the pseudo-square silicon wafer to form a first plurality of rectangular silicon solar cells including a plurality of corners of the one or more pseudo-square silicon wafers or chamfered corners corresponding to some of the plurality of corners; Forming a second plurality of rectangular silicon solar cells each having a first length extending over the full width of the one or more pseudo-square silicon wafers and having no chamfered corners. . The method includes removing the chamfered corners from each of the first plurality of rectangular silicon solar cells, each having a second length shorter than the first length, and including the chamfered corners. Forming a third plurality of rectangular silicon solar cells. The method is
The long sides of the adjacent rectangular silicon solar cells overlap and are conductively joined to each other, and the second plurality of rectangular silicon solar cells are arranged side by side while the second plurality of rectangular silicon solar cells are electrically connected in series. Forming a solar cell string having a width equal to the first length;
The long sides of the adjacent rectangular silicon solar cells overlap and are conductively joined to each other, and the third plurality of rectangular silicon solar cells are arranged and arranged in a state where the third plurality of rectangular silicon solar cells are electrically connected in series. Forming a solar cell string having a width equal to the second length.

In other embodiments,
A method of making two or more supercells,
Dicing the one or more pseudo-square silicon wafers along a plurality of lines parallel to the long edge of each of the one or more pseudo-square silicon wafers to form the one or more pseudo-square silicon wafers A first plurality of rectangular silicon solar cells including chamfered corners corresponding to a plurality of corners or a part of the plurality of corners; and a second plurality of rectangular silicon solar cells without chamfered corners. Forming a;
The long sides of the adjacent rectangular silicon solar cells overlap and are conductively joined to each other, and the first plurality of rectangular silicon solar cells are arranged side by side in a state where the first plurality of rectangular silicon solar cells are electrically connected in series. Process and
The long sides of adjacent rectangular silicon solar cells overlap and are conductively joined to each other, and the second plurality of rectangular silicon solar cells are arranged side by side in a state where the second plurality of rectangular silicon solar cells are electrically connected in series. And.

In another aspect, the supercell comprises:
A plurality of silicon solar cells that are arranged side by side in the first direction in a state where the ends of adjacent silicon solar cells overlap and are conductively joined to each other, and the adjacent silicon solar cells are electrically connected in series;
And an elongated flexible electrical interconnect,
A major axis of the elongated flexible electrical interconnect is oriented parallel to a second direction perpendicular to the first direction;
The elongated flexible electrical interconnect comprises:
Conductive bonding to a front or rear surface of an end silicon solar cell among the plurality of silicon solar cells at a plurality of discontinuous positions arranged along the second direction;
Extending in the second direction over at least the entire width of the solar cell at the end,
A conductor thickness measured in a direction perpendicular to the front or back surface of the edge silicon solar cell is less than or equal to about 100 microns;
Providing a resistance less than or equal to about 0.012 ohms for the flow of current in the second direction;
Configured to provide flexibility between the silicon solar cell at the end and the interconnect to accommodate differential expansion in the second direction in a temperature range from about -40C to about 85C. ing.

  The flexible electrical interconnect may, for example, have a conductor thickness measured in a direction perpendicular to the front and back surfaces of the silicon solar cell at the edge of less than or equal to about 30 microns. . The flexible electrical interconnect extends beyond the supercell in the second direction to provide at least an electrical connection to a second supercell positioned parallel and adjacent to the supercell in a solar module. An interconnect may be provided. Additionally or alternatively, the flexible electrical interconnect extends beyond the supercell in the first direction and is positioned parallel and side by side with the supercell in a solar module. An electrical interconnect to the supercell may be provided.

In another aspect, the solar module includes a plurality of supercells arranged in two or more parallel rows extending across the width of the solar module to form a front surface of the solar module. Each supercell includes a plurality of silicon solar cells arranged side by side with the ends of adjacent silicon solar cells overlapping and conductively joined to one another, with the adjacent silicon solar cells being electrically connected in series. At least the edge of the first supercell adjacent to the edge of the solar module in the first row,
Bonding to the front surface of the first supercell with an electrically conductive adhesive bonding agent at a plurality of discontinuous locations;
Extending parallel to the edge of the solar module,
At least a portion of the first supercell is broken around the end and hidden from view from the front of the solar module;
Via flexible electrical interconnects,
An electrical connection is made to the end of a second supercell adjacent to the same edge of the solar module in the second row.

In another aspect, a method of making a supercell comprises:
Laser scribing one or more scribe lines on each of the one or more silicon solar cells to define a plurality of rectangular regions on the one or more silicon solar cells;
Applying an electrically conductive adhesive to the scribed one or more silicon solar cells at one or more locations adjacent to the long sides of each rectangular region;
A plurality of rectangles each including a part of the electrically conductive adhesive bonding agent disposed on a front surface adjacent to a long side by separating the one or more silicon solar cells along the one or more scribe lines. Providing a silicon solar cell;
Long sides of adjacent rectangular silicon solar cells, a step of arranging the plurality of rectangular silicon solar cells in a state where a part of the electrically conductive adhesive bonding agent is interposed and overlapped in a shingle-like shape,
Curing the electrically conductive bonding agent, thereby bonding adjacent and overlapping rectangular silicon solar cells to each other and electrically connecting them in series.

In another aspect, a method of making a supercell comprises:
Laser scribing one or more scribe lines on each of the one or more silicon solar cells to define a plurality of rectangular regions on the one or more silicon solar cells;
Applying an electrically conductive adhesive to a portion of the top surface of the one or more silicon solar cells;
A vacuum is drawn between the bottom surface and the curved support surface of the one or more silicon solar cells, and the one or more silicon solar cells are bent toward the curved support surface, whereby the one or more silicon solar cells are bent. Cleaving the one or more silicon solar cells along a scribe line to provide a plurality of rectangular silicon solar cells each including a part of the electrically conductive adhesive bonding agent disposed on a front surface adjacent to a long side. The process of
Long sides of adjacent rectangular silicon solar cells, a step of arranging the plurality of rectangular silicon solar cells in a state where a part of the electrically conductive adhesive bonding agent is interposed and overlapped in a shingle-like shape,
Curing the electrically conductive bonding agent, thereby bonding adjacent and overlapping rectangular silicon solar cells to each other and electrically connecting them in series.

In another aspect, a method of making a solar module includes forming a plurality of rectangular silicon solar cells arranged side by side with a plurality of ends on the long sides of adjacent rectangular silicon solar cells being shingled. The method includes a step of assembling a plurality of supercells of each. The method also includes curing and heating the plurality of supercells to cure the electrically conductive bonding agent disposed between the overlapping ends of adjacent rectangular silicon solar cells, thereby causing the adjacent overlapping cells to overlap. Joining the rectangular silicon solar cells together and electrically connecting them in series. The method is also
Arranging and interconnecting the plurality of supercells in a desired solar module configuration in a layer stack including the encapsulant;
Heating and pressurizing the layer stack to form a laminated structure.

  Some variations of the method include heating and pressurizing the layer stack to heat and pressurize the plurality of supercells prior to forming the laminate structure, thereby forming the electrically conductive bonding agent. Curing or partially curing, thereby forming a cured or partially cured supercell as an intermediate product prior to forming the laminated structure. In some variations, as each additional rectangular silicon solar cell is added to the supercell during assembly of the supercell, the newly added solar cell and its adjacent overlapping solar cells The electrically conductive adhesive bond to the cell is cured or partially cured before any other rectangular silicon solar cells are added to the supercell. Alternatively, some variations include curing or partially curing all of the electrically conductive bonding agent in the supercell in the same step.

  When the supercell is formed as a partially cured intermediate product, a method comprises heating and pressing the layer stack while completing the curing of the electrically conductive bonding agent to form the laminated structure. May be included.

  Some variations of the method include heating and pressurizing the layer stack without forming a cured or partially cured supercell as an intermediate product prior to forming the laminated structure. Curing the agent to form a laminated structure.

  The method may include dicing one or more standard-sized silicon solar cells into a plurality of smaller-area rectangles to provide the plurality of rectangular silicon solar cells. The electrically conductive adhesive is applied to the one or more silicon solar cells prior to the step of dicing the one or more silicon solar cells, and has a previously applied electrically conductive adhesive. A plurality of rectangular silicon solar cells may be provided. Alternatively, the electrically conductive adhesive may be applied to the rectangular silicon solar cell after dicing the one or more silicon solar cells to provide the rectangular silicon solar cell.

In one aspect, a solar module includes a plurality of supercells arranged in two or more parallel rows. Each supercell has a plurality of rectangular or substantially rectangular silicons in which the long sides of adjacent silicon solar cells overlap and are directly conductively bonded to each other, and are arranged in a state where the adjacent silicon solar cells are electrically connected in series. Including solar cells. Solar panels also
A first hidden tap contact pad located on the rear surface of the first solar cell located at an intermediate position along the first super cell among the plurality of super cells;
A first electrical interconnect conductively connected to the first hidden tap contact pad. The first electrical interconnect includes stress relief features that accommodate differential thermal expansion between the interconnect and the silicon solar cell to which it is joined. The term "stress relaxation feature" as used herein with respect to an interconnect includes, for example, geometric features such as kinks, loops, or slots, the thickness of the interconnect (eg, very thin), and And / or may refer to the ductility of the interconnect. For example, a stress relief feature may be that the interconnect is formed from a very thin copper ribbon.

The solar module is
A second hidden tap contact pad located on the rear surface of the second solar cell located adjacent to the first solar cell at an intermediate position along the second supercell among the plurality of supercells in an adjacent supercell row. May include
The first hidden tap contact pad may be electrically connected to the second hidden tap contact pad through the first electrical interconnect. In such a case, the first electrical interconnect may extend across a gap between the first supercell and the second supercell and may be conductively connected to the second hidden tap contact pad. Alternatively, an electrical connection between the first hidden tap contact pad and the second hidden tap contact pad is conductively connected to the second hidden tap contact pad and electrically connected to the first electrical interconnect (eg, a conductive bond). Other electrical interconnects may be included. Either interconnect scheme may optionally extend over additional multiple supercell rows. For example, any interconnect scheme may optionally extend across the entire width of the module to interconnect each row of solar cells via hidden tap contact pads.

The solar module is
A second hidden tap contact pad located on the rear surface of the second solar cell located at another intermediate position along the first super cell among the plurality of super cells;
A second electrical interconnect conductively connected to the second hidden tap contact pad;
A bypass diode electrically connected by the first electrical interconnect and the second electrical interconnect in parallel with the solar cell located between the first hidden tap contact pad and the second hidden tap contact pad. May be included.

In any of the above variations, the first hidden tap contact pad comprises a plurality of hidden tap contacts disposed on the rear surface of the first solar cell in a row extending parallel to a long axis of the first solar cell. Can be one of the pads,
The first electrical interconnect is conductively joined to each of the plurality of hidden contacts and extends substantially over the length of the first solar cell along the long axis. Additionally or alternatively, the first hidden contact pad is one of a plurality of hidden tap contact pads located on a back surface of the first solar cell in a row extending perpendicular to the long axis of the first solar cell. obtain. In the latter case, the row of hidden tap contact pads may be located, for example, adjacent to the short edge of the first solar cell. The first hidden contact pad may be one of a plurality of hidden tap contact pads arranged in a two-dimensional array on a rear surface of the first solar cell.

Alternatively, in any of the above variations, the first hidden tap contact pad may be located adjacent a short side of the rear surface of the first solar cell;
The first electrical interconnect does not extend substantially inward from the hidden tap contact pad along the long axis of the solar cell;
The interconnect wherein the backside metallization pattern on the first solar cell preferably has a sheet resistance of less than or equal to about 5 ohms / square, or less than or equal to about 2.5 ohms / square. To provide a conductive path to In such a case, the first interconnect may include, for example, two tabs located on opposite sides of the stress relief feature;
One of the two tabs may be conductively connected to the first hidden tap contact pad. The two tabs can be of different lengths.

  In any of the above variations, the first electrical interconnect specifies a desired alignment with the first hidden tap contact pad or a desired alignment with an edge of the first supercell. Or an alignment feature that specifies a desired alignment with the first hidden tap contact pad and a desired alignment with the edge of the first supercell.

  In another aspect, the solar module comprises a front sheet made of glass, a back sheet, and a plurality of supercells arranged in two or more parallel rows between the front sheet made of glass and the back sheet. And Each supercell, the long sides of adjacent silicon solar cells overlap and are directly conductively joined to each other flexibly, and a plurality of rectangles or substantially arranged in a state where the adjacent silicon solar cells are electrically connected in series and arranged side by side It has a rectangular silicon solar cell. A first flexible electrical interconnect is rigidly conductively bonded to the first of the plurality of supercells. The plurality of flexible conductive junctions between overlapping solar cells may include a plurality of supercells in a direction parallel to the plurality of rows in a temperature range of about -40C to about 100C without damaging the solar module. Providing a plurality of supercells with mechanical compliance that accommodates thermal expansion mismatch between the glass and the glass frontsheet. The strong conductive joint between the first supercell and the first flexible electrical interconnect provides the first flexible electrical interconnect at a temperature in the range of about -40C to about 180C without damaging the solar module. The connection is adapted to accommodate a thermal expansion mismatch between the first supercell and the first flexible electrical interconnect in a direction perpendicular to the plurality of rows.

  The plurality of conductive junctions between overlapping adjacent solar cells in a supercell may utilize a different conductive adhesive than the plurality of conductive junctions between the supercell and the flexible electrical interconnect. The conductive junction on one side of at least one solar cell in the supercell may utilize a different conductive adhesive than the conductive junction on the other side. For example, the conductive adhesive that forms a strong bond between the supercell and the flexible electrical interconnect may be a solder. In some variations, the plurality of conductive joints between overlapping solar cells in the supercell are formed of a non-solder conductive adhesive, and the conductive joint between the supercell and the flexible electrical interconnect is a solder joint. Is formed.

  In some variations that utilize two different conductive adhesives as just described, both conductive adhesives may be used at the same processing step (eg, at the same temperature, at the same pressure, and / or at the same time). (Within an interval).

  The plurality of conductive junctions between overlapping adjacent solar cells can accommodate, for example, differential movements greater than or equal to about 15 microns between each cell and the glass frontsheet.

  The plurality of conductive junctions between overlapping adjacent solar cells are, for example, less than or equal to about 50 microns thick in a direction perpendicular to the adjacent solar cells, and Thermal conductivity in a direction perpendicular to the battery may be greater than or equal to about 1.5 W / (meter-K).

  The first flexible electrical interconnect may withstand, for example, thermal expansion or contraction of the first flexible interconnect that is greater than or equal to about 40 microns.

  The portion of the first flexible electrical interconnect, which is conductively bonded to the supercell, is in the form of a ribbon made of copper, for example, having a thickness in a direction perpendicular to the surface of the solar cell to which the solar cell is bonded. It may be less than or equal to 30 microns, or less than or equal to about 50 microns. The first flexible electrical interconnect has an integral conductive copper portion that is conductively bonded to the solar cell, provides higher conductivity than the portion of the first flexible electrical interconnect, and is not bonded to the solar cell. I can do it. The first flexible electrical interconnect has a thickness in a direction perpendicular to the surface of the solar cell to which it is joined is less than or equal to about 30 microns, or less than or equal to about 50 microns. The width in the direction perpendicular to the current flow through the interconnect at the surface of the solar cell may be greater than or equal to about 10 mm. The first flexible electrical interconnect may be conductively joined to a conductor proximate to the solar cell that provides higher conductivity than the first electrical interconnect.

  In another aspect, a solar module includes a plurality of supercells arranged in two or more parallel rows. Each supercell has a plurality of rectangular or substantially rectangular silicons in which the long sides of adjacent silicon solar cells overlap and are directly conductively bonded to each other, and are arranged in a state where the adjacent silicon solar cells are electrically connected in series. Including solar cells. A hidden tap contact pad that does not conduct substantial current in normal operation is located at an intermediate position along a first supercell of the plurality of supercells in a first of the two or more parallel rows of supercells. Is located on the rear surface of the first solar cell. The hidden tap contact pad electrically connects in parallel to at least a second solar cell in a second of the two or more parallel rows of supercells.

The solar module may include an electrical interconnect bonded to the hidden tap contact pad and electrically interconnecting the hidden tap contact pad to the second solar cell. In some variations, the electrical interconnect does not extend substantially across the length of the first solar cell,
A backside metallization pattern on the first solar cell provides a conductive path to the hidden tap contact pad having a sheet resistance less than or equal to about 5 ohms / square.

The plurality of supercells may be arranged in three or more parallel rows extending across a width of the solar module perpendicular to the plurality of rows;
The hidden tap contact pad is electrically connected to a hidden contact pad on at least one solar cell in each of the three or more parallel rows of the supercell to connect the three or more of the supercells. Electrically connect all of the parallel rows in parallel. In such a variant, the solar module is connected to at least one of the hidden tap contact pads or to an interconnect between the hidden tap contact pads, at least one of which connects to a bypass diode or other electronic device. It may include a bus connection.

  The solar module may include a flexible electrical interconnect that conductively connects to the hidden tap contact pad and electrically connects it to the second solar cell. The portion of the flexible electrical interconnect, which is conductively bonded to the hidden tap contact pad, is, for example, a ribbon formed of copper, and has a thickness in a direction perpendicular to the surface of the solar cell of the bonding destination. It may be less than or equal to 50 microns. The conductive junction between the hidden tap contact pad and the flexible electrical interconnect is connected to the flexible electrical interconnect at a temperature in the range of about -40C to about 180C without damaging the solar module. Tolerate thermal expansion mismatch between the first solar cell and the flexible interconnect and accommodate for relative movement between the first and second solar cells resulting from the thermal expansion. obtain.

  In some variations, in operation of the solar module, the first hidden contact pad may conduct a current greater than a current generated by any one of the plurality of solar cells.

  Typically, the front surface of the first solar cell overlying the first hidden tap contact pad is not occupied by a contact pad or any other interconnect feature. Typically, any area of the front surface of the first solar cell where parts of adjacent solar cells in the first supercell do not overlap is occupied by contact pads or any other interconnect features. Absent.

  In some variations, within each supercell, most of the batteries do not have a hidden tap contact pad. In such a variation, the cells having a hidden tap contact pad may have a larger light collection area than the cells having no hidden tap contact pad.

  In another aspect, the solar module comprises a front sheet made of glass, a back sheet, and a plurality of supercells arranged in two or more parallel rows between the front sheet made of glass and the back sheet. And Each supercell, the long sides of adjacent silicon solar cells overlap and are directly conductively joined to each other flexibly, and a plurality of rectangles or substantially arranged in a state where the adjacent silicon solar cells are electrically connected in series and arranged side by side It has a rectangular silicon solar cell. A first flexible electrical interconnect is rigidly conductively bonded to the first of the plurality of supercells. The flexible conductive junction between the overlapping solar cells is formed from a first conductive adhesive and has a rigidity less than or equal to about 800 megapascals. The strong conductive junction between the first supercell and the first flexible electrical interconnect is formed from a second conductive adhesive and has a rigidity greater than or equal to about 2000 megapascals.

  The first conductive adhesive may have, for example, a glass transition temperature less than or equal to about 0 ° C.

  In some variations, unlike the first conductive adhesive and the second conductive adhesive, both conductive adhesives can be cured in the same processing step.

  In some variations, the plurality of conductive junctions between overlapping adjacent solar cells have a thickness in a direction perpendicular to the solar cells less than or equal to about 50 microns and are perpendicular to the solar cells. The thermal conductivity in the direction is higher than or equal to about 1.5 W / (meter-K).

  In one aspect, the solar module includes N (greater than or equal to about 150) rectangular or substantially rectangular silicon solar cells arranged as a plurality of supercells in two or more parallel rows. Each supercell includes a plurality of silicon solar cells arranged side by side in such a manner that the long sides of adjacent silicon solar cells overlap and are conductively joined to each other, and the adjacent silicon solar cells are electrically connected in series. The supercell provides an electrical connection to provide a high DC voltage that is greater than or equal to about 90 volts.

  In one variation, the solar module includes one or more flexible electrical interconnects arranged to electrically connect the plurality of supercells in series to provide the high DC voltage. Solar modules may include module-level power electronics including an inverter that converts the high DC voltage to an AC voltage. The module-level power electronics can sense the high DC voltage and operate the module at an optimal current-voltage power point.

In another variation, the solar module comprises:
A module-level module for electrically connecting a plurality of individual, adjacent series-connected supercell row pairs and electrically connecting one or more of the plurality of supercell row pairs in series to provide the high DC voltage. Power electronics and
And an inverter for converting the high DC voltage into an AC voltage. Optionally, the module-level power electronics can sense the voltage across each individual supercell row pair and operate each individual supercell row pair at an optimal current-voltage power point. Optionally, if the voltage on an individual supercell row pair falls below a threshold, the module-level power electronics may switch out the row pair from the circuit providing the higher DC voltage.

In another variation, a solar module electrically connects to each individual supercell row and electrically connects two or more of the plurality of supercell rows in series to provide the high DC voltage. Level power electronics and
And an inverter for converting the high DC voltage into an AC voltage. Optionally, the module-level power electronics can sense the voltage across each individual supercell row and operate each individual supercell row at the optimal current-voltage power point. Optionally, if the voltage on an individual supercell row falls below a threshold, the module-level power electronics may switch out the supercell row from the circuit providing the higher DC voltage.

In another variation, a solar module is electrically connected to each individual supercell and two or more of the plurality of supercells are electrically connected in series to provide the module level power to provide the high DC voltage. Electronics and
And an inverter for converting the high DC voltage into an AC voltage. Optionally, the module level power electronics can sense the voltage across each individual supercell and operate each individual supercell at the optimal current-voltage power point. Optionally, if the voltage on an individual supercell falls below a threshold, the module-level power electronics may switch out the supercell from the circuit providing the higher DC voltage.

In another variation, each supercell in the module is electrically segmented into multiple segments by multiple hidden taps. The solar module electrically connects to each segment of each supercell through the plurality of hidden taps and electrically connects two or more segments in series to provide the module level power electronics providing the high DC voltage. Including
An inverter for converting the high DC voltage into an AC voltage is included. Optionally, the module-level power electronics can sense the voltage across each individual segment of each supercell and operate each individual segment at the optimal current-voltage power point. Optionally, if the voltage on an individual segment falls below a threshold, the module-level power electronics can switch out the segment from the circuit providing the higher DC voltage.

  In any of the above variations, the optimal current-voltage power point may be the maximum current-voltage power point.

  In any of the above variations, the module-level power electronics may not have a DC-DC boost component.

  In any of the above variations, N is greater than or equal to about 200, greater than or equal to about 250, greater than or equal to about 300, or greater than or equal to about 350, or greater than or equal to about 350. Greater than or equal to 400, greater than or equal to about 450, greater than or equal to about 500, greater than or equal to about 550, greater than or equal to about 600, or greater than or equal to about 650, or It may be equal to or greater than or equal to about 700.

  In any of the above variations, the high DC voltage is greater than or equal to about 120 volts, greater than or equal to about 180 volts, greater than or equal to about 240 volts, greater than about 300 volts. Or greater than or equal to about 360 volts, greater than or equal to about 420 volts, greater than or equal to about 480 volts, greater than or equal to about 540 volts, or about 600 volts It may be a higher or equal voltage.

  In another aspect, a photovoltaic system includes two or more solar modules electrically connected in parallel and an inverter. Each solar module includes N (greater than or equal to about 150) rectangular or nearly rectangular silicon solar cells arranged as a plurality of supercells in two or more parallel rows. Each supercell in each module, the long sides of the adjacent silicon solar cells overlap and are conductively joined to each other, and the adjacent silicon solar cells are arranged side by side in a state where they are electrically connected in series. Including two or more silicon solar cells among the plurality of silicon solar cells. Within each module, the supercell is electrically connected to provide a high voltage DC module output that is greater than or equal to about 90 volts. Inverters electrically connect to two or more solar modules to convert their high voltage DC output to AC.

  Each solar module may include one or more flexible electrical interconnects arranged to electrically connect the plurality of supercells in the solar module in series to provide a high voltage DC output of the solar module.

  The photovoltaic system may include at least a third solar module electrically connected in series with the first solar module of the two or more solar modules electrically connected in parallel. In such a case, the third solar module comprises N '(greater than or equal to about 150) rectangular or substantially rectangular silicon, arranged as multiple supercells in two or more parallel rows. It may include solar cells. The supercells in the third solar module are arranged side by side in such a manner that the long sides of adjacent silicon solar cells overlap and are conductively joined to each other, and the adjacent silicon solar cells are electrically connected in series. Including two or more silicon solar cells of the plurality of silicon solar cells within. Within the third solar module, the supercell is electrically connected to provide a high voltage DC module output greater than or equal to about 90 volts.

  As just described, the variant comprising a third of the two or more solar modules electrically connected in series with the first solar module is a variant of the two or more solar modules electrically connected in parallel. Among them, at least a fourth solar module electrically connected in series with the second solar module may be included. The fourth solar module may include N ″ (greater than or equal to about 150) rectangular or nearly rectangular silicon solar cells arranged as a plurality of supercells in two or more parallel rows. . The respective supercells in the fourth solar module are arranged side by side in such a manner that the long sides of adjacent silicon solar cells overlap and are conductively connected to each other, and the adjacent silicon solar cells are electrically connected in series. Including two or more silicon solar cells of the plurality of silicon solar cells within. Within the fourth solar module, the supercell is electrically connected to provide a high voltage DC module output greater than or equal to about 90 volts.

  The photovoltaic system may be configured such that a short circuit occurring in any one of the two or more solar modules dissipates power generated by another of the two or more solar modules. It may include a plurality of fuses and / or blocking diodes arranged to prevent flashing.

  The photovoltaic system may include a positive bus and a negative bus to which the two or more solar modules are connected in parallel and to which the inverter is connected. Alternatively, the photovoltaic system may include a combiner box to which the two or more solar modules are electrically connected by separate conductors. The combiner box electrically connects the solar modules in parallel, and optionally, a short circuit occurring in any one of the two or more solar modules dissipates power generated by other solar modules. A plurality of fuses and / or blocking diodes arranged to prevent

  The inverter may be configured to operate the two or more solar modules at a DC voltage higher than a minimum set to avoid reverse biasing the solar modules.

  The inverter may be configured to recognize a reverse bias condition occurring in one or more of the solar modules and operate the solar module at a voltage that avoids the reverse bias condition.

  The solar power system can be located on a roof.

  In any of the above variations, N, N ′, and N ″ are greater than or equal to about 200, greater than or equal to about 250, greater than or equal to about 300, or greater than or equal to about 350. Greater than or equal to, greater than or equal to about 400, greater than or equal to about 450, greater than or equal to about 500, or greater than, equal to or greater than about 550, greater than or equal to about 600, or greater It may be equal, greater than or equal to about 650, or greater than or equal to about 700. N, N ′, and N ″ may have the same or different values.

  In any of the above variations, the high DC voltage provided by the solar module is greater than or equal to about 120 volts, greater than or equal to about 180 volts, greater than or equal to about 240 volts, or Equal, greater than or equal to about 300 volts, greater than or equal to about 360 volts, greater than or equal to about 420 volts, greater than or equal to about 480 volts, greater than or equal to about 540 volts It may be equal, or higher than or equal to about 600 volts.

  In other aspects, the photovoltaic system comprises N (greater than or equal to about 150) rectangular or substantially rectangular silicon solar cells arranged as multiple supercells in two or more parallel rows Including a first solar module. Each supercell includes a plurality of silicon solar cells arranged side by side in such a manner that the long sides of adjacent silicon solar cells overlap and are conductively joined to each other, and the adjacent silicon solar cells are electrically connected in series. The system also includes an inverter. The inverter may be, for example, a micro inverter integrated with the first solar module. The plurality of supercells in the first solar module are electrically connected to provide a high DC voltage greater than or equal to about 90 volts to the inverter that converts the DC to AC.

  A first solar module may include one or more flexible electrical interconnects arranged to electrically connect the plurality of supercells in the solar module in series to provide a high voltage DC output of the solar module. .

  The photovoltaic power generation system may include at least a second solar module electrically connected in series with the first solar module. The second solar module may include N '(greater than or equal to about 150) rectangular or substantially rectangular silicon solar cells arranged as a plurality of supercells in two or more parallel rows. The respective supercells in the second solar module are arranged side by side in such a manner that the long sides of adjacent silicon solar cells overlap and are conductively connected to each other, and the adjacent silicon solar cells are electrically connected in series. Including two or more silicon solar cells of the plurality of silicon solar cells within. Within the second solar module, the supercell is electrically connected to provide a high voltage DC module output that is greater than or equal to about 90 volts.

  An inverter (e.g., a micro-inverter) may not have a DC-DC boost component.

  In any of the above variations, N and N ′ are greater than or equal to about 200, greater than or equal to about 250, greater than or equal to about 300, or greater than or equal to about 350, or Equal to, greater than or equal to about 400, greater than or equal to about 450, greater than or equal to about 500, or greater than or equal to about 550, greater than or equal to about 600, or greater than or equal to about 650 It can be greater than or equal to, or greater than or equal to about 700. N, N 'may have the same or different values.

  In any of the above variations, the high DC voltage provided by the solar module is greater than or equal to about 120 volts, greater than or equal to about 180 volts, greater than or equal to about 240 volts, or Equal, greater than or equal to about 300 volts, greater than or equal to about 360 volts, greater than or equal to about 420 volts, greater than or equal to about 480 volts, greater than or equal to about 540 volts It may be equal, or higher than or equal to about 600 volts.

  In another aspect, the solar module comprises N (greater than or equal to about 250) rectangular or substantially rectangular silicon solar cells arranged as a plurality of serially connected supercells in two or more parallel rows. Including batteries. Each supercell includes a plurality of silicon solar cells, and the plurality of silicon solar cells overlap with the long sides of adjacent silicon solar cells and are directly conductively joined to each other by an electric and heat conductive adhesive to form a supercell within the supercell. Silicon solar cells are arranged side by side in a state of being electrically connected in series. Solar modules have less than one bypass diode per 25 solar cells. The electrically and thermally conductive adhesive has a thickness in a direction perpendicular to the plurality of solar cells of less than or equal to about 50 microns, and a thermal conductivity in a direction perpendicular to the plurality of solar cells of about 50 microns. Form multiple junctions between adjacent solar cells that are greater than or equal to 1.5 W / (meter-K).

  The plurality of supercells may be encapsulated in a thermoplastic olefin layer between the front and back sheets. The supercells and their encapsulants can be sandwiched between glass front and back sheets.

  The solar module may comprise, for example, less than one bypass diode per 30 solar cells, or less than one bypass diode per 50 solar cells, or less than one bypass diode per 100 solar cells. The solar module may, for example, have no bypass diode, or only a single bypass diode, or no more than three bypass diodes, or no more than six bypass diodes, or no more than ten bypass diodes.

  Optionally, the plurality of conductive junctions between the overlapping solar cells are in a direction parallel to the plurality of rows at a temperature in a range of about −40 ° C. to about 100 ° C. without damaging the solar module. The plurality of supercells may be provided with mechanical compliance that accommodates thermal expansion mismatch between the supercell and the glass frontsheet.

  In any of the above variations, N is greater than or equal to about 300, greater than or equal to about 350, greater than or equal to about 400, or greater than or equal to about 450, or greater than or equal to about 450. It can be greater than or equal to 500, greater than or equal to about 550, greater than or equal to about 600, greater than or equal to about 650, or greater than or equal to about 700.

  In any of the above variations, the plurality of supercells are electrically connected to each other to be greater than or equal to about 120 volts, greater than or equal to about 180 volts, greater than or equal to about 240 volts, and Equal, greater than or equal to about 300 volts, greater than or equal to about 360 volts, greater than or equal to about 420 volts, greater than or equal to about 480 volts, greater than or equal to about 540 volts A high DC voltage that is equal to or greater than or equal to about 600 volts may be provided.

The solar energy system
A solar module of any of the above variations,
An inverter (eg, a micro-inverter) electrically connected to the solar module and configured to convert a DC output from the solar module to provide an AC output. The inverter may not have a DC-DC boost component. The inverter may be configured to operate the solar module at a DC voltage higher than a minimum set to avoid reverse biasing the solar cell. The minimum voltage value can be temperature dependent. The inverter may be configured to recognize a reverse bias condition and operate the solar module at a voltage that avoids the reverse bias condition. For example, the inverter may be configured to operate the solar module in a maximum region of a voltage-current output curve of the solar module to avoid the reverse bias condition.

  The present specification discloses a solar cell cleavage tool and a solar cell cleavage method.

In one aspect, a method of manufacturing a solar cell comprises:
Advancing the solar cell wafer along the curved surface;
A vacuum is drawn between the curved surface and the bottom surface of the solar cell wafer, and the solar cell wafer is bent toward the curved surface, thereby bending the solar cell along one or more scribe lines prepared in advance. Cleaving the battery wafer to separate the plurality of solar cells from the solar cell wafer. The solar cell wafer can be continuously advanced, for example, along a curved surface. Alternatively, the solar cell may be advanced along a curved surface with discontinuous movement.

  The curved surface may be, for example, a curved portion of a top surface of a vacuum manifold that draws the vacuum against the bottom surface of the solar cell wafer. The vacuum drawn on the bottom surface of the solar cell wafer by the vacuum manifold can vary along the direction of movement of the solar cell wafer, for example, the solar cell wafer is sequentially cleaved, the vacuum manifold of the The strongest may be in the area.

  The method comprises transporting the solar cell wafer by a perforated belt along the curved top surface of the vacuum manifold, wherein the vacuum is applied to the solar cell wafer through a plurality of perforations in the perforated belt. It may include a step of being pulled against the bottom surface. The plurality of perforations are optional, and a leading edge and a trailing edge of the solar cell wafer along the direction of movement of the solar cell wafer lie on at least one perforation of the perforated belt, and thus, due to vacuum, It may be placed on the belt to be pulled towards, but this is not required.

  The method comprises advancing the solar cell wafer along a flat region of the upper surface of the vacuum manifold to reach a transition curved region of the upper surface of the vacuum manifold having a first curvature, and thereafter the solar cell wafer Are sequentially cleaved, a step of advancing the solar cell wafer into a cleavage region on the upper surface of the vacuum manifold, wherein the cleavage region of the vacuum manifold has a second curvature higher than the first curvature. A step may be provided. The method may further comprise advancing the plurality of cleaved solar cells into a post-cleavage region of the vacuum manifold having a third curvature higher than the second curvature.

  In any of the above variations, the method comprises drawing a vacuum between the stronger solar cell wafer and the curved surface at one end of each scribe line, and then at the opposite end of each scribe line. Providing asymmetrical stress distribution along each scribe line, which facilitates nucleation and propagation of a single cleavage cleft along each scribe line. Alternatively, or in addition, in any of the above variations, the method may include, for each scribe line, such that one end reaches the curved cleavage region of the vacuum manifold before the other end. The method may include the step of directing the upper scribe line at an angle to the vacuum manifold.

  In any of the above variations, the method may include removing the cleaved solar cell from the curved surface before the edges of the cleaved solar cell meet. For example, the method may include removing the battery in a direction tangent to, or approximately tangent to, the curved surface of the manifold at a speed greater than the speed of movement of the battery along the manifold. This may be achieved, for example, by a tangentially arranged moving belt or by any other suitable mechanism.

  In any of the above variations, the method comprises scribing a scribe line on the solar cell wafer, and prior to cleaving the solar cell wafer along the scribe line, one of the top or bottom surfaces of the solar cell wafer. Applying an electrically conductive adhesive to the part. Each of the resulting cleaved solar cells may then include a portion of an electrically conductive adhesive bond disposed along a cleaved edge on its top or bottom surface. The scribe line may be formed before or after the electrically conductive adhesive is applied using any suitable scribe method. The scribe line can be formed by, for example, laser scribe.

  In any of the above variations, the solar cell wafer may be a square or pseudo-square silicon solar cell wafer.

  In another aspect, a method of making a solar cell string comprises arranging a plurality of rectangular solar cells in a manner that the long sides of adjacent rectangular solar cells with an electrically conductive adhesive bonding agent interposed therebetween are shingled. Disposing and curing the electrically conductive bonding agent, thereby bonding adjacent and overlapping rectangular solar cells together and electrically connecting them in series. The solar cell may be manufactured, for example, by any of the variations of the method for manufacturing a solar cell described above.

In one aspect, a method of making a solar cell string includes forming a backside metallization pattern on each square solar cell of one or more square solar cells;
Stencil printing a complete front metallization pattern on each of said one or more square solar cells using a single stencil in a single stencil printing step. These steps may be performed in any order or, where appropriate, simultaneously. "Complete front metallization pattern" means that after the stencil printing step, no additional metallization material needs to be deposited on the front surface of the square solar cell to complete the formation of the front metallization. The method is also
Separating each square solar cell into two or more rectangular solar cells, forming a plurality of rectangular solar cells each including a complete front metallization pattern and a back metallization pattern, Forming from a square solar cell;
A step of arranging the plurality of rectangular solar cells side by side in a state where the long sides of adjacent rectangular solar cells overlap in a shingle-like shape,
A step of conductively joining the rectangular solar cells included in each pair of rectangular solar cells adjacent to each other and overlapping with an electrically conductive bonding agent disposed therebetween, wherein one of the rectangular solar cells included in the pair Electrically connecting the front metallization pattern of the rectangular solar cell to the rear metallization pattern of the other rectangular solar cell of the rectangular solar cells included in the pair, thereby connecting the plurality of rectangular solar cells in series. Electrically connecting to the process.

  The stencil defines one or more features of the front metallization pattern on the one or more square solar cells, such that all portions of the stencil lie in the plane of the stencil during stencil printing. The stencil may be configured to be fastened by a physical connection to other parts.

  The front metallization pattern on each rectangular solar cell may include, for example, a plurality of fingers oriented in a direction perpendicular to the long sides of the rectangular solar cell, wherein the plurality of fingers in the front metallization pattern None are physically connected to each other by the front metallization pattern.

  The present specification describes, for example, a solar cell having no cleavage edges that promote carrier recombination and having reduced carrier recombination loss at the edge of the solar cell, methods for manufacturing such a solar cell, and formation of a supercell. And the use of such solar cells in a shingle-like (overlapping) arrangement.

In one aspect,
The method of manufacturing multiple solar cells is
Depositing one or more front-side amorphous silicon layers on the front side of the crystalline silicon wafer;
Depositing one or more backside amorphous silicon layers on the backside of the crystalline silicon wafer opposite the front side of the crystalline silicon wafer;
Patterning the one or more front amorphous silicon layers to form one or more front trenches in the one or more front amorphous silicon layers;
Depositing a front passivation layer on the one or more front amorphous silicon layers and in the one or more front trenches;
Patterning the one or more backside amorphous silicon layers to form one or more backside trenches in the one or more backside amorphous silicon layers;
Depositing a back surface passivation layer on the one or more back surface amorphous silicon layers and in the one or more back surface trenches. Each of the one or more backside trenches is formed alongside a corresponding one of the frontside trenches. The method comprises cleaving the crystalline silicon wafer at one or more cleave planes, each cleave plane being centered or substantially centered on a different pair of corresponding front and back trenches. And a step. In operation of the resulting solar cell, the front amorphous silicon layer will be illuminated by light.

  In some variations, only the front trench is formed and the back trench is not formed. In another variation, only the back trench is formed and the front trench is not formed.

  The method includes forming the one or more front trenches and penetrating the front amorphous silicon layer to reach the front surface of the crystalline silicon wafer, and / or forming the one or more back trenches. Then, the method may include a step of penetrating the one or more backside amorphous silicon layers to reach the backside of the crystalline silicon wafer.

  The method may include forming the front passivation layer and / or the back passivation layer from a transparent conductive oxide.

  A pulsed laser or diamond tip can be used to initiate a cleavage point (eg, approximately 100 microns long). The CW laser and cooling nozzles are used sequentially to induce high thermal stresses to compress and elongate, induce complete cleavage propagation within the crystalline silicon wafer, and to separate the crystalline silicon wafer at one or more cleavage planes Can be Alternatively, the crystalline silicon wafer may be cleaved mechanically at one or more cleavage planes. Any suitable cleavage method can be used.

  The one or more front amorphous crystalline silicon layers may form an np junction with the crystalline silicon wafer, in which case it may be preferable to cleave the crystalline silicon wafer from its back side. Alternatively, the one or more backside amorphous crystalline silicon layers may form an np junction with the crystalline silicon wafer, in which case it may be preferable to cleave the crystalline silicon wafer from its front side.

In another aspect, a method of manufacturing a plurality of solar cells comprises:
Forming one or more trenches in a first surface of the crystalline silicon wafer;
Depositing one or more amorphous silicon layers on the first surface of the crystalline silicon wafer;
Depositing a passivation layer in the one or more trenches on the first surface of the crystalline silicon wafer and on the one or more amorphous silicon layers;
Depositing one or more amorphous silicon layers on a second surface of the crystalline silicon wafer opposite the first surface of the crystalline silicon wafer;
Cleaving the crystalline silicon wafer at one or more cleavage planes, wherein each cleavage plane is centered or substantially centered on a different one of the one or more trenches. And.

  The method may include forming the passivation layer from a transparent conductive oxide.

  A laser may be used to cause thermal stress in the crystalline silicon wafer to cleave the crystalline silicon wafer at the one or more cleavage planes. Alternatively, the crystalline silicon wafer may be cleaved mechanically at one or more cleavage planes. Any suitable cleavage method can be used.

  The one or more front amorphous crystalline silicon layers may form an np junction with the crystalline silicon wafer. Alternatively, the one or more backside amorphous crystalline silicon layers may form an np junction with the crystalline silicon wafer.

In another aspect, the solar panels are arranged such that the ends of adjacent solar cells overlap in a shingle-like shape and are conductively joined to each other, and the adjacent solar cells are arranged side by side in a state of being electrically connected in series. And a plurality of supercells each having the same solar cell. Each solar cell is
A crystalline silicon substrate,
One or more first surface amorphous silicon layers disposed on a first surface of the crystalline silicon substrate to form an np junction;
One or more second surface amorphous silicon layers disposed on a second surface of the crystalline silicon substrate opposite the first surface of the crystalline silicon substrate;
At the edge of the one or more first surface amorphous silicon layers, at the edge of the one or more second surface amorphous silicon layers, or at the edge of the one or more first surface amorphous silicon layers, and at the one or more And a plurality of passivation layers for preventing carrier recombination at the edge of the second surface amorphous silicon layer. The plurality of passivation layers may include a transparent conductive oxide.

  Solar cells may be formed, for example, by any of the methods summarized above or otherwise disclosed herein.

  These and other embodiments, features, and advantages of the present invention will become apparent to those skilled in the art upon reference to the following more detailed description of the present invention, when taken in conjunction with the accompanying drawings, which are first briefly described. , Become more apparent.

FIG. 2 shows a cross-sectional view of a string of solar cells connected in series arranged in a shingle-like configuration with a shingle-like supercell in which the ends of adjacent solar cells overlap.

1 shows a diagram of the front (sun side) and front metallization patterns of an exemplary rectangular solar cell that can be used to form a shingled supercell. FIG.

FIG. 2 shows a diagram of the front (sun side) and front metallization patterns of two exemplary rectangular solar cells including rounded corners that may be used to form a shingled supercell. FIG. 2 shows a diagram of the front (sun side) and front metallization patterns of two exemplary rectangular solar cells including rounded corners that may be used to form a shingled supercell.

FIG. 2B illustrates a view of the backside and an exemplary backside metallization pattern of the solar cell shown in FIG. 2A. FIG. 2B illustrates a view of the backside and an exemplary backside metallization pattern of the solar cell shown in FIG. 2A.

FIG. 4 shows a diagram of the backside and exemplary backside metallization pattern of the solar cell shown in FIGS. 2B and 2C, respectively. FIG. 4 shows a diagram of the backside and exemplary backside metallization pattern of the solar cell shown in FIGS.

FIG. 4 shows an illustration of the front (sun side) and front metallization patterns of another exemplary rectangular solar cell that may be used to form a shingled supercell. The front metallization pattern includes discontinuous contact pads, each of the discontinuous contact pads having uncured conductive adhesive deposited on the contact pad flowing away from the contact pad. Surrounded by a barrier configured to prevent

FIG. 2H shows a cross-sectional view of the solar cell of FIG. 2H, identifying the details of the front metallization pattern shown in the enlarged views of FIGS.

2I shows an enlarged view of a detail of FIG. 2I.

FIG. 2I is an enlarged view of the detail of FIG. 2I with the uncured conductive adhesive bonded substantially confined to the location of the discontinuous contact pad by the barrier.

FIG. 2C shows a view of the backside and an exemplary backside metallization pattern for the solar cell of FIG. 2H. The backside metallization pattern includes discontinuous contact pads, each of the discontinuous contact pads having uncured conductive adhesive bonded thereon deposited flowing away from the contact pads. Surrounded by a barrier configured to prevent

FIG. 2C shows a cross-sectional view of the solar cell of FIG. 2L, specifying details of the backside metallization pattern shown in the enlarged view of FIG.

FIG. 2C shows an enlarged view of the details of FIG. 2M.

FIG. 9 illustrates another variation of a metallization pattern that includes a barrier configured to prevent uncured conductive adhesive bond from flowing away from the contact pads. The barrier abuts one side of the contact pad and is higher than the contact pad.

20 illustrates another variation of the metallization pattern of FIG. 2O with the barrier abutting at least two sides of the contact pad.

FIG. 4 shows a diagram of a backside and an example backside metallization pattern for another exemplary rectangular solar cell. The backside metallization pattern includes a continuous contact pad extending substantially the length of the solar cell along the edge of the solar cell. The contact pad is surrounded by a barrier configured to prevent uncured conductive adhesive deposited on the contact pad from flowing away from the contact pad.

FIG. 4 shows an illustration of the front (sun side) and front metallization patterns of another exemplary rectangular solar cell that may be used to form a shingled supercell. The front metallization pattern includes discontinuous contact pads arranged in rows along the edge of the solar cell and long, thin conductors extending parallel to and inward from the row of contact pads. The long, thin conductor forms a barrier configured to prevent uncured conductive adhesive bonding material deposited on its contact pads from flowing away from the contact pads and onto the active area of the solar cell. .

Separate (eg, cut or fold) standard size and shape pseudo-square silicon solar cells into two different length rectangular solar cells that can be used to form a shingled supercell. FIG. 4 shows a diagram illustrating an exemplary method of obtaining.

FIG. 7 shows a diagram illustrating another exemplary method by which pseudo-square silicon solar cells can be separated into rectangular solar cells. FIG. 3B shows the front side of the wafer and an exemplary front side metallization pattern. FIG. 3C shows the backside of the wafer and an exemplary backside metallization pattern. FIG. 7 shows a diagram illustrating another exemplary method by which pseudo-square silicon solar cells can be separated into rectangular solar cells. FIG. 3B shows the front side of the wafer and an exemplary front side metallization pattern. FIG. 3C shows the backside of the wafer and an exemplary backside metallization pattern.

FIG. 4 shows a diagram illustrating an exemplary method by which a square silicon solar cell can be separated into a rectangular solar cell. FIG. 3D shows the front side of the wafer and an exemplary front side metallization pattern. FIG. 3E shows the backside of the wafer and an exemplary backside metallization pattern. FIG. 4 shows a diagram illustrating an exemplary method by which a square silicon solar cell can be separated into a rectangular solar cell. FIG. 3D shows the front side of the wafer and an exemplary front side metallization pattern. FIG. 3E shows the backside of the wafer and an exemplary backside metallization pattern.

FIG. 2B shows a fragmentary front view of an exemplary rectangular supercell comprising a plurality of rectangular solar cells, for example, as shown in FIG. 2A, arranged in a shingled configuration as shown in FIG. 1.

A front view of an exemplary rectangular supercell comprising a plurality of “chevron” rectangular solar cells including a plurality of chamfered corners, eg, as shown in FIG. 2B, arranged in a shingled configuration as shown in FIG. 1 and The back views are shown respectively. A front view of an exemplary rectangular supercell comprising a plurality of “chevron” rectangular solar cells including a plurality of chamfered corners, eg, as shown in FIG. 2B, arranged in a shingled configuration as shown in FIG. 1 and The back views are shown respectively.

FIG. 4 shows a diagram of an exemplary rectangular solar module. The rectangular solar module includes a plurality of rectangular shingled supercells each having a long side approximately half the length of the short side of the module. A plurality of pairs of supercells are arranged end to end to form a plurality of rows with the long sides of the supercell parallel to the short sides of the module.

FIG. 4 shows a diagram of another exemplary rectangular solar module. The rectangular solar module includes a plurality of rectangular shingled supercells each having a long side approximately the same length as the short side of the module. These supercells are arranged with their long sides parallel to the short sides of the module.

FIG. 4 shows a diagram of another exemplary rectangular solar module. The rectangular solar module includes a plurality of rectangular shingled supercells each having a long side approximately equal to the long side of the module. These supercells are arranged with their long sides parallel to the sides of the module.

FIG. 4 shows a diagram of an exemplary rectangular solar module. The rectangular solar module includes a plurality of rectangular shingled supercells each having a long side approximately half the length of the long side of the module. A plurality of pairs of supercells are arranged end-to-end to form a plurality of rows with the long side of the supercell parallel to the long side of the module.

FIG. 5C shows a diagram of another exemplary rectangular solar module whose configuration is similar to that of FIG. 5C. In that configuration, all of the solar cells forming the supercell are chevron solar cells that include chamfered corners corresponding to the corners of the pseudo-square wafer from which the solar cells were separated.

FIG. 5C shows a diagram of another exemplary rectangular solar module whose configuration is similar to that of FIG. 5C. In that configuration, the solar cells forming the supercell include a mix of chevron and rectangular solar cells arranged to reproduce the shape of the pseudo-square wafer from which they were separated.

FIG. 5E shows a diagram of another exemplary rectangular solar module whose configuration is similar to that of FIG. 5E. The difference is that adjacent chevron solar cells in the supercell are arranged as mirror images of one another such that their overlapping edges are the same length.

FIG. 5 illustrates an exemplary arrangement of three supercell rows interconnected by a flexible electrical interconnect such that the supercells in each row are in series with each other and the rows are parallel to each other. These may be, for example, three rows in the solar module of FIG. 5D.

1 illustrates an exemplary flexible interconnect that may be used to interconnect supercells in series or parallel. Some of these examples exhibit patterning that increases their flexibility (mechanical compliance) along their long axis, along their short axis, or along their long and short axes. I have. FIG. 7A illustrates an exemplary long-stress interconnect configuration that may be used at a hidden tap to a supercell as described herein or as an interconnect to a front or back supercell end contact. . An example of the out-of-plane stress relaxation feature is illustrated. FIGS. 7B-1 and 7B-2 illustrate exemplary long interconnects that may be used at a hidden tap to a supercell or as an interconnect to a front or back supercell end contact, including out-of-plane stress relief features. The configuration is shown. An example of the out-of-plane stress relaxation feature is illustrated. FIGS. 7B-1 and 7B-2 illustrate exemplary long interconnects that may be used at a hidden tap to a supercell or as an interconnect to a front or back supercell end contact, including out-of-plane stress relief features. The configuration is shown.

Figure 5D shows detail A from Figure 5D. FIG. 5D is a cross-sectional view of the exemplary solar module of FIG. 5D, showing a cross-sectional detail of a flexible electrical interconnect joining back surface end contacts of a plurality of supercell rows.

5C shows detail C from FIG. 5D. FIG. 5D is a cross-sectional view of the exemplary solar module of FIG. 5D, showing cross-sectional details of a flexible electrical interconnect joining the front (sun side) face end contacts of a plurality of supercell rows.

5B shows detail B from FIG. 5D. FIG. 5D is a cross-sectional view of the exemplary solar module of FIG. 5D, showing a cross-sectional detail of a flexible interconnect arranged to interconnect two supercells in a row in series.

FIG. 7 illustrates a plurality of additional examples of electrical interconnects joining the front end contacts of the supercells at the end of the supercell row, adjacent to the edge of the solar module. The example interconnects are configured to have a small footprint on the front of the module. FIG. 7 illustrates a plurality of additional examples of electrical interconnects joining the front end contacts of the supercells at the end of the supercell row, adjacent to the edge of the solar module. The example interconnects are configured to have a small footprint on the front of the module. FIG. 7 illustrates a plurality of additional examples of electrical interconnects joining the front end contacts of the supercells at the end of the supercell row, adjacent to the edge of the solar module. The example interconnects are configured to have a small footprint on the front of the module. FIG. 7 illustrates a plurality of additional examples of electrical interconnects joining the front end contacts of the supercells at the end of the supercell row, adjacent to the edge of the solar module. The example interconnects are configured to have a small footprint on the front of the module.

FIG. 4 shows a diagram of another exemplary rectangular solar module. The rectangular solar module includes six rectangular shingled supercells, each having a long side approximately the same length as the long side of the module. The supercells are arranged in six rows that are electrically connected in parallel with each other and in parallel with a bypass diode arranged in a junction box on the back of the solar module. The electrical connection between the supercell and the bypass diode is established through a ribbon embedded in the stack of the module.

FIG. 4 shows a diagram of another exemplary rectangular solar module. The rectangular solar module includes six rectangular shingled supercells, each having a long side approximately the same length as the long side of the module. The supercells are arranged in six rows that are electrically connected in parallel with one another and in parallel with bypass diodes arranged in a junction box on the backside of the solar module and near the edge of the solar module. A second junction box is located on the back side near the opposite edge of the solar module. The electrical connection between the supercell and the bypass diode is established through an external cable between the junction boxes.

1 shows a diagram of an exemplary glass-glass rectangular solar module. FIG. The rectangular solar module includes six rectangular shingled supercells, each having a long side approximately the same length as the long side of the module. The supercells are arranged in six rows that are electrically connected to each other in parallel. Two junction boxes are mounted on opposing edges of the module to maximize the active area of the module.

FIG. 9C illustrates a side view of the solar module illustrated in FIG. 9C.

4 illustrates another exemplary solar module. The solar module includes six rectangular shingled supercells each having a long side approximately the same length as the long side of the module. The supercells are arranged in six rows, with three pairs of rows individually connected to power management devices on the solar module.

4 illustrates another exemplary solar module. The solar module includes six rectangular shingled supercells each having a long side approximately the same length as the long side of the module. The supercells are arranged in six rows, with each row individually connected to a power management device on the solar module.

5 illustrates another embodiment of a module-level power management structure using a shingled supercell. 5 illustrates another embodiment of a module-level power management structure using a shingled supercell.

FIG. 5B illustrates an exemplary schematic electrical diagram of a solar module as illustrated in FIG. 5B.

10B illustrates an example physical layout of various electrical interconnects for a solar module as illustrated in FIG. 5B having the schematic circuit diagram of FIG. 10A. 10B illustrates an example physical layout of various electrical interconnects for a solar module as illustrated in FIG. 5B having the schematic circuit diagram of FIG. 10A.

FIG. 5B illustrates an exemplary schematic electrical diagram of a solar module as illustrated in FIG. 5A.

FIG. 11B illustrates an exemplary physical layout of various electrical interconnects for a solar module as illustrated in FIG. 5A having the schematic electrical diagram of FIG. 11A. FIG. 11B illustrates an exemplary physical layout of various electrical interconnects for a solar module as illustrated in FIG. 5A having the schematic electrical diagram of FIG. 11A.

11B illustrates another exemplary physical layout of various electrical interconnections for a solar module as illustrated in FIG. 5A having the schematic electrical diagram of FIG. 11A. 11B illustrates another exemplary physical layout of various electrical interconnections for a solar module as illustrated in FIG. 5A having the schematic electrical diagram of FIG. 11A.

FIG. 5B illustrates another exemplary schematic circuit diagram of the solar module as illustrated in FIG. 5A.

FIG. 12B illustrates an exemplary physical layout of various electrical interconnects for a solar module as illustrated in FIG. 5A having the schematic circuit diagram of FIG. 12A. FIG. 12B illustrates an exemplary physical layout of various electrical interconnects for a solar module as illustrated in FIG. 5A having the schematic circuit diagram of FIG. 12A.

FIG. 12B illustrates another exemplary physical layout of various electrical interconnects for a solar module as illustrated in FIG. 5A having the schematic circuit diagram of FIG. 12A. FIG. 12B illustrates another exemplary physical layout of various electrical interconnects for a solar module as illustrated in FIG. 5A having the schematic circuit diagram of FIG. 12A. FIG. 12B illustrates another exemplary physical layout of various electrical interconnects for a solar module as illustrated in FIG. 5A having the schematic circuit diagram of FIG. 12A.

FIG. 5B illustrates another exemplary schematic circuit diagram of the solar module as illustrated in FIG. 5A.

FIG. 5B illustrates another exemplary schematic circuit diagram of the solar module as illustrated in FIG. 5B.

FIG. 13B illustrates an exemplary physical layout of various electrical interconnects for a solar module as illustrated in FIG. 5A having the schematic circuit diagram of FIG. 13A. Slightly modified, the physical layout of FIGS. 13C-1 and 13C-2 is suitable for a solar module as illustrated in FIG. 5B with the schematic circuit diagram of FIG. 13B. FIG. 13B illustrates an exemplary physical layout of various electrical interconnects for a solar module as illustrated in FIG. 5A having the schematic circuit diagram of FIG. 13A. Slightly modified, the physical layout of FIGS. 13C-1 and 13C-2 is suitable for a solar module as illustrated in FIG. 5B with the schematic circuit diagram of FIG. 13B.

FIG. 4 shows a diagram of another exemplary rectangular solar module. The rectangular solar module includes a plurality of rectangular shingled supercells each having a long side approximately half the length of the short side of the module. A plurality of pairs of supercells are arranged end to end to form a plurality of rows with the long sides of the supercell parallel to the short sides of the module.

FIG. 14C illustrates an exemplary schematic circuit diagram of a solar module as illustrated in FIG. 14A.

FIG. 15 illustrates an exemplary physical layout of various electrical interconnects for a solar module as illustrated in FIG. 14A having the schematic circuit diagram of FIG. 14B. FIG. 15 illustrates an exemplary physical layout of various electrical interconnects for a solar module as illustrated in FIG. 14A having the schematic circuit diagram of FIG. 14B.

10B illustrates another exemplary physical layout of various electrical interconnections for a solar module as illustrated in FIG. 5B having the schematic circuit diagram of FIG. 10A.

Fig. 4 shows an exemplary arrangement of a smart switch interconnecting two solar modules in series.

1 shows a flowchart of an exemplary method of making a solar module with a supercell.

5 shows a flowchart of another exemplary method of making a solar module with a supercell.

1 shows an exemplary arrangement in which a supercell can be cured by heat and pressure. 1 shows an exemplary arrangement in which a supercell can be cured by heat and pressure. 1 shows an exemplary arrangement in which a supercell can be cured by heat and pressure. 1 shows an exemplary arrangement in which a supercell can be cured by heat and pressure.

1 schematically illustrates an exemplary device that may be used to cleave a scribed solar cell. The device can be particularly advantageous when used to cleave a scribed supercell to which a conductive adhesive has been applied. 1 schematically illustrates an exemplary device that may be used to cleave a scribed solar cell. The device can be particularly advantageous when used to cleave a scribed supercell to which a conductive adhesive has been applied. 1 schematically illustrates an exemplary device that may be used to cleave a scribed solar cell. The device can be particularly advantageous when used to cleave a scribed supercell to which a conductive adhesive has been applied.

In a solar module containing a plurality of parallel supercell rows, a dark line that can be used to reduce the visual contrast between the supercell and a portion of the backsheet visible from the front of the module. Figure 3 shows an exemplary white back sheet "zebra-like".

1 shows a top view of a conventional module utilizing a traditional ribbon connection in a hot spot state. FIG. 4 shows a plan view of a module utilizing thermal diffusion according to an embodiment, also in a hot spot state.

4 shows an example of a layout of a string of supercells with chamfered batteries. 4 shows an example of a layout of a string of supercells with chamfered batteries.

FIG. 4 shows a simplified cross-sectional view of an array including a plurality of modules assembled in a shingled configuration. FIG. 4 shows a simplified cross-sectional view of an array including a plurality of modules assembled in a shingled configuration.

FIG. 2 shows a view of the back (shadow) side of the module, illustrating an exemplary electrical interconnection of the front (sun side) face end electrical contacts of the shingled supercell to the junction box on the back side of the solar module. .

Exemplary electrical of two or more parallel thatched supercells with the front (sun side) face end electrical contacts of the supercell connected to each other and to a junction box on the back of the solar module FIG. 4 shows a view of the back (shadow) side of the module, illustrating the interconnections.

Another example of two or more parallel thatched supercells with the front (sun side) face end electrical contacts of the supercell connected to each other and to a junction box on the back of the solar module FIG. 3 shows a view of the back (shadow) side of the module, illustrating the various electrical interconnections.

Fragmentation of two supercells, sandwiched between overlapping ends of adjacent supercells, illustrating the use of flexible interconnects to electrically connect the supercells in series and provide electrical connection to a junction box 1 shows a cross-sectional view and a perspective view. FIG. 30 is an enlarged view of a target area in FIG. 29.

FIG. 4 illustrates an exemplary supercell with electrical interconnects bonded to front and back end contacts. FIG. 30A shows two of the supercells of FIG. 30A interconnected in parallel.

FIG. 4 illustrates a diagram of an exemplary backside metallization pattern that may be employed to form hidden taps into supercells as described herein. FIG. 4 illustrates a diagram of an exemplary backside metallization pattern that may be employed to form hidden taps into supercells as described herein. FIG. 4 illustrates a diagram of an exemplary backside metallization pattern that may be employed to form hidden taps into supercells as described herein.

FIG. 4 shows an example of the use of a hidden tap with interconnects extending over approximately the full width of the supercell. FIG. 4 illustrates an example of the use of a hidden tap with interconnects extending over approximately the full width of the supercell.

FIG. 34 shows examples of interconnects joining the supercell back (FIG. 34A) end contacts and the front (FIGS. 34B-34C) end contacts. FIG. 34 shows examples of interconnects joining the supercell back (FIG. 34A) end contacts and the front (FIGS. 34B-34C) end contacts. FIG. 34 shows examples of interconnects joining the supercell back (FIG. 34A) end contacts and the front (FIGS. 34B-34C) end contacts.

FIG. 4 illustrates an example of the use of hidden taps with short interconnects that span the gap between adjacent supercells, but do not extend substantially inward along the long axis of the rectangular solar cell. FIG. 4 illustrates an example of the use of hidden taps with short interconnects that span the gap between adjacent supercells, but do not extend substantially inward along the long axis of the rectangular solar cell.

4 illustrates an exemplary configuration of a short hidden tap interconnect including in-plane stress relief features. 4 illustrates an exemplary configuration of a short hidden tap interconnect including in-plane stress relief features. 4 illustrates an exemplary configuration of a short hidden tap interconnect including in-plane stress relief features. 4 illustrates an exemplary configuration of a short hidden tap interconnect including in-plane stress relief features. 4 illustrates an exemplary configuration of a short hidden tap interconnect including in-plane stress relief features. 4 illustrates an exemplary configuration of a short hidden tap interconnect including in-plane stress relief features. 4 illustrates an exemplary configuration of a short hidden tap interconnect including in-plane stress relief features. 4 illustrates an exemplary configuration of a short hidden tap interconnect including in-plane stress relief features. 4 illustrates an exemplary configuration of a short hidden tap interconnect including in-plane stress relief features. 4 illustrates an exemplary configuration of a short hidden tap interconnect including in-plane stress relief features. 4 illustrates an exemplary configuration of a short hidden tap interconnect including in-plane stress relief features. 4 illustrates an exemplary configuration of a short hidden tap interconnect including in-plane stress relief features. 4 illustrates an exemplary configuration of a short hidden tap interconnect including in-plane stress relief features.

4 illustrates an exemplary configuration of a short hidden tap interconnect including out-of-plane stress relief features. 4 illustrates an exemplary configuration of a short hidden tap interconnect including out-of-plane stress relief features. 4 illustrates an exemplary configuration of a short hidden tap interconnect including out-of-plane stress relief features. 4 illustrates an exemplary configuration of a short hidden tap interconnect including out-of-plane stress relief features.

4 illustrates an exemplary configuration of a short hidden tap interconnect including alignment features. 4 illustrates an exemplary configuration of a short hidden tap interconnect including alignment features. FIG. 4 illustrates an exemplary configuration of a short hidden tap interconnect including an asymmetric tab length. FIG. 4 illustrates an exemplary configuration of a short hidden tap interconnect including an asymmetric tab length.

4 shows an exemplary solar module layout employing hidden taps. 4 shows an exemplary solar module layout employing hidden taps. 4 shows an exemplary solar module layout employing hidden taps. 4 shows an exemplary solar module layout employing hidden taps. 4 shows an exemplary solar module layout employing hidden taps. 4 shows an exemplary solar module layout employing hidden taps.

FIG. 47 shows an exemplary electrical diagram of the layout of the solar module of FIGS. 40 and 42A-44B.

4 illustrates current flow in a conductive state in an exemplary solar module having a bypass diode.

FIG. 3 shows relative motion between solar module components resulting from thermal cycling in a direction parallel to the plurality of supercell rows and in a direction perpendicular to the plurality of supercell rows in the solar module, respectively. FIG. 3 shows relative motion between solar module components resulting from thermal cycling in a direction parallel to the plurality of supercell rows and in a direction perpendicular to the plurality of supercell rows in the solar module, respectively.

FIG. 3 illustrates another exemplary solar module layout employing hidden taps, and a corresponding electrical schematic, respectively. FIG. 4 shows another exemplary solar module layout employing hidden taps and the corresponding electrical schematic, respectively.

Figure 3 shows an additional solar cell module layout employing hidden taps in combination with an embedded bypass diode. Figure 3 shows an additional solar cell module layout employing hidden taps in combination with an embedded bypass diode.

1 shows a block diagram of a solar module providing a conventional DC voltage to a micro-inverter and a high voltage solar module as described herein for providing a high DC voltage to a micro-inverter, respectively. 1 shows a block diagram of a solar module providing a conventional DC voltage to a microinverter and a high voltage solar module as described herein for providing a high DC voltage to a microinverter, respectively.

1 illustrates an example physical layout and electrical schematic of an example high voltage solar module incorporating a bypass diode. 1 illustrates an example physical layout and electrical schematic of an example high voltage solar module incorporating a bypass diode.

1 illustrates an exemplary structure for module level power management of a high voltage solar module including a shingled supercell. 1 illustrates an exemplary structure for module level power management of a high voltage solar module including a shingled supercell. 1 illustrates an exemplary structure for module level power management of a high voltage solar module including a shingled supercell. 1 illustrates an exemplary structure for module level power management of a high voltage solar module including a shingled supercell. 1 illustrates an exemplary structure for module level power management of a high voltage solar module including a shingled supercell. 1 illustrates an exemplary structure for module level power management of a high voltage solar module including a shingled supercell. 1 illustrates an exemplary structure for module level power management of a high voltage solar module including a shingled supercell. 1 illustrates an exemplary structure for module level power management of a high voltage solar module including a shingled supercell. 1 illustrates an exemplary structure for module level power management of a high voltage solar module including a shingled supercell. 1 illustrates an exemplary structure for module level power management of a high voltage solar module including a shingled supercell.

FIG. 5 illustrates an exemplary arrangement of six supercells in six parallel rows, with the ends of adjacent rows offset and interconnected in series by flexible electrical interconnects.

1 schematically illustrates a photovoltaic system including a plurality of high DC voltage shingled solar cell modules electrically connected to a string inverter in parallel with each other. FIG. 57B illustrates the photovoltaic system of FIG. 57A positioned on a roof.

To prevent a high DC voltage shingled solar module with a short circuit from dissipating a significant amount of power generated by other high DC voltage shingled solar modules to which it is connected in parallel. 2 shows an arrangement of a current limiting fuse and a blocking diode that can be used for the present invention. To prevent a high DC voltage shingled solar module with a short circuit from dissipating a significant amount of power generated by other high DC voltage shingled solar modules to which it is connected in parallel. 2 shows an arrangement of a current limiting fuse and a blocking diode, which can be used for the present invention. To prevent a high DC voltage shingled solar module with a short circuit from dissipating a significant amount of power generated by other high DC voltage shingled solar modules to which it is connected in parallel. 2 shows an arrangement of a current limiting fuse and a blocking diode that can be used for the present invention. To prevent a high DC voltage shingled solar module with a short circuit from dissipating a significant amount of power generated by other high DC voltage shingled solar modules to which it is connected in parallel. 2 shows an arrangement of a current limiting fuse and a blocking diode, which can be used for the present invention.

FIG. 3 illustrates an exemplary arrangement in which two or more high DC voltage shingled solar cell modules are electrically connected in parallel within a combiner box that may include a current limiting fuse and a blocking diode. FIG. 3 illustrates an exemplary arrangement in which two or more high DC voltage shingled solar cell modules are electrically connected in parallel in a combiner box that may include a current limiting fuse and a blocking diode.

2 shows a current vs. voltage plot and a power vs. voltage plot for a plurality of high DC voltage shingled solar cell modules electrically connected in parallel, respectively. The plot in FIG. 60A is for an exemplary case where none of the modules include reverse biased solar cells. The plot in FIG. 60B is for an exemplary case where some of the modules include one or more reverse-biased solar cells. 2 shows a current vs. voltage plot and a power vs. voltage plot for a plurality of high DC voltage shingled solar cell modules electrically connected in parallel, respectively. The plot in FIG. 60A is for an exemplary case where none of the modules include reverse biased solar cells. The plot in FIG. 60B is for an exemplary case where some of the modules include one or more reverse-biased solar cells.

FIG. 4 illustrates an example of a solar module utilizing approximately one bypass diode per supercell. An example of a solar module using a nested bypass diode is illustrated. FIG. 3 illustrates an exemplary configuration of a bypass diode connecting between two neighboring supercells using a flexible electrical interconnect.

FIG. 3 schematically illustrates a side view and a top view, respectively, of another exemplary cleavage tool. FIG. 3 schematically illustrates a side view and a top view, respectively, of another exemplary cleavage tool.

3 schematically illustrates the use of an exemplary asymmetric vacuum arrangement to control nucleation and propagation of a tear along a scribe line when cleaving a wafer. FIG. 63B schematically illustrates the use of an exemplary symmetrical vacuum configuration that provides less control over the cleavage provided than the configuration of FIG. 63A.

FIG. 62 schematically illustrates a top view of a portion of an exemplary vacuum manifold that may be used in the cleaving tools of FIGS. 62A-62B.

64 provides a schematic illustration of a top view and a perspective view, respectively, of the exemplary vacuum manifold of FIG. 64 with a perforated belt lying thereon. 64 provides a schematic illustration of a top view and a perspective view, respectively, of the exemplary vacuum manifold of FIG. 64 with a perforated belt lying thereon.

FIG. 62 schematically illustrates a side view of an exemplary vacuum manifold that may be used in the cleaving tool of FIGS. 62A-62B.

1 schematically illustrates a cleaved solar cell overlying an exemplary arrangement of perforated belts and vacuum manifolds.

1 schematically illustrates the relative position and orientation of a cleaved solar cell and an uncleaved portion of a standard size wafer from which the solar cell is cleaved in an exemplary cleavage process.

1 schematically illustrates an apparatus and method that can continuously remove cleaved solar cells from a cleavage tool. 1 schematically illustrates an apparatus and method that can continuously remove cleaved solar cells from a cleavage tool. 1 schematically illustrates an apparatus and method that can continuously remove cleaved solar cells from a cleavage tool. 1 schematically illustrates an apparatus and method that can continuously remove cleaved solar cells from a cleavage tool. 1 schematically illustrates an apparatus and method that can continuously remove cleaved solar cells from a cleavage tool. 1 schematically illustrates an apparatus and method that can continuously remove cleaved solar cells from a cleavage tool. 1 schematically illustrates an apparatus and method that can continuously remove cleaved solar cells from a cleavage tool.

FIG. 63 provides orthogonal views of another variation of the exemplary cleavage tool of FIGS. 62A-62B. FIG. 63 provides orthogonal views of another variation of the exemplary cleavage tool of FIGS. 62A-62B. FIG. 63 provides orthogonal views of another variation of the exemplary cleavage tool of FIGS. 62A-62B.

FIG. 70 provides perspective views of the exemplary cleavage tool of FIGS. 70A-70C at two different steps of the cleavage process. FIG. 70 provides perspective views of the exemplary cleavage tool of FIGS. 70A-70C at two different steps of the cleavage process.

FIG. 70 illustrates details of the perforated belt and vacuum manifold of the exemplary cleavage tool of FIGS. 70A-70C. FIG. 70 illustrates details of the perforated belt and vacuum manifold of the exemplary cleavage tool of FIGS. 70A-70C. FIG. 70 illustrates details of the perforated belt and vacuum manifold of the exemplary cleavage tool of FIGS. 70A-70C. FIG. 70 illustrates details of the perforated belt and vacuum manifold of the exemplary cleavage tool of FIGS. 70A-70C. FIG. 70 illustrates details of the perforated belt and vacuum manifold of the exemplary cleavage tool of FIGS. 70A-70C. FIG. 70 illustrates details of the perforated belt and vacuum manifold of the exemplary cleavage tool of FIGS. 70A-70C.

FIG. 11 illustrates details of some example hole patterns that may be used for the perforated vacuum belt in the example cleavage tool of FIGS. 10A-10C. FIG. 11 illustrates details of some example hole patterns that may be used for the perforated vacuum belt in the example cleavage tool of FIGS. 10A-10C. FIG. 11 illustrates details of some example hole patterns that may be used for the perforated vacuum belt in the example cleavage tool of FIGS. 10A-10C. FIG. 11 illustrates details of some example hole patterns that may be used for the perforated vacuum belt in the example cleavage tool of FIGS. 10A-10C. FIG. 11 illustrates details of some example hole patterns that may be used for the perforated vacuum belt in the example cleavage tool of FIGS. 10A-10C. FIG. 11 illustrates details of some example hole patterns that may be used for the perforated vacuum belt in the example cleavage tool of FIGS. 10A-10C. FIG. 11 illustrates details of some example hole patterns that may be used for the perforated vacuum belt in the example cleavage tool of FIGS. 10A-10C.

4 shows an exemplary front metallization pattern on a rectangular solar cell.

4 illustrates an exemplary backside metallization pattern on a rectangular solar cell. 4 illustrates an exemplary backside metallization pattern on a rectangular solar cell.

FIG. 79 illustrates an exemplary front metallization pattern on a square solar cell that may be diced to form a plurality of rectangular solar cells each having the front metallization pattern shown in FIG. 76.

FIG. 77B illustrates an exemplary backside metallization pattern on a square solar cell that may be diced to form a plurality of rectangular solar cells each having the backside metallization pattern shown in FIG. 77A.

FIG. 4 is a schematic diagram showing that a conventional sized HIT solar cell is diced into narrow strip solar cells using a conventional cleavage method, resulting in a cleavage edge that promotes carrier recombination.

1 schematically illustrates steps of an exemplary method of dicing a conventional sized HIT solar cell into a narrow solar cell strip having no cleavage edges to facilitate carrier recombination. 1 schematically illustrates steps of an exemplary method of dicing a conventional sized HIT solar cell into a narrow solar cell strip having no cleavage edges to facilitate carrier recombination. 1 schematically illustrates steps of an exemplary method of dicing a conventional sized HIT solar cell into a narrow solar cell strip having no cleavage edges to facilitate carrier recombination. 1 schematically illustrates steps of an exemplary method of dicing a conventional sized HIT solar cell into a narrow solar cell strip having no cleavage edges to facilitate carrier recombination. 1 schematically illustrates steps of an exemplary method of dicing a conventional sized HIT solar cell into a narrow solar cell strip having no cleavage edges to facilitate carrier recombination. 1 schematically illustrates steps of an exemplary method of dicing a conventional sized HIT solar cell into a narrow solar cell strip having no cleavage edges to facilitate carrier recombination. 1 schematically illustrates steps of an exemplary method of dicing a conventional sized HIT solar cell into a narrow solar cell strip having no cleavage edges to facilitate carrier recombination. 1 schematically illustrates steps of an exemplary method of dicing a conventional sized HIT solar cell into a narrow solar cell strip having no cleavage edges to facilitate carrier recombination. 1 schematically illustrates steps of an exemplary method of dicing a conventional sized HIT solar cell into a narrow solar cell strip having no cleavage edges to facilitate carrier recombination. 1 schematically illustrates steps of an exemplary method of dicing a conventional sized HIT solar cell into a narrow solar cell strip having no cleavage edges to facilitate carrier recombination.

2 schematically illustrates steps of another exemplary method of dicing a conventional sized HIT solar cell into a narrow solar cell strip without cleavage edges that promote carrier recombination. 2 schematically illustrates steps of another exemplary method of dicing a conventional sized HIT solar cell into a narrow solar cell strip without cleavage edges that promote carrier recombination. 2 schematically illustrates steps of another exemplary method of dicing a conventional sized HIT solar cell into a narrow solar cell strip without cleavage edges that promote carrier recombination. 2 schematically illustrates steps of another exemplary method of dicing a conventional sized HIT solar cell into a narrow solar cell strip without cleavage edges that promote carrier recombination. 2 schematically illustrates steps of another exemplary method of dicing a conventional sized HIT solar cell into a narrow solar cell strip without cleavage edges that promote carrier recombination. 2 schematically illustrates steps of another exemplary method of dicing a conventional sized HIT solar cell into a narrow solar cell strip without cleavage edges that promote carrier recombination. 2 schematically illustrates steps of another exemplary method of dicing a conventional sized HIT solar cell into a narrow solar cell strip without cleavage edges that promote carrier recombination. 2 schematically illustrates steps of another exemplary method of dicing a conventional sized HIT solar cell into a narrow solar cell strip without cleavage edges that promote carrier recombination. 2 schematically illustrates steps of another exemplary method of dicing a conventional sized HIT solar cell into a narrow solar cell strip without cleavage edges that promote carrier recombination. 2 schematically illustrates steps of another exemplary method of dicing a conventional sized HIT solar cell into a narrow solar cell strip without cleavage edges that promote carrier recombination.

  DETAILED DESCRIPTION The following detailed description should be read with reference to the drawings, wherein like reference numerals refer to like elements throughout the different figures. The drawings, which are not necessarily drawn to scale, depict selected embodiments and are not intended to limit the scope of the invention. The detailed description illustrates by way of example, not by way of limitation, the principles of the invention. Obviously, the present description will enable one of ordinary skill in the art to make and use the invention, which is set forth in the best mode for practicing the invention and includes several embodiments of the invention, including those presently contemplated. Adaptations, variations, alternatives, and uses are described.

  As used in this specification and the appended claims, the singular forms "a," "an," and "the" include plural referents unless the content clearly indicates otherwise. Also, the term "parallel" means "parallel or substantially parallel", and requires that any parallel arrangement described herein be exactly parallel. Rather, it is intended to encompass any deviations from geometry that are parallel. The term "vertical" means "perpendicular or substantially vertical" and requires that any vertical arrangement described herein be exactly vertical. Rather, it is intended to encompass some deviation from geometry that is vertical. The term "square" means "square or approximately square" and may deviate slightly from the square shape, for example, beveled (e.g., rounded or otherwise edged) It is intended to encompass shapes that are substantially square with corners (cut off). The term “rectangular” means “rectangular or substantially rectangular” and may deviate slightly from the rectangular shape, eg, beveled (eg, rounded or otherwise edged) It is intended to encompass shapes that are substantially rectangular, including corners.

  This specification discloses a highly efficient shingled arrangement of silicon solar cells in a solar cell module, and front and back metallization patterns and interconnects for solar cells that can be used in such an arrangement. I do. The present specification also discloses a method for manufacturing such a solar module. Photovoltaic modules can be advantageously employed under "one sun" (defocused) illumination, allowing them to be used in place of conventional silicon photovoltaic modules with physical dimensions and electrical Characteristic.

  FIG. 1 shows a cross-sectional view of a string of series-connected solar cells 10 arranged in a shingle-like configuration, with the ends of adjacent solar cells overlapping and electrically connected to form a supercell 100. Each solar cell 10 includes a semiconductor diode structure and a plurality of electrical contacts to the semiconductor diode structure. Thereby, the current generated in the solar cell 10 when the solar cell 10 is irradiated with light can be provided to an external load.

  In the example described herein, each solar cell 10 is a crystalline silicon having a front (sun side) and a back (shadow side) metallization pattern that provides electrical contact on opposing sides of the np junction. In a solar cell, a front metallization pattern is disposed on an n-type conductive semiconductor layer, and a rear metallization pattern is disposed on a p-type conductive semiconductor layer. However, instead of, or in addition to, the solar cells 10 in the solar modules described herein, any other suitable material systems, diode structures, physical dimensions, or any other electrical contact arrangements may be employed. Any suitable solar cell may be used. For example, the front (sun side) metallization pattern may be disposed on a p-type conductive semiconductor layer, and the back (shadow side) metallization pattern may be disposed on an n-type conductive semiconductor layer.

  Referring again to FIG. 1, in the supercell 100, adjacent solar cells 10 electrically connect the front metallization pattern of one solar cell to the back metallization pattern of an adjacent solar cell in the area where they overlap. Conductive bonding is performed by an electrically conductive bonding agent. Suitable electrically conductive bonding agents may include, for example, electrically conductive adhesives, electrically conductive adhesive films and tapes, and conventional solders. Preferably, the electrically conductive bonding agent has a mechanical compliance that accommodates stresses resulting from a mismatch between the coefficient of thermal expansion (CTE) of the electrically conductive bonding agent and the CTE of the solar cell (eg, the CTE of silicon). At the junction between adjacent solar cells. In order to provide such mechanical compliance, in some variations, the electrically conductive bonding agent is selected to have a glass transition temperature less than or equal to about 0 ° C. To further reduce and accommodate the stress in the direction parallel to the overlapping edges of the solar cells resulting from the CTE mismatch, the electrically conductive bonding agent is optionally provided with a substantially edge length of the solar cell. Rather than in a solid line extending over a plurality of discrete locations along the overlapping area of the solar cell.

  The thickness of the conductive junction formed by the electrically conductive bonding agent between adjacent overlapping solar cells, as measured in a direction perpendicular to the front and back surfaces of the solar cells, can be, for example, less than about 0.1 mm. Such a thin junction reduces ohmic losses in the interconnection between cells and also promotes the flow of heat along the supercell from any hotspots in the supercell that may appear during operation. . The thermal conductivity of the junction between the solar cells can be, for example, ≧ about 1.5 watts / (meter K).

  FIG. 2A shows the front side of an exemplary rectangular solar cell 10 that can be used in supercell 100. Other shapes can be used for the solar cell 10 as appropriate. In the illustrated example, the front metallization pattern of the solar cell 10 is positioned adjacent one of the long sides of the solar cell 10 and substantially parallel to the long side over the length of the long side. And a plurality of fingers 20 mounted in a direction perpendicular to the bus bar and extending substantially parallel to the short sides of the solar cell 10 and extending parallel to the short sides.

  In the example of FIG. 2A, the solar cell 10 has a length of about 156 mm and a width of about 26 mm, and therefore has an aspect ratio (short side length / long side length) of about 1: 6. is there. Six such solar cells can be provided on a standard 156 mm x 156 mm silicon wafer and then separated (diced) to provide a plurality of solar cells as shown. In another variation, eight solar cells 10 with dimensions of about 19.5 mm x 156 mm, and thus an aspect ratio of about 1: 8, can be prepared from a standard silicon wafer. More generally, the solar cell 10 can have an aspect ratio, for example, from about 1: 2 to about 1:20, and can be provided from a standard size wafer or from any other suitable sized wafer.

  FIG. 3A illustrates an exemplary pseudo-square silicon solar cell wafer 45 of standard size and shape that may be cut, broken, or otherwise split to form a plurality of rectangular solar cells as just described. Here's how. In this example, some full width rectangular solar cells 10L are cut from the center portion of the wafer, and in addition, some shorter rectangular solar cells 10S are cut from the edge of the wafer and the wafer is chamfered. Cut or rounded corners are discarded. Solar cell 10L can be used to form a single width shingled supercell, and solar cell 10S can be used to form a narrower shingled supercell.

  Alternatively, chamfered (eg, rounded) corners may be left on solar cells cut from the edge of the wafer. 2B and 2C show the front side of an exemplary "chevron" rectangular solar cell 10, substantially similar to that of FIG. 2A, but including the chamfered corners left from the wafer from which the solar cell was cut. . In FIG. 2B, the bus bar 15 is positioned adjacent to the shorter of the two long sides, extends substantially parallel to the same length over the length of the same side, and at least partially at both ends. , Extending around the chamfered corner of the solar cell. In FIG. 2C, the bus bar 15 is positioned adjacent to the longer one of the two long sides, and extends substantially the length of the same side in parallel with the same side. 3B and 3C show a plurality of solar cells 10 diced along the dashed line shown in FIG. 3C and having a front metallization pattern similar to that shown in FIG. 2A, and a front metallization similar to that shown in FIG. 2B. FIG. 3 shows a front view and a back view of a pseudo-square wafer 45 that can provide two chamfered solar cells 10 with a pattern.

  In the exemplary front metallization pattern shown in FIG. 2B, the two ends of the bus bar 15, extending around the chamfered corner of the battery, are each located adjacent the long side of the battery. It may have a width that gradually decreases (slows) as the distance from the portion increases. Similarly, in the exemplary front metallization pattern shown in FIG. 3B, the two ends of the thin conductor interconnecting the discontinuous contact pads 15 extend around the chamfered corners of the solar cell, As the distance from the long side of the solar cell, where the contact pads are arranged along, becomes smaller gradually. Such gradual width reduction is optional, but can advantageously reduce metal use and reduce shadowing of the active area of the solar cell without substantially increasing resistive losses .

  FIGS. 3D and 3E show a front view of a complete square wafer 47 that can be diced along the dashed line shown in FIG. 3E to provide a plurality of solar cells 10 having a front metallization pattern similar to that shown in FIG. 2A. FIG.

  Chamfered rectangular solar cells can be used to form supercells that include only chamfered solar cells. Additionally or alternatively, one or more such chamfered rectangular solar cells can be combined with one or more non-chamfered rectangular solar cells (eg, FIG. 2A) to form a supercell. Can be used. For example, the solar cell at the end of the supercell can be a chamfered solar cell, and the middle solar cell can be a non-chamfered solar cell. If a chamfered solar cell is used in combination with a non-chamfered solar cell in a supercell or, more generally, in a solar module, the resulting chamfered solar cell and the chamfered solar cell are used. It may be desirable to use solar cell dimensions such that no solar cell has the same area of the front surface exposed to light during operation of the solar cell. By matching the areas of the solar cells in this manner, the currents generated by the beveled and unchamfered solar cells are matched, which indicates that the Improve the performance of a series connected string containing both batteries. The area of the chamfered solar cells cut from the same pseudo-square wafer and the area of the non-chamfered solar cells are adjusted, for example, by adjusting the position of the line along which the dicing of the wafer is performed. Can be matched by making the width in the direction perpendicular to the long axis of the solar cell slightly wider than the unchamfered solar cell to compensate for missing corners on the chamfered solar cell.

  A solar module may include only supercells formed exclusively from unchamfered rectangular solar cells, or may include only supercells formed from chamfered rectangular solar cells, or a beveled solar cell. It may include only cells and supercells including unchamfered solar cells, or may include any combination of these three variations of supercells.

  In some instances, a portion of a standard size square or pseudo-square solar cell wafer (eg, wafer 45 or wafer 47) near the edges of the wafer is less than a portion of the wafer located away from those edges. It can convert light to electricity with low efficiency. To improve the efficiency of the resulting rectangular solar cell, in some variations, one or more edges of the wafer are trimmed to remove low efficiency portions before the wafer is diced. The portion that is trimmed from the edge of the wafer can be, for example, about 1 mm to about 5 mm in width. Further, as shown in FIGS. 3B and 3D, the two-end solar cells 10 to be diced from the wafer have their front busbars (or discontinuous contact pads) 15 along their outer edges. Therefore, it can be oriented along two of the edges of the wafer. In the supercell disclosed herein, the bus bars (or discontinuous contact pads) 15 typically have low light along their two edges of the wafer as adjacent solar cells overlap. Conversion efficiency typically does not affect the performance of the solar cell. As a result, in some variations, the edges of a square or pseudo-square wafer oriented parallel to the short sides of the rectangular solar cell are trimmed as just described, but parallel to the long sides of the rectangular solar cell. Is not trimmed. In other variations, one, two, three, or four edges of a square wafer (eg, wafer 47 of FIG. 3D) are trimmed as just described. In other variations, one, two, three, or four of the long edges of the pseudo-square wafer are trimmed as just described.

As shown, a solar cell having a long, narrow aspect ratio and an area smaller than the area of a standard 156 mm × 156 mm solar cell is the I ² in the solar cell module disclosed herein. It can be advantageously employed to reduce R resistance power loss. In particular, the reduced area of the solar cell 10 as compared to a standard size silicon solar cell reduces the current generated by the solar cell, and within that solar cell and within the series-connected strings of such solar cells. Directly reduce the resistive power loss. In addition, by arranging such a rectangular solar cell in the supercell such that the current passes through the supercell 100 parallel to the short sides of the solar cell, the current can be applied to reach the front metallization pattern fingers 20. The distance that must flow through the material may be reduced and the required finger length may be reduced, which may also reduce resistive power losses.

  As mentioned above, joining overlapping solar cells 10 together in the overlapping area and electrically connecting the overlapping solar cells in series is compared to a conventional tabbed, series-connected string of solar cells. To reduce the length of the electrical connection between adjacent solar cells. This also reduces resistive power losses.

  Referring back to FIG. 2A, in the illustrated example, the front metallization pattern on the solar cell 10 includes an optional bypass conductor 40 that extends parallel to and away from the busbar 15. (Such a bypass conductor may optionally be used in the metallization patterns shown in FIGS. 2B-2C, 3B and 3D, and is also shown in FIG. 2Q in combination with discontinuous contact pads 15 rather than continuous bus bars. The bypass conductor 40 interconnects the fingers 20 and electrically bypasses the tear that may be formed between the bus bar 15 and the bypass conductor 40. Such a rip that may cut the finger 20 at a location near the busbar 15 may otherwise separate the area of the solar cell 10 from the busbar 15. Bypass conductors provide an alternative electrical path between such cut fingers and busbars. The illustrated example shows a bypass conductor 40 positioned parallel to the bus bar 15 and extending approximately the entire length of the bus bar and interconnecting any fingers 20. This arrangement may be preferred, but not required. When present, the bypass conductor need not extend parallel to the busbar and need not extend the entire length of the busbar. Further, the bypass conductor interconnects at least two fingers, but not all fingers. For example, two or more short bypass conductors may be used instead of longer bypass conductors. Any suitable arrangement of bypass conductors can be used. The use of such bypass conductors is described in US Patent Application No. 13 / 371,790, filed February 13, 2012, entitled "Solar Cell With Metallization Compensating For Or Preventing Cracking". It is described in detail. This patent application is incorporated herein by reference in its entirety.

  The exemplary front metallization pattern of FIG. 2A also includes an optional end conductor 42 that interconnects the fingers 20 at the far end of the finger 20 opposite the bus bar 15. (Such end conductors may optionally be used in the metallization patterns shown in FIGS. 2B-2C, 3B and 3D and 2Q.) The width of the conductor 42 may be approximately the same as the width of the finger 20, for example. The conductors 42 interconnect the fingers 20 to electrically bypass the tears that may be formed between the bypass conductor 40 and the conductors 42, such that in other cases such tears may cause electrical rupture. It provides a current path to the bus bar 15 for areas of the solar cell 10 that may be separated.

  Some of the illustrated examples show the front bus bar 15 having a uniform width and extending substantially the length of the long side of the solar cell 10, but this is not required. For example, as mentioned above, the front busbars 15 can be arranged two or more, for example, as shown in FIGS. 2H, 2Q and 3B, which can be placed next to one another along the sides of the solar cell 10, for example. It can be replaced with a contact pad 15 discontinuous on the front surface. Such discontinuous contact pads may optionally be interconnected by thinner conductors extending between them, for example, as shown in the drawings just mentioned. In such a variation, the width of the contact pad, measured in a direction perpendicular to the long sides of the solar cell, can be, for example, about 2 to about 20 times the width of the thin conductor interconnecting the contact pads. There may be a separate (eg, small) contact pad for each finger in the front metallization pattern, or each contact pad may connect to two or more fingers. The front contact pad 15 can be, for example, square or have an elongated rectangular shape parallel to the edge of the solar cell. The front contact pad 15 may have a width in a direction perpendicular to the long side of the solar cell, for example, about 1 mm to about 1.5 mm, and a length in a direction parallel to the long side of the solar cell, for example, It can be from about 1 mm to about 10 mm. The spacing between contact pads 15, measured in a direction parallel to the long side of the solar cell, can be, for example, from about 3 mm to about 30 mm.

  Alternatively, solar cell 10 may not have both front bus bars 15 and discontinuous front contact pads 15 and may include only fingers 20 in the front metallization pattern. In such a variant, the current collecting function that would otherwise be performed by the front bus bar 15 or the contact pad 15 is instead replaced by joining the two solar cells 10 together in the overlapping configuration described above. May be implemented or partially implemented by the conductive material used for

  A solar cell having neither the bus bar 15 nor the contact pad 15 may include the bypass conductor 40 or may not include the bypass conductor 40. If the bus bar 15 and the contact pad 15 are not present, the bypass conductor 40 is arranged to bypass the tear formed between the bypass conductor and the portion of the front metallization pattern that is conductively joined to the overlying solar cell. Can be done.

  A front metallization pattern including busbars or discontinuous contact pads 15, fingers 20, bypass conductors 40 (if present), and end conductors 42 (if present) can be used, for example, for such purposes. It is formed from conventionally used silver paste and can be deposited, for example, by conventional screen printing methods. Alternatively, the front metallization pattern can be formed from electroplated copper. Any other suitable materials and processes may be used. In a variation where the front metallization pattern is formed from silver, the amount of silver on the solar cell can be reduced by using discontinuous front contact pads 15 instead of continuous bus bars 15 along the edges of the cell. And this can advantageously reduce costs. In variants where the front metallization pattern is formed from copper or other conductors less expensive than silver, a continuous bus 15 can be employed without cost penalties.

  2D to 2G, 3C and 3E show exemplary backside metallization patterns for solar cells. In these examples, the backside metallization pattern covers substantially all of the discontinuous backside contact pads 25 disposed along one of the long edges of the backside of the solar cell and the remaining backside of the solar cell. And a metal contact portion 30. In the shingled supercell, the contact pad 25 is connected to, for example, a bus bar located along the edge of the top surface of an adjacent, overlapping solar cell, or joined to a discontinuous contact pad by two solar cells. Connect the batteries in series. For example, each discontinuous back contact pad 25 is aligned with a corresponding discontinuous front contact pad 15 on the front side of the overlapping solar cell, and with an electrically conductive bonding agent applied only to the discontinuous contact pad. Can join. The discontinuous contact pads 25 can be, for example, square (FIG. 2D) or have an elongated rectangular shape parallel to the edges of the solar cell (FIGS. 2E-2G, 3C, 3E). The contact pad 25 may have a width in a direction perpendicular to the long side of the solar cell, for example, about 1 mm to about 5 mm, and a length in a direction parallel to the long side of the solar cell, for example, from about 1 mm. It can be about 10 mm. The spacing between contact pads 25, measured in a direction parallel to the long side of the solar cell, can be, for example, from about 3 mm to about 30 mm.

  The contacts 30 may be formed, for example, from aluminum and / or electroplated copper. The formation of the aluminum back contact 30 typically provides a back field that reduces back recombination in the solar cell, thereby improving solar cell efficiency. If the contacts 30 are formed from copper instead of aluminum, the contacts 30 may be used in combination with other passivation schemes (eg, aluminum oxide), as well to reduce back surface recombination. The discontinuous contact pads 25 can be formed, for example, from a silver paste. By using discontinuous silver contact pads 25 along the edges of the cell instead of continuous silver contact pads, the amount of silver in the backside metallization pattern is reduced, which has a cost advantage. Can be reduced.

  In addition, if the solar cell relies on the back surface field created by the formation of aluminum contacts to reduce back surface recombination, it will use discontinuous silver contacts instead of continuous silver contacts. By doing so, the solar cell efficiency can be improved. This is because the silver backside contact does not provide a backside field and therefore tends to promote carrier recombination and create a dead volume in the solar cell above the silver contact. Conventionally stringed solar strings with ribbon tabs, their dead volume is typically shadowed by the ribbon and / or busbar on the front of the solar cell, and thus did not result in any additional efficiency loss. . However, within the solar cells and supercells disclosed herein, the volume of the solar cell, above the silver contact pad 25 on the back surface, is typically not shadowed by any front metallization, and the silver back surface Any dead volume resulting from the use of metallization reduces the efficiency of the battery. Therefore, by using a discontinuous silver contact pad 25 instead of a continuous silver contact pad along the back edge of the solar cell, the volume of any corresponding dead zone is reduced and the efficiency of the solar cell is reduced. Increase.

  In a variation that does not rely on the backside field to reduce backside recombination, the backside metallization pattern extends along the length of the solar cell rather than the discontinuous contact pads 25, for example, as shown in FIG. 2Q. A continuous bus bar 25 may be employed. Such a bus bar 25 may be formed, for example, from tin or silver.

  Another variation of the backside metallization pattern may employ discontinuous tin contact pads 25. Variations of the backside metallization pattern may employ finger contacts similar to those shown in the front side metallization pattern of FIGS. 2A-2C, and may not have contact pads and busbars.

  Although the particular exemplary solar cells shown in the figures are described as having a particular combination of front and back metallization patterns, more generally, any suitable combination of front and back metallization patterns may be used. Can be used. For example, one suitable combination is a silver front metallization pattern that includes discontinuous contact pads 15, fingers 20, and optional bypass conductors 40, and an aluminum contact 30 that is discontinuous. A backside metallization pattern including silver contact pads 25 may be employed. Other suitable combinations include a copper front metallization pattern including a continuous bus bar 15, fingers 20, and optional bypass conductors 40, and a continuous bus bar 25 and copper contacts 30. A backside metallization pattern may be employed.

  In the supercell manufacturing process (described in more detail below), the electrically conductive bonding agent used to join adjacent and overlapping solar cells in the supercell is at the front or back edge of the solar cell (not It may be distributed only on the (continuous or continuous) contact pads and not on the peripheral part of the solar cell. This reduces the use of materials and, as explained above, may reduce or adapt to the stress resulting from the CTE mismatch between the electrically conductive bonding agent and the solar cell. However, during or after deposition, and before curing, a portion of the electrically conductive bonding agent can tend to spread beyond the contact pads and onto the peripheral portion of the solar cell. For example, the binding resin portion of the electrically conductive bonding agent may move away from the contact pads and be pulled by capillary forces onto a plurality of adjacent portions of the solar cell surface that have many rough or small holes. In addition, during the deposition process, some of the conductive bonding agent may fall off the contact pads, and instead is deposited on multiple adjacent portions of the solar cell surface, and possibly spread from there. It may be lost. This spreading of the conductive binder and / or incorrect deposition may weaken the bond between the overlapping solar cells, causing the conductive binder to spread over or become mis-deposited. May damage the department. Such spreading of the electrically conductive adhesive is reduced, for example, by metallization patterns that form dams or barriers near or around each contact pad to keep the electrically conductive adhesive substantially in place. Or may be prevented.

  As shown in FIGS. 2H-2K, for example, the front metallization pattern acts as a dam where each barrier 17 surrounds a corresponding discontinuous contact pad 15 and forms a moat between the contact pad and the barrier. The state may include a contact pad 15, a finger 20, and a barrier 17. Portions 19 of the uncured conductive adhesive 18 that flow away from the contact pads or dislodge from the contact pads when dispensed onto the solar cells can be enclosed in the moat by barriers 17. This further prevents the conductive adhesive bond from spreading from the contact pads onto the periphery of the cell. Barrier 17 may be formed, for example, from the same material as finger 20 and contact pad 15 (eg, silver), for example, may be about 10 microns to about 40 microns in height, for example, about 30 microns to about 30 microns in width. It can be about 100 microns. The moat formed between the barrier 17 and the contact pad 15 can be, for example, about 100 microns to about 2 mm wide. The illustrated example includes only a single barrier 17 around each front contact pad 15, but in other variations, two or more such barriers may be provided around each contact pad 15, for example. Can be positioned concentrically. The front contact pad and its surrounding barrier barrier (s) may, for example, form a shape similar to a “bullseye” target. As shown in FIG. 2H, for example, the barrier 17 may interconnect with the fingers 20 and the thin conductors that interconnect the contact pads 15.

  Similarly, as shown in FIGS. 2L-2N, for example, the backside metallization pattern covers substantially all of the discontinuous backside contact pads 25 (eg, silver) and the remaining backside of the solar cell (eg, , Aluminium) and barriers (eg, silver) each surrounding a corresponding back contact pad 25 and acting as a dam forming a moat between the contact pad and itself. obtain. As shown, a portion of the contact 30 may fill the moat. Portions of the uncured conductive adhesive that flow away from the contact pads 25 or dislodge from the contact pads when dispensed onto the solar cells can be enclosed in the moat by the barrier 27. This further prevents the conductive adhesive bond from spreading from the contact pads onto the periphery of the cell. Barrier 27 may be, for example, about 10 microns to about 40 microns in height, for example, about 50 microns to about 500 microns in width. The moat formed between the barrier 27 and the contact pad 25 can be, for example, about 100 microns to about 2 mm wide. Although the illustrated example includes only a single barrier 27 around each back contact pad 25, in other variations, two or more such barriers may be provided around each contact pad, for example. Can be positioned concentrically. The back contact pad and its surrounding barrier barrier (s) may, for example, form a shape similar to a “bullseye” target.

  A continuous bus bar or contact pad extending substantially the length of the edge of the solar cell may also be surrounded by a barrier that prevents the spread of the conductive adhesive. For example, FIG. 2Q shows such a barrier 27 surrounding the back busbar 25. The front busbar (eg, busbar 15 of FIG. 2A) may be similarly surrounded by a barrier. Similarly, rows of multiple front or back contact pads may be surrounded by such barriers rather than individually by separate barriers.

  As just described, rather than surrounding the bus bar or one or more contact pads, the front metallization pattern or the back metallization pattern feature allows the bus bar or contact pad to be positioned between the barrier and the overlapping edge of the solar cell. When formed, a barrier may be formed that extends substantially the length of the solar cell in a direction parallel to the edge of the solar cell. Such a barrier may serve two purposes as a bypass conductor (described above). For example, in FIG. 2R, bypass conductor 40 provides a barrier that helps prevent uncured conductive adhesive on contact pad 15 from spreading over the active area of the front surface of the solar cell. A similar arrangement can be used for the backside metallization pattern.

  The barrier to the spread of the conductive adhesive may be moat away from the contact pads or busbars, just as just described, but this is not required. Such a barrier may alternatively abut a contact pad or bus bar, for example, as shown in FIG. 2O or 2P. In such a variant, the barrier is preferably higher than the contact pads or busbars, keeping the uncured conductive adhesive on the contact pads or busbars. While FIGS. 2O and 2P show a portion of the front metallization pattern, a similar arrangement may be used for the back metallization pattern.

  A barrier to the spread of the conductive adhesive, and / or a moat between such a barrier and a contact pad or a busbar, and any conductive adhesive bonding that extends into such a moat is optionally super Adjacent solar cells in the cell may lie within an overlapping area of the solar cell surface, and thus may be hidden from view and shielded from exposure to solar radiation.

  Alternatively, or in addition to using a barrier as just described, the electrically conductive bonding agent can be deposited using a mask or by any other suitable method (eg, screen printing) It may require a smaller amount of electrically conductive bonding agent, which allows for less deposition, and thus less likely to spread beyond the contact pad or come off the contact pad during deposition.

  More generally, solar cell 10 may employ any suitable front and back metallization pattern.

  FIG. 4A shows a portion of the front surface of an exemplary rectangular supercell 100 including a solar cell 10 as shown in FIG. 2A, arranged in a shingle configuration as shown in FIG. As a result of the shingled geometry, there is no physical gap between pairs of solar cells 10. In addition, while the bus bar 15 of the solar cell 10 at one end of the supercell 100 is visible, the bus bars (or front contact pads) of other solar cells are hidden below the overlapping portions of adjacent solar cells. As a result, the supercell 100 efficiently uses its own area in the solar module. In particular, a larger portion of the area, compared to conventional tabbed solar cell arrangements and solar cell arrangements that include a number of visible bus bars on the illuminated surface of the solar cell, dissipates electricity. Can be used to generate. 4B-4C show front and back views, respectively, of another exemplary supercell 100 that includes a plurality of predominantly chamfered rectangular silicon solar cells, but is otherwise similar to that of FIG. 4A. Is shown.

  In the example illustrated in FIG. 4A, the bypass conductor 40 is hidden in an overlapping portion of an adjacent battery. Alternatively, the solar cells including the bypass conductors 40 may overlap as shown in FIG. 4A without covering the bypass conductors.

  The exposed front busbar 15 at one end of the supercell 100 and the backside metallization of the solar cell at the other end of the supercell 100 can be connected to other supercells and / or other electrical components as desired. Provide the supercell with (terminal) end contacts of the negative and positive electrodes that can be used to electrically connect 100.

  Adjacent solar cells in supercell 100 may overlap by any suitable amount, for example, from about 1 millimeter (mm) to about 5 mm.

  As shown in FIGS. 5A-5G, for example, a shingled supercell as just described can efficiently fill the area of a solar module. Such a solar module can be, for example, square or rectangular. A rectangular solar module as illustrated in FIGS. 5A-5G has a short side that is, for example, about 1 meter in length, and a long side that is, for example, about 1.5 to about 2.0 meters in length. I can do it. Any other suitable shape and size for the solar module may be used. Any suitable arrangement of supercells in a solar module can be used.

  Within a square or rectangular solar module, supercells are typically arranged in rows parallel to the short or long sides of the solar module. Each row may include one, two, or more supercells arranged end-to-end. The supercell 100 forming part of such a solar module may include any suitable number of solar cells 10 and may be of any suitable length. In some variations, the supercells 100 each have a length approximately equal to the length of the short side of the rectangular solar module of which they are a part. In another variation, the supercells 100 each have a length approximately equal to half the length of the short side of the rectangular solar module of which they are a part. In another variation, the supercells 100 each have a length approximately equal to the length of the long side of the rectangular solar module of which they are a part. In another variation, the supercells 100 each have a length approximately equal to half the length of the long sides of the rectangular solar module of which they are a part. The number of solar cells required to make a supercell of these lengths will, of course, depend on the size of the solar modules, the size of the solar cells, and the amount of overlapping adjacent solar cells. Any other suitable length may be used for the supercell.

  In a variant in which the length of the supercell 100 is approximately equal to the length of the short side of the rectangular solar module, the supercell has, for example, 56 rectangular solar cells having dimensions of about 19.5 millimeters (mm) x about 156 mm. The cells may include adjacent solar cells overlapping by about 3 mm. Eight such rectangular solar cells can be separated from a conventional square or pseudo-square 156 mm wafer. Alternatively, such a supercell may include, for example, 38 rectangular solar cells having dimensions of about 26 mm x about 156 mm with adjacent solar cells overlapping by about 2 mm. Six such rectangular solar cells can be separated from a conventional square or pseudo-square 156 mm wafer. In a variation where the length of the supercell 100 is approximately equal to half the length of the short side of the rectangular solar module, the supercell has, for example, twenty-eight (19.5) mm and dimensions of about 156 mm. A rectangular solar cell may be comprised of adjacent solar cells overlapping by about 3 mm. Alternatively, such a supercell may include, for example, 19 rectangular solar cells having dimensions of about 26 mm × about 156 mm, with adjacent solar cells overlapping by about 2 mm.

  In a variation in which the length of the supercell 100 is approximately equal to the length of the long side of the rectangular solar module, the supercell may, for example, include 72 rectangular solar cells having dimensions of about 26 millimeters (mm) x about 156 mm. , Adjacent solar cells may overlap by about 2 mm. In a variant in which the length of the supercell 100 is approximately equal to half the length of the long side of the rectangular solar module, the supercell adjoins 36 rectangular solar cells having dimensions of, for example, about 26 mm x about 156 mm. Interlocking solar cells may be included in an overlapping state for about 2 mm.

  FIG. 5A shows an exemplary rectangular solar module 200 that includes twenty rectangular supercells 100 each having a length approximately equal to half the length of the short side of the solar module. The supercells are arranged in pairs and end-to-end so that ten supercell rows are oriented with their rows and the long side of the supercell parallel to the short side of the solar module. It is formed in a state where it is set. In another variation, each supercell row may include three or more supercells. Also, similarly configured solar modules may include more or fewer supercell rows than shown in this example. (For example, FIG. 14A shows a solar module that includes 24 rectangular supercells, each arranged in 12 rows of two supercells.)

  In a variation where the supercells 100 in each row are arranged such that at least one of the supercells in each row has a front end contact on the edge of a supercell adjacent to other supercells in the row, FIG. 5A The gap 210 shown in FIG. 1 facilitates electrical contact with the front end contacts of the supercell (eg, exposed busbars or discontinuous contacts 15) along the centerline of the solar module. For example, two supercells in a row, one supercell has a front end contact along the centerline of the solar module and the other supercell has a back end contact along the centerline of the solar module. It can be arranged in a state where it is set. In such an arrangement, the two supercells in a row join the front end contact of one supercell and the back end contact of the other supercell, located along the centerline of the solar module. An electrical connection may be made in series by an interconnect. (See, for example, FIG. 8C described below.) In variations where each supercell row includes three or more supercells, there may be additional gaps between the supercells, as well as the solar module. Electrical contact with the front end contact located away from the side may be facilitated.

  FIG. 5B shows an exemplary rectangular solar module 300 that includes ten rectangular supercells 100 each having a length approximately equal to the length of the short side of the solar module. The supercells are arranged as ten parallel rows, with the long side oriented parallel to the short side of the module. A similarly configured solar module may include more or less rows of supercells of such a side length than shown in this example.

  FIG. 5B also shows how the solar module 200 of FIG. 5A would look if there were no gaps between adjacent supercells in multiple supercell rows within the solar module 200. The gap 210 in FIG. 5A can be removed, for example, by arranging the supercells such that both supercells in each row have a back end contact along the centerline of the module. In this case, since there is no need to approach the front of the supercell along the center of the module, the supercells can be placed substantially abutting each other with little or no additional gap between them. Alternatively, the two supercells 100 in a row may have one with a front edge contact along the sides of the module, one with a rear edge contact along the centerline of the module, and With the front edge contact along the centerline and the rear edge contact along the opposite side of the module, adjacent edges of the supercell can be arranged in an overlapping manner. The flexible interconnect is sandwiched between overlapping edges of the supercell without shadowing any part of the front of the solar module, contacting one front edge of the supercell and the back of the other supercell. An electrical connection may be provided to the end contacts. For rows containing three or more supercells, these two approaches may be used in combination.

  The supercell and multiple supercell rows shown in FIGS. 5A-5B may be interconnected by any suitable combination of series and parallel electrical connections, for example, as described further below with respect to FIGS. 10A-15. Interconnects between supercells may be established using flexible interconnects, for example, as described below with respect to FIGS. 5C-5G and subsequent figures. As shown by many of the examples described herein, the supercells in the solar modules described herein may be interconnected by a combination of series and parallel connections to form those of a conventional solar module. An output voltage may be provided to the module that is substantially the same as In such a case, the output current from the solar module may also be substantially the same as that of a conventional solar module. Alternatively, as described further below, the supercells in the solar module may interconnect to provide a substantially higher output voltage from the solar module than provided by a conventional solar module.

  FIG. 5C shows an exemplary rectangular solar module 350 that includes six rectangular supercells 100 each having a length approximately equal to the length of the long side of the solar module. The supercells are arranged as six parallel rows, with the long sides oriented parallel to the long sides of the module. A similarly configured solar module may include more or less rows of supercells of such a side length than shown in this example. In this example (and in some of the examples below), each supercell includes 72 rectangular solar cells, each having a width equal to approximately 1/6 the width of a 156 mm square or pseudo-square wafer. Any other suitable number of rectangular solar cells of any other suitable dimensions may be used. In this example, the front end contacts of the supercell are electrically connected to each other with the flexible interconnect 400 positioned adjacent and extending parallel to one short edge of the module. The backside end contacts of the supercell are similarly positioned behind the solar module, adjacent to the other short edge, and connected to each other by a flexible interconnect extending parallel to the same edge. The interconnects on the back are hidden from view in FIG. 5C. This arrangement electrically connects six module length supercells in parallel. Details of the flexible interconnects and their placement in this and other solar module configurations are described in more detail below with respect to FIGS. 6-8G.

  FIG. 5D illustrates an exemplary rectangular solar module 360 that includes twelve rectangular supercells 100 each having a length approximately equal to half the length of the long side of the solar module. The supercells are arranged in pairs and end-to-end so that six supercell rows are oriented with their rows and the long side of the supercell parallel to the long side of the solar module. It is formed in a state where it is set. In another variation, each supercell row may include three or more supercells. Also, similarly configured solar modules may include more or fewer supercell rows than shown in this example. In this example (and in some of the following examples), each supercell includes 36 rectangular solar cells, each having a width equal to approximately 1/6 the width of a 156 mm square or pseudo-square wafer. Any other suitable number of rectangular solar cells of any other suitable dimensions may be used. Gap 410 facilitates establishing electrical contact to the front end contact of supercell 100 along the centerline of the solar module. In this example, a flexible interconnect 400 positioned adjacent and extending parallel to one short edge of the module electrically interconnects the front end contacts of six of the supercells. Similarly, at the rear of the module, a flexible interconnect positioned adjacent to, and parallel to, the other short edge of the module electrically connects the back end contacts of the other six supercells. . A flexible interconnect (not shown in this figure) located along gap 410 interconnects each pair of supercells in a row in series, and optionally extends laterally to adjacent Interconnect the rows in parallel. This arrangement electrically connects six supercell rows in parallel. Optionally, within the first group of supercells, the first supercell in each row is electrically connected in parallel with the first supercell in each row of the other rows, and within the second group of supercells, The two supercells are electrically connected in parallel with the second supercell in each of the other rows, and the two groups of supercells are electrically connected in series. The latter arrangement allows each of the two groups of supercells to be individually paralleled with a bypass diode.

  Detail A of FIG. 5D identifies the location of the cross-section shown in FIG. 8A of the interconnection of the supercell back end contacts along one short edge of the module. Detail B also identifies the location of the cross-sectional view shown in FIG. 8B of the interconnection of the front end contacts of the supercell along the edge of the other short side of the module. Detail C identifies the cross-sectional view shown in FIG. 8C of the series interconnect of supercells in a row along gap 410.

  FIG. 5E shows a diagram of an exemplary rectangular solar module 370 configured similarly to that of FIG. 5C. The difference is that, in this example, all of the solar cells forming the supercell are chevron solar cells with chamfered corners corresponding to the corners of the pseudo-square wafer from which the solar cells were separated.

  FIG. 5F shows another exemplary rectangular solar module 380 configured similarly to that of FIG. 5C. The difference is that in this example, the solar cells forming the supercell include a mix of chevron and rectangular solar cells arranged to reproduce the shape of the quasi-square wafer from which they were separated. In the example of FIG. 5F, the chevron solar cell and the rectangular solar cell have the same active area exposed to solar radiation during operation of the module, and thus the chevron solar cell is shaped like a rectangular solar cell so that the currents match. They may be wider in the direction perpendicular to their long axis than the batteries, to compensate for missing corners on chevron batteries.

  FIG. 5G illustrates another exemplary rectangular solar module configured similarly to that of FIG. 5E (ie, including only chevron solar cells). The difference is that in the solar module of FIG. 5G, adjacent chevron solar cells in the supercell are arranged as mirror images of each other such that their overlapping edges are of the same length. This maximizes the length of each overlapping connection, thereby encouraging heat flow through the supercell.

  Other configurations of rectangular solar modules include one or more supercell rows formed solely from rectangular (non-chamfered) solar cells and one or more supercell rows formed solely from chamfered solar cells. Cell rows. For example, a rectangular solar module may be configured similarly to that of FIG. 5C, except that it has two outer supercell rows, each replaced by a supercell row formed only of chamfered solar cells. The chamfered solar cells in the rows can be arranged, for example, as mirror image pairs, as shown in FIG. 5G.

  In the exemplary solar module shown in FIGS. 5C-5G, the rectangular solar cells forming the supercells have an active area that is about 1/6 of the active area of a conventional size solar cell, and therefore, along each supercell row. The current drawn is about 1/6 of the current in a conventional solar module of the same area. However, in these examples, since the six supercell rows are electrically connected in parallel, the exemplary solar module may generate a total current equal to the total current generated by a conventional solar module of the same area. This facilitates replacing a conventional solar module with the exemplary solar module of FIGS. 5C-5G (and other examples described below).

  FIG. 6 shows, in greater detail than FIGS. 5C-5G, an exemplary arrangement of three supercell rows interconnected by a flexible electrical interconnect so that the supercells in each row are in series with each other and the rows are parallel to each other. Show. These may be, for example, three rows in the solar module of FIG. 5D. In the example of FIG. 6, each supercell 100 has a flexible interconnect 400 conductively joined to its front end contact and another flexible interconnect conductively joined to its back end contact. The two supercells in each row are electrically connected in series by a shared flexible interconnect that is conductively joined to the front end contact of one supercell and the back end contact of the other supercell. Each flexible interconnect is positioned adjacent and parallel to an end of the supercell to which it is joined, extends laterally beyond the supercell, and extends over the supercell in an adjacent row. Conductive bonding to the flexible interconnect may allow adjacent rows to be electrically connected in parallel. The dashed line in FIG. 6 represents the portion of the flexible interconnect that is hidden from view by the overlying portion of the supercell, or the portion of the supercell that is hidden from view by the portion overlying the flexible interconnect. Some are depicted.

  Flexible interconnect 400 may be conductively bonded to the supercell, for example, by an electrically conductive bonding agent having mechanical compliance as described above for use in bonding overlapping solar cells. Optionally, the electrically conductive bonding agent is located only at discrete locations along the edge of the supercell, rather than in a solid line extending substantially the length of the edge of the supercell, and is electrically conductive. Can reduce or accommodate stresses in a direction parallel to the edges of the supercell, resulting from a mismatch between the thermal expansion coefficients of the conductive bond or interconnect and the supercell. obtain.

  Flexible interconnect 400 may be formed, for example, from a thin copper plate, or may include a thin copper plate. The flexible interconnect 400 is optionally patterned or otherwise configured to increase mechanical compliance (flexibility) in both directions perpendicular and parallel to the edge of the supercell, It may reduce or accommodate stresses in directions perpendicular and parallel to the edges of the supercell, resulting from mismatches between the CTE of the interconnect and the CTE of the supercell. Such patterning may include, for example, slits, slots, or holes. The plurality of conductive portions of interconnect 400 may have a thickness of, for example, less than about 100 microns, less than about 50 microns, less than about 30 microns, or less than about 25 microns to increase interconnect flexibility. obtain. The mechanical compliance of the flexible interconnect, and its bonding to the supercell, during the lamination process, where the interconnecting supercell is described in more detail below with respect to the method of manufacturing shingled solar cell modules. It must be sufficient to withstand the stresses resulting from the CTE mismatch and the stresses resulting from the CTE mismatch during the temperature cycling test between about -40 ° C and about 85 ° C.

  Preferably, the flexible interconnects 400 have a resistance to current flow in a direction parallel to the edge of the supercell to which they are joined, of less than or equal to about 0.015 ohms, or less than about 0.012 ohms. Low or equal to or less than or equal to about 0.01 ohm.

  FIG. 7A illustrates some exemplary configurations identified by reference numerals 400A-400T that may be suitable for flexible interconnect 400.

  As shown in the cross-sectional views of FIGS. 8A-8C, for example, the solar modules described herein typically include a supercell and one or more encapsulant materials 4101, a transparent front sheet 420 and a rear face. It includes a laminated structure sandwiched between the sheet 430 and the sheet 430. The transparent front sheet can be, for example, glass. Optionally, the backsheet may also be transparent, which may allow for two-sided operation of the solar module. The back sheet can be, for example, a polymer sheet. Alternatively, the solar module can be a glass-glass module where both the front and back sheets are glass.

  The cross section of FIG. 8A (detail A from FIG. 5D) is conductively bonded to the back end contact of the supercell near the edge of the solar module, hidden from view from the front of the solar module, and inward below the supercell. 5 shows an example of a flexible interconnect 400 that extends. Additional strips of encapsulant may be disposed between interconnect 400 and the backside of the supercell, as shown.

  The cross-sectional view of FIG. 8B (detail B from FIG. 5B) shows an example of a flexible interconnect 400 that is conductively bonded to the front end contact of the supercell.

  The cross-sectional view of FIG. 8C (detail C from FIG. 5B) shows that the two supercells are electrically connected in series by conductively joining the front edge contact of one supercell and the rear edge contact of the other supercell. 4 shows an example of a shared flexible interconnect 400 to connect.

  Flexible interconnects that electrically connect to the front end contacts of the supercell may be configured or arranged to occupy only a narrow width of the front surface of the solar module, which may be located, for example, adjacent to the edge of the solar module. The area of the front of the module occupied by such interconnects may be as narrow as, for example, ≦ about 10 mm, ≦ about 5 mm, or ≦ about 3 mm, in a direction perpendicular to the edge of the supercell. In the arrangement shown in FIG. 8B, for example, the flexible interconnect 400 may be configured to extend beyond the edge of the supercell by no more than such a distance. 8D-8G show an additional example of an arrangement in which flexible interconnects electrically connecting to the front end contacts of the supercell can occupy only a small width of the front surface of the module. Such an arrangement facilitates efficient use of the frontal area of the module for electricity generation.

  FIG. 8D shows the flexible interconnect 400 conductively bonded to the distal front contact of the supercell and folded around the edge of the supercell to the back of the supercell. An insulating film 435, which may be pre-coated on the flexible interconnect 400, may be disposed between the flexible interconnect 400 and the backside of the supercell.

  FIG. 8E shows a flexible interconnect 400 that includes a thin narrow ribbon 440 that conductively joins a thin wide ribbon 445 that extends behind the supercell's backside and the backside of the supercell. An insulating film 435, which can be pre-coated on the ribbon 445, can be disposed between the ribbon 445 and the backside of the supercell.

  FIG. 8F shows a flexible interconnect 400 that is joined and rolled to the supercell's distal front contact and pressed into a flat coil that occupies only the narrow width of the front of the solar module.

  FIG. 8G shows a flexible interconnect 400 that includes a thin ribbon section that conductively joins the distal front contact of the supercell, and a thicker section located adjacent to the supercell.

  8A-8G, the flexible interconnect 400 may extend along the entire length of the edge of the supercell (eg, into a page of the drawing), for example, as shown in FIG.

  Optionally, a portion of the flexible interconnect 400, which is otherwise visible from the front of the module, is covered with a dark film or coating, or, in other cases, is colored to provide normal color vision. Can reduce the visible contrast between the interconnect and the supercell, as perceived by a person having For example, in FIG. 8C, an optional black film or coating 425 covers a portion of the interconnect 400 that would otherwise be visible from the front of the module. Portions of the interconnect 400, shown in other figures and otherwise visible, may be similarly covered or colored.

  Conventional solar modules typically include three or more bypass diodes, with each bypass diode connected in parallel with a serially connected group of 18 to 24 silicon solar cells. This is done to limit the amount of power that can be dissipated as heat in reverse-biased solar cells. The solar cell may be reverse biased due to, for example, defects that reduce the ability to pass the current generated by the string, dirty front surfaces, or uneven illumination. The heat generated in a reverse-biased solar cell depends on the voltage across the solar cell and the current through the solar cell. If the voltage across the reverse-biased solar cell exceeds the breakdown voltage of the solar cell, the heat dissipated in the cell will be equal to the breakdown voltage multiplied by the total current generated by the string. . Silicon solar cells typically have a breakdown voltage of 16 to 30 volts. Since each silicon solar cell generates a voltage of about 0.64 volts in operation, more than 24 strings of solar cells can generate a voltage above the breakdown voltage in a reverse-biased solar cell.

  It is not easy to transfer heat away from hot solar cells in conventional solar modules where the solar cells are separated from each other and interconnected by ribbons. As a result, the power dissipated in a solar cell subjected to a breakdown voltage can create hot spots in the solar cell that cause considerable thermal damage and possibly ignition. Thus, in a conventional solar module, a bypass diode is provided for each group of 18 to 24 series-connected solar cells to ensure that no solar cell in the string can be reverse biased beyond the breakdown voltage. is necessary.

  Applicants have discovered that heat is easily transferred along a silicon supercell through thin electrical and thermally conductive junctions between adjacent and overlapping silicon solar cells. Further, the supercells described herein typically shingle rectangular solar cells, each having a smaller active area (eg, ６) than the active area of conventional solar cells. , The current through the supercells in the solar modules described herein is typically less than the current through a string of conventional solar cells. Further, the rectangular aspect ratio of solar cells typically employed herein increases the area of thermal contact between adjacent solar cells. As a result, less heat is dissipated in the solar cell, which is reverse biased at the breakdown voltage, and heat spreads easily through the supercell and solar module without creating dangerous hot spots. Applicants have thus found that solar modules formed from supercells as described herein may employ much less bypass diodes than previously thought necessary.

  For example, in some variations of a solar module as described herein, N> 25 solar cells, N ≧ about 30 solar cells, N ≧ about 50 solar cells, N ≧ about 70 A single solar cell or a group of less than N solar cells in a supercell are individually electrically connected in parallel with a bypass diode in which one solar cell or a supercell containing N ≧ about 100 solar cells Can be adopted without doing so. Optionally, the entire supercell of these lengths can be electrically connected in parallel with a single bypass diode. Optionally, supercells of these lengths can be employed without bypass diodes.

  With some additional and optional design features, solar modules employing supercells as described herein have higher resistance to heat dissipated in reverse-biased solar cells It can be. 8A-8C, encapsulant 4101 can be or include a thermoplastic olefin (TPO) polymer. TPO encapsulants are more photothermally stable than standard ethylene vinyl acetate (EVA) encapsulants. EVA browns with temperature and ultraviolet light, leading to problems with hot spots created by current limiting batteries. These issues are alleviated or avoided by the TPO encapsulant. Further, the solar module may have a glass-glass structure where both the transparent front sheet 420 and the back sheet 430 are glass. Such glass-glass allows the solar module to operate safely at higher temperatures than conventional polymer backsheets can withstand. Still further, a junction box may be mounted on one or more edges of the solar module rather than behind the solar module. Here, the junction box will add an additional layer of thermal isolation to the module solar cells above it.

  FIG. 9A illustrates an exemplary rectangular solar module that includes six rectangular shingled supercells arranged in six rows extending across the length of the long side of the solar module. The six supercells are electrically connected to each other and in parallel with a bypass diode arranged in a junction box 490 on the back of the solar module. The electrical connection between the supercell and the bypass diode is established through a ribbon 450 embedded in the module stack.

  FIG. 9B shows another exemplary rectangular solar module that includes six rectangular shingled supercells arranged in six rows extending across the length of the long side of the solar module. The supercells are electrically connected to each other in parallel. Separate positive terminal connection boxes 490P and negative terminal connection boxes 490N are disposed on the back of the solar module at opposite ends of the solar module. The supercell is electrically connected in parallel with a bypass diode located on one of the junction boxes by an external cable 455 extending between the junction boxes.

  FIGS. 9C-9D show six rectangular shingled supercells arranged in six rows extending over the length of the long side of the solar module in a laminated structure including glass front and back sheets. 1 illustrates an exemplary glass-glass rectangular solar module comprising: The supercells are electrically connected to each other in parallel. Separate positive terminal connection boxes 490P and negative terminal connection boxes 490N are attached to opposing edges of the solar module.

  A shingled supercell is a unique module layout for module-level power management devices (eg, DC / AC micro-inverters, DC / DC module power optimizers, voltage intelligence and smart switches, and related devices). Create new opportunities. A key feature of a module-level power management system is power optimization. Supercells as described and employed herein can produce higher voltages than traditional panels. In addition, the layout of the supercell module may further divide the module. Both higher voltage and further splitting create potential benefits for power optimization.

  FIG. 9E illustrates one exemplary structure for module-level power management using a shingled supercell. In this figure, an exemplary rectangular solar module includes six rectangular shingled supercells arranged in six rows extending across the length of the long side of the solar module. The three pairs of supercells individually connect to a power management system 460, which allows for more individualized power optimization of the modules.

  FIG. 9F shows another exemplary structure of module-level power management using a shingled supercell. In this figure, an exemplary rectangular solar module includes six rectangular shingled supercells arranged in six rows extending across the length of the long side of the solar module. The six supercells individually connect to a power management system 460, which allows for even more individualized power optimization of the modules.

  FIG. 9G illustrates another exemplary structure of module-level power management using a shingled supercell. In this figure, an exemplary rectangular solar module includes six or more rectangular shingled supercells 998 arranged in six or more rows. Here, three or more supercell pairs are individually connected to a bypass diode or power management system 460 to allow for even more individualized power optimization of the module.

  FIG. 9H illustrates another exemplary structure of module-level power management using a shingled supercell. In this figure, an exemplary rectangular solar module includes six or more rectangular shingled supercells 998 arranged in six or more rows. Here, two supercells are connected in series, and all pairs are connected in parallel. A bypass diode or power management system 460 is connected in parallel with all pairs, which allows for power optimization of the module.

In some variations, module-level power management allows for elimination of all bypass diodes on the solar module while still eliminating the risk of hot spots. This is achieved by integrating voltage intelligence at the module level. By monitoring the voltage output of a solar cell circuit (eg, one or more supercells) in a solar module, a “smart switch” power management device determines whether the circuit contains any reverse-biased solar cells I can do it. If a reverse-biased solar cell is detected, the power management device can disconnect the corresponding circuit from the electrical system using, for example, a relay switch or other component. For example, if the voltage of the monitored solar cell circuit _drops below a predetermined threshold (V _Limit ), the power management device shuts off the circuit, while still keeping the module, or strings of modules, connected. (Open the circuit).

  In certain embodiments, where the voltage of a circuit is reduced by more than a certain percentage or magnitude (eg, 20% or 10V) than other circuits in the same solar array, that circuit will be shut off. The electronics will detect this change based on inter-module communication.

  Embodiments of such voltage intelligence can be incorporated into existing module-level power management solutions (eg, from Enphase Energy Inc., Solaredge Technologies, Inc., Tigo Energy, Inc.) or through custom circuit designs. obtain.

An example of how may calculate V _Limit threshold voltage,
CellVoc _{@Low Irr & High Temp xN number of cells in series} -Vrb _{Reverse breakdown voltage} ≤V _Limit
It is. here,
CellVoc @ _{Low Irr & High Temp} = Open circuit voltage of battery operating at low irradiation and high temperature (lowest expected operating Voc).
N _{number of cells in series} = _{number of} batteries connected in series in each supercell being monitored.
Vrb _{Reverse breakdown voltage} = the reverse polarity voltage required to pass current through the battery.

  This approach to module-level power management, using smart switches, allows more than 100 silicon solar cells to be connected in series in a single module without affecting safety or module reliability May be possible. In addition, such smart switches can be used to limit the string voltage going to the central inverter. Thus, longer module strings can be installed without concerns regarding safety or tolerance for overvoltage. If the string voltage rises against the limit, the weakest module can be bypassed (switched off).

  FIGS. 10A, 11A, 12A, 13A, 13B and 14B, described below, provide additional exemplary schematic electrical diagrams for solar modules employing a shingled supercell. 10B-1, 10B-2, 11B-1, 11B-2, 11C-1, 11C-2, 12B-1, 12B-2, 12C-1, 12C-2, 12C-3, 13C-1, 13C -2, 14C-1 and 14C-2 provide exemplary physical layouts corresponding to their schematic circuit diagrams. In the description of the physical layout, it is assumed that the front end contact portion of each supercell has a negative polarity and the back end contact portion of each supercell has a positive polarity. Alternatively, if the module employs a supercell having a front end contact having a positive polarity and a back end contact having a negative polarity, the following physical layout description will replace the positive and negative electrodes, and It can be changed by reversing the orientation of the bypass diode. Some of the various buses mentioned in the description of these figures may be formed, for example, by the interconnect 400 described above. The other buses described in these figures may be implemented, for example, with ribbons embedded in the stack of solar modules or with external cables.

  FIG. 10A is an exemplary schematic electrical diagram of a solar module as illustrated in FIG. 5B, including ten rectangular supercells 100 each having a length approximately equal to the length of the short side of the solar module. Is shown. The supercells are arranged in a solar module with the long side oriented parallel to the short side of the module. All of the supercells are electrically connected in parallel with the bypass diode 480.

  10B-1 and 10B-2 show an exemplary physical layout of the solar module of FIG. 10A. Bus 485N connects the negative (front) end contact of supercell 100 to the positive terminal of bypass diode 480 in junction box 490 located on the back of the module. The bus 485P connects the positive electrode (back surface) end contact portion of the supercell 100 to the negative terminal of the bypass diode 480. Bus 485P may lie entirely behind the supercell. Bus 485N and / or its interconnection to the supercell occupies a portion of the front of the module.

  FIG. 11A shows an exemplary schematic electrical diagram of a solar module as illustrated in FIG. 5A, including 20 rectangular supercells 100 each having a length approximately equal to half the length of the short side of the solar module. FIG. 2 shows a circuit diagram, where supercells are arranged in pairs and end-to-end to form ten supercell rows. The first supercell in each row is connected in parallel with the first supercell in the other row and in parallel with the bypass diode 500. The second supercell in each row is connected in parallel with the second supercell in the other row and in parallel with the bypass diode 510. Two groups of supercells are connected in series, like two bypass diodes.

  11B-1 and 11B-2 illustrate exemplary physical layouts of the solar module of FIG. 11A. In this layout, the first supercell in each row has a front (negative) end contact along the first side of the module, a back (positive) end contact along the centerline of the module, and In the second supercell, the front (negative) end contact portion is along the center line of the module, and the rear (positive) end contact portion is along the second side of the module opposite to the first side. . The bus 515N connects the front (negative) end contact of the first supercell in each row to the positive terminal of the bypass diode 500. The bus 515P connects the back (positive) end contact portion of the second supercell in each row to the negative terminal of the bypass diode 510. Bus 520 connects the back (positive) end contact of the first supercell of each row and the front (negative) end contact of the second supercell of each row to the negative terminal of bypass diode 500 and the positive terminal of bypass diode 510. I do.

  Bus 515P may lie entirely behind the supercell. Bus 515N and / or its interconnection to the supercell occupies a portion of the front of the module. Bus 520 occupies a portion of the front of the module and may require gap 210 as shown in FIG. 5A. Alternatively, the bus 520 may lie entirely behind the supercell and electrically connect to the supercell with the hidden interconnect sandwiched between overlapping ends of the supercell. In such cases, little or no gap 210 is needed.

  11C-1, 11C-2, and 11C-3 show other exemplary physical layouts of the solar module of FIG. 11A. In this layout, the first supercell in each row has a front (negative) edge contact along the first side of the module, a back (positive) edge contact along the centerline of the module, and a first supercell in each row. In the 2-supercell, the back (positive electrode) edge contact is along the center line of the module, and the front (negative electrode) edge contact is along the second side of the module opposite to the first side. The bus 525N connects the front (negative) end contact portion of the first supercell of each row to the positive terminal of the bypass diode 500. The bus 530N connects the front (negative) end contact portion of the second battery in each row to the negative terminal of the bypass diode 500 and the positive terminal of the bypass diode 510. The bus 535P connects the back (positive) end contact of the first battery in each row to the negative terminal of the bypass diode 500 and the positive terminal of the bypass diode 510. The bus 540P connects the back (positive) end contact portion of the second battery in each row to the negative terminal of the bypass diode 510.

  Bus 535P and bus 540P may lie entirely behind the supercell. Buses 525N and 530N and / or their interconnection to the supercell occupy a portion of the front of the module.

  FIG. 12A shows another exemplary solar module as illustrated in FIG. 5A, which includes twenty rectangular supercells 100 each having a length approximately equal to half the length of the short side of the solar module. FIG. 4 shows a schematic circuit diagram, where supercells are arranged in pairs and end-to-end to form ten supercell rows. In the circuit shown in FIG. 12A, supercells are arranged in four groups. In the first group, the first supercells in the top five rows are connected to each other and to the bypass diode 545 in parallel. In the second group, the second supercells in the top five rows connect in parallel with each other and with the bypass diode 505. In the third group, the first supercells in the bottom five rows are connected to each other and to the bypass diode 560 in parallel. In the fourth group, the second supercells in the bottom five rows are connected to each other and to the bypass diode 555 in parallel. These four groups of supercells are connected in series with each other. The fourth bypass diode is also in series.

  12B-1 and 12B-2 illustrate exemplary physical layouts of the solar module of FIG. 12A. In this layout, the first group of supercells has a front (negative) edge contact along the first side of the module, a back (positive) edge contact along the centerline of the module, and a second group of supercells. Has a front (negative) end contact portion along the center line of the module and a back (positive) end contact portion along the second side of the module on the side opposite to the first side. Has a back (positive) end contact along the first side of the module, a front (negative) end contact along the centerline of the module, and the fourth group of supercells has a back ( The (positive) end contact is along the centerline of the module and the front (negative) end contact is along the second side of the module.

  The bus 565N connects the front (negative) end contacts of the supercells included in the first group of supercells to each other and to the positive terminal of the bypass diode 545. The bus 570 connects the back (positive) end contact of the supercell included in the first group of supercells and the front (negative) end contact of the supercell included in the second group of supercells to each other. Connect to the negative terminal and to the positive terminal of bypass diode 550. The bus 575 connects the back (positive) end contact of the supercell included in the supercell of the second group and the front (negative) end contact of the supercell included in the supercell of the fourth group to each other, and Connect to the negative terminal and to the positive terminal of bypass diode 555. The bus 580 connects the back (positive) end contact of the supercell included in the fourth group of supercells and the front (negative) end contact of the supercell included in the third group of supercells to each other. Connect to the negative terminal and to the positive terminal of bypass diode 560. The bus 585P connects the back (positive) end contact portions of the supercells included in the third group of supercells to each other and to the negative terminal of the bypass diode 560.

  The bus 585P and the portion of the bus 575 that connects to the supercells of the second group of supercells may lie entirely behind the supercell. The remaining portions of bus 575 and bus 565N, and / or their interconnection to the supercell, occupy a portion of the front of the module.

  Buses 570 and 580 occupy a portion of the front of the module and may require a gap 210 as shown in FIG. 5A. Alternatively, they may lie entirely behind the supercell and electrically connect to the supercell with the hidden interconnect sandwiched between overlapping ends of the supercell. In such cases, little or no gap 210 is needed.

  12C-1, 12C-2, and 12C-3 show alternative physical layouts of the solar module of FIG. 12A. This layout uses two junction boxes 490A and 490B instead of the single junction box 490 shown in FIGS. 12B-1 and 12B-2, but is otherwise equivalent to that of FIGS. 12B-1 and 12B-2. It is.

  FIG. 13A shows another example of a solar module as illustrated in FIG. 5A, which includes twenty rectangular supercells 100 each having a length approximately equal to half the length of the short side of the solar module. FIG. 4 shows a schematic circuit diagram, where supercells are arranged in pairs and end-to-end to form ten supercell rows. In the circuit shown in FIG. 13A, supercells are arranged in four groups. In the first group, the first supercells in the top five rows are connected in parallel with each other. In the second group, the second supercells in the top five rows are connected to each other in parallel. In the third group, the first supercells in the bottom five rows are connected to each other in parallel. In the fourth group, the second supercells in the bottom five rows are connected to each other in parallel. The first group and the second group are connected in series with each other, and thus are connected in parallel with the bypass diode 590. The third group and the fourth group are connected in series with each other, and are therefore connected in parallel with another bypass diode 595. The first and second groups are connected in series with the third and fourth groups, and the two bypass diodes are also in series.

  13C-1 and 13C-2 illustrate exemplary physical layouts of the solar module of FIG. 13A. In this layout, the first group of supercells has a front (negative) edge contact along the first side of the module, a back (positive) edge contact along the centerline of the module, and a second group of supercells. Has a front (negative) end contact along the centerline of the module, a back (positive) end contact along a second side of the module opposite to the first side, The three groups of supercells have a back (positive) end contact along the first side of the module, a front (negative) end contact along the centerline of the module, and a fourth group of supercells. The back (positive) end contact is along the center line of the module and the front (negative) end contact is along the second side of the module.

  Bus 600 connects the front (negative) end contacts of the first group of supercells to one another, the back (positive) end contacts of the third group of supercells, to the positive terminal of bypass diode 590, and to the bypass diode 595. Connect to negative terminal. Bus 605 connects the back (positive) end contacts of the first group of supercells to each other and to the front (negative) end contacts of the second group of supercells. Bus 610P connects the back (positive) end contacts of the second group of supercells to each other and to the negative terminal of bypass diode 590. Bus 615N connects the front (negative) end contacts of the fourth group of supercells to each other and to the positive terminal of bypass diode 595. Bus 620 connects the front (negative) end contacts of the third group of supercells to each other and to the back (positive) end contacts of the fourth group of supercells.

  The bus 610P and the portion of the bus 600 that connects to the supercells included in the third group of supercells may lie entirely behind the supercell. The remaining portions of bus 600 and bus 615N, and / or their interconnection to the supercell, occupy a portion of the front of the module.

  Bus 605 and bus 620 occupy a portion of the front of the module and require a gap 210 as shown in FIG. 5A. Alternatively, they may lie entirely behind the supercell and electrically connect to the supercell with the hidden interconnect sandwiched between overlapping ends of the supercell. In such cases, little or no gap 210 is needed.

  FIG. 13B shows an exemplary schematic electrical diagram of a solar module as illustrated in FIG. 5B, wherein the solar module comprises ten solar modules each having a length approximately equal to the length of the short side of the solar module. Includes a rectangular supercell 100. The supercells are arranged in a solar module with the long side oriented parallel to the short side of the module. In the circuit shown in FIG. 13B, supercells are arranged in two groups. In the first group, the top five supercells are connected to each other and in parallel with the bypass diode 590, and in the second group, the bottom five supercells are connected to each other and the bypass diode 595. Connect to The two groups are connected in series with each other. A bypass diode is also connected in series.

  The schematic circuit of FIG. 13B differs from that of FIG. 13A in that each row of the two supercells of FIG. 13A is replaced with a single supercell. As a result, the physical layout of the solar module of FIG. 13B may be as shown in FIGS. 13C-1, 13C-2, and 13C-3 with buses 605 and 620 omitted.

  FIG. 14A shows an exemplary rectangular solar module 700 that includes 24 rectangular supercells 100 each having a length approximately equal to half the length of the short side of the solar module. The supercells are arranged in pairs, end-to-end, with 12 supercell rows oriented with the rows and the long side of the supercell parallel to the short side of the solar module. It is formed in a state.

  FIG. 14B shows an exemplary schematic circuit diagram of a solar module as illustrated in FIG. 14A. In the circuit shown in FIG. 14B, supercells are arranged in three groups. In the first group, the first supercells in the top eight rows are connected to each other and in parallel with the bypass diode 705, and in the second group, the four supercells in the bottom row are connected to each other and the bypass In the third group, the second supercells in the top eight rows are connected in parallel with each other and with the bypass diode 715 in the third group. The three groups of supercells are connected in series. The three bypass diodes are also in series.

  14C-1 and 14C-2 illustrate exemplary physical layouts of the solar module of FIG. 14B. In this layout, the first group of supercells has a front (negative) end contact along the first side of the module and a rear (positive) end contact along the centerline of the module. In the supercells of the second group, the first supercell included in each of the bottom four rows has a back (positive) end contact portion along the first side of the module and a front (negative) end contact. The second supercell included in each of the four lowermost rows has a front (negative) edge contact portion along the module centerline and a rear (positive) edge A contact is along a second side of the module opposite the first side. In the third solar cell group, the back (positive) end contact is along the center line of the module, and the back (negative) end contact is along the second side of the module.

  Bus 720N connects the front (negative) end contacts of the first group of supercells to each other and to the positive terminal of bypass diode 705. Bus 725 connects the back (positive) end contact of the first group of supercells, the front (negative) end contact of the second group of supercells, the negative terminal of bypass diode 705, and the positive terminal of bypass diode 710. Connect to terminal. Bus 730P connects the back (positive) end contacts of the third group of supercells to each other and to the negative terminal of bypass diode 715. The bus 735 connects the front (negative) end contacts of the third group of supercells to each other, the back (positive) end of the second group of supercells, the negative terminal of the bypass diode 710, and the Connect to positive terminal.

  The part of the bus 725 connecting to the supercell included in the first group of supercells, the bus 730P, and the part of the bus 735 connecting to the supercell included in the second group of supercells are entirely It can lie behind the supercell. Bus 720N and the rest of buses 725 and 735 and / or their interconnection to the supercell occupy a portion of the front of the module.

  Some of the examples described above contain a bypass diode in one or more junction boxes on the back of the solar module. However, this is not required. For example, some or all of the bypass diodes may be located in-plane with the supercell around the solar module, at the gap between the supercells, or behind the supercell. In such a case, the bypass diode may be arranged, for example, in a stacked structure in which the supercell is encapsulated. Thus, the location of the bypass diode is dispersed and removed from the junction box and is located on the back of the solar module in the central junction box containing both the positive and negative module terminals, for example, near the outer edge of the solar module. The resulting replacement with two separate single terminal junction boxes may be facilitated. This approach generally reduces the length of current paths in ribbon conductors in solar modules and in cabling between solar modules, both of which reduce material costs and reduce (resistive power losses Power) of the module.

  Referring to FIG. 15, for example, the physical layout of various electrical interconnects of a solar module as illustrated in FIG. 5B having the schematic circuit diagram of FIG. 10A is a bypass diode 480 located in a supercell stack. And two single terminal connection boxes 490P and 490N. FIG. 15 may be best understood by comparison with FIGS. 10B-1 and 10B-2. The layout of the other modules described above can be similarly modified.

  The use of an in-stack bypass diode as just described may be facilitated by the use of a reduced current (reduced area) rectangular solar cell, as described above. Because the solar cell with reduced current can dissipate less power in a forward biased bypass diode than would be dissipated in a conventional size solar cell. Thus, the bypass diodes in the solar modules described herein may absorb less heat than before, and consequently may be moved out of the junction box on the back of the module and into the stack.

  A single solar module corresponds to two or more electrical configurations, eg, interconnects, other conductors, and / or corresponding to two or more of the electrical configurations described above; It may include a bypass diode. In such a case, the particular configuration for operation of the solar module may be selected from two or more alternatives, for example, in conjunction with the use of switches and / or jumpers. Between different configurations, the number of supercells in series and / or in parallel may be different to provide different combinations of voltage and current output from the solar module. Thus, such solar modules may be selected from two or more different voltage and current combinations, for example, between a high voltage and low current configuration and a low voltage and high current configuration. May be configurable at the factory or site to

  FIG. 16 shows an exemplary arrangement of a smart switch module level power management device 750 as described above between two solar modules.

  Referring now to FIG. 17, an exemplary method 800 for making a solar module as disclosed herein includes the following steps. In step 810, a conventional size solar cell (eg, 156 mm × 156 mm or 125 mm × 125 mm) is cut and / or cleaved to form a plurality of narrow rectangular solar cell “strips”. (See also, for example, FIGS. 3A-3E and the related description above). The resulting solar strip can optionally be tested and sorted according to current-voltage performance. Batteries with matching or approximately matching current-voltage performance can be advantageously used in the same supercell or in the same row of supercells connected in series. For example, batteries connected in series within a supercell or within a row of supercells may advantageously produce matching or approximately matching currents under the same illumination.

  In step 815, a supercell is assembled from the strip solar cells with the conductive adhesive bonding agent disposed between overlapping portions of adjacent solar cells in the supercell. The conductive adhesive may be applied by, for example, inkjet printing or screen printing.

  In step 820, heat or pressure is applied to cure or partially cure the conductive adhesive between the solar cells in the supercell. In one variation, as each additional solar cell is added to the supercell, the newly added solar cell and its adjacent overlapping solar cells (which are already part of the supercell) Is cured or partially cured before the next solar cell is added to the supercell. In other variations, more than two solar cells, or all solar cells in a supercell, may be positioned in a desired overlapping manner before the conductive adhesive is cured or partially cured. The resulting supercell from this step can optionally be tested and sorted according to current-voltage performance. Supercells having matching or approximately matching current-voltage performance can be advantageously used in the same supercell row or in the same solar module. For example, it may be advantageous for a supercell or a plurality of supercell rows to be electrically connected in parallel to produce matched or approximately matched voltages under the same illumination.

  In step 825, the cured or partially cured supercell is assembled in the desired modular configuration in a layered structure including an encapsulant material, a transparent front (sun side) sheet, and (optionally, a transparent) back sheet. Placed and interconnected. The layered structure can be, for example, a first layer of encapsulant on a glass substrate, interconnecting supercells with the sun side down on the first layer of encapsulant, a second layer of encapsulant on the layer of supercells , And a backsheet on the second layer of encapsulant. Any other suitable arrangement may be used.

  In the laminating step 830, heat and pressure are applied to the layered structure to form a cured laminated structure.

  In a variation of the method of FIG. 17, conventional sized solar cells are separated into a plurality of solar cell strips, after which a conductive adhesive bond is applied to each individual solar cell strip. In an alternative variation, the conductive adhesive is applied to conventional sized solar cells before the solar cells are separated into multiple solar cell strips.

  In the curing step 820, the conductive adhesive may be completely cured or only partially cured. In the latter case, the conductive adhesive may first be partially cured in step 820 sufficiently to facilitate handling and interconnecting of the supercell, and may be fully cured during the subsequent laminating step 830.

  In some variations, the supercell 100 assembled as an intermediate product in the method 800 has the long sides of adjacent solar cells overlapped and conductively bonded as described above, and the plurality of interconnects are supercells. Includes a plurality of rectangular solar cells 10 arranged joined to the terminal contacts at opposing ends of the solar cells.

  FIG. 30A shows an exemplary supercell with the electrical interconnect bonded to the front and back end contacts. The electrical interconnect extends parallel to the distal edge of the supercell and extends laterally beyond the supercell to facilitate electrical interconnection with an adjacent supercell.

  FIG. 30B shows two of the supercells of FIG. 30A interconnected in parallel. In other cases, some of the interconnects, which are visible from the front of the module, may be covered or colored (eg, darkened) and perceived by a person having normal color vision. The visible contrast between the connection and the supercell may be reduced. In the example illustrated in FIG. 30A, an interconnect 850 is conductively joined to a front end contact of a first polarity (e.g., + or-) at one end (right side of the drawing) of the supercell and the other interconnect. Connection 850 is conductively bonded to the opposite end contact of the opposite polarity at the other end (left side of the drawing) of the supercell. As with the other interconnects described above, interconnect 850 may be conductively bonded to the supercell using, for example, the same conductive adhesive bond between the solar cells, but this is not required. In the illustrated example, a portion of each interconnect 850 extends beyond the edge of supercell 100 in a direction perpendicular to the long axis of the supercell (and parallel to the long axis of solar cell 10). I do. As shown in FIG. 30B, this causes two or more supercells 100 to be conductively joined such that the interconnect 850 of one supercell overlaps the corresponding interconnect 850 on an adjacent supercell. Two supercells can be positioned side by side with their electrical interconnections in parallel. Several such interconnects 850 that interconnect in series as just described may form a bus for the module. This arrangement may be suitable, for example, where individual supercells extend across the entire width or length of the module (eg, FIG. 5B). In addition, the interconnect 850 can be used to electrically connect the terminal contacts of two adjacent supercells in a supercell row in series. Such interconnecting supercell pairs or longer strings in a row overlap the interconnect 850 in one row and the interconnect 850 in an adjacent row, similar to that shown in FIG. 30B. Conductive bonding allows for electrical connection in parallel with similarly interconnected supercells in adjacent rows.

  The interconnect 850 can be die cut from, for example, a conductive sheet and optionally patterned to enhance its mechanical compliance both in a direction perpendicular and parallel to the edge of the supercell, It may reduce or adapt to stresses in directions perpendicular and parallel to the edges of the supercell, resulting from mismatches between the CTE of the connection and the CTE of the supercell. Such patterning may include, for example, slits, slots, or holes (not shown). The mechanical compliance of the interconnect 850 and its connection to the supercell or connections allows the connection to the supercell to withstand the stresses resulting from CTE mismatch during the lamination process described in more detail below. Should be sufficient. The interconnect 850 may be bonded to the supercell, for example, by an electrically conductive bonding agent having mechanical compliance as described above for use in bonding overlapping solar cells. Optionally, the electrically conductive bonding agent is located only at discrete locations along the edge of the supercell, rather than in a solid line extending substantially the length of the edge of the supercell, and is electrically conductive. Can reduce or accommodate stresses in a direction parallel to the edges of the supercell, resulting from a mismatch between the thermal expansion coefficients of the conductive bond or interconnect and the supercell. obtain.

  The interconnect 850 may be cut, for example, from a thin copper plate, and the supercell 100 may be formed from a solar cell having a smaller area than a standard silicon solar cell, and thus operate at a lower current than a conventional silicon solar cell. It may be thinner than the conductive interconnect. For example, interconnect 850 may be formed from a copper plate having a thickness of about 50 microns to about 300 microns. The interconnects 850, like the interconnects described above, can be thin enough and highly flexible so that they can be folded around and behind the edges of the supercells to which they are joined.

  19A-19D illustrate some exemplary arrangements in which heating and pressing may be performed during method 800 to cure or partially cure a conductive adhesive bond between adjacent solar cells in a supercell. . Any other suitable arrangement may be employed.

  In FIG. 19A, heating and local pressure are applied to cure or partially cure the conductive adhesive 12 at one connection (overlapping area) at a time. The supercell can be supported by the surface 1000, and the pressure can be applied mechanically to the connection from above by, for example, a bar, pin, or other mechanical contact. Heating may be applied to the connection by, for example, hot air (or other hot gas), by an infrared light bulb, or by heating a mechanical contact that applies local pressure to the connection. Can be done.

  In FIG. 19B, the arrangement of FIG. 19A has been extended to a batch process that simultaneously heats and locally pressurizes multiple connections in a supercell.

  In FIG. 19C, an uncured supercell is sandwiched between a release liner 1015 and a reusable thermoplastic sheet 1020 and positioned on a carrier plate 1010 supported by a surface 1000. The thermoplastic material of sheet 1020 is selected to melt at a temperature at which the supercell is cured. Release liner 1015 can be formed, for example, from fiberglass and PTFE, and does not stick to the supercell after the curing process. Preferably, the release liner 1015 is formed from a material having a CTE that matches or substantially matches the coefficient of thermal expansion of the solar cell (eg, the CTE of silicon). Because, if the CTE of the release liner is too different from the CTE of the solar cell, the solar cell and the release liner will be lengthened by different amounts during the curing process, which means that the supercell will be longer at the junction. Because they will tend to pull apart in the direction of their length. A vacuum bladder 1005 lies on this arrangement. The uncured supercell is heated from below, for example, through surface 1000 and carrier plate 1010, and a vacuum is drawn between bladder 1005 and support surface 1000. As a result, the bladder 1005 applies a static pressure to the supercell through the molten thermoplastic sheet 1020.

  In FIG. 19D, the uncured supercell is carried by a perforated moving belt 1025 through an oven 1035 that heats the supercell. The vacuum drawn through the perforations in the belt pulls the solar cells 10 toward the belt, thereby exerting pressure on the connections between them. The conductive adhesive at those connections is cured as the supercell passes through the oven. Preferably, perforated belt 1025 is formed from a material having a CTE that matches or substantially matches the CTE of a solar cell (eg, the CTE of silicon). Because if the CTE of the belt 1025 is too different from the CTE of the solar cell, the solar cell and the belt will be lengthened by different amounts in the oven 1035, which means that the supercell will Because they will tend to pull apart.

  The method 800 of FIG. 17 includes separate, supercell curing and laminating steps to produce an intermediate supercell product. In contrast, the method 900 shown in FIG. 18 combines the supercell curing and lamination steps. At step 910, a conventional size solar cell (eg, 156 mm × 156 mm or 125 mm × 125 mm) is cut and / or cleaved to form a plurality of narrow rectangular solar cell strips. The resulting solar strip can optionally be tested and screened.

  In step 915, the solar cell strips are arranged and interconnected in a desired modular configuration of a layered structure including an encapsulant material, a transparent front (sun side) sheet, and a back sheet. The solar cell strip is arranged as a supercell with an uncured conductive adhesive bonding agent disposed between overlapping portions of adjacent solar cells in the supercell. (The conductive adhesive bond may be applied, for example, by ink jet printing or screen printing.) Interconnects are arranged to electrically interconnect the uncured supercells in the desired configuration. The layered structure can be, for example, a first layer of encapsulant on a glass substrate, interconnecting supercells with the sun side down on the first layer of encapsulant, a second layer of encapsulant on the layer of supercells , And a backsheet on the second layer of encapsulant. Any other suitable arrangement may be used.

  In the laminating step 920, heat and pressure are applied to the layered structure to cure the conductive adhesive in the supercell and form a cured laminated structure. The conductive adhesive used to bond the interconnect to the supercell can also be cured in this step.

  In one variation of method 900, conventional sized solar cells are separated into a plurality of solar cell strips, after which a conductive adhesive bond is applied to each individual solar cell strip. In an alternative variation, the conductive adhesive is applied to a conventional sized solar cell before the solar cell is separated into a plurality of solar cell strips. For example, a plurality of conventional sized solar cells are placed on a large template, and then a conductive adhesive is dispensed onto the solar cells, after which the solar cells are simultaneously sized by a large fixture. It can be separated to be a battery strip. The resulting solar strips can then be transported as a group and arranged in the desired modular configuration as described above.

  As described above, in methods 800 and some variations of method 900, the conductive adhesive is applied to conventional sized solar cells before the solar cells are separated into multiple solar cell strips. You. When conventional-sized solar cells are separated to form a plurality of solar cell strips, the conductive adhesive is in an uncured state (ie, not yet "dried"). In some of these variations, a conductive adhesive bond is applied to a conventional size solar cell (eg, by ink jet or screen printing), and then scribe lines onto the solar cell using a laser. Defining the locations where the solar cells will be cleaved to form solar cell strips, and then the solar cells are cleaved along scribe lines. In these variations, the laser power, and / or the distance between the scribe lines, and the adhesive are selected to avoid accidental or partial curing of the conductive adhesive by heat from the laser. obtain. In another variation, a laser is used to scribe lines on a conventional size solar cell to define locations where the solar cell will be cleaved to form a solar cell strip, and then a conductive adhesive bond The agent is applied to the solar cell (eg, by inkjet or screen printing), and the solar cell is then cleaved along the scribe lines. In the latter variant, it may be preferred that the step of applying the conductive adhesive is accomplished without accidentally cleaving or breaking the scribed solar cell during this step.

  20A-20C, FIG. 20A schematically illustrates a side view of an exemplary device 1050 that may be used to cleave a scribed solar cell with a conductive adhesive applied. . (Scribing and application of the conductive adhesive may occur in any order.) In this apparatus, the scribed conventional size solar cell 45 with the conductive adhesive applied is a vacuum manifold. Above the curved portion of 1070 is carried by a perforated moving belt 1060. As the solar cell 45 passes over the curved portion of the vacuum manifold, the vacuum drawn through the perforations in the belt pulls the bottom surface of the solar cell 45 toward the vacuum manifold, thereby bending the solar cell. The radius of curvature R of the curved portion of the vacuum manifold can be selected to cleave the solar cell along the scribe line by bending the solar cell 45 in this manner. Advantageously, the solar cell 45 can be cleaved by the present method without contacting the top surface of the solar cell 45 to which the conductive adhesive has been applied.

  If cleavage preferably begins at one end of the scribe line (ie, one edge of the solar cell 45), this means that for each scribe line, one end reaches the curved portion of the vacuum manifold before the other end. As such, for example, by arranging the scribe lines to be oriented at an angle θ relative to the vacuum manifold, this can be achieved with the apparatus 1050 of FIG. 20A. As shown in FIG. 20B, for example, the solar cells are oriented such that their scribe lines are angled relative to the manifold oriented in the direction of belt movement and perpendicular to the direction of belt movement. Can be As another example, FIG. 20C shows a battery oriented with scribe lines perpendicular to the direction of belt travel and an manifold oriented at an angle.

  Any other suitable device is also used to cleave the scribed solar cell with the conductive adhesive applied thereto to form a strip solar cell with the pre-applied conductive adhesive. obtain. Such a device may, for example, use a roller to apply pressure to the top surface of the solar cell to which the conductive adhesive has been applied. In such a case, it is preferable that the roller touches the top surface of the solar cell only in the area where the conductive adhesive is not applied.

  In some variations, the solar module is not initially absorbed by the solar cells, and some of the solar radiation passing through the solar cells is reflected by the backsheet and returned into the solar cells to produce electricity As may be seen, it includes supercells arranged in multiple rows on a white or otherwise reflective backsheet. The reflective backsheet may be visible through the gaps between the rows of supercells, which results in the solar module having a plurality of parallel bright (eg, white) lines extending across its front surface. It may appear to have rows. Referring to FIG. 5B, for example, a plurality of parallel dark lines extending between rows of a plurality of supercells 100 appear as white lines when the supercells 100 are disposed on a white backsheet. Maybe. This may be aesthetically unpleasant for some applications of the solar module, for example, on a roof.

  Referring to FIG. 21, in order to enhance the aesthetic appearance of the solar module, some variations include a plurality of supercells located at positions corresponding to the gaps between the rows of supercells to be placed on the backsheet. A white rear sheet 1100 including a dark stripe 1105 is employed. The stripes 1105 are wide enough such that the white portion of the backsheet is not visible through the gaps between the plurality of supercell rows in the assembled module. This reduces the visual contrast between the supercell and the backsheet that is perceived by a person with normal color vision. The resulting module includes a white backsheet, but may have a frontal appearance similar to, for example, the appearance of the module illustrated in FIGS. 5A-5B. Dark stripes 1105 may be generated, for example, with multiple lengths of dark tape or in any other suitable manner.

  As previously mentioned, the shadowing of individual cells in the solar module can create "hot spots" where the power of the unshaded cells is dissipated by the shadowed cells. This dissipated power creates local temperature spikes that can degrade the module.

  Conventionally, bypass diodes have been inserted as part of the module to minimize the potential seriousness of these hot spots. The maximum number of batteries between the bypass diodes is set to limit the maximum temperature of the module and prevent irreversible damage to the module. A standard layout for silicon cells may utilize one bypass diode for every 20 or 24 cells, the number being determined by the typical breakdown voltage of silicon cells. In certain embodiments, the breakdown voltage can range between about 10-50V. In certain embodiments, the breakdown voltage can be about 10V, about 15V, about 20V, about 25V, about 30V, or about 35V.

  According to embodiments, the thermal contact between the solar cells is improved by shingling the strip of cut solar cells with a thin thermally conductive adhesive. This enhanced thermal contact allows for a higher degree of heat spreading than traditional interconnect technology. Such a thermal heat spreading design, based on shingling, is longer than 24 (or less) solar cells per bypass diode, which has been a constraint on conventional designs. A string of solar cells can be used. The heat spread facilitated by shingling in accordance with embodiments may thus alleviate the requirements for providing bypass diodes at short intervals and provide one or more advantages. For example, this allows the creation of a layout of modules of various solar cell string lengths without being hindered by the need to provide a large number of bypass diodes.

  According to embodiments, heat spreading is achieved by maintaining a physical and thermal bond with adjacent cells. This allows for sufficient heat dissipation through the joined joints.

  In certain embodiments, the connection is maintained at a thickness of about 200 micrometers or less and extends the length of the solar cell in a segmented pattern. Depending on the embodiment, the connection has a thickness of about 200 micrometers or less, about 150 micrometers or less, about 125 micrometers or less, about 100 micrometers or less, It may be about 90 micrometers or less, about 80 micrometers or less, about 70 micrometers or less, about 50 micrometers or less, or about 25 micrometers or less.

  Accurate adhesive curing may be important to ensure that a reliable connection is maintained, while maintaining a low thickness to promote thermal diffusion between the joined cells.

  The possibility of longer strings (e.g., more than 24 cells) allows flexibility in solar cell and module design. For example, in certain embodiments, a string of cut solar cells assembled in a shingle-like configuration may be utilized. Such an arrangement may utilize substantially more batteries per module than conventional modules.

  Without thermal diffusivity, one bypass diode would be required for every 24 cells. If the solar cell is cut in 1/6, the bypass diode per module is 6 times the conventional module (consisting of 3 uncut cells), for a total of 18 diodes Will. Thus, thermal diffusion allows a considerable reduction in the number of bypass diodes.

  In addition, a bypass circuit is required for each bypass diode to complete the bypass electrical path. Each diode requires two interconnection points and the routing of conductors to connect them to such interconnection points. This creates complex circuits and leads to considerable costs, which are greater than the standard layout costs associated with assembling solar modules.

  In contrast, heat spreading techniques may require only one bypass diode per module, or even no bypass diode at all. Such an arrangement streamlines the module assembly process and allows simple automation tools to perform the layout manufacturing steps.

  Thus, avoiding the need to bypass protect every 24 cells makes battery module manufacturing easier. Complex tap-outs in the middle of the module and long parallel connections for bypass circuits are avoided. This heat spreading is implemented by creating a long shingled strip of cells that extends across the width and / or length of the module.

  In addition to providing thermal heat diffusion, shingling according to embodiments also allows for improved hot spot performance by reducing the amount of current dissipated in the solar cell And Specifically, during a hot spot condition, the amount of current dissipated in the solar cell depends on the area of the cell.

  Since shingling allows the cell to be cut to a smaller area, the amount of current passing through one cell in a hot spot state is a function of the size being cut. During a hot spot condition, the current passes through a path of least resistance, which is typically a defective interface or grain boundary at the cell level. Reducing this current is an advantage and minimizes the failure of reliability risks in hot spot conditions.

  FIG. 22A shows a top view of a conventional module 2200 utilizing a traditional ribbon connection 2201 in a hot spot condition. Here, as a result of the shadow 2202 on one battery 2204, heat will be concentrated on that single battery.

  In contrast, FIG. 22B shows a plan view of a module utilizing thermal diffusion, also in a hot spot condition. Here, the shadow 2250 on the battery 2252 generates heat within the battery. However, this heat is dissipated to other electrically and thermally bonded cells 2254 in module 2256.

  Furthermore, the advantage of reducing the dissipated current is multiplied several times in polycrystalline solar cells. Such polycrystalline cells are known to perform poorly in hot spot conditions due to high levels of defective interfaces.

  As indicated above, certain embodiments may employ shingled chamfered and cut batteries. In such a case, there is a similar thermal diffusion advantage along the joint line between each cell and the adjacent cell.

  This maximizes the joint length of each overlapped connection. Since the joined connection is the primary interface for heat spread between the cells, maximizing this length may ensure optimal heat spread.

  FIG. 23A shows an example of a supercell string layout 2300 that includes a chamfered battery 2302. In this configuration, the chamfered cells are oriented in the same direction, so the conduction paths of all joined connections are the same (125 mm).

  As a result of the shadow 2306 on one battery 2304, the battery is reverse biased. Heat spreads to adjacent cells. The non-bonded end 2304a of the chamfered cell becomes the hottest due to the longer conduction length to the next cell.

  FIG. 23B shows another example of a supercell string layout 2350 including a chamfered battery 2352. In this configuration, the chamfered cells are oriented in different directions, and some of the long edges of the chamfered cells face each other. As a result of this, the length of the conduction path of the joined connection is two, 125 mm and 156 mm.

  When the cell 2354 is shaded 2356, the configuration of FIG. 23B exhibits improved heat spreading along a longer bond length. Thus, FIG. 23B shows the heat spread in the supercell with the chamfered batteries facing each other.

  The above description has focused on assembling a plurality of solar cells (which may be cut solar cells) on a common substrate in a shingle fashion. This results in a module having a single electrical interconnect-junction box (or j-box).

  However, to collect a sufficient amount of solar energy to be useful, equipment typically includes many such modules that will themselves be assembled together. According to embodiments, a plurality of solar cell modules may also be assembled in a shingle-like configuration to increase the area efficiency of the array.

  In certain embodiments, the module may include an upper conductive ribbon facing the direction of solar energy and a lower conductive ribbon facing away from the direction of solar energy.

  The lower ribbon is embedded below the battery. Therefore, it does not block the incident light and does not adversely affect the area efficiency of the module. In contrast, the upper ribbon is exposed and blocks incident light, which can adversely affect efficiency.

  According to an embodiment, the modules themselves are shingled so that the upper ribbon can be covered by neighboring modules. FIG. 24 shows a simplified cross-sectional view of such an arrangement 2400 in which the ends 2401 of adjacent modules 2402 function to overlap the upper ribbon 2404 of the module 2406 under consideration. Each module itself includes a plurality of shingled solar cells 2407.

  The lower ribbon 2408 of the module 2406 under consideration is embedded. It is located on the raised side of the shingled module under consideration to overlap the adjacent shingled module.

  This shingled module configuration may also provide additional area on the module for other elements without adversely affecting the final exposed area of the module array. Examples of modular elements that may be located in the overlapping area may include, but are not limited to, a junction box (j-box) 2410 and / or a bus ribbon.

  FIG. 25 illustrates another embodiment of a shingled module configuration 2500. Here, the j-boxes 2502, 2504 of each adjacent shingled module 2506 and 2508 are mated 2510 to achieve an electrical connection therebetween. This simplifies the construction of an array of shingled modules by eliminating wiring.

  In certain embodiments, the j box may be enhanced with additional structural standoffs and / or may be combined with standoffs. Such an arrangement may create an integrated, tilted modular roof mounting rack solution where the dimensions of the junction box determine the tilt. Such an embodiment may be particularly useful when an array of shingled modules is mounted on a flat roof.

  If the module includes a glass substrate and a glass cover (glass-glass module), the module reduces the overall module length (and thus the exposed length L resulting from shingling). By doing so, it can be used without additional frame members. Such a shortening would allow the modules of the tilted array to withstand the expected physical loads (eg, the snow load limit of 5400 Pa) without breaking due to strain.

  To emphasize, by using a supercell structure comprising a plurality of individual solar cells assembled in a shingle configuration, the module can be adapted to the specific length required by physical loads and other requirements. It is possible to easily adapt to changes in the length.

  FIG. 26 illustrates an exemplary electrical interconnection of the front (sun side) face end electrical contacts of a shingle supercell to a junction box on the back of the solar module, on the back (shadow) side of the module. The figure is shown. The front end contact of the shingled supercell may be located adjacent the edge of the module.

  FIG. 26 illustrates the use of a flexible interconnect 400 that makes electrical contact with the front edge contacts of the supercell 100. In the example shown, the flexible interconnect 400 includes a ribbon portion 9400A that extends parallel to and adjacent to the edge of the supercell 100, and a direction perpendicular to the ribbon portion to provide a conductive cell to which the supercell is to be conductively joined. And a finger 9400B that contacts the front metallization pattern (not shown) of the inner edge solar cell. A ribbon conductor 9410 that conductively joins the interconnect 9400 passes behind the supercell 100 and replaces the interconnect 9400 with electrical components (eg, junction boxes) on the back of the solar module of which the supercell forms a part. Module terminals and / or bypass diodes). An insulating film 9420 can be disposed between the conductor 9410 and the edge and back of the supercell 100 to electrically insulate the ribbon conductor 9410 from the supercell 100.

  The interconnect 400 may optionally be folded around the edges of the supercell such that the ribbon portion 9400A lies behind or partially behind the supercell. In such a case, an electrically insulating layer is typically provided between the interconnect 400 and the edge and back of the supercell 100.

  The interconnect 400 may be die cut from, for example, a conductive sheet and optionally patterned to enhance its mechanical compliance in both directions perpendicular and parallel to the edges of the supercell. It may reduce or adapt to stresses in directions perpendicular and parallel to the edges of the supercell, resulting from mismatches between the CTE of the connection and the CTE of the supercell. Such patterning may include, for example, slits, slots, or holes (not shown). The mechanical compliance of the interconnect 400 and its bonding to the supercell is sufficient so that the connection to the supercell can withstand the stresses resulting from CTE mismatch during the lamination process described in more detail below. Should be. The interconnect 400 may be bonded to the supercell, for example, by an electrically conductive bonding agent having mechanical compliance as described above for use in bonding overlapping solar cells. Optionally, the electrically conductive bonding agent is not a solid line extending substantially over the length of the edge of the supercell (e.g., corresponding to the location of discontinuous contact pads on the edge solar cells). The supercell, located only at discrete locations along the edge of the supercell, resulting from a mismatch between the coefficient of thermal expansion of the electrically conductive bonding agent or interconnect and the coefficient of thermal expansion of the supercell. May be reduced or adapted to stresses in a direction parallel to the edges of the.

  The interconnect 400 may be cut from, for example, a thin copper plate, and the supercell 100 may be formed from a solar cell having a smaller area than a standard silicon solar cell, and thus operate at a lower current than a conventional silicon solar cell. It may be thinner than the conductive interconnect. For example, interconnect 400 may be formed from a copper plate having a thickness of about 50 microns to about 300 microns. The interconnect 400, even if it was not patterned as described above, would be caused by a mismatch between the CTE of the interconnect and the CTE of the supercell, in a direction perpendicular to the edge of the supercell and It may be thin enough to accommodate stresses in parallel directions. The ribbon conductor 9410 can be formed, for example, from copper.

  FIG. 27 shows two or more parallel shingled supercells with their front (sun) front end electrical contacts connected to each other and to a junction box on the back of the solar module. FIG. 3 shows a view of the back (shadow) side of the module illustrating an exemplary electrical interconnect. The front end contact of the shingled supercell may be located adjacent the edge of the module.

  FIG. 27 illustrates the use of two flexible interconnects 400, as just described, in electrical contact with the front end contacts of two adjacent supercells 100. A bus 9430 extending parallel to and adjacent to the edge of the supercell 100 is conductively joined to the two flexible interconnects to electrically connect the supercells in parallel. This scheme can be extended to interconnect additional supercells 100 in parallel if desired. Bus 9430 may be formed from, for example, a copper ribbon.

  26, the interconnect 400 and the bus 9430 are optional such that the ribbon portion 9400A and the bus 9430 lie behind, or partially behind, the supercell. Then, it can break around the edge of the supercell. In such a case, an electrically insulating layer is typically provided between the interconnect 400 and the edge and back of the supercell 100, and between the bus 9430 and the edge and back of the supercell 100. You.

  FIG. 28 shows two or more parallel shingled supercells with the front (sun) front end electrical contacts of the supercell connected to each other and to a junction box on the back of the solar module. FIG. 4 shows a view of the back (shadow) side of the module illustrating another exemplary electrical interconnect. The front end contact of the shingled supercell may be located adjacent the edge of the module.

  FIG. 28 illustrates the use of another exemplary flexible interconnect 9440 that makes electrical contact to the front edge contacts of the supercell 100. In this example, the flexible interconnect 9440 includes a ribbon portion 9440A that extends parallel to and adjacent to the edge of the supercell 100, and extends in a direction perpendicular to the ribbon portion to form an end in the supercell that is conductively joined. A finger 9440B that contacts the front metallization pattern (not shown) of the solar cell, and a finger 9440C that extends in a direction perpendicular to the ribbon portion and behind the supercell. Finger 9440C is conductively connected to bus 9450. Bus 9450 extends along the back surface of supercell 100, parallel to and adjacent to the edge of supercell 100, and extends to overlap adjacent supercells, which may be similar electrical connections thereto. , Whereby super cells can be connected in parallel. A ribbon conductor 9410 that conductively couples to the bus 9450 electrically interconnects the supercell to electrical components on the back of the solar module (eg, module terminals and / or bypass diodes in a junction box). Electrical insulating film 9420 is provided between finger 9440C and the edge and back of supercell 100, between bus 9450 and back of supercell 100, and between ribbon conductor 9410 and back of supercell 100. Can be done.

  The interconnect 9440 can be die cut from, for example, a conductive sheet and optionally patterned to enhance its mechanical compliance in both directions perpendicular and parallel to the edges of the supercell, and It may reduce or adapt to stresses in directions perpendicular and parallel to the edges of the supercell, resulting from mismatches between the CTE of the connection and the CTE of the supercell. Such patterning may include, for example, slits, slots, or holes (not shown). The mechanical compliance of the interconnect 9440, and its bonding to the supercell, is sufficient so that the connection to the supercell can withstand the stresses resulting from CTE mismatch during the lamination process described in more detail below. Should be. The interconnect 9440 may be joined to the supercell, for example, by an electrically conductive adhesive having mechanical compliance as described above for use in joining overlapping solar cells. Optionally, the electrically conductive bonding agent is not a solid line extending substantially over the length of the edge of the supercell (e.g., corresponding to the location of a discontinuous contact pad on the edge solar cell). Supercell, located only at discrete locations along the edge of the supercell, resulting from a mismatch between the coefficient of thermal expansion of the electrically conductive bonding agent or interconnect and that of the supercell. May be reduced or adapted to stresses in a direction parallel to the edges of the.

  The interconnect 9440 may be cut from, for example, a thin copper plate, and the supercell 100 may be formed from a solar cell having a smaller area than a standard silicon solar cell, and thus operate at a lower current than a conventional silicon solar cell. It may be thinner than the conductive interconnect. For example, interconnect 9440 may be formed from a copper plate having a thickness of about 50 microns to about 300 microns. The interconnect 9440, even though it was not patterned as described above, may have a direction perpendicular to the supercell edge and resulting from a mismatch between the interconnect CTE and the supercell CTE. It may be thin enough to accommodate stresses in parallel directions. Bus 9450 may be formed from, for example, a copper ribbon.

  Finger 9440C may join bus 9450 after finger 9440B joins the front of supercell 100. In such a case, the finger 9440C may be bent away from the back surface of the supercell 100, for example, in a direction perpendicular to the supercell 100 when joining the bus 9450. Thereafter, finger 9440C may be bent and extend along the back surface of supercell 100, as shown in FIG.

  FIG. 29 illustrates the use of a flexible interconnect sandwiched between overlapping ends of adjacent supercells to electrically connect the supercells in series and provide electrical connection to a junction box. 1 shows a fragmentary cross-sectional view and a perspective view of a cell. FIG. 29A shows an enlarged view of the target area of FIG.

  29 and 29A are partially sandwiched between overlapping ends of two supercells 100, electrically interconnecting the ends to the front end contact of one of the supercells and the other supercell. 9 illustrates the use of an exemplary flexible interconnect 2960 to provide electrical connections to the back end contacts of the cells, thereby interconnecting the supercells in series. In the example shown, the interconnect 2960 is hidden from view from the front of the solar module by the upper one of the two overlapping solar cells. In another variation, the adjacent ends of the two supercells do not overlap and the portion of the interconnect 2960 that connects to the front end contact of one of the two supercells is visible from the front of the solar module. I can do it. Optionally, in such variations, portions of the interconnect that are otherwise visible from the front of the module may be covered or colored (eg, darkened) with normal color vision Can reduce the visible contrast between the interconnect and the supercell, as perceived by a person having The interconnect 2960 extends beyond the side edges of the two supercells, parallel to the adjacent edges of the supercells, and in parallel with a similarly arranged pair of supercells in adjacent rows. A pair of cells may be electrically connected.

  Ribbon conductors 2970 are conductively bonded to interconnects 2960 as shown, connecting adjacent ends of the two supercells to electrical components on the back of the solar module (eg, module terminals and terminals in a junction box). And / or a bypass diode). In another variation (not shown), instead of conductively bonding to the interconnects 2960, the ribbon conductors 2970 are electrically connected to the back contact of one of the supercells in an overlapping direction away from their overlapping ends. I can do it. That configuration may also provide one or more bypass diodes, or hidden taps to other electrical components on the back of the solar module.

  The interconnects 2960 can optionally be die cut from, for example, a conductive sheet, and are optionally patterned to enhance their mechanical compliance in both directions perpendicular and parallel to the edges of the supercell. May reduce or adapt to stresses in directions perpendicular and parallel to the edges of the supercell, resulting from mismatches between the CTE of the interconnect and the CTE of the supercell. Such patterning may include, for example, slits, slots (as shown), or holes. The mechanical compliance of the flexible interconnect, and its bonding to the supercell or multiple connections, allows the interconnecting supercell to withstand the stresses resulting from CTE mismatch during the lamination process described in more detail below. Should be sufficient. The flexible interconnect may be bonded to the supercell, for example, by an electrically conductive bonding agent having mechanical compliance as described above for use in bonding overlapping solar cells. Optionally, the electrically conductive bonding agent is located only at discrete locations along the edge of the supercell, rather than in a solid line extending substantially the length of the edge of the supercell, and is electrically conductive. Can reduce or accommodate stresses in a direction parallel to the edges of the supercell, resulting from a mismatch between the thermal expansion coefficients of the conductive bond or interconnect and the supercell. obtain. Interconnect 2960 may be cut, for example, from a thin copper plate.

  Embodiments may include one or more of the features described in the following U.S. Patent Publications. U.S. Patent Publication No. 2014/0124013 and U.S. Patent Publication No. 2014/0124014. Both of these are incorporated herein by reference in their entirety for all purposes.

  This specification describes a silicon solar cell that is arranged in a shingle-like configuration and electrically connected in series to form supercells with the supercells arranged in a plurality of physically parallel rows in a solar module. A highly efficient solar module is disclosed. The supercells may have a length that extends essentially over the entire length or width of the solar module, for example, or two or more supercells may be arranged end-to-end within a row . This arrangement hides the solar cell-to-solar cell electrical interconnections and thus forms a visually attractive solar module with little or no contrast between adjacent series connected solar cells. Can be used.

  A supercell may include any number of solar cells, including at least 19 solar cells in some embodiments, and in certain embodiments, for example, more than or equal to 100 silicon solar cells. Electrical contacts at intermediate locations along the supercell can electrically segment the supercell into two or more series connected segments while maintaining a physically continuous supercell. It might be desirable. The present specification discloses that such an electrical connection is established with the rear contact pads of one or more silicon solar cells in the supercell and is hidden from view from the front of the solar module, and is therefore referred to herein as "hidden". Disclose an arrangement that provides an electrical tap connection point called a "tap". The hidden tap is the electrical connection between the back of the solar cell and the conductive interconnect.

  The present specification describes a flexible interconnect for electrically interconnecting a front supercell end contact pad, a rear supercell end contact pad, or a hidden tap contact pad to other solar cells or to other electrical components in a solar module. The use of parts is also disclosed.

  In addition, the present specification describes a machine that directly joins adjacent solar cells within a supercell to accommodate thermal expansion mismatch between the supercell and the glass front sheet of the solar module. The use of an electrically conductive adhesive to provide a conductive joint with mechanical compliance allows the flexible interconnect to accommodate the thermal expansion mismatch between the flexible interconnect and the supercell. Disclosed in conjunction with the use of an electrically conductive adhesive to join the connection to the supercell. This may avoid damage to the solar module that may otherwise occur as a result of thermal cycling of the solar module.

  As further described below, the electrical connection to the hidden tap contact pad is used to electrically connect a segment of the supercell in parallel with a corresponding segment of one or more supercells in adjacent rows, and / or Alternatively, an electrical connection to the solar module circuit may be provided for a variety of applications, including but not limited to power optimization (eg, bypass diodes, AC / DC micro inverters, DC / DC converters) and reliability applications. Can be used to provide.

  The use of hidden taps, as just described, can further enhance the aesthetic appearance of the solar module by providing a substantially all black appearance to the solar module in combination with a hidden battery-to-cell connection, By allowing the working area to fill a larger portion of the module's surface area, the efficiency of the solar module may also be increased.

  Turning now to the drawings for a more detailed understanding of the solar modules described herein, FIG. 1 shows that the edges of adjacent solar cells overlap and are electrically connected to form a supercell 100. FIG. 2 shows a cross-sectional view of a string of solar cells 10 connected in series and arranged in a shingle-like shape in a state of being in a shingled state. Each solar cell 10 includes a semiconductor diode structure and a plurality of electrical contacts to the semiconductor diode structure. Thereby, the current generated in the solar cell 10 when the solar cell 10 is irradiated with light can be provided to an external load.

  In the example described herein, each solar cell 10 has a rectangular shape with metallized patterns on the front (sun side) and back (shadow side) surfaces that provide electrical contact on opposing sides of the np junction. A crystalline silicon solar cell, wherein a front metallization pattern is disposed on an n-type conductive semiconductor layer and a rear metallization pattern is disposed on a p-type conductive semiconductor layer. However, other material systems, diode structures, physical dimensions, or electrical contact arrangements may be used where appropriate. For example, the front (sun side) metallization pattern may be disposed on a p-type conductive semiconductor layer, and the back (shadow side) metallization pattern may be disposed on an n-type conductive semiconductor layer.

  Referring again to FIG. 1, in the supercell 100, adjacent solar cells 10 electrically connect the front metallization pattern of one solar cell to the back metallization pattern of an adjacent solar cell in the area where they overlap. It is directly conductively bonded to each other by an electrically conductive bonding agent. Suitable electrically conductive bonding agents may include, for example, electrically conductive adhesives, electrically conductive adhesive films and tapes, and conventional solders.

  FIGS. 31AA and 31A are partially sandwiched between overlapping ends of two supercells 100, electrically interconnecting the ends to the front end contact of one of the supercells and the other supercell. 10 illustrates the use of an exemplary flexible interconnect 3160 to provide electrical connections to the backside edge contacts of the, thereby interconnecting the supercells in series. In the example shown, the interconnect 3160 is hidden from view from the front of the solar module by the upper one of the two overlapping solar cells. In another variation, the adjacent ends of the two supercells do not overlap and the portion of the interconnect 3160 that connects to the front end contact of one of the two supercells is visible from the front of the solar module. I can do it. Optionally, in such variations, portions of the interconnect that are otherwise visible from the front of the module may be covered or colored (eg, darkened) with normal color vision Can reduce the visible contrast between the interconnect and the supercell, as perceived by a person having The interconnect 3160 extends beyond the side edges of the two supercells, parallel to the adjacent edges of the supercells, and in parallel with a similarly arranged pair of supercells in adjacent rows. A pair of cells may be electrically connected.

  A ribbon conductor 3170 is conductively bonded to the interconnect 3160 as shown, connecting the adjacent ends of the two supercells to the electrical components on the back of the solar module (eg, module terminals and terminals in a junction box). And / or a bypass diode). In another variation (not shown), instead of conductively bonding to the interconnects 3160, the ribbon conductors 3170 are electrically connected to the back contact of one of the overlapping supercells in a direction away from their overlapping ends. I can do it. That configuration may also provide one or more bypass diodes, or hidden taps to other electrical components on the back of the solar module.

  2A-2R illustrate an exemplary rectangular solar module 200 that includes six rectangular supercells 100 each having a length approximately equal to the length of the long side of the solar module. The supercells are arranged as six parallel rows, with the long sides oriented parallel to the long sides of the module. A similarly configured solar module may include more or less rows of supercells of such a side length than shown in this example. In another variation, the supercells each have a length approximately equal to the length of the short sides of the rectangular solar module, and are arranged in parallel rows with their long sides oriented parallel to the short sides of the module. Can be deployed. In still other arrangements, each row may include two or more supercells interconnected electrically in series. The module may have a short side that is, for example, about 1 meter in length, and a long side that is, for example, about 1.5 to about 2.0 meters in length. Any other suitable shape (eg, square) and dimensions may be used for the solar module.

  Each supercell in this example includes 72 rectangular solar cells, each having a width equal to approximately 1/6 the width of a 156 mm square or pseudo-square wafer. Any other suitable number of rectangular solar cells of any other suitable dimensions may be used.

As shown, a solar cell having a long, narrow aspect ratio and an area smaller than the area of a standard 156 mm × 156 mm solar cell is the I ² in the solar cell module disclosed herein. It can be advantageously employed to reduce R resistance power loss. In particular, the area of the solar cell 10 that is small compared to a standard size silicon solar cell reduces the current generated by the solar cell and reduces the resistance in that solar cell and in the series-connected strings of such solar cells. Reduce power loss directly.

  Hidden taps to the backside of the supercell may be established, for example, using electrical interconnects that are conductively bonded to one or more hidden tap contact pads located only at the edge of the backside metallization pattern of the solar cell. . Alternatively, the hidden tap may be established with interconnects extending substantially the entire length of the solar cell (perpendicular to the long axis of the supercell), and the length of the solar cell in the backside metallization pattern Conductive bonding to a plurality of hidden tap contact pads distributed along.

  FIG. 31A shows an exemplary solar cell backside metallization pattern 3300 suitable for use with a rim-connected hidden tap. The metallization pattern is a continuous aluminum electrical contact 3310, a plurality of silver contact pads 3315 arranged parallel to and adjacent to the long side edge of the back side of the solar cell, the short side of the back side of the solar cell. Include silver hidden tap contact pads 3320, each of which is arranged parallel to one of the adjacent edges. When a solar cell is placed in a supercell, the front surface of an adjacent rectangular solar cell overlaps the contact pad 3315 and is directly joined. The interconnect may be conductively bonded to one or the other of the hidden tap contact pads 3320 to provide a hidden tap to the supercell. (If desired, two such interconnects can be employed to provide two hidden taps.)

  In the arrangement shown in FIG. 31A, the flow of current to the hidden taps reaches the interconnection junction (contact 3320) through the rear battery metallization substantially parallel to the long sides of the solar cell. To encourage current flow along this path, the resistance of the back metallized sheet is preferably less than or equal to about 5 ohms / square, or less than or equal to about 2.5 ohms / square.

  FIG. 31B illustrates another exemplary solar cell backside metallization pattern 3301 suitable for use with hidden taps employing bus-like interconnects along the length of the solar cell backside. The metallization pattern includes a continuous aluminum electrical contact 3310, a plurality of silver contact pads 3315 disposed parallel to and adjacent to the long side edge of the rear surface of the solar cell, and the long side of the solar cell. And a plurality of silver hidden tap contact pads 3325 that are arranged in a row parallel to and are approximately centered on the rear face of the solar cell. An interconnect extending substantially the entire length of the solar cell may be conductively bonded to the hidden tap contact pad 3325 to provide a hidden tap to the supercell. The current flow to the hidden tap is mainly through the bus-like interconnects, making the conductivity of the backside metallization pattern less important for the hidden tap.

  The location and number of hidden tap contact pads to which the hidden tap interconnects on the back of the solar cell join affect the length of the current path through the back metallization, hidden tap contact pads, and the interconnects of the solar cell give. As a result, the placement of the hidden tap contact pad may be selected to minimize resistance to current collection to and through the hidden tap interconnect. In addition to the configuration shown in FIGS. 31A-31B (and FIG. 31C described below), suitable hidden tap contact pad arrangements may include, for example, a two-dimensional array and a row extending perpendicular to the long axis of the solar cell. . In the latter case, the row of hidden tap contact pads may be located, for example, adjacent to the short edge of the first solar cell.

  FIG. 31C illustrates another exemplary solar cell suitable for use with either edge-connecting hidden taps along the backside length of the solar cell or hidden taps employing bus-like interconnects. A rear metallization pattern 3303 is shown. The metallization pattern is connected to continuous copper contact pads 3315 and 3315 disposed parallel to and adjacent to the long side edge of the rear surface of the solar cell, and a plurality of metal pads extending vertically from the contact pads 3315 And a continuous copper bus hidden tap contact pad 3325 that extends parallel to the long sides of the solar cell and is located approximately in the center of the rear surface of the solar cell. An edge-connecting interconnect may be joined to the end of the copper bus 3325 to provide a hidden tap to the supercell. (If desired, two such interconnects may be employed at each end of the copper bus 3325 to provide two hidden taps.) Alternatively, substantially the entire length of the solar cell An extending interconnect may be conductively connected to the copper bus 3325 to provide a hidden tap to the supercell.

  The interconnect employed to form the hidden tap may be soldered, welded, conductive adhesive, or joined in any other suitable manner to the hidden tap contact pads in the backside metallization pattern. For metallization patterns employing silver pads as illustrated in FIGS. 31A-31B, the interconnects may be formed, for example, from copper coated with tin. Other approaches are directly to the aluminum back surface contact 3310 by an aluminum conductor forming an aluminum-aluminum bond, which can be formed, for example, by electrical or laser welding, soldering, or conductive adhesive. Is to establish a hidden tap. In certain embodiments, the contacts may include tin. In the case just described, the rear metallization of the solar cell may not have silver contact pads 3320 (FIG. 31A) or 3325 (FIG. 31B), but may be edge-connected or bus-like aluminum Interconnects may be bonded to aluminum (or tin) contacts 3310 at locations corresponding to the contact pads.

  Differential thermal expansion between the hidden tap interconnect (or the interconnect to the front or back supercell end contact) and the silicon solar cell, and the resulting solar cell and interconnect Stress can lead to tears and other forms of failure that can degrade the performance of the solar module. As a result, hidden taps and other interconnects are desirably configured to accommodate such differential expansion without substantial stress appearing. The interconnect may be formed, for example, from a highly ductile material (eg, soft copper, very thin copper plate) to provide a material having a low coefficient of thermal expansion (eg, Kovar, Invar, or other low thermal expansion). Iron-nickel alloy) or from a material having a coefficient of thermal expansion approximately matching that of silicon to accommodate differential thermal expansion between the interconnect and the silicon solar cell Out-of-plane geometry, such as kinks, jogs, or depressions, by incorporating in-plane geometric expansion features, such as slits, slots, holes, or truss structures, and / or to accommodate such differential thermal expansion Employing features may provide relief of stress and thermal expansion. Some of the interconnects that bond to the hidden tap contact pads (or to the front or back end contact pads of the supercell as described below) have a thickness, for example, less than about 100 microns, about Less than 50 microns, less than about 30 microns, or less than about 25 microns may increase the flexibility of the interconnect.

  Referring again to FIGS. 7A, 7B-1 and 7B-2, these figures employ stress relief geometric features and are intended for use as hidden tap interconnects, or for front or back supercell ends. FIG. 10 illustrates some example interconnect configurations identified by reference numerals 400A-400U that may be suitable for electrical connection to contacts. The length of these interconnects is typically approximately equal to the length of the long side of the rectangular solar cell to which they are joined, but can be any other suitable length. The exemplary interconnects 400A-400T shown in FIG. 7A employ various in-plane stress relief features. The exemplary interconnect 400U shown in the in-plane (xy) view of FIG. 7B-1 and the out-of-plane (xz) view of FIG. A bent portion 3705 is employed. The bends 3705 reduce the apparent tensile stiffness of the ribbon metal. The bend allows the ribbon material to bend locally, instead of only becoming longer when the ribbon is under tension. For thin ribbons, this can substantially reduce the apparent tensile stiffness, for example, by 90% or more. The exact amount of reduction in apparent tensile stiffness depends on several factors, including the number of bends, the geometry of the bends, and the thickness of the ribbon. Also, the interconnects may employ a combination of in-plane and out-of-plane stress relief features.

  37A-1 to 38B-2, described further below, may employ in-plane and / or out-of-plane stress relief geometric features and may be suitable for use as edge-connecting interconnects for hidden taps. 4 illustrates some possible interconnect configurations.

  To reduce or minimize the number of extending conductors required to connect each hidden tap, a hidden tap interconnect bus may be utilized. In this approach, hidden tap contact pads of adjacent supercells are connected to each other by using a hidden tap interconnect. (Electrical connections are typically positive-positive or negative-negative, ie, of the same polarity at each end.)

  For example, FIG. 32 illustrates a first hidden tap interconnect that extends over substantially the entire width of the solar cell 10 in the first supercell 100 and is conductively bonded to a hidden tap contact pad 3325 arranged as shown in FIG. 31B. 3400 and a second hidden tap interconnect that extends across the full width of the corresponding solar cell in supercell 100 in an adjacent row and is also conductively bonded to hidden tap contact pad 3325 arranged as shown in FIG. 31B 3400. The two interconnects 3400 are placed side by side and optionally abutting or overlapping each other, conductively joined to each other, or otherwise electrically connected to two adjacent super A bus that interconnects the cells may be formed. This scheme can be extended, if desired, over additional rows of supercells (eg, all rows) to form parallel segments of a solar module including multiple segments of several adjacent supercells. I can do it. FIG. 33 shows a perspective view of a portion of the supercell of FIG.

  FIG. 35 shows that the supercells in adjacent rows extend into the gaps between the supercells, to the hidden tap contact pads 3320 on one supercell, and to the other hidden tap contact pads 3320 on the other supercell. Shows an example of interconnecting via short interconnects 3400 that are conductively joined. Here, the contact pads are arranged as shown in FIG. FIG. 36 shows that a short interconnect extends into the gap between two supercells in adjacent rows, at the end of the central copper bus portion of the backside metallization on one supercell, and on the other supercell. A similar arrangement is shown with conductive bonding to the adjacent edge of the central copper bus portion of the back metallization of the cell. Here, the rear metal coating made of copper is configured as shown in FIG. 31C. In both of these examples, the interconnect scheme may be extended across additional rows of supercells (eg, all rows) to extend multiple segments of several adjacent supercells, as desired. A parallel segment of a solar module may be formed.

  37A-1 through 37F-3 illustrate in-plane (xy) and out-of-plane (xz) views of an exemplary short hidden tap interconnect 3400 that includes an in-plane stress relief feature 3405. FIG. (The xy plane is the surface of the backside metallization pattern of the solar cell.) In the examples of FIGS. 37A-1 through 37E-2, each interconnect 3400 is opposed to one or more in-plane stress relief features. Includes tabs 3400A and 3400B positioned on mating sides. Exemplary in-plane stress relief features include one, two or more hollow diamond-shaped arrangements, zigzag, and one, two or more slot arrangements.

  As used herein, the term "in-plane stress relief feature" may also refer to the thickness or ductility of an interconnect or of a portion of an interconnect. For example, the interconnect 3400 shown in FIGS. 37F-1 to 37F-3 may have a thickness T in the xy plane of some straight and flat length, for example, less than or equal to about 100 microns. Formed from a thin copper ribbon or copper foil that is less than or equal to about 50 microns, less than or equal to about 30 microns, or less than or equal to about 25 microns, increases the flexibility of the interconnect. Enhance. The thickness T can be, for example, about 50 microns. The length L of the interconnect may be, for example, about 8 centimeters (cm), and the width W of the interconnect may be, for example, about 0.5 cm. FIGS. 37F-3 and 37F-1 show front and back views of the interconnect in the xy plane, respectively. The front of the interconnect faces the back of the solar module. Since the interconnect may extend across the gap between two parallel supercell rows in the solar module, a portion of the interconnect may be visible through the gap from before the solar module. Optionally, the visible portion of the interconnect may be blackened, for example, coated with a black polymer layer to reduce its visibility. In the example shown, the central portion 3400C of the front face of the interconnect having a length L2 of about 0.5 cm is coated with a thin black polymer layer. Typically, L2 is greater than or equal to the width of the gap between the supercell rows. The black polymer layer can be, for example, about 20 microns thick. Such thin copper ribbon interconnects are optional and may also employ in-plane or out-of-plane stress relief features as described above. For example, the interconnect may include a stress relief out-of-plane bend as described above in connection with FIGS. 7B-1 and 7B-2.

  38A-1 to 38B-2 show in-plane (xy) and out-of-plane (xz) views of an exemplary short hidden tap interconnect 3400 that includes an out-of-plane stress relief feature 3407. In these examples, each interconnect 3400 includes tabs 3400A and 3400B located on opposing sides of one or more out-of-plane stress relief features. Exemplary out-of-plane stress relief features include one, two, or more bend arrangements, kinks, depressions, jogs, or bumps.

  The type and arrangement of stress relief features illustrated in FIGS. 37A-1 to 37E-2 and 38A-1 to 38B-2 and the interconnects described above in connection with FIGS. 37F-1 to 37F-3 Ribbon thickness can also be employed, as appropriate, at the long hidden tap interconnects as described above, and at the interconnect joining the back or front end contacts of the supercell. The interconnect may include a combination of both in-plane and out-of-plane stress relief features. The in-plane and out-of-plane stress relief features are designed to reduce or minimize the effects of strain and stress on the solar cell connections, thereby forming a reliable and resilient electrical connection.

  FIGS. 39A-1 and 39A-2 illustrate short hidden tap interconnects that include battery contact pad alignment and supercell edge alignment features to improve automation, manufacturability, and placement accuracy. Configuration is shown. FIGS. 39B-1 and 39B-2 illustrate exemplary configurations of short hidden tap interconnects that include asymmetric tab lengths. Such asymmetric interconnects may be used in the opposite orientation to avoid overlapping conductors running parallel to the long axis of the supercell. (See the description of FIGS. 42A-42B below.)

  Hidden taps as described herein may form the electrical connections required in the layout of the module to provide the desired module electrical circuit. Hidden tap connections may be established at intervals of, for example, 12, 24, 36, or 48 solar cells along the supercell, or at any other suitable intervals. The spacing between hidden taps can be determined depending on the application.

  Each supercell typically includes a front end contact at one end of the supercell and a back end contact at the other end of the supercell. In a variant in which the supercell extends over the length or width of the solar module, these end contacts are located adjacent opposing edges of the solar module.

  Flexible interconnects may be conductively connected to the front or back end contacts of the supercell to electrically connect the supercell to other solar cells or other electrical components within the module. For example, FIG. 34A shows a cross-sectional view of an exemplary solar module with an interconnect 3410 conductively bonded to a back end contact at the end of the supercell. The back end contact interconnect 3410 may have a thickness in a direction perpendicular to the surface of the solar cell to which it is bonded, for example, less than or equal to about 100 microns, less than or equal to about 50 microns, A thin copper ribbon or foil of less than or equal to about 30 microns, less than or equal to about 25 microns, or less, or including, may increase the flexibility of the interconnect. The interconnect may have a width in a direction perpendicular to the flow of current through the interconnect, in a plane of the surface of the solar cell, for example, greater than or equal to about 10 mm, to improve conductivity. As shown, the back end contact interconnect 3410 may lie behind the solar cell with no portion of the interconnect extending beyond the supercell in a direction parallel to the supercell row.

  Similar interconnects can be used to connect to the front end contacts. Alternatively, to reduce the area of the front of the solar module occupied by the front end interconnect, the front interconnect provides a thin, flexible portion that joins directly to the supercell and higher conductivity. And thicker portions. This arrangement reduces the width of the interconnect required to achieve the desired conductivity. The thicker portion of the interconnect may be, for example, an integral part of the interconnect, or may be a separate part that joins the thinner portion of the interconnect. For example, FIGS. 34B-34C show cross-sectional views of an exemplary interconnect 3410 that conductively joins to a front end contact at the end of the supercell, respectively. In both examples, the thin flexible portion 3410A of the interconnect, which directly joins the supercell, has a thickness in the direction perpendicular to the surface of the solar cell to which it is joined, less than about 100 microns. Or a thin copper ribbon or foil thinner than or equal to about 50 microns, less than or equal to about 30 microns, or less than or equal to about 25. The thicker copper ribbon portion 3410B of the interconnect is joined to the thinner portion 3410A to improve the conductivity of the interconnect. In FIG. 34B, an electrically conductive tape 3410C on the back of the thin interconnect portion 3410A joins the thin interconnect portion to the supercell and to the thick interconnect portion 3410B. In FIG. 34C, a thin interconnect portion 3410A is joined to a thick interconnect portion 3410B by an electrically conductive adhesive 3410D and to a supercell by an electrically conductive adhesive 3410E. Electrically conductive adhesives 3410D and 3410E can be the same or different. The electrically conductive adhesive 3410E may be, for example, a solder.

  The solar module described herein includes a laminated structure as shown in FIG. 34A with a supercell and one or more encapsulant materials 3610 sandwiched between a transparent front sheet 3620 and a rear sheet 3630. obtain. The transparent front sheet can be, for example, glass. The backsheet can also be glass, or any other suitable material. Additional strips of encapsulant may be disposed between the back end interconnect 3410 and the back of the supercell as shown.

  As mentioned above, hidden taps bring beauty to the "all black" module. Since these connections are typically established with highly reflective conductors, they will usually have a high contrast to the mounted solar cells. However, by making connections on the back of the solar cell and by routing other conductors in the solar module circuit behind the solar cell, the various conductors are hidden from view. This allows multiple connection points (hidden taps) while still maintaining an "all black" appearance.

  Hidden taps can be used to form the layout of various modules. In the example of FIG. 40 (physical layout) and FIG. 41 (electrical circuit diagram), the solar module includes six supercells, each extending over the length of the module. Hidden tap contact pads and short interconnects 3400 segment each supercell into one third and electrically connect adjacent supercell segments in parallel, thereby providing three groups of parallel connected supercells. A segment is formed. Each group connects in parallel with a different one of the bypass diodes 1300A-1300C incorporated (embedded therein) within the module stack. The bypass diode may be located, for example, directly behind the supercell or between the supercells. The bypass diode may be located, for example, approximately along the centerline of the solar module, parallel to the long sides of the solar module.

  In the example of FIGS. 42A-42B (which also corresponds to the electrical schematic of FIG. 41), the solar module includes six supercells each extending the length of the module. Hidden tap contact pads and short interconnects 3400 segment each supercell into one third and electrically connect adjacent supercell segments in parallel, thereby providing three groups of parallel connected supercells. A segment is formed. Each group is located behind the supercell and connects the hidden tap contact pads and short interconnects to the bypass diodes located on the back of the module in the junction box, bypass diodes 1300A-1300C through bus connections 1500A-1500C. Connected in parallel with different ones.

  FIG. 42B provides a detailed view of the connection between the short hidden tap interconnect 3400 and conductors 1500B and 1500C. As depicted, these conductors do not overlap each other. In the example shown, this is enabled by the use of asymmetric interconnects 3400 that are arranged in opposite orientations. An alternative approach to avoiding conductor overlap is to employ a first symmetric interconnect 3400 with tabs of one length and a second symmetric interconnect 3400 with tabs of different lengths.

  In the example of FIG. 43 (corresponding to the electric circuit diagram of FIG. 41), the solar module has the same configuration as that shown in FIG. 42A. The difference is that the hidden tap interconnect 3400 forms a continuous bus that extends over substantially the full width of the solar module. Each bus may be a single long interconnect 3400 that conductively connects to the back metallization of each supercell. Alternatively, the bus may be a plurality of buses, each extending over a single supercell, conductively joined to each other, or otherwise electrically interconnected as described above in connection with FIG. It may include individual interconnects. FIG. 43 illustrates a supercell end interconnect 3410 that forms a continuous bus along one end of the solar module to electrically connect the front end contacts of the supercell, and along the opposite end of the solar module. Also shown is an additional supercell end interconnect 3410 that forms a continuous bus to electrically connect the back end contacts of the supercell.

  The exemplary solar modules of FIGS. 44A-44B also correspond to the electrical schematic of FIG. This example includes a short hidden tap interconnect 3400 as in FIG. 42A and an interconnect 3410 that forms a continuous bus for supercell front and back end contacts as in FIG. adopt.

  In the example of FIG. 47A (physical layout) and FIG. 47B (electrical circuit diagram), the solar module includes six supercells, each extending the entire length of the solar module. Hidden tap contact pads and short interconnects 3400 segment each supercell into 2/3 length sections and 1/3 length sections. An interconnect 3410 at the lower edge of the solar module (as depicted in the drawing) has three rows on the left hand side parallel to each other, three rows on the right hand side parallel to each other, and three rows on the left hand side to the right hand side. Are interconnected in series with the three rows. This arrangement forms three groups of parallel connected supercell segments each having a length 2/3 of the length of the supercell. Each group connects in parallel with a different one of the bypass diodes 2000A-2000C. This arrangement provides about twice the voltage that would be provided by the same supercell instead if they were electrically connected as shown in FIG. 41 and about half the current that would be provided. I do.

  As described above with reference to FIG. 34A, the interconnect joining the supercell back end contact may lie entirely behind the supercell and be hidden from view from the front (sun) side of the solar module. The interconnect 3410 that joins the supercell front end contact may be visible in a back view of the solar module (eg, as in FIG. 43). Either because they extend beyond the edge of the supercell (eg, as in FIG. 44A), or because they fold around and below the edge of the supercell. It is.

  The use of hidden taps facilitates reducing the number of solar cells grouped per bypass diode. In the example of FIGS. 48A-48B (each showing a physical layout), the solar module includes six supercells each extending the length of the module. Hidden tap contact pads and short interconnects 3400 segment each supercell by a factor of five and electrically connect adjacent supercell segments in parallel, thereby providing five groups of parallel connected supercell segments. Is formed. Each group connects in parallel with a different one of the bypass diodes 2100A-2100E incorporated (embedded) within the stack of the module. The bypass diode may be located, for example, directly behind the supercell or between the supercells. The supercell end interconnect 3410 forms a continuous bus along one end of the solar module to electrically connect the front end contacts of the supercell and the additional supercell end interconnect 3410 A continuous bus is formed along the opposite end to electrically connect the back end contact of the supercell. In the example of FIG. 48A, a single junction box 2110 is electrically connected to the front and back end interconnect buses by conductors 2115A and 2115B. However, since there is no diode in the junction box, alternatively (FIG. 48B), the long return conductors 2215A and 2115B may be removed, and a single junction box 2110 may be located, for example, on the opposite edge of the module. It has been replaced by two unipolar (+ or-) junction boxes 2110A-2110B. This eliminates resistive losses in long return conductors.

  The examples described herein use hidden taps to electrically segment each supercell into three or five solar cell groups, but these examples are intended to be illustrative and not limiting. Have been. More generally, the hidden taps are superimposed so that there are more or fewer solar cells groups shown and / or more or less solar cells shown per group. It can be used to electrically segment cells.

  In the normal operation of the solar module described herein, little or no current flows through any hidden tap contact pads without a forward biased and conducting bypass diode. Instead, current flows through the length of each supercell through an intercell conductive junction formed between adjacent overlapping solar cells. In contrast, FIG. 45 shows the current flow when a portion of the solar module is bypassed through a forward biased bypass diode. As indicated by the arrows, in this example, the current in the leftmost supercell flows along the supercell until it reaches the tapped solar cell, and then the back metallization of the solar cell, A hidden tap contact pad (not shown), an interconnect 3400 to a second solar cell in an adjacent supercell, another hidden tap contact pad to which the interconnect is joined on the second solar cell ( (Not shown), through the rear metallization of the second solar cell, through additional hidden tap contact pads, interconnects, and the solar cell rear metallization to the bus connection 1500 to the bypass diode. To reach. The flow of current through the other supercells is similar. As is evident from the illustration, under such circumstances, the hidden tap contact pads conduct current from two or more rows of supercells, and therefore, with any single solar cell in the module. It can conduct a current greater than the generated current.

  Typically, there is no busbar, contact pad, or other light blocking element (other than the front metallized fingers or overlapping portions of adjacent solar cells) on the front of the solar cell opposite the hidden tap contact pad. As a result, if the hidden tap contact pad is formed from silver on a silicon solar cell, the light conversion efficiency of the solar cell in the area of the hidden tap contact pad will cause the silver contact pad to prevent rear carrier recombination If the effect of the rear field is reduced, it can be reduced. To avoid this loss of efficiency, most solar cells in a supercell typically do not include a hidden tap contact pad. (For example, in some variations, only solar cells that require a hidden tap contact pad for a bypass diode circuit will include such a hidden tap contact pad. To match the current generation of the solar cell with the current generation of the solar cell without the hidden tap contact pad, the solar cell including the hidden tap contact pad has a larger light collection area than the solar cell without the hidden tap contact pad. May be provided.

  Each hidden tap contact pad may have a rectangular dimension, for example, less than or equal to about 2 mm x less than or equal to about 5 mm.

  Solar modules undergo thermal cycling as a result of temperature changes during operation and during the environment in which they are installed. As shown in FIG. 46A, during such temperature cycling, as a result of thermal expansion mismatch between the silicon solar cells in the supercell and other parts of the module, for example, the glass front sheet of the module. Along the long axis of the supercell row, there will be relative movement between the supercell and the other parts of the module. This inconsistency tends to stretch or compress the supercell and may damage the solar cells or the conductive junctions between the solar cells in the supercell. Similarly, as shown in FIG. 46B, during temperature cycling, as a result of the mismatch in thermal expansion between the interconnect joining the solar cells and the solar cells, the direction perpendicular to the plurality of supercell rows is increased. , A relative movement between the interconnect and the solar cell will occur. This mismatch can pull and damage the solar cells, the interconnects, and the conductive junction between them. This can occur for interconnects joining the hidden tap contact pads and for interconnects joining the supercell front or back end contacts.

  Similarly, for example, during transport or from weather (eg, wind and snow), the periodic mechanical loads of the solar module can be reduced at the cell-to-cell junctions within the supercell and at the interconnect with the solar cells. Local shear forces can occur at the joint between the parts. These shear forces can also damage the solar module.

  Conductive bonding used to join adjacent and overlapping solar cells together to prevent problems arising from relative movement between the supercell and the rest of the solar module along the long axis of the supercell row The agent is thermally expanded between the supercell and the glass front sheet of the module in a direction parallel to the rows at a temperature range of about -40 ° C to about 100 ° C without damaging the solar module. May be selected to form a flexible conductive junction 3515 (FIG. 46A) between overlapping solar cells that provides mechanical compliance to the supercell that accommodates the mismatch of Under standard test conditions (ie, 25 ° C.), the conductive adhesive may be, for example, less than or equal to about 100 megapascals (MPa), less than or equal to about 200 MPa, less than about 300 MPa, or Equal to, less than or equal to about 400 MPa, less than or equal to about 500 MPa, less than or equal to about 600 MPa, less than or equal to about 700 MPa, less than or equal to about 800 MPa, or less than or equal to about 900 MPa. It may be selected to form a conductive joint having a rigidity lower or equal to, or lower than or equal to about 1000 MPa. A plurality of flexible conductive junctions between overlapping adjacent solar cells may accommodate, for example, differential movements greater than or equal to about 15 microns between each cell and the glass frontsheet. Suitable conductive adhesives may include, for example, ECM 1541-S3 available from Engineered Conductive Materials LLC.

  A supercell that reduces the risk of damage to the solar module from hot spots that may occur during operation of the solar module if the solar cells in the solar module are reverse biased as a result of shadowing or for some other reason In order to promote heat flow along the solar cell, for example, the thermal conductivity in the direction perpendicular to the solar cell is less than or equal to about 50 microns, and the thermal conductivity in the direction perpendicular to the solar cell is about 1.5 W / Conductive junctions between overlapping adjacent solar cells higher or equal to (meter-K) may be formed.

  To prevent problems arising from relative movement between the interconnect and the solar cell to which it is joined, the conductive adhesive used to join the interconnect to the solar cell damages the solar module In the temperature range from about -40 ° C to about 180 ° C without the interconnect being sufficiently rigid to accommodate the thermal expansion mismatch between the solar cell and the interconnect; To form a conductive junction between Under standard test conditions (ie, 25 ° C.), the conductive adhesive may have, for example, greater than or equal to about 1800 MPa, greater than or equal to about 1900 MPa, greater than or equal to about 2000 MPa, or greater than about 2000 MPa. Higher than or equal to 2100 MPa, higher than or equal to about 2200 MPa, higher than or equal to about 2300 MPa, higher than or equal to about 2400 MPa, higher than or equal to about 2500 MPa, higher than about 2600 MPa, or Equal to, greater than or equal to about 2700 MPa, greater than or equal to about 2800 MPa, greater than or equal to about 2900 MPa, or about 3000 MPa Higher or equal to, higher than or equal to about 3100 MPa, higher than or equal to about 3200 MPa, higher than or equal to about 3300 MPa, higher than or equal to about 3400 MPa, higher than or equal to about 3500 MPa, or higher A rigidity equal to, greater than or equal to about 3600 MPa, greater than or equal to about 3700 MPa, greater than or equal to about 3800 MPa, greater than or equal to about 3900 MPa, or greater than or equal to about 4000 MPa. May be selected to form a conductive junction. In such variations, the interconnect may withstand thermal expansion or contraction of the interconnect, for example, greater than or equal to about 40 microns. Suitable conductive adhesives may include, for example, Hitachi CP-450, and solder.

  Thus, the conductive junctions between overlapping adjacent solar cells in the supercell may utilize a different conductive adhesive than the conductive junctions between the supercell and the flexible electrical interconnect. For example, the conductive joint between the supercell and the flexible electrical interconnect may be formed from solder, and the conductive bond between overlapping adjacent solar cells may be formed from a non-solder conductive adhesive. In some variations, both conductive adhesives may be cured in a single process step, for example, with a process window of about 150 ° C to about 180 ° C.

  The above description has focused on assembling a plurality of solar cells (which may be cut solar cells) on a common substrate in a shingle fashion. As a result of this, a module is formed.

  However, to collect a sufficient amount of solar energy to be useful, equipment typically includes many such modules that will themselves be assembled together. According to embodiments, a plurality of solar cell modules may also be assembled in a shingle-like configuration to increase the area efficiency of the array.

  In certain embodiments, the module may include an upper conductive ribbon facing the direction of solar energy and a lower conductive ribbon facing away from the direction of solar energy.

  The lower ribbon is embedded below the battery. Therefore, it does not block the incident light and does not adversely affect the area efficiency of the module. In contrast, the upper ribbon is exposed and blocks incident light, which can adversely affect efficiency.

  According to an embodiment, the modules themselves are shingled so that the upper ribbon can be covered by neighboring modules. This shingled module configuration may also provide additional area on the module for other elements without adversely affecting the final exposed area of the module array. Examples of modular elements that may be located in the overlapping area may include, but are not limited to, a junction box (j-box) and / or a bus ribbon.

  In certain embodiments, the j-boxes of each adjacent shingled module are mated to achieve an electrical connection between them. This simplifies the construction of an array of shingled modules by eliminating wiring.

  In certain embodiments, the j box may be enhanced with additional structural standoffs and / or may be combined with standoffs. Such an arrangement may create an integrated, tilted modular roof mounting rack solution where the dimensions of the junction box determine the tilt. Such an embodiment may be particularly useful when an array of shingled modules is mounted on a flat roof.

  A shingled supercell is a unique module layout for module-level power management devices (eg, DC / AC micro-inverters, DC / DC module power optimizers, voltage intelligence and smart switches, and related devices). Create new opportunities. A key feature of a module-level power management system is power optimization. Supercells as described and employed herein can produce higher voltages than traditional panels. In addition, the layout of the supercell module may further divide the module. Both higher voltage and further splitting create potential benefits for power optimization.

  This specification describes a narrow rectangle that is arranged in a shingle-like configuration and electrically connected in series to form supercells with the supercells arranged in multiple physically parallel rows within the solar module. A highly efficient solar module (ie, solar panel) including a silicon solar cell is disclosed. The supercells may have a length that extends essentially over the entire length or width of the solar module, for example, or two or more supercells may be arranged end-to-end within a row . Each supercell may be any number, including, for example, at least 19 solar cells in some variations, and more than or equal to 100 silicon solar cells in certain variations. It may include a number of solar cells. Each solar module has a conventional size and shape, but still contains hundreds of silicon solar cells, so that the supercells within a single solar module can be electrically interconnected, for example, at about 90 volts. It may be possible to provide a direct current (DC) voltage from (V) to about 450 V or higher.

  As described further below, this high DC voltage allows the DC to AC (AC) conversion by the inverter (eg, a microinverter located on a solar module) to be converted to a DC- This is facilitated by eliminating or reducing the need for DC boost (raising the DC voltage). Also, as described further below, the high DC voltage is the high voltage DC output from the two or more high voltage shingled solar modules in which the DC / AC conversion is electrically connected to each other in parallel. Also facilitates the use of the arrangement performed by the receiving central inverter.

  Turning now to the drawings for a more detailed understanding of the solar modules described herein, FIG. 1 shows that the edges of adjacent solar cells overlap and are electrically connected to form a supercell 100. FIG. 2 shows a cross-sectional view of a string of solar cells 10 connected in series and arranged in a shingle-like shape in a state of being in a shingled state. Each solar cell 10 includes a semiconductor diode structure and a plurality of electrical contacts to the semiconductor diode structure. Thereby, the current generated in the solar cell 10 when the solar cell 10 is irradiated with light can be provided to an external load.

  In the example described herein, each solar cell 10 has a rectangular shape with metallized patterns on the front (sun side) and back (shadow side) surfaces that provide electrical contact on opposing sides of the np junction. A crystalline silicon solar cell, wherein a front metallization pattern is disposed on an n-type conductive semiconductor layer and a rear metallization pattern is disposed on a p-type conductive semiconductor layer. However, other material systems, diode structures, physical dimensions, or electrical contact arrangements may be used where appropriate. For example, the front (sun side) metallization pattern may be disposed on a p-type conductive semiconductor layer, and the back (shadow side) metallization pattern may be disposed on an n-type conductive semiconductor layer.

  Referring again to FIG. 1, in the supercell 100, adjacent solar cells 10 electrically connect the front metallization pattern of one solar cell to the back metallization pattern of an adjacent solar cell in the area where they overlap. Conductive bonding is performed by an electrically conductive bonding agent. Suitable electrically conductive bonding agents may include, for example, electrically conductive adhesives, electrically conductive adhesive films and tapes, and conventional solders.

  2A-2R illustrate an exemplary rectangular solar module 200 that includes six rectangular supercells 100 each having a length approximately equal to the length of the long side of the solar module. The supercells are arranged as six parallel rows, with the long sides oriented parallel to the long sides of the module. A similarly configured solar module may include more or less rows of supercells of such a side length than shown in this example. In another variation, the supercells each have a length approximately equal to the length of the short sides of the rectangular solar module, and are arranged in parallel rows with their long sides oriented parallel to the short sides of the module. Can be deployed. In still other arrangements, each row may include two or more supercells interconnected electrically in series. The module may have a short side that is, for example, about 1 meter in length, and a long side that is, for example, about 1.5 to about 2.0 meters in length. Any other suitable shape (eg, square) and dimensions may be used for the solar module.

  In some variations, the plurality of conductive junctions between the overlapping solar cells may have a plurality of rows in a direction parallel to the plurality of rows at a temperature in a range of about −40 ° C. to about 100 ° C. without damaging the solar module. Providing a plurality of supercells with mechanical compliance that accommodates thermal expansion mismatch between the supercell and the glass frontsheet of the solar module.

  Each supercell in the example shown has a width equal to or approximately equal to 1/6 of the width of a conventional 156 mm square or pseudo-square silicon wafer and a length of a square or pseudo-square wafer. Includes 72 rectangular solar cells equal or approximately equal in width. More generally, rectangular silicon solar cells employed in the solar modules described herein have a length that is, for example, equal to or approximately equal to the width of a conventional size square or pseudo-square silicon wafer, and has a width of For example, the width may be equal to or approximately equal to 1 / M of the width of a conventional size square or pseudo-square wafer. M is any integer satisfying ≦ 20. M can be, for example, 3, 4, 5, 6, or 12. M may be greater than 20. A supercell may include any suitable number of such rectangular solar cells.

  The supercells in the solar module 200 may be interconnected in series by electrical interconnects (optionally flexible electrical interconnects) or by module-level power electronics as described below to provide a conventional size solar module. Thus, a higher voltage than before can be provided. This is because the shingle approach just described incorporates more batteries per module than ever before. For example, a conventional size solar module including a supercell made from a 1/8 cut silicon solar cell may include more than 600 solar cells per module. In comparison, conventional sized solar modules, including conventional sized conventional interconnected silicon solar cells, typically include about 60 solar cells per module. In a conventional silicon solar module, square or pseudo-square solar cells are typically interconnected by copper ribbons and separated from each other to accommodate the interconnect. In such a case, cutting a conventional size square or pseudo-square wafer into a narrow rectangle would reduce the total amount of working solar cell area in the module, and thus the additional required The cell-to-cell interconnect will cause the module power to drop. In contrast, in the solar modules disclosed herein, the shingled arrangement hides the cell-to-cell electrical interconnect below the working solar cell area. As a result, the solar modules described herein have little or no trade-off between module power and the number of solar cells (and required cell-to-cell interconnects) in the solar module. , Can provide a high output voltage without reducing the module output power.

  When all solar cells are connected in series, a shingled solar cell module as described herein may provide a DC voltage in the range, for example, from about 90 volts to about 450 volts, or higher. . As mentioned above, this high DC voltage can be advantageous.

  For example, micro-inverters located on or near a solar module can be used for module-level power optimization and DC-AC conversion. Referring now to FIGS. 49A-49B, conventionally, a micro-inverter 4310 receives a 25V to 40V DC input from a single solar module 4300 and outputs a 230V AC output to match the grid to be connected. A micro-inverter typically includes two main components, a DC / DC boost, and a DC / AC inversion. DC / DC boost is used to increase the DC bus voltage required for DC / AC conversion and is typically the most costly and lossy component (2% efficiency loss). Since the solar modules described herein provide high voltage output, the need for DC / DC boost may be reduced or eliminated (FIG. 49B). This can reduce the cost of the solar module 200 and increase efficiency and reliability.

In a conventional arrangement using a central ("string") inverter instead of a micro-inverter, conventional low DC output solar modules electrically connect to each other and to the string inverter in series. The voltage generated by the strings of solar modules is equal to the sum of the individual module voltages, as they are connected in series. The allowed voltage range determines the maximum and minimum number of modules in the string. The maximum number of modules is set by the module voltage and the specified voltage limit. For example, N _max × V _oc <600 V (home standards in the United States) or N _max × V _oc <1,000 V (commercial standards). The minimum number of modules in series is set by the module voltage and the minimum operating voltage required by the string inverter. N _min × V _mp > V _Invertermin . String inverter (e.g., Fronius, powerOne or SMA inverters,) minimum operating voltage required by _{(V Invertermin)} is typically between about 180V and about 250V. Typically, the optimal operating voltage for a string inverter is about 400V.

  A single high DC voltage shingled solar cell module as described herein provides a voltage greater than the minimum operating voltage required by the string inverter, optionally at the optimal operating voltage of the string inverter. , Or at a voltage close thereto. As a result, the high DC voltage shingled solar cell modules described herein may be electrically connected to the string inverter in parallel with each other. This avoids string length requirements for strings of serially connected modules, which can complicate system design and installation. Also, in the series-connected strings of solar modules, the module with the lowest current dominates, and the system will operate with different multiple If the module receives different irradiation, it cannot operate efficiently. Because the current through each solar module is independent of the current through the other solar modules, the parallel high-voltage module configuration described herein may also avoid these problems. Moreover, such an arrangement does not require module-level power electronics, and thus may improve the reliability of the solar module, which is particularly important in variants where the solar module is located on a roof. possible.

  Referring now to FIGS. 50A-50B, as described above, the supercell may extend approximately the entire length or width of the solar module. Hidden electrical tap junctions (from the front view) can be integrated into the solar module structure to allow electrical connections along the length of the supercell. This can be achieved by connecting the electrical conductor to the rear metallization of the solar cell at the edge or in the middle of the supercell. Such hidden taps allow for electrical segmentation of the supercell, including bypass diodes, module-level power electronics (eg, microinverters, power optimizers, voltage intelligence and voltage intelligence) of the supercell, or segments of the supercell. Smart switches, and related devices), or other components. The use of hidden taps is further described in US Provisional Application No. 62 / 081,200, US Provisional Application No. 62 / 133,205, and US Application No. 14 / 674,983. Each of these is incorporated herein by reference in its entirety.

  In the example of FIGS. 50A (an exemplary physical layout) and 50B (an exemplary electrical schematic), the illustrated solar modules 200 each have six electrical connections in series to provide a high DC voltage. Super cell 100 is included. With each solar cell group electrically connected in parallel with a different bypass diode 4410, each supercell is electrically segmented by hidden taps 4400 into several solar cell groups. In these examples, the bypass diodes are arranged in a stacked structure of the solar module, i.e. the solar cells are in the encapsulant between the front transparent sheet and the backing sheet. Alternatively, the bypass diode may be located in a junction box located on the back or edge of the solar module and interconnected to hidden taps by extending conductors.

  In the example of FIGS. 51A (physical layout) and 51B (corresponding electrical schematic), the illustrated solar module 200 also includes six supercells 100 electrically connected in series to provide a high DC voltage. In this example, the solar module is electrically segmented into three pairs of supercells connected in series, with each pair of supercells electrically connected in parallel with a different bypass diode. In this example, the bypass diode is arranged in a junction box 4500 located on the rear surface of the solar module. The bypass diode may alternatively be located in the stack of solar modules or in a junction box attached to the rim.

  In the example of FIGS. 50A-51B, in normal operation of the solar module, each solar cell is forward biased, and therefore all bypass diodes are reverse biased and do not conduct. However, if one or more of the solar cells in the group is reverse biased at a sufficiently high voltage, the bypass diode corresponding to that group will be in the ON state and the current flow through the module will be reverse biased. Will bypass solar cells. This prevents dangerous hot spots from being formed in shadowed or failed solar cells.

  Alternatively, the functionality of the bypass diode may be achieved in module-level power electronics, for example, a micro-inverter located on or near a solar module. (Module-level power electronics, and their use, may also be referred to herein as module-level power management devices or systems, and module-level power management. Such modules optionally integrated with solar modules Level power electronics (e.g., by operating a supercell group, a supercell, or a supercell segment within an electrically segmented supercell at its maximum power point). Power electronics from each supercell or from each individual supercell segment may be optimized, thereby allowing individual power optimization within the module. The module-level power electronics may determine when to bypass one or more particular individual supercells and / or one or more particular supercell segments, so that May eliminate the need.

  This can be achieved, for example, by integrating voltage intelligence at the module level. By monitoring the voltage output of a photovoltaic circuit (eg, one or more supercells, or segments of supercells) in a solar module, a "smart switch" is used to determine whether the circuit contains any reverse-biased solar cells. "The power management device can be determined. If a reverse-biased solar cell is detected, the power management device can disconnect the corresponding circuit from the electrical system using, for example, a relay switch or other component. For example, if the voltage of the monitored solar cell circuit falls below a predetermined threshold, the power management device will shut off the circuit (open the circuit). The predetermined threshold may be, for example, a certain percentage or magnitude (eg, 20% or 10V) compared to the normal operation of the circuit. Embodiments of such voltage intelligence may be incorporated into existing module-level power electronics products (eg, from Enphase Energy Inc., Solarge Technologies, Inc., Tigo Energy, Inc.) or through custom circuit designs. obtain.

  Figures 52A (physical layout) and 52B (corresponding electrical schematic) show an exemplary structure for module-level power management of a high-voltage solar module that includes a shingled supercell. In this example, the rectangular solar module 200 includes six rectangular shingled supercells 100 arranged in six rows extending across the length of the long side of the solar module. The six supercells are electrically connected in series to provide a high DC voltage. Module level power electronics 4600 may perform voltage sensing, power management, and / or DC / AC conversion for the entire module.

  FIGS. 53A (physical layout) and 53B (corresponding electrical schematic) show another exemplary structure of module-level power management for a high-voltage solar module that includes a shingled supercell. In this example, the rectangular solar module 200 includes six rectangular shingled supercells 100 arranged in six rows extending across the length of the long side of the solar module. The six supercells are electrically grouped into three pairs of serially connected supercells. Each pair of supercells may individually perform voltage sensing and power optimization on an individual pair of supercells, connecting two or more of them in series to provide a high DC voltage, and And / or connect to module level power electronics 4600 that can perform DC / AC conversion.

  FIGS. 54A (physical layout) and 54B (corresponding electrical schematic) show another exemplary structure of module level power management for a high voltage solar module including a shingled supercell. In this example, the rectangular solar module 200 includes six rectangular shingled supercells 100 arranged in six rows extending across the length of the long side of the solar module. Each supercell may individually perform voltage sensing and power optimization for each supercell, connecting two or more of them in series to provide a high DC voltage, and / or Connect to module level power electronics 4600 that can perform AC conversion.

  FIGS. 55A (physical layout) and 55B (corresponding electrical schematic) show another exemplary structure of module-level power management for a high-voltage solar module including a shingled supercell. In this example, the rectangular solar module 200 includes six rectangular shingled supercells 100 arranged in six rows extending across the length of the long side of the solar module. Each supercell is electrically segmented by hidden taps 4400 to be two or more solar cell groups. Each resulting solar cell group may individually perform voltage sensing and power optimization for each solar cell group and connect a plurality of those groups in series to provide a high DC voltage, and / or Connect to module level power electronics 4600 that can perform DC / AC conversion.

  In some variations, two or more high voltage DC shingled solar modules, as described herein, are electrically connected in series to provide a high voltage that is converted to AC by an inverter. Provides a DC output. The inverter can be, for example, a micro inverter integrated with one of the solar modules. In such a case, the micro-inverter may optionally be a component of module-level power management electronics that also performs additional sensing and connection functions as described above. Alternatively, the inverter may be a central "string" inverter as described further below.

  As shown in FIG. 56, when stringing multiple supercells in series in a solar module, adjacent supercell rows are offset slightly along their long axes in a staggered manner. Can be Such offsetting saves module area (space / length) and streamlines manufacturing while placing adjacent edges of supercell rows on top of one supercell and the other supercell. Interconnects 4700 that join to the bottom of the device allow for electrical connection in series. Adjacent supercell rows may be offset, for example, by about 5 millimeters.

  The differential thermal expansion between the electrical interconnect 4700 and the silicon solar cell, and the resulting stress on the solar cell and the interconnect, can cause tears and other defects that can degrade the performance of the solar module It can lead to the form of As a result, the interconnect is desirably flexible and configured to accommodate such differential expansion without substantial stress. The interconnect may be formed, for example, from a highly ductile material (eg, soft copper, very thin copper plate) to provide a material having a low coefficient of thermal expansion (eg, Kovar, Invar, or other low thermal expansion). Iron-nickel alloy) or from a material having a coefficient of thermal expansion approximately matching that of silicon to accommodate differential thermal expansion between the interconnect and the silicon solar cell Out-of-plane geometry, such as kinks, jogs, or depressions, by incorporating in-plane geometric expansion features, such as slits, slots, holes, or truss structures, and / or to accommodate such differential thermal expansion Employing features may provide relief of stress and thermal expansion. The conductive portion of the interconnect may have a thickness of, for example, less than about 100 microns, less than about 50 microns, less than about 30 microns, or less than about 25 microns, to increase the flexibility of the interconnect. (The generally low current in these solar modules allows the use of thin flexible and conductive ribbons without excessive power loss resulting from the electrical resistance of the thin interconnect.)

  In some variations, the conductive junction between the supercell and the flexible electrical interconnect is connected to the flexible electrical interconnect at a temperature in the range of about -40C to about 180C without damaging the solar module. , Accommodate thermal expansion mismatches between the supercell and the flexible electrical interconnect.

  FIG. 7A (illustrated above) shows some exemplary interconnect configurations identified by reference numerals 400A-400T employing in-plane stress relaxation geometric features, and a diagram (also described above). 7B-1 and 7B-2 illustrate exemplary interconnect configurations identified by reference numerals 400U and 3705 that employ out-of-plane stress relaxation geometric features. Any one of these interconnect configurations, or any combination thereof, that employs stress relief features, electrically interconnect the supercells as described herein in series to provide a high DC voltage. May be suitable for

  The description associated with FIGS. 51A-55B has focused on module-level power management, possibly using DC / AC conversion of high DC module voltages with module-level power electronics to provide AC output from the module. As mentioned above, DC / AC conversion of high DC voltages from shingled solar cell modules as described herein may be alternatively performed by a central string inverter. For example, FIG. 57A illustrates a light including a plurality of high DC voltage shingled solar cell modules 200 electrically connected in parallel to a string inverter 4815 via a high DC voltage negative bus 4820 and a high DC voltage positive bus 4810. The electromotive system 4800 is schematically illustrated. Typically, each solar module 200 includes a plurality of shingled supercells electrically connected in series with the electrical interconnects to provide a high DC voltage, as described above. The solar module 200 may optionally include, for example, a bypass diode arranged as described above. FIG. 57B shows an exemplary arrangement of a photovoltaic system 4800 on a roof.

  In some variations of photovoltaic system 4800, two or more short series-connected strings of high DC voltage shingled solar cell modules may be electrically connected in parallel with the string inverter. Referring back to FIG. 57A, for example, each solar module 200 may be replaced with a series connection string of two or more high DC voltage shingled solar cell modules 200. This may be done, for example, to maximize the voltage provided to the inverter while complying with regulatory standards.

  Conventional solar modules typically produce about 8 amps Isc (short circuit current), about 50 Voc (open circuit voltage), and about 35 Vmp (maximum power point voltage). As described above, described herein includes M times the number of solar cells (each having an area of about 1 / M compared to the area of a conventional solar cell) as compared to the prior art. Such a high DC voltage shingled solar cell module generates a voltage that is roughly M times higher than a conventional solar module and a current of 1 / M. As noted above, M can be any suitable integer, typically ≦ 20, but may be greater than twenty. M can be, for example, 3, 4, 5, 6, or 12.

  When M = 6, the Voc of the high DC voltage shingled solar cell module can be, for example, about 300V. Connecting two such modules in series would provide about 600V DC to the bus. This is in accordance with the maximum set by US residential standards. If M = 4, the Voc of the high DC voltage shingled solar cell module can be, for example, about 200V. Connecting three such modules in series would provide about 600V DC to the bus. For M = 12, the Voc of the high DC voltage shingled solar cell module may be, for example, about 600V. Systems with bus voltages less than 600V can also be constructed. In such variations, the high DC voltage shingled solar cell module may be paired, for example, in a combiner box, or one in three, or any other suitable combination To provide the optimal voltage to the inverter.

  The problem arising from the parallel configuration of the high DC voltage shingled solar cell modules described above is that if a short circuit occurs in one solar module, the other solar modules could potentially short-circuit their power. It can be thrown up (ie, drive current through the shorted module and dissipate power in the shorted module), creating a hazard. The problem is, for example, the use of a blocking diode, the use of a current limiting fuse, or the use of a current limiting fuse in combination with a blocking diode arranged to prevent other modules from driving current through a shorted module. Can be avoided by using FIG. 57B schematically illustrates the use of two current limiting fuses 4830 on the positive and negative terminals of the high DC voltage shingled solar cell module 200.

  The arrangement intended for protection of the blocking diode and / or fuse may depend on whether the inverter includes a transformer. Systems using an inverter that includes a transformer typically ground the negative conductor. Systems using an inverter without a transformer typically do not ground the negative conductor. For a transformerless inverter, it may be preferable to have a current limiting fuse aligned with the positive terminal of the solar module and another current limiting fuse aligned with the negative terminal.

  The blocking diodes and / or current limiting fuses can be mounted, for example, with each module in a junction box or module stack. Suitable junction boxes, blocking diodes (eg, side-by-side blocking diodes), and fuses (eg, side-by-side fuses) may include those available from Shoals Technology Group.

  FIG. 58A shows an exemplary high voltage DC shingled solar cell module including a junction box 4840 in which a blocking diode 4850 is aligned with the positive terminal of the solar module. The junction box does not include a current limiting fuse. This configuration may be preferably used elsewhere (eg, in a combiner box) in combination with one or more current limiting fuses located alongside the positive and / or negative terminals of the solar module (eg, see below). See FIG. 58D). FIG. 58B shows an exemplary high voltage DC shingled solar cell module that includes a junction box 4840 with a blocking diode aligned with the positive terminal of the solar module and a current limiting fuse 4830 aligned with the negative terminal. FIG. 58C shows an exemplary high voltage DC shingled solar cell module including a junction box 4840 with current limiting fuses 4830 aligned with the positive terminal of the solar module and another current limiting fuse 4830 aligned with the negative terminal. Is shown. FIG. 58D illustrates an exemplary high voltage DC shingled that includes a junction box 4840 configured as in FIG. 58A and a fuse located outside the junction box alongside the positive and negative terminals of the solar module. 1 shows a solar cell module in a shape.

  Referring now to FIGS. 59A-59B, as an alternative to the configuration described above, all the blocking diodes and / or current limiting fuses of the high DC voltage shingled solar cell module are mounted together in combiner box 4860. Can be placed. In these variations, one or more individual conductors extend separately from each module to the combiner box. In one option, as shown in FIG. 59A. A single conductor of one polarity (eg, negative as shown) is shared between all modules. In another option (FIG. 59B), both polarities have individual conductors for each module. Although FIGS. 59A-59B show only fuses located within combiner box 4860, any suitable combination of fuses and / or blocking diodes may be located within the combiner box. In addition, electronics that perform other functions, such as, for example, monitoring, maximum power point tracking, and / or disconnection of individual modules, or groups of modules, may be implemented in the combiner box.

  Reverse bias operation of a solar module is where one or more solar cells in the solar module are shadowed or otherwise generate a small current, and the solar module is compatible with low current solar cells This can occur when operating at a voltage-current point that drives as much current as possible through the low current solar cell. Reverse-biased solar cells can get hot and create dangerous situations. For example, a parallel arrangement of high DC voltage shingled solar cell modules, as shown in FIG. 58A, may be able to protect these modules from reverse bias operation by setting a suitable operating voltage for the inverter. This is illustrated, for example, in FIGS. 60A-60B.

  FIG. 60A shows a current vs. voltage plot 4870 and a power vs. voltage plot 4880 for a parallel connection string of about 10 high DC voltage shingled solar modules. These curves were calculated for a model where none of the solar modules included reverse-biased solar cells. Since the solar modules are electrically connected in parallel, they all have the same operating voltage and their currents are added. Typically, an inverter varies the load on the circuit, searches the power-voltage curve, identifies the maximum pole on that curve, and then operates the module circuit at that point to maximize the output power. Become

  In contrast, FIG. 60B shows a plot of current versus voltage 4890 and the power of the model system of FIG. 60A for the case where some of the solar modules in the circuit include one or more reverse-biased solar cells. 38 shows a plot 4900 of voltage versus voltage. The reverse biased module has a knee that transitions from about 10 amps of operation down to about 210 volts to about 16 amps of operation at voltages less than about 200 volts in the exemplary current-voltage curve. Appears due to shape formation. At voltages less than about 210 volts, the shaded modules include reverse-biased solar cells. Reverse biased modules are also manifested in the power-voltage curve by the presence of two maxima, an absolute maximum at about 200 volts and a maximum at about 240 volts. The inverter may be configured to recognize such an indication of a reverse-biased solar module and operate the solar module at an absolute maximum or maximum power point voltage at which no module is reverse-biased. In the example of FIG. 60B, the inverter may operate the modules at a maximum power point to ensure that no modules are reverse biased. Additionally or alternatively, a minimum operating voltage may be selected for the inverter below which any module is less likely to be reverse biased. The minimum operating voltage may be adjusted based on other parameters such as ambient temperature, operating current and calculated or measured solar module temperature, and other information received from an external source, such as, for example, glitter.

  In some embodiments, the high DC voltage solar modules are themselves arranged such that adjacent solar modules are electrically interconnected in their overlapping areas, in a partially overlapping manner. It can be shingled. Such a shingled configuration is optionally for a high voltage solar module in parallel electrical connection, providing a high DC voltage to the string inverter, or a micro inverter for converting the high DC voltage of the solar module to an AC module output. Can be used for high voltage solar modules, each containing The pairs of high voltage solar modules may be shingled, for example, as just described, and electrically connected in series to provide the desired DC voltage.

Conventional string inverters often have 1) they must be able to accommodate different string lengths of modules in a series connection; 2) some modules in a string may be wholly or partially 3) Changes in ambient temperature and radiation need to have a fairly wide range of potential input voltages (or "dynamic ranges") because changes in ambient temperature and radiation change the module voltage. In a system employing a parallel configuration as described in Section 6, the length of the string of parallel-connected solar modules does not affect the voltage, and some modules are partially shaded, If not, then decide to run the system at the voltage of the unshaded module (eg, as described above). Therefore, the input voltage range of the inverter in the parallel structure system may need to be adapted only to the "dynamic range" of the "temperature and radiation change" of the element # 3. For example, an inverter employed with a parallel-structured system as described herein may have a narrower range, eg, about 250 at standard conditions, because it is about 30% of the conventional dynamic range required for the inverter. Volts and about 175 volts at high and low emissions, or, for example, about 450 volts at standard conditions, and about 350 volts at high and low emissions (in this case, 450 volts MPPT (maximum power point tracking) operation is may have a MPPT between the lowest may correspond to the V _OC of less than 600 volts at a temperature of operation). in addition, as described above The inverter can receive enough DC voltage to convert directly to AC, without the boost stage, and consequently the string inverter employed with a parallel structure system as described herein is simpler. Yes, lower cost and can operate with higher efficiency than string inverters employed in conventional systems.

  For both the micro and string inverters employed with the high voltage DC shingled solar cell modules described herein, the solar module (or short solar module) may be used to eliminate the need for DC boosting of the inverter. It may be preferable to configure the series connected strings) to provide a DC voltage that operates above the peak-to-peak AC (eg, the maximum power point Vmp). For example, for a 120V AC, the peak-to-peak is sqrt (2) * 120V = 170V. Thus, the solar module may be configured to provide a minimum Vmp of, for example, about 175V. The Vmp in a normal state may be about 212 V (assuming a negative voltage temperature coefficient of 0.35% and a maximum operating temperature of 75 ° C.), and at the lowest temperature operating state (eg, −15 ° C.), Vmp is , (Depending on the module fill factor) may be about 242V, and thus Voc below about 300V. For a single-phase 120V AC (or 240V AC), all of these numbers double, which is because 600V DC is the largest allowed in the United States for many residential applications. It is convenient. For commercial applications that require and allow higher voltages, these numbers can be even higher.

A high voltage shingled solar cell module as described herein may be configured to operate at a _VOC of> 600 or a _{VOC of} > 1000, where the module is provided by the module. It may include integrated power electronics to prevent external voltages from exceeding specified requirements. With such an arrangement, without problems _{of V OC} at low temperature exceeds 600V, operation _{V mp} is may be possible to be sufficient for a single-phase 120V (240V, requires about 350 V).

  If the building is disconnected from the grid, for example by a firefighter, a solar module that provides electricity to the building (eg, on the roof of the building) will still generate power if the sun is shining You can do it. A concern arising from this is that with such solar modules, the roof can remain "live" with dangerous voltages after disconnection of the building from the grid. To address this concern, the high voltage DC shingled solar cell modules described herein may optionally include a disconnect, for example, in or adjacent to the module junction box. The disconnector can be, for example, a physical disconnector or a solid-state disconnector. The disconnector may be configured to disconnect the high voltage output of the solar module from the roof circuit when it loses a particular signal (e.g., from an inverter), e.g., to be "normally OFF". Communication to the disconnector may occur, for example, on a high voltage cable, through a separate wire, or wirelessly.

  An important advantage of shingling high voltage solar modules is that heat is spread between the solar cells in the shingled supercell. Applicants have discovered that heat can be easily transferred along a silicon supercell through thin electrical and thermally conductive junctions between adjacent and overlapping silicon solar cells. The thickness of the conductive bond between adjacent and overlapping solar cells formed by the electrically conductive bonding agent, measured in a direction perpendicular to the front and back surfaces of the solar cell, is, for example, less than or equal to about 200 microns. Or less than or equal to about 150 microns, or less than or equal to about 125 microns, or less than or equal to about 100 microns, or less than or equal to about 90 microns, or greater than about 80 microns Small, equal to, or smaller than or equal to about 70 microns, or smaller than or equal to about 60 microns, or smaller than or equal to about 50 microns, or smaller than about 25 microns, At the same it may be the same thickness. Such thin junctions reduce ohmic losses in the interconnect between the cells and also promote heat flow along the supercell from any hot spots in the supercell that may appear during operation. . The thermal conductivity of the junction between the solar cells can be, for example, ≧ about 1.5 watts / (meter K). Further, the rectangular aspect ratio of solar cells typically employed herein increases the area of thermal contact between adjacent solar cells.

  In contrast, in a conventional solar module that employs a ribbon interconnect between adjacent solar cells, the heat generated by one solar cell passes through other ribbon cells in the module through those ribbon interconnects. Does not spread easily. This makes conventional solar modules more likely to generate hot spots than the solar modules described herein.

  Further, the supercells described herein typically shingle rectangular solar cells, each having a smaller active area (eg, ６) than the active area of conventional solar cells. , The current through the supercells in the solar modules described herein is typically less than the current through a string of conventional solar cells.

  As a result, within the solar module disclosed herein, less heat is dissipated in the reverse biased solar cell at the breakdown voltage, and without causing dangerous hot spots, the supercell and solar module Heat can be easily diffused through.

  With some additional and optional features, high voltage solar modules employing supercells as described herein are even more resistant to the heat dissipated in reverse-biased solar cells May be provided. For example, the supercell can be encapsulated within an olefin-based thermoplastic (TPO) polymer. TPO encapsulants are more photothermally stable than standard ethylene vinyl acetate (EVA) encapsulants. EVA browns with temperature and ultraviolet light, leading to problems with hot spots created by current limiting batteries. Further, the solar module may have a glass-glass structure in which the encapsulated supercell is sandwiched between a front glass sheet and a rear glass sheet. Such a glass-glass structure allows the solar module to operate safely at higher temperatures than conventional polymer backsheets can withstand. Furthermore, if present, the junction box may be mounted on one or more edges of the solar module rather than behind the solar module. Here, the junction box will add an additional layer of thermal isolation to the module solar cells above it.

  Accordingly, Applicants hereby note that the flow of heat through the supercell may allow the module to operate without substantial risk with the reverse-biased solar cell or cells. It has been recognized that high voltage solar modules formed from supercells as described herein can employ much less bypass diodes than are employed in conventional solar modules. For example, in some variations, a high voltage solar module as described herein may have less than one bypass diode per 25 solar cells, less than one bypass diode per 30 solar cells, 50 Less than one bypass diode per solar cell, less than one bypass diode per 75 solar cells, less than one bypass diode per 100 solar cells, only a single bypass diode may be employed, or It is not necessary to employ a bypass diode.

  Referring now to FIGS. 61A-61C, an exemplary high voltage solar module utilizing a bypass diode is provided. The use of bypass diodes may prevent or mitigate damage to the solar module if part of the module is shaded. For the example solar module 4700 shown in FIG. 61A, ten supercells 100 connect in series. As shown, the ten supercells are arranged in parallel rows. Each supercell includes forty series-connected solar cells 10, each of which is approximately one sixth of a square or pseudo-square, as described herein. Have been. In normal, unshaded operation, current flows in and out of junction box 4716 through each of the supercells 100 connected in series through connector 4715, after which current flows out through junction box 4717. Optionally, a single junction box may be used instead of separate junction boxes 4716 and 4717 so that the current returns to one junction box. The example shown in FIG. 61A shows an embodiment using approximately one bypass diode per supercell. As shown, a single bypass diode electrically connects between adjacent pairs of supercells at approximately midpoints along the supercell (eg, a single bypass diode 4901A connects to the first supercell). And the second bypass diode 4901B is electrically connected between the second solar cell in the second super cell and the neighboring solar cell in the second super cell. Connect, etc.). The first and last cell strings have only about half the number of solar cells in a supercell per bypass diode. For the example shown in FIG. 61A, the first and last battery strings include only 22 batteries per bypass diode. For the high voltage solar module variant illustrated in FIG. 61A, the total number of bypass diodes (11) is equal to the number of supercells plus one additional bypass diode.

  Each bypass diode may, for example, be incorporated into a flex circuit. Referring now to FIG. 61B, an enlarged view of the bypass diode connection area of two neighboring supercells is shown. The view of FIG. 61B is seen from the side where the sun does not hit. As shown, two solar cells 10 on a neighboring supercell are electrically connected using a flex circuit 4718 that includes a bypass diode 4720. Flex circuit 4718 and bypass diode 4720 are electrically connected to solar cell 10 using contact pads 4719 located on the back of the solar cell. (See also further discussion below on the use of hidden contact pads to provide hidden taps for bypass diodes.) Additional bypass diode electrical connection schemes reduce the number of solar cells per bypass diode. Can be adopted. One example is illustrated in FIG. 61C. As shown, one bypass diode makes an electrical connection between each pair of neighboring supercells, approximately midway along the supercell. A bypass diode 4901A electrically connects between neighboring solar cells on the first and second supercells, and a bypass diode 4901B electrically connects between neighboring solar cells on the second and third supercells. 4901C electrically connect between neighboring solar cells on the third and fourth supercells, and so on. A second set of bypass diodes may be included to reduce the number of solar cells that will be bypassed if a partial shadow occurs. For example, a bypass diode 4902A electrically connects between the first super cell and the second super cell at an intermediate point between the bypass diode 4901A and the bypass diode 4901B, and the bypass diode 4902B connects to the second super cell and the second super cell. Electrical connection with the 3 supercells at an intermediate point between bypass diode 4901B and bypass diode 4901C, etc., thereby reducing the number of batteries per bypass diode. Optionally, yet another set of bypass diodes may be electrically connected to further reduce the number of solar cells that are bypassed in the event of a partial shadow. A bypass diode 4903A is electrically connected between the first super cell and the second super cell at an intermediate point between the bypass diode 4902A and the bypass diode 4901B, and the bypass diode 4903B is electrically connected to the second super cell and the third super cell. Electrical connection to and from the cell is made at an intermediate point between bypass diode 4902B and bypass diode 4901C, which further reduces the number of batteries per bypass diode. The result of this configuration is a nested configuration of bypass diodes that allows a small group of batteries to be bypassed during partial shadowing. Additional diodes may thus be electrically connected until the desired number of solar cells per bypass diode is achieved, for example, about 8, about 6, about 4, or about 2 per bypass diode. I can do it. In some modules, about four solar cells per bypass diode are desirable. If desired, one or more of the bypass diodes illustrated in FIG. 61C may be incorporated into a hidden flexible interconnect as illustrated in FIG. 61B.

  The present specification discloses solar cell cleavage tools and methods that can be used, for example, to separate conventional sized square or pseudo-square solar cells into a plurality of narrow rectangular or substantially rectangular solar cells. . These cleavage tools and methods draw a vacuum between the bottom surface of the conventional size solar cell and the curved support surface to bend the conventional size solar cell against the curved support surface, thereby providing a previously prepared Cleave the solar cell along the scribe line. The advantage of these cleaving tools and methods is that they do not require physical contact with the top surface of the solar cell. As a result, these cleaving tools and methods can be employed to cleave solar cells that include soft and / or uncured material on top that can be damaged by physical contact. In addition, in some variations, these cleavage tools and methods may require contact with only a portion of the bottom surface of the solar cell. In such variations, these cleavage tools and methods may be employed to cleave solar cells that include a soft and / or uncured material on a portion of the bottom surface that is not contacted by the cleavage tool.

For example, one method of manufacturing a solar cell utilizing the cleavage tools and methods disclosed herein includes:
Laser scribing one or more scribe lines on each silicon solar cell of one or more conventional size silicon solar cells to define a plurality of rectangular regions on one or more silicon solar cells;
Applying an electrically conductive adhesive to a portion of the top surface of the one or more silicon solar cells;
A vacuum is drawn between the bottom surface of the one or more silicon solar cells and the curved support surface to bend the one or more silicon solar cells toward the curved support surface, thereby along one or more scribe lines. Cleaving one or more silicon solar cells to provide a plurality of rectangular silicon solar cells each including a portion of an electrically conductive adhesive bonding agent disposed on a front surface adjacent to a long side. The conductive adhesive bond may be applied to conventional sized silicon solar cells either before or after the solar cells are laser scribed.

  The resulting plurality of rectangular silicon solar cells are arranged side by side in such a manner that the long sides of adjacent rectangular silicon solar cells are overlapped in a shingle-like shape with a portion of the electrically conductive adhesive bonding agent interposed therebetween. Can be done. Thereafter, the electrically conductive bonding agent may be cured, thereby bonding adjacent and overlapping rectangular silicon solar cells to one another and electrically connecting them in series. This process forms a shingle-shaped “supercell” as described in the patent applications listed in “Cross-References to Related Applications” above.

  To better understand the cleavage tools and methods disclosed herein, turning now to the drawings, FIG. 20A shows a side view of an exemplary apparatus 1050 that can be used to cleave a scribed solar cell. FIG. In this apparatus, the scribed conventional size solar cell wafer 45 is carried by the perforated moving belt 1060 above the curved portion of the vacuum manifold 1070. As the solar cell wafer 45 passes over the curved portion of the vacuum manifold, the vacuum drawn through the perforations in the belt pulls the bottom surface of the solar cell wafer 45 toward the vacuum manifold, thereby bending the solar cell. The radius of curvature R of the curved portion of the vacuum manifold may be selected to cleave the solar cell along the scribe line to form a rectangular solar cell 10 by bending the solar cell wafer 45 in this manner. The rectangular solar cell 10 can be used, for example, in a supercell as illustrated in FIGS. The solar cell wafer 45 can be cleaved by the method without contacting the top surface of the solar cell wafer 45 to which the conductive adhesive has been applied.

  For each scribe line, cleave by arranging the scribe line to be oriented at an angle θ relative to the vacuum manifold, such that one end reaches the curved portion of the vacuum manifold before the other end. May be initiated preferentially at one end of the scribe line (ie, at one edge of solar cell 45). As shown in FIG. 20B, for example, the solar cells have a scribe line with respect to the direction of movement of the belt, and with respect to the curved cleavage portion of the manifold oriented in a direction perpendicular to the direction of movement of the belt. It can be oriented at an angle. As another example, FIG. 20C shows a cell oriented with the scribe line perpendicular to the direction of belt travel, and a curved cleaved portion of the manifold oriented at an angle to the direction of belt travel. Is shown.

  Cleavage tool 1050 may utilize, for example, a single perforated transfer belt 1060 having a width in a direction perpendicular to its direction of movement that is approximately equal to the width of solar cell wafer 45. Alternatively, tool 1050 may include, for example, two, three, four, or more perforated moving belts 1060 that may be arranged side by side and parallel, and optionally separated from one another. Cleavage tool 1050 may utilize, for example, a single vacuum manifold that may have a width in a direction perpendicular to the direction of solar cell movement, approximately equal to the width of solar cell wafer 45. Such vacuum manifolds are employed, for example, with a single full width perforated transfer belt 1060 or, for example, with two or more such parallel, side-by-side, and optionally separated belts. obtain.

  Cleavage tool 1050 may include two or more curved vacuum manifolds, each having the same curvature, spaced side-by-side and parallel. Such an arrangement may be employed, for example, with a single full-width perforated transfer belt 1060 or with two or more such side-by-side, parallel and optionally separated belts. For example, the tool may include a perforated transfer belt 1060 for each vacuum manifold. In the latter arrangement, the vacuum manifolds and their corresponding perforated moving belts may be arranged to contact the bottom of the solar cell wafer along only two narrow strips defined by the width of the belt. In such a case, the solar cell may include a soft material in the area of the bottom surface of the solar cell wafer that is not contacted by the belt, and there is no risk of damage to the soft material during the cleavage process.

  Any suitable arrangement of perforated transfer belts and vacuum manifolds may be used in cleaving tool 1050.

  In some variations, the scribed solar cell wafers 45 have uncured conductive adhesive and / or other soft material on their top and / or bottom surfaces before being cleaved using the cleaving tool 1050. Including materials. The scribing of the solar cell wafer and the application of the soft material may occur in any order.

  FIG. 62A schematically illustrates a side view of another exemplary cleavage tool 5210 similar to the cleavage tool 1050 described above, and FIG. 62B schematically illustrates a plan view thereof. In use of the cleavage tool 5210, a pair of corresponding, parallel, spaced-apart perforated belts 5230 move a conventional size scribed solar cell wafer 45 at a constant speed over a pair of parallel, spaced-apart vacuum manifolds 5235. Placed on top. Vacuum manifold 5235 typically has the same curvature. As the wafer moves with the belt over the vacuum manifold through the cleave region 5235C, the wafer is bent around the cleave area defined by the curved support surface of the vacuum manifold due to the vacuum force pulling the bottom of the wafer. As the wafer is bent around the cleave area, the scribe lines become rips that separate the wafer into individual rectangular solar cells. As described further below, the curvature of the vacuum manifold is such that the adjacent cleaved rectangular solar cells are not coplanar, and the edges of the adjacent cleaved rectangular solar cells result in a post-cleavage process. They are arranged so that they do not touch each other. The cleaved rectangular solar cells can be successively lowered from the perforated belt by any suitable method, some of which are described below. Typically, the unloading method further separates adjacent cleaved solar cells from each other and prevents them from touching each other if they lie on the same plane.

  62A-62B, each vacuum manifold includes, for example, a flat region 5235F that draws no vacuum or draws a low or high vacuum, and optionally, a low or high vacuum along its length. It may include a curved transition region 5235T that pulls or transitions from a low vacuum to a high vacuum, a cleaved region 5235C that draws a high vacuum, and a smaller radius post-cleavage region 5235PC that draws a low vacuum. Belt 5230 transports wafer 45 from flat region 5235F into and through transition region 5235T, and then into cleavage region 5235C where the wafer cleaves, and then the resulting cleaved sun. Battery 10 is transported out of cleavage region 5235C and into post-cleavage region 5235PC.

  Flat region 5235F typically operates at a low enough vacuum to secure wafer 45 to the belt and vacuum manifold. The vacuum here may be low (or absent) so as to reduce friction and thus the required belt tension and to keep wafer 45 on a flat surface easier than on a curved surface. . The vacuum at flat region 5235F may be, for example, from about 1 to about 6 inches of mercury.

  Transition region 5235T provides a curvature that transitions from flat region 5235F to cleavage region 5235C. The radius of curvature or the plurality of radii of curvature at the transition region 5235T is larger than the radius of curvature at the cleavage region 5235C. The curve at transition region 5235T may be, for example, a portion of an ellipse, but any suitable curve may be used. Bringing the wafer 45 closer to the cleavage region 5235C with a smaller curvature change through the transition region 5235T, rather than a direct transition from the flat orientation in the region 5235F to the cleavage region in the cleavage region 5235C, raises the edge of the wafer 45 This helps to ensure that the vacuum is no longer lost and that it becomes difficult to keep the wafer in the cleaved area at the cleaved region 5235C. The vacuum at transition region 5235T may be, for example, the same as at cleavage region 5235C, intermediate the vacuum at regions 5235F and 5235C, or between the vacuum at region 5235F and the vacuum at region 5235C. , Along the length of region 5235T. The vacuum at transition region 5235T may be, for example, from about 2 to about 8 inches of mercury.

  Cleavage region 5235C may have a varying radius of curvature, or, optionally, a constant radius of curvature. Such a constant radius of curvature may be, for example, about 11.5 inches, about 12.5 inches, or between about 6 inches and about 18 inches. Any suitable range of curvature may be used and may be selected based in part on the thickness of the wafer 45 and the depth and geometry of the scribe lines in the wafer 45. Typically, the thinner the wafer, the shorter the radius of curvature required to bend the wafer along the scribe line to tear the wafer sufficiently. The scribe line may have a depth of, for example, from about 60 microns to about 140 microns, but any other suitable shallower or deeper scribe line depth may be used. Typically, the shallower the scribe, the shorter the radius of curvature required to bend the wafer to tear the wafer sufficiently along the scribe line. The cross-sectional shape of the scribe line also affects the required radius of curvature. A scribe line having a wedge shape, or a scribe line having a wedge-shaped bottom, may more effectively concentrate stress than a scribe line having a rounded shape or a rounded bottom. A scribe line that concentrates stress more effectively may not require a smaller radius of curvature within the cleave region than a scribe line that concentrates stress less effectively.

  For at least one of the two parallel vacuum manifolds, the vacuum at the cleave region 5235C is typically higher than the vacuum at the other regions to ensure that the wafer remains properly at the cleave radius of curvature, Maintain constant bending stress. Optionally and as described further below, in this area, one manifold may draw a higher vacuum than the other to better control the tear along the scribe line. The vacuum at the cleave region 5235C can be, for example, about 4 to about 15 inches of mercury, or about 4 to about 26 inches of mercury.

  Post-cleavage region 5235PC typically has a smaller radius of curvature than cleavage region 5235C. This allows the cracked surfaces of adjacent cleaved solar cells to not be rubbed or touched, which can cause solar cell failures resulting from tears or other forms of failure. It becomes easy to transport the cleaved solar cell from the belt 5230. In particular, smaller radii of curvature result in greater separation between the edges of adjacent cleaved solar cells on the belt. The vacuum in the post-cleavage region 5235PC may be low because the wafer 45 has already been cleaved into a plurality of solar cells 10 and it is no longer necessary to keep the solar cells at the curved radius of the vacuum manifold ( For example, it is the same as or the same as in the flat region 5235F). The edge of the cleaved solar cell 10 may be lifted away from the belt 5230, for example. In addition, it may be desirable for the cleaved solar cell 10 not to be excessively stressed.

  The flat, transition, cleaved, and post-cleaved regions of the vacuum manifold may be discontinuous portions of different curves whose ends coincide. For example, the top surface of each manifold may have a flat planar portion, a portion of the ellipse for the transition region, an arc of a circle for the cleavage region, and another arc or portion of the ellipse for the post-cleavage region. May be included. Alternatively, some or all of the curved portion of the top surface of the manifold may include a continuous geometric function of increasing curvature (decreasing the diameter of the osculating circle). Suitable such functions may include, but are not limited to, for example, spiral functions such as clothoids, and natural log functions. Clothoids are curves whose curvature increases linearly along the length of the path of the curve. For example, in some variations, the transition region, the cleave region, and the post-cleave region are all part of a single clothoid curve, one end of which coincides with the flat region. In some other variations, the transition region is a clothoid curve with one end corresponding to a flat region and the other end matching a cleave region having a circular curvature. In the latter variant, the post-cleavage region may have, for example, a higher radius circular curvature, or a higher radius clothoid curvature.

  As described above, and as schematically illustrated in FIGS. 62B and 63A, in some variations, one manifold has a higher vacuum at the cleave region 5235C and the other manifold has a higher vacuum at the cleave region 5235C. Draw a low vacuum at. The high vacuum manifold clamps the edges of the wafers it supports generally into the curvature of the manifold, which causes the ends of the scribe lines that overlie the high vacuum manifold to start tearing along the scribe lines. To provide enough stress. Since the low vacuum manifold does not keep the edges of the wafer it supports in the entire curvature of the manifold, the bending radius of the wafer on that side may cause the necessary stress to initiate the tear at the scribe line. Is not small enough. However, the stress is high enough to propagate a tear initiated at the other end of the scribe line lying above the high vacuum manifold. Without some vacuum on the "low vacuum" side to partially and fully clamp that end of the wafer to the curvature of the manifold, a rupture initiated at the opposite "high vacuum" end of the wafer would traverse the entire wafer Risk of non-propagation. In the variation just described, one manifold may optionally draw a low vacuum along its entire length from the flat region 5235F through the post-cleavage region 5235PC.

  As just described, the asymmetric vacuum placement at the cleave region 5235C provides an asymmetric stress along the scribe line that controls the nucleation and propagation of the tear along the scribe line. For example, referring to FIG. 63B, if the two vacuum manifolds instead draw equal (eg, high) vacuum at the cleave region 5235C, the rips will nucleate at both ends of the wafer, propagate toward each other, and reach the center region of the wafer. You may meet somewhere. Under these circumstances, the rips may not be aligned with one another, so they risk creating a potential mechanical failure point in the resulting cleaved cell where the rips meet.

  As an alternative to, or in addition to, the asymmetric vacuum arrangement described above, the cleavage is preferentially scribed by placing one end of the scribe line in the cleavage region of the manifold before the other end. It can be started at one end of the line. This may be achieved, for example, by orienting the solar cell wafer at an angle to the vacuum manifold, as described above in connection with FIG. 20B. Alternatively, the vacuum manifold may be located along the belt path with the cleavage region of one of the two manifolds ahead of the cleavage region of the other vacuum manifold. For example, the two vacuum manifolds of the moving belt may be moved so that the solar cell wafer reaches the cleavage region of one of the two vacuum manifolds having the same curvature before reaching the cleavage region of the other vacuum manifold. It may be slightly offset in the direction of movement.

  Referring now to FIG. 64, in the illustrated example, each vacuum manifold 5235 includes through-holes 5240 arranged side-by-side below the center of vacuum channel 5245. As shown in FIGS. 65A-65B, the vacuum channel 5245 is recessed in the top surface of the manifold supporting the perforated belt 5230. Each vacuum manifold also includes a center post 5250 positioned between the through holes 5240 and arranged side by side below the center of the vacuum channel 5245. The center post 5250 effectively separates the vacuum channels 5245 into two parallel vacuum channels on each side of the plurality of center post rows. The center post 5250 also provides support for the belt 5230. Without the center post 5250, the belt 5230 would be exposed to longer unsupported areas and could be drawn into the through-hole 5240. As a result of this, the wafer 45 may be bent three-dimensionally (bending by the cleavage area and bending in a direction perpendicular to the cleavage area), which damages the solar cell and hinders the cleavage process. I can do it.

  As shown in FIGS. 65A-65B and FIGS. 66-67, in the illustrated example, the through holes 5240 are provided in the low vacuum chamber 5260L (the flat region 5235F and the transition region 5235T in FIG. 62A) and the high vacuum chamber (5260H ( 62A) and another low vacuum chamber 5260L (post-cleavage region 5235PC in FIG. 62A), which provides a smooth transition between the low and high vacuum regions in vacuum channel 5245. The through-hole 5240 allows the air flow to be completely unbiased to the hole if the corresponding area is left completely open, so that other areas can maintain a vacuum. The vacuum channel 5245 is positioned between the through holes 5240 with the vacuum belt holes 5255 always having a vacuum. It helps to ensure that it does not become a dead spot in the case that was.

  Referring again to FIGS. 65A-65B, and also to FIG. 67, the perforated belt 5230 is such that the leading and trailing edges 527 of the wafer 45 or cleaved solar cell 10 always remain as the belt advances along the manifold. It may include two rows of holes 5255 optionally positioned to be evacuated. In particular, the offset arrangement of the plurality of holes 5255 in the illustrated example ensures that the edge of the wafer 45 or cleaved solar cell 10 always overlaps at least one hole 5255 of each belt 5230. . This helps to prevent the wafer 45 or the edge of the cleaved solar cell 10 from lifting away from the belt 5230 and the manifold 5235. Any other suitable arrangement of holes 5255 may be used. In some variations, the arrangement of the plurality of holes 5255 does not ensure that the edge of the wafer 45 or the cleaved solar cell 10 is constantly evacuated.

  The perforated transfer belt 5230 in the illustrated example of the cleaving tool 5210 has a solar cell wafer 45 only along two narrow strips defined by the width of the belt along the lateral edges of the solar cell wafer. Touch the bottom of the As a result, the solar cell wafer may include soft materials, such as, for example, uncured adhesive, in areas of the bottom surface of the solar cell wafer that are not contacted by the belt 5230, and the risk of damage to those soft materials during the cleavage process Does not occur.

  In an alternative variation, the cleavage tool 5210 is not a two-perforated moving belt as just described, but has a width in a direction perpendicular to its direction of movement, for example, approximately equal to the width of the solar cell wafer 45. A single perforated moving belt 5230 may be utilized. Alternatively, the cleaving tool 5210 may include three, four, or more perforated moving belts 5230 that may be arranged side by side and parallel and optionally separated from one another. Cleavage tool 5210 may utilize a single vacuum manifold 5235, which may have a width in a direction perpendicular to the direction of solar cell movement, for example, approximately equal to the width of solar cell wafer 45. Such a vacuum manifold may be employed, for example, with a single full width perforated transfer belt 5230, or with two or more such parallel, side-by-side, and optionally separated belts. Cleavage tool 5210 may be, for example, a single perforation supported along opposing lateral edges by two curved vacuum manifolds 5235, each having the same curvature, spaced side-by-side and parallel. A transfer belt 5230 may be included. Cleavage tool 5210 may include three or more curved vacuum manifolds 5235, each having the same curvature, arranged side-by-side and parallel. Such an arrangement may be employed, for example, with a single full-width perforated transfer belt 5230 or with three or more such parallel, side-by-side, and optionally separated belts. The cleavage tool may include, for example, a perforated moving belt 5230 for each vacuum manifold.

  Any suitable arrangement of a perforated transfer belt and vacuum manifold may be used in the cleavage tool 5210.

  As described above, in some variations, the scribed solar cell wafers 45 that are cleaved by the cleavage tool 5210 may have uncured conductive adhesive bonds to their top and / or bottom surfaces prior to cleavage. Agents and / or other soft materials. The scribing of the solar cell wafer and the application of the soft material may occur in any order.

  The perforated belt 5230 in the cleaving tool 5210 (and the perforated belt 1060 in the cleaving tool 1050) may be at a certain speed, for example, from about 40 millimeters / second (mm / s) to about 2000 mm / s or faster, or , From about 40 mm / s to about 500 mm / s or faster, or about 80 mm / s or faster. Cleaving the solar cell wafer 45 may be easier to perform at a higher speed than at a lower speed.

  Referring now to FIG. 68, when cleaved, there is some separation between the leading edge 527 and the trailing edge 527 of adjacent cleaved cells 10 due to the bending geometry around the bend. Yes, this creates a wedge-shaped gap between adjacent cleaved solar cells. If the cleaved cells are allowed to return to a flat, co-planar orientation without first increasing the separation between the cleaved cells, the edges of adjacent cleaved cells may contact and cause damage There is. Therefore, it is advantageous to remove cleaved cells from belt 5230 (or belt 1060) while still being supported by the curved surface.

  FIGS. 69A-69G illustrate how a cleaved solar cell can be removed from belt 5230 (or belt 1060) and delivered to one or more additional moving belts or surfaces with increased separation between the cleaved solar cells. 1 schematically illustrates such an apparatus and method. In the example of FIG. 69A, the cleaved solar cells 10 travel faster than the belts 5230 and are thus collected from the belt 5230 by one or more transport belts 5265 that increase the separation between the cleaved solar cells 10. The transport belt 5265 may be positioned, for example, between two belts 5230. In the example of FIG. 69B, the cleaved wafer 10 is separated by sliding down a slide 5270 positioned between two belts 5230. In this example, the belt 5230 advances each cleaved cell 10 into a low vacuum (eg, no vacuum) region of the manifold 5235, where the uncleaved portion of the wafer 45 is still caught by the belt 5230. The used battery is released to the slide 5270. Providing an air cushion between the cleaved cell 10 and the slide 5270 helps to ensure that both the cell and the slide do not wear during this operation, and Allow for faster sliding away from the wafer 45, thereby allowing for higher cleaving belt operating speeds.

  In the example of FIG. 69C, a carriage 5275A of a rotating “ferris wheel” arrangement 5275 carries the cleaved solar cells 10 from the belt 5230 to one or more belts 5280.

  In the example of FIG. 69D, a rotating roller 5285 pulls a vacuum through the actuator 5285A to pick up the cleaved solar cells 10 from the belt 5230 and places them on the belt 5280.

  In the example of FIG. 69E, the carriage actuator 5290 includes a carriage 5290A and an extendable actuator 5290B mounted on the carriage. The carriage 5290A translates back and forth, positions the actuator 5290B, removes the cleaved solar cells 10 from the belt 5230, and then positions the actuator 5290B to place the cleaved solar cells on the belt 5280.

  In the example of FIG. 69F, the carriage track arrangement 5295 positions the carriage 5295A, removes the cleaved solar cells 10 from the belt 5230, and then positions the carriage 5295A to load the cleaved solar cells 10 on the belt 5280. And a carriage 5295A attached to a moving belt 5300 to be placed. The latter action occurs as the carriage falls or leaves the belt 5280 due to the path of the belt 5230.

  In the example of FIG. 69G, an inverted vacuum belt arrangement 5305 pulls a vacuum through one or more moving perforated belts to transport the cleaved solar cells 10 from belt 5230 to belt 5280.

  70A-70C provide orthogonal views of additional variations of the exemplary tools described above with reference to FIGS. 62A-62B and subsequent figures. In this modification 5310, as in the example of FIG. 69A, the cleaved solar cell 10 is removed from the perforated belt 5230 that transports the uncleaved wafer 45 into the cleavage region of the tool using the transport belt 5265. . The perspective views of FIGS. 71A-71B show this variation of the cleavage tool in two different operating steps. In FIG. 71A, the uncleaved wafer 45 is approaching the cleavage region of the tool, and in FIG. 71B, the wafer 45 is in the cleavage region, and the two cleaved solar cells 10 are separated from the wafer, Thereafter, they are further separated from each other as they are transported by the transport belt 5265.

  In addition to the features previously described, FIGS. 70A-71B show a plurality of vacuum ports 5315 on each manifold. Using multiple ports per manifold may allow a greater degree of control over the change in vacuum along the length of the top surface of the manifold. For example, a plurality of different vacuum ports 5315 may optionally communicate with different vacuum chambers (eg, 5260L and 5260H in FIGS. 66 and 72B) and / or optionally connect to a plurality of different vacuum pumps. Thus, a plurality of different vacuum pressures may be provided along the manifold. 70A-70B also show the entire path of the wheel 5325, the top surface of the vacuum manifold 5235, and the perforated belt 5230 looping around the wheel 5320. Belt 5230 may be driven, for example, by either wheel 5320 or wheel 5325.

  FIGS. 72A and 72B show perspective views of a portion of a vacuum manifold 5235 with a portion of the perforated belt 5230 overlying, with respect to the variation of FIGS. 70A-71B, and FIG. To provide a diagram. FIG. 73A shows a top view of a portion of a vacuum manifold 5235 with perforated belt 5230 overlying, and FIG. 73B shows the same vacuum manifold and perforated belt cut along line CC shown in FIG. 73A. FIG. As shown in FIG. 73B, the relative orientation of the through-holes 5240 is such that each through-hole is positioned perpendicular to the top surface of the manifold just above the through-hole, and the length of the vacuum manifold is Along. FIG. 74A shows another top view of a portion of vacuum manifold 5235 with perforated belt 5230 overlying, and vacuum chambers 5260L and 5260H are shown in local perspective. FIG. 74B shows a view close to a portion of FIG. 74A.

  75A-75G illustrate some exemplary hole patterns that may optionally be used on the perforated vacuum belt 5230. A common feature of these patterns is that the straight edges of the wafer 45 or cleaved solar cells 10 that traverse the pattern in any direction on the belt in a direction perpendicular to the long axis of the belt always have at least That is, it will overlap one hole 5255. The pattern may be, for example, two or more rows of square or rectangular holes offset from one another (FIGS. 75A, 75D), two or more rows of circular holes offset from one another (FIG. 75A). 75B, 75E, 75G), two or more rows of angled slots (FIGS. 75C, 75F), or any other suitable arrangement of holes.

  This specification describes supercells arranged in a plurality of physically parallel rows within a solar module, arranged in a series of overlapping shingles and electrically connected in series by conductive junctions between adjacent overlapping solar cells. Disclosed is a highly efficient solar module including a silicon solar cell that forms a supercell in a folded state. A supercell can include any suitable number of solar cells. The supercells may have a length that extends essentially over the entire length or width of the solar module, for example, or two or more supercells may be arranged end-to-end within a row . This arrangement hides the solar cell-to-solar cell electrical interconnections and thus forms a visually attractive solar module with little or no contrast between adjacent series connected solar cells. Can be used.

  The present specification further discloses a cell metallization pattern that facilitates stencil printing of the metallization on the front (and, optionally) back side of the solar cell. As used herein, "stencil printing" of a cell metallization refers to a metallization material (e.g., silver paste) applied to the solar cell surface through a patterning opening in an otherwise impermeable sheet of material. Refers to applying The stencil can be, for example, a patterned stainless steel sheet. The stencil patterning openings are entirely free of stencil material, eg, do not include any mesh or screen. The absence of a mesh or screen material at the patterned stencil openings distinguishes "stencil printing" from "screen printing" as used herein. In contrast, in screen printing, a metallized material is applied to a solar cell surface through a screen (eg, a mesh) that supports a patterned impermeable material. The pattern includes openings in an impermeable material through which the metallized material is applied to the solar cell. The supporting screen extends across an opening in the impermeable material.

  Compared to screen printing, stencil printing of battery metallized patterns has narrower line width, higher aspect ratio (line height versus width), better line uniformity and clarity And provides a number of advantages, including longer stencil life compared to screens. However, stencil printing cannot print "islands" in a single pass as would be required in a conventional three busbar metallization design. In addition, stencil printing would require that the stencil include unsupported structures that may not be placed in the plane of the stencil during printing, may impede placement and use of the stencil. The metallization pattern cannot be printed in one pass. For example, stencil printing cannot print in a single pass a metallization pattern in which metallization fingers arranged in parallel are interconnected by bus bars or other metallization features that extend perpendicular to the fingers. This is because a single stencil for such a design would include an unsupported tongue of sheet material defined by an opening for the busbar and an opening for the finger. The tongues will not be pinned by physical connections to other parts of the stencil so that they lie in the plane of the stencil during printing, and may slip out of the plane, distorting the placement and use of the stencil High in nature.

  As a result, attempts to use stencils to print traditional solar cells require two passes for front metallization by two different stencils or by a stencil printing process in combination with a screen printing process. This increases the total number of printing steps per battery and creates a "stitching" problem where the two prints overlap and are twice as tall. Stitching further complicates the process, and additional printing and related steps increase costs. Therefore, stencil printing is not common for solar cells.

  As described further below, the front metallization pattern described herein may include an array of fingers (eg, parallel lines) that are not connected to each other by the front metallization pattern. These patterns can be stencil printed in a single pass with a single stencil since the required stencil need not include unsupported portions or structures (eg, tongue). Such a front metallization pattern can be disadvantageous for standard sized solar cells and for strings of solar cells in which solar cells separated from one another are interconnected by copper ribbons. This is because the metallization pattern itself does not provide any substantial current spreading or conduction in a direction perpendicular to the fingers. However, in the front metallization pattern described in this specification, a part of the front metallization pattern of the solar cell overlaps with the back metallization pattern of the adjacent solar cell, and a part of the metallization pattern is conducted to the rear metallization pattern. A shingle-like arrangement of rectangular solar cells, as described herein, to be joined may work well. This is because the overlapping backside metallization of adjacent solar cells may allow current spreading and conduction in a direction perpendicular to the fingers in the frontside metallization pattern.

  Turning now to the drawings for a more detailed understanding of the solar modules described herein, FIG. 1 shows that the edges of adjacent solar cells overlap and are electrically connected to form a supercell 100. FIG. 2 shows a cross-sectional view of a string of solar cells 10 connected in series and arranged in a shingle-like shape in a state of being in a shingled state. Each solar cell 10 includes a semiconductor diode structure and a plurality of electrical contacts to the semiconductor diode structure. Thereby, the current generated in the solar cell 10 when the solar cell 10 is irradiated with light can be provided to an external load.

  In the example described herein, each solar cell 10 has a rectangular shape with metallized patterns on the front (sun side) and back (shadow side) surfaces that provide electrical contact on opposing sides of the np junction. A crystalline silicon solar cell, wherein a front metallization pattern is disposed on an n-type conductive semiconductor layer and a rear metallization pattern is disposed on a p-type conductive semiconductor layer. However, other material systems, diode structures, physical dimensions, or electrical contact arrangements may be used where appropriate. For example, the front (sun side) metallization pattern may be disposed on a p-type conductive semiconductor layer, and the back (shadow side) metallization pattern may be disposed on an n-type conductive semiconductor layer.

  Referring again to FIG. 1, in the supercell 100, adjacent solar cells 10 electrically connect the front metallization pattern of one solar cell to the back metallization pattern of an adjacent solar cell in the area where they overlap. It is directly conductively bonded to each other by an electrically conductive bonding agent. Suitable electrically conductive bonding agents may include, for example, electrically conductive adhesives, electrically conductive adhesive films and tapes, and conventional solders.

  Referring back to FIGS. 2A-2R, FIGS. 2A-2R illustrate an exemplary rectangular solar module 200 that includes six rectangular supercells 100 each having a length approximately equal to the length of the long side of the solar module. . The supercells are arranged as six parallel rows, with the long sides oriented parallel to the long sides of the module. A similarly configured solar module may include more or less rows of supercells of such a side length than shown in this example. In another variation, the supercells each have a length approximately equal to the length of the short sides of the rectangular solar module, and are arranged in parallel rows with their long sides oriented parallel to the short sides of the module. Can be deployed. In still other arrangements, for example, each row may include two or more supercells that may be electrically interconnected in series. The module may have a short side that is, for example, about 1 meter in length, and a long side that is, for example, about 1.5 to about 2.0 meters in length. Any other suitable shape (eg, square) and dimensions may be used for the solar module. Each supercell in this example includes 72 rectangular solar cells, each having a width equal to approximately 1/6 the width of a 156 millimeter (mm) square or pseudo-square wafer and a length of about 156 mm. Any other suitable number of rectangular solar cells of any other suitable dimensions may be used.

  FIG. 76 illustrates an exemplary frontside metallization pattern on a rectangular solar cell 10 that facilitates stencil printing as described above. The front metallization pattern can be formed, for example, from a silver paste. In the example of FIG. 76, the front metallization pattern includes a plurality of fingers 6015 extending parallel to each other, parallel to the short sides of the solar cell, and perpendicular to the long sides of the solar cell. The front metallization pattern also includes an optional plurality of rows of contact pads 6020 that extend parallel to and adjacent the long edge of the solar cell with each contact pad 6020 located at the end of a finger 6015. When present, each contact pad 6020 may be an electrically conductive adhesive (ECA), solder, or other material used to conductively join the front surface of the illustrated solar cell to an overlapping portion of the back surface of an adjacent solar cell. Forming areas for individual beads of the electrically conductive bonding agent. The pad may be, for example, circular, square, or rectangular, but any suitable pad shape may be used. As an alternative to using individual beads of electrically conductive bonding agent, solid or dashed ECAs, solders, conductive tapes, or other electrically conductive bondings located along the long edge of the solar cell Agents interconnect some or all of the fingers and may join the solar cells to adjacent and overlapping solar cells. Such a dashed or solid electrically conductive bonding agent may be used in combination with or without a conductive pad at the end of the finger.

  The solar cell 10 is, for example, about 156 mm in length and about 26 mm in width, and thus may have an aspect ratio (short side length / long side length) of about 1: 6. Six such solar cells can be provided on a standard 156 mm x 156 mm silicon wafer and then separated (diced) to provide a plurality of solar cells as shown. In another variation, eight solar cells 10 with dimensions of about 19.5 mm x 156 mm, and thus an aspect ratio of about 1: 8, can be prepared from a standard silicon wafer. More generally, the solar cell 10 can have an aspect ratio, for example, from about 1: 2 to about 1:20, and can be provided from a standard size wafer or from any other suitable sized wafer.

  Referring again to FIG. 76, the front metallization pattern may include, for example, from about 60 to about 120 fingers, eg, about 90 fingers, per 156 mm wide battery. Fingers 6015 can be, for example, about 10 to about 90 microns in width, such as about 30 microns. Fingers 6015 may have a height in a direction perpendicular to the surface of the solar cell of, for example, about 10 to about 50 microns. The finger height is, for example, about 10 microns or higher, about 20 microns or higher, about 30 microns or higher, about 40 microns or higher, or about 50 microns or higher. obtain. The diameter (circle) or side length (square or rectangular) of the pad 6020 can be, for example, from about 0.1 mm to about 1 mm, for example, about 0.5 mm.

  The backside metallization pattern of the rectangular solar cell 10 may be, for example, a plurality of discontinuous contact pad rows, a plurality of interconnecting contact pad rows, or a continuous row extending parallel to and adjacent to the long edge of the solar cell. May include a realistic bus bar. However, such contact pads or busbars are not required. If the front metallization pattern includes contact pads 6020 located along one of the long sides of the solar cell, the rows or busbars (if any) of the plurality of contact pads in the back metallization pattern are: It is arranged along the edge of the other long side of the solar cell. The backside metallization pattern may further include a metal back contact that covers substantially all of the remaining backside of the solar cell. The exemplary backside metallization pattern of FIG. 77A includes a plurality of discontinuous contact pad rows 6025 in combination with the metal back contact 6030 as just described, and the exemplary backside metallization pattern of FIG. 77B includes: It includes a continuous bus bar 35 in combination with the metal back contact 6030 as just described.

  In the shingled supercell, the front metallization pattern of the solar cell is conductively bonded to the overlapping portion of the back metallization pattern of the adjacent solar cell. For example, if the solar cell includes front metallized contact pads 6020, each contact pad 6020 is aligned and joined with a corresponding back metallized contact pad 6025 (if present) or the back metallized busbar 35 (present). (If present) and bonded to the metal back contact 6030 (if present) on the adjacent solar cell. This may include, for example, a discontinuity in the electrically conductive bonding agent disposed on each contact pad 6020 that extends parallel to the edge of the solar cell and optionally electrically interconnects two or more of the contact pads 6020. Can be achieved by a suitable portion (e.g., a bead) or by a dashed or solid line electrically conductive bonding agent.

  If the solar cell does not have front metallized contact pads 6020, for example, each front metallized pattern finger 6015 may be aligned and joined with a corresponding back metallized contact pad 6025 (if present), or It may be bonded to a metalized bus bar 35 (if present) or to a metal back contact 6030 (if present) on an adjacent solar cell. This may include, for example, the electrically conductive bonding agent disposed on the overlapping ends of each finger 6015, extending parallel to the edge of the solar cell and optionally electrically interconnecting two or more of the fingers 6015. It can be achieved by a discontinuous portion (eg, a bead) or by a dashed or solid line of electrically conductive bonding agent.

  As described above, a portion of the overlapping backside metallization of adjacent solar cells, for example, if present, the backside busbar 35 and / or rear metal contact 6030 may be oriented in a direction perpendicular to the fingers in the front side metallization pattern. Current spreading and conduction. In variations utilizing a dashed or solid line electrically conductive bond as described above, the conductive bond allows current spreading and conduction in a direction perpendicular to the fingers in the front metallization pattern. And Overlapping backside metallization and / or electrically conductive bonding agent can carry current, for example, by bypassing broken fingers or other finger breaks in the frontal metallization pattern.

  If present, backside metallized contact pads 6025 and busbars 35 may be formed from a silver paste that can be applied, for example, by stencil printing, screen printing, or any other suitable method. The metal back contact 6030 may be formed, for example, from aluminum.

  Any other suitable backside metallization pattern and material may be used.

  FIG. 78 shows an exemplary front metallization pattern of a square solar cell 6300 that can be diced to form a plurality of rectangular solar cells each having the front metallization pattern shown in FIG.

  FIG. 79 illustrates an exemplary backside metallization pattern of a square solar cell 6300 that may be diced to form a plurality of rectangular solar cells each having the backside metallization pattern shown in FIG. 77A.

  The front metallization pattern described herein may enable stencil printing of the front metallization on a standard three printer solar cell manufacturing line. For example, the manufacturing process uses a first printer to stencil or screen print a silver paste on the back surface of the square solar cell to form a back contact pad or a back silver bus bar, drying the back silver paste, Stencil or screen printing of aluminum contacts on the back of the solar cell using a second printer, drying of the aluminum contacts, a single stencil in a single stencil process with a third printer Use may include stenciling a silver paste on the front side of the solar cell to form a complete front metallization pattern, drying the silver paste, and firing the solar cell. These printing steps and related steps may occur or be omitted in any other order as appropriate.

  Printing the front metallization pattern with a stencil allows for the manufacture of narrower fingers than is possible with screen printing, which increases solar cell efficiency, uses silver, and therefore reduces manufacturing costs. Can be reduced. Stenciling the front metallization pattern in a single stencil printing step with a single stencil to overlap prints to define features having uniform height, e.g., extending in different directions. In addition, front metallization patterns can be produced without the stitching that can occur when stencil printing is used in combination with multiple stencils or screen printing.

  After the front and back metallization patterns have been formed on the square solar cells, each square solar cell can be separated into two or more rectangular solar cells. This can be achieved, for example, by laser scribe followed by cleavage or by any other suitable method. The rectangular solar cells can then be arranged in overlapping shingles and conductively joined to each other to form supercells, as described above. The present specification discloses, for example, a method for manufacturing a solar cell that has no cleavage edges that promote carrier recombination and that has reduced carrier recombination losses at the edges of the solar cell. The solar cell can be, for example, a silicon solar cell, and more specifically, a HIT silicon solar cell. The present specification also discloses a shingled (overlapping) supercell arrangement of such solar cells. The individual solar cells in such a supercell can have a narrow rectangular geometry (eg, strip-like shape) with the long sides of adjacent solar cells arranged to overlap.

  A major challenge in the cost-effective implementation of high efficiency solar cells such as HIT solar cells is the large volume of large currents that carry large currents from one such high efficiency solar cell to an adjacent series connected high efficiency solar cell. There is a previously recognized need for metals. Dicing such high efficiency solar cells into a plurality of narrow rectangular solar cell strips and then overlapping the resulting solar cells with conductive junctions between overlapping portions of adjacent solar cells ( Arranging in a shingle pattern to form a series-connected solar cell string in a supercell offers the opportunity to reduce module costs through process simplification. This is because it eliminates the tabbing process steps conventionally required to interconnect adjacent solar cells with metal ribbons. This shingle approach reduces the current through the solar cells (because individual solar cell strips can have a smaller area than conventional working areas) and between adjacent solar cells. Reducing the current path length can also increase module efficiency, both of which help reduce ohmic losses. The reduced current also allows less expensive but higher resistance conductors (eg, copper) to replace more expensive but lower resistance conductors (eg, silver) without substantial loss of performance. Can be used instead of. In addition, this shingle approach may reduce the inactive module area by removing the interconnect ribbon and associated contacts from the front of the solar cell.

  Conventional sized solar cells may have, for example, a substantially square front and back surface measuring about 156 millimeters (mm) by about 156 mm. In the shingle scheme just described, such solar cells are diced into two or more (eg, 2 to 20) solar cell strips of 156 mm in length. A potential difficulty with this shingle roofing technique is that dicing conventional-sized solar cells into thin strips allows the edge length of the cell per active area of the solar cell to be reduced compared to conventional-sized solar cells. Is longer, which can degrade performance due to carrier recombination at its edges.

  For example, FIG. 80 shows that the front and back sides are several solar strips (7100a, 7100b, 7100c, and 7100d), each having a front and back side that is a narrow rectangle of dimensions about 156 mm × about 40 mm. 9 schematically illustrates dicing of a HIT solar cell 7100 having a backside dimension of about 156 mm × about 156 mm. (The long 156 mm side of the solar cell strip extends into the page.) In the example shown, the HIT cell 7100 can be, for example, about 180 microns thick and have dimensions of about 156 mm x about 156 mm. Includes an n-type single crystal substrate 5105 that may have 156 mm front and back square faces. A layer of intrinsic amorphous Si: H (a-Si: H) with a thickness of about 5 nanometers (nm) and a layer of n + doped a-Si: H with a thickness of about 5 nm (both layers are reference numbers 7110) is disposed on the front surface of the crystalline silicon substrate 7105. An approximately 65 nm thick film 5120 of transparent conductive oxide (TCO) is disposed on the a-Si: H layer 7110. The conductive metal grid lines 7130 disposed on the TCO layer 7120 provide electrical contact to the front of the solar cell. A layer of intrinsic a-Si: H having a thickness of about 5 nm and a layer of p + doped a-Si: H having a thickness of about 5 nm (both layers are indicated by reference numeral 7115) are formed on the crystalline silicon substrate 7105. It is arranged on the back of. A film 7125 having a thickness of about 65 nm of a transparent conductive oxide (TCO) is disposed on the a-Si: H layer 7115, and the conductive metal grid line 7135 disposed on the TCO layer 7125 is a solar cell. To provide electrical contact to the backside of the (The dimensions and materials mentioned above are intended to be illustrative, not limiting, and may be modified as appropriate.)

  80, when HIT solar cell 7100 is cleaved by conventional methods to form strip solar cells 7100a, 7100b, 7100c, and 7100d, newly formed cleavage edges 7140 are not passivated. These non-passivated edges contain high-density dangling chemical bonds that promote carrier recombination and degrade the performance of the solar cell. In particular, the cleaved surface 7145 exposing the np junction and the cleaved surface exposing the heavily doped front field (in layer 7110) are not passivated and may substantially facilitate carrier recombination. Furthermore, if a conventional laser cutting or laser scribe process is used for dicing the solar cell 7100, thermal damage, such as amorphous silicon recrystallization 7150, may occur on the newly formed edges. As a result of the unpassivated edges and thermal damage, new edges formed on the cleaved solar cells 7100a, 7100b, 7100c and 7100d when conventional manufacturing processes are used, will result in a short-circuit current of the solar cells. , Open circuit voltage, and pseudo fill factor may be expected to be reduced. This, in turn, leads to a substantial reduction in the performance of the solar cell.

  The formation of edges that promote recombination during dicing of conventional sized HIT solar cells into narrower solar cell strips can be avoided by the method illustrated in FIGS. 81A-81J. The method uses isolation trenches on the front and back of a conventional sized solar cell 7100 to remove pn junctions and heavily doped fronts from cleaved edges that might otherwise serve as recombination sites for minority carriers. Separate the fields electrically. The trench edges are defined by chemical etching or laser patterning instead of conventional cleaving, followed by deposition of a passivation layer such as TCO to passivate both front and back trenches. Compared to a heavily doped region, the doping of the substrate is sufficiently low that the probability of electrons at the junction reaching the unpassivated cut edge of the substrate is low. In addition, a kerf-free wafer dicing technique, Thermal Laser Separation (TLS), can be used to cut the wafer, thereby avoiding potential thermal damage.

  In the example illustrated in FIGS. 81A-81J, the starting material is a square of about 156 mm, whose bulk resistance can be, for example, from about 1 to about 3 ohm centimeters and whose thickness can be, for example, about 180 microns. Is an n-type single crystal silicon as-cut wafer. (The wafer 7105 forms a substrate of a solar cell.)

  Referring to FIG. 81A, as-cut cut wafer 7105 is conventionally textured etched, acid washed, rinsed and dried.

  Next, in FIG. 81B, an intrinsic a-Si: H layer having a thickness of about 5 nm and a doped n + a-Si: H layer having a thickness of about 5 nm (both layers are indicated by reference numeral 7110). Is deposited on the front side of the wafer 7105 by, for example, plasma enhanced chemical vapor deposition (PECVD) at a temperature of, for example, about 150 ° C. to about 200 ° C.

  Next, in FIG. 81C, an intrinsic a-Si: H layer having a thickness of about 5 nm and a doped p + a-Si: H layer having a thickness of about 5 nm (both layers are indicated by reference numeral 7115). Is deposited on the backside of the wafer 7105 by, for example, PECVD at a temperature of, for example, about 150 ° C. to about 200 ° C.

  Next, in FIG. 81D, the front a-Si: H layer 7110 is patterned to form an isolation trench 7112. The isolation trench 7112 typically penetrates the layer 7110 to the wafer 7105 and may, for example, be about 100 microns to about 1000 microns, for example, about 200 microns in width. Typically, the trench has the narrowest width that can be used depending on the accuracy of the patterning technique and the subsequently applied cleavage technique. Patterning of the trench 7112 can be accomplished using, for example, laser patterning, or chemical etching (eg, inkjet wet patterning).

  Next, in FIG. 81E, the back a-Si: H layer 7115 is patterned to form an isolation trench 7117. Like isolation trench 7112, isolation trench 7117 typically penetrates layer 7115 to wafer 7105 and may be, for example, from about 100 microns to about 1000 microns, for example, about 200 microns in width. . Patterning of the trench 7117 may be accomplished using, for example, laser patterning, or chemical etching (eg, inkjet wet patterning). Each trench 7117 is aligned with a corresponding trench 7112 on the front of the structure.

  Next, in FIG. 81F, a TCO layer 7120 having a thickness of about 65 nm is deposited on the patterned a-Si: H layer 7110. This can be achieved, for example, by physical vapor deposition (PVD) or by ion plating. TCO layer 7120 fills trench 7112 in a-Si: H layer 7110 and coats the outer edge of layer 7110, thereby passivating the surface of layer 7110. TCO layer 7120 also functions as an anti-reflective coating.

  Next, in FIG. 81G, a TCO layer 7125 having a thickness of about 65 nm is deposited on the patterned backside a-Si: H layer 7115. This can be achieved, for example, by PVD or by ion plating. TCO layer 7125 fills trench 7115 in a-Si: H layer 7117 and coats the outer edge of layer 115, thereby passivating the surface of layer 7115. TCO layer 7125 also functions as an anti-reflective coating.

  Next, in FIG. 81H, a conductive (eg, metal) front grid line 7130 is screen printed on the TCO layer 7120. The grid lines 7130 can be formed, for example, from a low-temperature silver paste.

  Next, in FIG. 81I, a conductive (eg, metal) back grid line 7135 is screen printed on the TCO layer 7125. The grid lines 7135 can be formed, for example, from a low-temperature silver paste.

  Next, after deposition of grid lines 7130 and 7135, the solar cell is cured at a temperature of about 200 ° C., for example, for about 30 minutes.

  Next, in FIG. 81J, the solar cells are separated into solar cell strips 7155a, 7155b, 7155c, and 7155d by dicing the solar cells at the center of the trench. Dicing can be accomplished, for example, by cleaving the solar cell along the trench using conventional laser scribe and mechanical cleavage at the center of the trench. Alternatively, dicing is achieved using a Thermal Laser Separation process (eg, as developed by Jenoptik AG) where laser induced heating at the center of the trench causes mechanical stresses that lead to cleavage of the solar cell along the trench. Can be done. The latter approach can avoid thermal damage to the edges of the solar cell.

  The resulting strip solar cells 7155a-7155d are different from the strip solar cells 7100a-7100d shown in FIG. In particular, the edges of a-Si: H layer 7110 and a-Si: H layer 7115 in solar cells 7140a-7140d are formed not by mechanical cleavage but by etching or laser patterning. In addition, the edges of layers 7110 and 7115 in solar cells 7155a-7155d are passivated by a TCO layer. As a result, solar cells 7140a-7140d do not have the cleavage edges present in solar cells 7100a-7100d, which promote carrier recombination.

  The methods described in connection with FIGS. 81A-81J are intended to be illustrative, not limiting. Steps described as performed in a particular order may be performed in other orders or in parallel, as appropriate. Steps and material layers may be omitted, added, or replaced as appropriate. For example, if a copper plated metallization was used, additional patterning or seed layer deposition steps could be included in the process. Further, in some variations, only the front a-Si: H layer 7110 is patterned to form an isolation trench, and no isolation trench is formed in the back a-Si: H layer 7115. In another variation, only the back a-Si: H layer 7115 is patterned to form an isolation trench, and no isolation trench is formed in the front a-Si: H layer 7115. In these variations, as in the example of FIGS. 81A-81J, dicing occurs at the center of the trench.

  The formation of recombination promoting edges during dicing of conventional sized HIT solar cells into narrower solar cell strips may be employed in the method described in connection with FIGS. 81A-81J. It can also be avoided by the method illustrated in FIGS. 82A-82J, which also uses isolation trenches.

  Referring to FIG. 82A, in this example, the starting material is again about 156 mm square, which may have a bulk resistance, for example, from about 1 to about 3 ohm centimeters and a thickness, for example, about 180 microns. N-type single crystal silicon as-cut wafer 7105.

  Referring to FIG. 82B, a trench 7160 is formed on the front side of the wafer 7105. These trenches can have a depth, for example, from about 80 microns to about 150 microns, for example, about 90 microns, and a width, for example, from about 10 microns to about 100 microns. Isolation trench 7160 defines the geometry of the solar cell strip to be formed from wafer 7105. As described below, the wafer 7105 will be cleaved along these trenches. These trenches 7160 can be formed, for example, by a conventional laser wafer scribe.

  Next, in FIG. 82C, the wafer 7105 is textured etched, acid cleaned, rinsed, and dried in a conventional manner. The etching typically removes damage originally present on the surface of the as-cut wafer 7105 or caused during the formation of the trench 7160. The etching can also widen and deepen the trench 7160.

  Next, in FIG. 82D, an intrinsic a-Si: H layer having a thickness of about 5 nm and a doped n + a-Si: H layer having a thickness of about 5 nm (both layers are indicated by reference numeral 7110). Is deposited on the front side of the wafer 7105 by, for example, PECVD at a temperature of, for example, about 150 ° C. to about 200 ° C.

  Next, in FIG. 82E, an intrinsic a-Si: H layer having a thickness of about 5 nm and a doped p + a-Si: H layer having a thickness of about 5 nm (both layers are indicated by reference numeral 7115). Is deposited on the backside of the wafer 7105 by, for example, PECVD at a temperature of, for example, about 150 ° C. to about 200 ° C.

  Next, in FIG. 82F, a TCO layer 7120 having a thickness of about 65 nm is deposited on the front a-Si: H layer 7110. This can be achieved, for example, by physical vapor deposition (PVD) or by ion plating. The TCO layer 7120 fills the trench 7160 and typically coats the walls and bottom of the trench 7160 and the outer edges of the layer 7110, thereby passivating the coated surface. TCO layer 7120 also functions as an anti-reflective coating.

  Next, in FIG. 82G, a TCO layer 7125 having a thickness of about 65 nm is deposited on the backside a-Si: H layer 7115. This can be achieved, for example, by PVD or by ion plating. TCO layer 7125 passivates the surface (including, for example, the outer edge) of layer 7115 and also functions as an anti-reflective coating.

  Next, in FIG. 82H, a conductive (eg, metal) front grid line 7130 is screen printed on the TCO layer 7120. The grid lines 7130 can be formed, for example, from a low-temperature silver paste.

  Next, in FIG. 82I, a conductive (eg, metal) back grid line 7135 is screen printed on the TCO layer 7125. The grid lines 7135 can be formed, for example, from a low-temperature silver paste.

  Next, after deposition of grid lines 7130 and 7135, the solar cell is cured at a temperature of about 200 ° C., for example, for about 30 minutes.

  Next, in FIG. 82J, the solar cells are separated into solar cell strips 7165a, 7165b, 7165c, and 7165d by dicing the solar cells at the center of the trench. Dicing can be accomplished, for example, by cleaving the solar cells along the trench using conventional mechanical cleavage at the center of the trench. Alternatively, dicing can be achieved, for example, using a Thermal Laser Separation process as described above.

  The resulting strip solar cells 7165a-7165d are different from the strip solar cells 7100a-7100d shown in FIG. In particular, the edges of a-Si: H layer 7110 in solar cells 7165a-7165d are formed by etching, not by mechanical cleavage. In addition, the edges of layer 7110 in solar cells 7165a-7165d are passivated by a TCO layer. As a result, solar cells 7165a-7165d do not have the cleavage edges present in solar cells 7100a-7100d, which promote carrier recombination.

  The methods described in connection with FIGS. 82A-82J are intended to be illustrative, not limiting. Steps described as performed in a particular order may be performed in other orders or in parallel, as appropriate. Steps and material layers may be omitted, added, or replaced as appropriate. For example, if a copper plated metallization was used, additional patterning or seed layer deposition steps could be included in the process. Further, in some variations, trenches 7160 may be formed on the backside of wafer 7105, rather than on the front side of wafer 7105.

  The methods described above in connection with FIGS. 81A-81J and 86A-86J are applicable to both n-type and p-type HIT solar cells. Solar cells can be front emitters or back emitters. It may be preferable to apply a separation process on the side without the emitter. Further, using isolation trenches and passivation layers as described above to reduce recombination on cleaved wafer edges is applicable to other solar cell designs and solar cells using non-silicon material systems. is there.

  Referring again to FIG. 1, the string of a plurality of series-connected solar cells 10 formed by the method described above advantageously overlaps and electrically connects adjacent solar cell ends to form a supercell 100. It can be arranged in a shingle-like shape in a sloping state. In the supercell 100, adjacent solar cells 10 are connected to each other by an electrically conductive bonding agent that electrically connects the front metallization pattern of one solar cell to the rear metallization pattern of the adjacent solar cell in the area where they overlap. Conductive bonding. Suitable electrically conductive bonding agents may include, for example, electrically conductive adhesives, electrically conductive adhesive films and tapes, and conventional solders.

  5A-5B, FIG. 5A shows an exemplary rectangular solar module 200 that includes twenty rectangular supercells 100 each having a length approximately equal to half the length of the short side of the solar module. . The supercells are arranged in pairs, end-to-end, with 10 supercell rows oriented with the rows and the long side of the supercell parallel to the short side of the solar module. It is formed in a state. In another variation, each supercell row may include three or more supercells. Also, in other variations, the supercells may be oriented such that the rows and the long sides of the supercell are oriented parallel to the long sides of the rectangular solar module, or parallel to the sides of the square solar module. It can be arranged in a state where the ends are connected with each other. Further, the solar module may include more or less supercells and more or less supercell rows as shown in this example.

  In a variation where the supercells 100 in each row are arranged such that at least one of the supercells in each row has a front end contact on the edge of a supercell adjacent to other supercells in the row, FIG. 5A May be present to facilitate electrical contact with the front end contact of the supercell along the centerline of the solar module. In variations where each supercell row includes three or more supercells, there may be additional optional gaps between the supercells, as well as front end contacts located away from the sides of the solar module Electrical contact with the device.

  FIG. 5B illustrates another exemplary rectangular solar module 300 that includes ten rectangular supercells 100 each having a length approximately equal to the length of the short side of the solar module. The supercells are arranged with their long sides oriented parallel to the short sides of the module. In another variation, the supercell has a length approximately equal to the length of the long sides of the rectangular solar module, and the long sides can be oriented with the long sides of the solar module parallel. Also, the supercell has a length approximately equal to the length of the sides of the square solar module, and can be oriented with their long sides parallel to the sides of the solar module. Further, the solar module may include more or less such side-length supercells than shown in this example.

  FIG. 5B also shows how the solar module 200 would look if there were no gaps between adjacent supercells in multiple supercell rows in the solar module 200 of FIG. 5A. Any other suitable arrangement of the supercell 100 in a solar module may be used.

  The following enumerated paragraphs provide additional non-limiting aspects of the present disclosure.

1. A series-connected string of N (≥25) rectangular or substantially rectangular solar cells having an average breakdown voltage of greater than about 10 volts, wherein said rectangular or substantially rectangular solar cells are one or more supercells. The plurality of solar cells are grouped, and each of the one or more supercells is arranged side by side with the long sides of adjacent solar cells overlapping and conductively joined to each other by an electric and heat conductive adhesive. A series-connected string of rectangular or substantially rectangular solar cells comprising two or more of the cells,
A solar module, wherein no single solar cell or group of less than N solar cells in said string of solar cells is individually electrically connected in parallel with a bypass diode.

  2. Item 2. The solar module according to item 1, wherein N is greater than or equal to 30.

  3. Item 2. The solar module according to item 1, wherein N is greater than or equal to 50.

  4. Item 2. The solar module according to item 1, wherein N is greater than or equal to 100.

  5. The adhesive has a thickness in a direction perpendicular to the plurality of solar cells of less than or equal to about 0.1 mm and a thermal conductivity in a direction perpendicular to the plurality of solar cells of about 1.5 w / Item 2. The solar module according to item 1, forming a plurality of junctions between adjacent solar cells higher than or equal to m / k.

  6. Item 2. The solar module according to item 1, wherein the N solar cells are grouped into a single supercell.

  7. Item 2. The solar module according to Item 1, wherein the plurality of supercells are enclosed in a polymer.

  7A. Item 9. The solar module according to item 7, wherein the polymer includes a thermoplastic olefin polymer.

  7B. Item 7. The solar module according to Item 7, wherein the polymer is sandwiched between a front sheet and a rear sheet made of glass.

  7C. The solar module according to item 7B, wherein the rear sheet includes glass.

  8. Item 2. The solar module according to Item 1, wherein the plurality of solar cells are silicon solar cells.

9. A solar module,
A supercell substantially extending over the entire length or width of the solar module parallel to an edge of the solar module, wherein the supercell is formed by overlapping long sides of adjacent solar cells and electrically and thermally conductive adhesive. A supercell comprising a series connection string of N or rectangular or substantially rectangular solar cells having, on average, a breakdown voltage of greater than about 10 volts, arranged side by side in a conductive junction with each other,
A solar module, wherein no single solar cell or group of less than N solar cells in the supercell is individually electrically connected in parallel with a bypass diode.

  10. Item 10. The solar module according to item 9, wherein N> 24.

  11. Item 10. The solar module according to item 9, wherein the length of the supercell in the direction of current flow is at least about 500 mm.

  12. Item 10. The solar module according to item 9, wherein the plurality of supercells are sealed in a thermoplastic olefin polymer sandwiched between a front sheet and a rear sheet made of glass.

13. A supercell,
Equipped with multiple silicon solar cells,
Each silicon solar cell,
A rectangular or substantially rectangular front and rear face having a shape defined by opposing parallel first and second long sides and two opposing short sides; At least a portion of which is exposed to solar radiation during operation of the solar cell string; and
An electrically conductive front metallization pattern disposed on the front surface and including at least one front contact pad positioned adjacent the first long side;
An electrically conductive back metallization pattern disposed on the back surface and including at least one back contact pad positioned adjacent the second long side;
In the plurality of silicon solar cells, the first long side and the second long side of the adjacent silicon solar cells are overlapped, and the front and rear contact pads on the adjacent silicon solar cells are overlapped with each other. Conductively bonded to each other by a non-adhesive bonding agent, the adjacent silicon solar cells are arranged side by side in a state of being electrically connected in series,
The front metallization pattern of each silicon solar cell substantially encapsulates the conductive adhesive into at least one front contact pad prior to curing of the conductive adhesive during fabrication of the supercell. A supercell comprising a barrier configured as follows.

  14． For each pair of adjacent and overlapping silicon solar cells, the barrier on the front surface of one of the silicon solar cells partially overlaps the other silicon solar cell of the silicon solar cells, and the barrier is Concealed in part, thereby substantially enclosing the conductive adhesive in the overlapping area of the front surface of the silicon solar cell prior to curing of the conductive adhesive during manufacture of the supercell. 14. The supercell according to item 13.

  15. The barrier includes a continuous conductive line extending substantially the full length of the first long side parallel to the first long side, and the at least one front contact pad includes the continuous conductive line; Item 14. The supercell according to item 13, which is located between the solar cell and the first long side.

  16. The front metallization pattern electrically connects to the at least one front contact pad and includes the finger extending in a direction perpendicular to the first long side, and the continuous conductive line electrically interconnects the plurality of fingers. Clause 15 wherein the supercell provides a plurality of conductive paths from each finger to at least one front contact pad.

  17． The front metallization pattern includes a plurality of discontinuous contact pads arranged in a parallel row adjacent to the first long side, and the barrier includes, for each discontinuous contact pad, the superconductor. Prior to curing of the conductive adhesive during manufacture of the cell, including forming a plurality of distinct barriers that substantially enclose the conductive adhesive in the discontinuous contact pad. Item 14. A supercell according to item 13.

  18. 18. The supercell of clause 17, wherein the plurality of discrete barriers abut and are higher than their corresponding discontinuous contact pads.

19. A supercell,
Equipped with multiple silicon solar cells,
Each silicon solar cell,
A rectangular or substantially rectangular front and rear face having a shape defined by opposing parallel first and second long sides and two opposing short sides; At least a portion of which is exposed to solar radiation during operation of the solar cell string; and
An electrically conductive front metallization pattern disposed on the front surface and including at least one front contact pad positioned adjacent the first long side;
An electrically conductive back metallization pattern disposed on the back surface and including at least one back contact pad positioned adjacent the second long side;
In the plurality of silicon solar cells, the first long side and the second long side of the adjacent silicon solar cells are overlapped, and the front and rear contact pads on the adjacent silicon solar cells are overlapped with each other. Conductively bonded to each other by a non-adhesive bonding agent, the adjacent silicon solar cells are arranged side by side in a state of being electrically connected in series,
The backside metallization pattern of each silicon solar cell may include applying the conductive adhesive to the at least one rear contact pad prior to curing the conductive adhesive during manufacture of the supercell. A supercell that contains a barrier configured to contain it.

  20. The backside metallization pattern includes one or more discontinuous contact pads disposed in a parallel row adjacent to the second long side, wherein the barrier includes, for each discontinuous contact pad: Prior to curing the conductive adhesive during manufacture of the supercell, features are provided that form a plurality of separate barriers that substantially enclose the conductive adhesive in the discontinuous contact pad. Item 21. The supercell according to Item 19, including:

  21. 21. The supercell of clause 20, wherein the plurality of discrete barriers abut and are higher than their corresponding discontinuous contact pads.

22. A method of making a solar cell string,
Dicing the one or more pseudo-square silicon wafers along a plurality of lines of the one or more pseudo-square silicon wafers parallel to a long edge of each pseudo-square silicon wafer, and substantially dicing the same along the long axis. Forming a plurality of rectangular silicon solar cells each having a length;
A step of arranging the plurality of rectangular silicon solar cells in a state where the long sides of adjacent solar cells overlap and are conductively joined to each other, and the adjacent solar cells are electrically connected in series;
The plurality of rectangular silicon solar cells include: at least one rectangular solar cell including two chamfered corners corresponding to a plurality of corners of the pseudo-square wafer or a part of the plurality of corners; One or more rectangular silicon solar cells, each having no,
The spacing between the plurality of parallel lines along which the pseudo-square wafer is diced does not have the width perpendicular to the long axis of the rectangular silicon solar cell including the chamfered corner, and the chamfered corner. One or more rectangular silicon solar cells are selected to compensate for the chamfered corners by making the width greater than a length perpendicular to the long axis of the rectangular silicon solar cells, whereby one of the rectangular silicon solar cells in the solar cell string is selected. A method, wherein each has a front surface that has substantially the same area exposed to light in operation of the solar cell string.

23. A solar cell string,
An end portion of adjacent solar cells overlaps and is conductively joined to each other, comprising a plurality of silicon solar cells arranged side by side in a state where the adjacent solar cells are electrically connected in series,
At least one of the plurality of silicon solar cells has a plurality of corners of the quasi-square silicon wafer to be diced, or a chamfered corner corresponding to a part of the plurality of corners, and At least one of the plurality of silicon solar cells does not have a chamfered corner, and each of the plurality of silicon solar cells has a front surface having substantially the same area exposed to light during operation of the solar cell string. Having a solar cell string.

24. A method of making two or more solar cell strings, comprising:
Dicing the one or more pseudo-square silicon wafers along a plurality of lines parallel to the long edge of each of the one or more pseudo-square silicon wafers to form the one or more pseudo-square silicon wafers A first plurality of rectangular silicon solar cells including chamfered corners corresponding to a plurality of corners or a part of the plurality of corners, and a first plurality extending over the entire width of the one or more pseudo-square silicon wafers. Forming a second plurality of rectangular silicon solar cells each having a length and no chamfered corners;
Removing the chamfered corners from each of the first plurality of rectangular silicon solar cells, each having a second length shorter than the first length, and having no chamfered corners; Forming a plurality of rectangular silicon solar cells of 3;
The second plurality of rectangular silicon solar cells are arranged side by side with the long sides of adjacent rectangular silicon solar cells overlapping and conductively joined to each other, and the second plurality of rectangular silicon solar cells are electrically connected in series. Forming a solar cell string having a width equal to the first length;
The third plurality of rectangular silicon solar cells are arranged side by side with the long sides of adjacent rectangular silicon solar cells overlapping and conductively joined to each other, and the third plurality of rectangular silicon solar cells are electrically connected in series. Forming a solar cell string having a width equal to said second length.

25.2 A method of making two or more solar cell strings, comprising:
Dicing the one or more pseudo-square silicon wafers along a plurality of lines parallel to the long edge of each of the one or more pseudo-square silicon wafers to form the one or more pseudo-square silicon wafers A first plurality of rectangular silicon solar cells including chamfered corners corresponding to a plurality of corners or a part of the plurality of corners; and a second plurality of rectangular silicon solar cells without chamfered corners. Forming a;
The first plurality of rectangular silicon solar cells are arranged side by side with the long sides of adjacent rectangular silicon solar cells overlapping and conductively joined to each other, and the first plurality of rectangular silicon solar cells are electrically connected in series. Process and
The second plurality of rectangular silicon solar cells are arranged side by side with the long sides of adjacent rectangular silicon solar cells overlapping and conductively joined to each other, and the second plurality of rectangular silicon solar cells are electrically connected in series. A method comprising:

26. How to make a solar module,
Dicing the wafer along a plurality of lines parallel to a long edge of each pseudo-square silicon wafer among the plurality of pseudo-square silicon wafers, and chamfered corners corresponding to a plurality of corners of the plurality of pseudo-square silicon wafers. A plurality of rectangular silicon solar cells including, and a step of forming a plurality of rectangular silicon solar cells without chamfered corners from the plurality of pseudo-square silicon wafers,
At least some of the plurality of rectangular silicon solar cells having no chamfered corners are arranged, and long sides of the plurality of rectangular silicon solar cells overlap and are conductively joined to each other to form the plurality of rectangular silicon solar cells. Forming a first plurality of supercells, each comprising only a rectangular silicon solar cell without chamfered corners, arranged side by side in a state of being electrically connected in series;
Arranging at least some of the plurality of rectangular silicon solar cells including the chamfered corners, the long sides of the plurality of rectangular silicon solar cells overlap and are conductively joined to each other, and the plurality of rectangular silicon solar cells are connected in series. Forming a second plurality of supercells, each comprising only rectangular silicon solar cells having chamfered corners, arranged side by side in electrical connection;
A plurality of parallel supercell rows of substantially equal length, each row comprising only a plurality of supercells from the first plurality of supercells or only a plurality of supercells from the second plurality of supercells. Forming the front surface of the solar module by arranging the plurality of supercells in the solar module.

  27. Two of the plurality of supercell rows adjacent parallel opposing edges of the solar module include only the plurality of supercells from the second plurality of supercells, and all other plurality of supercells. Clause 26. The solar module of clause 26, wherein the cell row includes only supercells from the first plurality of supercells.

  28. Clause 27. The solar module of clause 27, wherein the solar module includes a total of six supercell rows.

29. A plurality of silicon solar cells that are arranged side by side in the first direction in a state where the ends of adjacent silicon solar cells overlap and are conductively joined to each other, and the adjacent silicon solar cells are electrically connected in series;
And an elongated flexible electrical interconnect,
A major axis of the elongated flexible electrical interconnect is oriented parallel to a second direction perpendicular to the first direction;
The elongated flexible electrical interconnect comprises:
Conducting bonding to the front or rear surface of an end silicon solar cell of the plurality of silicon solar cells at three or more discontinuous positions arranged along the second direction;
Extending in the second direction over at least the entire width of the solar cell at the end,
A conductor thickness measured in a direction perpendicular to the front or back surface of the edge silicon solar cell is less than or equal to about 100 microns;
Providing a resistance less than or equal to about 0.012 ohms for the flow of current in the second direction;
Configured to provide flexibility between the silicon solar cell at the end and the interconnect to accommodate differential expansion in the second direction in a temperature range from about -40C to about 85C. Is a supercell.

  30. 30. The supercell of clause 29, wherein the flexible electrical interconnect has a conductor thickness, measured in a direction perpendicular to the front and back surfaces of the silicon solar cell at the end, of less than or equal to about 30 microns. .

  31. The flexible electrical interconnect extends beyond the supercell in the second direction to provide at least an electrical connection to a second supercell positioned parallel and adjacent to the supercell in a solar module. Clause 30. The supercell of clause 29 providing an interconnect.

  32. The flexible electrical interconnect extends beyond the supercell in the first direction to provide electrical interconnection to a second supercell positioned parallel and alongside the supercell in a solar module. 30. The supercell of clause 29 provided.

33. A solar module,
Arranged in two or more parallel rows extending across the width of the solar module to form the front surface of the solar module, the ends of adjacent silicon solar cells overlap and are conductively joined to each other, Comprising a plurality of supercells each including a plurality of silicon solar cells arranged side by side in a state of electrically connecting the silicon solar cells in series,
At least the edge of the first supercell adjacent to the edge of the solar module in the first row,
Bonding to the front surface of the first supercell with an electrically conductive adhesive bonding agent at a plurality of discontinuous locations;
Extending parallel to the edge of the solar module,
At least a portion of the first supercell is broken around the end and hidden from view from the front of the solar module;
Via flexible electrical interconnects,
Electrically connecting to the end of a second supercell adjacent to the same edge of the solar module in the second row;
Solar module.

  34. Clause 33. The solar module of clause 33, wherein a surface of the flexible electrical interconnect on the front surface of the solar module is covered or colored to reduce visible contrast to the supercell.

35. The two or more parallel rows of supercells are disposed on a white backsheet to form a front surface of the solar module that will be illuminated by solar radiation during operation of the solar module;
The white backsheet includes a plurality of parallel dark stripes having positions and widths corresponding to the positions and widths of the plurality of gaps between two or more parallel rows of the supercell;
34. The solar module of clause 33, wherein the white portions of the backsheet are not visible through the gaps between two or more parallel rows of the supercell.

36. A method of making a solar cell string,
Laser scribing one or more scribe lines on each of the one or more silicon solar cells to define a plurality of rectangular regions on the one or more silicon solar cells;
Applying an electrically conductive adhesive to the scribed one or more silicon solar cells at one or more locations adjacent to the long sides of each rectangular region;
A plurality of rectangles each including a part of the electrically conductive adhesive bonding agent disposed on a front surface adjacent to a long side by separating the one or more silicon solar cells along the one or more scribe lines. Providing a silicon solar cell;
Long sides of adjacent rectangular silicon solar cells, a step of arranging the plurality of rectangular silicon solar cells in a state where a part of the electrically conductive adhesive bonding agent is interposed and overlapped in a shingle-like shape,
Curing the electrically conductive bonding agent, thereby bonding adjacent and overlapping rectangular silicon solar cells to each other and electrically connecting them in series.

37. A method of making a solar cell string,
One or more scribe lines are laser scribed on each of the one or more silicon solar cells among the one or more silicon solar cells each having a top surface and a bottom surface opposed to each other, and the one or more silicon solar cells are formed. Defining a plurality of rectangular areas on the battery;
Applying an electrically conductive adhesive to a portion of the top surface of the one or more silicon solar cells;
A vacuum is drawn between the bottom surface and the curved support surface of the one or more silicon solar cells, and the one or more silicon solar cells are bent toward the curved support surface, whereby the one or more silicon solar cells are bent. Cleaving the one or more silicon solar cells along a scribe line to provide a plurality of rectangular silicon solar cells each including a part of the electrically conductive adhesive bonding agent disposed on a front surface adjacent to a long side. The process of
Long sides of adjacent rectangular silicon solar cells, a step of arranging the plurality of rectangular silicon solar cells in a state where a part of the electrically conductive adhesive bonding agent is interposed and overlapped in a shingle-like shape,
Curing the electrically conductive bonding agent, thereby bonding adjacent and overlapping rectangular silicon solar cells to each other and electrically connecting them in series.

  38. Applying the electrically conductive adhesive bonding agent to the one or more silicon solar cells, and then laser scribe the one or more scribe lines on each of the one or more silicon solar cells. 38. The method of clause 37 comprising:

  39. Laser scribing the one or more scribe lines on each of the one or more silicon solar cells, and then applying the electrically conductive adhesive to the one or more silicon solar cells 38. The method of clause 37 comprising:

40. A solar module,
A plurality of supercells arranged in two or more parallel rows to form a front surface of the solar module, wherein each supercell overlaps an end of an adjacent silicon solar cell and is conductively joined to each other; Having a plurality of silicon solar cells arranged side by side in a state where adjacent silicon solar cells are electrically connected in series,
Each supercell has a front end contact at one end of the supercell and a rear end contact of opposite polarity at the opposite end of the supercell;
A first supercell row including a first supercell having a front end contact adjacent and parallel to a first edge of the solar module;
The solar module, wherein the solar module extends elongated parallel to the first edge of the solar module, is conductively connected to the front end contact of the first supercell, and is adjacent to the first edge of the solar module. A solar module comprising a first flexible electrical interconnect occupying only a narrow portion of the front surface of the solar module having a width measured in a direction perpendicular to the first edge of the solar module of about 1 cm or less.

  41. Clause 40: a portion of the first flexible electrical interconnect closest to the first edge of the solar module and extending behind the first supercell and around the end of the first supercell. The solar module according to 1.

  42. Clause 40: the first flexible interconnect includes a thin ribbon portion conductively joined to the front end contact of the first supercell and a thicker portion extending parallel to the first edge of the solar module. The solar module according to 1.

  43. The first flexible interconnect includes a thin ribbon portion conductively joined to the front end contact of the first supercell and a coiled ribbon portion extending parallel to the first edge of the solar module. 41. A solar module according to item 40.

  44. A second supercell row includes a second supercell having a front end contact adjacent and parallel to the first edge of the solar module, wherein the front end contact of the first supercell is disposed. 41. The solar module according to paragraph 40, wherein the portion electrically connects to the front end contact portion of the second supercell via the first flexible electrical interconnect.

45. The rear end contact portion of the first supercell is adjacent to and parallel to a second edge of the solar module opposite to the first edge of the solar module;
A second flexible electrical interconnect extending elongate parallel to the second edge of the solar module and conductively joined to the rear end contact of the first supercell and entirely lying rearward of the supercell. 40. The solar module according to 40.

46. A second supercell row has a front edge contact portion adjacent and parallel to the first edge of the solar module, and a rear edge contact portion adjacent to the second edge of the solar module. And a second supercell arranged in a parallel position,
The front end contact of the first supercell is electrically connected to the front end contact of the second supercell via the first flexible electrical interconnect;
Item 46. The solar module of Item 45, wherein the rear end contact of the first supercell is electrically connected to the rear end contact of the second supercell via the second flexible electrical interconnect.

47. A rear end contact portion is arranged in the first supercell row in series with the first supercell in a state in which the rear end contact portion is adjacent to the second edge of the solar module opposite to the first edge of the solar module. Two supercells,
A second flexible electrical interconnect extending elongate parallel to the second edge of the solar module and conductively joined to the rear end contact of the first supercell and entirely lying rearward of the supercell. Item 40. A solar module according to item 40.

48. A second supercell row has a front edge contact of a third supercell adjacent the first edge of the solar module and a rear edge contact of a fourth supercell adjacent the second edge of the solar module. Including the third supercell and the fourth supercell arranged in series in a state,
The front end contact of the first supercell is electrically connected to the front end contact of the third supercell via the first flexible electrical interconnect and the rear end contact of the second supercell. 48. The solar module of clause 47, wherein the portion is electrically connected to the rear end contact of the fourth supercell via the second flexible electrical interconnect.

49. The plurality of supercells have a white back surface including a plurality of parallel dark stripes having positions and widths corresponding to the positions and widths of the plurality of gaps between the two or more parallel rows of supercells. Placed on the sheet,
41. The solar module of clause 40, wherein the white portions of the backsheet are not visible through the gaps between two or more parallel rows of the supercell.

  50. Item 41. The solar cell of item 40 wherein all portions of the first flexible electrical interconnect located on the front surface of the solar module are covered or colored to reduce visible contrast to the supercell. module.

51. Each silicon solar cell,
A rectangular or substantially rectangular front and rear face having a shape defined by opposing parallel first and second long sides and two opposing short sides; At least a portion of which is exposed to solar radiation during operation of the solar cell string; and
A plurality of fingers disposed on the front surface and extending perpendicular to the first long side and the second long side; and a plurality of discontinuous front contact pads positioned in a row adjacent to the first long side. An electrically conductive front metallization pattern, wherein each front contact pad electrically connects to at least one of the plurality of fingers;
An electrically conductive backside metallization pattern disposed on the backside and including a plurality of discontinuous backside contact pads positioned in rows adjacent to the second long side;
In each supercell, the plurality of silicon solar cells are arranged such that the first long side and the second long side of the adjacent silicon solar cell overlap with each other, and that the corresponding silicon solar cells do not correspond to each other. A continuous front contact pad and a discontinuous rear contact pad are aligned with each other, overlapped, conductively bonded by a conductive adhesive bonding agent, and arranged adjacently in a state where the adjacent silicon solar cells are electrically connected in series. Item 41. The solar module according to Item 40, wherein

  52. The front metallization pattern of each silicon solar cell includes a plurality of thin conductors that electrically interconnect adjacent discontinuous front contact pads, each thin conductor being perpendicular to the long side of the plurality of solar cells. 52. The solar module of claim 51, wherein the solar module is thinner than a width of the plurality of discontinuous contact pads measured in a direction.

  53. The conductive adhesive bonding agent forms one or more barriers adjacent to the plurality of discontinuous front contact pads, and the plurality of discontinuous front contact pads are formed by a plurality of features of the front metallization pattern. 52. The solar module of paragraph 51, wherein the solar module is substantially confined to the plurality of locations.

  54. The conductive adhesive bond forms one or more barriers adjacent to the plurality of discontinuous back contact pads, wherein the plurality of discontinuous back contact pads are formed by a plurality of features of the back metallization pattern. 52. The solar module of paragraph 51, wherein the solar module is substantially confined to the plurality of locations.

55. In a process of assembling a plurality of supercells, each of a plurality of rectangular silicon solar cells arranged side by side with a plurality of ends on the long sides of adjacent rectangular silicon solar cells overlapping in a shingle-like shape. A process comprising a supercell and heating and pressurizing the plurality of supercells to cure the electrically conductive bonding agent disposed between the overlapping ends of the adjacent rectangular silicon solar cells, whereby the adjacent supercell is cured. Joining together overlapping rectangular silicon solar cells and electrically connecting them in series;
Arranging and interconnecting the plurality of supercells in a desired solar module configuration in a layer stack including the encapsulant;
Heating and pressurizing the layer stack to form a laminated structure.

  56. Heating and pressurizing the layer stack, prior to the step of forming the laminated structure, by heating and pressurizing the plurality of supercells, curing or partially curing the electrically conductive bonding agent, Clause 55. The method of clause 55, comprising the step of forming a cured or partially cured supercell as an intermediate product prior to forming the laminated structure.

  57. As each additional rectangular silicon solar cell is added to the supercell during assembly of the supercell, the electrical connection between the newly added solar cell and its adjacent overlapping solar cell 57. The method of paragraph 56, wherein the conductive adhesive bond is cured or partially cured before another rectangular silicon solar cell is added to the supercell.

  58. Clause 56. The method of clause 56 comprising curing or partially curing all of the electrically conductive bonding agent in the supercell in the same step.

59. Heating and pressurizing the layer stack, prior to the step of forming the laminated structure, heating and pressurizing the plurality of supercells to partially cure the electrically conductive bonding agent, By forming a supercell partially cured as an intermediate product before the formation of the laminated structure, and by heating and pressing the layer stack, the curing of the electrically conductive bonding agent is completed, Item 56. The method according to Item 56, comprising: forming the laminated structure.

  60. Prior to the formation of the laminated structure, the electrically conductive bonding agent is cured while heating and pressing the layer stack without forming a cured or partially cured supercell as an intermediate product, thereby forming a laminated structure. 56. The method of clause 55 comprising the step of forming.

  61. 56. The method of clause 55 comprising dicing one or more silicon solar cells into a plurality of rectangles to provide the plurality of rectangular silicon solar cells.

  62. Applying the electrically conductive adhesive to the one or more silicon solar cells before the step of dicing the one or more silicon solar cells, the method comprising: 61. The method of clause 61 comprising providing the rectangular silicon solar cell of item 61.

  63. Applying the electrically conductive adhesive bonding agent to the one or more silicon solar cells, and then scribe one or more lines on each of the one or more silicon solar cells using a laser. 63. The method of clause 62, further comprising cleaving the one or more silicon solar cells along the one or more scribed lines.

  64. Using a laser, scribe one or more wires on each of the one or more silicon solar cells, and then apply the electrically conductive adhesive to the one or more silicon solar cells. 63. The method of claim 62, further comprising cleaving the one or more silicon solar cells along the one or more scribed lines.

65. The electrically conductive adhesive bonding agent is applied to a top surface of each of the one or more silicon solar cells, and is positioned opposite to each of the one or more silicon solar cells. Does not apply to the bottom
A vacuum is drawn between the bottom surface and the curved support surface of the one or more silicon solar cells, and the one or more silicon solar cells are bent toward the curved support surface, thereby forming a plurality of scribe lines. 63. The method of clause 62, comprising cleaving the one or more silicon solar cells along.

  66. A step of applying the electrically conductive adhesive to the plurality of rectangular silicon solar cells after the step of dicing the one or more silicon solar cells to provide the plurality of rectangular silicon solar cells. 61. The method according to 61.

  67. 55. The method of paragraph 55, wherein the conductive adhesive has a glass transition temperature less than or equal to about 0 ° C.

1A. A solar module,
Comprising a plurality of supercells arranged in two or more parallel rows to form a front surface of said solar module;
Each supercell has a plurality of silicon solar cells arranged side by side with the ends of adjacent silicon solar cells overlapping and conductively joined to each other, and the adjacent silicon solar cells are electrically connected in series. ,
Each supercell has a front end contact at one end of the supercell and a rear end contact of opposite polarity at the opposite end of the supercell;
A first supercell row including a first supercell having a front end contact adjacent and parallel to a first edge of the solar module;
The solar module, wherein the solar module extends elongated parallel to the first edge of the solar module, is conductively connected to the front end contact of the first supercell, and is adjacent to the first edge of the solar module. A solar module comprising a first flexible electrical interconnect occupying only a narrow portion of the front surface of the solar module having a width measured in a direction perpendicular to the first edge of the solar module of about 1 cm or less.

  2A. Clause 1A, wherein a portion of the first flexible electrical interconnect is closest to the first edge of the solar module and extends behind the first supercell and around the end of the first supercell. The solar module according to 1.

  3A. Clause 1A wherein the first flexible interconnect includes a thin ribbon portion conductively joined to the front end contact of the first supercell and a thicker portion extending parallel to the first edge of the solar module. The solar module according to 1.

  4A. The first flexible interconnect includes a thin ribbon portion conductively joined to the front end contact of the first supercell and a coiled ribbon portion extending parallel to the first edge of the solar module. The solar module according to item 1A.

  5A. A second supercell row includes a second supercell having a front end contact adjacent and parallel to the first edge of the solar module, wherein the front end contact of the first supercell is disposed. The solar module of paragraph 1A, wherein the section is electrically connected to the front end contact of the second supercell via the first flexible electrical interconnect.

6A. The rear end contact portion of the first supercell is adjacent to and parallel to a second edge of the solar module opposite to the first edge of the solar module;
A second flexible electrical interconnect extending parallel to the second edge of the elongate solar module and conductively connected to the rear end contact of the first supercell, and entirely lying rearward of the supercell. Item 1. A solar module according to item 1A.

7A. A second supercell row has a front edge contact portion adjacent and parallel to the first edge of the solar module, and a rear edge contact portion adjacent to the second edge of the solar module. And a second supercell arranged in a parallel position,
The front end contact of the first supercell is electrically connected to the front end contact of the second supercell via the first flexible electrical interconnect;
The solar module of paragraph 6A, wherein the rear end contact of the first supercell is electrically connected to the rear end contact of the second supercell via the second flexible electrical interconnect.

8A. A rear end contact portion is arranged in the first supercell row in series with the first supercell in a state in which the rear end contact portion is adjacent to the second edge of the solar module opposite to the first edge of the solar module. Two supercells,
A second flexible electrical interconnect extending elongate parallel to the second edge of the solar module and conductively joined to the rear end contact of the first supercell and entirely lying rearward of the supercell. Item 1. A solar module according to item 1A.

9A. A second supercell row has a front edge contact of a third supercell adjacent the first edge of the solar module and a rear edge contact of a fourth supercell adjacent the second edge of the solar module. Including the third supercell and the fourth supercell arranged in series in a state,
The front end contact of the first supercell is electrically connected to the front end contact of the third supercell via the first flexible electrical interconnect and the rear end contact of the second supercell. The solar module of paragraph 8A, wherein the section is electrically connected to the rear end contact of the fourth supercell via the second flexible electrical interconnect.

  10A. The solar module of paragraph 1A, wherein there is no electrical interconnection between the plurality of supercells in a direction away from a plurality of outer edges of the solar module that reduces an active area of the front surface of the solar module.

  11A. At least one super cell pair is arranged in a row with the back contact end of one super cell included in the super cell pair adjacent to the back contact end of the other super cell included in the super cell pair. The solar module according to paragraph 1A, wherein the solar module is arranged.

12A. At least one pair of supercells arranged side by side in a row with adjacent ends of the two supercells having opposite polarity end contacts;
The adjacent ends of the pair of supercells overlap;
The solar module of paragraph 1A, wherein the two supercells in the pair of supercells are sandwiched between their overlapping ends and electrically connected in series by a flexible interconnect that does not shadow the front surface.

13A. The plurality of supercells are a white backing comprising a plurality of parallel dark stripes having positions and widths corresponding to the positions and widths of a plurality of gaps between two or more parallel rows of the supercells. Placed on the sheet,
The solar module of paragraph 1A, wherein the white portions of the backing sheets are not visible through the gaps between two or more parallel rows of the supercell.

  14A. The solar module of paragraph 1A, wherein all portions of the first flexible electrical interconnect located on the front surface of the solar module are covered or colored to reduce visible contrast to the supercell. module.

15A. Each silicon solar cell,
A rectangular or substantially rectangular front and rear face having a shape defined by opposing parallel first and second long sides and two opposing short sides; At least a portion of which is exposed to solar radiation during operation of the solar cell string; and
A plurality of fingers disposed on the front surface and extending perpendicular to the first long side and the second long side; and a plurality of discontinuous front contact pads positioned in a row adjacent to the first long side. An electrically conductive front metallization pattern, wherein each front contact pad electrically connects to at least one of the plurality of fingers;
An electrically conductive backside metallization pattern disposed on the backside and including a plurality of discontinuous backside contact pads positioned in rows adjacent to the second long side;
In each supercell, the plurality of silicon solar cells are arranged such that the first long side and the second long side of the adjacent silicon solar cell overlap with each other, and the corresponding silicon solar cells on the adjacent silicon solar cell do not correspond to each other. The continuous front contact pad and the discontinuous rear contact pad are aligned with each other, overlapped, conductively bonded by a conductive adhesive bonding agent, and arranged side by side in a state where the adjacent silicon solar cells are electrically connected in series. Item 1. The solar module according to Item 1A.

  16A. The front metallization pattern of each silicon solar cell includes a plurality of thin conductors that electrically interconnect adjacent discontinuous front contact pads, each thin conductor being perpendicular to the long side of the plurality of solar cells. Clause 15A. The solar module according to clause 15A, wherein the width of the plurality of discontinuous contact pads measured in a direction is thinner.

  17A. The conductive adhesive bond forms a plurality of barriers around each discontinuous front contact pad, due to a plurality of features of the front metallization pattern, at the plurality of locations of the plurality of discontinuous front contact pads. The solar module of paragraph 15A, wherein the solar module is substantially contained.

  18A. The conductive adhesive bond forms a plurality of barriers around each discontinuous back contact pad, due to a plurality of features of the back metallization pattern, at the plurality of locations of the plurality of discontinuous back contact pads. The solar module of paragraph 15A, wherein the solar module is substantially contained.

  19A. The plurality of discontinuous back contact pads are a plurality of discontinuous silver back contact pads, except for the plurality of discontinuous silver back contact pads, the back metallization pattern of each silicon solar cell, The solar module of paragraph 15A, wherein the solar module does not include a silver contact at any position lying beneath a portion of the front surface of the solar cell where adjacent silicon solar cells do not overlap.

20A. A solar module,
A plurality of supercells, wherein the ends of adjacent silicon solar cells overlap and are conductively joined to each other, and the plurality of silicon solar cells are arranged side by side in a state where the adjacent silicon solar cells are electrically connected in series. Each super cell has a plurality of super cells,
Each silicon solar cell,
A rectangular or substantially rectangular front and rear face having a shape defined by opposing parallel first and second long sides and two opposing short sides; At least a portion of which is exposed to solar radiation during operation of the solar cell string; and
A plurality of fingers disposed on the front surface and extending perpendicular to the first long side and the second long side; and a plurality of discontinuous front contact pads positioned in a row adjacent to the first long side. An electrically conductive front metallization pattern, wherein each front contact pad electrically connects to at least one of the plurality of fingers;
An electrically conductive backside metallization pattern disposed on the backside and including a plurality of discontinuous backside contact pads positioned in rows adjacent to the second long side;
In each supercell, the plurality of silicon solar cells are arranged such that the first long side and the second long side of the adjacent silicon solar cell overlap with each other, and the corresponding silicon solar cells on the adjacent silicon solar cell do not correspond to each other. A continuous front contact pad and a discontinuous rear contact pad are aligned with each other, overlapped, conductively bonded by a conductive adhesive bonding agent, and arranged adjacently in a state where the adjacent silicon solar cells are electrically connected in series. Has been
The plurality of supercells may be arranged in a single row that extends substantially across the length or width of the solar module, or in two or more parallel rows, so that during operation of the solar module, A solar module forming the front side of the solar module to be irradiated by radiation.

  21A. The plurality of discontinuous back contact pads are a plurality of discontinuous silver back contact pads, except for the plurality of discontinuous silver back contact pads, the back metallization pattern of each silicon solar cell, The solar module of paragraph 20A, wherein the solar module does not include a silver contact anywhere in the solar cell that lies beneath a portion of the front surface of the solar cell where adjacent silicon solar cells do not overlap.

  22A. The front metallization pattern of each silicon solar cell includes a plurality of thin conductors that electrically interconnect adjacent discontinuous front contact pads, each thin conductor being perpendicular to the long side of the plurality of solar cells. The solar module of paragraph 20A, wherein the solar module is thinner than the width of the plurality of discontinuous contact pads, as measured in a direction.

  23A. The conductive adhesive bond forms a plurality of barriers around each discontinuous front contact pad, due to a plurality of features of the front metallization pattern, at the plurality of locations of the plurality of discontinuous front contact pads. The solar module of paragraph 20A, wherein the solar module is substantially contained.

  24A. The conductive adhesive bond forms a plurality of barriers around each discontinuous back contact pad, due to a plurality of features of the back metallization pattern, at the plurality of locations of the plurality of discontinuous back contact pads. The solar module of paragraph 20A, wherein the solar module is substantially contained.

25A. A supercell,
Equipped with multiple silicon solar cells,
Each silicon solar cell,
A rectangular or substantially rectangular front and rear face having a shape defined by opposing parallel first and second long sides and two opposing short sides; At least a portion of which is exposed to solar radiation during operation of the solar cell string; and
A plurality of fingers disposed on the front surface and extending perpendicular to the first long side and the second long side; and a plurality of discontinuous front contact pads positioned in a row adjacent to the first long side. An electrically conductive front metallization pattern, wherein each front contact pad electrically connects to at least one of the plurality of fingers;
An electrically conductive backside metallization pattern disposed on the backside and including a plurality of discontinuous silver backside contact pads positioned in rows adjacent to the second long side;
The plurality of silicon solar cells have a first long side and a second long side of adjacent silicon solar cells overlapping with each other, and a corresponding discontinuous front contact pad on the adjacent silicon solar cells. A supercell in which discontinuous rear contact pads are aligned with each other, overlapped, conductively bonded by a conductive adhesive bonding agent, and arranged side by side in a state where the adjacent silicon solar cells are electrically connected in series. .

  26A. The plurality of discontinuous back contact pads are a plurality of discontinuous silver back contact pads, except for the plurality of discontinuous silver back contact pads, the back metallization pattern of each silicon solar cell, The solar module of paragraph 25A, wherein the solar module does not include a silver contact at any position lying beneath a portion of the front surface of the solar cell where adjacent silicon solar cells do not overlap.

  27A. The front metallization pattern includes a plurality of thin conductors electrically interconnecting adjacent discontinuous front contact pads, each thin conductor being measured in a direction perpendicular to the long sides of the plurality of solar cells. The solar cell string according to item 25A, wherein the solar cell string is thinner than the width of the plurality of discontinuous contact pads.

  28A. The conductive adhesive bond forms a plurality of barriers around each discontinuous front contact pad, due to a plurality of features of the front metallization pattern, at the plurality of locations of the plurality of discontinuous front contact pads. The solar cell string of paragraph 25A, wherein the solar cell string is substantially contained.

  29A. The conductive adhesive bond forms a plurality of barriers around each discontinuous back contact pad, due to a plurality of features of the back metallization pattern, at the plurality of locations of the plurality of discontinuous back contact pads. The solar cell string of paragraph 25A, wherein the solar cell string is substantially contained.

  30A. The solar cell string of paragraph 25A, wherein the conductive adhesive bond has a glass transition less than or equal to about 0 ° C.

31A. In a process of assembling a plurality of supercells, each of a plurality of rectangular silicon solar cells arranged side by side with a plurality of ends on the long sides of adjacent rectangular silicon solar cells overlapping in a shingle-like shape. A process comprising a supercell and heating and pressurizing the plurality of supercells to cure the electrically conductive bonding agent disposed between the overlapping ends of the adjacent rectangular silicon solar cells, whereby the adjacent supercell is cured. Joining together overlapping rectangular silicon solar cells and electrically connecting them in series;
Arranging and interconnecting the plurality of supercells in a desired solar module configuration in a layer stack including the encapsulant;
Heating and pressurizing the layer stack to form a laminated structure.

  32A. Heating and pressurizing the layer stack, prior to the step of forming the laminated structure, by heating and pressurizing the plurality of supercells, curing or partially curing the electrically conductive bonding agent, 31. The method of paragraph 31A, further comprising the step of forming a cured or partially cured supercell as an intermediate product prior to forming the laminated structure.

  33A. As each additional rectangular silicon solar cell is added to the supercell during assembly of the supercell, the electrical connection between the newly added solar cell and its adjacent overlapping solar cell The method of paragraph 32A wherein the conductive adhesive is cured or partially cured before another rectangular silicon solar cell is added to the supercell.

  34A. The method of paragraph 32A comprising curing or partially curing all of the electrically conductive bonding agent in the supercell in the same step.

35A. Heating and pressurizing the layer stack, prior to the step of forming the laminated structure, heating and pressurizing the plurality of supercells to partially cure the electrically conductive bonding agent, By forming a supercell partially cured as an intermediate product before the formation of the laminated structure, and by heating and pressing the layer stack, the curing of the electrically conductive bonding agent is completed, The method according to Item 32A, comprising: forming the laminated structure.

  36A. Prior to the formation of the laminated structure, the electrically conductive bonding agent is cured while heating and pressing the layer stack without forming a cured or partially cured supercell as an intermediate product, thereby forming a laminated structure. The method of paragraph 31A comprising the step of forming.

  37A. 31. The method of clause 31A, comprising dicing one or more silicon solar cells into a plurality of rectangles to provide the plurality of rectangular silicon solar cells.

  38A. Applying the electrically conductive adhesive to the one or more silicon solar cells before the step of dicing the one or more silicon solar cells, the method comprising: 37. The method of clause 37A, comprising providing the rectangular silicon solar cell of item 37A.

  39A. Applying the electrically conductive adhesive bonding agent to the one or more silicon solar cells, and then scribe one or more lines on each of the one or more silicon solar cells using a laser. 38. The method of paragraph 38A, further comprising cleaving the one or more silicon solar cells along the one or more scribed lines.

  40A. Using a laser, scribe one or more wires on each of the one or more silicon solar cells, and then apply the electrically conductive adhesive to the one or more silicon solar cells. 38. The method of paragraph 38A further comprising cleaving the one or more silicon solar cells along the one or more scribed lines.

41A. The electrically conductive adhesive bonding agent is applied to a top surface of each of the one or more silicon solar cells, and is positioned opposite to each of the one or more silicon solar cells. Does not apply to the bottom
A vacuum is drawn between the bottom surface and the curved support surface of the one or more silicon solar cells, and the one or more silicon solar cells are bent toward the curved support surface, thereby forming a plurality of scribe lines. 38. The method of clause 38A, comprising cleaving the one or more silicon solar cells along.

  42A. A step of applying the electrically conductive adhesive to the plurality of rectangular silicon solar cells after the step of dicing the one or more silicon solar cells to provide the plurality of rectangular silicon solar cells. The method according to 37A.

  43A. The method of paragraph 31A wherein the conductive adhesive bond has a glass transition temperature of less than or equal to about 0 ° C.

44A. How to make a supercell,
Laser scribing one or more scribe lines on each of the one or more silicon solar cells to define a plurality of rectangular regions on the one or more silicon solar cells;
Applying an electrically conductive adhesive to the scribed one or more silicon solar cells at one or more locations adjacent to the long sides of each rectangular region;
A plurality of rectangles each including a part of the electrically conductive adhesive bonding agent disposed on a front surface adjacent to a long side by separating the one or more silicon solar cells along the one or more scribe lines. Providing a silicon solar cell;
Long sides of adjacent rectangular silicon solar cells, a step of arranging the plurality of rectangular silicon solar cells in a state where a part of the electrically conductive adhesive bonding agent is interposed and overlapped in a shingle-like shape,
Curing the electrically conductive bonding agent, thereby bonding adjacent and overlapping rectangular silicon solar cells to each other and electrically connecting them in series.

45A. How to make a supercell,
One or more scribe lines are laser scribed on each of the one or more silicon solar cells among the one or more silicon solar cells each having a top surface and a bottom surface opposed to each other, and the one or more silicon solar cells are formed. Defining a plurality of rectangular areas on the battery;
Applying an electrically conductive adhesive to a portion of the top surface of the one or more silicon solar cells;
A vacuum is drawn between the bottom surface and the curved support surface of the one or more silicon solar cells, and the one or more silicon solar cells are bent toward the curved support surface, whereby the one or more silicon solar cells are bent. Cleaving the one or more silicon solar cells along a scribe line to provide a plurality of rectangular silicon solar cells each including a part of the electrically conductive adhesive bonding agent disposed on a front surface adjacent to a long side. The process of
Long sides of adjacent rectangular silicon solar cells, a step of arranging the plurality of rectangular silicon solar cells in a state where a part of the electrically conductive adhesive bonding agent is interposed and overlapped in a shingle-like shape,
Curing the electrically conductive bonding agent, thereby bonding adjacent and overlapping rectangular silicon solar cells to each other and electrically connecting them in series.

46A. How to make a supercell,
Dicing the one or more pseudo-square silicon wafers along a plurality of lines of the one or more pseudo-square silicon wafers parallel to a long edge of each pseudo-square silicon wafer, and substantially dicing the same along the long axis. Forming a plurality of rectangular silicon solar cells each having a length;
A step of arranging the plurality of rectangular silicon solar cells in a state where the long sides of adjacent solar cells overlap and are conductively joined to each other, and the adjacent solar cells are electrically connected in series;
The plurality of rectangular silicon solar cells include: at least one rectangular solar cell including two chamfered corners corresponding to a plurality of corners of the pseudo-square wafer or a part of the plurality of corners; One or more rectangular silicon solar cells, each having no,
The spacing between the plurality of parallel lines along which the pseudo-square wafer is diced does not have the width perpendicular to the long axis of the rectangular silicon solar cell including the chamfered corner, and the chamfered corner. One or more rectangular silicon solar cells are selected to compensate for the chamfered corners by making the width greater than a length perpendicular to the long axis of the rectangular silicon solar cells, whereby one of the rectangular silicon solar cells in the solar cell string is selected. A method, wherein each has a front surface that has substantially the same area exposed to light in operation of the solar cell string.

47A. A supercell,
An end portion of adjacent solar cells overlaps and is conductively joined to each other, comprising a plurality of silicon solar cells arranged side by side in a state where the adjacent solar cells are electrically connected in series,
At least one of the plurality of silicon solar cells has a plurality of corners of the quasi-square silicon wafer to be diced, or a chamfered corner corresponding to a part of the plurality of corners, and At least one of the plurality of silicon solar cells does not have a chamfered corner, and each of the plurality of silicon solar cells has a front surface having substantially the same area exposed to light during operation of the solar cell string. Have a supercell.

48A. A method of making two or more supercells,
Dicing the one or more pseudo-square silicon wafers along a plurality of lines parallel to the long edge of each of the one or more pseudo-square silicon wafers to form the one or more pseudo-square silicon wafers A first plurality of rectangular silicon solar cells including chamfered corners corresponding to a plurality of corners or a part of the plurality of corners, and a first plurality extending over the entire width of the one or more pseudo-square silicon wafers. Forming a second plurality of rectangular silicon solar cells each having a length and no chamfered corners;
Removing the chamfered corners from each of the first plurality of rectangular silicon solar cells, each having a second length shorter than the first length, and having no chamfered corners; Forming a plurality of rectangular silicon solar cells of 3;
The second plurality of rectangular silicon solar cells are arranged side by side with the long sides of adjacent rectangular silicon solar cells overlapping and conductively joined to each other, and the second plurality of rectangular silicon solar cells are electrically connected in series. Forming a solar cell string having a width equal to the first length;
The third plurality of rectangular silicon solar cells are arranged side by side with the long sides of adjacent rectangular silicon solar cells overlapping and conductively joined to each other, and the third plurality of rectangular silicon solar cells are electrically connected in series. Forming a solar cell string having a width equal to said second length.

49A. A method of making two or more supercells,
Dicing the one or more pseudo-square silicon wafers along a plurality of lines parallel to the long edge of each of the one or more pseudo-square silicon wafers to form the one or more pseudo-square silicon wafers A first plurality of rectangular silicon solar cells including chamfered corners corresponding to a plurality of corners or a part of the plurality of corners; and a second plurality of rectangular silicon solar cells without chamfered corners. Forming a;
The first plurality of rectangular silicon solar cells are arranged side by side with the long sides of adjacent rectangular silicon solar cells overlapping and conductively joined to each other, and the first plurality of rectangular silicon solar cells are electrically connected in series. Process and
The second plurality of rectangular silicon solar cells are arranged side by side with the long sides of adjacent rectangular silicon solar cells overlapping and conductively joined to each other, and the second plurality of rectangular silicon solar cells are electrically connected in series. A method comprising:

50A. A series-connected string of N (≥25) rectangular or substantially rectangular solar cells having an average breakdown voltage of greater than about 10 volts, wherein said rectangular or substantially rectangular solar cells are one or more supercells. The plurality of solar cells are grouped, and each of the one or more supercells is arranged side by side with the long sides of adjacent solar cells overlapping and conductively joined to each other by an electric and heat conductive adhesive. A series-connected string of rectangular or substantially rectangular solar cells comprising two or more of the cells,
A solar module, wherein no single solar cell or group of less than N solar cells in said string of solar cells is individually electrically connected in parallel with a bypass diode.

  51A. The solar module of clause 50A, wherein N is greater than or equal to 30.

  52A. The solar module of clause 50A, wherein N is greater than or equal to 50.

  53A. The solar module of paragraph 50A wherein N is greater than or equal to 100.

  54A. The adhesive has a thickness in a direction perpendicular to the plurality of solar cells of less than or equal to about 0.1 mm and a thermal conductivity in a direction perpendicular to the plurality of solar cells of about 1.5 w / The solar module of paragraph 50A wherein the plurality of junctions between adjacent solar cells is formed that is greater than or equal to m / k.

  55A. The solar module of paragraph 50A, wherein the N solar cells are grouped into a single supercell.

  56A. The solar module according to item 50A, wherein the plurality of solar cells are silicon solar cells.

57A. A solar module,
A supercell substantially extending over the entire length or width of the solar module parallel to an edge of the solar module, wherein the supercell is formed by overlapping long sides of adjacent solar cells and electrically and thermally conductive adhesive. A supercell comprising a series connection string of N or rectangular or substantially rectangular solar cells having, on average, a breakdown voltage of greater than about 10 volts, arranged side by side in a conductive junction with each other,
A solar module, wherein no single solar cell or group of less than N solar cells in the supercell is individually electrically connected in parallel with a bypass diode.

  58A. The solar module according to clause 57A, wherein N> 24.

  59A. The solar module of paragraph 57A wherein the length of the supercell in the direction of current flow is at least about 500 mm.

60A. A supercell,
Equipped with multiple silicon solar cells,
Each silicon solar cell,
A rectangular or substantially rectangular front and rear face having a shape defined by opposing parallel first and second long sides and two opposing short sides; At least a portion of which is exposed to solar radiation during operation of the solar cell string; and
An electrically conductive front metallization pattern disposed on the front surface and including at least one front contact pad positioned adjacent the first long side;
An electrically conductive back metallization pattern disposed on the back surface and including at least one back contact pad positioned adjacent the second long side;
In the plurality of silicon solar cells, the first long side and the second long side of the adjacent silicon solar cells are overlapped, and the front and rear contact pads on the adjacent silicon solar cells are overlapped with each other. Conductively bonded to each other by a non-adhesive bonding agent, the adjacent silicon solar cells are arranged side by side in a state of being electrically connected in series,
The front metallization pattern of each silicon solar cell includes substantially applying the conductive adhesive to the at least one front contact pad prior to curing of the conductive adhesive during manufacture of the supercell. A supercell that contains a barrier configured to contain it.

  61A. For each pair of adjacent and overlapping silicon solar cells, the barrier on the front surface of one of the silicon solar cells partially overlaps the other silicon solar cell of the silicon solar cells, and the barrier is Covert in part, thereby substantially enclosing the conductive adhesive in the overlapping area of the front surface of the silicon solar cell prior to curing of the conductive adhesive during manufacture of the supercell. , The supercell of paragraph 60A.

  62A. The barrier includes a continuous conductive line extending substantially the full length of the first long side parallel to the first long side, and the at least one front contact pad includes the continuous conductive line; The supercell according to item 60A, which is located between the solar cell and the first long side.

  63A. The front metallization pattern electrically connects to the at least one front contact pad and includes the finger extending in a direction perpendicular to the first long side, and the continuous conductive line electrically interconnects the plurality of fingers. Clause 62A. And provides a plurality of conductive paths from each finger to at least one front contact pad.

  64A. The front metallization pattern includes a plurality of discontinuous contact pads arranged in a parallel row adjacent to the first long side, and the barrier includes, for each discontinuous contact pad, the superconductor. Prior to curing of the conductive adhesive during manufacture of the cell, including forming a plurality of distinct barriers that substantially enclose the conductive adhesive in the discontinuous contact pad. The supercell of clause 60A.

  65A. Clause 64A. The supercell of Clause 64A wherein the plurality of discrete barriers abut and are higher than their corresponding discontinuous contact pads.

66A. A supercell,
Equipped with multiple silicon solar cells,
Each silicon solar cell,
A rectangular or substantially rectangular front and rear face having a shape defined by opposing parallel first and second long sides and two opposing short sides; At least a portion of which is exposed to solar radiation during operation of the solar cell string; and
An electrically conductive front metallization pattern disposed on the front surface and including at least one front contact pad positioned adjacent the first long side;
An electrically conductive back metallization pattern disposed on the back surface and including at least one back contact pad positioned adjacent the second long side;
In the plurality of silicon solar cells, the first long side and the second long side of the adjacent silicon solar cells are overlapped, and the front and rear contact pads on the adjacent silicon solar cells are overlapped with each other. Conductively bonded to each other by a non-adhesive bonding agent, the adjacent silicon solar cells are arranged side by side in a state of being electrically connected in series,
The backside metallization pattern of each silicon solar cell may include applying the conductive adhesive to the at least one rear contact pad prior to curing the conductive adhesive during manufacture of the supercell. A supercell that contains a barrier configured to contain it.

  67A. The backside metallization pattern includes one or more discontinuous contact pads arranged in parallel rows adjacent to the second long side, and the barrier includes, for each discontinuous contact pad, Prior to curing the conductive adhesive during manufacture of the supercell, features are provided that form a plurality of separate barriers that substantially enclose the conductive adhesive in the discontinuous contact pad. Clause 66A. The supercell of clause 66A.

  68A. The supercell of clause 67A, wherein the plurality of distinct barriers abut and are higher than their corresponding discontinuous contact pads.

69A. A method of making a solar cell string,
Dicing the one or more pseudo-square silicon wafers along a plurality of lines of the one or more pseudo-square silicon wafers parallel to a long edge of each pseudo-square silicon wafer, and substantially dicing the same along the long axis. Forming a plurality of rectangular silicon solar cells each having a length;
A step of arranging the plurality of rectangular silicon solar cells in a state where the long sides of adjacent solar cells overlap and are conductively joined to each other, and the adjacent solar cells are electrically connected in series;
The plurality of rectangular silicon solar cells include: at least one rectangular solar cell including two chamfered corners corresponding to a plurality of corners of the pseudo-square wafer or a part of the plurality of corners; One or more rectangular silicon solar cells, each having no,
The spacing between the plurality of parallel lines along which the pseudo-square wafer is diced does not have the width perpendicular to the long axis of the rectangular silicon solar cell including the chamfered corner, and the chamfered corner. One or more rectangular silicon solar cells are selected to compensate for the chamfered corners by making the width greater than a length perpendicular to the long axis of the rectangular silicon solar cells, whereby one of the rectangular silicon solar cells in the solar cell string is selected. A method, wherein each has a front surface that has substantially the same area exposed to light in operation of the solar cell string.

70A. A solar cell string,
An end portion of adjacent solar cells overlaps and is conductively joined to each other, comprising a plurality of silicon solar cells arranged side by side in a state where the adjacent solar cells are electrically connected in series,
At least one of the plurality of silicon solar cells has a plurality of corners of the quasi-square silicon wafer to be diced, or a chamfered corner corresponding to a part of the plurality of corners, and At least one of the plurality of silicon solar cells does not have a chamfered corner, and each of the plurality of silicon solar cells has a front surface having substantially the same area exposed to light during operation of the solar cell string. Having a solar cell string.

71A. A method of making two or more solar cell strings,
Dicing the one or more pseudo-square silicon wafers along a plurality of lines parallel to the long edge of each of the one or more pseudo-square silicon wafers to form the one or more pseudo-square silicon wafers A first plurality of rectangular silicon solar cells including chamfered corners corresponding to a plurality of corners or a part of the plurality of corners, and a first plurality extending over the entire width of the one or more pseudo-square silicon wafers. Forming a second plurality of rectangular silicon solar cells each having a length and no chamfered corners;
Removing the chamfered corners from each of the first plurality of rectangular silicon solar cells, each having a second length shorter than the first length, and having no chamfered corners; Forming a plurality of rectangular silicon solar cells of 3;
The second plurality of rectangular silicon solar cells are arranged side by side with the long sides of adjacent rectangular silicon solar cells overlapping and conductively joined to each other, and the second plurality of rectangular silicon solar cells are electrically connected in series. Forming a solar cell string having a width equal to the first length;
The third plurality of rectangular silicon solar cells are arranged side by side with the long sides of adjacent rectangular silicon solar cells overlapping and conductively joined to each other, and the third plurality of rectangular silicon solar cells are electrically connected in series. Forming a solar cell string having a width equal to said second length.

72A. A method of making two or more solar cell strings,
Dicing the one or more pseudo-square silicon wafers along a plurality of lines parallel to the long edge of each of the one or more pseudo-square silicon wafers to form the one or more pseudo-square silicon wafers A first plurality of rectangular silicon solar cells including chamfered corners corresponding to a plurality of corners or a part of the plurality of corners; and a second plurality of rectangular silicon solar cells without chamfered corners. Forming a;
The first plurality of rectangular silicon solar cells are arranged side by side with the long sides of adjacent rectangular silicon solar cells overlapping and conductively joined to each other, and the first plurality of rectangular silicon solar cells are electrically connected in series. Process and
The second plurality of rectangular silicon solar cells are arranged side by side with the long sides of adjacent rectangular silicon solar cells overlapping and conductively joined to each other, and the second plurality of rectangular silicon solar cells are electrically connected in series. A method comprising:

73A. How to make a solar module,
Dicing the wafer along a plurality of lines parallel to a long edge of each pseudo-square silicon wafer among the plurality of pseudo-square silicon wafers, and chamfered corners corresponding to a plurality of corners of the plurality of pseudo-square silicon wafers. A plurality of rectangular silicon solar cells including, and a step of forming a plurality of rectangular silicon solar cells without chamfered corners from the plurality of pseudo-square silicon wafers,
At least some of the plurality of rectangular silicon solar cells having no chamfered corners are arranged, and long sides of the plurality of rectangular silicon solar cells overlap and are conductively joined to each other to form the plurality of rectangular silicon solar cells. Forming a first plurality of supercells, each comprising only a rectangular silicon solar cell without chamfered corners, arranged side by side in a state of being electrically connected in series;
Arranging at least some of the plurality of rectangular silicon solar cells including the chamfered corners, the long sides of the plurality of rectangular silicon solar cells overlap and are conductively joined to each other, and the plurality of rectangular silicon solar cells are connected in series. Forming a second plurality of supercells, each comprising only a rectangular silicon solar cell without chamfered corners, arranged side by side in electrical connection;
A plurality of parallel supercell rows of substantially equal length, each row comprising only a plurality of supercells from the first plurality of supercells or only a plurality of supercells from the second plurality of supercells. Forming the front surface of the solar module by arranging the plurality of supercells in the solar module.

  74A. Two of the plurality of supercell rows adjacent parallel opposing edges of the solar module include only the plurality of supercells from the second plurality of supercells, and all other plurality of supercells. The solar module of clause 73A, wherein the cell row comprises only supercells from the first plurality of supercells.

  75A. The solar module of clause 74A, wherein the solar module includes a total of six supercell rows.

76A. A plurality of silicon solar cells that are arranged side by side in the first direction in a state where the ends of adjacent silicon solar cells overlap and are conductively joined to each other, and the adjacent silicon solar cells are electrically connected in series;
And an elongated flexible electrical interconnect,
A major axis of the elongated flexible electrical interconnect is oriented parallel to a second direction perpendicular to the first direction;
The elongated flexible electrical interconnect comprises:
Conducting bonding to the front or rear surface of an end silicon solar cell of the plurality of silicon solar cells at three or more discontinuous positions arranged along the second direction;
Extending in the second direction over at least the entire width of the solar cell at the end,
A conductor thickness measured in a direction perpendicular to the front or back surface of the edge silicon solar cell is less than or equal to about 100 microns;
Providing a resistance less than or equal to about 0.012 ohms for the flow of current in the second direction;
Configured to provide flexibility between the silicon solar cell at the end and the interconnect to accommodate differential expansion in the second direction in a temperature range from about -40C to about 85C. Is a supercell.

  77A. The supercell of clause 76A wherein the flexible electrical interconnect has a conductor thickness measured in a direction perpendicular to the front and back surfaces of the edge silicon solar cell of less than or equal to about 30 microns. .

  78A. The flexible electrical interconnect extends beyond the supercell in the second direction to provide at least an electrical connection to a second supercell positioned parallel and adjacent to the supercell in a solar module. The supercell of clause 76A, providing an interconnect.

  79A. The flexible electrical interconnect extends beyond the supercell in the first direction to provide electrical interconnection to a second supercell positioned parallel and alongside the supercell in a solar module. The supercell of clause 76A, provided.

80A. A solar module,
Arranged in two or more parallel rows extending across the width of the solar module to form the front surface of the solar module, the ends of adjacent silicon solar cells overlap and are conductively joined to each other, Comprising a plurality of supercells each including a plurality of silicon solar cells arranged side by side in a state of electrically connecting the silicon solar cells in series,
At least the edge of the first supercell adjacent to the edge of the solar module in the first row,
Bonding to the front surface of the first supercell with an electrically conductive adhesive bonding agent at a plurality of discontinuous locations;
Extending parallel to the edge of the solar module,
At least a portion of the first supercell is broken around the end and hidden from view from the front of the solar module;
Via flexible electrical interconnects,
Electrically connecting to the end of a second supercell adjacent to the same edge of the solar module in the second row;
Solar module.

  81A. The solar module of paragraph 80A, wherein the surface of the flexible electrical interconnect on the front surface of the solar module is covered or colored to reduce visible contrast to the supercell.

82A. The two or more parallel rows of supercells are disposed on a white backing sheet to form a front surface of the solar module that is to be illuminated by solar radiation during operation of the solar module;
The white backing sheet includes a plurality of parallel dark-colored stripes having positions and widths corresponding to the positions and widths of the plurality of gaps between two or more parallel rows of the supercell;
The solar module of paragraph 80A, wherein the white portions of the backing sheets are not visible through the gaps between two or more parallel rows of the supercell.

83A. A method of making a solar cell string,
Laser scribing one or more scribe lines on each of the one or more silicon solar cells to define a plurality of rectangular regions on the one or more silicon solar cells;
Applying an electrically conductive adhesive to the scribed one or more silicon solar cells at one or more locations adjacent to the long sides of each rectangular region;
A plurality of rectangles each including a part of the electrically conductive adhesive bonding agent disposed on a front surface adjacent to a long side by separating the one or more silicon solar cells along the one or more scribe lines. Providing a silicon solar cell;
Long sides of adjacent rectangular silicon solar cells, a step of arranging the plurality of rectangular silicon solar cells in a state where a part of the electrically conductive adhesive bonding agent is interposed and overlapped in a shingle-like shape,
Curing the electrically conductive bonding agent, thereby bonding adjacent and overlapping rectangular silicon solar cells to each other and electrically connecting them in series.

84A. A method of making a solar cell string,
One or more scribe lines are laser scribed on each silicon solar cell among one or more silicon solar cells each having a top surface and a bottom surface positioned opposite to each other, and a plurality of scribe lines are formed on the silicon solar cell. Defining a rectangular area of
Applying an electrically conductive adhesive to a portion of the top surface of the one or more silicon solar cells;
A vacuum is drawn between the bottom surface and the curved support surface of the one or more silicon solar cells, and the one or more silicon solar cells are bent toward the curved support surface, whereby the one or more silicon solar cells are bent. Cleaving the one or more silicon solar cells along a scribe line to provide a plurality of rectangular silicon solar cells each including a part of the electrically conductive adhesive bonding agent disposed on a front surface adjacent to a long side. The process of
Long sides of adjacent rectangular silicon solar cells, a step of arranging the plurality of rectangular silicon solar cells in a state where a part of the electrically conductive adhesive bonding agent is interposed and overlapped in a shingle-like shape,
Curing the electrically conductive bonding agent, thereby bonding adjacent and overlapping rectangular silicon solar cells to each other and electrically connecting them in series.

  85A. Applying the electrically conductive adhesive bonding agent to the one or more silicon solar cells, and then laser scribe the one or more scribe lines on each of the one or more silicon solar cells. The method of paragraph 84A, comprising:

  86A. Laser scribing the one or more scribe lines on each of the one or more silicon solar cells, and then applying the electrically conductive adhesive to the one or more silicon solar cells The method of paragraph 84A, comprising:

1B. A series connection string of at least 25 solar cells connected in parallel with a common bypass diode;
Each solar cell has a breakdown voltage of greater than about 10 volts and is a supercell including the at least 25 solar cells arranged with the long sides of adjacent solar cells overlapping and conductively bonded by an adhesive. Devices, grouped as such.

  2B. The apparatus of paragraph 1B wherein N is greater than or equal to 30.

  3B. The apparatus according to paragraph 1B wherein N is greater than or equal to 50.

  4B. The apparatus according to paragraph 1B, wherein N is greater than or equal to 100.

  5B. The apparatus of paragraph 1B, wherein the adhesive has a thickness less than or equal to about 0.1 mm and a thermal conductivity greater than or equal to about 1.5 W / m / K.

  6B. The apparatus of paragraph 1B, wherein the N solar cells are grouped into a single supercell.

  7B. The apparatus of paragraph 1B, wherein the N solar cells are grouped into multiple supercells on the same backing.

  8B. The device of paragraph 1B wherein the at least 25 solar cells are silicon solar cells.

  9B. The apparatus of paragraph 1B, wherein the length of the supercell in the direction of current flow is at least about 500 mm.

  10B. The apparatus of paragraph 1B, wherein the at least 25 solar cells include features configured to contain the adhesive spread.

  11B. The apparatus of paragraph 10B wherein the features include elevated features.

  12B. The device of paragraph 10B wherein the features include a metallization.

13B. The metal coating includes a line extending over the entire length of the first long side,
The apparatus of clause 12B, further comprising at least one contact pad located between the line and the first long side.

14B. The metallization further includes a plurality of fingers electrically connected to the at least one contact pad and extending in a direction perpendicular to the first long side;
The apparatus of paragraph 13B wherein the conductive wires interconnect the plurality of fingers.

  15B. The device of claim 10B, wherein the feature is on a front side of the solar cell.

  16B. The device of paragraph 10B wherein the feature is on the back side of the solar cell.

  17B. The apparatus of clause 10B, wherein the features include recessed features.

  18B. The device of clause 10B wherein the feature is hidden in a solar cell adjacent to the supercell.

  19B. The first solar cell of the supercell has a plurality of chamfered corners, the second solar cell of the supercell has no chamfered corners, and the first solar cell and the second solar cell The apparatus according to Item 1B, wherein the area exposed to light is the same.

20B. A flexible electrical interconnect having a major axis parallel to a second direction perpendicular to the first direction;
The apparatus of paragraph 1B, wherein the flexible electrical interconnect is conductively bonded to a surface of the solar cell and accommodates thermal expansion of the solar cell in two dimensions.

  21B. The apparatus of paragraph 20B wherein the flexible electrical interconnect is less than or equal to about 100 microns in thickness and provides a resistance less than or equal to about 0.012 ohms.

  22B. The device of paragraph 20B wherein the surface comprises a back surface.

  23B. The apparatus of paragraph 20B wherein the flexible electrical interconnect contacts another supercell.

  24B. The apparatus of clause 23B, wherein the other supercell is side by side with the supercell.

  25B. The apparatus according to clause 23B, wherein the other super cell is adjacent to the super cell.

  26B. 21. The apparatus of paragraph 20B, wherein the first portion of the interconnect breaks around an edge of the supercell such that a remaining second interconnect is behind the supercell.

  27B. The apparatus of paragraph 20B wherein the flexible electrical interconnect electrically connects to a bypass diode.

28B. A plurality of supercells arranged in two or more parallel rows on the backing sheet to form a solar module front;
The apparatus of paragraph 1B, wherein the backing sheet is white and includes dark stripes of position and width corresponding to gaps between the plurality of supercells.

  29B. The apparatus of paragraph 1B, wherein the supercell includes at least one battery string pair that connects to a power management system.

30B. Further comprising a power management device that performs telecommunication with the supercell,
The power management device,
Receiving the voltage output of the supercell,
Based on the above voltage, determine whether the solar cell is reverse biased,
The apparatus of paragraph 1B configured to disconnect the reverse biased solar cell from a supercell module circuit.

31B. The supercell is disposed on a first backing to form a first module having an upper conductive ribbon on a first side facing a direction of solar energy;
A further supercell disposed on a second backing to form a second module having a lower ribbon on a second side facing away from the direction of the solar energy;
The apparatus of paragraph 1B, wherein the second module overlaps and joins a portion of the first module including the upper ribbon.

  32B. The apparatus according to paragraph 31B, wherein the second module is joined to the first module by an adhesive.

  33B. The apparatus according to paragraph 31B, wherein the second module is joined to the first module by a fitting arrangement.

  34B. The apparatus of paragraph 31B further comprising a junction box over which the second module overlaps.

  35B. Clause 34B. The apparatus according to clause 34B, wherein the second module is joined to the first module by a fitting arrangement.

  36B. Clause 35B. The apparatus of clause 35B wherein the mating arrangement is between the junction box and another junction box on the second module.

  37B. The device of paragraph 31B wherein the first backing comprises glass.

  38B. The device of paragraph 31B wherein the first backing comprises other than glass.

  39B. The apparatus of paragraph 1B, wherein the solar cell includes a chamfered portion cut from a larger component.

40B. The supercell further includes another solar cell having a chamfered portion,
The device of clause 39B wherein the long side of the solar cell is in electrical contact with the long side of the other solar cell of similar length.

1C1. Forming, on the same backing, a supercell comprising at least N (≧ 25) series-connected strings of solar cells, wherein each solar cell has a breakdown voltage of greater than about 10 volts and is adjacent A process in which the long sides of the solar cells are arranged in a state where they are overlapped and conductively joined by an adhesive,
Connecting each supercell with at most a single bypass diode.

  2C1. The method of paragraph 1C1 wherein N is greater than or equal to 30.

  3C1. The method of paragraph 1C1 wherein N is greater than or equal to 50.

  4C1. The method of paragraph 1C1 wherein N is greater than or equal to 100.

  5C1. The method of paragraph 1C1 wherein the adhesive has a thickness of less than or equal to about 0.1 mm and a thermal conductivity greater than or equal to about 1.5 w / m / k.

  6C1. The method of claim 1C1, wherein the plurality of solar cells are silicon solar cells.

  7C1. The method of clause 1C1, wherein the length of the supercell in the direction of current flow is at least about 500 mm.

  8C1. The first solar cell of the supercell has a plurality of chamfered corners, the second solar cell of the supercell has no chamfered corners, and the first solar cell and the second solar cell The method according to item 1C1, wherein the area exposed to light is the same.

  9C1. Clause 1C1. The method of clause 1C1, further comprising the step of enclosing the spread of the adhesive by utilizing features of a solar cell surface.

  10C1. The method of paragraph 9C1 wherein the features include elevated features.

  11C1. The method of clause 9C1 wherein the features include metallization.

12C1. The metal coating includes a line extending over the entire length of the first long side,
The method of clause 11C1, wherein at least one contact pad is located between the line and the first long side.

13C1. The metallization further includes a plurality of fingers electrically connected to the at least one contact pad and extending in a direction perpendicular to the first long side;
The method of clause 12C1 wherein the conductive wire interconnects the plurality of fingers.

  14C1. The method of claim 9C1, wherein the features are on the front side of the solar cell.

  15C1. The method of claim 9C1, wherein the feature is on the rear side of the solar cell.

  16C1. The method of clause 9C1, wherein the features include concave features.

  17C1. The method of clause 9C1, wherein the feature is hidden in a solar cell adjacent to the supercell.

  18C1. The method of clause 1C1, further comprising forming another supercell on the same backing.

19C1. Conductively bonding a flexible electrical interconnect having a major axis parallel to a second direction perpendicular to the first direction on the surface of the solar cell;
Clause 1C1 wherein the flexible electrical interconnect accommodates thermal expansion of the solar cell in two dimensions.

  20C1. The method of clause 19C1, wherein the flexible electrical interconnect is less than or equal to about 100 microns in thickness and provides a resistance less than or equal to about 0.012 ohms.

  21C1. The method according to clause 19C1, wherein the surface includes a posterior surface.

  22C1. The method of clause 19C1 further comprising contacting another supercell with the flexible electrical interconnect.

  23C1. The method of clause 22C1 wherein the other supercell is side by side with the supercell.

  24C1. The method of clause 22C1 wherein the other supercell is adjacent to the supercell.

  25C1. The method of clause 19C1, further comprising folding the first portion of the interconnect around an edge of the supercell such that a remaining second interconnect is behind the supercell.

  26C1. The method of clause 19C1, further comprising electrically connecting the flexible electrical interconnect to a bypass diode.

27C1. Arranging a plurality of supercells in two or more parallel rows on the same backing to form a solar module front surface,
The method of paragraph 1C1 wherein the backing sheet is white and includes dark stripes of position and width corresponding to gaps between the plurality of supercells.

  28C1. The method of clause 1C1, further comprising connecting at least one battery string pair to a power management system.

29C1. Electrically connecting a power management device to the supercell;
Causing the power management device to receive the voltage output of the supercell;
A step of causing the power management device to determine whether a reverse bias is applied to the solar cell based on the voltage,
The method of clause 1 C1, further comprising: causing the power management device to disconnect the reverse-biased solar cell from a supercell module circuit.

30C1. The supercell is disposed on the backing to form a first module having an upper conductive ribbon on a first side facing a direction of solar energy;
Disposing another supercell on another backing to form a second module having a lower ribbon on a second side facing away from the direction of the solar energy;
The method of paragraph 1C1, wherein the second module overlaps and joins a portion of the first module including the upper ribbon.

  31C1. The method according to paragraph 30C1, wherein the second module is joined to the first module by an adhesive.

  32C1. The method according to paragraph 30C1, wherein the second module is joined to the first module by a fitting arrangement.

  33C1. Clause 30C1. The method of clause 30C1, further comprising the step of overlaying a junction box with the second module.

  34C1. The method according to paragraph 33C1, wherein the second module is joined to the first module by a fitting arrangement.

  35C1. The method of clause 34C1 wherein the mating arrangement is between the junction box and another junction box on the second module.

  36C1. The method of clause 30C1 wherein the backing comprises glass.

  37C1. The method according to paragraph 30C1, wherein the backing includes a material other than glass.

38C1. Electrically connecting a relay switch in series between the first module and the second module;
Sensing an output voltage of the first module by a controller;
Activating the relay switch by the controller when the output voltage falls below a limit.

  39C1. The method of clause 1C1, wherein the solar cell includes a chamfered portion cut from a larger component.

  40C1. 39. The method of clause 39C1, wherein forming the supercell comprises making a long side of the solar cell into electrical contact with a similar long side of another solar cell having a chamfered portion.

1C2. A solar panel including a front surface including a first series-connected string of at least 19 solar cells grouped into a first supercell arranged such that long sides of adjacent solar cells overlap and are conductively joined by an adhesive. Modules and
A ribbon conductor electrically connected to the back contact of the first supercell to provide a hidden tap to electrical components.

  2C2. The apparatus of paragraph 1C2 wherein the electrical component includes a bypass diode.

  3C2. The device according to paragraph 2C2, wherein the bypass diode is located on a back surface of the solar module.

  4C2. The apparatus according to paragraph 3C2, wherein the bypass diode is located outside a junction box.

  5C2. The apparatus of paragraph 4C2 wherein the junction box includes a single terminal.

  6C2. The apparatus of clause 3C2 wherein the bypass diode is located near an edge of the solar module.

  7C2. The device of paragraph 2C2 wherein the bypass diode is located within the stack.

  8C2. The apparatus of clause 7C2, wherein the first supercell is encapsulated in the stacked structure.

  9C2. The apparatus of paragraph 2C2 wherein the bypass diode is located around the solar module.

  10C2. The electrical component of clause 1C2, wherein the electrical component includes a module terminal, junction box, power management system, smart switch, relay, voltage sensing controller, central inverter, DC / AC micro inverter, or DC / DC module power optimizer. Equipment.

  11C2. The apparatus of paragraph 1C1 wherein the electrical component is located on a back side of the solar module.

  12C2. Clause 1C1 wherein the solar module further comprises a second series-connected string of at least 19 solar cells grouped such that a first end is a second supercell that electrically connects the first supercell in series. The described device.

  13C2. The apparatus of clause 12C2 wherein the second supercell overlaps the first supercell and is electrically connected in series with the first supercell by a conductive adhesive.

  14C2. The device according to paragraph 12C2, wherein the back contact portion is located away from the first end.

  15C2. The apparatus of clause 12C2, further comprising a flexible interconnect between the first end and the first supercell.

  16C2. The flexible interconnect extends beyond a side edge of the first supercell and the second supercell and electrically connects the first supercell and the second supercell in parallel with other supercells. The device of paragraph 15C2.

  17C2. The apparatus of paragraph 1C2 wherein the adhesive has a thickness less than or equal to about 0.1 mm and a thermal conductivity greater than or equal to about 1.5 w / m / k.

  18C2. The apparatus of clause 1C2, wherein the plurality of solar cells are silicon solar cells having a breakdown voltage greater than about 10V.

  19C2. The apparatus of paragraph 1C2, wherein the length of the first supercell in the direction of current flow is at least about 500 mm.

  20C2. The apparatus of paragraph 1C2, wherein the solar cells of the first supercell include features configured to contain the spread of the adhesive.

  21C2. The device of paragraph 20C2 wherein the features include elevated features.

  22C2. The device of paragraph 21C2 wherein the features include a metallization.

23C2. The metal coating includes a conductive wire extending over the entire length of the first long side,
The device of clause 22C2 further comprising at least one contact pad located between the conductive line and the first long side.

24C2. The metallization further includes a plurality of fingers electrically connected to the at least one contact pad and extending in a direction perpendicular to the first long side;
The device of clause 23C2 wherein the conductive wire interconnects the plurality of fingers.

  25C2. The device of claim 20C2, wherein the features are on the front side of the solar cell.

  26C2. The device of paragraph 20C2 wherein the feature is on the back side of the solar cell.

  27C2. The device of clause 20C2, wherein the features include concave features.

  28C2. The device of paragraph 20C2 wherein the feature is hidden in a solar cell adjacent to the first supercell.

  29C2. The apparatus of paragraph 1C2, wherein the solar cell of the first supercell includes a chamfered portion.

30C2. The first supercell further includes another solar cell having a chamfered portion,
The device of clause 29C2 wherein the long side of the solar cell is in electrical contact with the long side of the other solar cell of similar length.

31C2. The first supercell further includes another solar cell having no chamfered corners,
The device according to clause 29C2, wherein the solar cell and the other solar cell have the same area exposed to light.

32C2. The first supercell is arranged in a plurality of parallel rows on the front surface of the backing sheet together with the second supercell,
The apparatus of paragraph 1C2 wherein the backing sheet is white and includes dark stripes of position and width corresponding to the gap between the first supercell and the second supercell.

  33C2. The apparatus of clause 1C2, wherein the first supercell includes at least one battery string pair that connects to a power management system.

34C2. Further comprising a power management device for performing electrical communication with the first supercell,
The power management device,
Receiving the voltage output of the first supercell,
Based on the voltage, determine whether the solar cell of the first supercell is reverse biased,
The apparatus of paragraph 1C2 configured to disconnect the reverse-biased solar cell from a supercell module circuit.

  35C2. The apparatus of clause 34C2, wherein the power management device comprises a relay.

36C2. The first supercell is disposed on a first backing to form the module having an upper conductive ribbon on a first side facing a direction of solar energy;
A further supercell disposed on the second backing to form a different module having a lower ribbon on a second side facing away from the direction of the solar energy;
The apparatus of paragraph 1C2, wherein the different module overlaps and joins a portion of the module including the upper ribbon.

  37C2. The device of clause 36C2 wherein the different modules are joined to the modules by an adhesive.

  38C2. The apparatus of paragraph 36C2 wherein the different modules are joined to the modules by a mating arrangement.

  39C2. The device of clause 36C2 further comprising a junction box where the different modules overlap.

  40C2. Clause 39C2. The apparatus according to clause 39C2, wherein the different module is joined to the module by a fitting arrangement between the junction box and another junction box on a different solar module.

1C3. A first supercell disposed on the front of the solar module and having a plurality of solar cells each having a breakdown voltage higher than about 10 V;
A first ribbon conductor electrically connected to the back contact of the first supercell to provide a first hidden tap to an electrical component;
A second supercell disposed on the front of the solar module and having a plurality of solar cells each having a breakdown voltage higher than about 10 V;
A second ribbon conductor that is electrically connected to the back contact of the second supercell to provide a second hidden tap.

  2C3. The device of paragraph 1C3 wherein the electrical component includes a bypass diode.

  3C3. The apparatus according to paragraph 2C3, wherein the bypass diode is located on a back surface of the solar module.

  4C3. The apparatus according to clause 3C3, wherein the bypass diode is located outside a junction box.

  5C3. The apparatus of paragraph 4C3 wherein the junction box includes a single terminal.

  6C3. The apparatus of clause 3C3 wherein the bypass diode is located near an edge of the solar module.

  7C3. The device of clause 2C3 wherein the bypass diode is located in a stacked structure.

  8C3. The apparatus of clause 7C3, wherein the first supercell is encapsulated in the stacked structure.

  9C3. The device of paragraph 8C3 wherein the bypass diode is located around the solar module.

  10C3. The apparatus of clause 1C3, wherein the first supercell is connected in series with the second supercell.

11C3. The first supercell and the second supercell form a first pair,
The apparatus of clause 10C3, further comprising two additional supercells included in a second pair connected in parallel with the first pair.

  12C3. The apparatus of clause 10C3, wherein the second hidden tap connects to the electrical component.

  13C3. The device of clause 12C3 wherein the electrical component includes a bypass diode.

  14C3. The apparatus of clause 13C3, wherein the first supercell includes 19 or more solar cells.

  15C3. The device of paragraph 12C3 wherein the electrical component comprises a power management system.

  16C3. The device of paragraph 1C3 wherein the electrical component comprises a switch.

  17C3. The device of paragraph 16C3, further comprising a voltage sensing controller in communication with the switch.

  18C3. The device of clause 16C3, wherein the switch is in communication with a central inverter.

19C3. The electrical component further includes a power management device,
The power management device,
Receiving the voltage output of the first supercell,
Based on the voltage, determine whether the solar cell of the first supercell is reverse biased,
The device of paragraph 1C3 configured to disconnect the reverse biased solar cell from a supercell module circuit.

  20C3. The device of claim 1 wherein said electrical component comprises an inverter.

  21C3. The apparatus of clause 20C3, wherein the inverter comprises a DC / AC micro inverter.

  22C3. The device of paragraph 1C3 wherein the electrical components include solar module terminals.

  23C3. The apparatus of clause 22C3 wherein the solar module terminal is a single solar module terminal in a junction box.

  24C3. The device of paragraph 1C3 wherein the electrical component is located on the back of the solar module.

  25C3. The apparatus according to paragraph 1C3, wherein the back contact portion overlaps with the second super cell and is located away from an end of the first super cell.

  26C3. The device of paragraph 1C3 wherein the first supercell has a length in the direction of current flow of at least about 500 mm.

  27C3. The device of paragraph 1C3 wherein the first supercell solar cell comprises features configured to contain the adhesive spread.

  28C3. The device of clause 27C3 wherein the features include elevated features.

  29C3. The device of clause 28C3 wherein the features include a metallization.

  30C3. The device of clause 27C3 wherein the features include concave features.

  31C3. The device of clause 27C3 wherein the feature is on the rear side of the solar cell.

  32C3. The device of clause 27C3 wherein the feature is hidden in a solar cell adjacent to the first supercell.

  33C3. The device of paragraph 1C3 wherein the solar cell of the first supercell includes a chamfered portion.

34C3. The first supercell further includes another solar cell having a chamfered portion,
The device of paragraph 33C3 wherein the long side of the solar cell is in electrical contact with the long side of the other solar cell of similar length.

35C3. The first supercell further includes another solar cell having no chamfered corners,
The device according to paragraph 33C3, wherein the solar cell and the other solar cell have the same area exposed to light.

36C3. The first supercell is arranged in a plurality of parallel rows on the front surface of the backing sheet together with the second supercell,
The apparatus of paragraph 1C3 wherein the backing sheet is white and includes dark stripes of position and width corresponding to the gap between the first and second supercells.

37C3. The first supercell being disposed on a first backing to form the module having an upper conductive ribbon in front of the module facing the direction of solar energy;
A third supercell disposed on a second backing to form a different module having a lower ribbon on a second side facing away from the direction of the solar energy;
The apparatus of paragraph 1C3, wherein the different module overlaps and joins a portion of the module including the upper ribbon.

  38C3. The device of clause 37C3 wherein the different modules are joined to the modules by an adhesive.

  39C3. The device of clause 37C3, further comprising a junction box over which the different modules overlap.

  40C3. The apparatus of clause 39C3 wherein the different module is joined to the module by a mating arrangement between the junction box and another junction box on the different module.

1C4. A solar module including a front surface including a first series-connected solar cell string grouped into a first supercell arranged such that sides of adjacent solar cells overlap and are conductively joined by an adhesive;
A solar cell surface feature configured to contain the adhesive.

  2C4. The device of paragraph 1C4 wherein the solar cell surface features include concave features.

  3C4. The device of paragraph 1C4 wherein the solar cell surface features include elevated features.

  4C4. The device of paragraph 3C4 wherein the raised feature is on the front of the solar cell.

  5C4. The apparatus of paragraph 4C4 wherein the raised features include a metallization pattern.

  6C4. The apparatus of clause 5C4, wherein the metallization pattern extends parallel to a long side of the solar cell and includes a conductive line substantially along the long side.

  7C4. The apparatus of clause 6C4, further comprising a contact pad between the conductive line and the long side.

8C4. The metallization pattern further includes a plurality of fingers,
The apparatus of clause 7C4 wherein the conductive line electrically interconnects the plurality of fingers to provide a plurality of conductive paths from each finger to the contact pad.

9C4. Further comprising a plurality of discontinuous contact pads adjacent to the long side and arranged in parallel rows,
The apparatus of clause 7C4 wherein the metallization pattern forms a plurality of discrete barriers to encapsulate the adhesive in the plurality of discontinuous contact pads.

  10C4. The apparatus of clause 8C4, wherein the plurality of distinct barriers abut a plurality of corresponding discontinuous contact pads.

  11C4. The device of clause 8C4, wherein the plurality of discrete barriers are higher than a corresponding plurality of discontinuous contact pads.

  12C4. The device of paragraph 1C4 wherein the solar cell surface features are hidden by overlapping sides of other solar cells.

  13C4. The device of clause 12C4 wherein the other solar cell is part of the supercell.

  14C4. The device of clause 12C4 wherein the other solar cell is part of another supercell.

  15C4. The device of paragraph 3C4 wherein the raised feature is on a rear surface of the solar cell.

  16C4. The device of paragraph 15C4 wherein the raised features include a metallization pattern.

  17C4. The apparatus of paragraph 16C4 wherein the metallization pattern forms a plurality of discrete barriers to encapsulate the adhesive in a plurality of discontinuous contact pads located in front of other solar cells on which the solar cell overlaps. .

  18C4. The apparatus of clause 17C4, wherein the plurality of distinct barriers abut a plurality of corresponding discontinuous contact pads.

  19C4. The device of clause 17C4, wherein the plurality of distinct barriers are higher than a corresponding plurality of discontinuous contact pads.

  20C4. The apparatus of paragraph 1C1 wherein each solar cell of the supercell has a breakdown voltage of 10V or higher.

  21C4. The apparatus of paragraph 1C1 wherein the length of the supercell in the direction of current flow is at least about 500 mm.

  22C4. The apparatus of paragraph 1C1 wherein the solar cells of the first supercell include chamfered portions.

23C4. The supercell further includes another solar cell having a chamfered portion,
The device of paragraph 22C4 wherein the long side of the solar cell is in electrical contact with the long side of the other solar cell of similar length.

24C4. The supercell further includes another solar cell having no chamfered corners,
The apparatus according to paragraph 22C4, wherein the solar cell and the other solar cell have the same area exposed to light.

  25C4. The apparatus of clause 1C4, wherein the supercell is disposed on a front surface of the first backing sheet with a second supercell to form a first module.

  26C4. The device of clause 25C4 wherein the backing sheet is white and includes a plurality of dark stripes of a position and width corresponding to a gap between the supercell and the second supercell.

27C4. The first module has an upper conductive ribbon on the front of the first module facing the direction of solar energy;
A third supercell disposed on the second backing to form a second module having a lower ribbon on a side of the second module facing away from solar energy;
The device of paragraph 25C4 wherein the second module overlaps and joins a portion of the first module including the upper ribbon.

  28C4. The device of clause 27C4 wherein the second module is joined to the first module by an adhesive.

  29C4. The device of clause 27C4 further comprising a junction box with which the second module overlaps.

  30C4. Clause 29C4. The apparatus according to clause 29C4, wherein the second module is joined to the first module by the fitting arrangement between the junction box and another junction box on the second module.

  31C4. The device of clause 29C4 wherein the junction box houses a single module terminal.

  32C4. The device of clause 27C4 further comprising a switch between the first module and the second module.

  33C4. The device of clause 32C4, further comprising a voltage sensing controller in communication with the switch.

  34C4. The device of clause 27C4 wherein the supercell comprises 19 or more solar cells individually electrically connected in parallel with a single bypass diode.

  35C4. The apparatus of clause 34C4 wherein the single bypass diode is located near an edge of the first module.

  36C4. The device of clause 34C4 wherein the single bypass diode is located within a stacked structure.

  37C4. The device of clause 36C4 wherein the supercell is encapsulated within the laminated structure.

  38C4. The apparatus of clause 34C4, wherein the single bypass diode is positioned around the first module.

  39C4. The apparatus according to paragraph 25C4, wherein the supercell and the second supercell form a pair individually connected to a power management device.

40C4. Further comprising a power management device,
The power management device,
Receiving the voltage output of the supercell,
Based on the voltage, determine whether the solar cell of the super cell is reverse biased,
The device of paragraph 25C4 configured to disconnect the reverse-biased solar cell from a supercell module circuit.

1C5. A solar module including a front surface including a first series-connected string of a plurality of silicon solar cells grouped to be a first supercell;
The device wherein the first supercell has a plurality of chamfered corners and includes a first silicon solar cell disposed with the sides overlapping the second silicon solar cell and conductively bonded by an adhesive.

2C5. The second silicon solar cell has no chamfered corners,
The apparatus of clause 1C5, wherein each silicon solar cell of the first supercell has substantially the same area of the front surface exposed to light.

3C5. The first silicon solar cell and the second silicon solar cell have the same length,
The apparatus of clause 2C5, wherein the width of the first silicon solar cell is greater than the width of the second silicon solar cell.

  4C5. The apparatus according to paragraph 3C5, wherein the length reproduces the shape of the pseudo-square wafer.

  5C5. The device according to paragraph 3C5, wherein the length is 156 mm.

  6C5. The device according to paragraph 3C5, wherein the length is 125 mm.

  7C5. The device of paragraph 3C5 wherein the aspect ratio between the width and the length of the first solar cell is between about 1: 2 and about 1:20.

  8C5. The apparatus of clause 3C5, wherein the first silicon solar cell overlaps the second silicon solar cell by about 1 mm to about 5 mm.

  9C5. The apparatus of clause 3C5, wherein the first supercell includes at least 19 silicon solar cells, each having a breakdown voltage greater than about 10 volts.

  10C5. The device of paragraph 3C5 wherein the first supercell has a length in the direction of current flow of at least about 500 mm.

11C5. The first supercell is connected in parallel with the second supercell at the front face;
The apparatus of clause 3C5, wherein the front surface includes a white backing having a plurality of dark stripes at locations and widths corresponding to a gap between the first supercell and the second supercell.

  12C5. The device of paragraph 1C5 wherein the second silicon solar cell includes a chamfered corner.

  13C5. The device according to paragraph 12C5, wherein a long side of the first silicon solar cell overlaps a long side of the second silicon solar cell.

  14C5. The device of clause 12C5, wherein a long side of the first silicon solar cell overlaps a short side of the second silicon solar cell.

15C5. The front is
A first row including the first supercell comprising a plurality of solar cells including a plurality of chamfered corners;
A second row comprising a second series-connected string of silicon solar cells connected in parallel with the first supercell and grouped into a second supercell of chamfered cornerless solar cells. And
The apparatus of clause 1C5, wherein the length of the second row is substantially the same as the length of the first row.

  16C5. The apparatus of paragraph 15C5, wherein the first row is adjacent to a module edge and the second row is not adjacent to the module edge.

17C5. The first supercell includes at least 19 solar cells, each having a breakdown voltage greater than about 10 volts;
The device of paragraph 15C5 wherein the first supercell has a length in the direction of current flow of at least about 500 mm.

  18C5. The apparatus of clause 15C5, wherein the front surface includes a white backing having a plurality of dark stripes of a location and width corresponding to a gap between the first supercell and the second supercell.

  19C5. The device of paragraph 1C5 further comprising a metallization pattern on a front side of the second solar cell.

  20C5. The apparatus of clause 19C5 wherein the metallization pattern includes a tapered portion extending around a chamfered corner.

  21C5. The apparatus of clause 19C5 wherein the metallization pattern includes an elevated feature that encloses the spread of the adhesive.

22C5. The metal coating pattern,
A plurality of discontinuous contact pads;
A plurality of fingers electrically connected to the plurality of discontinuous contact pads;
The apparatus of clause 19C5 comprising: a conductive line interconnecting the plurality of fingers.

  23C5. The apparatus of clause 22C5 wherein the metallization pattern forms a plurality of discrete barriers to encapsulate the adhesive in the plurality of discontinuous contact pads.

  24C5. The apparatus of clause 23C5, wherein the plurality of distinct barriers abut a plurality of corresponding discontinuous contact pads and are higher than the plurality of corresponding discontinuous contact pads.

  25C5. The apparatus of clause 1C5, further comprising a flexible electrical interconnect that is conductively bonded to a surface of the first solar cell and accommodates thermal expansion of the first solar cell in two dimensions.

  26C5. The apparatus of clause 25C5, wherein the first portion of the interconnect folds around an edge of the first supercell such that a remaining second interconnect portion is behind the first supercell.

27C5. The module has an upper conductive ribbon on the front facing the direction of solar energy;
Another module having a second supercell disposed on the front surface, wherein the lower ribbon on the other module further faces the other module facing away from the solar energy;
The apparatus of paragraph 1C5 wherein the second module overlaps and joins a portion of the first module including the upper ribbon.

  28C5. The device of clause 27C5 wherein the other module is joined to the module by an adhesive.

  29C5. The device of clause 27C5 further comprising a junction box on which the other module overlaps.

  30C5. The apparatus according to clause 29C5, wherein the other module is joined to the module by a fitting arrangement between the connection box and another connection box on the other module.

  31C5. The device of clause 29C5 wherein the junction box houses a single module terminal.

  32C5. The device of clause 27C5 further comprising a switch between the module and the other module.

  33C5. The device of clause 32C5, further comprising a voltage sensing controller in communication with the switch.

  34C5. The device of clause 27C5 wherein the first supercell comprises 19 or more solar cells in electrical connection with a single bypass diode.

  35C5. The apparatus of clause 34C5 wherein the single bypass diode is located near an edge of the first module.

  36C5. The device of clause 34C5 wherein the single bypass diode is located in a stacked structure.

  37C5. The apparatus according to clause 36C5, wherein the supercell is enclosed within the laminated structure.

  38C5. The apparatus of clause 34C5, wherein the single bypass diode is positioned around the first module.

  39C5. The apparatus according to clause 27C5, wherein the first supercell and the second supercell form a pair connected to a power management device.

40C5. Further comprising a power management device,
The power management device,
Receiving the voltage output of the first supercell,
Based on the voltage, determine whether the solar cell of the first supercell is reverse biased,
The device of clause 27C5 configured to disconnect the reverse biased solar cell from a supercell module circuit.

1C6. A solar module including a front surface including a first series-connected string of silicon solar cells grouped to be a first supercell;
The device wherein the first supercell has a plurality of chamfered corners and includes a first silicon solar cell disposed with the sides overlapping the second silicon solar cell and conductively bonded by an adhesive.

2C6. The second silicon solar cell has no chamfered corners,
The apparatus of clause 1C6, wherein each silicon solar cell of the first supercell has substantially the same area of the front surface exposed to light.

3C6. The first silicon solar cell and the second silicon solar cell have the same length,
The device of clause 2C6, wherein the width of the first silicon solar cell is greater than the width of the second silicon solar cell.

  4C6. The apparatus according to paragraph 3C6, wherein the length reproduces the shape of the pseudo-square wafer.

  5C6. The device according to paragraph 3C6, wherein the length is 156 mm.

  6C6. The device of clause 3C6 wherein the length is 125 mm.

  7C6. The device of paragraph 3C6, wherein the aspect ratio between the width and the length of the first solar cell is between about 1: 2 and about 1:20.

  8C6. The apparatus of paragraph 3C6, wherein the first silicon solar cell overlaps the second silicon solar cell by about 1 mm to about 5 mm.

  9C6. The apparatus of clause 3C6, wherein the first supercell includes at least 19 silicon solar cells, each having a breakdown voltage greater than about 10 volts.

  10C6. The device of paragraph 3C6 wherein the first supercell has a length in the direction of current flow of at least about 500 mm.

11C6. The first supercell is connected in parallel with the second supercell at the front face;
The apparatus of clause 3C6, wherein the front surface includes a white backing having a plurality of dark stripes at locations and widths corresponding to a gap between the first supercell and the second supercell.

  12C6. The device of paragraph 1C6, wherein the second silicon solar cell includes a chamfered corner.

  13C6. The device of clause 12C6, wherein a long side of the first silicon solar cell overlaps a long side of the second silicon solar cell.

  14C6. The device of paragraph 12C6, wherein a long side of the first silicon solar cell overlaps a short side of the second silicon solar cell.

15C6. The front is
A first row including the first supercell comprising a plurality of solar cells including a plurality of chamfered corners;
A second row comprising a second series-connected string of silicon solar cells connected in parallel with the first supercell and grouped into a second supercell of chamfered cornerless solar cells. And
The apparatus of paragraph 1C6, wherein the length of the second row is substantially the same as the length of the first row.

  16C6. The apparatus of clause 15C6, wherein the first row is adjacent to a module edge and the second row is not adjacent to the module edge.

17C6. The first supercell includes at least 19 solar cells, each having a breakdown voltage greater than about 10 volts;
The device of paragraph 15C6 wherein the first supercell has a length in the direction of current flow of at least about 500 mm.

  18C6. The apparatus of clause 15C6, wherein the front surface includes a white backing having a plurality of dark stripes at locations and widths corresponding to the gap between the first supercell and the second supercell.

  19C6. The device of paragraph 1C6 further comprising a metallization pattern on a front side of the second solar cell.

  20C6. The apparatus of clause 19C6, wherein the metallization pattern includes a tapered portion extending around a chamfered corner.

  21C6. Clause 19C6. The apparatus of clause 19C6 wherein the metallization pattern includes an elevated feature to contain the spread of the adhesive.

22C6. The metal coating pattern,
A plurality of discontinuous contact pads;
A plurality of fingers electrically connected to the plurality of discontinuous contact pads;
The apparatus of clause 19C6, comprising: a conductive line that interconnects the plurality of fingers.

  23C6. The apparatus of clause 22C6 wherein the metallization pattern forms a plurality of discrete barriers to encapsulate the adhesive in the plurality of discontinuous contact pads.

  24C6. The device of clause 23C6, wherein the plurality of discrete barriers abut a plurality of corresponding discontinuous contact pads and are higher than the plurality of corresponding discontinuous contact pads.

  25C6. The apparatus of clause 1C6, further comprising a flexible electrical interconnect that is conductively bonded to a surface of the first solar cell and accommodates thermal expansion of the first solar cell in two dimensions.

  26C6. The apparatus of clause 25C6, wherein the first portion of the interconnect folds around an edge of the first supercell such that a remaining second interconnect portion is behind the first supercell.

27C6. The module has an upper conductive ribbon on the front facing the direction of solar energy;
Another module having a second supercell disposed on the front surface, wherein the lower ribbon on the other module further faces the other module facing away from the solar energy;
The apparatus of paragraph 1C6, wherein the second module overlaps and joins a portion of the first module including the upper ribbon.

  28C6. The device of clause 27C6 wherein the other module is joined to the module by an adhesive.

  29C6. The device of clause 27C6 further comprising a junction box over which the other module overlaps.

  30C6. The apparatus according to clause 29C6, wherein the other module is joined to the module by a fitting arrangement between the connection box and another connection box on the other module.

  31C6. The device of clause 29C6 wherein the junction box houses a single module terminal.

  32C6. The device of clause 27C6 further comprising a switch between the module and the other module.

  33C6. The device of clause 32C6, further comprising a voltage sensing controller in communication with the switch.

  34C6. The device of clause 27C6, wherein the first supercell comprises 19 or more solar cells in electrical connection with a single bypass diode.

  35C6. The apparatus of clause 34C6, wherein the single bypass diode is located near an edge of the first module.

  36C6. The device of clause 34C6 wherein the single bypass diode is located in a stacked structure.

  37C6. The device according to clause 36C6, wherein the supercell is encapsulated in the laminated structure.

  38C6. The apparatus of clause 34C6, wherein the single bypass diode is positioned around the first module.

  39C6. The apparatus according to clause 27C6, wherein the first supercell and the second supercell form a pair that connects to a power management device.

40C6. Further comprising a power management device,
The power management device,
Receiving the voltage output of the first supercell,
Based on the voltage, determine whether the solar cell of the first supercell is reverse biased,
The device of clause 27C6 configured to disconnect the reverse biased solar cell from a supercell module circuit.

1C7. A solar module having a front surface including a first series-connected string of at least 19 solar cells, wherein each of the at least 19 solar cells has a breakdown voltage greater than about 10 V and ends at a second silicon solar cell. A solar module that is grouped into a supercell that includes a first silicon solar cell placed in a conductive bond with the battery overlying an adhesive;
An interconnect that is conductively bonded to the solar cell surface.

  2C7. The device of clause 1C7, wherein the solar cell surface includes a back surface of the first silicon solar cell.

  3C7. The apparatus of clause 2C7 further comprising a ribbon conductor that electrically connects the supercell to an electrical component.

  4C7. The apparatus of clause 3C7, wherein the ribbon conductor is conductively joined to the solar cell surface in a direction away from the overlapping end.

  5C7. The device of clause 4C7 wherein the electrical component is on the back of the solar module.

  6C7. The device of clause 4C7 wherein the electrical component comprises a junction box.

  7C7. The apparatus of paragraph 6C7 wherein the junction box is in mating engagement with another junction box on a different module on which the module overlaps.

  8C7. The device of paragraph 4C7 wherein the electrical component includes a bypass diode.

  9C7. The device of paragraph 4C7 wherein the electrical components include module terminals.

  10C7. The device of paragraph 4C7 wherein the electrical component comprises an inverter.

  11C7. The device of clause 10C7 wherein the inverter comprises a DC / AC micro inverter.

  12C7. The device of clause 11C7 wherein the DC / AC micro inverter is on the back of the solar module.

  13C7. The apparatus of paragraph 4C7 wherein the electrical component comprises a power management device.

  14C7. The apparatus of clause 13C7, wherein the power management device includes a switch.

  15C7. The device of clause 14C7, further comprising a voltage sensing controller in communication with the switch.

16C7. The power management device,
Receiving the voltage output of the supercell,
Based on the voltage, determine whether the solar cell of the super cell is reverse biased,
The apparatus of paragraph 13C7 wherein the solar cell is reverse biased and is configured to disconnect the solar cell from a supercell module circuit.

  17C7. The apparatus of clause 16C7 wherein the power management device is in electrical communication with a central inverter.

  18C7. The apparatus of clause 13C7, wherein the power management device comprises a DC / DC module power optimizer.

  19C7. The apparatus of clause 3C7 wherein the interconnect is sandwiched between the supercell and another supercell on the front of the solar module.

  20C7. The device of clause 3C7 wherein the ribbon conductor is conductively joined to the interconnect.

  21C7. The device of clause 3C7 wherein the interconnect provides a resistance to current flow of less than or equal to about 0.012 ohms.

  22C7. The interconnect being configured to accommodate differential expansion between the first silicon solar cell and the interconnect in a temperature range between about −40 ° C. to about 85 ° C .; The device according to 3C7.

  23C7. The device of clause 3C7 wherein the thickness of the interconnect is less than or equal to about 100 microns.

  24C7. The device of clause 3C7 wherein the thickness of the interconnect is less than or equal to about 30 microns.

  25C7. The device of clause 3C7 wherein the length of the supercell in the direction of current flow is at least about 500 mm.

  26C7. The apparatus of clause 3C7 further comprising another supercell of the front of the solar module.

  27C7. The apparatus of clause 26C7, wherein the interconnect connects the other supercell in series with the supercell.

  28C7. The apparatus of clause 26C7, wherein the interconnect connects the other supercell in parallel with the supercell.

  29C7. Clause 26C7. The apparatus of clause 26C7 wherein the front surface includes a white backing having a plurality of dark stripes at locations and widths corresponding to the gap between the supercell and the other supercell.

  30C7. The device of paragraph 3C7 wherein the interconnect comprises a pattern.

  31C7. The device of clause 30C7 wherein the pattern comprises slits, slots, and / or holes.

  32C7. The device of clause 3C7 wherein a portion of the interconnect is dark.

33C7. The first silicon solar cell includes a plurality of chamfered corners,
The second silicon solar cell has no chamfered corners,
The device of clause 3C7 wherein each silicon solar cell of the supercell has substantially the same area of the front surface exposed to light.

34C7. The first silicon solar cell includes a plurality of chamfered corners,
The second silicon solar cell includes a plurality of chamfered corners,
The device according to paragraph 3C7, wherein the side includes a long side overlapping a long side of the second silicon solar cell.

  35C7. The apparatus of clause 3C7, wherein the interconnect forms a bus.

  36C7. The device of paragraph 3C7 wherein the interconnect is conductively bonded to the solar cell surface with an adhesive connection.

  37C7. The apparatus of clause 3C7, wherein the first portion of the interconnect is folded around an edge of the supercell such that a remaining second portion is behind the supercell.

38C7. A metallization pattern on the front surface, the metalization pattern including a line extending along a long side,
The apparatus of clause 3C7, further comprising a plurality of discontinuous contact pads located between the line and the long side.

39C7. The metallization further includes a plurality of fingers extending in a direction perpendicular to the long side, electrically connecting to respective discontinuous contact pads;
The device of clause 38C7 wherein the conductive wire interconnects the plurality of fingers.

  40C7. The apparatus of paragraph 38C7 wherein the metallization pattern includes an elevated feature that encloses the spread of the adhesive.

1C8. A plurality of supercells arranged in a plurality of rows on the front side of the solar module, wherein each supercell has an end of an adjacent silicon solar cell overlapped and conductively joined to connect the adjacent silicon solar cells in series. A plurality of supercells comprising at least 19 silicon solar cells having a breakdown voltage of at least 10 V, arranged side by side in electrical connection;
A second supercell adjacent to the module edge in the second row via a flexible electrical interconnect joining the front surface of the first supercell to a module edge in the first row; Electrical connection to the end of the device.

  2C8. The device of paragraph 1C8 wherein a portion of the flexible electrical interconnect is covered by a dark colored film.

  3C8. The apparatus of paragraph 2C8 wherein the solar module front surface includes a backing sheet with low visual contrast to the flexible electrical interconnect.

  4C98. The device of paragraph 1C8 wherein a portion of the flexible electrical interconnect is colored.

  5C8. The apparatus of paragraph 4C8 wherein the front of the solar module includes a backing sheet with low visual contrast to the flexible electrical interconnect.

  6C8. The apparatus according to paragraph 1C8, wherein the solar module front surface includes a white backing sheet.

  7C8. The apparatus of clause 6C8, further comprising a plurality of dark stripes corresponding to gaps between the plurality of rows.

  8C8. The device of paragraph 6C8 wherein the n-type semiconductor layer of the silicon solar cell faces the backing sheet.

9C8. The front of the solar module includes a backing sheet,
The apparatus of clause 1C8, wherein the backing sheet, the flexible electrical interconnect, the first supercell, and the encapsulant form a laminated structure.

  10C8. The device of clause 9C8 wherein the encapsulant comprises a thermoplastic polymer.

  11C8. The device of paragraph 10C8 wherein the thermoplastic polymer comprises a thermoplastic olefin polymer.

  12C8. The device of paragraph 9C8 further comprising a glass front sheet.

  13C8. The device of clause 12C8 wherein the backing sheet comprises glass.

  14C8. The device of paragraph 1C8 wherein the flexible electrical interconnect joins at a plurality of discontinuous locations.

  15C8. The apparatus of clause 1C8, wherein the flexible electrical interconnects are joined with an electrically conductive adhesive.

  16C8. The device of paragraph 1C8 further comprising a bonded connection.

  17C8. The device of paragraph 1C8 wherein the flexible electrical interconnect extends parallel to the module edge.

  18C8. The apparatus of clause 1C8, wherein a portion of the flexible electrical interconnect folds and hides around the first supercell.

  19C8. The apparatus of clause 1C8, further comprising a ribbon conductor that electrically connects the first supercell to an electrical component.

  20C8. The device of clause 19C8 wherein the ribbon conductor is conductively joined to the flexible electrical interconnect.

  21C8. The device of clause 19C8 wherein the ribbon conductor is conductively joined to the solar cell surface in a direction away from the overlapping end.

  22C8. The device of clause 19C8 wherein the electrical component is on the back of the solar module.

  23C8. The device according to clause 19C8, wherein the electrical component comprises a junction box.

  24C8. The device of clause 23C8 wherein the junction box is in meshing engagement with another junction box on the front of another solar module.

  25C8. The apparatus of clause 23C8 wherein the junction box comprises a single terminal junction box.

  26C8. The device of clause 19C8 wherein the electrical component includes a bypass diode.

  27C8. The device of paragraph 19C8 wherein the electrical component includes a switch.

28C8. Further comprising a voltage sensing controller,
The voltage sensing controller,
Receiving the voltage output of the first supercell,
Based on the voltage, determine whether the solar cell of the first supercell is reverse biased,
The device of clause 27C8 configured to communicate with the switch to disconnect the reverse biased solar cell from a supercell module circuit.

  29C8. The apparatus of clause 1C8, wherein the first supercell is in series with the second supercell.

30C8. The first silicon solar cell of the first supercell includes a plurality of chamfered corners,
The second silicon solar cell of the first supercell has no chamfered corners,
The apparatus of paragraph 1C8, wherein each silicon solar cell of the first supercell has substantially the same area of the front surface exposed to light.

31C8. The first silicon solar cell of the first supercell includes a plurality of chamfered corners,
The second silicon solar cell of the first supercell includes a plurality of chamfered corners,
The device according to paragraph 1C8, wherein a long side of the first silicon solar cell overlaps a long side of the second silicon solar cell.

  32C8. The apparatus of paragraph 1C8, wherein the first supercell silicon solar cell comprises a strip having a length of about 156 mm.

  33C8. The apparatus of paragraph 1C8 wherein the first supercell silicon solar cell comprises a strip having a length of about 125 mm.

  34C8. The apparatus of paragraph 1C8, wherein the silicon solar cell of the first supercell comprises a strip having an aspect ratio between about 1: 2 and about 1:20.

35C8. The adjacent silicon solar cells overlapping the first supercell are conductively bonded by an adhesive,
The device of paragraph 1C8, further comprising features configured to contain the spread of the adhesive.

  36C8. The device of paragraph 35C8 wherein the features include a moat.

  37C8. The apparatus according to clause 36C8, wherein the moat is formed by a metallization pattern.

38C8. The metallization pattern includes a line extending along a long side of the silicon solar cell,
The apparatus of clause 37C8, further comprising a plurality of discontinuous contact pads located between the line and the long side.

  39C8. The device of clause 37C8 wherein the metallization pattern is located on a front of a silicon solar cell of the first supercell.

  40C8. The device of clause 37C8 wherein the metallization pattern is located on the back of the silicon solar cell of the second supercell.

1C9. A solar module including a front surface including a plurality of silicon solar cells connected in series,
The apparatus, wherein the plurality of silicon solar cells are grouped into a first supercell that includes a first cut strip having a front metallization pattern along a first outer edge where a second cut strip overlaps.

  2C9. The apparatus according to paragraph 1C9, wherein the lengths of the first cut strip and the second cut strip reproduce the shape of a wafer from which the first cut strip is divided.

  3C9. The device according to paragraph 2C9, wherein the length is 156 mm.

  4C9. The device according to paragraph 2C9, wherein the length is 125 mm.

  5C9. The apparatus of paragraph 2C9 wherein the aspect ratio between the width of the first cut strip and the length is between about 1: 2 and about 1:20.

  6C9. The apparatus of clause 2C9 wherein the first cut strip includes a first chamfered corner.

  7C9. The apparatus of paragraph 6C9 wherein the first chamfered corner is along the first outer edge.

  8C9. The apparatus of paragraph 6C9, wherein the first chamfered corner does not follow the first outer edge.

  9C9. The apparatus of paragraph 6C9 wherein the second cut strip includes a second chamfered corner.

  10C9. The apparatus of paragraph 9C9 wherein the overlapping edge of the second cut strip includes the second chamfered corner.

  11C9. The apparatus of paragraph 9C9 wherein the overlapping edge of the second cut strip does not include the second chamfered corner.

  12C9. The apparatus according to paragraph 6C9, wherein the length reproduces the shape of the pseudo-square wafer from which the first cut strip is divided.

  13C9. The apparatus of paragraph 6C9, wherein the width of the first cut strip is different from the width of the second cut strip such that the first cut strip and the second cut strip have approximately the same area.

  14C9. The apparatus according to paragraph 1C9, wherein the second cut strip overlaps the first cut strip by about 1 to 5 mm.

  15C9. The apparatus of clause 1C9, wherein the front metallization pattern comprises a bus bar.

  16C9. The device of clause 15C9 wherein the busbar includes a tapered portion.

  17C9. The apparatus of clause 1C9, wherein the front metallization pattern comprises discontinuous contact pads.

18C9. The second cut strip is joined to the first cut strip by an adhesive,
The device of clause 17C9, wherein the discontinuous contact pads further include features to contain the spread of adhesive.

  19C9. The device of clause 18C9, wherein the features include a moat.

  20C9. The apparatus of clause 1C9, wherein the front metallization pattern includes a bypass conductor.

  21C9. The apparatus of clause 1C9, wherein the front metallization pattern includes fingers.

  22C9. The apparatus of clause 1C9, wherein the first cut strip further comprises a backside metallization pattern along a second outer edge opposite the first outer edge.

  23C9. The device of clause 22C9 wherein the backside metallization pattern comprises a contact pad.

  24C9. The device of clause 22C9 wherein the back side metallization pattern comprises a bus bar.

  25C9. The apparatus of clause 1C9, wherein the supercell includes at least 19 silicon cut strips each having a breakdown voltage greater than about 10 volts.

  26C9. The apparatus of clause 1C9, wherein the supercell connects with another supercell on the front of the solar module.

  27C9. The apparatus of clause 26C9, wherein the front surface of the solar module comprises a white backing having a plurality of dark stripes corresponding to a gap between the supercell and the other supercell.

28C9. The front side of the solar module includes a backing sheet,
The device of clause 26C9 wherein the backing sheet, the interconnect, the supercell, and the encapsulant form a laminated structure.

  29C9. The device of clause 28C9 wherein the encapsulant comprises a thermoplastic polymer.

  30C9. The device according to clause 29C9 wherein the thermoplastic polymer comprises a thermoplastic olefin polymer.

  31C9. The apparatus of clause 26C9, further comprising an interconnect between the supercell and the other supercell.

  32C9. The device of clause 31C9 wherein a portion of the interconnect is covered by a dark film.

  33C9. The device of clause 31C9 wherein a portion of the interconnect is colored.

  34C9. The device of clause 31C9 further comprising a ribbon conductor that electrically connects the supercell to an electrical component.

  35C9. The apparatus of clause 34C9 wherein the ribbon conductor is conductively bonded to the back side of the first cut strip.

  36C9. The device of clause 34C9 wherein the electrical component includes a bypass diode.

  37C9. The device of clause 34C9 wherein the electrical component includes a switch.

  38C9. The device of clause 34C9 wherein the electrical component includes a junction box.

  39C9. The apparatus according to paragraph 38C9, wherein the connection box overlaps with another connection box and is fitted and arranged with the other connection box.

  40C9. The device according to clause 26C9, wherein the supercell and the other supercell are connected in series.

1C10. Laser scribing a scribe line on a silicon wafer to define a solar cell area;
Applying an electrically conductive adhesive to the top surface of the scribed silicon wafer adjacent to a long side of the solar cell region;
Separating the silicon wafer along the scribe line to provide a solar cell strip including a part of the electrically conductive adhesive bonding agent disposed adjacent to a long side of the solar cell strip. ,Method.

  2C10. The method of clause 1C10, further comprising providing the metallization pattern to the silicon wafer such that the separating step produces the solar cell strip having a metallization pattern along the long side. .

  3C10. The method of clause 2C10, wherein the metallization pattern comprises a bus bar or discontinuous contact pads.

  4C10. The method of paragraph 2C10 wherein the providing step comprises printing the metallization pattern.

  5C10. The method of paragraph 2C10 wherein the providing step comprises electroplating the metallization pattern.

  6C10. The method of clause 2C10, wherein the metallization pattern includes features configured to contain the spread of the electrically conductive adhesive.

  7C10. The device of clause 6C10 wherein the features include a moat.

  8C10. The method according to paragraph 1C10, wherein the applying step includes a printing step.

  9C10. The method according to paragraph 1C10, wherein the applying step includes depositing using a mask.

  10C10. The method according to paragraph 1C10, wherein the length of the long side of the solar cell strip reproduces the shape of the wafer.

  11C10. The method according to paragraph 10C10, wherein the length is 156 mm or 125 mm.

  12C10. The method of paragraph 10C10, wherein the aspect ratio between the width of the solar cell strip and the length is between about 1: 2 and about 1:20.

  13C10. In the separating step, a vacuum is drawn between the bottom surface of the wafer and the curved support surface, and the solar cell region is bent toward the curved support surface, thereby bending the silicon wafer along the scribe line. The method according to paragraph 1C10, wherein the cleavage is performed.

14C10. A step of arranging a plurality of solar cell strips in a state where the long sides of adjacent solar cell strips overlap and a part of the electrically conductive adhesive bonding agent is arranged therebetween,
Curing the electrically conductive bonding agent, thereby bonding adjacent overlapping solar cell strips together and electrically connecting them in series. The method of paragraph 1C10, further comprising:

  15C10. The method according to item 14C10, wherein the step of curing includes a step of heating.

  16C10. The method according to item 14C10, wherein the step of curing includes a step of applying pressure.

  17C10. The method according to clause 14C10, wherein the disposing step comprises forming a layered structure.

  18C10. The method according to item 17C10, wherein the step of curing includes a step of pressing and heating the layered structure.

  19C10. The method according to clause 17C10 wherein the layered structure includes an encapsulant.

  20C10. The method according to clause 19C10 wherein the encapsulant comprises a thermoplastic polymer.

  21C10. The method of paragraph 20C10 wherein the thermoplastic polymer comprises a thermoplastic olefin polymer.

  22C10. The method according to clause 17C10 wherein the layered structure comprises a backing sheet.

23C10. The backing sheet is white,
The method according to clause 22C10 wherein the layered structure further comprises dark stripes.

  24C10. The method of clause 14C10 wherein the arranging step comprises arranging at least 19 solar cell strips side by side.

  25C10. The method of clause 24C10, wherein each of the at least 19 solar cell strips has a breakdown voltage of at least 10V.

  26C10. The method of clause 24C10, further comprising the step of bringing the at least 19 solar cell strips into communication with only a single bypass diode.

  27C10. The method of clause 26C10, further comprising forming a ribbon conductor between one of the at least 19 solar cell strips and the single bypass diode.

  28C10. The method according to clause 27C10 wherein the single bypass diode is located in a junction box.

  29C10. The method according to clause 28C10, wherein the junction box is on the rear side of the solar module in a mating arrangement with another junction box of a different solar module.

  30C10. The method of clause 14C10, wherein the overlapping battery strip of the plurality of solar strips overlaps the solar strip by about 1 to 5 mm.

  31C10. The method of clause 14C10 wherein the solar cell strip includes a first chamfered corner.

  32C10. The method of clause 31C10, wherein a long side of the overlapping solar cell strips of the plurality of solar cell strips does not include a second chamfered corner.

  33C10. The method of clause 32C10, wherein the width of the solar cell strip is greater than the width of the overlapping solar cell strip such that the solar cell strip and the overlapping solar cell strip have approximately the same area.

  34C10. The method of clause 31C10, wherein a long side of the overlapping solar cell strips of the plurality of solar cell strips includes a second chamfered corner.

  35C10. The method of clause 34C10, wherein the long side of the overlapping solar cell strip of the plurality of solar cell strips overlaps the long side of the battery strip including the first chamfered corner.

  36C10. The method of clause 34C10, wherein the long side of the overlapping solar cell strip of the plurality of solar cell strips overlaps a long side of the battery strip not including the first chamfered corner.

  37C10. The method of clause 14C10 further comprising connecting the plurality of solar cell strips to another plurality of solar cell strips using an interconnect.

  38C10. The method of clause 37C10, wherein a portion of the interconnect is covered by a dark film.

  39C10. The method of paragraph 37C10 wherein a portion of the interconnect is colored.

  40C10. The method of clause 37C10, wherein the plurality of solar cell strips are connected in series with the other plurality of solar cell strips.

1C11. Providing a silicon wafer having a length;
Scribing a scribe line on the silicon wafer to define a solar cell area;
Applying an electrically conductive adhesive bonding agent to the surface of the silicon wafer,
Separating the silicon wafer along the scribe line to provide a solar cell strip including a part of the electrically conductive adhesive bonding agent disposed adjacent to a long side of the solar cell strip. ,Method.

  2C11. The method according to paragraph 1C11, wherein the scribe includes a laser scribe.

  3C11. The method according to paragraph 2C11, comprising a step of laser scribing the scribe line and thereafter applying the electrically conductive adhesive bonding agent.

  4C11. The method according to item 2C11, comprising applying the electrically conductive adhesive bonding agent to the wafer, and thereafter performing laser scribe on the scribe line.

5C11. The applying step includes a step of applying an uncured electrically conductive adhesive bonding agent,
The method according to paragraph 4C11, wherein the step of laser scribing includes a step of avoiding curing of the uncured conductive pressure-sensitive adhesive with heat from the laser.

  6C11. The method of paragraph 5C11 wherein the avoiding comprises selecting a laser power and / or a distance between the scribe line and the uncured conductive adhesive.

  7C11. The method according to paragraph 1C11, wherein the applying step includes a printing step.

  8C11. The method according to paragraph 1C11, wherein the applying step includes a step of depositing using a mask.

  9C11. The method according to Item 1C11, wherein the scribe line and the electrically conductive adhesive are on the surface.

  10C11. In the separating step, a vacuum is drawn between the surface of the silicon wafer and the curved support surface, and the solar cell region is bent toward the curved support surface, whereby the silicon wafer is stretched along the scribe line. The method according to item 1C11, wherein the cleavage is performed.

  11C11. The method according to paragraph 10C11, wherein the step of separating includes the step of arranging the scribe line at an angle with respect to the vacuum manifold.

  12C11. The method according to item 1C11, wherein the step of separating includes a step of pressing the wafer using a roller.

  13C11. Item 1C11, wherein the providing step includes providing the metallization pattern on the silicon wafer such that the separating step produces the solar cell strip having the metallization pattern along the long side. The method described in.

  14C11. The method of clause 13C11, wherein the metallization pattern comprises a bus bar or discontinuous contact pads.

  15C11. Clause 13C11. The method according to clause 13C11, wherein the providing comprises printing the metallization pattern.

  16C11. The method of paragraph 13C11 wherein the providing step comprises electroplating the metallization pattern.

  17C11. The method of clause 13C11, wherein the metallization pattern includes features configured to contain the spread of the electrically conductive adhesive.

  18C11. The method according to item 1C11, wherein the length of the long side of the solar cell strip reproduces the shape of the wafer.

  19C11. The method according to paragraph 18C11, wherein the length is 156 mm or 125 mm.

  20C11. The method of clause 18C11, wherein the aspect ratio between the width of the solar cell strip and the length is between about 1: 2 and about 1:20.

21C11. A step of arranging a plurality of solar cell strips in a state where the long sides of adjacent solar cell strips overlap and a part of the electrically conductive adhesive bonding agent is arranged therebetween,
Curing the electrically conductive bonding agent, thereby bonding adjacent and overlapping solar cell strips to each other and electrically connecting them in series.

22C11. The disposing step includes a step of forming a layered structure,
The method according to item 21C11, wherein the step of curing includes a step of heating and / or pressurizing the layered structure.

  23C11. The method according to clause 22C11 wherein the layered structure comprises a thermoplastic olefin polymer encapsulant.

24C11. The method of clause 22C11 wherein the layered structure comprises a white backing sheet and dark stripes on the white backing sheet.

25C11. A plurality of wafers are provided on the template,
The conductive adhesive bonding agent is distributed on the plurality of wafers,
21. The method of clause 21C11, wherein the plurality of wafers are cells that have been simultaneously separated by a fixture into a plurality of solar cell strips.

26C11. The method further includes a step of transporting the plurality of solar cell strips as a group,
The method according to paragraph 25C11, wherein the arranging step includes arranging the plurality of solar cell strips in a module.

  27C11. Clause 21C11. The method of clause 21C11 wherein the arranging comprises arranging only a single bypass diode and at least 19 solar cell strips having a breakdown voltage of at least 10V.

  28C11. The method of clause 27C11, further comprising forming a ribbon conductor between one of the at least 19 solar cell strips and the single bypass diode.

  29C11. Clause 28C11. The method according to clause 28C11, wherein the single bypass diode is located within a first junction box of the first solar module mated with a second junction box of the second solar module.

  30C11. The method of clause 27C11, further comprising forming a ribbon conductor between one of the at least 19 solar cell strips and the smart switch.

  31C11. The method of paragraph 21C11, wherein the overlapping battery strip of the plurality of solar cell strips overlaps the solar cell strip by about 1 to 5 mm.

  32C11. The method of clause 21C11 wherein the solar cell strip includes a first chamfered corner.

  33C11. The method of clause 32C11, wherein a long side of the overlapping solar cell strips of the plurality of solar cell strips does not include a second chamfered corner.

  34C11. The method of clause 33C11, wherein the width of the solar cell strip is greater than the width of the overlapping solar cell strip such that the solar cell strip and the overlapping solar cell strip have approximately the same area.

  35C11. The method of clause 32C11, wherein a long side of the overlapping solar cell strips of the plurality of solar cell strips includes a second chamfered corner.

  36C11. The method according to paragraph 35C11, wherein the long side of the overlapping solar cell strip of the plurality of solar cell strips overlaps the long side of the battery strip including the first chamfered corner.

  37C11. The method according to paragraph 35C11, wherein the long side of the overlapping solar cell strip of the plurality of solar cell strips overlaps a long side of the battery strip not including the first chamfered corner.

  38C11. The method of clause 21C11, further comprising connecting the plurality of solar cell strips to another plurality of solar cell strips using an interconnect.

  39C11. The method of clause 38C11 wherein a portion of the interconnect is covered or colored with a dark film.

  40C11. The method of clause 38C11, wherein the plurality of solar cell strips are connected in series with the other plurality of solar cell strips.

1C12. Providing a silicon wafer having a length;
Scribing a scribe line on a silicon wafer to define a solar cell area;
Separating the silicon wafer along the scribe line to provide a solar cell strip;
Applying an electrically conductive adhesive bonding agent disposed adjacent to a long side of the solar cell strip.

  2C12. The method according to Item 1C12, wherein the scribing step includes a laser scribing step.

  3C12. The method according to paragraph 1C12, wherein the applying step includes a screen printing step.

  4C12. The method according to Item 1C12, wherein the applying step includes an inkjet printing step.

  5C12. The method according to paragraph 1C12, wherein the applying step includes depositing using a mask.

  6C12. The method of paragraph 1C12, wherein the step of separating comprises drawing a vacuum between the surface of the wafer and the curved surface.

  7C12. The method of clause 6C12, wherein the curved surface includes a vacuum manifold, and wherein the separating comprises directing the scribe line at an angle to the vacuum manifold.

  8C12. The method of clause 7C12 wherein the angle is vertical.

  9C12. The method of clause 7C12 wherein the angle is other than perpendicular.

  10C12. The method of clause 6C12 wherein the vacuum is drawn through a moving belt.

11C12. A step of arranging a plurality of solar cell strips in a state where the long sides of adjacent solar cell strips overlap the electrically conductive adhesive bonding agent disposed therebetween,
Curing the electrically conductive bonding agent to bond adjacent and overlapping solar cell strips that are electrically connected in series.

12C12. The disposing step includes a step of forming a layered structure including the encapsulating material,
The method according to item 11C12, further comprising a step of laminating the layered structure.

  13C12. The method of clause 12C12 wherein the curing step occurs at least partially during the laminating step.

  14C12. The method of clause 12C12 wherein the curing step occurs separately from the laminating step.

  15C12. The method according to item 12C12, wherein the step of stacking includes a step of applying a vacuum.

  16C12. The method of clause 15C12 wherein the vacuum is pulled against a bladder.

  17C12. The method of clause 15C12 wherein the vacuum is drawn against a belt.

  18C12. The method of clause 12C12 wherein the encapsulant comprises a thermoplastic olefin polymer.

19C12. The method of clause 12C12 wherein the layered structure comprises a white backing sheet and dark stripes on the white backing sheet.

  20C12. Clause 11C12: providing the metallization pattern to the silicon wafer such that the separating step produces the solar cell strip having a metallization pattern along the long side by the separating step. The method described in.

  21C12. The method of paragraph 20C12 wherein the metallization pattern comprises a bus bar or discontinuous contact pads.

  22C12. The method of paragraph 20C12 wherein the providing step comprises printing or electroplating the metallization pattern.

  23C12. The method of clause 20C12, wherein the disposing step comprises the step of using the metallization pattern feature to confine the spread of the electrically conductive adhesive.

  24C12. The method of clause 23C12 wherein the feature is on a front side of the solar cell strip.

  25C12. The method of clause 23C12 wherein the feature is on the back side of the solar cell strip.

  26C12. The method according to item 11C12, wherein the length of the long side of the solar cell strip reproduces the shape of the wafer.

  27C12. The method according to paragraph 26C12, wherein the length is 156 mm or 125 mm.

  28C12. The method of paragraph 26C12, wherein the aspect ratio between the width of the solar cell strip and the length is between about 1: 2 and about 1:20.

  29C12. The method of clause 11C12, wherein the arranging comprises arranging only a single bypass diode and at least 19 solar cell strips having a breakdown voltage of at least 10V side by side as a first supercell.

  30C12. The method of clause 29C12, further comprising applying the electrically conductive adhesive bond between the first supercell and the interconnect.

  31C12. The method of clause 30C12, wherein the interconnect connects the first supercell in parallel with a second supercell.

  32C12. The method of clause 30C12, wherein the interconnect connects the first supercell in series with a second supercell.

  33C12. The method of clause 29C12, further comprising forming a ribbon conductor between the first supercell and the single bypass diode.

  34C12. The method of clause 33C12, wherein the single bypass diode is located within a first junction box of the first solar module that is mated with a second junction box of the second solar module.

  35C12. The method of clause 11C12 wherein the solar strip comprises a first chamfered corner.

  36C12. The method of paragraph 35C12 wherein the long side of the overlapping solar cell strips of the plurality of solar cell strips does not include a second chamfered corner.

  37C12. The method of paragraph 36C12, wherein the width of the solar cell strip is greater than the width of the overlapping solar cell strip such that the solar cell strip and the overlapping solar cell strip have approximately the same area.

  38C12. The method of clause 35C12, wherein a long side of the overlapping solar cell strips of the plurality of solar cell strips includes a second chamfered corner.

  39C12. The method of paragraph 38C12, wherein the long side of the overlapping solar cell strip of the plurality of solar cell strips overlaps the long side of the battery strip including the first chamfered corner.

  40C12. The method of paragraph 38C12, wherein the long side of the overlapping solar cell strip of the plurality of solar cell strips overlaps a long side of the battery strip not including the first chamfered corner.

1C13. A semiconductor wafer having a first surface including a first metallization pattern along a first outer edge and a second metallization pattern along a second outer edge opposite the first outer edge;
The apparatus wherein the semiconductor wafer further comprises a first scribe line between the first metallization pattern and the second metallization pattern.

  2C13. The apparatus of clause 1C13, wherein the first metallization pattern comprises discontinuous contact pads.

  3C13. The apparatus of clause 1C13, wherein the first metallization pattern includes a first finger pointing away from the first outer edge toward the second metallization pattern.

  4C13. The apparatus of clause 3C13, wherein the first metallization pattern further comprises a bus bar extending along the first outer edge and intersecting the first finger.

5C13. The second metallization pattern,
A second finger pointing in a direction away from the second outer edge toward the first metallization pattern;
The device of clause 4C13, comprising: a second busbar extending along the second outer edge and intersecting the second finger.

  6C13. The device of clause 3C13 further comprising an electrically conductive adhesive extending along the first outer edge and in contact with the first finger.

  7C13. The apparatus of clause 3C13 wherein the first metallization pattern further comprises a first bypass conductor.

  8C13. The apparatus of clause 3C13 wherein the first metallization pattern further comprises a first end conductor.

  9C13. The device of clause 1C13 wherein the first metallization pattern comprises silver.

  10C13. The apparatus of clause 9C13 wherein the first metallization pattern comprises a silver paste.

  11C13. The apparatus of clause 9C13 wherein the first metallization pattern includes discontinuous contacts.

  12C13. The apparatus of paragraph 1C13 wherein the first metallization pattern comprises tin, aluminum, or other less expensive conductor than silver.

  13C13. The apparatus of clause 1C13, wherein the first metallization pattern comprises copper.

  14C13. The apparatus of clause 13C13 wherein the first metallization pattern comprises electroplated copper.

  15C13. The apparatus of clause 13C13, further comprising providing a passivation scheme to reduce recombination.

16C13. A third metallization pattern on the first surface of the semiconductor wafer that is not proximate to the first outer edge or the second outer edge;
A second scribe line between the third metallization pattern and the second metallization pattern,
The apparatus according to clause 1C13, wherein the first scribe line is between the first metallization pattern and the third metallization pattern.

  17C13. Item 16C13 wherein the ratio of the first width defined between the first scribe line and the second scribe line divided by the length of the semiconductor wafer is between about 1: 2 and about 1:20. An apparatus according to claim 1.

  18C13. The device according to clause 17C13 wherein the length is about 156 mm or about 125 mm.

  19C13. The apparatus of clause 17C13 wherein the semiconductor wafer includes chamfered corners.

20C13. The first scribe line, together with the first outer edge, defines a first rectangular area including two chamfered corners and the first metallization pattern;
The first rectangular region has an area corresponding to a value obtained by subtracting an area obtained by combining the two chamfered corners from a product of the length and a second width larger than the first width. ,
The second scribe line, together with the first scribe line, defines a second rectangular area that does not include the chamfered corners and that includes the third metallization pattern;
The apparatus of clause 19C13, wherein the second rectangular area has an area corresponding to a product of the length and the first width.

  21C13. The apparatus of clause 16C13 wherein the third metallization pattern includes fingers pointing to the second metallization pattern.

  22C13. The apparatus of clause 1C13, further comprising a third metallization pattern on a second surface of the semiconductor wafer opposite the first surface.

  23C13. The apparatus of clause 22C13 wherein the third metallization pattern has a contact pad proximate to the location of the first scribe line.

  24C13. The apparatus according to paragraph 1C13, wherein the first scribe line is formed by a laser.

  25C13. The apparatus of clause 1C13, wherein the first scribe line is within the first surface.

  26C13. The apparatus of clause 1C13, wherein the first metallization pattern includes features configured to contain the spread of the electrically conductive adhesive.

  27C13. The device of paragraph 26C13 wherein the features include elevated features.

  28C13. The device of clause 27C13 wherein the first metallization pattern comprises a contact pad, and wherein the feature comprises a dam abutting the contact pad and higher than the contact pad.

  29C13. The device of clause 26C13 wherein the features include concave features.

  30C13. The device of clause 29C13 wherein the recessed features include a moat.

  31C13. The device of clause 26C13 further comprising the electrically conductive adhesive in contact with the first metallization pattern.

  32C13. The device according to paragraph 31C13 wherein the electrically conductive adhesive is printed.

  33C13. The apparatus according to paragraph 1C13, wherein the semiconductor wafer includes silicon.

  34C13. The apparatus according to clause 33C13, wherein the semiconductor wafer includes crystalline silicon.

  35C13. The device of clause 33C13 wherein the first surface is n-type conductive.

  36C13. The device of clause 33C13 wherein the first surface is p-type conductive.

37C13. The first metallization pattern is 5 mm or less from the first outer edge;
The second metallization pattern is 5 mm or less from the second outer edge;
The device according to Item 1C13.

  38C13. The apparatus of clause 1C13, wherein the semiconductor wafer includes a plurality of chamfered corners, and wherein the first metallization pattern includes a tapered portion extending around the chamfered corner.

  39C13. The device of clause 38C13 wherein the tapered portion includes a bus bar.

  40C13. The device of clause 38C13 wherein the tapered portion includes a conductor connecting the discontinuous contact pads.

1C14. Scribing a first scribe line on the wafer;
Using a vacuum to separate the wafers along the first scribe line to provide a solar cell strip.

  2C14. The method according to paragraph 1C14, wherein the scribing step includes a laser scribing step.

  3C14. The method of clause 2C14, wherein the step of separating comprises drawing the vacuum between a surface of the wafer and a curved surface.

  4C14. The method of clause 3C14, wherein the curved surface comprises a vacuum manifold.

5C14. The wafer is supported on a belt that moves to the vacuum manifold,
The method of clause 4C14 wherein the vacuum is drawn through the belt.

6C14. The separating step includes:
Orienting the first scribe line at an angle to the vacuum manifold;
Starting cleavage at one end of the first scribe line. The method according to item 5C14, wherein

  7C14. The method according to paragraph 6C14, wherein the angle is substantially vertical.

  8C14. The method of clause 6C14 wherein the angle is an angle other than substantially perpendicular.

  9C14. The method of clause 3C14 further comprising applying an uncured electrically conductive adhesive.

  10C14. The method according to clause 9C14, wherein the first scribe line and the uncured electrically conductive adhesive are on the same surface of the wafer.

  11C14. The step of laser scribing comprises curing the uncured conductive adhesive by selecting a laser power and / or a distance between the first scribe line and the uncured conductive adhesive. The method of paragraph 10C14, which avoids.

  12C14. The method of clause 10C14, wherein the same surface is opposite the wafer surface supported by a belt that moves the wafer to the curved surface.

  13C14. The method of clause 12C14 wherein the curved surface comprises a vacuum manifold.

  14C14. The method of paragraph 9C14 wherein the applying step occurs after the scribing step.

  15C14. The method according to paragraph 9C14 wherein the applying step occurs after the separating step.

  16C14. The method according to paragraph 9C14, wherein the applying step includes a screen printing step.

  17C14. The method according to paragraph 9C14, wherein the applying step includes an inkjet printing step.

  18C14. The method of clause 9C14, wherein the applying step comprises depositing using a mask.

19C14. The first scribe line is
A first metallization pattern on the surface of the wafer along a first outer edge;
The method of clause 3C14 wherein the second metallization pattern on the surface of the wafer along a second outer edge.

20C14. The wafer further includes a third metallization pattern on the surface of the semiconductor wafer that is not proximate to the first outer edge or the second outer edge;
A second scribe line is scribed between the third metallization pattern and the second metallization pattern such that the first scribe line is between the first metallization pattern and the third metallization pattern. The process of
Clause 19C14. Separating the wafer along the second scribe line to provide another solar cell strip.

  21C14. The distance between the first scribe line and the second scribe line defines an aspect ratio of between about 1: 2 and about 1:20 for a length of the wafer that is about 125 mm or about 156 mm. The method according to paragraph 20C14, wherein the width is formed.

  22C14. The method of clause 19C14, wherein the first metallization pattern includes fingers pointing to the second metallization pattern.

  23C14. The method of clause 22C14 wherein the first metallization pattern further comprises a bus bar intersecting the finger.

  24C14. The method of clause 23C14 wherein the busbar is within 5 mm of the first outer edge.

  25C14. The method of clause 22C14 further comprising an uncured electrically conductive adhesive bonding agent that contacts the finger.

  26C14. The method according to clause 19C14, wherein the first metallization pattern includes discontinuous contact pads.

  27C14. The method of clause 19C14, further comprising printing or electroplating the first metallization pattern on the wafer.

28C14. A first supermarket comprising at least 19 solar cell strips, each having a breakdown voltage of at least 10 V, with the long sides of adjacent solar cell strips overlapping the electrically conductive adhesive disposed therebetween. Arranging the solar cell strip in a cell;
Curing the electrically conductive bonding agent to bond adjacent, overlapping, series electrically connected solar cell strips.

29C14. The disposing step includes a step of forming a layered structure including an encapsulant,
The method according to clause 28C14, further comprising the step of laminating the layered structure.

  30C14. The method according to clause 29C14 wherein the curing step occurs at least partially during the laminating step.

  31C14. The method of clause 29C14 wherein the curing step occurs separately from the laminating step.

  32C14. The method according to clause 29C14 wherein the encapsulant comprises a thermoplastic olefin polymer.

33C14. The method according to clause 29C14, wherein the layered structure comprises: a white backing sheet; and dark stripes on the white backing sheet.

  34C14. Clause 28C14. The method according to clause 28C14, wherein the disposing step comprises using the metallization pattern feature to contain the spread of the electrically conductive adhesive.

  35C14. The method according to clause 34C14 wherein the metallization pattern feature is on the front side of the solar cell strip.

  36C14. The method according to clause 34C14 wherein the metallization pattern feature is on a rear surface of the solar cell strip.

  37C14. The method of clause 28C14 further comprising applying the electrically conductive adhesive between the interconnects connecting the first supercell and the second supercell in series.

38C14. Forming a ribbon conductor between the single bypass diodes of the first supercell;
The method according to clause 28C14, wherein the single bypass diode is located within the first junction box of the first solar module in a mating arrangement with the second junction box of the second solar module.

39C14. The solar cell strip includes a first chamfered corner;
The long side of the overlapping solar cell strips of the plurality of solar cell strips does not include the second chamfered corner,
The method of clause 28C14, wherein the width of the solar strip is greater than the width of the overlapping solar strip such that the solar strip and the overlapping solar strip have approximately the same area.

40C14. The solar cell strip includes a first chamfered corner;
A long side of the overlapping solar cell strips of the plurality of solar cell strips includes a second chamfered corner,
The method of clause 28C14, wherein the long side of the overlapping solar cell strip of the plurality of solar cell strips overlaps a long side of the solar cell strip that does not include the first chamfered corner.

1C15. Forming a first metallization pattern along a first outer edge of a first surface of the semiconductor wafer;
Forming a second metallization pattern along a second outer edge of the first surface opposite the first outer edge;
Forming a first scribe line between the first metallization pattern and the second metallization pattern.

2C15. The first metallization pattern includes a first finger pointing to the second metallization pattern,
The method of clause 1C15, wherein the second metallization pattern includes a second finger pointing to the first metallization pattern.

3C15. The first metallization pattern further includes a first bus bar intersecting the first finger and located within 5 mm of the first outer edge,
The method of paragraph 2C15, wherein the second metallization pattern includes a second busbar intersecting the second finger and located within 5 mm of the second outer edge.

4C15. The method further comprises the step of forming a third metal coating pattern not along the first outer edge or not along the second outer edge on the first surface.
A third bus bar parallel to the first bus bar;
And a third finger pointing to the second metallization pattern.
Forming a second scribe line between the third metal coating pattern and the second metal coating pattern,
The method of clause 3C15, wherein the first scribe line is between the first metallization pattern and the third metallization pattern.

  5C15. The method of clause 4C15, wherein the first scribe line and the second scribe line are separated by a width having a ratio to a length of the semiconductor wafer that is between about 1: 2 and about 1:20. the method of.

  6C15. The method according to paragraph 5C15, wherein the length of the semiconductor wafer is about 156 mm or about 125 mm.

  7C15. The method of clause 4C15 wherein the semiconductor wafer includes chamfered corners.

8C15. The first scribe line, together with the first outer edge, defines a first solar cell region including two chamfered corners and the first metallization pattern;
The first solar cell region has a first area corresponding to a value obtained by subtracting a combined area of the two chamfered corners from a product of a length of the semiconductor wafer and a first width. And
The second scribe line, together with the first scribe line, defines a second solar cell area that does not include the chamfered corners and that includes the third metallization pattern;
The second solar cell region has a second area that is approximately the same as the first area, corresponding to a product of the length and a second width smaller than the first width, according to item 7C15. Method.

  9C15. The method of clause 8C15 wherein the length is about 156 mm or about 125 mm.

  10C15. The method according to paragraph 4C15, wherein the step of forming the first scribe line and the step of forming the second scribe line include a step of laser scribing.

  11C15. The method according to paragraph 4C15, wherein forming the first metallization pattern, forming the second metallization pattern, and forming the third metallization pattern include printing.

  12C15. The method according to paragraph 11C15, wherein forming the first metallization pattern, forming the second metallization pattern, and forming the third metallization pattern comprises screen printing. .

  13C15. The method of clause 11C15, wherein forming the first metallization pattern comprises forming a plurality of contact pads including silver.

  14C15. The method according to clause 4C15, wherein forming the first metallization pattern, forming the second metallization pattern, and forming the third metallization pattern comprises electroplating. .

  15C15. The method of clause 14C15 wherein the first metallization pattern, the second metallization pattern, and the third metallization pattern comprise copper.

  16C15. The method of clause 4C15 wherein the first metallization pattern comprises a conductor that is less expensive than aluminum, tin, silver, copper, and / or silver.

  17C15. The method of clause 4C15, wherein the semiconductor wafer comprises silicon.

  18C15. The method according to clause 17C15, wherein the semiconductor wafer comprises crystalline silicon.

  19C15. The method of paragraph 4C15, further comprising forming a fourth metallization pattern on the second surface of the semiconductor wafer between the first outer edge and within 5 mm of the position of the second scribe line.

  20C15. The method of clause 4C15, wherein the first surface has a first conductivity type and the second surface has a second conductivity type opposite to the first conductivity type.

  21C15. The method according to paragraph 4C15, wherein the fourth metallization pattern includes a contact pad.

  22C15. The method of clause 3C15 further comprising applying a conductive adhesive to the semiconductor wafer.

  23C15. Clause 22C15. The method of clause 22C15 further comprising the step of contacting the first finger and applying the conductive adhesive.

  24C15. Clause 23C15. The method according to clause 23C15, wherein applying the conductive adhesive comprises screen printing or depositing using a mask.

  25C15. The method of clause 3C15, further comprising separating the semiconductor wafer along the first scribe line to form a first solar cell strip including the first metallization pattern.

  26C15. Item 25C15. The method according to Item 25C15, wherein the separating includes a step of applying a vacuum to the first scribe line.

  27C15. Clause 26C15. The method of clause 26C15, further comprising placing the semiconductor wafer on the belt moving to the vacuum.

  28C15. The method of paragraph 25C15 further comprising applying a conductive adhesive to the first solar cell strip.

29C15. The first supercell including at least 19 solar strips each having a breakdown voltage of at least 10 V, with the long sides of adjacent solar strips overlapping the conductive adhesive disposed therebetween. Arranging a first solar cell strip;
Curing the conductive adhesive to bond adjacent and overlapping solar cell strips that are electrically connected in series.

30C15. The disposing step includes a step of forming a layered structure including the encapsulating material,
The method according to clause 29C15, further comprising the step of laminating the layered structure.

  31C15. The method according to clause 30C15 wherein the curing step occurs at least partially during the laminating step.

  32C15. The method of clause 30C15 wherein the curing step occurs separately from the laminating step.

  33C15. The method of paragraph 30C15 wherein the encapsulant comprises a thermoplastic olefin polymer.

34C15. The method according to paragraph 30C15, wherein the layered structure includes: a white backing sheet; and dark stripes on the white backing sheet.

  35C15. Clause 29C15. The method according to clause 29C15, wherein the disposing step comprises confining the spread of the conductive adhesive with the metallization pattern feature.

  36C15. The method according to paragraph 35C15 wherein the metallization pattern feature is on a front side of the first solar cell strip.

  37C15. The method of clause 29C15, further comprising applying the conductive adhesive between the interconnects connecting the first supercell and the second supercell in series.

38C15. Forming a ribbon conductor between the single bypass diodes of the first supercell;
The method of clause 29C15, wherein the single bypass diode is located within the first junction box of the first solar module in a mating arrangement with the second junction box of the second solar module.

39C15. The first solar cell strip includes a first chamfered corner;
The long side of the overlapping solar cell strip of the first supercell does not include the second chamfered corner,
Clause 29C15 wherein the width of the first solar cell strip is greater than the width of the overlapping solar cell strips such that the first solar cell strip and the overlapping solar cell strip have approximately the same area. Method.

40C15. The first solar cell strip includes a first chamfered corner;
A long side of the overlapping solar cell strip of the first supercell includes a second chamfered corner,
The method of clause 29C15, wherein the long side of the overlapping solar cell strip overlaps a long side of the first solar cell strip not including the first chamfered corner.

1C16. A first row of bus bars or contact pads arranged parallel and adjacent to a first outer edge of the silicon wafer; and a second row of the silicon wafer opposite and parallel to the first edge of the silicon wafer. Obtaining or providing said silicon wafer including a front metallization pattern including a second bus bar or contact pad row disposed parallel and adjacent to an outer edge;
Separating the silicon wafer along one or more scribe lines parallel to the first outer edge and the second outer edge of the silicon wafer to form a plurality of rectangular solar cells; The bus bar or the contact pad row is disposed in parallel with and adjacent to the long outer edge of the first rectangular solar cell of the plurality of rectangular solar cells, and the second bus bar or the contact pad row is disposed in the plurality of rectangular solar cells. Arranged parallel to and adjacent to the long outer edge of the second rectangular solar cell;
Forming a supercell by arranging the plurality of rectangular solar cells in a state where the long sides of adjacent solar cells are overlapped and conductively joined to each other, and the adjacent solar cells are electrically connected in series. Prepare,
The method according to claim 1, wherein the first bus bar or the contact pad row of the first rectangular solar cell of the plurality of rectangular solar cells is overlapped with the bottom surface of an adjacent rectangular solar cell in the supercell and is conductively joined.

  2C16. Item 1C16, wherein the bottom surface of an adjacent rectangular solar cell in the supercell overlaps and is conductively connected to the second bus bar or contact pad row on the second rectangular solar cell among the plurality of rectangular solar cells. the method of.

  3C16. The method according to paragraph 1C16, wherein the silicon wafer is a square or pseudo-square silicon wafer.

  4C16. The method of clause 3C16, wherein the silicon wafer has sides that are about 125 mm in length, or about 156 mm in length.

  5C16. The method of clause 3C16 wherein the length to width ratio of each rectangular solar cell is between about 2: 1 and about 20: 1.

  6C16. The method according to paragraph 1C16, wherein the silicon wafer is a crystalline silicon wafer.

  7C16. The first bus bar or contact pad row and the second bus bar or contact pad row are located in a plurality of edge regions of the silicon wafer that convert light to electricity with lower efficiency than a plurality of central regions of the silicon wafer. The method of paragraph 1C16, wherein the method is located.

  8C16. A first plurality of parallel fingers extending inward from the first outer edge of the silicon wafer and electrically connected to the first bus bar or contact pad row; and the second bus bar. Or a second plurality of parallel fingers extending inward from the second outer edge of the silicon wafer for making electrical connection to a contact pad row.

  9C16. The front metallization pattern is oriented at least parallel to the first bus bar or contact pad row and the second bus bar or contact pad row, and the first bus bar or contact pad row and the second bus bar Alternatively, a third bus bar or contact pad row located between the third bus bar or contact pad row and a direction perpendicular to the third bus bar or contact pad row and electrically connected to the third bus bar or contact pad row. The third plurality of parallel fingers, wherein the third bus bar or contact pad row comprises a plurality of parallel fingers, the plurality of rectangular solar cells being separated from the silicon wafer to form the plurality of rectangular solar cells. Item 1 is disposed in parallel with and adjacent to the long outer edge of the third rectangular solar cell. The method according to 16.

  10C16. The method of clause 1C16, comprising applying a conductive adhesive to the first bus bar or contact pad row to conductively join the first rectangular solar cell to an adjacent solar cell.

  11C16. The method of paragraph 10C16 wherein the metallization pattern includes a barrier configured to contain the spread of the conductive adhesive.

  12C16. The method of clause 10C16 comprising applying the conductive adhesive by screen printing.

  13C16. The method according to paragraph 10C16, comprising applying the conductive adhesive by inkjet printing.

  14C16. The method of clause 10C16, wherein the conductive adhesive is applied before forming the one or more scribe lines in the silicon wafer.

  15C16. The step of separating the silicon wafer along the one or more scribe lines includes drawing a vacuum between a bottom surface of the silicon wafer and a curved support surface, bending the silicon wafer toward the curved support surface, The method according to paragraph 1C16, further comprising cleaving the silicon wafer along the one or more scribe lines.

16C16. The silicon wafer is a pseudo-square silicon wafer including a plurality of chamfered corners, and after separating the silicon wafer to form the plurality of rectangular solar cells, one or more of the rectangular solar cells The plurality includes one or more of the plurality of chamfered corners,
The interval between the scribe lines, the width perpendicular to the major axis of the rectangular solar cell including a plurality of chamfered corners, than the width perpendicular to the major axis of the rectangular solar cell without a plurality of chamfered corners Enlargement is selected to compensate for the chamfered corners, such that each of the plurality of rectangular solar cells in the supercell has substantially an area exposed to light during operation of the supercell. The method according to paragraph 1C16 having a front surface that is the same.

  17C16. The method according to paragraph 1C16, comprising arranging the supercells in a layered structure between a transparent front sheet and a rear sheet, and laminating the layered structure.

  18C16. The step of laminating the layered structure completes the curing of the conductive adhesive disposed between the adjacent rectangular solar cells in the supercell, and conductively joins the adjacent rectangular solar cells to each other. The method according to item 17C16.

  19C16. The supercells are arranged in the laminar structure in one of two or more parallel rows of supercells, and the backsheet is positioned at a gap between two or more parallel rows of the supercells and A white sheet comprising a plurality of parallel dark stripes having a position and a width corresponding to the width, whereby a plurality of white portions of the back sheet in the assembled module are replaced by two or more of the supercells; The method according to clause 17C16 wherein no visibility is made through more gaps between parallel rows.

  20C16. The method according to paragraph 17C16, wherein the front sheet and the rear sheet are glass sheets, and the supercell is enclosed in a thermoplastic olefin layer sandwiched between the glass sheets.

  21C16. The method of paragraph 1C16, comprising the step of disposing the supercell on a first module that includes a junction box that is mated with a second junction box of a second solar module.

1D. A plurality of supercells arranged in two or more parallel rows, wherein each supercell has a long side of an adjacent silicon solar cell overlapped and is directly conductively bonded to each other to form an adjacent silicon solar cell. Having a plurality of rectangular or substantially rectangular silicon solar cells arranged side by side in a state of being electrically connected in series, and a plurality of super cells,
A first hidden tap contact pad located on the rear surface of the first solar cell located at an intermediate position along the first super cell among the plurality of super cells;
A first electrical interconnect that is conductively joined to the first hidden tap contact pad;
With
A solar module, wherein the first electrical interconnect includes stress relief features that accommodate differential thermal expansion between the interconnect and the silicon solar cell to which it is joined.

2D. A second hidden tap contact pad located on a rear surface of a second solar cell positioned adjacent to the first solar cell at an intermediate position along the second super cell among the plurality of super cells;
The solar module of paragraph 1D, wherein the first hidden tap contact pad is electrically connected to the second hidden tap contact pad through the first electrical interconnect.

  3D. The solar cell of paragraph 2D, wherein the first electrical interconnect extends across a gap between the first supercell and the second supercell and is conductively joined to the second hidden tap contact pad. module.

4D. A second hidden tap contact pad located on the rear surface of the second solar cell located at another intermediate position along the first super cell among the plurality of super cells;
A second electrical interconnect conductively connected to the second hidden tap contact pad;
A bypass diode electrically connected by the first electrical interconnect and the second electrical interconnect in parallel with the solar cell located between the first hidden tap contact pad and the second hidden tap contact pad. Item 1. The solar module according to Item 1D.

5D. The first hidden tap contact pad is one of a plurality of hidden tap contact pads disposed on the rear surface of the first solar cell in a row extending parallel to a long axis of the first solar cell;
Clause 1D, wherein the first electrical interconnect is conductively joined to each of the plurality of hidden contacts and extends substantially across the length of the first solar cell along the long axis. Solar module.

6D. The first hidden tap contact pad is located adjacent to a short side of the rear surface of the first solar cell,
The first electrical interconnect does not extend substantially inward from the hidden tap contact pad along the long axis of the solar cell;
The solar module of paragraph 1D, wherein the backside metallization pattern on the first solar cell provides a conductive path to the interconnect having a sheet resistance less than or equal to about 5 ohms / square.

  7D. The solar module of paragraph 6D, wherein the sheet resistance is less than or equal to about 2.5 ohms / square.

8D. The first interconnect includes two tabs located on opposite sides of the stress relief feature;
The solar module of paragraph 6D, wherein one of the two tabs is conductively joined to the first hidden tap contact pad.

  9D. The solar module of paragraph 8D, wherein the two tabs have different lengths.

  10D. The solar module of clause 1D, wherein the first electrical interconnect includes an alignment feature that specifies a desired alignment with the first hidden tap contact pad.

  11D. The solar module of paragraph 1D, wherein the first electrical interconnect includes an alignment feature that specifies a desired alignment with an edge of the first supercell.

  12D. The solar module according to item 1D, wherein the solar module is arranged in a shingle-like shape that overlaps with another solar module at an electrical connection destination in the overlapping area.

13D. A solar module,
Glass front sheet,
A back sheet,
A plurality of supercells arranged in two or more parallel rows between the glass front sheet and the rear sheet, wherein each supercell overlaps a long side of an adjacent silicon solar cell. A plurality of supercells having a plurality of rectangular or substantially rectangular silicon solar cells arranged side by side in a state in which the adjacent silicon solar cells are electrically connected in series with each other in a flexible and direct conductive manner,
A first flexible electrical interconnect that is strongly conductively bonded to a first supercell of the plurality of supercells;
The plurality of flexible conductive junctions between overlapping solar cells can be connected to the plurality of supercells and the glass front sheet at a temperature in a range of about −40 ° C. to about 100 ° C. without damaging the solar module. Providing the plurality of supercells with mechanical compliance that accommodates a mismatch in thermal expansion in a direction parallel to the two or more parallel rows between the plurality of supercells;
The strong conductive junction between the first supercell and the first flexible electrical interconnect provides the first conductive layer at a temperature in the range of about −40 ° C. to about 180 ° C. without damaging the solar module. A solar module for adapting a flexible electrical interconnect to a thermal expansion mismatch between the first supercell and the first flexible interconnect in a direction perpendicular to the two or more parallel rows. .

  14D. The plurality of conductive junctions between overlapping adjacent solar cells in a supercell utilize a different conductive adhesive than the plurality of conductive junctions between the supercell and the flexible electrical interconnect; The solar module according to 13D.

  15D. The solar module according to clause 14D, wherein both conductive adhesives can be cured in the same processing step.

  16D. The solar module of clause 13D, wherein the conductive junction on one side of at least one solar cell in the supercell utilizes a different conductive adhesive than the conductive junction on the other side.

  17D. The solar module according to paragraph 16D, wherein both conductive adhesives can be cured in the same process step.

  18D. The method of clause 13D, wherein the plurality of conductive junctions between overlapping adjacent solar cells accommodate differential movement of greater than or equal to about 15 microns between each cell and the glass frontsheet. Solar module.

  19D. The plurality of conductive junctions between overlapping adjacent solar cells have a thickness in a direction perpendicular to the plurality of solar cells less than or equal to about 50 microns, and a thickness in a direction perpendicular to the plurality of solar cells. Clause 13D. The solar module of clause 13D, wherein the thermal conductivity is greater than or equal to about 1.5 W / (meter-K).

  20D. Clause 13D. The solar module of clause 13D, wherein the first flexible electrical interconnect withstands thermal expansion or contraction of the first flexible interconnect greater than or equal to about 40 microns.

  21D. The portion of the first flexible electrical interconnect, which is conductively bonded to the supercell, is in the form of a ribbon made of copper, and has a thickness in the direction perpendicular to the surface of the solar cell to which it is bonded. The solar module of clause 13D, wherein the solar module is less than or equal to 50 microns.

  22D. The portion of the first flexible electrical interconnect, which is conductively bonded to the supercell, is in the form of a ribbon made of copper, and has a thickness in the direction perpendicular to the surface of the solar cell to which it is bonded. The solar module according to clause 21D, wherein the solar module is less than or equal to 30 microns.

  23D. The first flexible electrical interconnect has an integral conductive copper portion that is conductively bonded to the solar cell, provides higher conductivity than a portion of the first flexible electrical interconnect, and is not bonded to the solar cell. 21. A solar module according to item 21D.

  24D. 21. The method of claim 21D, wherein the first flexible electrical interconnect has a width, in a direction perpendicular to a current flow through the interconnect, in a plane of the surface of the solar cell that is greater than or equal to about 10 mm. Solar module.

  25D. 21. The solar module of paragraph 21D, wherein the first flexible electrical interconnect is conductively joined to a conductor proximate to the solar cell that provides higher conductivity than the first electrical interconnect.

  26D. Item 13D. The solar module according to Item 13D, wherein the solar module is arranged in a shingle-like shape that overlaps with another solar module to which the electrical connection is made in the overlapping area.

27D. A plurality of supercells arranged in two or more parallel rows, wherein each supercell has a long side of an adjacent silicon solar cell overlapped and is directly conductively bonded to each other to form an adjacent silicon solar cell. Having a plurality of rectangular or substantially rectangular silicon solar cells arranged side by side in a state of being electrically connected in series, and a plurality of super cells,
A hidden tap contact pad located on the rear surface of the first solar cell and not conducting a substantial current in a normal operation;
The first solar cell is located at an intermediate position along the first supercell among the plurality of supercells in the first row of the two or more parallel rows of supercells, and the hidden tap contact pad is provided. A solar module electrically connected in parallel with at least a second solar cell in a second of the two or more parallel rows of the supercell.

28D. An electrical interconnect that is joined to the hidden tap contact pad and electrically interconnects the hidden tap contact pad to the second solar cell;
The electrical interconnect does not extend substantially across the length of the first solar cell;
The solar module of clause 27D, wherein the backside metallization pattern on the first solar cell provides a conductive path to the hidden tap contact pad having a sheet resistance less than or equal to about 5 ohms / square.

29D. The plurality of supercells are arranged in the three or more parallel rows extending across the width of the solar module perpendicular to three or more parallel rows;
The hidden tap contact pad is electrically connected to a hidden contact pad on at least one solar cell in each of the three or more parallel rows of the supercell to connect the three or more of the supercells. Electrical connection of parallel rows in parallel,
Clause 27D wherein at least one bus connection to at least one of the plurality of hidden tap contact pads or to an interconnect between the plurality of hidden tap contact pads connects to a bypass diode or other electronic device. The solar module according to 1.

30D. A flexible electrical interconnect that conductively connects to the hidden tap contact pad and electrically connects it to the second solar cell;
The portion of the flexible electrical interconnect, which is conductively bonded to the hidden tap contact pad, is a ribbon formed of copper and has a thickness in a direction perpendicular to the surface of the solar cell to which it is bonded. Less than or equal to 50 microns,
The conductive junction between the hidden tap contact pad and the flexible electrical interconnect is connected to the flexible electrical interconnect at a temperature in a range of about -40C to about 180C without damaging the solar module. Withstand the thermal expansion mismatch between the first solar cell and the flexible interconnect and accommodate the relative movement between the first and second solar cells resulting from the thermal expansion. 27. A solar module according to item 27D.

  31D. Clause 27D. The solar module of clause 27D, wherein in operation of the solar module, the first hidden contact pad can conduct a current greater than a current generated by any one of the plurality of solar cells.

  32D. The solar module of clause 27D, wherein the front surface of the first solar cell overlying the first hidden tap contact pad is not occupied by a contact pad or any other interconnect feature.

  33D. Clause 27D, wherein any area of the front surface of the first solar cell where portions of adjacent solar cells in the first supercell do not overlap is not occupied by contact pads or any other interconnect features. The described solar module.

  34D. The solar module of paragraph 27D wherein in each supercell, most of the plurality of batteries do not have a hidden tap contact pad.

  35D. 34. The solar module according to clause 34D, wherein the plurality of batteries having a hidden tap contact pad have a larger light collection area than the plurality of batteries having no hidden tap contact pad.

  36D. 27. The solar module according to item 27D, wherein the solar module is arranged in a shingle-like shape that overlaps with another solar module to which electrical connection is made in the overlapping area.

37D. Glass front sheet,
A back sheet,
A plurality of supercells arranged in two or more parallel rows between the glass front sheet and the rear sheet, wherein each supercell overlaps a long side of an adjacent silicon solar cell. A plurality of supercells having a plurality of rectangular or substantially rectangular silicon solar cells arranged side by side in a state in which the adjacent silicon solar cells are electrically connected in series with each other in a flexible and direct conductive manner,
A first flexible electrical interconnect that is strongly conductively bonded to a first supercell of the plurality of supercells;
The plurality of flexible conductive junctions between overlapping solar cells are formed from a first conductive adhesive and have a rigidity less than or equal to about 800 megapascals;
The strong conductive junction between the first supercell and the first flexible electrical interconnect is formed from a second conductive adhesive and has a rigidity greater than or equal to about 2000 megapascals; Solar module.

  38D. The solar module of paragraph 37D, wherein the first conductive adhesive and the second conductive adhesive are different, and both conductive adhesives can be cured in the same processing step.

  39D. The plurality of conductive junctions between overlapping adjacent solar cells have a thickness in a direction perpendicular to the plurality of solar cells less than or equal to about 50 microns, and a thickness in a direction perpendicular to the plurality of solar cells. The solar module of paragraph 37D, wherein the thermal conductivity is greater than or equal to about 1.5 W / (meter-K).

  40D. 37. The solar module according to paragraph 37D, wherein the solar module is arranged in a shingle-like configuration overlapping with another solar module to which the electrical connection is made in the overlapping area.

1E. Comprising N (greater than or equal to about 150) rectangular or substantially rectangular silicon solar cells arranged as a plurality of supercells in two or more parallel rows;
Each supercell includes a plurality of silicon solar cells that are arranged side by side with the long sides of adjacent silicon solar cells overlapping and conductively joined to each other, with the adjacent silicon solar cells electrically connected in series,
A solar module, wherein the plurality of supercells are electrically connected to provide a high DC voltage of greater than or equal to about 90 volts.

  2E. The solar module of paragraph 1E, comprising one or more flexible electrical interconnects arranged to electrically connect the plurality of supercells in series to provide the high DC voltage.

  3E. The solar module of clause 2E comprising module level power electronics including an inverter that converts the high DC voltage to an AC voltage.

  4E. The solar module of paragraph 3E wherein the module-level power electronics senses the high DC voltage and causes the module to operate at an optimal current-voltage power point.

5E. A module-level module for electrically connecting a plurality of individual, adjacent series-connected supercell row pairs and electrically connecting one or more of the plurality of supercell row pairs in series to provide the high DC voltage. Power electronics and
The solar module according to item 1E, comprising: an inverter configured to convert the high DC voltage into an AC voltage.

  6E. The solar module of clause 5E, wherein the module level power electronics senses a voltage across each individual supercell row pair and operates each individual supercell row pair at an optimal current-voltage power point.

  7E. The solar module of paragraph 6E, wherein the module-level power electronics switches out the row pair from the circuit providing the higher DC voltage if the voltage across an individual supercell row pair drops below a threshold. .

8E. Module level power electronics for electrically connecting to each individual supercell row and electrically connecting two or more of the plurality of supercell rows in series to provide the high DC voltage;
The solar module according to item 1E, comprising: an inverter configured to convert the high DC voltage into an AC voltage.

  9E. The solar module of clause 8E, wherein the module-level power electronics senses a voltage across each individual supercell row and operates each individual supercell row at an optimal current-voltage power point.

  10E. The solar module of clause 9E, wherein the module-level power electronics switches out the supercell row from the circuit providing the higher DC voltage if the voltage across an individual supercell row drops below a threshold. .

11E. Module-level power electronics electrically connected to each individual supercell and electrically connecting two or more of the plurality of supercells in series to provide the high DC voltage;
The solar module according to item 1E, comprising: an inverter configured to convert the high DC voltage into an AC voltage.

  12E. The solar module of clause 11E, wherein the module-level power electronics senses a voltage across each individual supercell and operates each individual supercell at an optimal current-voltage power point.

  13E. The solar module of clause 12E, wherein the module-level power electronics switches out the supercell from the circuit providing the high DC voltage if the voltage across an individual supercell falls below a threshold.

14E. Each supercell is electrically segmented into multiple segments by multiple hidden taps,
Module level power electronics for electrically connecting to each segment of each supercell through the plurality of hidden taps and electrically connecting two or more segments in series to provide the high DC voltage;
The solar module according to item 1E, comprising: an inverter configured to convert the high DC voltage into an AC voltage.

  15E. The solar module of clause 14E, wherein the module-level power electronics senses a voltage across each individual segment of each supercell and operates each individual segment at an optimal current-voltage power point.

  16E. The solar module of clause 15E, wherein the module-level power electronics switches out the segment from the circuit providing the higher DC voltage if the voltage on an individual segment falls below a threshold.

  17E. The solar module according to any one of clauses 4E, 6E, 9E, 12E or 15E, wherein the optimal current-voltage power point is a maximum current-voltage power point.

  18E. The solar module of any one of clauses 3E to 17E, wherein the module-level power electronics has no DC-DC boost components.

  19E. N is greater than or equal to about 200, greater than or equal to about 250, greater than or equal to about 300, greater than or equal to about 350, or greater than or equal to about 400, or greater than or equal to about 450; Greater than or equal to, greater than or equal to about 500, greater than or equal to about 550, greater than or equal to about 600, or greater than or equal to about 650, or greater than or equal to about 700; The solar module according to any one of paragraphs 1E to 18E, or equivalent thereto.

  20E. The high DC voltage is greater than or equal to about 120 volts, greater than or equal to about 180 volts, greater than or equal to about 240 volts, greater than or equal to about 300 volts, greater than about 360 volts. Item 1E high or equal to, greater than or equal to about 420 volts, greater than or equal to about 480 volts, greater than or equal to about 540 volts, or greater than or equal to about 600 volts The solar module according to any one of claims 1 to 19E.

21E. Two or more solar modules electrically connected in parallel;
With an inverter and
Each solar module has N (greater than or equal to about 150) rectangular or nearly rectangular silicon solar cells arranged as a plurality of supercells in two or more parallel rows;
Each supercell in each module is arranged side by side in the module, with the long sides of adjacent silicon solar cells overlapping and conductively joined to each other, and electrically connecting the adjacent silicon solar cells in series. Comprising two or more of said silicon solar cells,
In each module, the plurality of supercells are electrically connected to provide a high voltage DC module output greater than or equal to about 90 volts,
The photovoltaic system wherein the inverter is electrically connected to the two or more solar modules to convert their high voltage DC output to AC.

  22E. Each solar module includes one or more flexible electrical interconnects arranged to electrically connect the plurality of supercells in the solar module in series to provide a high voltage DC output of the solar module. The solar power generation system according to 21E.

23E. At least a third solar module electrically connected in series with the first solar module of the two or more solar modules electrically connected in parallel;
The third solar module comprises N ′ (greater than or equal to about 150) rectangular or substantially rectangular silicon solar cells arranged as a plurality of supercells in two or more parallel rows. ,
The supercells in the third solar module are arranged in the module in such a manner that the long sides of adjacent silicon solar cells overlap and are conductively connected to each other to electrically connect the adjacent silicon solar cells in series. Comprising two or more of said silicon solar cells arranged in
The solar power system of clause 21E, wherein, within the third solar module, the plurality of supercells are electrically connected to provide a high voltage DC module output greater than or equal to about 90 volts.

24E. At least a fourth solar module electrically connected in series with the second solar module of the two or more solar modules electrically connected in parallel;
The fourth solar module comprises N ″ rectangular or substantially rectangular silicon solar cells (greater than or equal to about 150) arranged as a plurality of supercells in two or more parallel rows. And
The supercells in the fourth solar module are arranged in the module so that the long sides of adjacent silicon solar cells overlap and are conductively joined to each other, and the adjacent silicon solar cells are electrically connected in series. Comprising two or more of said silicon solar cells arranged in
The solar power system of clause 23E, wherein, within the fourth solar module, the plurality of supercells are electrically connected to provide a high voltage DC module output greater than or equal to about 90 volts.

  25E. 21E, comprising a plurality of fuses arranged to prevent a short circuit occurring in any one of the two or more solar modules from dissipating power generated in other solar modules. The solar power generation system according to 24E.

  26E. Arranged to prevent a short circuit occurring in any one of the two or more solar modules from dissipating power generated in other of the two or more solar modules. The photovoltaic power generation system according to any one of Items 21E to 25E, comprising a plurality of blocking diodes.

  27E. The solar power generation system according to any one of clauses 21E to 26E, comprising: a parallel electric connection destination of the two or more solar modules; and a positive electrode bus and a negative electrode bus to which the inverter is electrically connected.

28E. Comprising a combiner box for electrical connection by separate conductors of the two or more solar modules,
The photovoltaic system according to any one of paragraphs 21E to 26E, wherein the combiner box electrically connects the two or more solar modules in parallel.

  29E. The combiner box includes a plurality of fuses arranged to prevent a short circuit occurring in any one of the two or more solar modules from dissipating power generated in other solar modules. The solar power generation system according to Item 28E, having the following formula.

  30E. The combiner box is such that a short circuit occurring in any one of the two or more solar modules dissipates power generated by other of the two or more solar modules. 28E or 29E, comprising a plurality of blocking diodes arranged to prevent phenomena.

  31E. The inverter of any one of clauses 21E to 30E, wherein the inverter is configured to operate the two or more solar modules at a DC voltage higher than a minimum set to avoid reverse biasing the module. The photovoltaic power generation system according to the paragraph.

  32E. The solar inverter of any one of clauses 21E to 30E, wherein the inverter is configured to recognize a reverse bias condition and operate the two or more solar modules at a voltage that avoids the reverse bias condition. Light generation system.

  33E. N is greater than or equal to about 200, greater than or equal to about 250, greater than or equal to about 300, greater than or equal to about 350, or greater than or equal to about 400, or greater than or equal to about 450; Greater than or equal to, greater than or equal to about 500, greater than or equal to about 550, greater than or equal to about 600, or greater than or equal to about 650, or greater than or equal to about 700; The solar module according to any one of paragraphs 21E to 32E, or equivalent thereto.

  34E. The high DC voltage is greater than or equal to about 120 volts, greater than or equal to about 180 volts, greater than or equal to about 240 volts, greater than or equal to about 300 volts, greater than about 360 volts. Item 21E, which is higher or equal, higher than or equal to about 420 volts, higher than or equal to about 480 volts, higher than or equal to about 540 volts, or higher than or equal to about 600 volts The solar module according to any one of claims to 33E.

  35E. The photovoltaic power generation system according to any one of Items 21E to 34E, which is located on a roof.

36E. N (greater than or equal to about 150) rectangular or substantially rectangular silicon solar cells arranged as a plurality of supercells in two or more parallel rows, each supercell being adjacent A rectangular or substantially rectangular silicon solar cell including a plurality of silicon solar cells in which the long sides of the matching silicon solar cells overlap and are conductively joined to each other, and are arranged side by side with the adjacent silicon solar cells electrically connected in series; A first solar module having:
With an inverter and
A photovoltaic system, wherein the plurality of supercells are electrically connected to provide a high DC voltage greater than or equal to about 90 volts to the inverter that converts the DC to AC.

  37E. The solar power generation system according to paragraph 36E, wherein the inverter is a microinverter integrated with the first solar module.

  38E. The first solar module includes one or more flexible electrical interconnects arranged to electrically connect the plurality of supercells in the solar module in series to provide a high voltage DC output of the solar module. The solar power generation system according to Item 36E, including the solar battery.

39E. At least a second solar module electrically connected in series with the first solar module;
The second solar module comprises N ′ (greater than or equal to about 150) rectangular or substantially rectangular silicon solar cells arranged as a plurality of supercells in two or more parallel rows. ,
The supercells in the second solar module are arranged in the module so that the long sides of adjacent silicon solar cells overlap and are conductively joined to each other, and the adjacent silicon solar cells are electrically connected in series. Comprising two or more of said silicon solar cells arranged in
39. The method of any one of clauses 36E to 38E wherein, within the second solar module, the plurality of supercells are electrically connected to provide a high voltage DC module output greater than or equal to about 90 volts. Solar power system.

  40E. The solar module of any one of clauses 36E to 39E, wherein the inverter has no DC-DC boost component.

  41E. N is greater than or equal to about 200, greater than or equal to about 250, greater than or equal to about 300, greater than or equal to about 350, or greater than or equal to about 400, or greater than or equal to about 450; Greater than or equal to, greater than or equal to about 500, greater than or equal to about 550, greater than or equal to about 600, or greater than or equal to about 650, or greater than or equal to about 700; The solar module according to any one of paragraphs 36E to 40E, or equivalent thereto.

  42E. The high DC voltage is greater than or equal to about 120 volts, greater than or equal to about 180 volts, greater than or equal to about 240 volts, greater than or equal to about 300 volts, greater than about 360 volts. Term 36E, high or equal to, greater than or equal to about 420 volts, greater than or equal to about 480 volts, greater than or equal to about 540 volts, or greater than or equal to about 600 volts The solar module according to any one of claims 1 to 41E.

43E. N (greater than or equal to or equal to about 250) rectangular or substantially rectangular silicon solar cells arranged as a plurality of series-connected supercells in two or more parallel rows, each supercell being However, having a plurality of silicon solar cells, the plurality of silicon solar cells, the long sides of adjacent silicon solar cells are overlapped, and are directly conductively joined to each other by an electric and heat conductive adhesive, so that the inside of the supercell is The plurality of silicon solar cells are arranged side by side in a state of being electrically connected in series, a rectangular or substantially rectangular silicon solar cell,
Less than one bypass diode per 25 solar cells,
The electrically and thermally conductive adhesive has a thickness in a direction perpendicular to the plurality of solar cells of less than or equal to about 50 microns and a thermal conductivity in a direction perpendicular to the plurality of solar cells of about 50 microns. A solar module that forms a plurality of junctions between adjacent solar cells greater than or equal to 1.5 W / (meter-K).

  44E. The solar module of paragraph 43E, wherein the plurality of supercells are encapsulated in a thermoplastic olefin layer between the front and back sheets.

  45E. Item 43E. The solar module according to Item 43E, wherein the plurality of supercells are sealed between a front sheet and a rear sheet made of glass.

  46E. Less than one bypass diode per 30 solar cells, or less than one bypass diode per 50 solar cells, or less than one bypass diode per 100 solar cells, or only a single bypass diode The solar module according to clause 43E, comprising or without a bypass diode.

  47E. The solar module of clause 43E, comprising no bypass diode, or only a single bypass diode, or no more than three, no more than six, or no more than ten bypass diodes.

  48E. The plurality of conductive junctions between overlapping solar cells can be connected to the plurality of supercells and the glass front sheet at a temperature in a range of about −40 ° C. to about 100 ° C. without damaging the solar module. 43. The solar module of clause 43E, wherein the plurality of supercells are provided with mechanical compliance that accommodates thermal expansion mismatches in a direction parallel to the two or more parallel rows.

  49E. N is greater than or equal to about 300, greater than or equal to about 350, greater than or equal to about 400, or greater than or equal to about 450, or greater than or equal to about 500, or greater than or equal to about 550. The solar module of any one of paragraphs 43E to 48E, wherein is greater than or equal to, greater than or equal to about 600, greater than or equal to about 650, or greater than or equal to about 700. .

  50E. The plurality of supercells are electrically connected to each other to be greater than or equal to about 120 volts, greater than or equal to about 180 volts, greater than or equal to about 240 volts, greater than or equal to about 300 volts, or more. Equal to, greater than or equal to about 360 volts, greater than or equal to about 420 volts, greater than or equal to about 480 volts, greater than or equal to about 540 volts, or greater than about 600 volts; The solar module of any one of paragraphs 43E to 49E, wherein the solar module provides a high DC voltage.

51E. A solar module according to item 43E;
An inverter electrically connected to the solar module and configured to convert a DC output from the solar module to provide an AC output.

  52E. The solar energy system of clause 51E, wherein the inverter has no DC-DC boost component.

  53E. The solar energy system of clause 51E, wherein the inverter is configured to operate the solar module at a DC voltage higher than a minimum set to avoid reverse biasing the solar cell.

  54E. The solar energy system of clause 53E wherein the minimum voltage value is temperature dependent.

  55E. The solar energy system of paragraph 51E wherein the inverter is configured to recognize a reverse bias condition and operate the solar module at a voltage that avoids the reverse bias condition.

  56E. The solar energy system of clause 55E wherein the inverter is configured to operate the solar module in a maximum region of the voltage-current output curve of the solar module to avoid the reverse bias condition.

  57E. The solar energy system according to any one of clauses 51E to 56E, wherein the inverter is a micro inverter integrated with the solar module.

1F. Advancing the solar cell wafer along the curved surface;
A vacuum is drawn between the curved surface and the bottom surface of the solar cell wafer, and the solar cell wafer is bent toward the curved surface, thereby bending the solar cell along one or more scribe lines prepared in advance. Cleaving the battery wafer to separate the plurality of solar cells from the solar cell wafer.

  2F. The method of paragraph 1F, wherein the curved surface is a curved portion of the top surface of the vacuum manifold that draws the vacuum against the bottom surface of the solar cell wafer.

  3F. The vacuum drawn by the vacuum manifold against the bottom surface of the solar cell wafer changes along the direction of movement of the solar cell wafer, and the solar cell wafer is cleaved, which is the strongest in the area of the vacuum manifold. , Item 2F.

  4F. Along the curved top surface of the vacuum manifold, transporting the solar cell wafer by a perforated belt, wherein the vacuum is applied to the bottom surface of the solar cell wafer through a plurality of perforations of the perforated belt. The method of paragraph 2F or 3F, comprising the step of drawing.

  5F. The plurality of perforations of the perforated belt are arranged such that a leading edge and a trailing edge of the solar cell wafer along the moving direction of the solar cell wafer lie on at least one perforation of the perforated belt. , Item 4F.

  6F. Advancing the solar cell wafer along the flat region of the upper surface of the vacuum manifold to reach a transition curved region of the upper surface of the vacuum manifold having a first curvature, after which the solar cell wafer is cleaved; Moving the solar cell wafer into a cleavage region on the upper surface of the vacuum manifold, wherein the cleavage region of the vacuum manifold has a second curvature higher than the first curvature. The method according to any one of items 2F to 5F.

  7F. The method of clause 6F, wherein the curvature of the transition region is defined by a continuous geometric function of increasing curvature.

  8F. The method of clause 7F, wherein the curvature of the cleavage region is defined by a continuous geometric function that increases the curvature.

  9F. The method of paragraph 6F, comprising the step of advancing the plurality of cleaved solar cells within a post-cleavage region of the vacuum manifold having a third curvature higher than the second curvature.

  10F. The method of clause 9F, wherein the curvatures of the transition curve region, the cleavage region, and the post-cleavage region are defined by a single continuous geometric function that increases curvature.

  11F. The method according to clause 7F, clause 8F, or clause 10F, wherein the continuous geometric function that increases the curvature is a clothoid.

  12F. At one end of each scribe line, and then at the opposite end of each scribe line, a stronger vacuum was drawn between the solar cell wafer and the curved surface to create a single cleavage tear along each scribe line. The method of any of paragraphs 1F to 11F, comprising providing an asymmetric stress distribution along each scribe line that promotes nucleation and propagation.

  13F. Removing the cleaved plurality of solar cells from the curved surface, wherein the plurality of edges of the cleaved plurality of solar cells are touched before removing the solar cells from the curved surface. The method of any one of paragraphs 1F to 12F, comprising the steps of:

14F. Laser scribing the one or more scribe lines on the solar cell wafer;
Applying a conductive adhesive to a part of the top surface of the solar cell wafer before cleaving the solar cell wafer along the one or more scribe lines;
The method of any of paragraphs 1F to 13F, wherein each cleaved solar cell includes a portion of the electrically conductive adhesive bonding agent disposed along a cleaved edge on a top surface thereof.

  15F. Clause 14F. The method of clause 14F comprising laser scribing the one or more scribe lines and thereafter applying the electrically conductive adhesive bonding agent.

  16F. Clause 14F. The method of clause 14F comprising applying the electrically conductive adhesive bond and then laser scribing the one or more scribe lines.

17F. A method of making a solar cell string from a plurality of cleaved solar cells manufactured by the method according to any one of paragraphs 14F to 16F, comprising:
The plurality of cleaved solar cells are a plurality of rectangular solar cells,
Long sides of adjacent rectangular solar cells, a step of arranging the plurality of rectangular solar cells in a state of being overlapped in a shingle-like shape with a part of the electrically conductive adhesive bonding agent interposed therebetween,
Curing the electrically conductive adhesive bond, thereby joining adjacent and overlapping rectangular solar cells to each other and electrically connecting them in series.

  18F. The method according to any one of paragraphs 1F to 17F, wherein the solar cell wafer is a square or pseudo-square silicon solar cell wafer.

1G. Forming a backside metallization pattern on each square solar cell of the one or more square solar cells;
Stencil printing a complete front metallization pattern on each of the one or more square solar cells using a single stencil in a single stencil printing step;
Separating each square solar cell into two or more rectangular solar cells, forming a plurality of rectangular solar cells, each including a complete front metallization pattern and a back metallization pattern, into the one or more square solar cells Forming from a solar cell;
A step of arranging the plurality of rectangular solar cells side by side in a state where the long sides of adjacent rectangular solar cells overlap in a shingle-like shape,
A step of conductively bonding the rectangular solar cells included in each pair of rectangular solar cells adjacent to each other and overlapping with an electrically conductive bonding agent disposed therebetween, wherein one of the rectangular solar cells included in the pair Electrically connecting the front metallization pattern of the rectangular solar cell to the rear metallization pattern of the other rectangular solar cell of the rectangular solar cells included in the pair, thereby connecting the plurality of rectangular solar cells in series. Making a solar cell string, comprising: electrically connecting to a solar cell.

  2G. All parts of the stencil, defining one or more features of the front metallization pattern on the one or more square solar cells, rest on the stencil so as to lie in the plane of the stencil during stencil printing. The method according to paragraph 1G, wherein the connection is made by a physical connection to the part.

  3G. The front metallization pattern on each rectangular solar cell includes a plurality of fingers oriented in a direction perpendicular to the long sides of the rectangular solar cell, and any of the plurality of fingers in the front metallization pattern includes: The method of paragraph 1G wherein the front metallization patterns do not physically connect to each other.

  4G. The method of clause 3G, wherein the plurality of fingers are between about 10 microns and about 90 microns in width.

  5G. The method of clause 3G, wherein the plurality of fingers are between about 10 microns and about 50 microns in width.

  6G. The method of clause 3G, wherein the plurality of fingers are between about 10 microns and about 30 microns in width.

  7G. The method of clause 3G, wherein the plurality of fingers have a height in a direction perpendicular to a front surface of the rectangular solar cell of about 10 microns to about 50 microns.

  8G. The method of paragraph 3G wherein the plurality of fingers have a height in a direction perpendicular to the front surface of the rectangular solar cell of about 30 microns or greater.

  9G. The front metallization pattern on each rectangular solar cell includes a plurality of contact pads, each located at an end of a corresponding finger, disposed parallel to and adjacent to a long edge of the rectangular solar cell, The method according to item 3G.

10G. The back metallization pattern on each rectangular solar cell includes a plurality of contact pads arranged in a row parallel to, and adjacent to, a long edge of the rectangular solar cell,
Each pair of rectangular solar cells that are adjacent and overlap each other, each of the plurality of contact pads on the back surface on one of the rectangular solar cells included in the rectangular solar cell pair, of the rectangular solar cell included in the pair. The method of clause 3G wherein the other rectangular solar cell is aligned with a corresponding finger in the front metallization pattern and placed in electrical connection.

11G. The backside metallization pattern on each rectangular solar cell includes a bus bar extending parallel to and adjacent to a long side edge of the rectangular solar cell,
Each pair of rectangular solar cells that are adjacent to each other and overlapped, the bus bar on one rectangular solar cell included in the rectangular solar cell pair is on the other rectangular solar cell of the rectangular solar cells included in the pair. The method of clause 3G, wherein the plurality of fingers in the front metallization pattern are arranged in overlapping electrical connection.

12G. The front metallization pattern on each rectangular solar cell includes a plurality of contact pads disposed parallel to and adjacent to a long side edge of the rectangular solar cell and each located at an end of a corresponding finger,
The back metallization pattern on each rectangular solar cell includes a plurality of contact pads arranged in a row parallel to, and adjacent to, a long edge of the rectangular solar cell,
Each pair of rectangular solar cells that are adjacent and overlap each other, each of the plurality of contact pads on the back surface on one of the rectangular solar cells included in the rectangular solar cell pair, of the rectangular solar cell included in the pair Clause 3G. The method of Clause 3G wherein the contacts are overlaid and electrically connected to corresponding contact pads in the front metallization pattern on the other rectangular solar cell.

  13G. The rectangular solar cells included in each pair of adjacent and overlapping rectangular solar cells include a discontinuity of an electrically conductive bonding agent disposed between the overlapping front contact pads and the rear contact pads. 12G. The method of clause 12G wherein the portions are conductively joined to each other.

  14G. The rectangular solar cells included in each pair of adjacent and overlapping rectangular solar cells are included in the front metallization pattern of one rectangular solar cell included in the rectangular solar cell pair, and in the rectangular solar cell pair. The method of paragraph 3G wherein the other rectangular solar cells are conductively joined to each other by a discontinuous portion of an electrically conductive cement disposed between overlapping ends of the fingers in the backside metallization pattern.

15G. The rectangular solar cells included in each pair of adjacent and overlapping rectangular solar cells are included in the front metallization pattern of one rectangular solar cell included in the rectangular solar cell pair, and in the rectangular solar cell pair. Conductively bonding to each other by a dashed or solid electrically conductive bonding agent disposed between overlapping ends of the plurality of fingers in the backside metallization pattern of the other rectangular solar cell;
The method of clause 3G, wherein the dashed or solid electrically conductive bonding agent electrically interconnects one or more of the plurality of fingers.

16G. The front metallization pattern on each rectangular solar cell includes a plurality of contact pads, each positioned at an end of a corresponding finger, disposed parallel to and adjacent to a long side edge of the rectangular solar cell,
The rectangular solar cells included in each pair of adjacent and overlapping rectangular solar cells include the plurality of contact pads of the front metallization pattern of one of the rectangular solar cells included in the rectangular solar cell pair, and the rectangular solar cell. The method of paragraph 3G wherein the non-continuous portions of the electrically conductive bonding agent disposed between the backside metallization pattern of the other rectangular solar cell included in the cell pair are conductively bonded to each other.

17G. The front metallization pattern on each rectangular solar cell includes a plurality of contact pads, each positioned at an end of a corresponding finger, disposed parallel to and adjacent to a long side edge of the rectangular solar cell,
The rectangular solar cells included in each pair of adjacent and overlapping rectangular solar cells include the plurality of contact pads of the front metallization pattern of one of the rectangular solar cells included in the rectangular solar cell pair, and the rectangular solar cell. Conductive bonding with each other by a dashed or solid line electrically conductive bonding agent disposed between the back metallization pattern of the other rectangular solar cell included in the battery pair,
The method of clause 3G, wherein the dashed or solid electrically conductive bonding agent electrically interconnects one or more of the plurality of fingers.

  18G. The method of any of paragraphs 1G to 17G, wherein the front metallization pattern is formed from a silver paste.

1H. A method of manufacturing a plurality of solar cells, comprising:
Depositing one or more front amorphous silicon layers on the front side of the crystalline silicon wafer, wherein the front amorphous silicon layers are irradiated with light during operation of the plurality of solar cells;
Depositing one or more backside amorphous silicon layers on the backside of the crystalline silicon wafer opposite the front side of the crystalline silicon wafer;
Patterning the one or more front amorphous silicon layers to form one or more front trenches in the one or more front amorphous silicon layers;
Depositing a front passivation layer on the one or more front amorphous silicon layers and in the one or more front trenches;
Patterning the one or more backside amorphous silicon layers to form one or more backside trenches in the one or more backside amorphous silicon layers, wherein each of the one or more backside trenches is , Formed alongside a corresponding one of the one or more front trenches;
Depositing a back surface passivation layer on the one or more back surface amorphous silicon layers and in the one or more back surface trenches;
Cleaving the crystalline silicon wafer at one or more cleavage planes, wherein each cleavage plane is centered or substantially centered on a different pair of corresponding front and back trenches. A method comprising:

  2H. Clause 1H. The method of clause 1H comprising forming the one or more front trenches and penetrating the front amorphous silicon layer to reach the front surface of the crystalline silicon wafer.

  3H. Clause 1H. The method of clause 1H comprising forming the one or more backside trenches and penetrating the one or more backside amorphous silicon layers to reach the backside of the crystalline silicon wafer.

  4H. The method of paragraph 1H comprising forming the front passivation layer and the back passivation layer from a transparent conductive oxide.

  5H. The method according to paragraph 1H, wherein a laser is used to cause thermal stress in the crystalline silicon wafer to cleave the crystalline silicon wafer at the one or more cleavage planes.

  6H. Clause 1H. The method of clause 1H comprising mechanically cleaving the crystalline silicon wafer at the one or more cleavage planes.

  7H. The method of paragraph 1H, wherein the one or more front-side amorphous crystalline silicon layers form an np junction with the crystalline silicon wafer.

  8H. The method according to Item 7H, comprising cleaving the crystalline silicon wafer from the back surface side.

  9H. The method of paragraph 1H, wherein the one or more backside amorphous crystalline silicon layers form an np junction with the crystalline silicon wafer.

  10H. Item 9H. The method according to Item 9H, further comprising cleaving the crystalline silicon wafer from a front side thereof.

11H. A method of manufacturing a plurality of solar cells, comprising:
Forming one or more trenches in a first surface of the crystalline silicon wafer;
Depositing one or more amorphous silicon layers on the first surface of the crystalline silicon wafer;
Depositing a passivation layer in the one or more trenches on the first surface of the crystalline silicon wafer and on the one or more amorphous silicon layers;
Depositing one or more amorphous silicon layers on a second surface of the crystalline silicon wafer opposite the first surface of the crystalline silicon wafer;
Cleaving the crystalline silicon wafer at one or more cleavage planes, wherein each cleavage plane is centered or substantially centered on a different one of the one or more trenches. A method comprising: and

  12H. Clause 11H. The method of clause 11H comprising forming the passivation layer from a transparent conductive oxide.

  13H. Clause 11H. The method of clause 11H comprising using a laser to cause thermal stress in the crystalline silicon wafer to cleave the crystalline silicon wafer at the one or more cleavage planes.

  14H. Clause 11H. The method of clause 11H comprising mechanically cleaving the crystalline silicon wafer at the one or more cleavage planes.

  15H. The method of paragraph 11H, wherein the one or more amorphous crystalline silicon layers on the first surface form an np junction with the crystalline silicon wafer.

  16H. The method of clause 11H, wherein the one or more amorphous crystalline silicon layers on the second surface form an np junction with the crystalline silicon wafer.

  17H. Clause 11H. The method of clause 11H, wherein the first surface of the crystalline silicon wafer will be illuminated with light during operation of the plurality of solar cells.

  18H. Clause 11H. The method of clause 11H wherein the second surface of the crystalline silicon wafer will be illuminated with light during operation of the plurality of solar cells.

19H. Ends of adjacent solar cells overlap with each other in a shingle-like shape and are conductively joined, and a plurality of solar cells each having a plurality of solar cells arranged side by side in a state where the adjacent solar cells are electrically connected in series Equipped with a supercell
Each solar cell is
A crystalline silicon substrate,
One or more first surface amorphous silicon layers disposed on a first surface of the crystalline silicon substrate to form an np junction;
One or more second surface amorphous silicon layers disposed on a second surface of the crystalline silicon substrate opposite the first surface of the crystalline silicon substrate;
At the edge of the one or more first surface amorphous silicon layers, at the edge of the one or more second surface amorphous silicon layers, or at the edge of the one or more first surface amorphous silicon layers, and at the one or more A plurality of passivation layers to prevent carrier recombination at the edge of the second surface amorphous silicon layer.

  20H. Clause 19H. The solar panel of Clause 19H, wherein the plurality of passivation layers include a transparent conductive oxide.

  21H. The plurality of supercells are arranged in a single row, or in two or more parallel rows, to be illuminated by solar radiation during operation of the solar panel, Item 19. The solar panel according to Item 19H, wherein

Z1. A solar module,
N (greater than or equal to or equal to about 250) rectangular or substantially rectangular silicon solar cells arranged as a plurality of series-connected supercells in two or more parallel rows, each supercell being However, having a plurality of silicon solar cells, the plurality of silicon solar cells, the long sides of adjacent silicon solar cells are overlapped, and are directly conductively joined to each other by an electric and heat conductive adhesive, so that the inside of the supercell is The plurality of silicon solar cells are arranged side by side in a state of being electrically connected in series, a rectangular or substantially rectangular silicon solar cell,
And one or more bypass diodes.
Each pair of adjacent parallel rows in the solar module is conductively joined to a backside electrical contact on a centrally located solar cell in one of the rows included in the pair, and in the other row included in the pair. Electrically connected by a bypass diode conductively connected to the backside electrical contact on the adjacent solar cell,
Solar module.

  Z2. Each pair of adjacent parallel rows is conductively joined to a backside electrical contact on a solar cell in one row of the pair and a backside electrical contact on an adjacent solar cell in the other row of the pair. The solar module according to paragraph Z1, wherein the solar module is electrically connected by at least one other bypass diode that is conductively joined to the section.

  Z3. Each pair of adjacent parallel rows is conductively joined to a backside electrical contact on a solar cell in one row of the pair and a backside electrical contact on an adjacent solar cell in the other row of the pair. The solar module of paragraph Z2, wherein the solar module is electrically connected by at least one other bypass diode that is conductively joined to the section.

  Z4. The electrically and thermally conductive adhesive has a thickness in a direction perpendicular to the plurality of solar cells of less than or equal to about 50 microns and a thermal conductivity in a direction perpendicular to the plurality of solar cells of about 50 microns. The solar module of paragraph Z1 forming a plurality of junctions between adjacent solar cells that is greater than or equal to 1.5 W / (meter-K).

  Z5. The solar module according to paragraph Z1, wherein the plurality of supercells are enclosed in a thermoplastic olefin layer between a front sheet and a rear sheet made of glass.

  Z6. The plurality of conductive junctions between overlapping solar cells can be connected to the plurality of supercells and the glass front sheet at a temperature in a range of about −40 ° C. to about 100 ° C. without damaging the solar module. The solar module of paragraph Z1, wherein the plurality of supercells are provided with a mechanical compliance that accommodates thermal expansion mismatch in a direction parallel to the two or more parallel rows.

  Z7. N is greater than or equal to about 300, greater than or equal to about 350, greater than or equal to about 400, or greater than or equal to about 450, or greater than or equal to about 500, or greater than or equal to about 550. The solar module of any one of paragraphs Z1-Z6, wherein is greater than or equal to, greater than or equal to about 600, greater than or equal to about 650, or greater than or equal to about 700. .

  Z8. The plurality of supercells are electrically connected to each other to be greater than or equal to about 120 volts, greater than or equal to about 180 volts, greater than or equal to about 240 volts, greater than or equal to about 300 volts, or more. Equal to, greater than or equal to about 360 volts, greater than or equal to about 420 volts, greater than or equal to about 480 volts, greater than or equal to about 540 volts, or greater than about 600 volts; A solar module according to any one of the preceding paragraphs Z1 to Z7, which provides a high DC voltage equivalent thereto.

Z9. A solar module according to item Z1,
An inverter electrically connected to the solar module and configured to convert a DC output from the solar module to provide an AC output.

  Z10. The solar energy system of clause Z9, wherein the inverter has no DC-DC boost components.

  Z11. The solar energy system of paragraph Z9, wherein the inverter is configured to operate the solar module at a DC voltage higher than a minimum set to avoid reverse biasing the solar cell.

  Z12. The solar energy system according to paragraph Z11, wherein the minimum voltage value is temperature-dependent.

  Z13. The solar energy system of paragraph Z9, wherein the inverter is configured to recognize a reverse bias condition and operate the solar module at a voltage that avoids the reverse bias condition.

  Z14. The solar energy system of paragraph Z13, wherein the inverter is configured to operate the solar module in a maximum region of a voltage-current output curve of the solar module to avoid the reverse bias state.

  Z15. The solar energy system of any one of clauses Z9 to Z14, wherein the inverter is a microinverter integrated with the solar module.

This disclosure is illustrative and not limiting. Further modifications will become apparent to those skilled in the art in light of the present disclosure, and such further modifications are intended to be included within the scope of the appended claims.
[Item 1]
A plurality of supercells arranged in two or more parallel rows, wherein each supercell has a long side of an adjacent silicon solar cell overlapped and is directly conductively bonded to each other to form an adjacent silicon solar cell. Having a plurality of rectangular or substantially rectangular silicon solar cells arranged side by side in a state of being electrically connected in series, and a plurality of super cells,
A hidden tap contact pad, located behind the first solar cell, that does not conduct substantial current during normal operation;
With
The first solar cell is located at an intermediate position along the first supercell among the plurality of supercells in the first row of the two or more parallel rows of supercells, and the hidden tap contact pad is provided. A solar module electrically connected in parallel with at least a second solar cell in a second of the two or more parallel rows of the supercell.
[Item 2]
An electrical interconnect that is joined to the hidden tap contact pad and electrically interconnects the hidden tap contact pad to the second solar cell;
The electrical interconnect does not extend substantially across the length of the first solar cell;
The solar module of claim 1, wherein the backside metallization pattern on the first solar cell provides a conductive path to the hidden tap contact pad having a sheet resistance less than or equal to about 5 ohms / square.
[Item 3]
The plurality of supercells are arranged in the three or more parallel rows extending across the width of the solar module perpendicular to three or more parallel rows;
The hidden tap contact pad is electrically connected to a hidden contact pad on at least one solar cell in each of the three or more parallel rows of the supercell to connect the three or more of the supercells. Electrical connection of parallel rows in parallel,
Item 1 wherein at least one bus connection to at least one of the plurality of hidden tap contact pads or to an interconnect between the plurality of hidden tap contact pads connects to a bypass diode or other electronic device. The solar module according to 1.
[Item 4]
A flexible electrical interconnect that conductively connects to the hidden tap contact pad and electrically connects it to the second solar cell;
The portion of the flexible electrical interconnect, which is conductively bonded to the hidden tap contact pad, is a ribbon formed of copper and has a thickness in a direction perpendicular to the surface of the solar cell to which it is bonded. Less than or equal to 50 microns,
The conductive junction between the hidden tap contact pad and the flexible electrical interconnect is connected to the flexible electrical interconnect at a temperature in the range of about -40C to about 180C without damaging the solar module. Withstand the thermal expansion mismatch between the first solar cell and the flexible interconnect and accommodate the relative movement between the first and second solar cells resulting from the thermal expansion. , A solar module according to item 1.
[Item 5]
The solar module of claim 1, wherein in operation of the solar module, the first hidden contact pad is capable of conducting a current greater than a current generated by any one of the plurality of solar cells.
[Item 6]
The solar module of claim 1, wherein a front surface of the first solar cell overlying the first hidden tap contact pad is not occupied by a contact pad or any other interconnect feature.
[Item 7]
Item 1 wherein no area of the front surface of the first solar cell where non-overlapping portions of adjacent solar cells in the first supercell overlap is occupied by contact pads or any other interconnect features. The described solar module.
[Item 8]
2. The solar module of item 1, wherein in each supercell, most of the plurality of batteries do not have a hidden tap contact pad.
[Item 9]
9. The solar module of item 8, wherein the plurality of cells having a hidden tap contact pad have a larger light collection area than the plurality of cells without a hidden tap contact pad.
[Item 10]
Item 2. The solar module according to item 1, wherein the solar module is arranged in a shingle-like shape that overlaps with another solar module to which the electric connection is made in the overlapping area.
[Item 11]
A solar module,
Glass front sheet,
A back sheet,
A plurality of supercells, each having a plurality of rectangular or substantially rectangular silicon solar cells, arranged in two or more parallel rows between the glass front sheet and the rear sheet; Rectangular or substantially rectangular silicon solar cells, the long sides of adjacent silicon solar cells overlap and are directly and conductively joined to each other flexibly, and are arranged side by side with the adjacent silicon solar cells electrically connected in series, Multiple supercells,
A first flexible electrical interconnect that is strongly conductively bonded to the first of the plurality of supercells;
With
The plurality of flexible conductive junctions between overlapping solar cells can be connected to the plurality of supercells and the glass front sheet at a temperature in a range of about −40 ° C. to about 100 ° C. without damaging the solar module. Providing the plurality of supercells with mechanical compliance that accommodates a mismatch in thermal expansion in a direction parallel to the two or more parallel rows between the plurality of supercells;
The strong conductive junction between the first supercell and the first flexible electrical interconnect provides the first conductive layer at a temperature in the range of about −40 ° C. to about 180 ° C. without damaging the solar module. A solar module for adapting a flexible electrical interconnect to a thermal expansion mismatch between the first supercell and the first flexible interconnect in a direction perpendicular to the two or more parallel rows. .
[Item 12]
The plurality of conductive junctions between overlapping adjacent solar cells in a supercell utilize a different conductive adhesive than the plurality of conductive junctions between the supercell and the flexible electrical interconnect. 12. The solar module according to item 11.
[Item 13]
13. A solar module according to item 12, wherein both conductive adhesives can be cured in the same processing step.
[Item 14]
12. The solar module of item 11, wherein the conductive junction on one side of at least one solar cell in the supercell utilizes a different conductive adhesive than the conductive junction on the other side.
[Item 15]
Item 15. The solar module according to item 14, wherein both conductive adhesives can be cured in the same processing step.
[Item 16]
14. The method of claim 11, wherein the plurality of conductive junctions between overlapping adjacent solar cells accommodate differential movements greater than or equal to about 15 microns between each cell and the glass frontsheet. Solar module.
[Item 17]
The plurality of conductive junctions between overlapping adjacent solar cells have a thickness in a direction perpendicular to the plurality of solar cells less than or equal to about 50 microns, and a thickness in a direction perpendicular to the plurality of solar cells. 12. The solar module according to item 11, wherein the thermal conductivity is higher than or equal to about 1.5 W / (meter-K).
[Item 18]
12. The solar module of item 11, wherein the first flexible electrical interconnect withstands thermal expansion or contraction of the first flexible interconnect greater than or equal to about 40 microns.
[Item 19]
The portion of the first flexible electrical interconnect, which is conductively bonded to the supercell, is in the form of a ribbon made of copper, and has a thickness in the direction perpendicular to the surface of the solar cell to which it is bonded. 12. The solar module according to item 11, wherein the solar module is smaller than or equal to 50 microns.
[Item 20]
The portion of the first flexible electrical interconnect, which is conductively bonded to the supercell, is in the form of a ribbon made of copper, and has a thickness in the direction perpendicular to the surface of the solar cell to which it is bonded. Item 20. The solar module of item 19, which is less than or equal to 30 microns.
[Item 21]
The first flexible electrical interconnect has an integral conductive copper portion that is conductively bonded to the solar cell, provides higher conductivity than a portion of the first flexible electrical interconnect, and is not bonded to the solar cell. Item 19. The solar module according to item 19.
[Item 22]
20. The first flexible electrical interconnect according to item 19, wherein the width in a direction perpendicular to the flow of current through the interconnect at a surface of the surface of the solar cell is greater than or equal to about 10 mm. Solar module.
[Item 23]
20. The solar module of item 19, wherein the first flexible electrical interconnect is conductively joined to a conductor proximate to the solar cell, providing higher conductivity than the first electrical interconnect.
[Item 24]
Item 12. The solar module according to item 11, wherein the solar module is arranged in a shingle-like shape overlapping with another solar module to which it is electrically connected in the overlapping area.
[Item 25]
Glass front sheet,
A back sheet,
A plurality of supercells, each having a plurality of rectangular or substantially rectangular silicon solar cells, arranged in two or more parallel rows between the glass front sheet and the rear sheet; Rectangular or substantially rectangular silicon solar cells, the long sides of adjacent silicon solar cells overlap and are directly and conductively joined to each other flexibly, and are arranged side by side with the adjacent silicon solar cells electrically connected in series, Multiple supercells,
A first flexible electrical interconnect that is strongly conductively bonded to the first of the plurality of supercells;
With
The plurality of flexible conductive junctions between overlapping solar cells are formed from a first conductive adhesive and have a rigidity less than or equal to about 800 megapascals;
The strong conductive junction between the first supercell and the first flexible electrical interconnect is formed from a second conductive adhesive and has a rigidity greater than or equal to about 2000 megapascals; Solar module.
[Item 26]
26. The solar module according to item 25, wherein, unlike the first conductive adhesive and the second conductive adhesive, both conductive adhesives can be cured in the same processing step.
[Item 27]
The plurality of conductive junctions between overlapping adjacent solar cells have a thickness in a direction perpendicular to the plurality of solar cells less than or equal to about 50 microns, and a thickness in a direction perpendicular to the plurality of solar cells. 26. The solar module of item 25, wherein the thermal conductivity is greater than or equal to about 1.5 W / (meter-K).
[Item 28]
26. The solar module according to item 25, wherein the solar module is arranged in a shingle-like configuration overlapping with another solar module to which the electric connection is made in the overlapping area.
[Item 29]
A first row of bus bars or contact pads arranged parallel and adjacent to a first outer edge of the silicon wafer; and a second row of the silicon wafer opposite and parallel to the first edge of the silicon wafer. Obtaining or providing said silicon wafer including a front metallization pattern including a second bus bar or contact pad row disposed parallel and adjacent to an outer edge;
Separating the silicon wafer along one or more scribe lines parallel to the first outer edge and the second outer edge of the silicon wafer to form a plurality of rectangular solar cells; The bus bar or the contact pad row is disposed in parallel with and adjacent to the long outer edge of the first rectangular solar cell of the plurality of rectangular solar cells, and the second bus bar or the contact pad row is disposed in the plurality of rectangular solar cells. Arranged parallel to and adjacent to the long outer edge of the second rectangular solar cell;
The plurality of rectangular solar cells, the long sides of adjacent solar cells overlap and are conductively joined to each other, and the adjacent solar cells are arranged side by side in a state of being electrically connected in series, and forming a supercell.
With
The method according to claim 1, wherein the first bus bar or contact pad row on the first rectangular solar cell of the plurality of rectangular solar cells is overlapped and conductively connected to the bottom surface of an adjacent rectangular solar cell in the supercell.
[Item 30]
30. The bottom surface of an adjacent rectangular solar cell in the supercell overlaps and is conductively connected to the second bus bar or contact pad row on the second rectangular solar cell of the plurality of rectangular solar cells. the method of.
[Item 31]
30. The method according to item 29, wherein the silicon wafer is a square or pseudo-square silicon wafer.
[Item 32]
32. The method according to item 31, wherein the silicon wafer has a side having a length of about 125 mm or a length of about 156 mm.
[Item 33]
32. The method according to item 31, wherein the length to width ratio of each rectangular solar cell is between about 2: 1 and about 20: 1.
[Item 34]
30. The method according to item 29, wherein the silicon wafer is a crystalline silicon wafer.
[Item 35]
The first bus bar or contact pad row and the second bus bar or contact pad row are connected to a plurality of edge regions of the silicon wafer that convert light to electricity with lower efficiency than a plurality of central regions of the silicon wafer. Item 30. The method according to Item 29.
[Item 36]
A first plurality of parallel fingers extending inward from the first outer edge of the silicon wafer and electrically connected to the first bus bar or contact pad row; and the second bus bar. Or a second plurality of parallel fingers extending inward from the second outer edge of the silicon wafer for making electrical connection to a contact pad row.
[Item 37]
The front metallization pattern is oriented at least parallel to the first bus bar or contact pad row and the second bus bar or contact pad row, and the first bus bar or contact pad row and the second bus bar Or a third bus bar or contact pad row located between the third bus bar or contact pad row and a third bus bar or contact pad row oriented in a direction perpendicular to the third bus bar or contact pad row. A third plurality of parallel fingers for connecting, wherein the third bus bar or contact pad row comprises a plurality of rectangular solar cells after the silicon wafer is separated to form the plurality of rectangular solar cells. Of the third rectangular solar cell is disposed parallel to and adjacent to the long outer edge of the third rectangular solar cell The method according to 29.
[Item 38]
30. The method of item 29, comprising applying a conductive adhesive to the first bus bar or contact pad row to conductively join the first rectangular solar cell to an adjacent solar cell.
[Item 39]
39. The method of claim 38, wherein the metallization pattern includes a barrier configured to contain the spread of the conductive adhesive.
[Item 40]
39. The method according to item 38, comprising applying the conductive adhesive by screen printing.
[Item 41]
39. The method according to item 38, comprising applying the conductive adhesive by inkjet printing.
[Item 42]
39. The method according to item 38, wherein the conductive adhesive is applied before forming the one or more scribe lines in the silicon wafer.
[Item 43]
The step of separating the silicon wafer along the one or more scribe lines includes drawing a vacuum between a bottom surface of the silicon wafer and a curved support surface, bending the silicon wafer toward the curved support surface, 30. The method according to item 29, comprising cleaving the silicon wafer along the one or more scribe lines.
[Item 44]
The silicon wafer is a pseudo-square silicon wafer including a plurality of chamfered corners, and after separating the silicon wafer to form the plurality of rectangular solar cells, one or more of the rectangular solar cells The plurality includes one or more of the plurality of chamfered corners,
The interval between the scribe lines, the width perpendicular to the major axis of the rectangular solar cell including a plurality of chamfered corners, than the width perpendicular to the major axis of the rectangular solar cell without a plurality of chamfered corners Enlargement is selected to compensate for the chamfered corners, so that each of the plurality of rectangular solar cells in the supercell has substantially the area exposed to light during operation of the supercell. 30. The method according to item 29, wherein the front surface is the same.
[Item 45]
30. The method of item 29, comprising placing the supercells in a layered structure between a transparent front sheet and a back sheet, and laminating the layered structure.
[Item 46]
The step of laminating the layered structure completes the curing of the conductive adhesive disposed between the adjacent rectangular solar cells in the supercell, and conductively joins the adjacent rectangular solar cells to each other. Item 45. The method according to Item 45.
[Item 47]
The supercells are arranged in the laminar structure in one of two or more parallel rows of supercells, and the backsheet is positioned at a gap between two or more parallel rows of the supercells and A white sheet comprising a plurality of parallel dark stripes having a position and a width corresponding to the width, whereby a plurality of white portions of the back sheet in the assembled module are replaced by two or more of the supercells; 46. The method of item 45, wherein the method is not visible through more gaps between parallel rows.
[Item 48]
Item 46. The method according to Item 45, wherein the front sheet and the rear sheet are glass sheets, and the supercell is enclosed in a thermoplastic olefin layer sandwiched between the glass sheets.
[Item 49]
30. The method according to item 29, comprising arranging the supercell in a first module including a junction box that is fitted with a second junction box of a second solar module.
[Item 50]
Advancing the solar cell wafer along the curved surface;
A vacuum is drawn between the curved surface and the bottom surface of the solar cell wafer to bend the solar cell wafer toward the curved surface, whereby the solar cell is moved along one or more scribe lines prepared in advance. Cleaving the battery wafer and separating a plurality of solar cells from the solar cell wafer;
A method for manufacturing a solar cell, comprising:
[Item 51]
51. The method of claim 50, wherein the curved surface is a curved portion of a top surface of a vacuum manifold that draws the vacuum against the bottom surface of the solar cell wafer.
[Item 52]
The vacuum drawn by the vacuum manifold against the bottom surface of the solar cell wafer changes along the direction of movement of the solar cell wafer, and the solar cell wafer is cleaved, which is the strongest in the area of the vacuum manifold. 50. The method according to item 50.
[Item 53]
Along the curved top surface of the vacuum manifold, transporting the solar cell wafer by a perforated belt, wherein the vacuum is applied to the bottom surface of the solar cell wafer through a plurality of perforations of the perforated belt. 53. A method according to item 51 or 52, comprising the step of drawing.
[Item 54]
The plurality of perforations of the perforated belt are arranged such that a leading edge and a trailing edge of the solar cell wafer along the moving direction of the solar cell wafer lie on at least one perforation of the perforated belt. 53. The method according to item 53.
[Item 55]
Advancing the solar cell wafer along the flat region of the upper surface of the vacuum manifold to reach a transition curved region of the upper surface of the vacuum manifold having a first curvature, after which the solar cell wafer is cleaved; Moving the solar cell wafer into a cleavage region on the upper surface of the vacuum manifold, wherein the cleavage region of the vacuum manifold has a second curvature higher than the first curvature. 55. The method according to any one of items 50 to 54.
[Item 56]
56. The method of claim 55, wherein the curvature of the transition region is defined by a continuous geometric function of increasing curvature.
[Item 57]
57. The method according to item 56, wherein the curvature of the cleavage region is defined by a continuous geometric function in which the curvature increases.
[Item 58]
58. The method of item 57, comprising advancing the plurality of cleaved solar cells into a post-cleavage region of the vacuum manifold having a third curvature greater than the second curvature.
[Item 59]
58. The method of claim 57, wherein the curvatures of the transition curve region, the cleavage region, and the post-cleavage region are defined by a single continuous geometric function of increasing curvature.
[Item 60]
Item 60. The method according to Item 57, 58 or 59, wherein the curvature increasing continuous geometric function is clothoid.
[Item 61]
At one end of each scribe line, and then at the opposite end of each scribe line, a stronger vacuum was drawn between the solar cell wafer and the curved surface to create a single cleavage tear along each scribe line. 61. The method of any one of items 50 to 60, comprising providing an asymmetric stress distribution along each scribe line that promotes nucleation and propagation.
[Item 62]
Removing the cleaved plurality of solar cells from the curved surface, wherein the plurality of edges of the cleaved plurality of solar cells are touched before removing the solar cells from the curved surface. 62. The method according to any one of items 50-61, comprising no steps.
[Item 63]
Laser scribing the one or more scribe lines on the solar cell wafer;
Applying an electrically conductive adhesive to a portion of the top surface of the solar cell wafer before cleaving the solar cell wafer along the one or more scribe lines;
Prepared,
63. The method of any of items 50-62, wherein each cleaved solar cell comprises a portion of the electrically conductive adhesive bonding agent disposed along a cleaved edge on a top surface thereof.
[Item 64]
64. The method of claim 63, comprising laser scribed the one or more scribe lines, and then applying the electrically conductive adhesive bonding agent.
[Item 65]
65. The method of claim 64, comprising applying the electrically conductive adhesive bonding agent, and then laser scribing the one or more scribe lines.
[Item 66]
66. A method of making a solar cell string from a plurality of cleaved solar cells manufactured by the method according to any one of items 63 to 65,
The plurality of cleaved solar cells are a plurality of rectangular solar cells,
Long sides of adjacent rectangular solar cells, a step of arranging the plurality of rectangular solar cells in a state of being overlapped in a shingle-like shape with a part of the electrically conductive adhesive bonding agent interposed therebetween,
Curing the electrically conductive adhesive bonding agent, thereby joining adjacent and overlapping rectangular solar cells to each other, and electrically connecting them in series; and
A method comprising:
[Item 67]
67. The method according to any one of items 50 to 66, wherein the solar cell wafer is a square or pseudo-square silicon solar cell wafer.
[Item 68]
Forming a backside metallization pattern on each square solar cell of the one or more square solar cells;
Stencil printing a complete front metallization pattern on each of the one or more square solar cells using a single stencil in a single stencil printing step;
Separating each square solar cell into two or more rectangular solar cells, forming a plurality of rectangular solar cells, each including a complete front metallization pattern and a back metallization pattern, into the one or more square solar cells Forming from a solar cell;
A step of arranging the plurality of rectangular solar cells side by side in a state where the long sides of adjacent rectangular solar cells overlap in a shingle-like shape,
A step of conductively joining the rectangular solar cells included in each pair of adjacent and overlapping rectangular solar cells with an electrically conductive bonding agent disposed therebetween, wherein one of the rectangular solar cells included in the pair Electrically connecting the front metallization pattern of the rectangular solar cell to the rear metallization pattern of the other rectangular solar cell of the rectangular solar cells included in the pair, thereby connecting the plurality of rectangular solar cells in series. Electrical connection to the process and
A method of making a solar cell string, comprising:
[Item 69]
All parts of the stencil, defining one or more features of the front metallization pattern on the one or more square solar cells, rest on the stencil so as to lie in the plane of the stencil during stencil printing. 68. The method according to item 68, wherein the method is stopped by a physical connection to the part.
[Item 70]
The front metallization pattern on each rectangular solar cell includes a plurality of fingers oriented in a direction perpendicular to a long side of the rectangular solar cell, and any of the plurality of fingers in the front metallization pattern includes: 69. The method according to item 68, wherein the front metallization pattern does not physically connect to each other.
[Item 71]
70. The method of claim 68, wherein the plurality of fingers are between about 10 microns and about 90 microns in width.
[Item 72]
70. The method of claim 68, wherein the plurality of fingers are between about 10 microns and about 50 microns in width.
[Item 73]
70. The method of claim 68, wherein the plurality of fingers are between about 10 microns and about 30 microns in width.
[Item 74]
70. The method of claim 68, wherein the plurality of fingers have a height in a direction perpendicular to a front surface of the rectangular solar cell of about 10 microns to about 50 microns.
[Item 75]
69. The method of claim 68, wherein the plurality of fingers have a height in a direction perpendicular to a front surface of the rectangular solar cell of about 30 microns or greater.
[Item 76]
The front metallization pattern on each rectangular solar cell includes a plurality of contact pads, each located at an end of a corresponding finger, disposed parallel to and adjacent to a long edge of the rectangular solar cell, Item 68. The method according to Item 68.
[Item 77]
The back metallization pattern on each rectangular solar cell includes a plurality of contact pads arranged in a row parallel to, and adjacent to, a long edge of the rectangular solar cell,
Each pair of rectangular solar cells that are adjacent and overlap each other, each of the plurality of contact pads on the back surface on one of the rectangular solar cells included in the rectangular solar cell pair, of the rectangular solar cell included in the pair 69. The method according to item 68, wherein the other rectangular solar cell is aligned with and electrically connected to a corresponding finger in the front metallization pattern.
[Item 78]
The backside metallization pattern on each rectangular solar cell includes a bus bar extending parallel to and adjacent to a long side edge of the rectangular solar cell,
Each pair of rectangular solar cells adjacent and overlapping each other has the bus bar on one rectangular solar cell included in the rectangular solar cell pair, and the bus bar on the other rectangular solar cell among the rectangular solar cells included in the pair. 69. The method of claim 68, wherein the plurality of fingers in the front metallization pattern are positioned in overlapping electrical connection.
[Item 79]
The front metallization pattern on each rectangular solar cell includes a plurality of contact pads disposed parallel to and adjacent to a long side edge of the rectangular solar cell and each located at an end of a corresponding finger,
The back metallization pattern on each rectangular solar cell includes a plurality of contact pads arranged in a row parallel to, and adjacent to, a long edge of the rectangular solar cell,
Each pair of rectangular solar cells that are adjacent and overlap each other, each of the plurality of contact pads on the back surface on one of the rectangular solar cells included in the rectangular solar cell pair, of the rectangular solar cell included in the pair 70. The method according to item 68, wherein the other rectangular solar cell is disposed so as to overlap with and electrically connect to a corresponding contact pad in the front metallization pattern.
[Item 80]
The rectangular solar cells included in each pair of adjacent and overlapping rectangular solar cells include a discontinuity of an electrically conductive bonding agent disposed between the overlapping front contact pads and the rear contact pads. 68. The method of paragraph 68, wherein the portions are conductively joined to each other.
[Item 81]
The rectangular solar cells included in each pair of adjacent and overlapping rectangular solar cells are included in the front metallization pattern of one rectangular solar cell included in the rectangular solar cell pair, and in the rectangular solar cell pair. 69. The method of claim 68, wherein the plurality of fingers are conductively joined to each other by a discontinuous portion of an electrically conductive cement disposed between overlapping ends of the plurality of fingers in the backside metallization pattern of the other rectangular solar cell.
[Item 82]
The rectangular solar cells included in each pair of adjacent and overlapping rectangular solar cells are included in the front metallization pattern of one rectangular solar cell included in the rectangular solar cell pair, and in the rectangular solar cell pair. Conductively bonding to each other by a dashed or solid electrically conductive bonding agent disposed between overlapping ends of the plurality of fingers in the backside metallization pattern of the other rectangular solar cell;
69. The method of claim 68, wherein the dashed or solid electrically conductive bonding agent electrically interconnects one or more of the plurality of fingers.
[Item 83]
The front metallization pattern on each rectangular solar cell includes a plurality of contact pads, each positioned at an end of a corresponding finger, disposed parallel to and adjacent to a long side edge of the rectangular solar cell,
The rectangular solar cells included in each pair of adjacent and overlapping rectangular solar cells include the plurality of contact pads of the front metallization pattern of one of the rectangular solar cells included in the rectangular solar cell pair, and the rectangular solar cell. 70. The method according to item 68, wherein the two rectangular solar cells included in the pair of cells are conductively joined to each other by a discontinuous portion of the electrically conductive bonding agent disposed between the backside metallization patterns.
[Item 84]
The front metallization pattern on each rectangular solar cell includes a plurality of contact pads, each positioned at an end of a corresponding finger, disposed parallel to and adjacent to a long side edge of the rectangular solar cell,
The rectangular solar cells included in each pair of adjacent and overlapping rectangular solar cells include the plurality of contact pads of the front metallization pattern of one of the rectangular solar cells included in the rectangular solar cell pair, and the rectangular solar cell. Conductive bonding with each other by a dashed or solid line electrically conductive bonding agent disposed between the back metallization pattern of the other rectangular solar cell included in the battery pair,
69. The method of claim 68, wherein the dashed or solid electrically conductive bonding agent electrically interconnects one or more of the plurality of fingers.
[Item 85]
85. The method according to any one of items 68 to 84, wherein the front metallization pattern is formed from a silver paste.
[Item 86]
N (greater than or equal to or equal to about 250) rectangular or substantially rectangular silicon solar cells arranged as a plurality of series-connected supercells in two or more parallel rows, each supercell being However, having a plurality of silicon solar cells, the plurality of silicon solar cells, the long sides of adjacent silicon solar cells are overlapped, and are directly conductively joined to each other by an electric and heat conductive adhesive, so that the inside of the supercell is The plurality of silicon solar cells are arranged side by side in a state of being electrically connected in series, a rectangular or substantially rectangular silicon solar cell,
With less than one bypass diode per 25 solar cells
With
The electrically and thermally conductive adhesive has a thickness in a direction perpendicular to the plurality of solar cells of less than or equal to about 50 microns and a thermal conductivity in a direction perpendicular to the plurality of solar cells of about 50 microns. A solar module that forms multiple junctions between adjacent solar cells that is greater than or equal to 1.5 W / (meter-K).
[Item 87]
87. The solar module according to item 86, wherein the plurality of supercells are encapsulated in a thermoplastic olefin layer between a front sheet and a back sheet.
[Item 88]
89. The solar module according to item 86, wherein the plurality of supercells are enclosed between a front sheet and a rear sheet made of glass.
[Item 89]
Less than one bypass diode per 30 solar cells, or less than one bypass diode per 50 solar cells, or less than one bypass diode per 100 solar cells, or only a single bypass diode 89. The solar module according to item 86, comprising or without a bypass diode.
[Item 90]
89. The solar module of item 86, comprising no bypass diode, or only a single bypass diode, or no more than three, no more than six, or no more than ten bypass diodes.
[Item 91]
The plurality of conductive junctions between overlapping solar cells can be connected to the plurality of supercells and the glass front sheet at a temperature in a range of about −40 ° C. to about 100 ° C. without damaging the solar module. 87. The solar module of item 86, wherein the plurality of supercells are provided with mechanical compliance that accommodates a thermal expansion mismatch in a direction parallel to the two or more parallel rows during the plurality.
[Item 92]
N is greater than or equal to about 300, greater than or equal to about 350, greater than or equal to about 400, or greater than or equal to about 450, or greater than or equal to about 500, or greater than or equal to about 550. 92. The solar module of any one of items 86-91, wherein the solar module is greater than or equal to, greater than or equal to about 600, greater than or equal to about 650, or greater than or equal to about 700. .
[Item 93]
The plurality of supercells are electrically connected to each other to be greater than or equal to about 120 volts, greater than or equal to about 180 volts, greater than or equal to about 240 volts, greater than or equal to about 300 volts, or more. Equal to, greater than or equal to about 360 volts, greater than or equal to about 420 volts, greater than or equal to about 480 volts, greater than or equal to about 540 volts, or greater than about 600 volts; 93. The solar module according to any one of items 86 to 92, wherein the solar module provides a high DC voltage.
[Item 94]
A solar module according to item 86;
An inverter electrically connected to the solar module and configured to convert a DC output from the solar module to provide an AC output;
A solar energy system comprising:
[Item 95]
95. The solar energy system according to item 94, wherein the inverter does not have a DC-DC boost component.
[Item 96]
95. The solar energy system of item 94, wherein the inverter is configured to operate the solar module at a DC voltage higher than a minimum set to avoid reverse biasing the solar cell.
[Item 97]
97. The solar energy system according to item 96, wherein the minimum voltage value is temperature-dependent.
[Item 98]
95. The solar energy system of item 94, wherein the inverter is configured to recognize a reverse bias condition and operate the solar module at a voltage that avoids the reverse bias condition.
[Item 99]
100. The solar energy system of item 98, wherein the inverter is configured to operate the solar module in a local maximum region of the voltage-current output curve of the solar module to avoid the reverse bias condition.
[Item 100]
100. The solar energy system according to any one of items 94-99, wherein the inverter is a micro inverter integrated with the solar module.
[Item 101]
A series-connected string of N (≥25) rectangular or substantially rectangular solar cells having an average breakdown voltage of greater than about 10 volts, wherein said rectangular or substantially rectangular solar cells are one or more supercells. The plurality of solar cells are grouped, and each of the one or more supercells is arranged side by side with the long sides of adjacent solar cells overlapping and conductively joined to each other by an electric and heat conductive adhesive. A series-connected string of rectangular or substantially rectangular solar cells comprising two or more of the cells,
A solar module, wherein no single solar cell or group of less than N solar cells in said string of solar cells is individually electrically connected in parallel with a bypass diode.
[Item 102]
The solar module of item 101, wherein N is greater than or equal to 30.
[Item 103]
The solar module of item 101, wherein N is greater than or equal to 50.
[Item 104]
Item 101. The solar module of item 101, wherein N is greater than or equal to 100.
[Item 105]
The adhesive has a thickness in a direction perpendicular to the plurality of solar cells of less than or equal to about 0.1 mm and a thermal conductivity in a direction perpendicular to the plurality of solar cells of about 1.5 W / 102. The solar module of item 101, wherein the solar module forms a plurality of junctions between adjacent solar cells that is greater than or equal to m / K.
[Item 106]
101. The solar module of item 101, wherein the N solar cells are grouped into a single supercell.
[Item 107]
102. The solar module according to item 101, wherein the plurality of supercells are enclosed in a polymer.
[Item 108]
108. The solar module according to item 107, wherein the polymer comprises a thermoplastic olefin polymer.
[Item 109]
108. The solar module of item 107, wherein the polymer is sandwiched between a front sheet and a rear sheet made of glass.
[Item 110]
109. The solar module according to item 109, wherein the back sheet includes glass.
[Item 111]
102. The solar module according to item 101, wherein the plurality of solar cells are silicon solar cells.
[Item 112]
A solar module,
A supercell substantially extending over the entire length or width of the solar module parallel to an edge of the solar module, wherein the supercell is formed by overlapping long sides of adjacent solar cells and electrically and thermally conductive adhesive. A supercell comprising a series connection string of N or rectangular or substantially rectangular solar cells having, on average, a breakdown voltage of greater than about 10 volts, arranged side by side in a conductive junction with each other,
A solar module, wherein no single solar cell or group of less than N solar cells in the supercell is individually electrically connected in parallel with a bypass diode.
[Item 113]
112. The solar module according to item 112, wherein N> 24.
[Item 114]
112. The solar module of item 112, wherein the length of the supercell in the direction of current flow is at least about 500 mm.
[Item 115]
113. The solar module according to item 112, wherein the plurality of supercells are enclosed in a thermoplastic olefin polymer sandwiched between a front sheet and a rear sheet made of glass.
[Item 116]
A solar module,
N (greater than or equal to or equal to about 250) rectangular or substantially rectangular silicon solar cells arranged as a plurality of series-connected supercells in two or more parallel rows, each supercell being However, having a plurality of silicon solar cells, the plurality of silicon solar cells, the long sides of adjacent silicon solar cells are overlapped, and are directly conductively joined to each other by an electric and heat conductive adhesive, so that the inside of the supercell is The plurality of silicon solar cells are arranged side by side in a state of being electrically connected in series, a rectangular or substantially rectangular silicon solar cell,
With one or more bypass diodes
With
Each pair of adjacent parallel rows in the solar module is conductively joined to a backside electrical contact on a centrally located solar cell in one of the rows included in the pair, and in the other row included in the pair. Electrically connected by a bypass diode conductively connected to the backside electrical contact on the adjacent solar cell,
Solar module.
[Item 117]
Each pair of adjacent parallel rows is conductively joined to a backside electrical contact on a solar cell in one row of the pair and a backside electrical contact on an adjacent solar cell in the other row of the pair. 116. The solar module according to item 116, wherein the solar module is electrically connected by at least one other bypass diode conductively connected to the portion.
[Item 118]
Each pair of adjacent parallel rows is conductively joined to a backside electrical contact on a solar cell in one row of the pair and a backside electrical contact on an adjacent solar cell in the other row of the pair. 118. The solar module according to item 117, wherein the solar module is electrically connected by at least one other bypass diode conductively connected to the portion.
[Item 119]
The electrically and thermally conductive adhesive has a thickness in a direction perpendicular to the plurality of solar cells of less than or equal to about 50 microns and a thermal conductivity in a direction perpendicular to the plurality of solar cells of about 50 microns. 116. The solar module according to item 116, wherein the plurality of junctions between adjacent solar cells is formed to be higher than or equal to 1.5 W / (meter-K).
[Item 120]
116. The solar module according to item 116, wherein the plurality of supercells are encapsulated in a thermoplastic olefin layer between a front sheet and a rear sheet made of glass.
[Item 121]
The plurality of conductive junctions between overlapping solar cells can be connected to the plurality of supercells and the glass front sheet at a temperature in a range of about −40 ° C. to about 100 ° C. without damaging the solar module. 116. The solar module of item 116, wherein the plurality of supercells are provided with mechanical compliance that accommodates thermal expansion mismatches in a direction parallel to the two or more parallel rows during the plurality.
[Item 122]
N is greater than or equal to about 300, greater than or equal to about 350, greater than or equal to about 400, or greater than or equal to about 450, or greater than or equal to about 500, or greater than or equal to about 550. 122. The solar module according to any one of items 116-121, wherein is greater than or equal to, greater than or equal to about 600, greater than or equal to about 650, or greater than or equal to about 700. .
[Item 123]
The plurality of supercells are electrically connected to each other to be greater than or equal to about 120 volts, greater than or equal to about 180 volts, greater than or equal to about 240 volts, greater than or equal to about 300 volts, or more. Equal to, greater than or equal to about 360 volts, greater than or equal to about 420 volts, greater than or equal to about 480 volts, greater than or equal to about 540 volts, or greater than about 600 volts; 123. A solar module according to any one of items 116 to 122, wherein the solar module provides a high DC voltage.
[Item 124]
A solar module according to item 116;
An inverter electrically connected to the solar module and configured to convert a DC output from the solar module to provide an AC output;
A solar energy system comprising:
[Item 125]
125. The solar energy system according to item 124, wherein the inverter has no DC-DC boost component.
[Item 126]
125. The solar energy system of item 124, wherein the inverter is configured to operate the solar module at a DC voltage higher than a minimum set to avoid reverse biasing the solar cell.
[Item 127]
127. The solar energy system according to item 126, wherein the minimum voltage value is temperature-dependent.
[Item 128]
125. The solar energy system of item 124, wherein the inverter is configured to recognize a reverse bias condition and operate the solar module at a voltage that avoids the reverse bias condition.
[Item 129]
130. The solar energy system of item 128, wherein the inverter is configured to operate the solar module in a maximum region of a voltage-current output curve of the solar module to avoid the reverse bias condition.
[Item 130]
130. The solar energy system as in any one of items 124-129, wherein the inverter is a micro inverter integrated with the solar module.

Claims (25)

A solar module,
A plurality of supercells arranged in two or more physically parallel rows, each supercell being adjacent to electrically connect a plurality of cleavable crystalline solar cells in series. A plurality of solar cells, each comprising a plurality of solar cells arranged to overlap and conduct a conductive junction, each having a front surface illuminated by sunlight during operation of the solar module and a back surface positioned opposite. Cells and
One or more first terminal interconnects extending transversely to the plurality of rows to electrically interconnect each solar cell located at a first end of each row;
One or more second terminal interconnects extending transversely to the plurality of rows to electrically interconnect each solar cell located at a second end of each row opposite the first end;
At one or more longitudinal positions in the plurality of rows between the first end and the second end of the plurality of rows, along a plurality of back surfaces of a plurality of solar cells with respect to the plurality of rows. A plurality of hidden tap interconnects extending through the plurality of hidden tap contact pads on the plurality of back surfaces of the plurality of solar cells located at the same one of the one or more longitudinal positions in each row. A plurality of hidden tap interconnects that electrically interconnect;
A plurality of bypass diodes,
With
The one or more first terminal interconnects, the one or more second terminal interconnects, and the plurality of hidden tap interconnects connected to the plurality of hidden tap contact pads together each form two or more rows. Electrically segmenting into longitudinal segments and electrically connecting a plurality of adjacent row segments in a plurality of adjacent rows in parallel, thereby forming two or more groups of row segments;
The solar module is
A solar module, wherein each group of a plurality of row segments further comprises a plurality of said longitudinally extending conductors for electrically connecting in parallel with a different one of said plurality of bypass diodes.   2. The solar module according to claim 1, wherein each row comprises two or more supercells electrically connected in series. Each row has only a single supercell,
The one or more first end interconnects, the one or more second end interconnects, and the plurality of hidden tap interconnects together electrically connect each supercell into two or more longitudinal segments. Segmenting and electrically connecting a plurality of adjacent supercell segments in a plurality of adjacent rows in parallel, thereby forming two or more groups of segments of supercells;
The solar module according to claim 1, wherein each group of a plurality of supercell segments is electrically connected in parallel with a different one of the plurality of bypass diodes.   4. The method of claim 1, wherein a single first terminal interconnect extends laterally for all of the plurality of rows to electrically interconnect each solar cell located at the first end of each row. The solar module according to claim 1.   4. The method of claim 1, wherein a plurality of first terminal interconnects extend transversely to all of the plurality of rows to electrically interconnect solar cells located at the first end of each row. Item 2. The solar module according to item 1.   A plurality of solar cells, wherein a single hidden tap interconnect electrically interconnects the plurality of solar cells located at that longitudinal position in each row at each of the one or more longitudinal positions. The solar module according to any one of claims 1 to 5, wherein the solar module extends laterally with respect to the plurality of rows along a plurality of back surfaces.   The solar module according to any one of claims 1 to 6, wherein the plurality of bypass diodes are located along one or more edges of the solar module.   The solar module according to any one of claims 1 to 6, wherein the plurality of bypass diodes are located behind one or more of the plurality of solar cells.   The solar module according to any one of claims 1 to 8, wherein the plurality of bypass diodes are located in a plane of the plurality of supercells.   The solar module according to claim 1, wherein the plurality of bypass diodes are located between a plurality of adjacent rows of a plurality of supercells.   The solar module according to any one of claims 1 to 6, wherein the plurality of bypass diodes are located along a centerline of the solar module oriented parallel to the plurality of rows of supercells. .   The solar module according to any one of claims 1 to 8, wherein the plurality of bypass diodes are provided in a connection box located on a back surface of the solar module that is not directly irradiated by sunlight during operation of the solar module. Each row has a single supercell,
A single first end interconnect extending transversely to the plurality of rows to electrically interconnect solar cells at a plurality of ends in each supercell at the first end of each row;
A single second end interconnect extending transversely to the plurality of rows to electrically interconnect solar cells at a plurality of ends in each supercell at the second end of each row;
A single hidden tap interconnect is provided at each of the one or more longitudinal locations to electrically interconnect the plurality of solar cells located at that longitudinal location in each row. Extending transversely to the plurality of rows along a plurality of back surfaces;
The one or more first end interconnects, the one or more second end interconnects, and the plurality of hidden tap interconnects together electrically connect each supercell into two or more longitudinal segments. Segmenting and electrically connecting a plurality of adjacent supercell segments in a plurality of adjacent rows in parallel, thereby forming two or more groups of supercell segments;
The solar module according to claim 1, wherein each group of a plurality of supercell segments is electrically connected in parallel with a different one of the plurality of bypass diodes.   14. The solar module according to claim 13, wherein the plurality of bypass diodes are located along one or more perimeters of the solar module.   14. The solar module according to claim 13, wherein the plurality of bypass diodes are located along a centerline of the solar module oriented parallel to the plurality of rows of the plurality of supercells. A solar module,
A plurality of supercells arranged in two or more physically parallel rows, each supercell being adjacent to electrically connect a plurality of cleavable crystalline solar cells in series. Comprising a plurality of solar cells arranged side by side so as to overlap and conduct a conductive junction, wherein each solar cell has a front surface illuminated by sunlight during operation of the solar module and a back surface positioned opposite. Supercell and
One or more first terminal interconnects extending transversely to the plurality of rows to electrically interconnect each solar cell located at a first end of each row;
One or more second terminal interconnects extending transversely to the plurality of rows to electrically interconnect each solar cell located at a second end of each row opposite the first end;
At a first longitudinal position in the plurality of rows between the first end and the second end of the plurality of rows, along a plurality of back surfaces of a plurality of solar cells, and laterally with respect to the plurality of rows. One or more first hidden tap interconnects extending and electrically interconnecting a plurality of hidden tap contact pads on the plurality of back surfaces of the plurality of solar cells located at the first longitudinal position in each row. Connecting one or more first hidden tap interconnects;
At a second longitudinal position in the plurality of rows between the first end and the second end of the plurality of rows, along a plurality of back surfaces of a plurality of solar cells, laterally with respect to the plurality of rows. One or more second hidden tap interconnects extending electrically interconnecting a plurality of hidden tap contact pads on the plurality of back surfaces of the plurality of solar cells located at the second longitudinal position in each row. Connecting one or more second hidden tap interconnects;
A first bypass diode electrically interconnected between the one or more first terminal interconnects and the one or more first hidden tap interconnects;
A second bypass diode electrically interconnected between the one or more first hidden tap interconnects and the one or more second hidden tap interconnects;
A third bypass diode electrically interconnected between the one or more second hidden tap interconnects and the one or more second terminal interconnects;
A solar module comprising:   17. The solar module according to claim 16, wherein each row comprises two or more supercells electrically connected in series.   17. The solar module according to claim 16, wherein each row comprises only a single supercell. A single first end interconnect extending transversely to the plurality of rows to electrically interconnect solar cells at a plurality of ends in each supercell at the first end of each row;
A single second end interconnect extending transversely to the plurality of rows to electrically interconnect solar cells at a plurality of ends in each supercell at the second end of each row;
A single first hidden tap interconnect connects a plurality of back surfaces of the plurality of solar cells at the first longitudinal position in the plurality of rows between the first end and the second end of the plurality of rows. Extending laterally along the plurality of rows along the plurality of rows, wherein the first hidden tap interconnects are connected to the plurality of hidden sides on the plurality of backsides of the plurality of solar cells located at the first longitudinal position in each row. Electrically interconnect the tap contact pads,
A single second hidden tap interconnect connects a plurality of back surfaces of the plurality of solar cells at the second longitudinal position in the plurality of rows between the first end and the second end of the plurality of rows. Extending laterally with respect to the plurality of rows along the plurality of rows, wherein the second hidden tap interconnects are connected to the plurality of hidden sides at the plurality of backsides of the plurality of solar cells located at the second longitudinal position in each row. 19. The solar module according to claim 18, wherein the tap contact pads are electrically interconnected. The plurality of hidden tap contact pads collect current from the plurality of back surfaces of the plurality of solar cells to the plurality of hidden tap interconnects at a same position as the one or more longitudinal positions in the plurality of rows. The plurality of solar cells are disposed on the plurality of back surfaces of the plurality of solar cells at the one or plurality of longitudinal positions in the plurality of rows,
During normal operation, if there is no forward biased bypass diode, little or no current will flow through any of the plurality of hidden tap contact pads,
During bypass operation, at least a portion of the solar module is bypassed through a forward-biased bypass diode, and one or more of the plurality of hidden tap interconnects is connected to any one of the solar modules. The solar module according to any one of claims 1 to 19, wherein the solar module conducts a current larger than a current generated by one solar cell. A solar module,
A plurality of supercells arranged in three or more physically parallel rows, each supercell being a plurality of solar cells adjacent to electrically connect in series a plurality of cleavable crystal solar cells. A plurality of solar cells, each comprising a plurality of solar cells arranged to overlap and conduct a conductive junction, each having a front surface illuminated by sunlight during operation of the solar module and a back surface positioned opposite. Cells and
A plurality of hidden tap interconnects extending transversely to the plurality of rows along a plurality of backsides of the plurality of solar cells, to a plurality of series connected segments having adjacent series connected segments electrically connected in parallel; And a plurality of hidden tap interconnects interconnecting a plurality of hidden tap contact pads on the plurality of backsides of the plurality of solar cells located along each hidden tap interconnect to electrically segment each supercell. ,
A solar module comprising: A first of the plurality of row segments electrically interconnects between two of the plurality of hidden tap interconnects for electrically connecting in parallel with a first bypass diode. 22. The solar module according to claim 21, further comprising a first bypass diode. The plurality of hidden tap interconnects electrically interconnect the plurality of hidden tap contact pads located at the same one of the one or more longitudinal locations in the plurality of rows;
The plurality of hidden tap contact pads collect current from the plurality of back surfaces of the plurality of solar cells to the plurality of hidden tap interconnects at a same position as the one or more longitudinal positions in the plurality of rows. The plurality of solar cells are disposed on the plurality of back surfaces of the plurality of solar cells at the one or plurality of longitudinal positions in the plurality of rows,
During normal operation, if there is no forward biased bypass diode, little or no current will flow through any of the plurality of hidden tap contact pads,
During bypass operation, at least a portion of the solar module is bypassed through a forward-biased bypass diode, and one or more of the plurality of hidden tap interconnects is connected to any one of the solar modules. The solar module according to claim 21, wherein the solar module conducts a current larger than a current generated by one solar cell.   24. The solar module according to any of the preceding claims, wherein each row segment electrically connected in parallel with one bypass diode comprises more than 24 crystalline silicon solar cells. The one or more first end interconnects and the one or more second end interconnects extend laterally for all of the plurality of rows;
The solar module according to claim 1, wherein the plurality of hidden tap interconnects extend laterally between adjacent rows.