Method for manufacturing a foil-like electrical connector for connecting solar cells

1. A method for manufacturing a foil-like electrical connector for connecting solar cells to form at least one solar module, the method comprising:

providing an insulating carrier film sheet having a width which essentially corresponds to the width of the solar cells to be connected;

subsequently introducing into the carrier film sheet (i) recesses in an area corresponding to future soldering points, and (ii) adjustment and transport perforations into side strip edge areas;

providing a conductive foil sheet having a width corresponding to the carrier film sheet, wherein (i) adjustment and transport perforations are introduced into the conductive foil sheet at side strip edge areas, (ii) comb structures configured to function as electrical connection fingers are provided in the conductive foil sheet, and (iii) retaining webs are provided in a direction of the adjustment and transport perforation to ensure secure positioning of the comb structures;

positioning the conductive foil sheet on the carrier film sheet with the aid of pin-shaped extensions of one of a transport belt or a transport roller, the extensions engaging in the corresponding adjustment and transport perforations of the conductive foil sheet and the insulating carrier film sheet;

joining the carrier film sheet to the conductive foil sheet via an adhesive bond to form a composite sheet;

separating the side edge strips and severing the retaining webs;

laminating an insulating cover film at each side edge of the composite sheet, the cover film having lateral overhangs in relation to the side edges of the composite sheet; and

folding the lateral overhangs of the cover film and fixing the folded lateral overhangs to the bottom side of the composite sheet to form the foil-like electrical connector, wherein the folded lateral overhangs insulate the edges of the composite sheet.

2. The method as recited in claim 1 , wherein the recesses and perforations are produced by one of punching or with the aid of laser radiation, and wherein the solar cells to be connected are pseudosquare solar cells, and wherein additional recesses are introduced in areas of bevels of the pseudosquare solar cells.

3. The method as recited in claim 1 , wherein the comb structures have a surface shape which is adapted to contact configurations and expected current intensity conditions of the solar module.

4. The method as recited in claim 1 , wherein the carrier film sheet is provided with an adhesive layer.

5. The method as recited in claim 1 , wherein prior to applying the cover film, an adhesive layer is provided on the cover film.

6. The method as recited in claim 5 , further comprising:

rolling the foil-like electrical connector into a roll for subsequent processing;

wherein, prior to winding the foil-like electrical connector into a roll, the adhesives are cured, and exposed conductive surfaces are wetted with at least one of a fluxing agent and a solder.

7. The method as recited in claim 6 , wherein the wetting is carried out with the aid of a flow soldering bath.

8. The method as recited in claim 1 , wherein separating points are formed in the foil-like electrical connector after a predefined length of the foil-like electrical connector corresponding to a predefined number of the solar cells, and wherein wider conductive transverse sheets are provided in the section of the foil-like electrical connector containing the separating points.

9. The method as recited in claim 1 , wherein the conductive foil sheet is made of copper and has recesses located in the area of the soldering points, and wherein the dimensions of the recesses in the conductive foil sheet are smaller than the dimensions of the recesses in the carrier film sheet.

10. The method as recited in claim 9 , wherein the cover film includes recesses in the area of the soldering points, and wherein the dimensions of the recesses in the cover film are larger than the dimensions of the recesses in the conductive foil sheet.

11. The method as recited in claim 1 , wherein the carrier film sheet and the cover film are provided with an adhesive layer which is at least one of pressure-activatable and heat-activatable, and wherein the step of folding and fixing of the lateral overhangs of the cover film is carried out in the same furnace chamber in which the lamination of the cover film to the composite sheet is performed.

12. The method as recited in claim 1 , wherein prior to positioning the conductive foil sheet on the carrier film sheet, the carrier film sheet is wetted with an adhesive, and wherein the conductive foil sheet and the carrier film sheet are subsequently laminated together under pressure.

13. The method as recited in claim 1 , wherein prior to folding, the cover film edges are cut from the outside toward the middle of the composite sheet.

14. A method for electrically connecting at least two solar cells to form a solar module, comprising:

providing a foil-like electrical connector for connecting solar cells, wherein the foil-like electrical connector is prepared by a process including:

providing an insulating carrier film sheet having a width which essentially corresponds to the width of the solar cells to be connected;

subsequently introducing into the carrier film sheet (i) recesses in an area corresponding to future soldering points, and (ii) adjustment and transport perforations into side strip edge areas;

providing a conductive foil sheet having a width corresponding to the carrier film sheet, wherein (i) adjustment and transport perforations are introduced into the conductive foil sheet at side strip edge areas, (ii) comb structures configured to function as electrical connection fingers are provided in the conductive foil sheet, and (iii) retaining webs are provided in a direction of the adjustment and transport perforation to ensure secure positioning of the comb structures;

positioning the conductive foil sheet on the carrier film sheet with the aid of pin-shaped extensions of one of a transport belt or a transport roller, the extensions engaging in the corresponding adjustment and transport perforations of the conductive foil sheet and the insulating carrier film sheet;

joining the carrier film sheet to the conductive foil sheet via an adhesive bond to form composite sheet;

separating the side edge strips and severing the retaining webs;

laminating an insulating cover film at each side edge of the composite sheet, the cover film having lateral overhangs in relation to the side edges of the composite sheet;

folding the lateral overhangs of the cover film and fixing the folded lateral overhangs to the bottom side of the composite sheet to form the foil-like electrical connector, wherein the folded lateral overhangs insulate the edges of the composite sheet; and

rolling the foil-like electrical connector into a roll;

unwinding the roll and connecting a predetermined number of solar cells to the unwound section of the foil-like electrical connector to form a string, wherein the connecting includes soldering at soldering points of the solar cells to contact points of the foil-like electrical connector which are exposed through punched holes in the carrier film sheet;

positioning the produced string on a transparent sheet provided with an encapsulation material, wherein the position of the produced string is rotated by 180° relative to a preceding string; and

providing a series connection of multiple strings via transverse connectors.

15. The method as recited in claim 14 , wherein the predetermined number of solar cells are aligned with the structures of the foil-like electrical connector in that solder passage openings of the foil-like electrical connector and solder reservoirs are placed congruently on the solar cells, and wherein the solar cells are visible through the solder passage openings.