SOLAR MODULE STRUCTURES AND ASSEMBLY METHODS FOR THREE-DIMENSIONAL THIN-FILM SOLAR CELLS
Solar module structures 210 and 270 and methods for assembling solar module structures. The solar module structures 210 and 270 comprise three-dimensional thin-film solar cells 110 arranged in solar module structures 210 and 270 . The three-dimensional thin-film solar cell comprises a three-dimensional thin-film solar cell substrate ( 124 and 122 , respectively) with emitter junction regions 1352 and doped base regions 1360 . The three-dimensional thin-film solar cell further includes emitter metallization regions and base metallization regions. The 3-D TFSC substrate comprises a plurality of single-aperture or dual-aperture unit cells. The solar module structures 270 using three-dimensional thin-film solar cells comprising three-dimensional thin-film solar cell substrates with a plurality of dual-aperture unit cells may be used in solar glass applications. The solar module structures 210 using three-dimensional thin-film solar cells comprising three-dimensional thin-film solar cell substrates with a plurality of single-aperture unit cells may be used in building façade and rooftop installation applications as well as for centralized solar electricity generation.
1 . A solar module structure, comprising:
a top encapsulant layer;
a plurality of three-dimensional thin-film solar cells, each thin-film solar cell comprising:
a three-dimensional thin-film solar cell substrate comprising emitter junction regions and doped base regions;
emitter metallization regions; and
base metallization regions;
wherein said three-dimensional thin-film solar cell substrate comprises a plurality of single-aperture unit cells;
a printed circuit board;
a rear encapsulant layer; and
a protective back plate.
2 . The solar module structure of claim 1 , further comprising a glass layer.
3 . The solar module structure of claim 2 , wherein said glass layer comprises a separate glass cover.
4 . The solar module structure of claim 2 , wherein said glass layer comprises a glass-like protective coating formed by a coating method.
5 . The solar module structure of claim 1 , further comprising a top patterned cell interconnect layer.
6 . The solar module structure of claim 1 , further comprising a rear patterned cell interconnect layer.
7 . The solar module structure of claim 1 , wherein said protective back plate comprises a Tedlar protective back plate.
8 . The solar module structure of claim 1 , wherein each three-dimensional thin-film solar cell further comprises a rear mirror.
9 . The solar module structure of claim 8 , wherein said rear mirror comprises an integrated rear mirror.
10 . The solar module structure of claim 8 , wherein said rear mirror comprises a detached rear mirror.
11 . The solar module structure of claim 1 , wherein each three-dimensional thin-film solar cell further comprises a peripheral cell frame.
12 . The solar module structure of claim 11 , wherein said peripheral cell frame may be used to produce wrap-through or wrap-around emitter metallization for making contacts to the cell emitter at the bottom of each three-dimensional thin-film solar cell.
13 . A method for assembling a solar module structure, comprising:
patterning a frontside and a backside of a double-sided printed circuit board coated with metallic foils according to desired frontside and backside interconnect layouts;
applying a first coating layer to the rear side of a plurality of three-dimensional thin-film solar cells, each three-dimensional thin-film solar cell comprising:
a three-dimensional thin-film solar cell substrate comprising emitter junction regions and doped base regions;
emitter metallization regions; and
base metallization regions;
wherein said three-dimensional thin-film solar cell substrate comprises a plurality of single-aperture unit cells;
placing said plurality of three-dimensional thin-film solar cells on the frontside of said double-sided printed circuit board;
preparing a solar module assembly, comprising:
a glass layer;
a top encapsulant layer;
said plurality of three-dimensional thin-film solar cells on the frontside of said double-sided printed circuit board;
a rear encapsulant layer;
a protective back plate; and
sealing and packaging said solar module assembly.
14 . The method for assembling a solar module structure of claim 13 , wherein each three-dimensional thin-film solar cell further comprises a rear mirror.
15 . The method for assembling a solar module structure of claim 13 , further comprising arranging a plurality of said solar module assemblies in series.
16 . The method for assembling a solar module structure of claim 13 , further comprising arranging a plurality of said solar module assemblies in parallel.
17 . The method for assembling a solar module structure of claim 15 , further comprising connecting at least one pair of module power output electrical leads.
18 . The method for assembling a solar module structure of claim 16 , further comprising connecting at least one pair of module power output electrical leads.
19 . A solar module structure, comprising:
a top glass plate;
a plurality of three-dimensional thin-film solar cells, each three-dimensional thin-film solar cell comprising:
a three-dimensional thin-film solar cell substrate comprising emitter junction regions and doped base regions;
emitter metallization regions; and
base metallization regions;
wherein said three-dimensional thin-film solar cell substrate comprises a plurality of dual-aperture unit cells;
a rear patterned cell interconnect layer; and
a bottom glass plate.
20 . The solar module structure of claim 19 , wherein each three-dimensional thin-film solar cell further comprises a peripheral cell frame.