Method for Manufacturing a Solar Module

Simple SummaryContent extracted from patent full text and abstract with AI.

The patent describes a novel method for manufacturing and serially connecting solar modules made of strip-shaped photovoltaic elements. The process involves depositing multiple layers (including contacts and semiconductors) continuously on a substrate, and then structuring the module by selectively exposing and etching parts of the layers to form distinct, electrically isolated photovoltaic cell stripes. Lasers and chemical etching are used for precise removal and contact formation, enabling a more efficient and streamlined production process compared to existing techniques.

Use CasesContent extracted from patent full text and abstract with AI.

• Manufacturing of thin-film solar panels for use in residential, commercial, or utility-scale solar energy installations.
• Production of lightweight and flexible solar modules suitable for integration into building facades, vehicles, or portable devices.
• High-throughput fabrication of cost-effective photovoltaic modules for emerging markets and large-scale deployment.
• Production process for custom-shaped or segmented solar panels required in architectural or specialty applications.

BenefitsContent extracted from patent full text and abstract with AI.

• The process allows continuous deposition of all layers, reducing downtime and increasing manufacturing speed.
• Eliminates the need for complex masking, significantly simplifying production and lowering costs.
• Provides precise electrical isolation and reliable series connections between solar cell stripes, improving module performance.
• Supports utilization of a variety of materials and substrate types, increasing flexibility and adaptability in solar module design.
• The process is compatible with state-of-the-art laser and etching technology, enabling high-resolution and scalable fabrication.
• Facilitates production of thin, lightweight, and potentially flexible solar modules.

Technical Classifications (CPCs)

Inventors & Applicants

Patent Abstract

The invention relates to a method for producing and serially connecting a solar module comprising strip-shaped photovoltaic elements along the length of the solar module, having the following steps: a) a first electric contact layer (2) is disposed on a substrate (1), b) active semiconductor layers (3) are disposed on the first electric contact layer (2), c) a second electric contact layer (4) is disposed on the active semiconductor layers (3), d) the surface of the first electric contact layer is exposed along the length of the module in holes (5) in a perforated manner in order to form parallel strip-shaped photovoltaic elements, e) the layer sequence is exposed to an etching solution, wherein the material of the first electric contact layer (2) is etched, f) the etching step after step e) is continued until first trenches (8) are formed between the semiconductor layers (3) and the substrate (1) along the length of the module, g) an equal number of second trenches (7) are formed along the length the module parallel to the first trenches (5) in an adjacent and laterally offset manner, the surface of the first electric contact layer being exposed in the second trenches, h) between the first trenches (8) and the second trenches (7), an electric contact is formed from the second electric contact layer of a strip-shaped photovoltaic element (A) to the first electric contact layer of a strip-shaped photovoltaic element (B) that is directly adjacent to said element (A).