Thin-film Solar Module Which Is Contact-Connected on One Side and Has an Internal Contact Layer

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This invention describes a thin-film solar module that is contacted on one side and features an internal contact layer, simplifying the electrical connection structure. Unlike conventional designs requiring precise alignment of multiple contact points and complex structuring, the module uses a flat, continuous contact layer internally, with point or line contacts connected through regions that link the cells in series. An insulating layer separates these contact systems except where electrical connection is needed for serial linking. This innovation reduces manufacturing complexity, renders precise alignment unnecessary, minimizes inactive areas, and increases efficiency.

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

• Photovoltaic panels for residential and commercial solar power generation.
• Large-scale solar farms seeking efficient, easily manufacturable modular panels.
• Flexible or lightweight solar modules for integration into building materials (BIPV).
• Specialized solar panels for portable/transportable renewable energy systems.
• High-throughput manufacturing lines optimized for cost-effective thin-film solar panel production.

BenefitsContent extracted from patent full text and abstract with AI.

• Significantly reduces the complexity and precision required in solar panel manufacturing by eliminating the need for precise alignment of point contacts.
• Decreases the area of inactive (non-power producing) portions in a solar module, thereby increasing the overall efficiency per area.
• Enables high production throughput and cost savings due to streamlined manufacturing processes.
• Supports a wide variety of thin-film solar cell material configurations (pn or pin), allowing for flexibility in materials and design.
• Minimizes losses from front-side shading or absorption by facilitating rear-side only contact configurations when desired.
• Facilitates easier integration of additional functional layers (such as antireflection or passivation layers) for enhanced performance.

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Patent Abstract

The closest known thin-film solar module which is contact-connected on the rear side is based on two contact systems with different point contact-connections, the structuring of which, however, limits the quality of the absorber material used, with the result that pin configurations, in particular, can be achieved only with difficulty. For connection in series, the point contact-connections of the first and second contact systems must be exactly aligned with one another. In contrast, the thin-film solar cell module (00) according to the invention has a second contact system (13) having only one flat internal contact layer (16). The first contact system (12) has contact-connections (14) which are detected by an outer contact layer (15). For connection in series, the contact-connections (14) are connected to the internal contact area (16) in connection regions (21) between adjacent solar cell regions (09, 10) using series contact-connections (22). Outside the connection regions (22), the two contact systems (12, 13) are electrically insulated with respect to one another by the interposition of an insulation layer (17). The thin-film solar module (00) according to the invention can be implemented in a simple manner in all possible embodiments (pn or pin configuration, contact-connection on the rear side or front side, superstrate or substrate, integration of additional functional layers) without any alignment problems and yields the greatest possible degree of efficiency.