Abstract: A method of manufacturing a solar cell module includes the use of low cost polymeric materials with improved mechanical properties. A transparent encapsulant layer is placed adjacent a rear surface of a front support layer. Interconnected solar cells are positioned adjacent a rear surface of the transparent encapsulant layer to form a solar cell assembly. A backskin layer is placed adjacent a rear surface of the solar cell assembly. At least one of the transparent encapsulant layer and the backskin layer are predisposed to electron beam radiation.

Abstract: A method of manufacturing a solar cell module includes the use of low cost polymeric materials with improved mechanical properties. A transparent encapsulant layer is placed adjacent a rear surface of a front support layer. Interconnected solar cells are positioned adjacent a rear surface of the transparent encapsulant layer to form a solar cell assembly. A backskin layer is placed adjacent a rear surface of the solar cell assembly. At least one of the transparent encapsulant layer and the backskin layer are predisposed to electron beam radiation.

Abstract: A decal for use in forming a solar cell comprises an antireflective precursor material and a patterned electrically conductive material. The antireflective precursor material and the patterned electrically conductive material are disposed over a base material. The antireflective precursor material can be one or more layers of paste which form an antireflective coating upon being fired. A cover layer can be disposed over the antireflective precursor material and the electrically conductive material.

Abstract: An ultraviolet light stabilization additive package is used in an encapsulant material that may be used in solar cell modules, laminated glass and a variety of other applications. The ultraviolet light stabilization additive package comprises a first hindered amine light stabilizer and a second hindered amine light stabilizer. The first hindered amine light stabilizer provides thermal oxidative stabilization, and the second hindered amine light stabilizer providing photo-oxidative stabilization.

Abstract: A method of manufacturing a solar cell module includes the use of low cost polymeric materials with improved mechanical properties. A transparent encapsulant layer is placed adjacent a rear surface of a front support layer. Interconnected solar cells are positioned adjacent a rear surface of the transparent encapsulant layer to form a solar cell assembly. A backskin layer is placed adjacent a rear surface of the solar cell assembly. At least one of the transparent encapsulant layer and the backskin layer are predisposed to electron beam radiation.

Abstract: A decal for use in forming a solar cell comprises an antireflective precursor material and a patterned electrically conductive material. The antireflective precursor material and the patterned electrically conductive material are disposed over a base material. The antireflective precursor material can be one or more layers of paste which form an antireflective coating upon being fired. A cover layer can be disposed over the antireflective precursor material and the electrically conductive material.

Abstract: A decal for use in forming a solar cell comprises an antireflective precursor material and a patterned electrically conductive material. The antireflective precursor material and the patterned electrically conductive material are disposed over a base material. The antireflective precursor material can be one or more layers of paste which form an antireflective coating upon being fired. A cover layer can be disposed over the antireflective precursor material and the electrically conductive material.

Abstract: An encapsulant material includes a layer of metallocene polyethylene disposed between two layers of an acid copolymer of polyethylene. More specifically, the layer of metallocene polyethylene is disposed adjacent a rear surface of the first layer of the acid copolymer of polyethylene, and a second layer of the acid copolymer of polyethlene is disposed adjacent a rear surface of the layer of metallocene polyethylene. The encapsulant material can be used in solar cell module and laminated glass applications.

Abstract: A decal for use in forming a solar cell includes an antireflective precursor material and a patterned electrically conductive material. The antireflective precursor material and the patterned electrically conductive material are disposed over a base material. The antireflective precursor material can be one or more layers of paste which form an antireflective coating upon being fired. A cover layer can be disposed over the antireflective precursor material and the electrically conductive material.

Abstract: An encapsulant material includes a layer of metallocene polyethylene disposed between two layers of ionomer. More specifically, the layer of metallocene polyethylene is disposed adjacent a rear surface of the first ionomer layer, and a second layer of ionomer is disposed adjacent a rear surface of the layer of metallocene polyethylene. The encapsulant material can be used in solar cell module and laminated glass applications.

Abstract: A solar cell roof tile includes a front support layer, a transparent encapsulant layer, a plurality of interconnected solar cells and a backskin layer. The front support layer is formed of light transmitting material and has first and second surfaces. The transparent encapsulant layer is disposed adjacent the second surface of the front support layer. The interconnected solar cells has a first surface disposed adjacent the transparent encapsulant layer. The backskin layer has a first surface disposed adjacent a second surface of the interconnected solar cells, wherein a portion of the backskin layer wraps around and contacts the first surface of the front support layer to form the border region. A portion of the border region has an extended width. The solar cell roof tile may have stand-offs disposed on the extended width border region for providing vertical spacing with respect to an adjacent solar cell roof tile.

Abstract: A laminated solar cell module includes an integral mounting structure. The solar cell module includes a rigid front support layer formed of light transmitting material having first and second surfaces. A transparent encapsulant layer has a first surface disposed adjacent the second surface of the front support layer. A plurality of interconnected solar cells have a first surface disposed adjacent a second surface of the transparent encapsulant layer. The backskin is formed of a thermoplastic olefin, which includes first ionomer, a second ionomer, glass fiber and carbon black. A first surface of the backskin is disposed adjacent a second surface of the interconnected solar cells. At least one mounting bracket is bonded directly to a second surface of the backskin layer.

Abstract: A laminated solar cell module with a backskin layer that reduces the materials and labor required during the manufacturing process. The solar cell module includes a rigid front support layer formed of light transmitting material having first and second surfaces. A transparent encapsulant layer has a first surface disposed adjacent the second surface of the front support layer. A plurality of interconnected solar cells have a first surface disposed adjacent a second surface of the transparent encapsulant layer. The backskin layer is formed of a thermoplastic olefin, which includes first ionomer, a second ionomer, glass fiber, and carbon black. A first surface of the backskin layer is disposed adjacent a second surface of the interconnected solar cells. The transparent encapsulant layer and the backskin layer, in combination, encapsulate the interconnected solar cells.

Abstract: An improved photovoltaic solar cell module and method of manufacture is provided wherein the module comprises a plurality of solar cells and a novel and improved arrangement for hermetically sealing off the solar cells from the surrounding environment. A preferred embodiment of the invention has an edge seal arrangement that comprises a plurality of U-shaped channel members made of a selected thermoplastic material, such as high density polyethylene, and strips made of an ionomer positioned between and bonded to the U-shaped channel members and the outer surfaces of the front and back support sheets of the module. An alternative embodiment omits the U-shaped channel members and uses a thermoplastic backskin that overlaps and is bonded to the front support sheet of the module.

Abstract: A solar cell fabrication procedure is described in which a silicon substrate having a layer of silicon nitride on one side is selectively coated with a paste that contains silver metal and a glass frit. Upon heating to a temperature in excess of 760 degrees C. for a time not exceeding about 20 seconds, the glass penetrates the silicon nitride and the substrate surface is metallized by the silver metal, with the result that the finished solar cell has a fill factor of at least about 0.75 even though the paste contains no phosphorus.

Abstract: Methods for forming a wraparound electrical contact on a solar cell require minimal labor and result in high device yields at low cost. A decal having a patterned electrically conductive material is disposed on a first surface of the solar cell. The decal may be a liquid-transfer or heat-transfer decal. A portion of the decal is wrapped around at least one edge of the solar cell for contacting a second surface of the solar cell. The decal is processed to remove organic matter and form an ohmic contact.

Abstract: Apparatus for forming shallow p-n junctions in silicon substrates to produce photovoltaic cells, which apparatus provides three processing chambers. An ultrasonic spray is mounted in the first processing chamber to coat a front surface of the substrate with a liquid dopant-containing material. The second processing chamber dries the coated substrates leaving a dopant-containing residue on the front surface. The third processing chamber fires the substrates in an oxygen-containing environment to diffuse the dopant into the substrate and provide a p-n junction. The apparatus conducts humidified air to each chamber to control polymerization of the dopant source and to prevent non-humidified air from entering the chambers.

Abstract: A photovoltaic solar cell module and method of manufacture is provided wherein an ionomer is used as an encapsulant.

Abstract: A photovoltaic solar cell module and method of manufacture is provided wherein an ionomer is used as an encapsulant, wherein said ionomer being modified by the presence of 0.3 to 2.0 wt. percent of a UV absorber and 0.3 to 2.0 wt. percent of a UV stabilizer.

Abstract: An improved photovoltaic cell and a method for making such cells is provided. In a generic sense, the preferred method comprises the step of (1) applying a coating of an aluminum metal paste onto the rear surface of the substrate in a suitable rear contact pattern, (2) applying a layer of a glass frit paste so as to envelop the rear contact, and (3) firing those pastes so as to form a rear contact protected by a glass overcoating. A front contact also is formed by applying a silver metal/glass frit paste onto the anti-reflection coating in a related front contact pattern. The front and rear contacts may be fired simultaneously or in two different steps. However, a single firing method is preferred because thicker aluminum contacts are possible.