Abstract: A photovoltaic module includes a first photovoltaic cell, a second photovoltaic cell, and a collector-connector which is configured to collect current from the first photovoltaic cell and to electrically connect the first photovoltaic cell with the second photovoltaic cell. The collector-connector may include an electrically insulating carrier and at least one electrical conductor which electrically connects the first photovoltaic cell to the second photovoltaic cell.

Abstract: Apparatus and techniques for mounting frameless photovoltaic modules reduce module stress induced by the mounting configuration. Interface strips and strip/rail spacing configured to relieve module stress by reducing or eliminating module sag are used.

Abstract: Provided are novel interconnecting strips for electrically connecting building integrable photovoltaic (BIPV) modules in a photovoltaic array. An interconnecting strip can be provided between a building structure and the BIPV modules, with electrical connections established by lowering the modules onto the strip previously positioned on the structure. The strip can includes two or more terminal groups aligned with different rows of BIPV modules. Each terminal group includes two or more connector terminals for connecting to the modules in that row. The interconnecting strip also includes leads extending between terminal groups and connecting connector terminals of different groups. In certain embodiments, terminal groups are offset with respect to adjacent groups to align with BIPV modules that are similarly offset to provide a moisture barrier. The interconnecting strip may be reconfigured in the field to provide different electrical connection schemes among BIPV modules.

Abstract: Provided are novel building integrable photovoltaic (BIP) modules having flexible connectors and methods of fabricating thereof. According to various embodiments, a BIP module includes a photovoltaic insert having one or more photovoltaic cells and a flexible connector having a flexible member and a connector member. The flexible member provides flexible mechanical support to the connector member with respect to the insert. The flexible member may include a flat conductive strip, a portion of which is shaped to provide additional flexibility to the flexible member along its width. The connector member encloses one or more conductive elements, such as louvered sockets, which are electrically connected to the photovoltaic insert by the flexible member. In certain embodiments, the same flat conductive strip is used to form a shaped portion as well as conductive element and/or a portion of a bus bar extending into the photovoltaic insert.

Abstract: Apparatus and techniques for mounting frameless photovoltaic modules reduce module stress induced by the mounting configuration. Cable clamps and cable spacing configured to relieve module stress by reducing or eliminating module sag are used.

Abstract: Provided are novel building integrable photovoltaic (BIP) modules and methods of fabricating thereof. A module may be fabricated from an insert having one or more photovoltaic cells by electrically interconnecting and mechanically integrating one or more connectors with the insert. Each connector may have one or more conductive elements, such as metal sockets and/or pins. At least two of all conductive elements are electrically connected to the photovoltaic cells using, for example, bus bars. These and other electrical components are electrically insulated using a temperature resistant material having a Relative Temperature Index (RTI) of at least about 115° C. The insulation may be provided before or during module fabrication by, for example, providing a prefabricated insulating housing and/or injection molding the temperature resistant material. The temperature resistant material and/or other materials may be used for mechanical integration of the one or more connectors with the insert.

Abstract: Provided herein are methods, apparatuses and systems for fabricating photovoltaic cells and modules. In certain embodiments, the methods, apparatuses and systems involve coating ferromagnetic substrates with thin film solar cell materials and using magnetic force to constrain, move or otherwise manipulate partially fabricated cells or modules. According to various embodiments, the methods, apparatuses and systems provide magnetically actuated handling throughout a photovoltaic cell or module fabrication process, from forming photovoltaic cell layers on a substrate to packaging the module for transport and installation. The magnetically manipulated processing provides advantages over conventional photovoltaic module processing operations, including fewer mechanical components, greater control over placement and tolerances, and ease of handling. As a result, the methods, apparatuses and systems provide highly efficient, low maintenance photovoltaic module fabrication processes.

Abstract: Apparatus and techniques for mounting frameless photovoltaic modules reduce module stress induced by the mounting configuration. Mounting clamps and rail/clamp spacing configured to relieve module stress by reducing or eliminating module sag are used.

Abstract: Provided herein are high throughput apparatuses for fabricating wire current collector and/or interconnect assemblies for solar cells. In certain embodiments, the wire assemblies include uniformly pitched serpentine wires. According to various embodiments, the apparatuses include a plurality of link heads connected to collapsible links, with the heads spaced apart when the links are in an uncollapsed position and stacked when the links are in a collapsed position. Alternating link heads engage opposite sides of the wire such that, when collapsed, the wire is threaded through engaging members of the heads in a serpentine configuration.

Abstract: Provided are bypass diode assemblies for use in photovoltaic modules. Also provided are methods of fabricating such assemblies and a method of fabricating photovoltaic modules using such assemblies. A diode assembly may include an insulating strip, at least one lead-diode assembly having a diode and two leads, and at least two interconnecting conductors overlapping with and electrically contacting the leads of the lead-diode assembly. The insulating strip supports the lead-diode assembly and conductors and at least partially insulates these components from photovoltaic cells. Specifically, during module fabrication, the interconnecting conductors make electrical connections to the back sides of the cells through cutouts in the insulating strip. The electrical connections may be made to every cell in a row or a subset of selected cells in that row. In certain embodiments, the same interconnecting conductor is connected to two or more cells positioned in adjacent rows.

Abstract: A solar-cell module. The solar-cell module includes a plurality of solar cells that are electrically coupled together. The solar-cell module further includes an in-laminate-diode assembly electrically coupled with the plurality of solar cells. The in-laminate-diode assembly is configured to prevent power loss. The solar-cell module also includes a protective structure at least partially encapsulating the plurality of solar cells. In addition, the solar-cell module includes a plurality of external-connection mechanisms mounted to a respective plurality of edge regions of the protective structure. An external-connection mechanism of the plurality of external-connection mechanisms is configured to enable collection of current from the plurality of solar cells and to allow interconnection with at least one other external device.

Abstract: A photovoltaic device is made using a method and a system disclosed herein. The method may comprise: providing a web of photovoltaic material; providing a web of interconnect material; cutting the web of photovoltaic material into a plurality of photovoltaic cells; cutting the web of interconnect material into a plurality of interconnects; providing a respective one of the plurality of interconnects between adjacent photovoltaic cells to electrically connect a first string of photovoltaic cells in series; and laminating the first string of photovoltaic cells which are electrically connected in series between a top laminating sheet and a bottom laminating sheet. The system may comprise: a first conveyor, an optical inspection apparatus, a removal apparatus, a sorter, a second conveyor, and an assembly apparatus configured to place an interconnect between adjacent photovoltaic cells to electrically connect a first string of photovoltaic cells in series.

Abstract: Provided are novel methods of fabricating photovoltaic modules using pressure sensitive adhesives (PSA) to secure wire networks of interconnect assemblies to one or both surfaces of photovoltaic cells. A PSA having suitable characteristics is provided near the interface between the wire network and the cell's surface. It may be provided together as part of the interconnect assembly or as a separate component. The interconnect assembly may also include a liner, which may remain as a part of the module or may be removed later. The PSA may be distributed in a void-free manner by applying some heat and/or pressure. The PSA may then be cured by, for example, exposing it to UV radiation to increase its mechanical stability at high temperatures, in particular at a, for example the maximum, operating temperature of the photovoltaic module. For example, the modulus of the PSA may be substantially increased during this curing operation.

Abstract: Provided are flexible photovoltaic modules having header structures for protecting, reinforcing, and sealing edges formed by sealing sheets of the modules. A flexible module may include one or more header structures. In certain embodiments, two header structures are provided on the same edge or two opposite edges of the module. A header structure may enclose a portion of the edge or the entire edge. A header structure may be a sleeve enclosing an edge formed by two sealing sheets. In other embodiment, in which an edge is formed by only one shorter sealing sheet, a header structure may extend over this edge. A header structure may enclose one or more electrical leads protruding from a sealed space formed by the sealing sheets. These electrical leads may be connected to conductive elements provided within the header structure and used for establishing electrical connections to other components of the photovoltaic array.

Abstract: Provided are flexible photovoltaic modules having flaps for supporting junction boxes. Junction boxes are used for making electrical connections to photovoltaic cells sealed inside the modules. A flap may be formed by one or two flexible sealing sheets extending beyond the boundary of the photovoltaic cells. A junction box is attached to the front surface of the flap. In certain embodiments, a flap is formed by one sealing sheet, such as a back side sheet. Materials of the back side sheet may be different from materials of the front side sheet and be selected to ensure support to the junction box. Additional support to the junction box may be provided by extending one of its edges in between the two sealing sheets. This edge extension or other features may be used for mechanical protection of electrical leads extending between the junction box and photovoltaic cells.