Abstract: Disclosed herein are approaches to fabricating solar cells, solar cell strings and solar modules using roll-to-roll foil-based metallization approaches. Methods disclosed herein can comprise the steps of providing at least one solar cell wafer on a first roll unit and conveying a metal foil to the first roll unit. The metal foil can be coupled to the solar cell wafer on the first roll unit to produce a unified pairing of the metal foil and the solar cell wafer. We disclose solar energy collection devices and manufacturing methods thereof enabling reduction of manufacturing costs due to simplification of the manufacturing process by a high throughput foil metallization process.

Abstract: Aspects of the disclosure provide a solar device and a method for making the solar device. The solar device can include solar cells configured to form a solar cell string with at least a string terminal, and an insulated interconnector including two conductive ends configured to connect the string terminal to peripheral circuitry of the solar device. The method can include disposing the solar cells to form a solar cell string with at least a string terminal, and disposing an insulated interconnector with two conductive ends to connect the string terminal to peripheral circuitry of the solar device.

Abstract: A photovoltaic panel having a photovoltaic module supported by a distributed support frame is described. The distributed support frame may include a support member extending over a back surface of the photovoltaic module. For example, one or more support members may extend laterally from a support hub mounted on the back surface. The distributed support frame may reduce a span length of the photovoltaic module between support locations, and thus, may reduce a likelihood that a module laminate will crack under a design load.

Abstract: Photovoltaic module systems are provided. These systems can comprise multiple photovoltaic laminates connected with one or more mechanical coupling pairs that extend beyond perimeter edges of individual photovoltaic laminates. The mechanical coupling pairs can be connected to ends of support members positioned beneath the photovoltaic laminates. During assembly, an additional photovoltaic laminate may be added to connected photovoltaic laminates that are previously connected and lie along a shared plane of reference via pairs of mechanical couplings.

Abstract: A photovoltaic panel having a distributed support frame adhered to a photovoltaic module is described. For example, the distributed support frame may include one or more support member or support mounts adhered to the photovoltaic module by an adhesive layer. The photovoltaic module may include layers bound together by an encapsulant. Accordingly, the distributed support frame may be attached to the photovoltaic module during a same lamination process used to laminate the photovoltaic module.

Abstract: A photovoltaic panel having a distributed support frame adhered to a photovoltaic module is described. For example, the distributed support frame may include one or more support member or support mounts adhered to the photovoltaic module by an adhesive layer. The photovoltaic module may include layers bound together by an encapsulant. Accordingly, the distributed support frame may be attached to the photovoltaic module during a same lamination process used to laminate the photovoltaic module.

Abstract: A photovoltaic module having an external electrical connector is described. For example, the photovoltaic module may include a plug receptacle mounted on a module laminate, and a contact may extend from a photovoltaic cell within the module laminate into a plug channel of the plug receptacle. The plug receptacle may receive a mating electrical connector, e.g., an electrical plug, of off-panel electronics. Accordingly, the contact may be removably connected to the mating electrical connector, and the photovoltaic cell may be placed in electrical connection with the off-panel electronics.

Abstract: Photovoltaic module systems are provided. These systems can comprise multiple photovoltaic laminates connected with one or more mechanical coupling pairs that extend beyond perimeter edges of individual photovoltaic laminates. The mechanical coupling pairs can be connected to ends of support members positioned beneath the photovoltaic laminates. During assembly, an additional photovoltaic laminate may be added to connected photovoltaic laminates that are previously connected and lie along a shared plane of reference via pairs of mechanical couplings.

Abstract: A photovoltaic (PV) module having bi-directional couplings is described. The bi-directional couplings include a first coupling mounted on a support frame under a first edge of the PV module and a second coupling mounted on the support frame under a second edge of the PV module. The PV module can be a keystone module and the bi-directional couplings of the keystone module can connect to respective couplings of several adjacent PV modules. The bi-directional couplings can form male-to-female connections with the respective couplings to quickly combine the PV modules into a PV module assembly. The PV module assembly includes the bi-directionally connected PV modules supporting each other in both an x-direction and a y-direction.

Abstract: Disclosed herein are approaches to fabricating solar cells, solar cell strings and solar modules using roll-to-roll foil-based metallization approaches. Methods disclosed herein can comprise the steps of providing at least one solar cell wafer on a first roll unit and conveying a metal foil to the first roll unit. The metal foil can be coupled to the solar cell wafer on the first roll unit to produce a unified pairing of the metal foil and the solar cell wafer. We disclose solar energy collection devices and manufacturing methods thereof enabling reduction of manufacturing costs due to simplification of the manufacturing process by a high throughput foil metallization process.

Abstract: A photovoltaic panel having a photovoltaic module supported by a distributed support frame is described. The distributed support frame may include a support member extending over a back surface of the photovoltaic module. For example, one or more support members may extend laterally from a support hub mounted on the back surface. The distributed support frame may reduce a span length of the photovoltaic module between support locations, and thus, may reduce a likelihood that a module laminate will crack under a design load.

Abstract: A photovoltaic panel having a photovoltaic module supported by a distributed support frame is described. The distributed support frame may include a support member extending over a back surface of the photovoltaic module. For example, one or more support members may extend laterally from a support hub mounted on the back surface. The distributed support frame may reduce a span length of the photovoltaic module between support locations, and thus, may reduce a likelihood that a module laminate will crack under a design load.

Abstract: Disclosed herein are approaches to fabricating solar cells, solar cell strings and solar modules using roll-to-roll foil-based metallization approaches. Methods disclosed herein can comprise the steps of providing at least one solar cell wafer on a first roll unit and conveying a metal foil to the first roll unit. The metal foil can be coupled to the solar cell wafer on the first roll unit to produce a unified pairing of the metal foil and the solar cell wafer. We disclose solar energy collection devices and manufacturing methods thereof enabling reduction of manufacturing costs due to simplification of the manufacturing process by a high throughput foil metallization process.

Abstract: A photovoltaic (PV) module having bi-directional couplings is described. The bi-directional couplings include a first coupling mounted on a support frame under a first edge of the PV module and a second coupling mounted on the support frame under a second edge of the PV module. The PV module can be a keystone module and the bi-directional couplings of the keystone module can connect to respective couplings of several adjacent PV modules. The bi-directional couplings can form male-to-female connections with the respective couplings to quickly combine the PV modules into a PV module assembly. The PV module assembly includes the bi-directionally connected PV modules supporting each other in both an x-direction and a y-direction.

Abstract: Photovoltaic (PV) cells that can be interconnected with improved interconnect joints to form PV cell strings and PV modules. The improved interconnect joints comprise at least two types of adhesive bonding regions to maximize both electrical conductivity and mechanical strength of interconnect joints coupling terminals of PV cells. The disclosed approaches to PV cell interconnection provide greater manufacturing rates and higher quality PV cell strings and PV modules.

Abstract: A photovoltaic (PV) module having bi-directional couplings is described. The bi-directional couplings include a first coupling mounted on a support frame under a first edge of the PV module and a second coupling mounted on the support frame under a second edge of the PV module. The PV module can be a keystone module and the bi-directional couplings of the keystone module can connect to respective couplings of several adjacent PV modules. The bi-directional couplings can form male-to-female connections with the respective couplings to quickly combine the PV modules into a PV module assembly. The PV module assembly includes the bi-directionally connected PV modules supporting each other in both an x-direction and a y-direction.

Abstract: Disclosed herein are approaches to fabricating solar cells, solar cell strings and solar modules using roll-to-roll foil-based metallization approaches. Methods disclosed herein can comprise the steps of providing at least one solar cell wafer on a first roll unit and conveying a metal foil to the first roll unit. The metal foil can be coupled to the solar cell wafer on the first roll unit to produce a unified pairing of the metal foil and the solar cell wafer. We disclose solar energy collection devices and manufacturing methods thereof enabling reduction of manufacturing costs due to simplification of the manufacturing process by a high throughput foil metallization process.

Abstract: A photovoltaic module having an external electrical connector is described. For example, the photovoltaic module may include a plug receptacle mounted on a module laminate, and a contact may extend from a photovoltaic cell within the module laminate into a plug channel of the plug receptacle. The plug receptacle may receive a mating electrical connector, e.g., an electrical plug, of off-panel electronics. Accordingly, the contact may be removably connected to the mating electrical connector, and the photovoltaic cell may be placed in electrical connection with the off-panel electronics.

Abstract: Disclosed herein are approaches to fabricating solar cells, solar cell strings and solar modules using roll-to-roll foil-based metallization approaches. Methods disclosed herein can comprise the steps of providing at least one solar cell wafer on a first roll unit and conveying a metal foil to the first roll unit. The metal foil can be coupled to the solar cell wafer on the first roll unit to produce a unified pairing of the metal foil and the solar cell wafer. We disclose solar energy collection devices and manufacturing methods thereof enabling reduction of manufacturing costs due to simplification of the manufacturing process by a high throughput foil metallization process.

Abstract: Aspects of the disclosure provide a solar device and a method for making the solar device. The solar device can include solar cells configured to form a solar cell string with at least a string terminal, and an insulated interconnector including two conductive ends configured to connect the string terminal to peripheral circuitry of the solar device. The method can include disposing the solar cells to form a solar cell string with at least a string terminal, and disposing an insulated interconnector with two conductive ends to connect the string terminal to peripheral circuitry of the solar device.