Abstract: A battery charging system includes a charging rack comprising multiple receptacle, multiple battery assemblies. Each of the battery assemblies includes a housing having a handle, rechargeable battery cells disposed within the housing, and a mating feature protruding away from the housing, wherein the mating feature is configured to selectively connect the battery assembly with the receptacle of the charging rack and includes multiple ports electrically connected to the battery cells and configured receive power from the charging rack to charge the battery cells, and wherein the handle comprises a release button configured to selectively disengage the battery assembly from the receptacle of the charging rack.

Abstract: Various processes can apply pressure and/or heat to a photovoltaic (PV) layer, including processes that integrate solar cells into different types of industrial glass such as an autoclave lamination process. The disclosure describes a planarization technique that can be used on the PV layer to eliminate point loads caused by such processes. In an aspect, a method for producing a component is described that includes disposing or placing a planarization material on a PV layer, modifying a physical form of the planarization material to provide a planar surface made of the planarization material on one side of the PV layer having surface irregularities, and forming a stack of layers (e.g., as part of an autoclave lamination process) for the component by disposing a first layer over the planar surface on the one side of the PV layer and a second layer over the other, opposite side of the PV layer.

Abstract: Removable solar panels from corresponding body parts (removable or fixed) of a vehicle may allow removal and replacement of the panels without removing and replacing the corresponding body parts. In an example, a removable photovoltaic panel for a vehicle may include an array of photovoltaic devices interconnected and assembled together, the array of photovoltaic devices may have a form factor of a surface of a corresponding body panel of the vehicle. The removable photovoltaic panel may also include an attachment layer configured to attach the array of photovoltaic devices to the surface of the corresponding body panel.

Abstract: Various processes can apply pressure and/or heat to a photovoltaic (PV) layer, including processes that integrate solar cells into different types of industrial glass such as an autoclave lamination process. The disclosure describes techniques that can be used on the PV layer to eliminate point loads caused by such processes and protect the PV layer from damage. In an aspect, a method for producing an intermediate PV component protected from mechanical damage in one or more subsequent processing steps is described, where the method includes disposing a protective material on a PV layer having topographical height changes, processing the protective material to provide a planar surface made of the protective material on one or both sides of the PV layer, and providing the PV layer with planarized topographical height changes as the intermediate PV component to the one or more subsequent processing steps for further processing.

Abstract: Various processes can apply pressure and/or heat to a photovoltaic (PV) layer, including processes that integrate solar cells into different types of industrial glass such as an autoclave lamination process. The disclosure describes a planarization technique that can be used on the PV layer to eliminate point loads caused by such processes. In an aspect, a method for producing a component is described that includes disposing or placing a planarization material on a PV layer, modifying a physical form of the planarization material to provide a planar surface made of the planarization material on one side of the PV layer having surface irregularities, and forming a stack of layers (e.g., as part of an autoclave lamination process) for the component by disposing a first layer over the planar surface on the one side of the PV layer and a second layer over the other, opposite side of the PV layer.

Abstract: Various processes can apply pressure and/or heat to a photovoltaic (PV) layer, including processes that integrate solar cells into different types of industrial glass such as an autoclave lamination process. The disclosure describes a planarization technique that can be used on the PV layer to eliminate point loads caused by such processes. In an aspect, a method for producing a component is described that includes disposing or placing a planarization material on a PV layer, modifying a physical form of the planarization material to provide a planar surface made of the planarization material on one side of the PV layer having surface irregularities, and forming a stack of layers (e.g., as part of an autoclave lamination process) for the component by disposing a first layer over the planar surface on the one side of the PV layer and a second layer over the other, opposite side of the PV layer.

Abstract: A photovoltaic module includes front and back sealing layers and at least one photovoltaic cell positioned located therebetween. A moisture resistant layer provided between the first and second sealing layers extends around a portion of a perimeter of the at least one photovoltaic cell. A moisture barrier structure including moisture barrier particles is operatively connected to the sealing layers. The moisture barrier structure improves the moisture resistance of the sealing layer and decreases the water vapor transmission rate into the photovoltaic module.

Abstract: Disclosed are wire assemblies for solar cells. One wire assembly includes a first polymer film and a second polymer film overlaying the first polymer film. The second polymer film has a wire embedded in it such that a surface of the wire that is facing away from the first polymer film is exposed. The gauge of the wire is about 36 to 46 gauge. The thickness of the second polymer film is about ¼ to ½ the diameter of the wire and about 0.5 to 1.5 mils.

Abstract: A solar panel includes a first photovoltaic cell, a second photovoltaic cell, and a flexible electrical connection structure which comprises an electrically conductive connector that electrically connects the first photovoltaic cell and the second photovoltaic cell in series along a connection direction. The electrically conductive connector does not extend from a first major surface of a flexible transparent insulating sheet through a thickness of the flexible transparent insulating sheet to a second major surface of the flexible transparent insulating sheet.

Abstract: Disclosed are wire assemblies for solar cells. One wire assembly includes a first polymer film and a second polymer film overlaying the first polymer film. The second polymer film has a wire embedded in it such that a surface of the wire that is facing away from the first polymer film is exposed. The gauge of the wire is about 36 to 46 gauge. The thickness of the second polymer film is about ¼ to ½ the diameter of the wire and about 0.5 to 1.5 mils.

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.

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.

Abstract: A solar panel includes a first photovoltaic cell, a second photovoltaic cell, and a flexible electrical connection structure which comprises an electrically conductive connector that electrically connects the first photovoltaic cell and the second photovoltaic cell in series along a connection direction. The electrically conductive connector does not extend from a first major surface of a flexible transparent insulating sheet through a thickness of the flexible transparent insulating sheet to a second major surface of the flexible transparent insulating sheet.

Abstract: A photovoltaic module includes front and back sealing layers and at least one photovoltaic cell positioned located therebetween. A moisture resistant layer provided between the first and second sealing layers extends around a portion of a perimeter of the at least one photovoltaic cell. A moisture barrier structure including moisture barrier particles is operatively connected to the sealing layers. The moisture barrier structure improves the moisture resistance of the sealing layer and decreases the water vapor transmission rate into the photovoltaic module.

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 novel methods of fabricating photovoltaic modules using thermoplastic materials to support wire networks to surfaces of photovoltaic cells. A thermoplastic material goes through a molten state during module fabrication to distribute the material near the wire-cell surface interface. In certain embodiments, a thermoplastic material is provided as a melt and coated over a cell surface, with a wire network positioned over this surface. In other embodiments, a thermoplastic material is provided as a part of an interconnect assembly together with a wire network and is melted during one of the later operations. In certain embodiments, a thermoplastic material is provided as a shell over individual wires of the wire network. A thermoplastic material is then solidified, at which point it may be relied on to support the interconnect assembly with respect to the cell. Also provided are novel photovoltaic module structures that include thermoplastic materials used for support.

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: 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: 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 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.