Solar cell arrangement and method for manufacturing the same

Abstract

A method for manufacturing a solar cell arrangement (700) comprising: providing a first solar cell (100) with a first terminal (104, 105) arranged on a top surface (101) of the first solar cell (100) adjacent to a first edge (111) of the first solar cell (100), and a second terminal (103, 102) arranged on said top surface (101) of the solar cell (100) adjacent to a second edge (110) of the first solar cell (100) opposite the first edge (111); providing a second solar cell (200) with a first terminal (204, 205) arranged on a top surface (201) of the second solar cell (200) adjacent to a first edge (211) of the second solar cell (200), and with a second terminal (203, 202) arranged on said top surface (201) of the second solar cell (200) adjacent to a second edge (210) of the second solar cell (200) opposite to the first edge (211) of the second solar cell (200);Providing a first L-shaped metal connecting element (108, 109) with a first base section having a width approximately equal to or wider than the width of the first terminal (104, 105) of the first solar cell (199), and a second section attached to the aforementioned first base section of the first metal connecting element (108, 109) and extending perpendicularly thereto; securely fastening the first base section of the first metal connecting element (108, 109) to the first terminal (104, 105) of the first solar cell (100); Providing a second L-shaped metal connecting element (207, 206) with a first base section having a width approximately equal to or less than the width of the second terminal (203, 202) of the second solar cell (200), and with a second section attached to the first base section of the second metal connecting element (207, 206) and extending perpendicularly thereto extending;Securely attaching the first base part of the second metal connecting member (207, 206) to the second terminal (203, 202) of the second solar cell (200); aligning the first edge (111) of the first solar cell (100) with the second edge (210) of the second solar cell (200) such that the two edges (111, 210) are substantially parallel to each other and are uniformly spaced apart by not less than 0.0254 cm (0.01 in) and not more than 0.381 cm (0.15 in), and wherein the second part of the first metal connecting member (108, 109) is adjacent to the second part of the second metal connecting member (207, 206);insecure attachment of the second part of the first metal connecting element (108, 109) to the second part of the second metal connecting element (207, 206) such that an electrically conductive connection is established between the first terminal (104, 105) of the first solar cell (100) and the second terminal (203, 202) of the second solar cell (200), wherein at least one end part of the second part of the first metal connecting element (108, 109) is bent together with at least one end part of the second part of the second metal connecting element (207, 206).

Description

BACKGROUND OF THE INVENTIONField of the InventionThe present invention relates to a solar cell array and a method of manufacturing the same.Description of Related ArtIn recent years, solar cells have been widely used in various fields and applications. For example, solar cells composites and solar cell arrays comprising one or more solar cells may be used in communication devices, in electrical / electronic equipment, industrial equipment, and also for military and space applications.In order to increase the total power size of the solar cell array, it is possible to increase the number of solar cells in a unit area. For example, in the field of space technology (satellites, aerospace stations, space telescope and the like), a very limited area (for example for solar wings) can be provided to attach solar cells or a solar cell arrangement. Thus, the density of solar cells becomes of particular importance in space applications (aerospace applications).Reliability, on the other hand, becomes a critical problem, especially in aerospace applications, it has heretofore been difficult, if not impossible, to repair, replace or service the solar cell array mounted on an aerospace body.Further, since solar wings in aerospace aircraft are generally folded or wound / rolled when the aircraft is brought into space by a rocket or space shuttle, it is advantageous if the aspect ratio of the solar cell array is reduced to a minimum. In other words, it is desirable to reduce the height of the solar cell array.In addition, an aerospace body on which a solar cell array or arrangement is disposed generally operates in an aerospace environment where there is no ambient air to block particulate space (also called cosmetic) beams. In such applications, a tip of the solar cell array may possibly cause electrical spark discharges in a space environment, for example, due to the Kosmic rays.U.S. Pat. No. 5,180,442 A describes photovoltaic solar modules which are assembled to form an array with the aid of a grid and conductive mounting electrodes. The grid consists of parallel conductive strips which are fastened to a supporting frame at a distance corresponding to the width of a module. The electrodes are fastened to the busbars produced on the modules, which are sealed with the protruding ends of the electrodes against the environment. The protruding ends fit into slots stamped in the traces, thereby both securing the modules and electrically connecting them to the grid.GB 1 328 324 A describes a solar cell provided with a connector attached to a contact on its upper (photosensitive) surface and protected by a cover glass (or a deposited glass layer) covering the whole upper surface together with the contact and the attached part of the connector. The connector is soldered or welded to a vapor deposited contact on top of a Si photocell. The surface is then protected by a cover glass which is attached to the cell by an adhesive layer and extends over the part of the connector which is attached to the contact.DE 24 11 690 A1 describes a solar cell which preferably consists of monocrystalline silicon in the n-on-p or p-on-n structure, which has metal contacts and contact strips as connecting elements on the p- and n-sides. The two contact systems are electrically connected to the respective contact strips. The contact systems and the connection strips form an integral material unit which is applied to the semiconductor component by vapor deposition or sputtering. The semiconductor device is preferably set on a lower step surface of a two-stage positioning block so that the block top surface is at the same level as the semiconductor top surface. Then, an auxiliary sheet is fixed on the upper surface and the front edge of the upper surface. After a mask for evaporation corresponding to the bonding pattern is deposited, evaporation or sputtering is performed.SUMMARYThe object on which the invention is based is achieved by the subject matter of the independent claims. Further advantageous embodiments are specified in the dependent claims.With an embodiment of the present disclosure, there is provided a solar cell assembly including: a solar cell; and a conductive interconnect member including a first part and a second part attached to the first part together with an angle formed therebetween, the first part being attached to an upper surface (upper surface) of the solar cell, wherein at least one end part of the second part is capable of being bent together with at least one end part of a second part of an interconnect member of another of the mentioned solar cell assembly in an operation state.According to another embodiment, there is provided a solar cell assembly, which may include a first solar cell assembly including a first solar cell and a first conductive interconnect member, the first interconnect member including first and second portions attached to the first portion with an angle formed therebetween, the first portion attached to a surface (upper surface) of the first solar cell, and a second solar cell assembly including a second solar cell, and a second conductive interconnect member including first and second portions attached to the first portion with an angle formed therebetween, the first portion of the second interconnect member attached to an upper surface of the second solar cell, the first solar cell and the second solar cell being disposed adjacent to each other such that the second portion of the first interconnect member and the second portion of the second interconnect member are adjacent to each other, and, wherein at least the end portion of the second portion of the first intermediate link is bent together with at least the end portion of the second portion of the second intermediate link.In an implementation of the embodiment, at least the end portions of the second portions of the first and second intermediate links are attached to each other before bending. According to another implementation of the embodiment, the first and second intermediate links are integrally formed with at least the end portions of the second portions thereof attached to each other.According to another embodiment of the present disclosure, the solar cell assembly may further include a support, wherein the first and second solar cells are mounted on the support with bottom surfaces of the first and second solar cells facing the support.According to another embodiment of the present disclosure, there is provided a method of manufacturing a solar cell array, the method comprising: providing a first solar cell array including a first solar cell and a first conductive interconnect member, the first interconnect member including a first part and a second part attached to the first part with an angle formed therebetween, the first part being attached to the top surface of the first solar cell; providing a second solar cell array including a second solar cell and a second conductive interconnect member, the second interconnect member including a first part and a second part attached to the first part with an angle formed therebetween, the first part of the second interconnect member being attached to the top surface of the second solar cell; disposing the first solar cell and the second solar cell adjacent to each other such that the second part of the first intermediate connector and the second part of the second intermediate connector are provided adjacent to each other; and bending at least the end part of the second part of the first intermediate connector together with at least the end part of the second part of the second intermediate connector.In yet another embodiment, a method of manufacturing a solar cell assembly is provided, which may include: providing a first solar cell; attaching a first conductive interconnect member to the first solar cell with a first portion of the interconnect member attached to the top surface of the solar cell, the interconnect member including first and second portions attached to the first portion with an angle formed therebetween; providing a second solar cell; attaching a second conductive interconnect member to the second solar cell with a first portion of the second interconnect member attached to the top surface of the second solar cell, the second interconnect member including the first portion and a second portion attached to the first portion with an angle formed therebetween; disposing the first solar cell and the second solar cell adjacent to each other such that the second part of the first intermediate connector and the second part of the second intermediate connector are adjacent to each other; and bending at least the end part of the second part of the first intermediate connector together with at least the end part of the second part of the second intermediate connector.In a further exemplary embodiment, the method further comprises the following:attaching at least the end portions of the second portions of the first and second intermediate links to each other before bending. In another implementation of the embodiment, first and second intermediate links are integrally formed with at least the end portions of the second portions thereof and fastened together.Other aspects, features and advantages of the invention will be understood based on the following description with reference to the drawings.BRIEF DESCRIPTION OF THE DRAWINGSThe accompanying drawings form a part of the disclosure and illustrate embodiments of the invention, and together with the description, these are used to explain the principles of the invention. FIG. 1 is a schematic perspective view of an example of a solar cell array according to an embodiment of the invention. FIG. 2 illustrates a cross-sectional view taken along line 2- 2 of FIG. 1. FIG. 3 is a schematic perspective view of an example of the solar cell according to the embodiment of the present disclosure. FIG. 4 illustrates a longitudinal section of 4-4 of FIG. 3. FIG. 5 is a schematic sectional view of a solar cell array according to another embodiment of the invention, in which a glass cover is disposed on an upper surface of the solar cell; FIG. 6 is a schematic perspective view of another solar cell array according to the embodiment of the invention. FIG. 7 is a perspective view of a solar cell array according to another embodiment of the invention. FIG. 8 is a fragmentary view of the solar cell assembly taken along line 7--7 of FIG. 7 showing the adjacent portions of the adjacent interconnection members. FIG. 9 illustrates a situation where at least the end parts of two adjacent second parts of the intermediate links are fastened to each other as shown in FIG. 8. FIG. 10 is a partial sectional view of the solar cell array in which at least the end portions of the adjacent second portions of the adjacent intermediate members are bent as shown in FIG. 9. FIGS. 11 and 12 each illustrate an example of the method for manufacturing a solar cell array according to an embodiment of the present disclosure.DESCRIPTION OF THE EMBODIMENTSEmbodiments of the present invention will be described in detail with reference to the drawings. Note that like reference numerals refer to like elements throughout the drawings, and thus repetitive descriptions are omitted.FIG. 1 is a schematic view of a solar cell array 300 according to an embodiment of the invention in which conductive interconnection members 106 to 109 are attached to a solar cell 100. FIG. 2 illustrates a cross-sectional view taken along line 2- 2 of FIG. 1, FIG. 3 is a schematic perspective view of an embodiment of the solar cell 100 according to the embodiment of the present disclosure. FIG. 4 illustrates a cross-sectional view taken along line 4- 4 of FIG. 3.According to an embodiment of the present disclosure, the solar cell assembly 300 may include a solar cell 100 and a conductive interconnection member ( 102, 103, 104, or 105) mounted on an upper surface (upper surface) 101 of the solar cell 100, as illustrated in FIG. 1.The solar cell 100 (hereinafter also referred to as a first solar cell) may be cut out from a wafer, a wafer in which a number (for example, two or more or less) of solar cells are fabricated, as known to those skilled in the art. An example of the solar cell 100 is shown in FIG. 3 ; however, the present invention is not limited thereto.In some preferred embodiments, as shown in FIG. 3, the solar cell 100 may have four (4) connecting parts 102 to 105 (which may be referred to as first connecting parts hereinafter) formed on the top surface of the solar cell. However, the invention is not limited thereto as long as at least one connection part can be formed on the upper surface (surface) 101 of the solar cell 100. In a preferred embodiment, at least two connecting parts may be formed on the top side of the solar cell 100, one for connecting a node of the first solar cell and another one or more for connecting to a cathode of the solar cell 100. It should be noted that one or more additional connecting parts or parts may also be formed on the surface of the solar cell, namely for connection to / from a bypass circuit which may be formed in or external to the solar cell.It should be noted that the connecting parts 102 to 105 as shown are to be understood only by way of example and are not intended to limit the scope of the invention. For example, the connecting portions 102- 105 may be arranged in line with or in a recess of the surface 101, although they are shown as being excellent from the top 101. A specific embodiment provides: terminals formed on the top surface of the solar cell may be surrounded by a passivation layer, for example, and may be used as the connection part. Further, as the connection parts, for example, various terminals formed on the surface of the solar cell may also be used as appropriate.Further, in some embodiments, it is preferable that the connection part is formed adjacent to an edge of the top surface of the solar cell. As shown in Figure 3, two of the connecting parts 102 and 103 are formed adjacent an edge 110 of the top side (surface) 101, whereas two further connecting parts 104 and 105 are formed adjacent an opposite edge 111 of the top side 101. It should be noted that the number and arrangement of the connecting parts on the surface of the solar cell is not intended to be limited to the relationships shown in the drawings.Although the outer edges of the connecting parts are shown as being aligned with the edge of the top surface of the solar cell in FIG. 4, the invention should not be limited thereto. For example, in an implementation of the embodiment, the outer edges of the connecting parts may be somewhat spaced apart from the edge of the top side of the solar cell.The interconnection members 106-109 may be attached to the surface 101 of the solar cell 100 by, for example, welding or soldering. Each of the intermediate links 106-109 has a first portion and a second portion attached to the first portion with an angle formed therebetween. By way of example, FIG. 2 illustrates the interconnection members 107 and 108, each of which may include a first portion 1071 / 1081 and a second portion 1072 / 1082 attached to the first portion with an angle (not specifically shown) formed therebetween.In a preferred embodiment, the angle formed by the first portion and the second portion of an intermediate link may be in the range of 85 degrees to 90 degrees. In a more preferred embodiment, the first part is substantially perpendicular to the second part, as exemplarily shown in FIG. 2. That is, the intermediate links may have any L-shaped shape in a sectional view. In some more preferred embodiments, the interconnection members may be formed of metal, for example, a metal plate. As the material for forming the interconnecting member, molybdenum, a nickel-cobalt-iron alloy material designed to be compatible with the thermal expansion characteristics of fused silica glass as available under the trade name Covariance from Carpenter Technology Corporation; a nickel-iron alloy material having a uniquely low thermal expansion coefficient under the trade name Invar, FeNi36or 64FeNi; or the like may be considered.As can be further seen in FIGS. 3 and 4, the first part and the second part of the intermediate connecting member may have a substantially rectangular shape. In a preferred embodiment, the intermediate connector comprising first and second connecting portions may have a thickness in the range of about 0.0007 inches and 0.0013 inches (or between about 0.0178 mm and 0.033 mm).In certain embodiments, the intermediate connector may be used for, among other things, providing an electrical connection to / from the solar cell. In such a case, the first portions of the interconnection members 106- 109 may be attached to corresponding connection portions 102- 105 of the solar cell 100. In a preferred embodiment, the intermediate connector(s) are attached to a corresponding connecting part such that the second part is provided closer to the edge adjacent thereto than the first part thereof, as shown in Figures 1 and 2. In a further preferred embodiment, the underside (lower surface) of the first part of the intermediate connection member (e.g. 106) is arranged inside the surface (upper upper surface) of the corresponding connection part, e.g. 102, formed on the surface of the solar cell 100, i.e. not outside the perimeter of the connection part. In a more specific embodiment, the first part of the intermediate connection member (for example, any one of the 106-109) formed in the corresponding connection part and attached to the top surface of the solar cell 100 has a dimension (for example, width) equal to or smaller than the corresponding connection part. It is to be noted that the above embodiments are only exemplary embodiments and do not limit the scope of the invention. There is no particular limitation on the shapes of the connecting parts or on the development of the intermediate connecting parts.As mentioned above, the number and shape of the connecting parts formed on the upper surface of the solar cell is not limited to the case illustrated in FIGS. 1 to 2, and thus the number and arrangement of the interconnection members are not limited to the case illustrated in FIGS. 3 to 4. Note that the correspondence between the connection parts and the connection members is not limited in a one-to-one manner, for example, there may be such a case where the interconnection members are attached to the same connection part on the surface of the solar cell; and vice versa.Further, at least one end portion of the second portion is capable of being bent together with at least one end portion at a second portion of an intermediate link of the other mentioned solar cell assembly in an operating state. The intermediate connector of the above-mentioned another solar cell assembly may be formed similarly to the intermediate connector as described above and may include a first part and a second part attached to the first part with an angle formed therebetween, and the first part of the another intermediate connector is attached to a connection part formed on a surface or top of the other solar cell.FIG. 5 is a schematic sectional view of a solar cell 500 according to another embodiment of the invention, in which a glass cover 120 is disposed over the top surface 101 of the solar cell 100. In one embodiment, the glass cover 120 is disposed above the surface of the solar cell 100 to which the interconnection members (e.g., 107 and 108) are attached. That is, the glass cover is disposed over the top surface of the solar cell 100 after the intermediate connector (for example, 107) is attached to the solar cell; and further, it is to be noted that the invention is not limited thereto. It is preferred that the glass cover is transparent to light. Since the materials for forming the glass cover and the method for disposing or attaching the glass cover on the surface of the solar cell do not relate to the invention, specific descriptions thereof are omitted and those skilled in the art can use or develop materials and methods known in the art.According to the above embodiments of the present disclosure, the density of solar cells, for example, in a solar cell array, can be increased, that is, more solar cells can be mounted in a limited area in a limited area, which would be advantageous.FIG. 6 is a schematic view of another solar cell array 600 according to the embodiment of the invention. The solar cell array 600 according to this embodiment is substantially identical to the solar cell array shown in FIG. 1, and may include a solar cell 200 (hereinafter referred to as a second solar cell) and interconnection members 206 to 209, each of which includes a first part and a second part, attached to the first part with an angle therebetween, the first part of the second interconnection member being fixed to the upper surface (surface) 201 of the second solar cell.In this embodiment, the solar cell 200 may include connection parts (hereinafter, also referred to as second connection parts) 202 to 205 formed on the upper surface 201 and adjacent to the respective edges of the upper surface; and the first parts of the second intermediate connection members 206 to 209 are fixed to the respective connection parts 202 to 205 of the second solar cell.The above explanations regarding the solar cell array illustrated in conjunction with FIGS. 1-5 can also be equivalently applied to the solar cell array according to this embodiment, and thus repetitive descriptions are omitted here.FIG. 7 is a schematic perspective view according to a further exemplary embodiment of the invention, namely, it has at least one solar cell arrangement (for example 500) and a second solar cell arrangement (for example 600), wherein the first solar cell and the second solar cell are arranged adjacent to one another. As shown, the first solar cell 100 and the second solar cell 200 are arranged adjacent to each other such that second parts of the adjacent interconnection members for the first and second solar cells are adjacent to each other. In this way, the upper side 101 of the first solar cell 100 and the upper side 201 of the second solar cell 200 are arranged adjacent to one another, for example laterally, as shown in FIG. 7. In a preferred embodiment of the present disclosure, the edges 111 and 210 of the first and second solar cells are respectively disposed adjacent to the adjacent second parts (e.g., 108 and 207) such that a maximum distance between these two edges of the first and second solar cells is 0.15 inch or less, and more preferably, not less than 0.1 inch (or about 0.254 mm) and not more than about 0.15 inch (or about 0.38 mm).The one or both glass covers 120 and 220 may be disposed above the corresponding surface(s) 101 and / or 201 of the solar cell(s), after or before the placement on the surfaces 101 and 201.FIG. 8 is a partial cross-sectional view of the solar cell assembly, taken along line 7- 7 of FIG. 7, illustrating the adjacent second portions 1082and 2072of the adjacent interconnection members 108 and 207. As can be seen from FIG. 8, the second parts (for example 1082 and 2072) extend sufficiently beyond the glass cover. However, the present invention is not limited to the embodiment shown in FIG. 8. In some preferred embodiments, the length of a portion of the second portion that extends across an upper surface of the respective glass cover (e.g., 1082 / 2072) may be in a range of about 0 to 0.1 inches (or about 2.54 mm).According to the above embodiments of the present disclosure, the solar cells may be arranged or fixed very close to each other, in which way the density of the solar cells in a unit area can be increased. Further, in some particular embodiments of the present disclosure, the aspect ratio (aspect ratio) of the solar cell arrays may be reduced, in other words, the height of the solar cell array and the solar cell array may be reduced. Moreover, the resistance to stress or stress when the assembly is wound or stretched can be increased by using the intermediate connector according to the present disclosure.Then, as illustrated in FIG. 9, at least end portions of the second portions 1082 and 2072 of the intermediate links 108 and 207 may be fastened to each other. In this way, an electrical connection between the corresponding first connection part 104 (e.g., connected to a positive / positive electrode) of the first solar cell 100 and the corresponding second connection part 203 (e.g., connected to a negative / negative electrode) can be made of the second connection part of the second solar cells 200. In this way, the solar cells can be electrically connected in series or in parallel.FIG. 10 is a partial cross-sectional view of the solar cell assembly in which at least end portions of the adjacent second portions 1082 and 2072 of adjacent intermediate links 108 and 207 are bent with each other as shown in FIG. 9. For example, they may be bent to be wound or rolled in a spiral shape as indicated by reference numeral 130 in FIG. 10 ; and it should be noted that the present disclosure is not limited thereto.Due to the bending of the end parts, the aspect ratio or the aspect ratio of the solar cell array can be further reduced, or in other words, the height of the solar cell array can be further reduced. This is of particular advantage in a case where the solar cell arrangement is to be wound or rolled, for example in the case where the spacecraft on which the solar cell arrangement according to the present disclosure is mounted on its wings is launched into space by a rocket. Further, due to the bending of the end portions, the resistance to stress due to, for example, the rolling or stretching of the solar cell array is further improved, and thus the reliability of the solar cell array can be improved.Moreover, it should be noted that the aerospace crab (SAW) on which the solar cell array according to the present disclosure is mounted is generally operated in a space environment in which no air environment is present to block spatial particle beams (COS beams). In such applications, the tip 131 attached to end portions of the second portions 1081 and 2072 may possibly cause spark discharge in a space environment due to the Kosmic rays. According to the above embodiments of the present disclosure, the spark discharge can be reduced or eliminated by reducing the length of the second part extending over the upper side of the glass cover and / or by bending the end parts.In some examples of the embodiment, at least the end parts of the second parts 1082 and 2072 may be attached by welding, brazing, or the like, and then the second parts 1082 and 2072 may be bent, for example, to be rolled up as illustrated in FIGS. 9 and 10. In some alternative examples of the embodiment, at least the end portions of the second portions 1082 and 2072 may be bent directly together without the fastening process. Alternatively, the first and second intermediate links 108 and 207 may be integrally formed with at least the first end portions of the second portions 1082 and 2072 thereof being fixed to each other.According to another embodiment of the present disclosure, the solar cell assembly may further include a support (not shown), wherein the solar cell, for example, cells 100 and / or 200 may be mounted on the support by, for example, silicone adhesive, the bottom surfaces or the bottom surfaces thereof facing the support. In one embodiment, the carrier may be formed of aluminum or titanium. In a preferred embodiment, the carrier is capable of being bent and stretched.Accordingly, methods for manufacturing the solar cell array are also provided. A method of manufacturing the solar cell array according to the embodiments of the present disclosure will be described below with reference to FIGS. 11 and 12.FIGS. 11 and 12 each illustrate a flowchart of an example of a method of manufacturing a solar cell array according to an embodiment of the present disclosure.

[0058] A method for manufacturing a solar cell array according to an exemplary embodiment of the present disclosure may include: providing (S 1101) a first solar cell array including a first solar cell and a first intermediate connector, the first intermediate connector including a first part and a second part attached to the first part with an angle therebetween, the first part being attached to an upper surface of the first solar cell; providing (S 1103) a second solar cell array including a second solar cell and a second intermediate connector, the second intermediate connector including a first part and a second part attached to the first part with an angle therebetween, further the first part of the second intermediate connector being attached to an upper surface of the second solar cell; arranging (S 1105) the first solar cell and the second solar cell adjacent to each other such that the second part of the first intermediate link and the second part of the second intermediate link are adjacent to each other; and bending (S 1107) at least the end part of the second part of the first intermediate link together with at least the end part of the second part of the second intermediate link.

[0059] A method for manufacturing a solar cell assembly according to another embodiment of the present disclosure may include: providing (S 1201) a first solar cell; attaching (S 1203) a first intermediate connector to the first solar cell with a first part of the intermediate connector attached to the top surface of the solar cell, the intermediate connector to include the first part and a second part attached to the first part formed with an angle therebetween; providing (S 1205) a second solar cell; attaching (S 1207) a second intermediate connector to the second solar cell with a first part of the second intermediate connector attached to the top surface of the second solar cell, the second intermediate connector having the first part and a second part attached to the first part formed with an angle therebetween; arranging (S 1209) the first solar cell and the second solar cell adjacent to each other such that the second part of the first intermediate link and the second part of the second intermediate link are adjacent to each other; and bending (S 1211) at least the end part of the second part of the first intermediate link together with at least the end part of the second part of the second intermediate link.

[0060] In an implementation of the embodiment, the methods may further include: attaching at least the end parts of the second parts of the first and second intermediate links attached to each other before the mentioned bending. In another implementation of the embodiment, the first and second intermediate links are integrally molded with at least the end portions of the second portions attached to each other.In an implementation of the embodiment, the bending causes at least the end portions of the second portions of the first and second intermediate links to be curved into a spiral shape.In an implementation of the embodiment, at least one of the first and second interconnection members is an L-shaped metal plate.In one implementation of the embodiment, at least one of the first and second intermediate links is formed of molybdenum; a nickel-cobalt-iron alloy material configured to be compatible with the thermal expansion characteristics of borosilicate glass, such as is available under the trade name Covariance from Carpenter Technology Corporation; or a nickel-iron alloy material having a uniquely low coefficient of thermal expansion available under the trade name Invar, FeNi36, or 64FeNi.In one implementation of the embodiment, the first and second portions of at least one of the first and second interconnection members are substantially rectangular in shape, having a thickness in the range of 0.001778 cm to 0.003302 cm (0.0007 inch to about 0.0013 inch).In an implementation of the embodiment, the methods may further include: disposing a glass cover over the top surface of any of the first or second solar cells after the corresponding interconnect member is attached to any of the first and second solar cells.In an implementation of the embodiment, the length of a portion of the second portion of one of the first and second solar cells that extends across a top surface of the glass cover is in a range from 0 to about 0.254 cm (0.1 inch).In an implementation of the embodiment, each of the first and second solar cells has a connection part formed at an upper surface thereof and adjacent to an edge of the upper surface (surface), and the first parts of the first and second interconnection members are attached to corresponding connection parts of the first and second solar cells.In one implementation of the embodiment, the attachment of any of the first and second is performed. Intermediate connecting members are made by welding or soldering.In an implementation of the embodiment, the arranging causes a maximum distance between the edges of the first and second solar cells adjacent to the first and second interconnection members to be 0.381 cm (0.15 inches) or less.In one implementation of the exemplary embodiment, the first solar cell has at least two of the first connecting parts, wherein one of the first connecting parts serves for connection to a node of the first solar cell and another of the first connecting parts serves for connection to a cathode of the first solar cell.In an implementation of the embodiment, the attaching of the first intermediate connector includes: attaching at least two of the intermediate connectors to the corresponding first connection parts of the first solar cell.In one implementation of the embodiment, the attachment of at least one of the first and second intermediate links causes the second portion of the at least one of the first and second intermediate links to be closer to the corresponding edge that is adjacent thereto than is the case for the first portion.In an implementation of the embodiment, the method may further include: mounting the first and second solar cells on the substrate, with bottom surfaces of the first and second solar cells facing the substrate. The attaching step may be performed after or before attaching the intermediate connector for the first and / or second solar cells to the respective solar cells, depending on different implementations of the embodiment.It should be noted that the embodiments of the present disclosure can be freely combined with each other without departing from the scope of the invention.It is possible to carry out the solar cell arrays or the methods for manufacturing the same according to the disclosure in different ways. The orders and steps described above for the methods are to be considered as illustrations, and the steps and methods of the present invention are not limited to the orders specifically described above unless otherwise stated.Although some specific embodiments of the present invention have been demonstrated in detail with examples, those skilled in the art should appreciate that the above examples are illustrative only and are not intended to limit the scope of the invention. It is to be noted that the above embodiments may be modified without departing from the scope of the invention as defined in the claims.

Claims

A method of manufacturing a solar cell arrangement (700), wherein there is provided: providing a first solar cell (100) having a first terminal (104, 105) arranged on an upper side (101) of the first solar cell (100) adjacent to a first edge (111) of the first solar cell (100), and a second terminal (103, 102) arranged on the mentioned upper side (101) of the solar cell (100) adjacent to a second edge (110) of the first solar cell (100) opposite to the first edge (111); providing a second solar cell (200) having a first terminal (204, 205) disposed on a top surface (201) of the second solar cell (200) adjacent to a first edge (211) of the second solar cell (200) and a second terminal (203, 202) disposed on said top surface (201) of the second solar cell (200) adjacent to a second edge (210) of the second solar cell (200) opposite to the first edge (211) of the second solar cell (200); providing a first metal interconnect member (108, 109) having an L-shape with a first bottom portion having a width approximately equal to or wider than the width of the first terminal (104, 105) of the first solar cell (199) and a second portion attached to said first bottom portion of the first metal interconnect member (108, 109) and extending perpendicularly thereto; secure attachment of the first bottom part of the first metal interconnect member (108, 109) to the first terminal (104, 105) of the first solar cell (100); provision of a second metal interconnect member (207, 206) having an L-shape with a first bottom part having a width approximately equal to or less than the width of the second terminal (203, 202) of the second solar cell (200), and with a second part attached to the first bottom part of the second metal interconnect member (207, 206) and extending perpendicularly thereto; secure attachment of the first bottom part of the second metal interconnect member (207, 206) to the second terminal (203, 202) of the second solar cell (200); aligning the first edge (111) of the first solar cell (100) with the second edge (210) of the second solar cell (200) such that the two edges (111, 210) are substantially parallel to each other and are uniformly spaced by not less than 0.0254 cm (0.01 inches) and not more than 0.381 cm (0.15 inches), and further wherein the second portion of the first metal interconnect (108, 109) is adjacent the second portion of the second metal interconnect (207, 206); and securely attaching the second part of the first metal interconnect member (108, 109) to the second part of the second metal interconnect member (207, 206) such that an electrically conductive connection is established between the first terminal (104, 105) of the first solar cell (100) and the second terminal (203, 202) of the second solar cell (200), wherein at least one end part of the second part of the first metal interconnect member (108, 109) is bent together with at least one end part of the second part of the second metal interconnect member (207, 206).The method of manufacturing a solar cell array (700) of claim 1, wherein the attaching steps are performed by welding.The method of manufacturing a solar cell assembly (700) of claim 1, wherein the first and / or second metal interconnect member (108, 109, 206, 207) is constructed of molybdenum with a nickel-cobalt-iron alloy material configured to be compatible with the expansion characteristics of the borosilicate glass, or a nickel-iron alloy material having a uniquely low coefficient of thermal expansion.The method of manufacturing a solar cell assembly (700) of claim 1, wherein the first and / or second metal interconnect members (108, 109, 206, 207) have a rectangular shape with a thickness of 0.001778 cm to 0.003302 cm (0.0007 to 0.0013 inches).Method for producing a solar cell arrangement (700) according to claim 1, wherein provision is further made for a glass cover (120) to be attached to the upper side (101) of the first solar cell (100).The method of manufacturing a solar cell assembly (700) of claim 5, wherein the glass cover (120) is attached to the first solar cell (100) after the first metal interconnect member (108, 109) is attached to the first solar cell (100).The method of manufacturing a solar cell assembly (700) of claim 1, further comprising: attaching a bottom side of the first and second solar cells (100, 200) to a carrier.The method of manufacturing a solar cell array (700) of claim 7, wherein a silicone adhesive is used for attachment to the carrier.The method of manufacturing a solar cell array (700) of claim 7, wherein the carrier is constructed of aluminum or titanium.The method of manufacturing a solar cell array (700) according to claim 1, wherein it is further provided that the end portions of the second portions of the first and second metal interconnection members (108, 109, 206, 207) attached to each other are bent so that the end portions are rolled into a spiral.The method of manufacturing a solar cell assembly (700) of claim 6, wherein the height of the second portion of the first metal interconnect member (108, 109) above a top surface of the glass cover (120) may be in the range of between 0.0 cm and 0.254 cm (0.1 inch).The method for manufacturing a solar cell arrangement (700) of claim 1, wherein the first terminal (104, 105, 204, 205) of the first and / or the second solar cell (100, 200) corresponds to an anode terminal and wherein the second terminal (103, 102, 203, 202) of the first and / or the second solar cell (100, 200) corresponds to a cathode terminal.A solar cell arrangement (700) comprising: a first solar cell (100) having a first terminal (104, 105) arranged on a top side (101) of the first solar cell (100) adjacent to a first edge (111) of the first solar cell (100), and a second terminal (103, 102) arranged on said top side (101) of the first solar cell (100) adjacent to a second edge (110) of the first solar cell (100) opposite to the first edge (111); a second solar cell (200) having a first terminal (204, 205) disposed on a top surface (201) of the second solar cell (200) adjacent a first edge (211) of the second solar cell (200) and a second terminal (203, 202) disposed on said top surface (201) of the second solar cell (200) adjacent a second edge (210) of the second solar cell (200) opposite the first edge (211) of the second solar cell (200); a first metal interconnect (108, 109) having an L-shape with a first bottom portion and a second portion attached to said first portion of said first metal interconnect (108, 109) and extending perpendicular thereto; wherein the first bottom portion of the first metal interconnect (108, 109) is attached to the first terminal (104, 105) of the first solar cell (100); and a second metal interconnect member (207, 206) having an L-shape, having a first bottom portion and a second portion attached to and extending perpendicular to the first portion of the second metal interconnect member (207, 206), wherein the first bottom portion of the second metal interconnect member (207, 206) is attached to the second terminal (203, 202) of the second solar cell (200), the first edge (111) of the first solar cell (100) is aligned with the second edge (210) of the second solar cell (200) such that the two edges (111, 210) are substantially parallel to each other and uniformly spaced by not less than 0.0254 cm (0.01 inches) and not more than 0.381 cm (0.15 inches), and further wherein the second portion of the first metal interconnect member (108, 108, 109) is adjacent to the second part of the second metal interconnect member (207, 206); and the second part of the first metal interconnect member (108, 109) is attached to the second part of the second metal interconnect member (207, 206) such that an electrically conductive connection is established between the first terminal (104, 105) of the first solar cell (100) and the second terminal (203, 202) of the second solar cell (200), and wherein at least one end part of the second part of the first metal interconnect member (108, 109) is bent together with at least one end part of the second part of the second metal interconnect member (207, 206).

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