Flexible circuits for solar cell assemblies

Abstract

To provide a flexible circuit used in a solar cell assembly.SOLUTION: A solar cell assembly with flexible circuit includes a solar cell with a cell corner, a sun-opposing surface and a non-sun-opposing surface. The solar cell assembly further includes a flexible circuit joined to the non-sun-opposing surface of the sun. The flexible circuit has the substantially same extension as the solar cell. The flexible circuit includes a flexible insulator having a plurality of edge parts aligned with the solar cell, a flexible corner extending over the cell corner, and a flexible tab extending from one edge part of the plurality of edge parts. The flexible circuit includes a circuit substantially embedded into the flexible insulator. The circuit includes a first electric contact point exposed on the sun-opposing side of the flexible corner, and a second electric contact point exposed on the sun-opposing side of the flexible tab.SELECTED DRAWING: None

Description

[Technical Field]

[0001]

[0001] This disclosure relates generally to solar cell assemblies. Specifically, this disclosure relates to flexible circuits used in solar cell assemblies. [Background technology]

[0002]

[0002] Solar cells are used to convert thermal energy from sunlight into electrical energy. To increase the energy output of a solar cell system, multiple solar cells can be interconnected. Solar cells are typically modular, facilitating adaptive configurations.

[0003]

[0003] Assembling solar cells into a single system can involve multiple components and several steps. In particular, assembling solar cells can include welding several different types of interconnects between adjacent solar cells and encasing the interconnected solar cells in an enclosure. These steps may be impractical for some installations and may require pre-assembly by the manufacturer, increasing handling costs and reducing flexibility for the end user of the solar cell system.

[0004] What is needed is a solar cell assembly that allows for consistent and timely assembly of a system of solar cells. Summary of the Invention

[0005] In one embodiment, a solar cell assembly having a flexible circuit is described. The solar cell assembly includes a solar cell having a sun-facing surface and a non-sun-facing surface, the solar cell having cell corners. The solar cell assembly further includes a flexible circuit coupled to the non-sun-facing surface of the solar cell, the flexible circuit being substantially coextensive with the solar cell. The flexible circuit includes a flexible insulator having a plurality of edges aligned with the solar cell, a flexible corner extending past the cell corners, and a flexible tab extending from one edge of the plurality of edges, with a circuit substantially embedded in the flexible insulator, the circuit including a first electrical contact exposed on the sun-facing side of the flexible corner and a second electrical contact exposed on the sun-facing side of the flexible tab.

[0006] In another embodiment, a flexible circuit for a solar cell assembly is described. The flexible circuit includes a plurality of edges, the plurality of edges configured to align with a solar cell such that the flexible insulator is coextensive with the solar cell. The flexible circuit includes a flexible corner, the flexible corner configured to extend past a cell corner of the solar cell. The flexible circuit includes a flexible tab extending from one edge of the plurality of edges. The flexible circuit includes a circuit substantially embedded in the flexible insulator, the circuit including a first electrical contact exposed on a sun-facing side of the flexible corner and a second electrical contact exposed on a sun-facing side of the flexible tab.

[0007] In another embodiment, a solar cell system with a flexible circuit is described. The system includes a plurality of solar cell assemblies. Each solar cell assembly includes a solar cell having a sun-facing side and a non-sun-facing side and including cell corners. Each solar cell assembly includes a flexible circuit coupled to the non-sun-facing side of the solar cell, the flexible circuit being substantially coextensive with the solar cell. The flexible circuit includes a flexible insulator including a plurality of edges aligned with the solar cell, a flexible corner extending past the cell corners, and a flexible tab extending from one of the edges. The circuit is substantially embedded in the flexible insulator and includes a first electrical contact exposed on the sun-facing side of the flexible corner and a second electrical contact exposed on the sun-facing side of the flexible tab. The plurality of solar cell assemblies includes at least one pair of adjacent solar cell assemblies, with a first solar cell assembly electrically coupled to the second solar cell assembly via the first electrical contact and the second electrical contact.

[0008]

[0008] The above-described features, functions, and advantages may be realized individually in various embodiments or may be combined in yet other embodiments. Further details of the embodiments may be understood by reference to the following description and drawings.

[0009] The novel features believed characteristic of the embodiments are set forth in the appended claims. However, the embodiments, as well as the preferred mode of use and further objects and explanations thereof, will best be understood by reading the following detailed description of the embodiments of the present disclosure in conjunction with the accompanying drawings. [Brief explanation of the drawings]

[0010] [Figure 1A]

[0010] FIG. 1 illustrates an exploded view of a solar cell assembly according to an exemplary embodiment. [Figure 1B]

[0011] 1 illustrates a side-by-side view of a solar cell and a flexible circuit in a solar cell assembly, according to an exemplary embodiment. [Figure 2A]

[0012] 1 illustrates a top view of a solar cell assembly according to an exemplary embodiment. [Figure 2B]

[0013] 1 illustrates a top view of another solar cell assembly according to an exemplary embodiment. [Figure 3]

[0014] 1 illustrates a flexible circuit according to an exemplary embodiment. [Figure 4]

[0015] 1 illustrates a flexible circuit according to another exemplary embodiment. [Figure 5A]

[0016] 1 illustrates a corner of a solar cell assembly according to an exemplary embodiment. [Figure 5B]

[0017] 10 illustrates another corner of a solar cell assembly according to another exemplary embodiment. [Figure 6]

[0018] 1 illustrates a solar cell system according to an exemplary embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0011]

[0019] The disclosed embodiments will now be described more comprehensively with reference to the accompanying drawings, which illustrate some, but not all, of the disclosed embodiments. Indeed, several different embodiments may be described, and these embodiments should not be construed as being limited to the embodiments set forth herein. Rather, such embodiments are described so that this disclosure will be comprehensive and complete, and will fully convey the scope of the disclosure to those skilled in the art.

[0012]

[0020] Exemplary solar cell assemblies and solar cell systems are described. In the examples, solar cell assemblies including flexible circuits are described. The flexible circuit includes a flexible insulator and a circuit substantially embedded in the flexible insulator. In the examples described herein, the circuit "substantially embedded" in the flexible insulator refers to the metal traces of the circuit being surrounded by the flexible insulator, and other surfaces of the circuit (e.g., electrical contacts) being exposed. For example, the flexible insulator may have a top layer and a bottom layer, and the metal traces may be sandwiched between the top layer and the bottom layer, with the other surface being disposed on the bottom layer without being covered by the top layer. The exposed circuit surfaces allow contact between adjacent solar cells in the solar cell system. Including an individual flexible circuit for each solar cell assembly in the solar cell system can facilitate manufacturing and increase flexibility in final system design by reducing the amount of welding involved in assembly.

[0013]

[0021] In an embodiment, a flexible circuit is attached to the non-sun-facing surface of the solar cell to reduce shadowing on the sun-facing surface, thereby enabling additional power output by the solar cell assembly.

[0014]

[0022] In an embodiment, the flexible circuit includes a flexible insulator having a plurality of openings configured to allow one or more tabs of adjacent flexible circuits to contact the non-sun-facing surfaces of the solar cells. Because the flexible insulator includes a plurality of openings, each corresponding to a different edge of the solar cells, adjacent solar cells can be connected in orientations other than a straight string of solar cells. This allows for an adaptable and modular system of solar cells. As used herein in terms of solar cells, the term "adjacent" refers to solar cells aligned next to each other with no intermediate solar cells in between.

[0015]

[0023] In one embodiment, the flexible circuit includes multiple contacts located at the corners of the solar cell. Because the contacts are located at multiple locations on the edge of the cell, the lead wires on the sun-facing surface of the solar cell can be shorter, thereby reducing resistive losses in the solar cell system.

[0016]

[0024] In some embodiments, corners of the flexible circuit may be folded toward the sun-facing surface of the solar cell to contact one or more leads, thereby reducing the number of individual parts required in the solar cell system and reducing the amount of welding during assembly.

[0017]

[0025] Generally, therefore, embodiments are provided herein that facilitate rapid, robust, and adaptive assembly of solar cell systems. As described further below, these systems can be implemented by incorporating flexible circuits into individual solar cell assemblies.

[0018]

[0026] Referring now to the figures, FIG. 1A shows an exploded view of a solar cell assembly 100 according to an exemplary embodiment. The solar cell assembly includes an enclosure 102 (e.g., a cover glass), an adhesive 104, solar cells 106 coupled to the enclosure 102 via the adhesive 104, and a flexible circuit 110 coupled to the solar cells 106. The solar cells 106 include a sun-facing surface 108 and a non-sun-facing surface 109 disposed opposite the sun-facing surface 108. In this context, "sun-facing" refers to the portion of the solar cell assembly that faces a light source, such as the sun. In the exemplary embodiment, the solar cells 106 have four notched cell corners. The flexible circuit 110 is coupled to the non-sun-facing surface 109 of the solar cells 106. Attaching the flexible circuit to the non-sun-facing surface 109 of the solar cell 106 allows fewer electrical components to be located on the sun-facing surface 108 of the solar cell 106, which may reduce cell shadowing and may also reduce resistive losses on the sun-facing surface 108 of the solar cell 106.

[0019]

[0027] The flexible circuit 110 includes multiple edges 111 aligned with the solar cells 106. Furthermore, the flexible circuit 110 is substantially coextensive with the solar cells 106 such that only portions of the flexible circuit 110 extend past the solar cells 106. The flexible circuit 110 includes multiple flexible corners 112, a first tab 114 associated with a bypass diode 118, a second tab 115 associated with one or more metal traces (not shown) within the flexible circuit 110, and a third tab 116 associated with one or more other metal traces (not shown) within the flexible circuit 110. As shown in FIG. 1A , the bypass diode 118 is embedded within the flexible circuit 110. FIG. 1A also illustrates an alternative embodiment in which a bypass diode 122 and corresponding flexible tab 120 are connected to the flexible corners of the flexible circuit 110. This illustrates that having multiple contacts at multiple flexible corners 112 within the flexible circuit 110 allows for adaptive and robust construction of the solar cell assembly 100.

[0020]

[0028] 1B shows a side-by-side view of solar cells 106 and flexible circuit 110 in solar cell assembly 100, according to an exemplary embodiment. Specifically, FIG. 1B shows flexible circuit 110 including flexible insulator 126 and circuit 128 embedded in flexible insulator 126. Circuit 128 includes bypass diode 118 and multiple electrical contacts. The electrical contacts include a first contact 130 disposed at a first flexible corner 132 of multiple flexible corners 112 and a second contact 134 disposed at first flexible tab 114.

[0021]

[0029] FIG. 1B shows that each of the flexible corners 112 extends past the notched corners 124 of the solar cells 106. This allows electrical contacts in the circuit 128 to be exposed at each cell corner of each solar cell assembly in the system, facilitating connections between adjacent solar cells. FIG. 1B also shows that the solar cells 106 are square with four notched cell corners, and the flexible circuit 110 is square with four notched flexible corners. Each notched flexible corner of the flexible circuit 110 extends past the notched cell corner of the solar cells 106. This configuration can increase the number of possible configurations within a solar cell system. For example, because each edge of the solar cells 106 is the same length, each solar cell assembly can be rotated relative to the other solar cell assemblies while still remaining aligned with the other solar cell assemblies.

[0022]

[0030] FIG. 2A shows a top view of a solar cell assembly 200 according to an exemplary embodiment. The solar cell assembly 200 includes a solar cell 201 having a sun-facing surface 202 and a non-sun-facing surface (not shown). The sun-facing surface 202 is the portion of the solar cell assembly 200 oriented toward a light source and configured to convert light energy into electrical power. The non-sun-facing surface is the surface disposed opposite the sun-facing surface. The solar cell assembly 200 includes a plurality of edges 204 and a plurality of electrical leads 206 disposed on the sun-facing surface 202 and configured to conduct electrical power generated by the solar cell assembly 200. The solar cell assembly 200 further includes a plurality of cell corners 208 that join the edges of the solar cells 201 together. As shown in FIG. 2A , the cell corners 208 are truncated to form notched cell corners. The notched cell corners provide space between adjacent cells in a solar cell system for forming connections.

[0023]

[0031] 1A and 1B, the flexible circuit in the solar cell assembly 200 is substantially coextensive with the solar cells 201. Therefore, only a portion of the flexible circuit is shown in FIG. 2A. In particular, FIG. 2A shows multiple flexible corners 210 extending past the cell corners 208. The flexible circuit further includes multiple tabs, including a first flexible tab 212 associated with a bypass diode of the flexible circuit, a second flexible tab 214 associated with one or more metal traces within the flexible circuit, and a third flexible tab 215 associated with one or more other metal traces within the flexible circuit. Further details regarding the metal traces and multiple tabs are provided further below with respect to FIGS. 3 and 4.

[0024]

[0032] Each of the flexible corners 210 may include an electrical contact used to connect to other components in the solar cell system, such as an adjacent solar cell. As an example, a first electrical contact 211 of the multiple electrical contacts is shown in FIG. 2A (other electrical contacts are omitted for simplicity). As shown in FIG. 2A, the sun-facing surface 202 of the solar cell includes a central portion 203, and multiple electrical leads 206 extend from the central portion 203 toward the first electrical contact 211. In an embodiment, as shown in FIG. 2A, the electrical leads 206 may extend toward each of the multiple electrical contacts of the flexible corners 210. For example, the electrical leads 206 extending from the central portion 203 reduce the length of the electrical leads 206 relative to leads that extend across the entire solar cell 201. This may reduce resistive losses when transmitting power across the electrical leads 206.

[0025]

[0033] 2B shows a top view of another solar cell assembly 220 according to an example embodiment. Solar cell assembly 220 illustrates an alternative configuration of a flexible circuit in which a first flexible tab 222 is disposed at one of a plurality of notched flexible corners 228 that extends past a plurality of notched cell corners 226. Thus, in the example shown in FIG. 2B , a bypass diode may be disposed at the flexible corner rather than within the flexible circuit. This may further facilitate assembly of the solar cell assembly or system of solar cell assemblies.

[0026]

[0034] FIG. 3 illustrates a flexible circuit 300 according to an exemplary embodiment. The flexible circuit 300 includes a flexible insulator 301, such as a polyimide material. Other types of flexible insulators are possible. The flexible insulator 301 includes a bottom layer 302 and a top layer 303, and the electrical circuit surface can be disposed between the bottom layer 302 and the top layer 303. The flexible insulator 301 includes multiple edges 304, multiple flexible corners 305, a first flexible tab 306, a second flexible tab 307, and a third flexible tab 308. The flexible insulator 301 further includes multiple openings 310 configured to interact with one or more flexible tabs of an adjacent flexible circuit, and a partial opening 312. The partial opening 312 includes a portion of the bottom layer 302 but not the top layer 303. The bottom layer 302 can correspond to the bottom of the solar cell assembly, and the top layer 303 can be attached to the non-sun-facing side of the solar cell. In this way, the partial opening 312 may insulate the electrical components on one side but allow the electrical components to contact the solar cell. In the embodiment shown in Figure 3, the bypass diode 318 may be partially embedded in the flexible insulator 301 and contact the non-sun-facing surface of the solar cell.

[0027]

[0035] 3, the flexible insulator 301 is configured such that the edge 304 is configured to align with the solar cell such that the flexible insulator 301 is coextensive with the solar cell, allowing the solar assembly, including the solar cell and flexible circuit 300, to efficiently interact with other solar cell assemblies in a system of solar cells.

[0028]

[0036] The flexible insulator includes an opening 309 that exposes a portion of the non-sun-facing surface of a solar cell attached to the flexible circuit 300. The opening 309 is a first opening of a plurality of openings 310. As described above, the opening 309 is configured to receive adjacent flexible tabs of adjacent flexible circuits, thereby allowing the adjacent flexible circuits to connect with the solar cells attached to the flexible circuit 300. In this manner, the opening 309 reduces the need for non-sun-facing welding for the solar cell system. Furthermore, as shown in FIG. 3 , each opening of the plurality of openings 310 corresponds to a different edge of the flexible insulator 301. This allows solar cell assemblies to be oriented in various directions relative to other solar cell assemblies, enabling a more flexible and simplified assembly process. For example, the solar cell assemblies can be assembled into solar cell strings (e.g., multiple series-connected solar cells) that are oriented in a non-linear manner.

[0029]

[0037] The flexible circuit 300 further includes circuitry 314 that is substantially embedded in the flexible insulator 301. The circuitry 314 includes one or more metal traces 315, a plurality of electrical contacts exposed on at least one side, and a bypass diode 318. In an exemplary embodiment, the metal traces 315 are surrounded by the flexible insulator 301 such that the flexible circuit 314 is substantially embedded in the flexible insulator 301, while the electrical contacts and the bypass diode 318 are exposed. For example, the plurality of contacts in FIG. 3 includes a first electrical contact 316 exposed on the sun-facing side of a flexible corner and a second electrical contact 317 exposed on the sun-facing side of a flexible tab.

[0030]

[0038] As described for flexible insulator 301, flexible circuit 300 includes multiple tabs, including first flexible tab 306, which is associated with bypass diode 318 of circuit 314. Additionally, second flexible tab 307 of the multiple tabs is configured to provide a current path between the solar cell and an adjacent solar cell. In the embodiment shown in FIG. 3, each of the multiple tabs extends from the same edge of flexible insulator 301. This allows each tab to connect to the same adjacent solar cell and also leaves more edge available for multiple openings 310.

[0031]

[0039] As described above, the bypass diode 318 for a solar cell (e.g., solar cell 106) is partially embedded in the partial opening 312. In the partial opening 312, the top layer 303 includes an opening, and the bypass diode 318 is configured to contact the non-sun-facing side of the solar cell through the opening. The bottom layer 302 corresponds to the bottom of the solar cell assembly, and the top layer 303 is attached to the non-sun-facing side of the solar cell during manufacturing of the solar cell assembly. In this manner, the partial opening 312 insulates the bypass diode 318 on one side but allows the bypass diode to contact the solar cell. In this manner, the bypass diode 318 can be installed in the solar cell assembly simultaneously with other portions of the circuit 314.

[0032]

[0040] The first electrical contact 316 is configured to connect to another component within the solar cell system. For example, the first electrical contact 316 can be connected to one or more conductors of an adjacent solar cell via an interconnect. The second electrical contact 317 is connected to a bypass diode 318, which is configured to contact the non-sun-facing surface of another solar cell (e.g., an adjacent solar cell) via the second electrical contact 317. In this manner, the first flexible tab 306 allows for easy installation of the connection between the bypass diode embedded in the first solar cell assembly and the non-sun-facing surface of the adjacent solar cell assembly.

[0033]

[0041] In an embodiment, a solar cell (e.g., solar cell 106) includes an N-side associated with negative doping and a P-side associated with positive doping. First electrical contact 316 and associated metal trace may correspond to the N-side, and second electrical contact 317 may correspond to the P-side. Additionally, electrical contacts at second flexible tab 307 and third flexible tab 308 may correspond to the N-side. The flexible tabs are configured to contact the non-sun-facing sides of adjacent solar cells, while flexible corner 305 is configured to contact other components on the sun-facing side of flexible circuit 300. Thus, the embodiment shown in FIG. 3 includes N-type electrical contacts configured for sun-facing and non-sun-facing connections, as well as P-type electrical contacts configured only for non-sun-facing connections.

[0034]

[0042] In an embodiment, all of the electrical circuitry for the solar cell assembly is contained within the flexible circuit 300. This may simplify and expedite assembly, but may also allow testing and troubleshooting of the electrical circuitry of the flexible circuit 300 prior to assembly.

[0035]

[0043] FIG. 4 illustrates a flexible circuit 400 according to another exemplary embodiment. The flexible circuit 400 includes a flexible insulator 402, such as a polyimide material. The flexible insulator 402 includes a plurality of notched flexible corners 404, a first flexible tab 406, a second flexible tab 407, and a third flexible tab 408. In particular, FIG. 4 illustrates that the flexible insulator 402 is rectangular (e.g., square) with four notched flexible corners. As discussed above, this allows the flexible circuit 400 to align with and coexist with similarly shaped solar cells. Unlike the embodiment illustrated in FIG. 3, the flexible insulator 402 does not include a plurality of openings configured to interact with one or more flexible tabs of an adjacent flexible circuit. Rather, additional contacts are provided on the sun-facing side of the flexible circuit 400.

[0036]

[0044] The flexible circuit 400 further includes a circuit 409 substantially embedded in the flexible insulator 402. The circuit 409 includes a first electrical contact 410 located at the first notched flexible corner, a second electrical contact located at the first flexible tab 406, a third electrical contact 414 located at the second notched flexible corner, a fourth electrical contact 416 located at the third notched flexible corner, a fifth electrical contact 424 located at the third notched flexible corner, and a sixth electrical contact 428 located at the third flexible tab 408. The other electrical contacts are not labeled for simplicity.

[0037]

[0045] The circuit 409 further includes a first metal trace 420 providing a current path between the first electrical contact 410 and the third electrical contact 414. This current path also corresponds to the second flexible tab 407. The circuit 409 further includes a bypass diode 418 embedded in the flexible insulator 401, and a second metal trace 422 providing a current path between the second electrical contact 412 and the fourth electrical contact 416 via the bypass diode 418. The circuit 409 further includes a third metal trace 426 providing a current path between the fifth electrical contact 424 and the sixth electrical contact 428.

[0038]

[0046] Similar to the embodiment shown in FIG. 3 , flexible circuit 400 is configured to interface with a solar cell and at least one adjacent solar cell. The solar cell includes an N-side associated with negative doping and a P-side associated with positive doping. First electrical contact 410, third electrical contact 414, fifth electrical contact 424, and sixth electrical contact 428 may correspond to the N-side, and second electrical contact 412 and fourth electrical contact 416 may correspond to the P-side. The flexible tab is configured to contact the non-sun-facing side of the adjacent solar cell, while notched flexible corner 404 is configured to contact other components on the sun-facing side of flexible circuit 400. Thus, the embodiment shown in FIG. 4 includes N-type electrical contacts configured for both sun-facing connections (e.g., first electrical contact 410, third electrical contact 414, and fifth electrical contact 424) and non-sun-facing connections (e.g., sixth electrical contact 428), as well as P-type electrical contacts configured for both sun-facing connections (e.g., fourth electrical contact 416) and non-sun-facing connections (e.g., second electrical contact 412).

[0039]

[0047] 4, the fourth electrical contact 416 and the fifth electrical contact 424 are located on the same cut flexible corner, each corresponding to a different metal trace. Thus, in some embodiments, a single flexible corner may include multiple electrical contacts. This may allow the bypass diode 418 to be accessed in a more flexible manner during manufacturing of the solar cell system.

[0040]

[0048] 5A shows a corner 500 of a solar cell assembly, according to an exemplary embodiment. Corner 500 includes a cell corner 502, a top layer 504 of a flexible circuit, electrical contacts 506 of the flexible circuit, and a bottom layer 508 of the flexible circuit. One or more electrical leads 510 are disposed on the sun-facing surface of cell corner 502, and an interconnect 512 is provided connecting electrical contacts 506 to one or more electrical leads 510. Interconnect 512 may be welded or ribbon-bonded to electrical contacts 506 and one or more electrical leads 510, or, for example, to the ends of one or more electrical leads.

[0041]

[0049] Electrical contact 506 may be a first of a plurality of electrical contacts. In an embodiment, interconnect 512 may be a wire bonded between one or more electrical leads 510 on the sun-facing surface of the solar cell and the first electrical contact.

[0042]

[0050] FIG. 5B shows another corner 520 of a solar cell assembly according to another exemplary embodiment. The corner 520 includes a cell corner 502, a top layer 524 of a flexible circuit, an electrical contact 526 of the flexible circuit, and a bottom layer 528 of the flexible circuit. The electrical contact 526 can be a first electrical contact of multiple electrical contacts. The flexible circuit has a flexible corner configured to bend such that the first electrical contact is configured to couple to one or more electrical leads 530 on the sun-facing surface of the solar cell. In particular, the electrical contact 526 bends toward the one or more electrical leads 530. By having a flexible corner that extends past the corner 520, the flexible circuit can reduce the number of components in a system. For example, the interconnect 512 shown in FIG. 5A is not included in FIG. 5B because the flexible corner is configured to bend toward the sun-facing surface of the solar cell. Connecting the electrical contact 526 to the one or more electrical leads can include soldering the electrical contact 526.

[0043]

[0051] 6 illustrates a solar cell system 600 according to an exemplary embodiment. System 600 includes multiple solar cell strings, including a first solar cell string 602, a second solar cell string 604, and a third solar cell string 606. The first solar cell string includes a first solar cell assembly 608, a second solar cell assembly 610, and a third solar cell assembly 612. Faces of the solar cell assemblies are omitted for simplicity.

[0044]

[0052] Each solar cell assembly in system 600 may be configured similarly to solar cell assembly 100 shown in FIGS. 1A and 1B. For example, each solar cell assembly includes a solar cell 106 having a sun-facing surface 108 and a non-sun-facing surface 109. The solar cell includes cell corners. Each solar cell assembly further includes a flexible circuit 110 coupled to the non-sun-facing surface 109 of the solar cell 106, the flexible circuit 110 being substantially coextensive with the solar cell 106. The flexible circuit 110 includes a flexible insulator including a plurality of edges 111 aligned with the solar cell 106, flexible corners 112 extending past the cell corners, and flexible tabs extending from edges of the plurality of edges 111. The flexible circuit 110 further includes a circuit substantially embedded in the flexible insulator, the circuit including a first electrical contact exposed on the sun-facing side of the flexible corner and a second electrical contact exposed on the sun-facing side of the flexible tab.

[0045]

[0053] Figure 6 includes at least one pair of adjacent solar cell assemblies. Pair 609 includes a first solar cell assembly 608 electrically coupled to a second solar cell assembly 610 via a first electrical contact 614 and a second electrical contact 618. For example, as shown in Figure 6, first electrical contact 614 may be connected to second solar cell assembly 610 via interconnect 616, which electrically couples the first electrical contact to a corresponding contact of an adjacent solar cell. Second electrical contact 618 may be connected via space 620 within the flexible insulator of second solar cell assembly 610.

[0046]

[0054] As shown in Figure 6, a second solar cell assembly 610 is connected to a third solar cell assembly 612 to complete the first solar cell string 602. The second solar cell string 604 and the third solar cell string 606 are configured in a similar manner to the first solar cell string. However, as shown in Figure 6, the solar cell assemblies may be connected to each other to form a single source of solar power. Thus, the system 600 may be adapted and quickly assembled by an end user rather than requiring specialized manufacturing facilities.

[0047]

[0055] Thus, the exemplary systems, solar cell assemblies, and flexible circuits described herein enable rapid, adaptable, and reliable assembly of solar cell systems, reducing manufacturing costs while also providing a convenient way for end users to assemble the solar cell systems at their own location. Furthermore, having a modular solar cell assembly allows for simplified changes to the system in a reconfiguration scenario. Furthermore, embedding the solar cell system components, including substantially all electrical circuitry, within the flexible circuit in the solar cell assembly reduces the number of system parts required and further enables pre-assembly testing and troubleshooting. This can be particularly impactful for space applications, where welding or soldering is impractical. Furthermore, including a flexible circuit on the non-sun-facing side of the solar cell system reduces shadowing and allows for shorter lead wires, thereby reducing resistive losses on the sun-facing side of the solar cell system.

[0048]

[0056] Furthermore, the present disclosure includes embodiments according to the following clauses:

[0049] Clause 1. A solar cell assembly having a flexible circuit, comprising: a solar cell having a sun-facing surface and a non-sun-facing surface and having cell corners; a flexible circuit coupled to the non-sun-facing surface of the solar cell, the flexible circuit being substantially coextensive with the solar cell; a flexible insulator including a plurality of edges aligned with the solar cells; a flexible corner extending past the cell corner; and the flexible circuit having a flexible tab extending from one of the edges; a circuit substantially embedded in the flexible insulator, the circuit including a first electrical contact exposed on the sun-facing side of the flexible corner and a second electrical contact exposed on the sun-facing side of the flexible tab; A solar cell assembly comprising:

[0050] Clause 2. The solar cell assembly of clause 1, wherein the flexible insulator includes an opening exposing a portion of the non-sun-facing surface of the solar cell, the opening configured to receive adjacent flexible tabs of adjacent solar cell assemblies.

[0051] Clause 3. The solar cell assembly of clause 2, wherein the opening is a first opening of a plurality of openings, each opening corresponding to a different edge of the flexible insulator.

[0052] Clause 4. A solar cell assembly described in any one of clauses 1 to 3, wherein the circuit further includes a bypass diode for the solar cell, the flexible insulator includes a bottom layer and a top layer, the top layer is connected to the non-sun-facing surface of the solar cell, the top layer includes an opening, and the bypass diode contacts the non-sun-facing surface of the solar cell through the opening.

[0053] Clause 5. A solar cell assembly described in any one of clauses 1 to 4, wherein the circuit further includes a bypass diode for the solar cell, the first electrical contact being connected to the bypass diode, and the bypass diode contacting the non-sun-facing surface of another solar cell via the second electrical contact.

[0054] Clause 6. The solar cell assembly of any one of clauses 1 to 5, wherein the flexible corner is configured to bend such that the first electrical contact couples to one or more electrical leads on the sun-facing surface of the solar cell.

[0055] Clause 7. The solar cell assembly of any one of clauses 1 to 6, further comprising a wire bonded between one or more conductive wires on the sun-facing surface of the solar cell and the first electrical contact.

[0056] Clause 8. The solar cell assembly of any one of clauses 1 to 7, wherein the solar cell is a square with four notched cell corners, the flexible circuit is a square with four notched flexible corners, and each of the notched flexible corners of the flexible circuit extends past the notched cell corners of the solar cell.

[0057] Clause 9. A solar cell assembly as described in any one of clauses 1 to 8, wherein the flexible tab is a first flexible tab of a plurality of tabs, the first flexible tab being associated with a bypass diode of the circuit, and a second flexible tab of the plurality of tabs being configured to provide a current path between the solar cell and an adjacent solar cell, and each of the plurality of tabs extending from the same edge of the flexible insulator.

[0058] Clause 10. The solar cell assembly of any one of clauses 1 to 9, wherein the flexible insulator comprises a polyimide material.

[0059] Clause 11. The solar cell assembly of any one of clauses 1 to 10, wherein the sun-facing surface of the solar cell includes a central portion, and a plurality of electrical leads extend from the central portion toward the first electrical contact.

[0060] Clause 12. A flexible circuit for a solar cell assembly, comprising: A flexible insulator, a flexible insulator including a plurality of edges configured to align with the solar cell such that the flexible insulator is coextensive with the solar cell; a flexible corner configured to extend past a cell corner of the solar cell; a flexible tab extending from one of the edges; a circuit substantially embedded in the flexible insulator, the circuit including a first electrical contact exposed on the sun-facing side of the flexible corner and a second electrical contact exposed on the sun-facing side of the flexible tab; A flexible circuit comprising:

[0061] Clause 13. The flexible circuit of clause 12, wherein the flexible insulator includes openings exposing portions of the non-sun-facing surfaces of the solar cells, the openings configured to receive adjacent flexible tabs of adjacent flexible circuits.

[0062] Clause 14. The flexible circuit of clause 13, wherein the opening is a first of a plurality of openings, each opening corresponding to a different edge of the flexible insulator.

[0063] Clause 15. A flexible circuit described in any one of clauses 12 to 14, wherein the circuit further includes a bypass diode for the solar cell, and the flexible insulator includes a bottom layer and a top layer, the top layer configured to couple to the non-sun-facing surface of the solar cell, the top layer including an opening, and the bypass diode configured to contact the non-sun-facing surface of the solar cell through the opening.

[0064] Clause 16. A flexible circuit described in any one of clauses 12 to 15, wherein the circuit further includes a bypass diode for the solar cell, the first electrical contact being connected to the bypass diode, and the bypass diode being configured to contact the non-sun-facing surface of another solar cell via the second electrical contact.

[0065] Clause 17. The flexible circuit of any one of clauses 12 to 16, wherein the flexible corner is configured to bend such that the first electrical contact is configured to couple to one or more conductive wires on the sun-facing surface of the solar cell.

[0066] Clause 18. The flexible circuit of any one of clauses 12 to 17, wherein the flexible insulator is rectangular with four notched flexible corners.

[0067] Clause 19. The flexible circuit of any one of clauses 12 to 18, wherein the flexible tab is a first flexible tab of a plurality of tabs, the first flexible tab being associated with a bypass diode of the circuit, and a second flexible tab of the plurality of tabs being configured to provide a current path between the solar cell and an adjacent solar cell, and each of the plurality of tabs extending from the same edge of the flexible insulator.

[0068] Clause 20. A system of solar cells with flexible circuits, comprising: a plurality of solar cell assemblies, each solar cell assembly comprising: a solar cell having a sun-facing surface and a non-sun-facing surface and having cell corners; a flexible circuit coupled to the non-sun-facing surface of the solar cell, the flexible circuit being substantially coextensive with the solar cell; a flexible insulator including a plurality of edges aligned with the solar cells; a flexible corner extending past the cell corner; and the flexible circuit having a flexible tab extending from one of the edges; a circuit substantially embedded in the flexible insulator, the circuit including a first electrical contact exposed on the sun-facing side of the flexible corner and a second electrical contact exposed on the sun-facing side of the flexible tab; the plurality of solar cell assemblies comprises at least one pair of adjacent solar cell assemblies including a first solar cell assembly electrically coupled to a second solar cell assembly via the first electrical contact and the second electrical contact; Solar cell system.

[0069]

[0057] As used in this specification, the terms "substantially," "similarity," and "about" mean that the described characteristic, parameter, or value need not be exactly achieved, but that deviations or variations, including tolerances, measurement errors, measurement accuracy limits, and other factors known to those skilled in the art, may occur to an extent that does not negate the effect that the characteristic is intended to achieve.

[0070] The various embodiments of the system(s), device(s), and method(s) disclosed herein include a wide variety of components, features, and functions. It should be understood that the various embodiments of the system(s), device(s), and method(s) disclosed herein may include any of the components, features, and functions of any of the other embodiments of the system(s), device(s), and method(s) disclosed herein, in any combination or subcombination, and all such possibilities are intended to be within the scope of the present disclosure.

[0071] The description of the various advantageous configurations has been presented for purposes of illustration and description and is not intended to be exhaustive or to limit the examples to the disclosed exemplary forms. Numerous modifications and variations will be apparent to those skilled in the art. Moreover, various advantageous embodiments may offer distinct advantages over other advantageous embodiments. The selected embodiment or embodiments have been chosen and described in order to best explain the principles and practical application of those embodiments and to enable others skilled in the art to understand that the disclosure of the various embodiments, together with their various modifications, is suitable for the particular use contemplated.

Claims

1. A solar cell assembly (100) having a flexible circuit (300), a solar cell (106) having a sun-facing surface (108) and a non-sun-facing surface (109) and having cell corners (208); a flexible circuit (300) coupled to the non-sun-facing surface (109) of the solar cell (106), the flexible circuit (300) being substantially coextensive with the solar cell (106); a flexible insulator (301) including a plurality of edges (304) aligned with the solar cells (106); a flexible corner (112) extending past said cell corner (208); and the flexible circuit (300) having a flexible tab (222) extending from one of the edges (304); a circuit (314) substantially embedded in the flexible insulator (301), the circuit (314) including a first electrical contact (316) exposed on the sun-facing side of the flexible corner (112) and a second electrical contact (317) exposed on the sun-facing side of the flexible tab (222); A solar cell assembly (100) comprising:

2. 2. The solar cell assembly (100) of claim 1, wherein the flexible insulator (301) includes an opening (309) that exposes a portion of the non-sun-facing surface (109) of the solar cell (106), the opening (309) being configured to receive adjacent flexible tabs of adjacent solar cell assemblies.

3. 3. The solar cell assembly (100) of claim 2, wherein the opening (309) is a first opening (309) of a plurality of openings (310), each opening (309) corresponding to a different edge of the flexible insulator (301).

4. 4. The solar cell assembly (100) of claim 1, wherein the circuit (314) further includes a bypass diode (318) for the solar cell (106), the flexible insulator (301) includes a bottom layer and a top layer, the top layer is connected to the non-sun-facing surface (109) of the solar cell (106), the top layer includes an opening, and the bypass diode (318) contacts the non-sun-facing surface (109) of the solar cell (106) through the opening.

5. 5. The solar cell assembly (100) of claim 1, wherein the circuit (314) further includes a bypass diode (318) for the solar cell (106), the second electrical contact (317) is connected to the bypass diode, and the bypass diode (318) contacts a non-sun-facing surface (109) of another solar cell (106) via the second electrical contact (317).

6. 6. The solar cell assembly (100) of claim 1, wherein the flexible corner (112) is configured to bend so that the first electrical contact (316) connects to one or more electrical leads (510) on the sun-facing surface (108) of the solar cell (106).

7. 7. The solar cell assembly (100) of claim 1, further comprising a wire bonded between one or more conductive wires (510) on the sun-facing surface (108) of the solar cell (106) and the first electrical contact (316).

8. 8. The solar cell assembly (100) of claim 1, wherein the solar cells (106) are rectangular with four notched cell corners, the flexible circuit (300) is rectangular with four notched flexible corners (128), and each of the notched flexible corners (128) of the flexible circuit (300) extends past the notched cell corners of the solar cells (106).

9. 9. The solar cell assembly (100) of claim 1, wherein the flexible tab (222) is a first flexible tab (222) of a plurality of tabs, the first flexible tab (222) being associated with a bypass diode (318) of the circuit (314), and a second flexible tab (114) of the plurality of tabs being configured to provide a current path between the solar cell (106) and an adjacent solar cell (106), and each of the plurality of tabs extending from the same edge of the flexible insulator (301).

10. The solar cell assembly (100) of any one of claims 1 to 9, wherein the flexible insulator (301) comprises a polyimide material.

11. 11. The solar cell assembly (100) of claim 1, wherein the sun-facing surface (108) of the solar cell (106) includes a central portion (203), and a plurality of electrical conductors (510) extend from the central portion (203) toward the first electrical contact (316).

12. A flexible circuit (300) for a solar cell assembly (100), comprising: A flexible insulator (301), a flexible insulator (301) including a plurality of edges (304) configured to align with the solar cells (106) so that the flexible insulator (301) is coextensive with the solar cells (106); a flexible corner (112) configured to extend past a cell corner (208) of the solar cell (106); a flexible tab (222) extending from one of said edges (304); a circuit (314) substantially embedded in the flexible insulator (301), the circuit (314) including a first electrical contact (316) exposed on the sun-facing side of the flexible corner (112) and a second electrical contact (317) exposed on the sun-facing side of the flexible tab (222); A flexible circuit (300) comprising:

13. 13. The flexible circuit (300) of claim 12, wherein the flexible insulator (301) includes an opening (309) that exposes a portion of the non-sun-facing surface (109) of the solar cell (106), the opening (309) being configured to receive adjacent flexible tabs (222) of adjacent flexible circuits (314).

14. 14. The flexible circuit (300) of claim 13, wherein the opening (309) is a first opening (309) of a plurality of openings (310), each opening (309) corresponding to a different edge of the flexible insulator (301).

15. 15. The flexible circuit (300) of claim 12, wherein the circuit (314) further comprises a bypass diode (318) for the solar cell (106), the flexible insulator (301) comprises a bottom layer and a top layer, the top layer configured to couple to a non-sun-facing surface (109) of the solar cell (106), the top layer comprising an opening, and the bypass diode (318) configured to contact the non-sun-facing surface (109) of the solar cell (106) through the opening.

16. 16. The flexible circuit (300) of any one of claims 12 to 15, wherein the circuit (314) further includes a bypass diode (318) for the solar cell (106), the second electrical contact (317) is connected to the bypass diode, and the bypass diode (318) is configured to contact a non-sun-facing surface (109) of another solar cell (106) via the second electrical contact (317).

17. 17. The flexible circuit (300) of any one of claims 12 to 16, wherein the flexible corner (112) is configured to bend such that the first electrical contact (316) is configured to connect to one or more conductors (510) on the sun-facing surface (108) of the solar cell (106).

18. 18. The flexible circuit (300) of any one of claims 12 to 17, wherein the flexible insulator (301) is rectangular with four notched flexible corners.

19. 19. The flexible circuit (300) of any one of claims 12 to 18, wherein the flexible tab (222) is a first flexible tab (222) of a plurality of tabs, the first flexible tab (222) being associated with a bypass diode (318) of the circuit (314), and a second flexible tab (114) of the plurality of tabs being configured to provide a current path between the solar cell (106) and an adjacent solar cell (106), and each of the plurality of tabs extending from the same edge of the flexible insulator (301).

20. A solar cell with flexible circuit system (600), comprising: A plurality of solar cell assemblies, each solar cell assembly (100) comprising: a solar cell (106) having a sun-facing surface (108) and a non-sun-facing surface (109) and having cell corners (208); a flexible circuit (300) coupled to the non-sun-facing surface (109) of the solar cell (106), the flexible circuit (300) being substantially coextensive with the solar cell (106); a flexible insulator (301) including a plurality of edges (304) aligned with the solar cells (106); a flexible corner (112) extending past said cell corner (208); and the flexible circuit (300) having a flexible tab (222) extending from one of the edges (304); a circuit (314) substantially embedded in the flexible insulator (301), the circuit (314) including a first electrical contact (316) exposed on the sun-facing side of the flexible corner (112) and a second electrical contact (317) exposed on the sun-facing side of the flexible tab (222); the plurality of solar cell assemblies comprises at least one pair (609) of adjacent solar cell assemblies, including a first solar cell assembly (608) electrically coupled to a second solar cell assembly (610) via the first electrical contact (316) and the second electrical contact (317); A solar cell system (600).

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