Solar cell array connections using corner conductors

Abstract

A solar cell array is comprised of at least one solar cell and a substrate for the solar cell. The solar cell has at least one cropped corner that defines a corner region, wherein the corner region includes at least one contact for making an electrical connection to the solar cell. The contact comprises a front contact on a front side of the solar cell and/or a back contact on a back side of the solar cell, wherein the contact extends into the corner region. The solar cell is attached to the substrate such that corner regions of adjacent solar cells are aligned, thereby exposing an area of the substrate where electrical connections between the solar cells are made using corner conductors. The electrical connections are up/down and/or left/right series connections that determine a flow of current through the cells.

1 . A solar cell panel, comprising:
 a solar cell array comprised of one or more solar cells and a substrate for the solar cells, wherein:   an area of the substrate remains exposed when at least one of the solar cells having at least one cropped corner is attached to the substrate;   the area of the substrate that remains exposed includes one or more corner conductors; and   one or more electrical connections between the solar cells and the corner conductors are made in a corner region resulting from the cropped corner of the at least one of the solar cells.   
     
     
         2 . The solar cell panel of  claim 1 , wherein the at least one solar cell comprises a plurality of solar cells attached to a substrate such that corner regions of adjacent ones of the solar cells are aligned, thereby exposing an area of the substrate, and the electrical connections between the solar cells are made in the exposed area of the substrate using the corner conductors formed on or in the exposed area of the substrate. 
     
     
         3 . The solar cell panel of  claim 1 , wherein the solar cells are individually attached to the substrate. 
     
     
         4 . The solar cell panel of  claim 1 , wherein the solar cells are attached to the substrate as cell, interconnect and coverglass (CIC) units. 
     
     
         5 . The solar cell panel of  claim 1 , wherein the corner conductors are attached to, printed on, or integrated with the substrate before the solar cells are attached. 
     
     
         6 . The solar cell panel of  claim 1 , wherein the substrate includes conductive paths on its surface, beneath its surface, or both on its surface and beneath its surface. 
     
     
         7 . The solar cell panel of  claim 6 , wherein the conductive paths are electrically insulated from the solar cells. 
     
     
         8 . The solar cell panel of  claim 1 , wherein at least one of the electrical connections between at least one of the solar cells and at least one of the corner conductors is made after the at least one of the solar cells has been attached to the substrate. 
     
     
         9 . A method for fabricating a solar cell panel, comprising:
 fabricating a solar cell array comprised of one or more solar cells and a substrate for the solar cells, wherein:   an area of the substrate remains exposed when at least one of the solar cells having at least one cropped corner is attached to the substrate;   the area of the substrate that remains exposed includes one or more corner conductors; and   one or more electrical connections between the solar cells and the corner conductors are made in a corner region resulting from the cropped corner of the at least one of the solar cells.   
     
     
         10 - 16 . (canceled) 
     
     
         17 . A device, comprising:
 at least one solar cell, wherein the solar cell has at least one cropped corner that defines a corner region, such that the corner region resulting from the cropped corner includes at least one contact for making an electrical connection to the solar cell.   
     
     
         18 . The device of  claim 17 , wherein the contact comprises a front contact on a front side of the solar cell. 
     
     
         19 . The device of  claim 17 , wherein the contact comprises a back contact on a back side of the solar cell. 
     
     
         20 . The device of  claim 17 , wherein the contact extends into the corner region. 
     
     
         21 . The device of  claim 17 , wherein the at least one solar cell comprises a plurality of solar cells attached to a substrate such that corner regions of adjacent ones of the solar cells are aligned, thereby exposing an area of the substrate, and electrical connections between the solar cells are made in the exposed area of the substrate using corner conductors formed on or in the exposed area of the substrate. 
     
     
         22 . The device of  claim 21 , wherein the electrical connections are series connections that determine a flow of power through the solar cells. 
     
     
         23 . The device of  claim 22 , wherein the series connections are up/down series connections. 
     
     
         24 . The device of  claim 22 , wherein the series connections are left/right series connections. 
     
     
         25 . The device of  claim 21 , wherein one or more bypass diodes are added to the exposed area of the substrate for use in one or more of the electrical connections. 
     
     
         26 . The device of  claim 17 , wherein a bypass diode is applied to a back side of the cell, with an interconnect or contact for the bypass diode extending into the corner region. 
     
     
         27 . A method, comprising:
 fabricating at least one solar cell, wherein the solar cell has at least one cropped corner that defines a corner region, such that the corner region resulting from the cropped corner includes at least one contact for making an electrical connection to the solar cell.   
     
     
         28 - 36 . (canceled)