US 11,876,145 B2
Solar panel plant for making laminated solar panel product having preformed substrate with convex surface and method for continuously processing the same
Anuj M. Thakkar, San Diego, CA (US); Nathan T. Engler, San Diego, CA (US); Reed Thurber, San Diego, CA (US); and Jesse H. Wood, San Diego, CA (US)
Assigned to APTERA MOTORS CORP., San Diego, CA (US)
Filed by APTERA MOTORS CORP., San Diego, CA (US)
Filed on Feb. 13, 2023, as Appl. No. 18/168,274.
Claims priority of provisional application 63/345,419, filed on May 24, 2022.
Claims priority of provisional application 63/309,581, filed on Feb. 13, 2022.
Prior Publication US 2023/0261133 A1, Aug. 17, 2023
Int. Cl. H01L 31/18 (2006.01); H01L 31/048 (2014.01); B32B 37/02 (2006.01); B32B 3/26 (2006.01); B32B 38/00 (2006.01); B32B 27/36 (2006.01); B32B 27/32 (2006.01); B32B 27/30 (2006.01); B32B 27/28 (2006.01); B32B 27/40 (2006.01); B32B 27/08 (2006.01)
CPC H01L 31/1876 (2013.01) [B32B 3/266 (2013.01); B32B 37/02 (2013.01); B32B 38/0004 (2013.01); H01L 31/0488 (2013.01); H01L 31/188 (2013.01); B32B 27/08 (2013.01); B32B 27/283 (2013.01); B32B 27/30 (2013.01); B32B 27/304 (2013.01); B32B 27/306 (2013.01); B32B 27/32 (2013.01); B32B 27/325 (2013.01); B32B 27/36 (2013.01); B32B 27/365 (2013.01); B32B 27/40 (2013.01); B32B 2250/40 (2013.01); B32B 2274/00 (2013.01); B32B 2323/10 (2013.01); B32B 2327/06 (2013.01); B32B 2329/06 (2013.01); B32B 2331/04 (2013.01); B32B 2333/12 (2013.01); B32B 2367/00 (2013.01); B32B 2369/00 (2013.01); B32B 2375/00 (2013.01); B32B 2607/00 (2013.01)] 14 Claims
OG exemplary drawing
 
1. A method for continuously producing a laminated solar panel product, the method comprising:
providing a preformed substrate oriented so that the convex surface faces upwardly;
disposing a first encapsulant proximate said convex surface of said preformed substrate, so that said first encapsulant substantially conforms to said convex surface thereof;
disposing a solar cell array proximate said first encapsulant, said solar cell array being manufactured by steps comprising:
coupling an interconnect between two adjacent solar cells to form a row comprising a plurality of solar cells;
coupling a Z-bar interconnect between two adjacent solar cells, each adjacent solar cells being formed within an adjacent row of solar cells, to form said solar cell array comprising at least two rows, wherein said coupling said Z-bar interconnect between said two adjacent solar cells and said coupling said interconnect between said two adjacent solar cells face upwardly, and coupling a termination bar to said solar cell at both ends of said solar cell array;
flipping said solar cell array so that said coupling said Z-bar interconnect between said two adjacent solar cells, and said coupling said interconnect between said two adjacent solar cells, face downwardly;
picking said solder cell array; and
placing said solar cell array proximate said first encapsulant so that said solar cells of said solar cell array substantially conform to said first encapsulant;
cutting at least one termination opening through said preformed substrate;
routing said each of said termination bars of said solar cell array through said at least one terminal opening, such that said termination bars remain electrically decoupled;
disposing a second encapsulant proximate said solar cell array, so that said second encapsulant substantially conforms to said solar cell array;
disposing a preformed superstrate proximate said second encapsulant, wherein said preformed substrate and said preformed superstrate forma complementary shape when arranged in an assembled configuration, thereby forming a lamination stack;
laminating said lamination stack in a laminator to produce a solar cell;
trimming at least one edge of said solar panel;
feeding said termination bars of said solar cell array through a junction box and soldering said termination bars to said junction box; and
potting said junction box to form said laminated solar panel product.