Manufacturing and tests of aluminium interconnected solar modules

摘要

This paper is the third devoted to the subject of aluminium alloy interconnectors joined to the solar cell surface by ultrasonic welding. Previous studies had shown that AlMg 3 is the best alloy for this application because of its resistance to fatigue. This is now confirmed on experimental modules assembling Si (6x4cm) and GaAs (4x4cm) cells submitted to extensive simulated LEO (+100, -100 DEGREE) thermal cycling. In-plane loop interconnectors made of AlMg3 have already survived 48.000 such cycles. Out-of-plane ones have been so far tested until 42,000 cycles without showing mechanical fatigue or electrical degradation and the test is proceeding further. These modules also embody AlMg3 bus bars and Al wiring and therefore might be the forerunners of a lightweight and ATOX insensitive solar panel technology.