Metal working – Method of mechanical manufacture – Electrical device making
Reexamination Certificate
1997-10-01
2001-03-27
Arbes, Carl J. (Department: 3729)
Metal working
Method of mechanical manufacture
Electrical device making
C029S564100, C029S740000, C029S832000
Reexamination Certificate
active
06205656
ABSTRACT:
BACKGROUND OF THE INVENTION
The present invention relates to manufacturing of articles incorporating photovoltaic cells and more particularly deals with an improved process for manufacturing photovoltaic charging panels.
Photovoltaic cells have been cut up and made into circuits for years. This was done by hand soldering wire to first one side of a piece of cell and then to the opposite side. Since one side of each cell is negative, and the other is positive this process will produce an electrical circuit. However this process is slow, labor intensive and subject to a high failure rate. In the past this process has been used mostly for producing small panels that have been used in novelties or hobby products. Presently there are a large number of rechargeable devices such as cellular phones, laptop computers and cordless phones, that are capable of having their use extended by the use of a small, high output photovoltaic panels. For further details about these applications, please refer to U.S. patent application Ser. No. 08/1476,234.
Some related patents are described below.
U.S. Pat. No. 5,460,659 describes fabrication of small solar cells. Each cell is mounted on an individual carrier and electrical connections are made between the cell and the carrier by automated wire bonding. The carriers are then mounted and electrically connected to a substrate. Finally a concentrator lens is placed over the array.
U.S. Pat. No. 5,096,505 describes mounting of solar cells on a light weight, honeycomb panel. The cells are mounted on metallized surfaces of a heat spreader and a circuit carrier, adhered to the rear, is bonded to islands on one side of the heat spreader.
While the basic concepts presented in the above mentioned patents are of interest, and an improvement over traditional hand assembly, none of the processes employed create photovoltaic cell assemblies that are able to fit into rechargeable batteries for electronic devices and the processes use many more steps than are necessary.
Development of an improved process for manufacturing miniature, photovoltaic panels which can speed up and optimize the assembly process represents a great improvement in the field of electronics assembly and satisfies a long felt need of the electronics manufacturer.
SUMMARY OF THE INVENTION
The subject invention solves all of these fabrication problems in a new and unique manner which has not been part of the art previously. The present invention is an improved process for manufacturing charging circuits from pieces of photovoltaic cells. The photovoltaic pieces are interconnected to each other in series. Interconnection of the rears of the photovoltaic pieces to their fronts, in series is accomplished by automated soldering of the pieces to a specially designed, printed circuit board. The pieces are placed on the board by robotic means.
Additionally, the circuit incorporates a Light Emitting Diode (LED) to indicate whether a supplemental photovoltaic charge is being produced. The LED also functions as a backflow preventer to ensure that the device's battery does not discharge itself through the panel when the photovoltaic cells are not in use. The printed circuit incorporates a location for soldering the LED so that the LED can also be automatically soldered in place when the pieces are soldered to the circuit board. The circuit board design also incorporates a location for subsequent electrical connection to the rechargeable battery.
It is the object of the present invention to provide a process for making photovoltaic panels for a plethora of battery powered devices which is fast, easy, reproducible and low in cost. The main advantages of the present invention are:
it is much quicker than methods now in use;
failure rates are much lower than the methods now in use because the process is standardized and automated;
the output is consistently higher because of the use of circuit boards and automation;
the cost of producing photovoltaic panels is lower because of savings through standardization; and
there is a savings in nationwide energy costs because of increased use of photovoltaic energy.
An appreciation of the other aims and objectives of the present invention and an understanding of it may be achieved by referring to the accompanying drawings and description of a preferred embodiment.
REFERENCES:
patent: 3849880 (1974-11-01), Haynos
patent: 3973996 (1976-08-01), Kennedy
patent: 4149665 (1979-04-01), Frosch
patent: 4219926 (1980-09-01), Frosch
Adams Arthur Henry
Pourtahmassebi Sorhab
Arbes Carl J.
Schaap Robert J.
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