WO2009006230A2 - Collector grid and interconnect structures for photovoltaic arrays and modules - Google Patents

Abstract

The invention teaches novel structure and methods for producing electrical current collectors and electrical interconnection structure. Such articles find particular use in facile production of modular arrays of photovoltaic cells. The current collector and interconnecting structures may be initially produced separately from the photovoltaic cells thereby allowing the use of unique materials and manufacture. Subsequent application of the structures to the cells allows facile and efficient completion of modular arrays. Methods for combining the collector and interconnection structures with cells and final interconnecting into modular arrays are taught. Additional structure and methods for assembling multiple modules for large scale photovoltaic power collection are taught.

Description

COLLECTOR GRID AND INTERCONNECT STRUCTURES FOR PHOTOVOLTAIC

ARRAYS AND MODULES

RELATED APPLICATIONS

[0001] This Application claims priorities to U.S. Patent Application Nos.

11/824,047 filed June 30, 2007, 11/980,010 filed October 29, 2007, and 12/156,505 filed June 2, 2008, which are incorporated herein by references.

BACKGROUND OF THE INVENTION

[0002] Photovoltaic cells have developed according to two distinct methods. The initial operational cells employed a matrix of single crystal silicon appropriately doped to produce a planar p-n junction. An intrinsic electric field established at the p-n junction produces a voltage by directing solar photon produced holes and free electrons in opposite directions. Despite good conversion efficiencies and long-term reliability, widespread energy collection using single-crystal silicon cells is thwarted by the high cost of single crystal silicon material and interconnection processing.

[0003] A second approach to produce photovoltaic cells is by depositing thin photovoltaic semiconductor films on a supporting substrate. Material requirements are minimized and technologies can be proposed for mass production. Thin film photovoltaic cells employing amorphous silicon, cadmium telluride, copper indium gallium diselenide, dye sensitized polymers and the like have received increasing attention in recent years.

[0004] Despite significant improvements in individual cell conversion efficiencies for both single crystal and thin film approaches, photovoltaic energy collection has been generally restricted to applications having low power requirements. One factor impeding development of bulk power systems is the problem of economically collecting the energy from an extensive collection surface. Photovoltaic cells can be described as high current, low voltage devices. Typically individual cell voltage is less than about two volts, and often less than 0.6 volt. The current component is a substantial characteristic of the power generated. Efficient energy collection from an expansive surface must minimize resistive losses associated with the high current characteristic.

[0005] A way to minimize resistive losses is to reduce the size of individual cells and connect them in series. Thus, voltage is stepped through each cell while current and associated resistive losses are minimized. Such interconnected multi-cell arrangements are commonly re4ferred to as "modules". However, it is readily recognized that making effective, durable series connections among multiple small cells can be laborious, difficult and expensive. Regarding traditional crystalline silicon cells, the individual cells are normally discrete and comprise rigid wafers approximately 200 micrometers thick and approximately 230 square centimeters in area. A common way to convert multiple such cells into modules is to use a conventional "string and tab" arrangement. In this process multiple discrete cells are arranged in "strings" and the topside electrodes of cells are connected to backside electrodes of adjacent cells using "tabs" or ribbons of conductive material. The cell connections often involve manual tedious operations such as soldering and handling of multiple interconnected cells. Next, unwieldy flexible leads from the terminal cells must be directed and secured in position for outside connections, again a tediou operation. Finally, weight and assembly concerns limit the ultimate size of the module. These limitations impede adoption of the modules for large scale power generation.

[0006] In order to approach economical mass production of modules of series connected individual cells, a number of factors must be considered in addition to the type of photovoltaic materials chosen. These include the substrate employed and the process envisioned. Since thin films can be deposited over expansive areas, thin film technologies offer additional opportunities for mass production of interconnected modules compared to inherently small, discrete single crystal silicon cells. Thus a number of U.S. Patents have issued proposing designs and processes to achieve series interconnections among the thin film photovoltaic cells. Many of these technologies comprise deposition of photovoltaic thin films on glass substrates followed by scribing to form smaller area individual cells. Multiple steps then follow to electrically connect the individual cells in series while maintaining the original common glass substrate. These "common substrate approaches have come to be known as "monolithic integration". Examples of these proposed processes are presented in U.S. patents 4,443,651 , 4,724,011 , and 4,769,086 to Swartz, Turner et al. and Tanner et al. respectively. While expanding the opportunities for mass production of interconnected cell modules compared with inherently discrete approaches for crystal silicon cells, monolithic integration employing common glass substrates must inherently be performed on an individual batch basis.

[0007] More recently, developers have explored depositing wide area films using continuous roll-to-roll processing. This technology generally involves depositing thin films of photovoltaic material onto a continuously moving web. However, a challenge still remains regarding subdividing the expansive films into individual cells followed by interconnecting into a series connected array. For example, U.S. Patents 4,965,655 to Grimmer et. al. and U.S. Patent 4,697,041 to Okamiwa teach processes requiring expensive laser scribing and interconnections achieved with laser heat staking. In addition, these two references teach a substrate of thin vacuum deposited metal on films of relatively expensive polymers. The electrical resistance of thin vacuum metallized layers may significantly limit the active area of the individual interconnected cells.

[0008] It has become well known in the art that the efficiencies of certain promising thin film photovoltaic junctions can be substantially increased by high temperature treatments. These treatments involve temperatures at which even the most heat resistant plastics suffer rapid deterioration. Use of a metal foil as a substrate allows high temperature treatments and continuous roll-to-roll processing. However, the subsequent conversion to an interconnected module of multiple cells has proven difficult, in part because the metal foil substrate is electrically conducting.

[0009] U.S. Patent 4,746,618 to Nath et al. teaches a design and process to achieve interconnected arrays using roll-to-roll processing of a metal web substrate such as stainless steel. The process includes multiple operations of cutting, selective deposition, and riveting. These operations add considerably to the final interconnected array cost.

[0010] U.S. Patent 5,385,848 to Grimmer teaches roll-to-roll methods to achieve integrated series connections of adjacent thin film photovoltaic cells supported on an electrically conductive metal substrate. The process includes mechanical or chemical etch removal of a portion of the photovoltaic semiconductor and transparent top electrode to expose a portion of the electrically conductive metal substrate. The exposed metal serves as a contact area for interconnecting adjacent cells. These material removal techniques are troublesome for a number of reasons. First, many of the chemical elements involved in the best photovoltaic semiconductors are expensive and environmentally unfriendly. This removal subsequent to controlled deposition involves containment, dust and dirt collection and disposal, and possible cell contamination. This is not only wasteful but considerably adds to expense. Secondly, the removal processes are difficult to control dimensionally. Thus a significant amount of the valuable photovoltaic semiconductor is lost to the removal process. Ultimate module efficiencies are further compromised in that the spacing between adjacent cells grows, thereby reducing the effective active collector area for a given module area.

[0011] Thus there remains a need for acceptable mass manufacturing processes and articles to achieve effective integrated interconnections among photovoltaic cells. [0012] A further unsolved problem which has thwarted production of expansive surface photovoltaic modules is that of collecting the photogenerated current from the top, light incident surface of individual cells so that it can be conveyed to the rear electrode of an adjacent cell. Transparent conductive oxide (TCO) layers are normally employed as a top surface electrode. However, these TCO layers are relatively resistive compared to pure metals. Thus, efforts must be made to minimize resistive losses in transport of current through the TCO layer. One approach is simply to reduce the surface area of individual cells to a manageable amount. However, as cell widths decrease, the width of the area between individual cells (interconnect area) should also decrease so that the relative portion of inactive surface of the interconnect area does not become excessive. Typical cell widths of one centimeter are often taught in the art. These small cell widths demand very fine interconnect area widths, which dictate delicate and sensitive techniques to be used to electrically connect the top TCO surface of one cell to the bottom electrode of an adjacent series connected cell. Furthermore, achieving good stable ohmic contact to the TCO cell surface has proven difficult, especially when one employs those sensitive techniques available when using the TCO only as the top collector electrode. Another method is to form a current collector grid over the surface. This approach positions highly conductive material in contact with the surface of the TCO in a spaced arrangement such that the travel distance of current through the TCO is reduced. In the case of the classic single crystal silicon or polycrystal silicon cells, a common approach is to form a collector grid pattern of traces using a silver containing paste and then fuse the paste to sinter the silver particles into continuous conductive silver paths. These highly conductive traces normally lead to a collection buss such as a copper foil strip which also functions as a tab extending to the back electrode of an adjacent cell.. One notes that this approach involves use of expensive silver and requires the photovoltaic semiconductors tolerate the high fusion temperatures. Another approach is to attach an array of fine copper wires to the surface of the TCO. The wires may also lead to a collection buss or tab which may extend to an electrode of an adjacent cell. This wire approach requires positioning and fixing of multiple fine fragile wires which makes mass production difficult and expensive. Another approach is to print a collector grid array on the surface of the TCO using a conductive ink, usually one containing a heavy loading of fine particulate silver. The ink is simply dried or cured at mild temperatures which do not adversely affect the cell. This approach requires the use of relatively expensive inks because of the high loading of finely divided silver. In addition, batch printing on the individual cells is laborious and expensive. [0013] Thus there remains a need for improved materials and structure for collecting the current from the top light incident surface of a photovoltaic cell.

[0014] A further issue that has impeded adoption of photovoltaic technology, especially for bulk power collection in the form of solar farms, involves installation of multiple modules over expansive regions of surface. Traditionally, multiple individual modules have been mounted on racks, normally at an incline to horizontal appropriate to the latitude of the site. Conducting leads from each module are then physically coupled with leads from an adjacent module in order to interconnect multiple modules. This arrangement results in a string of modules each of which is coupled to an adjacent module. At one end of the string, the power is transferred from the end module to be conveyed to a separate site for further treatment such as voltage adjustment. This arrangement avoids having to run conductive cabling from each individual module to the separate treatment site.

[0015] The traditional solar farm installation described in the above paragraph has some drawbacks. First, traditional modules are limited in size due to weight and manufacturing constraints. This fact increases the number of individual modules required to cover a desired surface area. Next, the module itself comprises a string of individual cells. In the conventional module lead conductors in the form of flexible wires or ribbons are attached to an electrode on the two cells positioned at each end of the string in order to convey the power from the module. After mounting the individual modules on their support at the installation site, the respective leads from adjacent modules must be connected in order to couple adjacent modules, and the connection must be protected to avoid environmental deterioration or separation. These are intrinsically tedious manual operations. Finally, since the module leads and cell interconnections are not of high current carrying capacity, the adjacent cells are normally connected in series arrangement. Thus voltage builds up to high levels even at relatively short strings of modules. While not an overriding problem security and insulation must be appropriate to eliminate a shock hazard.

[0016] Thus there remains a need for improved module form factors and complimentary installation structure to reduce the cost and complexity of achieving large area "utility" scale photovoltaic installations.

[0017] In a somewhat removed segment of technology, a number of electrically conductive fillers have been used to produce electrically conductive polymeric materials. This technology generally involves mixing of a conductive filler such as silver particles with the polymer resin prior to fabrication of the material into its final shape. Conductive fillers may have high aspect ratio structure such as metal fibers, metal flakes or powder, or highly structured carbon blacks, with the choice based on a number of cost/performance considerations. More recently, fine particles of intrinsically conductive polymers have been employed as conductive fillers within a resin binder. Electrically conductive polymers have been used as bulk thermoplastic compositions, or formulated into paints and inks. Their development has been spurred in large part by electromagnetic radiation shielding and static discharge requirements for plastic components used in the electronics industry. Other known applications include resistive heating fibers and battery components and production of conductive patterns and traces. The characterization "electrically conductive polymer" covers a very wide range of intrinsic resistivities depending on the filler, the filler loading and the methods of manufacture of the filler/polymer blend. Resistivities for filled electrically conductive polymers may be as low as .00001 ohm-cm, for very heavily filled silver inks, yet may be as high as 10,000 ohm- cm or even more for lightly filled carbon black materials or other "anti-static" materials. "Electrically conductive polymer" has become a broad industry term to characterize all such materials. In addition, it has been reported that recently developed intrinsically conducting polymers (absent conductive filler) may exhibit resistivities comparable to pure metals.

[0018] In yet another separate technological segment, coating plastic substrates with metal electrodeposits has been employed to achieve decorative effects on items such as knobs, cosmetic closures, faucets, and automotive trim. The normal conventional process actually combines two primary deposition technologies. The first is to deposit an adherent metal coating using chemical (electroless) deposition to first coat the nonconductive plastic and thereby render its surface highly conductive. This electroless step is then followed by conventional electroplating. ABS (acrylonitrile-butadiene-styrene) plastic dominates as the substrate of choice for most applications because of a blend of mechanical and process properties and ability to be uniformly etched. The overall plating process comprises many steps. First, the plastic substrate is chemically etched to microscopically roughen the surface. This is followed by depositing an initial metal layer by chemical reduction (typically referred to as "electroless plating"). This initial metal layer is normally copper or nickel of thickness typically one-half micrometer. The object is then electroplated with metals such as bright nickel and chromium to achieve the desired thickness and decorative effects. The process is very sensitive to processing variables used to fabricate the plastic substrate, limiting applications to carefully prepared parts and designs. In addition, the many steps employing harsh chemicals make the process intrinsically costly and environmentally difficult. Finally, the sensitivity of ABS plastic to liquid hydrocarbons has prevented certain applications. ABS and other such polymers have been referred to as "electroplateable" polymers or resins. This is a misnomer in the strict sense, since ABS (and other nonconductive polymers) are incapable of accepting an electrodeposit directly and must be first metallized by other means before being finally coated with an electrodeposit. The conventional technology for electroplating on plastic (etching, chemical reduction, electroplating) has been extensively documented and discussed in the public and commercial literature. See, for example, Saubestre, Transactions of the Institute of Metal Finishing, 1969, Vol. 47., or Arcilesi et al., Products Finishing, March 1984.

[0019] Many attempts have been made to simplify the process of electroplating on plastic substrates. Some involve special chemical techniques to produce an electrically conductive film on the surface. Typical examples of this approach are taught by U.S. Patent No. 3,523,875 to Minklei, U.S. Patent No. 3,682,786 to Brown et. al., and U.S. Patent No. 3,619,382 to Lupinski. The electrically conductive film produced was then electroplated. None of these attempts at simplification have achieved any recognizable commercial application.

[0020] A number of proposals have been made to make the plastic itself conductive enough to allow it to be electroplated directly thereby avoiding the "electroless plating" process. It is known that one way to produce electrically conductive polymers is to incorporate conductive or semiconductive fillers into a polymeric binder. Investigators have attempted to produce electrically conductive polymers capable of accepting an electrodeposited metal coating by loading polymers with relatively small conductive particulate fillers such as graphite, carbon black, and silver or nickel powder or flake. Heavy such loadings are sufficient to reduce volume resistivity to a level where electroplating may be considered. However, attempts to make an acceptable electroplateable polymer using the relatively small metal containing fillers alone encounter a number of barriers. First, the most conductive fine metal containing fillers such as silver are relatively expensive. The loadings required to achieve the particle-to-particle proximity to achieve acceptable conductivity increases the cost of the polymer/filler blend dramatically. The metal containing fillers are accompanied by further problems. They tend to cause deterioration of the mechanical properties and processing characteristics of many resins. This significantly limits options in resin selection. All polymer processing is best achieved by formulating resins with processing characteristics specifically tailored to the specific process (injection molding, extrusion, blow molding, printing etc.). A required heavy loading of metal filler severely restricts ability to manipulate processing properties in this way. A further problem is that metal fillers can be abrasive to processing machinery and may require specialized screws, barrels, and the like.

[0021] Another major obstacle involved in the electroplating of electrically conductive polymers is a consideration of adhesion between the electrodeposited metal and polymeric substrate (metal/polymer adhesion). In most cases sufficient adhesion is required to prevent metal/polymer separation during extended environmental and use cycles. Despite being electrically conductive, a simple metal-filled polymer offers no assured bonding mechanism to produce adhesion of an electrodeposit since the metal particles may be encapsulated by the resin binder, often resulting in a resin-rich "skin".

[0022] A number of methods to enhance electrodeposit adhesion to electrically conductive polymers have been proposed. For example, etching of the surface prior to plating can be considered. Etching can be achieved by immersion in vigorous solutions such as chromic/sulfuric acid. Alternatively, or in addition, an etchable species can be incorporated into the conductive polymeric compound. The etchable species at exposed surfaces is removed by immersion in an etchant prior to electroplating. Oxidizing surface treatments can also be considered to improve metal/plastic adhesion. These include processes such as flame or plasma treatments or immersion in oxidizing acids. In the case of conductive polymers containing finely divided metal, one can propose achieving direct metal-to-metal adhesion between electrodeposit and filler. However, here the metal particles are generally encapsulated by the resin binder, often resulting in a resin rich "skin". To overcome this effect, one could propose methods to remove the "skin", exposing active metal filler to bond to subsequently electrodeposited metal.

[0023] Another approach to impart adhesion between conductive resin substrates and electrodeposits is incorporation of an "adhesion promoter" at the surface of the electrically conductive resin substrate. This approach was taught by Chien et al. in U.S. Patent No. 4,278,510 where maleic anhydride modified propylene polymers were taught as an adhesion promoter. Luch, in U.S. Patent No. 3,865,699 taught that certain sulfur bearing chemicals could function to improve adhesion of initially electrodeposited Group VIII metals.

[0024] For the above reasons, electrically conductive polymers employing metal fillers have not been widely used as bulk substrates for electroplateable articles. Such metal containing polymers have found use as inks or pastes in production of printed circuitry. Revived efforts and advances have been made in the past few years to accomplish electroplating onto printed conductive patterns formed by silver filled inks and pastes.

[0025] An additional physical obstacle confronting practical electroplating onto electrically conductive polymers is the initial "bridge" of electrodeposit onto the surface of the electrically conductive polymer. In electrodeposition, the substrate to be plated is often made cathodic through a pressure contact to a metal rack tip, itself under cathodic potential. However, if the contact resistance is excessive or the substrate is insufficiently conductive, the electrodeposit current favors the rack tip to the point where the electrodeposit will not bridge to the substrate.

[0026] Moreover, a further problem is encountered even if specialized racking or cathodic contact successfully achieves electrodeposit bridging to the substrate. Many of the electrically conductive polymers have resistivities far higher than those of typical metal substrates. Also, many applications involve electroplating onto a thin (less than 25 micrometer) printed substrate. The conductive polymeric substrate may be relatively limited in the amount of electrodeposition current which it alone can convey. Thus, the conductive polymeric substrate does not cover almost instantly with electrodeposit as is typical with metallic substrates. Except for the most heavily loaded and highly conductive polymer substrates, a large portion of the electrodeposition current must pass back through the previously electrodeposited metal growing laterally over the surface of the conductive plastic substrate. In a fashion similar to the bridging problem discussed above, the electrodeposition current favors the electrodeposited metal and the lateral growth can be extremely slow and erratic. This restricts the size and "growth length" of the substrate conductive pattern, increases plating costs, and can also result in large non- uniformities in electrodeposit integrity and thickness over the pattern.

[0027] This lateral growth is dependent on the ability of the substrate to convey current. Thus, the thickness and resistivity of the conductive polymeric substrate can be defining factors in the ability to achieve satisfactory electrodeposit coverage rates. When dealing with selectively electroplated patterns long thin metal traces are often desired, deposited on a relatively thin electrically conductive polymer substrate. These factors of course often work against achieving the desired result.

[0028] This coverage rate problem likely can be characterized by a continuum, being dependent on many factors such as the nature of the initially electrodeposited metal, electroplating bath chemistry, the nature of the polymeric binder and the resistivity of the electrically conductive polymeric substrate. As a "rule of thumb", the instant inventor estimates that coverage rate issue would demand attention if the resistivity of the conductive polymeric substrate rose above about .001 ohm-cm. Alternatively, a "rule of thumb" appropriate for thin film substrates would be that attention is appropriate if the substrate film to be plated had a surface "sheet" resistance of greater than about 0.1 ohm per square.

[0029] The least expensive (and least conductive) of the readily available conductive fillers for plastics are carbon blacks. Attempts have been made to electroplate electrically conductive polymers using carbon black loadings. Examples of this approach are the teachings of U.S. Patents 4,038,042, 3,865,699, and 4,278,510 to Adelman, Luch, and Chien et al. respectively.

[0030] Adelman taught incorporation of conductive carbon black into a polymeric matrix to achieve electrical conductivity required for electroplating. The substrate was pre-etched in chromic/sulfuric acid to achieve adhesion of the subsequently electroplated metal. A fundamental problem remaining unresolved by the Adelman teaching is the relatively high resistivity of carbon loaded polymers. The lowest "microscopic resistivity" generally achievable with carbon black loaded polymers is about 1 ohm-cm. This is about five to six orders of magnitude higher than typical electrodeposited metals such as copper or nickel. Thus, the electrodeposit bridging and coverage rate problems described above remained unresolved by the Adelman teachings.

[0031] Luch in U.S. Patent 3,865,699 and Chien et al. in U.S. Patent 4,278,510 also chose carbon black as a filler to provide an electrically conductive surface for the polymeric compounds to be electroplated. The Luch Patent 3,865,699 and the Chien Patent 4,278,510 are hereby incorporated in their entirety by this reference. However, these inventors further taught inclusion of materials to increase the rate of metal coverage or the rate of metal deposition on the polymer. These materials can be described herein as "electrodeposit growth rate accelerators" or "electrodeposit coverage rate accelerators". An electrodeposit coverage rate accelerator is a material functioning to increase the electrodeposition coverage rate over the surface of an electrically conductive polymer independent of any incidental affect it may have on the conductivity of an electrically conductive polymer. In the embodiments, examples and teachings of U.S. Patents 3,865,699 and 4,278,510, it was shown that certain sulfur bearing materials, including elemental sulfur, can function as electrodeposit coverage or growth rate accelerators to overcome problems in achieving electrodeposit coverage of electrically conductive polymeric surfaces having relatively high resistivity or thin electrically conductive polymeric substrates having limited current carrying capacity.

[0032] In addition to elemental sulfur, sulfur in the form of sulfur donors such as sulfur chloride, 2-mercapto-benzothiazole, N-cyclohexyle-2-benzothiaozole sulfonomide, dibutyl xanthogen disulfide, and tetramethyl thiuram disulfide or combinations of these and sulfur were identified. Those skilled in the art will recognize that these sulfur donors are the materials which have been used or have been proposed for use as vulcanizing agents or accelerators. Since the polymer-based compositions taught by Luch and Chien et al. could be electroplated directly they could be accurately defined as directly electroplateable resins (DER). These directly electroplateable resins (DER) can be generally described as electrically conductive polymers with the inclusion of a growth rate accelerator.

[0033] Specifically for the present invention, specification, and claims, directly electroplateable resins, (DER), are characterized by the following features:

(a) presence of an electrically conductive polymer;

(b) presence of an electrodeposit coverage rate accelerator;

(c) presence of the electrically conductive polymer and the electrodeposit coverage rate accelerator in the directly electroplateable composition in cooperative amounts required to achieve direct coverage of the composition with an electrodeposited metal or metal-based alloy.

[0034] In his Patents, Luch specifically identified unsaturated elastomers such as natural rubber, polychloroprene, butyl rubber, chlorinated butyl rubber, polybutadiene rubber, acrylonitrile-butadiene rubber, styrene-butadiene rubber etc. as suitable for the matrix polymer of a directly electroplateable resin. Other polymers identified by Luch as useful included polyvinyls, polyolefins, polystyrenes, polyamides, polyesters and polyurethanes.

[0035] When used alone, the minimum workable level of carbon black required to achieve "microscopic" electrical resistivities of less than 1000 ohm-cm, for a polymer/carbon black mix appears to be about 8 weight percent based on the combined weight of polymer plus carbon black. The "microscopic" material resistivity generally is not reduced below about 1 ohm-cm, by using conductive carbon black alone. This is several orders of magnitude larger than typical metal resistivities. [0036] It is understood that in addition to carbon blacks, other well known, highly conductive fillers can be considered in DER compositions. Examples include but are not limited to metallic fillers or flake such as silver. In these cases the more highly conductive fillers can be used to augment or even replace the conductive carbon black. Furthermore, one may consider using intrinsically conductive polymers to supply the required conductivity. In this case, it may not be necessary to add conductive fillers to the polymer.

[0037] The "bulk, macroscopic" resistivity of conductive carbon black filled polymers can be further reduced by augmenting the carbon black filler with additional highly conductive, high aspect ratio fillers such as metal containing fibers. This can be an important consideration in the success of certain applications. Furthermore, one should realize that incorporation of non-conductive fillers may increase the "bulk, macroscopic" resistivity of conductive polymers loaded with finely divided conductive fillers without significantly altering the "microscopic resistivity" of the conductive polymer "matrix" encapsulating the non-conductive filler particles.

[0038] Regarding electrodeposit coverage rate accelerators, both Luch and Chien et al. in the above discussed U.S. Patents demonstrated that sulfur and other sulfur bearing materials such as sulfur donors and vulcanization accelerators function as electrodeposit coverage rate accelerators when using an initial Group VIII metal electrodeposit "strike" layer. Thus, an electrodeposit coverage rate accelerator need not be electrically conductive, but may be a material that is normally characterized as a nonconductor. The coverage rate accelerator need not appreciably affect the conductivity of the polymeric substrate. As an aid in understanding the function of an electrodeposit coverage rate accelerator the following is offered:

a. A specific conductive polymeric structure is identified as having insufficient current carrying capacity to be directly electroplated in a practical manner. b. A material is added to the conductive polymeric material forming said structure. Said material addition may have insignificant affect on the current carrying capacity of the structure (i.e. it does not appreciably reduce resistivity or increase thickness). c. Nevertheless, inclusion of said material greatly increases the speed at which an electrodeposited metal laterally covers the electrically conductive surface.

It is contemplated that a coverage rate accelerator may be present as an additive, as a species absorbed on a filler surface, or even as a functional group attached to the polymer chain. One or more growth rate accelerators may be present in a directly electroplateable resin (DER) to achieve combined, often synergistic results.

[0039] A hypothetical example might be an extended trace of conductive ink having a dry thickness of 1 micrometer. Such inks typically include a conductive filler such as silver, nickel, copper, conductive carbon etc. The limited thickness of the ink reduces the current carrying capacity of this trace thus preventing direct electroplating in a practical manner. However, inclusion of an appropriate quantity of a coverage rate accelerator may allow the conductive trace to be directly electroplated in a practical manner.

[0040] One might expect that other Group 6A elements, such as oxygen, selenium and tellurium, could function in a way similar to sulfur. In addition, other combinations of electrodeposited metals, such as copper and appropriate coverage rate accelerators may be identified. It is important to recognize that such an electrodeposit coverage rate accelerator is important in order to achieve direct electrodeposition in a practical way onto polymeric substrates having low conductivity or very thin electrically conductive polymeric substrates having restricted current carrying ability.

[0041] It has also been found that the inclusion of an electrodeposit coverage rate accelerator promotes electrodeposit bridging from a discrete cathodic metal contact to a DER surface. This greatly reduces the bridging problems described above.

[0042] Due to multiple performance problems associated with their intended end use, none of the attempts identified above to directly electroplate electrically conductive polymers or plastics has ever achieved any recognizable commercial success. Nevertheless, the current inventor has persisted in personal efforts to overcome certain performance deficiencies associated with the initial DER technology. Along with these efforts has come a recognition of unique and eminently suitable applications employing the DER technology. Some examples of these unique applications for electroplated articles include solar cell electrical current collection grids, electrodes, electrical circuits, electrical traces, circuit boards, antennas, capacitors, induction heaters, connectors, switches, resistors, inductors, batteries, fuel cells, coils, signal lines, power lines, radiation reflectors, coolers, diodes, transistors, piezoelectric elements, photovoltaic cells, emi shields, biosensors and sensors. One readily recognizes that the demand for such functional applications for electroplated articles is relatively recent and has been particularly explosive during the past decade. [0043] It is important to recognize a number of important characteristics of directly electroplateable resins (DERs) which facilitate the current invention. One such characteristic of the DER technology is its ability to employ polymer resins and formulations generally chosen in recognition of the fabrication process envisioned and the intended end use requirements. In order to provide clarity, examples of some such fabrication processes are presented immediately below in subparagraphs 1 through 7.

(1) Should it be desired to electroplate an ink, paint, coating, or paste which may be printed or formed on a substrate, a good film forming polymer, for example a soluble resin such as an elastomer, can be chosen to fabricate a DER ink (paint, coating, paste etc.). For example, in some embodiments thermoplastic elastomers having an olefin base, a urethane base, a block copolymer base or a random copolymer base may be appropriate. In some embodiments the coating may comprise a water based latex. Other embodiments may employ more rigid film forming polymers. The DER ink composition can be tailored for a specific process such flexographic printing, rotary silk screening, gravure printing, flow coating, spraying etc. Furthermore, additives can be employed to improve the adhesion of the DER ink to various substrates. One example would be tackifiers.

(2) Very thin DER traces often associated with collector grid structures can be printed and then electroplated due to the inclusion of the electrodeposit growth rate accelerator.

(3) Should it be desired to cure the DER substrate to a 3 dimensional matrix, an unsaturated elastomer or other "curable" resin may be chosen.

(4) DER inks can be formulated to form electrical traces on a variety of flexible substrates. For example, should it be desired to form electrical structure on a laminating film, a DER ink adherent to the sealing surface of the laminating film can be effectively electroplated with metal and subsequently laminated to a separate surface.

(5) Should it be desired to electroplate a fabric, a DER ink can be used to coat all or a portion of the fabric intended to be electroplated. Furthermore, since DER's can be fabricated out of the thermoplastic materials commonly used to create fabrics, the fabric itself could completely or partially comprise a DER. This would eliminate the need to coat the fabric.

(6) Should one desire to electroplate a thermoformed article or structure, DER's would represent an eminently suitable material choice. DER's can be easily formulated using olefinic materials which are often a preferred material for the thermoforming process. Furthermore, DER's can be easily and inexpensively extruded into the sheet like structure necessary for the thermoforming process.

(7) Should one desire to electroplate an extruded article or structure, for example a sheet or film, DER's can be formulated to possess the necessary melt strength advantageous for the extrusion process.

(8) Should one desire to injection mold an article or structure having thin walls, broad surface areas etc. a DER composition comprising a high flow polymer can be chosen.

(9) Should one desire to vary adhesion between an electrodeposited DER structure supported by a substrate the DER material can be formulated to supply the required adhesive characteristics to the substrate. For example, the polymer chosen to fabricate a DER ink can be chosen to cooperate with an "ink adhesion promoting" surface treatment such as a material primer or corona treatment. In this regard, it has been observed that it may be advantageous to limit such adhesion promoting treatments to a single side of the substrate. Treatment of both sides of the substrate in a roll to roll process may adversely affect the surface of the DER material and may lead to deterioration in plateability. For example, it has been observed that primers on both sides of a roll of PET film have adversely affected plateability of DER inks printed on the PET. It is believed that this is due to primer being transferred to the surface of the DER ink when the PET is rolled up.

[0044] All polymer fabrication processes require specific resin processing characteristics for success. The ability to "custom formulate" DER's to comply with these changing processing and end use requirements while still allowing facile, quality electroplating is a significant factor in the teachings of the current invention.

[0045] Another important recognition regarding the suitability of DER's for the teachings of the current invention is the simplicity of the electroplating process. Unlike many conventional electroplated plastics, DER's do not require a significant number of process steps prior to actual electroplating. This allows for simplified manufacturing and improved process control. It also reduces the risk of cross contamination such as solution dragout from one process bath being transported to another process bath. The simplified manufacturing process will also result in reduced manufacturing costs.

[0046] Another important recognition regarding the suitability of DER's for the teachings of the current invention is the wide variety of metals and alloys capable of being electrodeposited. Deposits may be chosen for specific attributes. Examples may include copper for conductivity and nickel for corrosion resistance.

[0047] Yet another recognition of the benefit of DER's for the teachings of the current invention is the ability they offer to selectively electroplate an article or structure. The articles of the current invention often consist of metal patterns selectively positioned in conjunction with insulating materials. Such selective positioning of metals is often expensive and difficult. However, the attributes of the DER technology make the technology eminently suitable for the production of such selectively positioned metal structures. As will be shown in later embodiments, it is often desired to electroplate a polymer or polymer-based structure in a selective manner. DER's are eminently suitable for such selective electroplating.

[0048] Yet another recognition of the benefit of DER's for the teachings of the current invention is the ability they offer to continuously electroplate an article or structure. As will be shown in later embodiments, it is often desired to continuously electroplate articles. DER's are eminently suitable for such continuous electroplating. Furthermore, DER's allow for selective electroplating in a continuous manner.

[0049] Yet another recognition of the benefit of DER's for the teachings of the current invention is their ability to withstand the pre-treatments often required to prepare other materials for plating. For example, were a DER to be combined with a metal, the DER material would be resistant to many of the pre-treatments such as cleaning which may be necessary to electroplate the metal.

[0050] Yet another recognition of the benefit of DER's for the teachings of the current invention is that the desired plated structure often requires the plating of long and/or broad surface areas. As discussed previously, the coverage rate accelerators included in DER formulations allow for such extended surfaces to be covered in a relatively rapid manner thus allowing one to consider the use of electroplating of conductive polymers.

[0051] These and other attributes of DER's may contribute to successful articles and processing of the instant invention. However, it is emphasized that the DER technology is but one of a number of alternative metal deposition or positioning processes suitable to produce many of the embodiments of the instant invention. Other approaches, such as electroless metal deposition or electroplating onto silver ink patterns may be suitable alternatives. These choices will become clear in light of the teachings to follow in the remaining specification, accompanying figures and claims.

[0052] In order to eliminate ambiguity in terminology, for the present invention the following definitions are supplied:

[0053] While not precisely definable, for the purposes of this specification, electrically insulating materials may generally be characterized as having electrical resistivities greater than 10,000 ohm-cm. Also, electrically conductive materials may generally be characterized as having electrical resistivities less than .001 ohm-cm. Also electrically resistive or semi-conductive materials may generally be characterized as having electrical resistivities in the range of .001 ohm-cm to 10,000 ohm-cm. The characterization "electrically conductive polymer" covers a very wide range of intrinsic resistivities depending on the filler, the filler loading and the methods of manufacture of the filler/polymer blend. Resistivities for electrically conductive polymers may be as low as .00001 ohm-cm, for very heavily filled silver inks, yet may be as high as 10,000 ohm- cm or even more for lightly filled carbon black materials or other "anti-static" materials. "Electrically conductive polymer" has become a broad industry term to characterize all such materials. Thus, the term "electrically conductive polymer" as used in the art and in this specification and claims extends to materials of a very wide range of resitivities from about .00001 ohm-cm, to about 10,000 ohm-cm and higher.

[0054] An "electroplateable material" is a material having suitable attributes that allow it to be coated with a layer of electrodeposited material.

[0055] A "metallizable material" is a material suitable to be coated with a metal deposited by any one or more of the available metallizing process, including chemical deposition, vacuum metallizing, sputtering, metal spraying, sintering and electrodeposition.

[0056] "Metal-based" refers to a material or structure having at least one metallic property and comprising one or more components at least one of which is a metal or metal-containing alloy.

[0057] "Alloy" refers to a substance composed of two or more intimately mixed materials.

[0058] "Group VIII metal-based" refers to a substance containing by weight 50% to

100% metal from Group VIII of the Periodic Table of Elements. [0059] A "bulk metal foil" refers to a thin structure of metal or metal-based material that may maintain its integrity absent a supporting structure. Generally, metal films of thickness greater than about 2 micrometers may have this characteristic. Thus, in most cases a "bulk metal foil" will have a thickness between about 2 micrometers and 250 micrometers and may comprise a laminate of multiple layers.

[0060] The term "monolithic" or "monolithic structure" is used in this specification and claims as is common in industry to describe an object that is made or formed into or from a single item.

OBJECTS OF THE INVENTION

[0061] An object of the invention is to eliminate the deficiencies in the prior art methods of producing expansive area, series or parallel interconnected photovoltaic modules and arrays.

[0062] A further object of the present invention is to provide improved substrates to achieve series or parallel interconnections among photovoltaic cells.

[0063] A further object of the invention is to provide structures useful for collecting current from an electrically conductive surface.

[0064] A further object of the invention is to provide current collector electrode structures useful in facilitating mass production of optoelectric devices such as photovoltaic cell modules and arrays.

[0065] A further object of the present invention is to provide improved processes whereby interconnected photovoltaic modules can be economically mass produced.

[0066] A further object of the invention is to provide a process and means to accomplish interconnection of photovoltaic cells into an integrated array through continuous processing.

[0067] A further object of the invention is to teach methods and structure to reduce cost and complexity of photovoltaic power installations.

[0068] Other objects and advantages will become apparent in light of the following description taken in conjunction with the drawings and embodiments. SUMMARY OF THE INVENTION

[0069] The current invention provides a solution to the stated needs by producing the active photovoltaic cells and interconnecting structures separately and subsequently combining them to produce the desired interconnected array or module. One embodiment of the invention contemplates deposition of thin film photovoltaic junctions on metal foil substrates which may be heat treated following deposition if required in a continuous fashion without deterioration of the metal support structure. In a separate operation, interconnection structures are produced. In an embodiment, interconnection structures are produced in a continuous roll-to-roll fashion. In an embodiment, the interconnecting structure is laminated to the foil supported photovoltaic cell and conductive connections are applied to complete the array. Application of a separate interconnection structure subsequent to cell manufacture allows the interconnection structures to be uniquely formulated using polymer-based materials. Interconnections are achieved without the need to use the expensive and intricate material removal operations currently taught in the art to achieve interconnections.

[0070] In another embodiment, a separately prepared current collector grid structure is taught. In an embodiment the current collector structure is produced in a continuous roll-to-roll fashion. The current collector structure comprises conductive material positioned on a first surface of a laminating sheet or positioning carrier sheet. This combination is prepared such that the first surface of the laminating or positioning sheet and the conductive material can be positioned in abutting contact with a conductive surface. In one embodiment the conductive surface is the light incident surface of a photovoltaic cell. In another embodiment the conductive surface is the rear conductive surface of a photovoltaic cell.

BRIEF DESCRIPTION OF THE DRAWINGS

[0071] The various factors and details of the structures and manufacturing methods of the present invention are hereinafter more fully set forth with reference to the accompanying drawings wherein:

[0072] Figure 1 is a top plan view of a thin film photovoltaic structure including its support structure.

[0073] Figure 1A is a top plan view of the article of Figure 1 following an optional processing step of subdividing the article of Figure 1 into cells of smaller dimension. [0074] Figure 2 is a sectional view taken substantially along the line 2-2 of

Figure 1.

[0075] Figure 2A is a sectional view taken substantially along the line 2A-2A of

Figure 1A.

[0076] Figure 2B is a simplified sectional depiction of the structure embodied in

Figure 2A.

[0077] Figure 3 is an expanded sectional view showing a form of the structure of semiconductor 11 of Figures 2 and 2A.

[0078] Figure 4 illustrates a possible process for producing the structure shown in

Figures 1-3.

[0079] Figure 5 is a sectional view illustrating the problems associated with making series connections among thin film photovoltaic cells shown in Figures 1-3.

[0080] Figure 6 is a top plan view of a starting structure for an embodiment of the instant invention.

[0081] Figure 7 is a sectional view, taken substantially along the lines 7-7 of

Figure 6, illustrating a possible laminate structure of the embodiment.

[0082] Figure 8 is a simplified sectional depiction of the Figure 7 structure suitable for ease of presentation of additional embodiments..

[0083] Figure 9 is a top plan view of the structure embodied in Figures 6 through 8 following an additional processing step.

[0084] Figure 10 is a sectional view taken substantially from the perspective of lines 10-10 of Figure 9.

[0085] Figure 11 is a sectional view taken substantially from the perspective of lines 11-11 of Figure 9.

[0086] Figure 12 is a top plan view of an article resulting from exposing the Figure

9 article to an additional processing step.

[0087] Figure 13 is a sectional view taken substantially from the perspective of lines 13-13 of Figure 12. [0088] Figure 14 is a sectional view taken substantially from the perspective of lines 14-14 of Figure 12.

[0089] Figure 15 is a sectional view taken substantially from the perspective of lines 15-15 of Figure 12.

[0090] Figure 16 is a top plan of an alternate embodiment similar in structure to the embodiment of Figure 9.

[0091] Figure 17 is a sectional view taken substantially from the perspective of lines 17-17 of Figure 16.

[0092] Figure 18 is a sectional view taken substantially from the perspective of lines 18-18 of Figure 16.

[0093] Figure 19 is a simplified sectional view of the article embodied in Figures

16-18 suitable for ease of clarity of presentation of additional embodiments.

[0094] Figure 20 is a sectional view showing the article of Figures 16 through 19 following an additional optional processing step.

[0095] Figure 21 is a simplified depiction of a process useful in producing objects of the instant invention.

[0096] Figure 22 is a sectional view taken substantially from the perspective of lines 22-22 of Figure 21 showing an arrangement of three components just prior to the Process 92 depicted in Figure 21.

[0097] Figure 23 is a sectional view showing the result of combining the components of Figure 22 using the process of Figure 21.

[0098] Figure 24 is a sectional view embodying a series interconnection of multiple articles as depicted in Figure 23

[0099] Figure 25 is an exploded sectional view of the region within the box "K" of

Figure 24.

[0100] Figure 26 is a top plan view of a starting article in the production of another embodiment of the instant invention. [0101] Figure 27 is a sectional view taken from the perspective of lines 27-27 of

Figure 26.

[0102] Figure 28 is a simplified sectional depiction of the article of Figures 26 and

27 useful in preserving clarity of presentation of additional embodiments.

[0103] Figure 29 is a top plan view of the original article of Figures 26-28 following an additional processing step.

[0104] Figure 30 is a sectional view taken substantially from the perspective of lines 30-30 of Figure 29.

[0105] Figure 31 is a sectional view of the article of Figures 29 and 30 following an additional optional processing step.

[0106] Figure 32 is a sectional view, similar to Figure 22, showing an arrangement of articles just prior to combination using a process such as depicted in Figure21.

[0107] Figure 33 is a sectional view showing the result of combining the arrangement depicted in Figure 32 using a process as depicted in Figure 21.

[0108] Figure 34 is a sectional view a series interconnection of a multiple of articles such as depicted in Figure 33.

[0109] Figure 35 is a top plan view of a starting article used to produce another embodiment of the instant invention.

[0110] Figure 36 is a simplified sectional view taken substantially from the perspective of lines 36-36 of Figure 35.

[0111] Figure 37 is a expanded sectional view of the article embodied in Figures

35 and 36 showing a possible multi-layered structure of the article.

[0112] Figure 38 is a sectional view showing a structure combining repetitive units of the article embodied in Figures 35 and 36.

[0113] Figure 39 is a top plan view of the article of Figures 35 and 36 following an additional processing step.

[0114] Figure 40 is a sectional view taken from the perspective of lines 40-40 of

Figure 39. [0115] Figure 41 is a sectional view similar to that of Figure 40 following an additional optional processing step.

[0116] Figure 42 is a sectional view showing a possible combining of the article of

Figure 41 with a photovoltaic cell.

[0117] Figure 43 is a sectional view showing multiple articles as in Figure 42 arranged in a series interconnected array.

[0118] Figure 44 is a top plan view of a starting article in the production of yet another embodiment of the instant invention.

[0119] Figure 45 is a sectional view taken substantially from the perspective of lines 45-45 of Figure 44 showing a possible layered structure for the article.

[0120] Figure 46 is a sectional view similar to Figure 45 but showing an alternate structural embodiment.

[0121] Figure 47 is a simplified sectional view of the articles embodied in Figures

44-46 useful in maintaining clarity and simplicity for subsequent embodiments.

[0122] Figure 48 is a top plan view of the articles of Figures 44-47 following an additional processing step.

[0123] Figure 49 is a sectional view taken substantially from the perspective of lines 49-49 of Figure 48.

[0124] Figure 50 is a top plan view of the article of Figures 48 and 49 following an additional processing step.

[0125] Figure 51 is a sectional view taken substantially from the perspective of lines 51-51 of Figure 50.

[0126] Figure 52 is a sectional view of the article of Figures 50 and 51 following an additional optional processing step.

[0127] Figure 53 is a top plan view of an article similar to that of Figure 50 but embodying an alternate structure.

[0128] Figure 54 is a sectional view taken substantially from the perspective of lines 54-54 of Figure 53. [0129] Figure 55 is a sectional view showing an article combining the article of

Figure 52 with a photovoltaic cell.

[0130] Figure 56 is a sectional view embodying series interconnection of multiple articles as depicted in Figure 55.

[0131] Figure 57 is a sectional view embodying a possible condition when using a circular form in a lamination process.

[0132] Figure 58 is a sectional view embodying a possible condition resulting from choosing a low profile form in a lamination process.

[0133] Figure 59 is a top plan view embodying a possible process to achieve positioning and combining of photovoltaic cells into a series interconnected array.

[0134] Figure 60 is a perspective view of the process embodied in Figure 59.

[0135] Figure 61 is a top plan view showing a simplified depiction of structure useful to explain a concept of the invention.

[0136] Figure 62 is a sectional view taken substantially from the perspective of lines 62 - 62 of Figure 61.

[0137] Figure 63 is a top plan view of a section of photovoltaic module produced according to an embodiment of the invention.

[0138] Figure 64 is a sectional view taken from the perspective of lines 64 - 64 of figure 63.

[0139] Figure 65 is a simplified overall top plan view of a photovoltaic module useful for the instant invention showing some important features contributing to the invention.

[0140] Figure 66 is a top plan view of an embodiment of a mounting structure.

[0141] Figure 67 is sectional view taken substantially from the perspective of lines

67 - 67 of Figure 66.

[0142] Figure 68 is a perspective view showing the overall arrangement of an embodiment of mounting structure prior to installation of photovoltaic modules. [0143] Figure 69 is a perspective view showing multiple modules installed on the mounting structure of Figures 66 through 68.

[0144] Figure 70 is a perspective view exploding the region within circle "70-70" of

Figure 69 and illustrating the details of one form of electrical and structural joining of the module to the mounting structure.

[0145] Figure 71 is a view partially in section further illustrating the details of the mounting arrangement shown in the perspective view of Figure 70.

[0146] Figure 72 is a view similar to Figure 71 showing the addition of another optional component of the expansive module.

[0147] Figure 73 is a top plan of another structural embodiment of the novel installations of the instant invention.

[0148] Figure 74 is a perspective view of a portion of the structure depicted in

Figure 73.

[0149] Figure 75 is a view partially in section taken substantially from the perspective of lines 75 - 75 of Figure 73 following the installation of a photovoltaic module and rigid fasteners.

[0150] Figure 76 is a view similar to Figure 75 of an alternate fastening structure for mounting multiple modules.

[0151] Figure 77 is a view similar to those of Figures 75 and 76 showing yet another fastening structure for mounting multiple modules.

[0152] Figure 78 is a top plan view of another embodiment of the novel supporting structure used in the installations of the instant invention.

[0153] Figure 79 is a sectional view taken from the perspective of lines 79 - 79 of

Figure 78.

[0154] Figure 80 is a view similar to Figure 79 following an additional installation step.

[0155] Figure 81 is a view similar to figure 80 following application of additional optional materials to the Figure 80 structure. [0156] Figure 82 is a side view of an arrangement to maximize radiation impingement on the arrangement of modules.

DESCRIPTION OF PREFERRED EMBODIMENTS

[0157] Reference will now be made in detail to the preferred embodiments of the invention, examples of which are illustrated in the accompanying drawings. In the drawings, like reference numerals designate identical, equivalent or corresponding parts throughout several views and an additional letter designation is characteristic of a particular embodiment.

[0158] Referring to Figures 1 and 2, an embodiment of a thin film photovoltaic structure is generally indicated by numeral 1. it is noted here that "thin film" has become commonplace in the industry to designate certain types of semiconductor materials in photovoltaic applications. These include amorphous silicon, cadmium telluride, copper- indium-gallium diselenide, dye sensitized polymers, so-called "Graetzel" electrolyte cells and the like. While the characterization "thin film" may be used to describe many of the embodiments of the instant invention, principles of the invention may extend to photovoltaic devices not normally considered "thin film" such as single crystal or polysilicon devices, as those skilled in the art will readily appreciate. Structure 1 has a light-incident top surface 59 and a bottom surface 66. Structure 1 has a width X-1 and length Y-1. It is contemplated that length Y- 1 may be considerably greater than width X-1 such that length Y-1 can generally be described as "continuous" or being able to be processed in a roll-to-roll fashion. Figure 2 shows that structure 1 embodiment comprises a thin film semiconductor structure 11 supported by "bulk" metal-based foil 12. "Bulk" foil 12 is often self supporting to allow continuous processing. Foil 12 has a top surface 65, bottom surface 66, and thickness "Z". In the embodiment, bottom surface 66 of foil 12 also forms the bottom surface of photovoltaic structure 1. Metal-based foil 12 may be of uniform composition or may comprise a laminate of multiple layers. For example, foil 12 may comprise a base layer of inexpensive and processable metal 13 with an additional metal-based layer 14 disposed between base layer 13 and semiconductor structure 11. The additional metal-based layer 14 may be chosen to ensure good ohmic contact between the top surface 65 of foil 12 and photovoltaic semiconductor structure 11. Bottom surface 66 of foil 12 may comprise a material 75 chosen to achieve good electrical and mechanical joining characteristics as will be shown. The thickness "Z" of foil 12 is often between 2 micrometers and 250 micrometers (i.e. 5 micrometers, 10 micrometers, 25 micrometers, 50 micrometers, 100 micrometers, 250 micrometers), although thicknesses outside this range may be functional in certain applications. One notes for example that should additional support be possible, such as that supplied by a supporting plastic film, metal foil thickness may be far less (.1 to 1 micrometer) than those characteristic of a "bulk" foil. Nevertheless, a foil thickness between 2 micrometers and 250 micrometers may normally provide adequate handling strength while still allowing flexibility if roll-to-roll processing were employed, as further taught hereinafter.

[0159] In its simplest form, a photovoltaic structure combines an n-type semiconductor with a p-type semiconductor to from a p-n junction. Often an optically transparent "window electrode" such as a thin film of zinc oxide or tin oxide is employed to minimize resistive losses involved in current collection. Figure 3 illustrates an example of a typical photovoltaic structure in section. In Figures 2 and 3 and other figures, an arrow labeled "hv" is used to indicate the light incident side of the structure. In Figure 3, 15 represents a thin film of a p-type semiconductor, 16 a thin film of n-type semiconductor and 17 the resulting photovoltaic junction. Window electrode 18 completes a typical photovoltaic structure. The exact nature of the photovoltaic semiconductor structure 11 does not form the subject matter of the present invention. For example, cells can be multiple junction or single junction and comprise homo or hetero junctions. Semiconductor structure 11 may comprise any of the thin film structures known in the art, including but not limited to CIS, CIGS, CdTe, Cu2S, amorphous silicon, so-called "Graetzel" electrolyte cells, polymer based semiconductors and the like. Structure 11 may also comprise organic solar cells such as dye sensitized cells. Further, semiconductor structure 11 may also represent characteristically "non-thin film" cells such as those based on single crystal or polycrystal silicon since many embodiments of the invention may encompass such cells, as will be evident to those skilled in the art in light of the teachings to follow.

[0160] In the following, photovoltaic cells having a metal based support foil will be used to illustrate the embodiments and teachings of the invention. However, those skilled in the art will recognize that many of the embodiments of the instant invention do not require the presence of a "bulk" foil as represented in Figures 1 and 2. In many embodiments, other conductive substrate structures, such as a metallized polymer film or glass having a thin metallized or conductive resin layer, may be substituted for the "bulk" metal foil.

[0161] Figure 4 refers to a method of manufacture of the bulk thin film photovoltaic structures generally illustrated in Figures 1 and 2. In the Figure 4 embodiment, a metal- based support foil 12 is moved in the direction of its length Y through a deposition process, generally indicated as 19. Process 19 accomplishes deposition of the active photovoltaic structure onto foil 12. Foil 12 is unwound from supply roll 20a, passed through deposition process 19 and rewound onto takeup roll 20b. Process 19 can comprise any of the processes well-known in the art for depositing thin film photovoltaic structures. These processes include electroplating, vacuum evaporation and sputtering, chemical deposition, and printing of nanoparticle precursors. Process 19 may also include treatments, such as heat treatments, intended to enhance photovoltaic cell performance.

[0162] Those skilled in the art will readily realize that the deposition process 19 of

Figure 4 may often most efficiently produce photovoltaic structure 1 having dimensions far greater than those suitable for individual cells in an interconnected array. Thus, the photovoltaic structure 1 may be subdivided into cells 10 having dimensions X-10 and Y-10 as indicated in Figures 1A and 2A for further fabrication. In Figure 1A, width X-10 defines a first photovoltaic cell terminal edge 45 and second photovoltaic cell terminal edge 46. In one embodiment, for example, X-10 of Figure 1A may be from .25 inches to 12 inches and Y-10 of Figure 1A may be characterized as "continuous". In other embodiments the final form of cell 10 may be rectangular, such as 6 inch by 6 inch, 4 inch by 3 inch or 8 inch by 2 inch. In other embodiments, the photovoltaic structure 1 of Figure 1 may be subdivided in the "X" dimension only thereby retaining the option of further processing in a "continuous" fashion in the "Y" direction. In the following, cell structure 10 in a form having dimensions suitable for interconnection into a multi-cell array may be referred to as "cell stock" or simply as cells. "Cell stock" can be characterized as being either continuous or discreet.

[0163] Figure 2B is a simplified depiction of cell 10 shown in Figure 2A. In order to facilitate presentation of the aspects of the instant invention, the simplified depiction of cell 10 shown in Figure 2B will normally be used.

[0164] Referring now to Figure 5, there are illustrated cells 10 as shown in Figure

2A. The cells have been positioned to achieve spatial positioning on the support substrate 21. Support structure 21 is by necessity non-conductive at least in a space indicated by numeral 27 separating the adjacent cells 10. This insulating space prevents short circuiting from metal foil electrode 12 of one cell to foil electrode 12 of an adjacent cell. In order to achieve series connection, electrical communication must be made from the top surface of window electrode 18 to the foil electrode 12 of an adjacent cell. This communication is shown in the Figure 5 as a metal wire or tab 41. The direction of the net current flow for the arrangement shown in Figure 5 is indicated by the double pointed arrow "i". It should be noted that foil electrode 12 is normally relatively thin, on the order of 5 micrometer to 250 micrometer. Therefore, connecting to its edge as indicated in Figure 5 would be impractical. Thus, such connections are normally made to the top surface 65 or the bottom surface 66 of foil 12. One readily recognizes that connecting metal wire or tab 41 is laborious, making inexpensive production difficult.

[0165] Figure 6 is a top plan view of a starting article in production of a laminating current collector grid or electrode according to the instant invention. Figure 6 embodies a polymer based film or glass substrate 70. Substrate 70 has width X-70 and length Y-70. When substrate 70 comprises glass, it would typically be processes as discrete articles having defined width and length dimensions. In other embodiments, taught in detail below, Y-70 may be much greater than width X-70, whereby film 70 can generally be described as "continuous" in length and able to be processed in length direction Y-70 in a continuous roll-to-roll fashion. Figure 7 is a sectional view taken substantially from the view 7-7 of Figure 6. Thickness dimension Z-70 is small in comparison to dimensions Y-70, X-70 and thus substrate 70 may have a flexible sheetlike, or web structure contributing to possible roll-to-roll processing. As shown in Figure 7, substrate 70 may be a laminate of multiple layers 72, 74, 76 etc. or may comprise a single layer of material. Any number of layers 72, 74, 76 etc. may be employed. The layers 72, 74, 76 etc. may comprise inorganic or organic components such as thermoplastics, thermosets or silicon containing glass-like layers. The various layers are intended to supply functional attributes such as environmental barrier protection or adhesive characteristics. Such functional layering is well-known and widely practiced in the plastic packaging art. Sheetlike substrate 70 has first surface 80 and second surface 82. In particular, in light of the teachings to follow, one will recognize that it may be advantageous to have layer 72 forming surface 80 comprise a polymeric adhesive sealing material such as an ethylene vinyl acetate (EVA), ethylene ethyl acetate (EEA), an ionomer, or a polyolefin based adhesive to impart adhesive characteristics during a possible subsequent lamination process. It may be advantageous for the adhesive layer to have elastomeric characteristics to insure flexibility and stress relief for the composite. Other sealing materials useful in certain embodiments include those comprising silicones, silicone gels, epoxies, polydimethyl siloxane (PDMS), RTV rubbers, polyvinyl butyral (PVB), thermoplastic polyurethanes (TPU), acrylics and urethanes. An adhesive layer 72 forming surface 80 may further comprise a curing component which would activate to produce a cross linked structure. Such cross linking may improve adhesion of surface 80 to a mating surface or also function to resist permanent deformation during thermal cycling. Suitable curatives may be activated by heat and/or radiation.

[0166] Lamination of such sheetlike films employing such sealing materials is a common practice in the packaging industry. In the packaging industry lamination is known and understood as applying a film, normally polymer based and having a surface comprising a sealing material, to a second surface and sealing them together with heat and/or pressure. Suitable sealing materials may be made tacky and flowable, often under heated conditions, and retain their adhesive bond to many surfaces upon cooling. A wide variety of laminating films with associated sealing materials is possible, depending on the surface to which the adhesive seal or bond is to be made. Sealing materials such as olefin copolymers or atactic polyolefins may be advantageous, since these materials allow for the minimizing of materials which may be detrimental to the longevity of a solar cell with which it is in contact. Additional layers 74, 76 etc. may comprise materials which assist in support or processing such as polypropylene, polyethylene terepthalate and polycarbonate. Additional layers 74, 76 may comprise barrier materials such as fluorinated polymers, biaxially oriented polypropylene (BOPP), poly(vinylidene chloride), such as Saran, a product of Dow Chemical, and Siox. Saran is a tradename for poly (vinylidene chloride) and is manufactured by Dow Chemical Corporation. Siox refers to a vapor deposited thin film of silicon oxide often deposited on a polymer support. Additional layers 74, 76 etc. may also comprise materials intended to afford protection against ultraviolet radiation and may also comprise materials to promote curing. The instant invention does not depend on the presence of any specific material for layers 72, 74, or 76. In many embodiments substrate 70 may be generally be characterized as a laminating material. For example, the invention has been successfully demonstrated using standard laminating films sold by GBC Corp., Northbrook, IL, 60062.

[0167] Figure 8 depicts the structure of substrate 70 (possibly laminate) as a single layer for purposes of presentation simplicity. Substrate 70 will be represented as this single layer in the subsequent embodiments, but it will be understood that structure 70 may be a laminate of any number of layers. In addition, substrate 70 is shown in Figures 6 through 8 as a uniform, unvarying monolithic sheet. In this specification and claims, the term "monolithic" or "monolithic structure" is used as is common in industry to describe an object that is made or formed into or from a single item. However, it is understood that various regions of substrate 70 may differ in composition through thickness Z-70. For example, selected regions of substrate 70 may comprise differing sheetlike structures patched together using appropriate seaming techniques. A purpose for such a "patchwork" structure will become clear in light of the teachings to follow.

[0168] Figure 9 is a plan view of the structure following an additional manufacturing step.

[0169] Figure 10 is a sectional view taken along line 10-10 of Figure 9.

[0170] Figure 11 is a sectional view taken along line 11-11 of Figure 9.

[0171] In Figures 9, 10, and 11, a structure is now designated 71 to reflect the additional processing. It is seen in these embodiments that a pattern of "fingers" or "traces", designated 84, extends from "buss" or "tab" structures, designated 86. In the embodiments of Figures 9, 10, and 11 , both "fingers" 84 and "busses" 86 are positioned on supporting substrate 70 in a grid pattern. "Fingers" 84 extend in the width X-71 direction of article 71 and "busses" ("tabs") extend in the Y-71 direction substantially perpendicular to the "fingers". As suggested above, structure 71 may be processed and extend continuously in the length "Y-71" direction. Repetitive multiple "finger/buss" arrangements are shown in the Figure 9 embodiment with a repeat dimension "F" as indicted. Portions of substrate 70 not overlayed by "fingers" 84 and "busses" 86 remain transparent or translucent to visible light. In the embodiment of Figures 9 through 11 , the "fingers" 84 and "busses" 86 are shown to be a single layer for simplicity of presentation. However, the "fingers" and "busses" can comprise multiple layers of differing materials chosen to support various functional attributes. For example the material in direct contact with substrate 70 defining the "buss" or "finger" patterns may be chosen for its adhesive affinity to surface 80 of substrate 70 and also to a subsequently applied constituent of the buss or finger structure. Further, it may be advantageous to have the first visible material component of the fingers and busses be of dark color or black. As will be shown, the light incident side (outside surface) of the substrate 70 will eventually be surface 82. By having the first visible component of the fingers and busses be dark, they will aesthetically blend with the generally dark color of the photovoltaic cell. This eliminates the often objectionable appearance of a metal colored grid pattern. Permissible dimensions and structure for the "fingers" and "busses" will vary somewhat depending on materials and fabrication process used for the fingers and busses, and the dimensions of the individual cell.

[0172] "Fingers" 84 and "busses" 86 may comprise electrically conductive material. Examples of such materials are metal wires and foils, stamped or die cut metal patterns, conductive metal containing inks and pastes such as those having a conductive filler comprising silver or stainless steel, patterned deposited metals such as etched metal patterns or masked vacuum deposited metals, intrinsically conductive polymers and DER formulations. In a preferred embodiment, the "fingers and "busses" comprise electroplateable material such as DER or an electrically conductive ink which will enhance or allow subsequent metal electrodeposition. "Fingers" 84 and "busses" 86 may also comprise non-conductive material which would assist accomplishing a subsequent deposition of conductive material in the pattern defined by the "fingers" and "busses". For example, "fingers" 84 or "busses" 86 could comprise a polymer which may be seeded to catalyze chemical deposition of a metal in a subsequent step. An example of such a material is seeded ABS. Patterns comprising electroplateable materials or materials facilitating subsequent electrodeposition are often referred to as "seed" patterns or layers. "Fingers" 84 and "busses" 86 may also comprise materials selected to promote adhesion of a subsequently applied conductive material. "Fingers" 84 and "busses" 86 may differ in actual composition and be applied separately. For example, "fingers" 84 may comprise a conductive ink while "buss/tab" 86 may comprise a conductive metal foil strip. Alternatively, fingers and busses may comprise a continuous unvarying monolithic material structure forming portions of both fingers and busses. Fingers and busses need not both be present in certain embodiments of the invention.

[0173] One will recognize that while shown in the embodiments as a continuous void free surface, "buss" 86 could be selectively structured. Such selective structuring may be appropriate to enhance functionality, such as flexibility, of article 71 or any article produced there from. Furthermore, regions of substrate 70 supporting the "buss" regions 86 may be different than those regions supporting "fingers" 84. For example, substrate 70 associated with "buss region" 86 may comprise a fabric while substrate 70 may comprise a film devoid of thru-holes in the region associated with "fingers" 84. A "holey" structure in the "buss region" would provide increased flexibility, increased surface area and increased structural characteristic for an adhesive to grip. Moreover, the embodiments of Figures 9 through 11 show the "fingers" and "busses" as essentially planar rectangular structures. Other geometrical forms are clearly possible, especially when design flexibility is associated with the process used to establish the material pattern of "fingers" and "busses". "Design flexible" processing includes printing of conductive inks or "seed" layers, foil etching or stamping, masked deposition using paint or vacuum deposition, and the like. For example, these conductive paths can have triangular type surface structures increasing in width (and thus cross section) in the direction of current flow. Thus the resistance decreases as net current accumulates to reduce power losses. Alternatively, one may select more intricate patterns, such as a "watershed" pattern as described in U.S. Patent Application Publication 2006/0157103 A1 which is hereby incorporated in its entirety by reference. Various structural features, such as radiused connections between fingers and busses may be employed to improve structural robustness.

[0174] The embodiment of Figure 9 shows multiple "busses" 86 extending in the direction Y-71 with "fingers" extending from one side of the "busses" in the X-71 direction. Many different such structural arrangements of the laminating current collector structures are possible within the scope and purview of the instant invention. It is important to note however that the laminating current collector structures of the instant invention may be manufactured utilizing continuous, bulk roll to roll processing. While the collector grid embodiments of the current invention may advantageously be produced using continuous processing, one will recognize that combining of grids or electrodes so produced with mating conductive surfaces may be accomplished using either continuous or batch processing. In one case it may be desired to produce photovoltaic cells having discrete defined dimensions. For example, single crystal silicon cells are often produced having X- Y dimensions of 6 inches by 6 inches. In this case the collector grids of the instant invention, which may be produced continuously, may then be subdivided to dimensions appropriate for combining with such cells. In other cases, such as production of many thin film photovoltaic structures, a continuous roll-to-roll production of an expansive surface article can be accomplished in the "Y" direction as identified in Figure 1. Such a continuous expansive photovoltaic structure may be combined with a continuous arrangement of collector grids of the instant invention in a semicontinuous or continuous manner. Alternatively the expansive semiconductor structure may be subdivided into continuous strips of cell stock. In this case, combining a continuous strip of cell stock with a continuous strip of collector grid of the instant invention may be accomplished in a continuous or semi-continuous manner.

[0175] Figures 12, 13 and 14 correspond to the views of Figures 9, 10 and 11 respectively following an additional optional processing step. Figure 15 is a sectional view taken substantially along line 15-15 of Figure 12. Figures 12 through 15 show additional conductive material deposited onto the "fingers" 84 and "busses" 86 of Figures 9 through 11. In this embodiment additional conductive material is designated by one or more layers 88, 90 and the fingers and busses project above surface 80 as shown by dimension "H". In some cases it may be desirable to reduce the height of projection "H" prior to eventual combination with a conductive surface such as 59 or 66 of photovoltaic cell 10. This reduction may be accomplished by passing the structures as depicted in Figures 12- 15 through a pressurized and/or heated roller or the like to embed "fingers" 84 and/or "busses" 86 into layer 72 of substrate 70.

[0176] While shown as two layers 88, 90, it is understood that this conductive material could comprise more than two layers or be a single layer. In addition, while each additional conductive layer is shown in the embodiment as having the same continuous monolithic material extending over both the buss and finger patterns, one will realize that selective deposition techniques would allow the additional "finger" layers to differ from additional "buss" layers. For example, as best shown in Figure 38, "fingers" 84 have top free surface 98 and "busses" 86 have top free surface 100. As noted, selective deposition techniques such as brush electroplating or masked deposition would allow different materials to be considered for the "buss" surface 100 and "finger" surface 98. In a preferred embodiment, at least one of the additional layers 88, 90 etc. are deposited by electrodeposition, taking advantage of the deposition speed, compositional choice, low cost and selectivity of the electrodeposition process. Many various metals, including highly conductive silver, copper and gold, nickel, tin and alloys can be readily electrodeposited. In these embodiments, it may be advantageous to utilize electrodeposition technology giving an electrodeposit of low tensile stress to prevent curling and promote flatness of the metal deposits. In particular, use of nickel deposited from a nickel sulfamate bath, nickel deposited from a bath containing stress reducing additives such as brighteners, or copper from a standard acid copper bath have been found particularly suitable. Electrodeposition also permits precise control of thickness and composition to permit optimization of other requirements of the overall manufacturing process for interconnected arrays. Thus, the electrodeposited metal may significantly increase the current carrying capacity of the "buss" and "finger" structure and may be the dominant current carrying material for these structures. In general, electrodeposit thicknesses characterized as "low profile", less than about .002 inch, supply adequate current carrying capacity for the grid "fingers" of the instant invention. Thus electrodeposited metal offers a very appropriate material to achieve the dominant current carrying capacity for the "buss" and "finger" structure. Alternatively, these additional conductive layers may be deposited by selective chemical deposition or registered masked vapor deposition. These additional layers 88, 90 may also comprise conductive inks applied by registered printing.

[0177] It has been found very advantageous to form surface 98 of "fingers" 84 or top surface 100 of "busses" 86 with a material compatible with the conductive surface with which eventual contact is made. In preferred embodiments, electroless deposition or electrodeposition is used to form a suitable metallic surface. Specifically electrodeposition offers a wide choice of potentially suitable materials to form the top surface. Corrosion resistant materials such as nickel, chromium, tin, indium, silver, gold and platinum are readily electrodeposited. These corrosion resistant coatings, often referred to as "flash" coatings, are normally thin, less than about two micrometer (i.e. 0.1 micrometer, 1 micrometer, 2 micrometer). The "flash" coatings normally need not exhibit exceptional current carrying capacity since the bulk of the current may be carried by the underlying material such as the above described electroplated metals such as copper. When compatible, of course, surfaces comprising metals such as copper or zinc or alloys of copper or zinc may be considered. Alternatively, the surface 98 may comprise a conversion coating, such as a chromate coating, of a material such as copper or zinc. Further, as will be discussed below, it may be highly advantageous to choose a material to form surfaces 98 or 100 which exhibits adhesive or bonding ability to a subsequently positioned abutting conductive surface. For example, it may be advantageous to form surfaces 98 and 100 using an electrically conductive adhesive. Alternatively, it may be advantageous to form surfaces 98of "fingers" 84 or 100 of "busses" 86 with a conductive material such as a low melting point metal such as tin or tin containing alloys in order to facilitate electrical joining to a complimentary conductive surface. Such low melting point materials can be caused to melt at temperatures below that of many polymer processing operations such as lamination (i.e. below about 325 degree C. One will note that materials forming "fingers" surface 98 and "buss" surface 100 need not be the same. It is emphasized that many of the principles taught in detail with reference to Figures 6 through 15 extend to additional embodiments of the invention taught in subsequent Figures.

[0178] Figure 16 is a top plan view of an article 102 embodying another form of the electrodes of the current invention. Figure 16 shows article 102 having structure comprising "fingers" 84a extending from "buss/tab" 86a arranged on a substrate 70a. The structure of Figure 16 is similar to that shown in Figure 9. However, whereas Figure 9 depicted multiple finger and buss/tab structures arranged in a substantially repetitive pattern in direction "X-71", the Figure 16 embodiment consists of one finger/buss pattern. Thus, the dimension "X-102" of Figure 16 may be roughly equivalent to the repeat dimension "F" shown in Figure 9. Indeed, it is contemplated that article 102 of Figure 16 may be produced by subdividing the Figure 9 structure 71 according to repeat dimension "F" shown in Figure 9. Dimension "Y-102" may be chosen appropriate to the particular processing scheme envisioned for the eventual lamination to a conductive surface such as a photovoltaic cell. However, it is envisioned that "Y-102" may be much greater than

"X-102" such that article 102 may be characterized as continuous or capable of being processed in a roll-to-roll fashion. Article 102 has a first terminal edge 104 and second terminal edge 106. In the Figure 16 embodiment "fingers" 84a are seen to terminate prior to intersection with terminal edge 106. One will understand that this is not a requirement.

[0179] "Fingers" 84a and "buss/tab" 86a of Figure 16 have the same characterization as "fingers" 84 and "busses" 86 of Figures 9 through 11. Like the "fingers" 84 and "busses" 86 of Figures 9 through 11 , "fingers" 84a and "buss" 86a of Figure 16 may comprise materials that are either conductive, assist in a subsequent deposition of conductive material or promote adhesion of a subsequently applied conductive material to substrate 70a. While shown as a single layer, one appreciates that "fingers" 84a and "buss" 86a may comprise multiple layers. The materials forming "fingers" 84a and "buss" 86a may be different or the same. In addition, the substrate 70a may comprise different materials or structures in those regions associated with "fingers" 84a and "buss region" 86a. For example, substrate 70a associated with "buss region" 86a may comprise a fabric to provide thru-hole communication and enhance flexibility, while substrate 70a in the region associated with "fingers" 84a may comprise a film devoid of thru-holes such as depicted in Figures 6-8. A "holey" structure in the "buss region" would provide increased flexibility, surface area and structural characteristic for an adhesive to grip.

[0180] Figure 17 and 18 are sectional embodiments taken substantially from the perspective of lines

[0181] 17-17 and 18-18 respectively of Figure 16. Figures 17 and 18 show that article 102 has thickness Z-102 which may be much smaller than the X and Y dimensions, thereby allowing article 102 to be flexible and processable in roll form. Also, flexible sheet-like article 102 may comprise any number of discrete layers (three layers 72a, 74a, 76a are shown in Figures 17 and 18). These layers contribute to functionality as previously pointed out in the discussion of Figure 7. As will be understood in light of the following discussion, it is normally helpful for layer 72a forming free surface 80a to exhibit adhesive characteristics to the eventual abutting conductive surface.

[0182] Figure 19 is an alternate representation of the sectional view of Figure 18.

Figure 19 depicts substrate 70a as a single layer for ease of presentation. The single layer representation will be used in many following embodiments, but one will understand that substrate 70a may comprise multiple layers. [0183] Figure 20 is a sectional view of the article now identified as 110, similar to

Figure 19, after an additional optional processing step. In a fashion like that described above for production of the current collector structure of Figures 12 through 15, additional conductive material (88a/90a) has been deposited by optional processing to produce the article 110 of Figure 20. The discussion involving processing to produce the article of Figures 12 through 15 is proper to describe production of the article of Figure 20. Thus, while additional conductive material has been designated as a single layer (88a/90a) in the Figure 20 embodiment, one will understand that layer (88a/90a) of Figure 20 may represent any number of multiple additional layers. In subsequent embodiments, additional conductive material (88a/90a) will be represented as a single layer for ease of presentation. In its form prior to combination with cells 10, the structures such as shown in Figures 9-15, and 16-20 can be referred to as "current collector stock". For the purposes of this specification and claims a current collector in its form prior to combination with a conductive surface can be referred to as "current collector stock". "Current collector stock" can be characterized as being either continuous or discrete. Further, in light of the teachings to follow one will recognize that the structures shown in Figures 9-15 and 16-20 may function and be characterized as electrodes employing a laminated contact (laminating electrodes)..

[0184] It has been found that a particularly attractive conductive joining may be achieved through a technique described herein as a laminated contact. One structure involved in the laminated contact is a first portion of conductive structure which is to be electrically joined to a second conductive surface. The first portion comprises a conductive pattern positioned over a surface of an adhesive. In preferred embodiments, the adhesive is characterized as a hot melt adhesive. A hot melt adhesive is one whose full adhesive affinity is activated by heating, normally to a temperature where the material softens or melts sufficiently for it to flow under simultaneously applied pressure. Many various hot melt materials, such as ethylene vinyl acetate (EVA), are well known in the art.

[0185] In the process of producing a laminated contact, the exposed surface of a conductive material pattern positioned on the surface of a hot melt adhesive is brought into facing relationship with a second conductive surface to which is electrically joining is intended. Heat and pressure are applied to soften the adhesive which then flows around edges or through openings in the conductive pattern to also contact and adhesively "grab" the exposed second surface portions adjacent the conductive pattern. When heat and pressure are removed, the adhesive adjacent edges of the conductive pattern firmly fixes features of conductive pattern in secure mechanical contact with the second surface. [0186] The laminated contact is particularly suitable for the electrical joining requirements of many embodiments of the instant invention. A simplified depiction of structure to assist understanding the concept of a laminating electrode is embodied in Figures 61 and 62. Figure 61 shows a top plan view of an article 350. Article 350 comprises a metal mesh 352 positioned on the surface of hot melt adhesive 351. Numeral 354 indicates holes through the mesh. One will realize that many different patterns of conductive material will be suitable for a laminated contact as taught here, including comb-like patterns, serpentine traces, monolithic metal mesh patterns, etc.

[0187] Figure 62 show a sectional view of article 350 juxtaposed in facing relationship to a mating conductive surface 360 of article 362 to which electrical joining is desired. In the embodiment, article 350 is seen to be a composite of the conductive material pattern 352 positioned on a top surface of hot melt adhesive film 351. In the embodiment, an additional support film 366 is included for structural and process integrity, and possibly barrier properties. Additional film 366 may be a polymer film of a material such as polyethylene terephthalate, polypropylene, polycarbonate, etc., or comprise a rigid structure such as glass. Article 350 can include additional layered materials (not shown) to achieve desired functional characteristics similar to article 70 discussed above. Also depicted in Figure 62 is article 362 having a bottom surface 360. Surface 360 may represent, for example, the bottom surface 66 of solar cell structure 10 (Figure 2A).

[0188] In order to achieve the laminated contact, articles 350 and 362 are brought together in the facing relationship depicted and heat and pressure are applied. The adhesive layer 351 softens and flows to contact surface 360. In the case of the Figure 62 embodiment, flow occurs through the holes 354 in the mesh 352. Upon cooling and removal of the pressure, the metal mesh 352 is held in secure and firm electrical contact with surface 360.

[0189] Figures 21 illustrates a process 92 by which the current collector grids of

Figures 16 through 20 may be combined with the structure illustrated in Figure 1A, 1A and 2B to accomplish lamination of current collecting electrodes of top and bottom surfaces photovoltaic cell stock. The process envisioned in Figure 21 has been demonstrated using standard lamination processing such as roll lamination and vacuum lamination. In a preferred embodiment, roll lamination allows continuous processing and a wide choice of application temperatures and pressure. Temperatures employed are typical for lamination of standard polymeric materials used in the high volume plastics packaging industry, normally less than about 325 degree Centigrade. Process 92 is but one of many processes possible to achieve such application. In Figure 21 rolls 94 and 97 represent "continuous" feed rolls of grid/buss structure on a flexible sheetlike substrate (current collector stock) as depicted in Figures 16 through 20. Roll 96 represents a "continuous" feed roll of the sheetlike cell stock as depicted in Figures 1A, 2A and 2B. Figure 22 is a sectional view taken substantially from the perspective of line 22-22 of Figure 21. Figure 22 shows a photovoltaic cell 10 such as embodied in Figure 2A and 2B disposed between two current collecting electrodes 110a and 110b such as article 110 embodied in Figure 20. Figure 23 is a sectional view showing the article 112 resulting from using process 92 to laminate the three individual structures of Figure 22 while substantially maintaining the relative positioning depicted in Figure 22. Figure 23 shows that a laminating current collector electrode 110a has now been applied to the top conductive surface 59 of cell 10. Laminating current collector electrode 110b mates with and contacts the bottom conductive surface 66 of cell 10. Grid "fingers" 84a of a top current collector electrode 110a project laterally across the top surface 59 of cell stock 10 and extend to a "buss" region 86a located outside terminal edge 45 of cell stock 10. The grid "fingers" 84a of a bottom current collector electrode 110b project laterally across the bottom surface 66 of cell stock 10 and extend to a "buss" region 86a located outside terminal edge 46 of cell stock 10. Thus article 112 is characterized as having readily accessible conductive surface portions 100a in the form of tabs in electrical communication with both top cell surface 59 and bottom cell surface 66. Article 112 can be described as a "tabbed cell stock". In the present specification and claims, a "tabbed cell stock" is defined as a photovoltaic cell structure combined with electrically conducting material in electrical communication with a conductive surface of the cell structure, and further wherein the electrically conducting material extends outside a terminal edge of the cell structure to present a readily accessible contact surface. In light of the present teachings, one will understand that "tabbed cell stock" can be characterized as being either continuous or discrete. One will also recognize that electrodes 110a and 110b can be used independently of each other. For example, 110b could be employed as a back side electrode while a current collector electrode different than 110a is employed on the top side of cell 10. Also, one will understand that while electrodes 110a and 110b are shown in the embodiment to be the same structure, different structures and compositions may be chosen for electrodes 110a and 110b.

[0190] A "tabbed cell stock" 112 has a number of fundamental advantageous attributes. First, it can be produced as a continuous cell "strip" and in a continuous roll-to- roll fashion in the Y direction (direction normal to the paper in the sectional view of Figure

23). Following the envisioned lamination, the " tabbed cell stock" strip can be continuously monitored for quality since there is ready access to the exposed free surfaces 100a in electrical communication with top cell surface 59 and the cell bottom surface 66. Thus defective cell material can be identified and discarded prior to final interconnection into an array. Finally, the laminated current collector electrodes protect the surfaces of the cell from defects possibly introduced by the further handing associated with final interconnections.

[0191] The lamination process 92 of Figure 21 normally involves application of heat and pressure. Temperatures will vary depending on materials and exposure time. Typical temperatures less than about 325 degree Centigrade are envisioned. Lamination temperatures of less than 325 degree centigrade would be more than sufficient to melt and activate not only typical polymeric sealing materials but also many low melting point metals, alloys and metallic solders. For example, tin melts at about 230 degree Centigrade and its alloys even lower. Tin alloys with for example bismuth, lead and indium are common industrial materials. Many conductive "hot melt" adhesives can be activated at even lower temperatures such as . Typical thermal curing temperatures for polymers are in the range 95 to 175 degree Centigrade. Thus, typical lamination practice widespread in the packaging industry is normally appropriate to simultaneously accomplish many conductive joining possibilities.

[0192] It will be understood that while the process 92 of Figure 21 envisions a roll type lamination, other forms of laminating process are appropriate in practice of the invention. For example, a semi-continuous or indexed feed lamination process, perhaps augmented by vacuum, may be employed. Moreover, should the substrate 70a comprise a rigid or discrete component such as glass, a discrete batch lamination process may be envisioned.

[0193] The sectional drawings of Figures 24 and 25 show the result of joining multiple articles 112a, 112b. Each article has a readily accessible downward facing conductive surface pattern (in the drawing perspective) 114 in communication with the cell top surface 59. A readily accessible upward facing conductive surface pattern 116 extends from the cell bottom surfaces 66. One will appreciate that in this embodiment, current collector 110b functions as an interconnecting substrate unit. Series connections are easily achieved by overlapping the top surface extension 114 of one article 112b and a bottom surface extension 116 of a second article 112a and electrically connecting these extensions with electrically conductive joining means such as conductive adhesive 42 shown in Figures 24 and 25. Other electrically conductive joining means including those defined above may be selected in place of conductive adhesive 42. For example, surfaces 114 and 116 could overlap and be electrically joined to top and bottom surfaces of a metal foil member. Finally, since the articles 112 of Figure 23 can be produced in a continuous form (in the direction normal to the paper in Figure 23) the series connections and array production embodied in Figures 24 and 25 may also be accomplished in a continuous manner by using continuous feed rolls of "tabbed cell stock" 112. However, while continuous assembly may be possible, other processing may be envisioned to produce the interconnection embodied in Figures 24 and 25. For example, defined lengths of "tabbed cell stock" 112 could be produced by subdividing a continuous strip of "tabbed cell stock" 112 in the Y dimension and the individual articles thereby produced could be arranged as shown in Figures 24 and 25 using, for example, standard pick and place positioning.

[0194] Figure 26 is a top plan view of an article in production of another embodiment of a laminating current collector grid or electrode according to the instant invention. Figure 26 embodies a polymer based film or glass substrate 120. Substrate 120 has width X-120 and length Y120. In embodiments, taught in detail below, Y-120 may be much greater than width X-120, whereby film 120 can generally be described as "continuous" in length and able to be processed in length direction Y-120 in a continuous roll-to-roll fashion. Figure 27 is a sectional view taken substantially from the view 27-27 of Figure 26. Thickness dimension Z-120 is small in comparison to dimensions Y-120, X- 120 and thus substrate 120 may have a flexible sheetlike, or web structure contributing to possible roll-to-roll processing. As shown in Figure 27, substrate 120 may be a laminate of multiple layers 72b, 74b, 76b etc. or may comprise a single layer of material. Thus substrate 120 may have structure similar to that of the Figures 6 through 8 embodiment, and the discussion of the characteristics of article 70 of Figures 6 through 8 is proper to characterize article 120 as well. As with the representation of the article 70 of Figures 6 through 8, and as shown in Figure 28, article 120 (possibly multilayered) will be embodied as a single layer in the following for simplicity of presentation.

[0195] Figure 29 is a top plan view of an article 124 following an additional processing step using article 120. Figure 30 is a sectional view substantially from the perspective of lines 30-30 of Figure 29. The structure depicted in Figures 29 and 30 is similar to that embodied in Figures 16 and 18. It is seen that article 124 comprises a pattern of "fingers" or "traces", designated 84b, extending from "buss" or "tab" structures, designated 86b. In the embodiments of Figures 29 and 30, both "fingers" 84b and "busses" 86b are positioned on supporting substrate 120 in a grid pattern. "Fingers" 84b extend in the width X-124 direction of article 124 and "busses" ("tabs") extend in the Y-124 direction substantially perpendicular to the "fingers". In the Figure 29 embodiment, it is seen that the ends of the fingers opposite the "buss" 86b are joined by connecting trace of material 128 extending in the "Y-124" direction. In the embodiment of Figures 29 and 30, the buss 86b region is characterized as having multiple regions 126 devoid of material forming "buss" 86b. In the Figure 29 embodiment, the voided regions 126 are presented as circular regions periodically spaced in the "Y-124" direction. One will understand in light of the teachings to follow that the circular forms 126 depicted in Figure 29 is but one of many different patterns possible for the voided regions 126. The sectional view of Figure 30 shows the voided regions 126 leave regions of the top surface 80b of substrate 120 exposed. Surface 80b of substrate 120 remains exposed in those regions not covered by the finger/buss pattern. These exposed regions are further indicated by numeral 127 in Figure 29.

[0196] Structure 124 may be produced, processed and extend continuously in the length "Y-124" direction.

[0197] Portions of substrate 120 not overlayed by material forming "fingers" 84b and "busses" 86b remain transparent or translucent to visible light. These regions are generally identified by numeral 127 in Figure 29. In the embodiment of Figures 29 and 30, the "fingers" 84b and "busses" 86b are shown to be a single layer for simplicity of presentation. However, the "fingers" and "busses" can comprise multiple layers of differing materials chosen to support various functional attributes. For example the material defining the "buss" or "finger" patterns which is in direct contact with substrate 120 may be chosen for its adhesive affinity to surface 80b of substrate 120 and also to a subsequently applied constituent of the buss or finger structure. Further, it may be advantageous to have the first visible material component of the fingers and busses be of dark color or black. As will be shown, the light incident side (outside surface) of the substrate 120 will eventually be surface 82. By having the first visible component of the fingers and busses be dark, they will aesthetically blend with the generally dark color of the photovoltaic cell. This eliminates the often objectionable appearance of a metal colored grid pattern. Permissible dimensions and structure for the "fingers" and "busses" will vary somewhat depending on materials and fabrication process used for the fingers and busses, and the dimensions of the individual cell.

[0198] "Fingers" 84b and "busses" 86b may comprise electrically conductive material. Examples of such materials are metal wires and foils, stamped metal patterns, conductive metal containing inks and pastes such as those having a conductive filler comprising silver or stainless steel, patterned deposited metals such as etched metal patterns or masked vacuum deposited metals, intrinsically conductive polymers and DER formulations. In a preferred embodiment, the "fingers and "busses" comprise electroplateable material such as DER or an electrically conductive ink which will enhance or allow subsequent metal electrodeposition. "Fingers" 84b and "busses" 86b may also comprise non-conductive material which would assist accomplishing a subsequent deposition of conductive material in the pattern defined by the "fingers" and "busses". For example, "fingers" 84b or "busses" 86b could comprise a polymer which may be seeded to catalyze chemical deposition of a metal in a subsequent step. An example of such a material is seeded ABS. Patterns comprising electroplateable materials or materials facilitating subsequent electrodeposition are often referred to as "seed" patterns or layers. "Fingers" 84b and "busses" 86b may also comprise materials selected to promote adhesion of a subsequently applied conductive material. "Fingers" 84b and "busses" 86b may differ in actual composition and be applied separately. For example, "fingers" 84b may comprise a conductive ink while "buss/tab" 86b may comprise a conductive metal foil strip. Alternatively, fingers and busses may comprise a continuous unvarying monolithic material structure forming portions of both fingers and busses. Fingers and busses need not both be present in certain embodiments of the invention.

[0199] The embodiments of Figures 29 and 30 show the "fingers" 84b, "busses"

86b, and connecting trace 128 as essentially planar rectangular structures. Other geometrical forms are clearly possible, especially when design flexibility is associated with the process used to establish the material pattern of "fingers" and "busses". "Design flexible" processing includes printing of conductive inks or "seed" layers, foil etching or stamping, masked deposition using paint or vacuum deposition, and the like. For example, these conductive paths can have triangular type surface structures increasing in width (and thus cross section) in the direction of current flow. Thus the resistance decreases as net current accumulates to reduce power losses. Alternatively, one may select more intricate patterns, such as a "watershed" pattern as described in U.S. Patent Application Publication 2006/0157103 A1 which is hereby incorporated in its entirety by reference. Various structural features, such as radiused connections between fingers and busses may be employed to improve structural robustness.

[0200] It is important to note however that the laminating current collector structures of the instant invention may be manufactured utilizing continuous, bulk roll to roll processing. While the collector grid embodiments of the current invention may advantageously be produced using continuous processing, one will recognize that combining of grids or electrodes so produced with mating conductive surfaces may be accomplished using either continuous or batch processing. In one case it may be desired to produce photovoltaic cells having discrete defined dimensions. For example, single crystal silicon cells are often produced having X-Y dimensions of 6 inches by 6 inches. In this case the collector grids of the instant invention, which may be produced continuously, may then be subdivided to dimensions appropriate for combining with such cells. In other cases, such as production of many thin film photovoltaic structures, a continuous roll-to- roll production of an expansive surface article can be accomplished in the "Y" direction as identified in Figure 1. Such a continuous expansive photovoltaic structure may be combined with a continuous arrangement of collector grids of the instant invention in a semicontinuous or continuous manner. Alternatively the expansive semiconductor structure may be subdivided into continuous strips of cell stock. In this case, combining a continuous strip of cell stock with a continuous strip of collector grid of the instant invention may be accomplished in a continuous or semi-continuous manner.

[0201] Figure 31 corresponds to the view of Figure 30 following an additional optional processing step. The Figure 31 article is now designated by numeral 125 to reflect this additional processing. Figure 31 shows additional conductive material deposited onto the "fingers" 84b and "buss" 86b. In this embodiment additional conductive material is designated by one or more layers (88b, 90b) and the fingers and busses project above surface 80b as shown by dimension "H". It is understood that conductive material could comprise more than two layers or be a single layer. Conductive material (88b, 90b) is shown as a single layer in the Figure 31 embodiment for ease of presentation. Article 125 is another embodiment of a "current collector stock". Dimension "H" is normally smaller than about 50 micrometers and thus the structure of fingers and busses depicted in Figure 31 can be considered as a "low profile" structure. In some cases it may be desirable to reduce the height of projection "H" prior to eventual combination with a conductive surface such as 59 or 66 of photovoltaic cell 10. This reduction may be accomplished by passing the structures as depicted in Figures 12-15 through a pressurized and/or heated roller or the like to embed "fingers" 84b and/or "busses" 86b into layer 72b of substrate 120.

[0202] While each additional conductive material is shown the Figure 31 embodiment as having the same continuous monolithic material extending over both the buss and finger patterns, one will realize that selective deposition techniques would allow the additional "finger" layers to differ from additional "buss" layers. For example, as shown in Figure 31 , "fingers" 84b have top free surface 98b and "busses" 86b have top free surface 100b. As noted, selective deposition techniques such as brush electroplating or masked deposition would allow different materials to be considered for the "buss" surface 100b and "finger" surface 98b. In a preferred embodiment, at least one of the additional layers (88b, 90b) etc. are deposited by electrodeposition, taking advantage of the deposition speed, compositional choice, low cost and selectivity of the electrodeposition process. Many various metals, including highly conductive silver, copper and gold, nickel, tin and alloys can be readily electrodeposited. In these embodiments, it may be advantageous to utilize electrodeposition technology giving an electrodeposit of low tensile stress to prevent curling and promote flatness of the metal deposits. In particular, use of nickel deposited from a nickel sulfamate bath, nickel deposited from a bath containing stress reducing additives such as brighteners, or copper from a standard acid copper bath have been found particularly suitable. Electrodeposition also permits precise control of thickness and composition to permit optimization of other requirements of the overall manufacturing process for interconnected arrays. Alternatively, these additional conductive layers may be deposited by selective chemical deposition or registered masked vapor deposition. These additional layers (88, 90) may also comprise conductive inks applied by registered printing.

[0203] It has been found very advantageous to form surface 98b of "fingers" 84b or top surface 100b of "busses" 86b with a material compatible with the conductive surface with which eventual contact is made. In preferred embodiments, electroless deposition or electrodeposition is used to form a suitable metallic surface. Specifically electrodeposition offers a wide choice of potentially suitable materials to form the top surface. Corrosion resistant materials such as nickel, chromium, tin, indium, silver, gold and platinum are readily electrodeposited. When compatible, of course, surfaces comprising metals such as copper or zinc or alloys of copper or zinc may be considered. Alternatively, the surface 98b may comprise a conversion coating, such as a chromate coating, of a material such as copper or zinc. Further, as will be discussed below, it may be highly advantageous to choose a material to form surfaces 98b or 100b which exhibits adhesive or bonding ability to a subsequently positioned abutting conductive surface. For example, it may be advantageous to form surfaces 98b and 100b using an electrically conductive adhesive. Alternatively, it may be advantageous to form surface 100b of "busses" 86b with a conductive material such as a low melting point alloy solder in order to facilitate electrical joining to a complimentary conductive surface having electrical communication with an electrode of an adjacent photovoltaic cell. For example, forming surfaces 98b and 100b with materials such as tin or alloys of tin with an alloying element such as lead, bismuth or indium would result in a low melting point surface to facilitate electrical joining during subsequent lamination steps. One will note that materials forming "fingers" surface 98b and "buss" surface 100b need not be the same.

[0204] Figure 32 depicts an arrangement of 3 articles just prior to a laminating process according to a process embodiment such as that of Figure 21. In the Figure 32 embodiment, "current collector stock" 125 is positioned above a photovoltaic cell 10. A second article of laminating "current collector stock", identified by numeral 129, is positioned beneath cell 10. Article 129 may be similar in structure to article 110 of Figure 20.

[0205] Figure 33 shows the article 130 resulting from passing the Figure 32 arrangement through a lamination process as depicted in Figure 21. The lamination process has applied article 125 to the top surface 59 of cell 10. Thus, the conductive surface 98b of grid "fingers" 84b of article 125 are fixed by the lamination in intimate contact with conductive top surface 59 of cell 10. The lamination process has similarly positioned the conductive surface 98a of "fingers" 84a of article 129 in intimate contact with the bottom surface 66 of cell 10. The conductive material associated with current collector stock 125 extends past a first terminal edge 46 of cell 10. The conductive material associated with current collector stock 129 extends past second terminal edge 45 of cell 10. These extensions, identified by numerals 134 and 136 in Figure 33, form convenient "tab" surfaces to facilitate electrical connections to and from the actual cell. Thus article 130 can be properly characterized as a form or embodiment of a "tabbed cell stock".

[0206] Figure 34 embodies the combination of multiple portions of "tabbed cell stock" 130. In the Figure 34 embodiment, an extension 134a associated with a first unit of "tabbed cell stock" 130a overlaps extension 136b of an adjacent unit of "tabbed cell stock" 130b. The same spatial arrangement exists between "tabbed cell stock" units 130b and 130c. The conductive surfaces associated with the mating extensions are positioned and held in secure contact as a result of an adhesive material forming surface 80b of the substrate 120 melting and filling the voided regions 126 as shown. The mating contact is additionally secured by adhesive bonding produced by additional originally exposed regions of substrates. These originally exposed regions of substrate surface in the region of the mechanical and pressure induced electrical joining between adjacent units of "tabbed cell stock" are identified by the numeral 127 in the Figure 34. It is clear that in the Figure 34 embodiment a secure and robust series electrical connection is achieved between adjacent units of "tabbed cell stock" by virtue of the lamination process taught herein.

[0207] Referring now to Figures 35 through 38, there are shown embodiments of a starting structure for another grid/interconnect article of the invention. Figure 35 is a top plan view of an article 198. Article 198 comprises a polymeric film or glass sheet substrate generally identified by numeral 200. Substrate 200 has width X-200 and length Y-200. Length Y-200 is sometimes much greater the width X-200 such that film 200 can be processed in essentially a "roll-to-roll" fashion. However, this is not necessarily the case. Dimension "Y" can be chosen according to the application and process envisioned. Figure 36 is a sectional view taken substantially from the perspective of lines 36-36 of Figure 35. Thickness dimension Z-200 is normally small in comparison to dimensions Y-

200 and X-200 and thus substrate 200 has a sheetlike structure and is often flexible. Substrate 200 is further characterized by having regions of essentially solid structure combined with regions having holes 202 extending through the thickness Z-200. In the Figure 35 embodiment, a substantially solid region is generally defined by a width Wcc, representing a current collection region. The region with through-holes (holey region) is generally defined by width Win, representing an interconnection region. Imaginary line

201 separates the two regions. Holes 202 may be formed by simple punching, laser drilling and the like. Alternatively, holey region Win may comprise a fabric joined to region Wcc along imaginary line 201 , whereby the fabric structure comprises through-holes. The reason for these distinctions and definitions will become clear in light of the following teachings.

[0208] Referring now to Figure 36, region Wcc of substrate 200 has a first surface

210 and second surface 212. The sectional view of substrate 200 shown in Figure 36 shows a single layer structure. This depiction is suitable for simplicity and clarity of presentation. Often, however, film 200 will comprise a laminate of multiple layers as depicted in Figure 37. In the Figure 37 embodiment, substrate 200 is seen to comprise multiple layers 204, 206, 208, etc. As previously taught herein, the multiple layers may comprise inorganic or organic components such as thermoplastics, thermosets, or silicon containing glass-like layers. The various layers are intended to supply functional attributes such as environmental barrier protection or adhesive characteristics. In particular, in light of the teachings to follow, one will recognize that it may be advantageous to have layer 204 forming surface 210 comprise a sealing material such as ethylene vinyl acetate (EVA), an ionomer, an olefin based adhesive, atactic polyolefin, or a polymer containing polar functional groups for adhesive characteristics during a possible subsequent lamination process. For example, the invention has been successfully demonstrated using a standard laminating material sold by GBC Corp., Northbrook, IL, 60062. Additional layers 206, 208 etc. may comprise materials which assist in support or processing such as polypropylene and polyethylene terepthalate, barrier materials such as fluorinated polymers and biaxially oriented polypropylene, and materials offering protection against ultraviolet radiation as previously taught in characterizing substrate 70 of Figure 6.

[0209] As embodied in Figures 35 and 36, the solid regions Wcc and "holey" regions Win of substrate 200 may comprise the same material. This is not necessarily the case. For example, the "holey" regions Win of substrate 200 could comprise a fabric, woven or non-woven, joined to an adjacent substantially solid region along imaginary line 201. However, the materials forming the solid region Wcc should be relatively transparent or translucent to visible light, as will be understood in light of the teachings to follow.

[0210] Figure 38 depicts an embodiment wherein multiple widths 200-1 , 200-2 etc. of the general structure of Figures 35 and 36 are joined together in a generally repetitive pattern in the width direction. Such a structure allows simultaneous production of multiple repeat structures corresponding to widths 200-1 , 200-2 in a fashion similar to that taught in conjunction with the embodiments of Figures 6 through 15.

[0211] Figure 39 is a plan view of the Figure 35 substrate 200 following an additional processing step, and Figure 40 is a sectional view taken along line 40-40 of Figure 39. In Figures 39 and 40, the article is now designated by the numeral 214 to reflect this additional processing. In Figures 39 and 40, it is seen that a pattern of "fingers" 216 has been formed by material 218 positioned in a pattern onto surface 210 of original sheetlike substrate 200. "Fingers" 216 extend over the width Wcc of the solid portion of sheetlike structure 214. The "fingers" 216 extend to the "holey" interconnection region generally defined by Win. Portions of the Wcc region not overlayed by "fingers" 216 remain transparent or translucent to visible light. The "fingers" may comprise electrically conductive material. Examples of such materials are metal containing inks, patterned deposited metals such as etched metal patterns, stamped metal patterns, masked vacuum deposited metal patterns, fine wires, intrinsically conductive polymers and DER formulations. In other embodiments the "fingers" may comprise materials intended to facilitate subsequent deposition of conductive material in the pattern defined by the fingers. An example of such a material would be ABS, catalyzed to constitute a "seed" layer to initiate chemical "electroless" metal deposition. Another example would be a material functioning to promote adhesion of a subsequently applied conductive material to the film 200. In a preferred embodiment, the "fingers" comprise material which will enhance or allow subsequent metal electrodeposition such as a DER or electrically conductive ink. In the embodiment of Figures 39 and 40, the "fingers" 216 are shown to be a single layer of material 218 for simplicity of presentation. However, the "fingers" can comprise multiple layers of differing materials chosen to support various functional attributes as has previously been taught.

[0212] Continuing reference to Figures 39 and 40 also shows additional material

220 applied to the "holey" region Wi of article 214. As with the material comprising the "fingers" 216, the material 220 applied to the "holey" region Wi is either conductive or material intended to facilitate subsequent deposition of conductive material. One will understand that "holey" region Wi may comprise a fabric which may further comprise conductive material extending through the natural holes of the fabric. Further, such a fabric may comprise fibrils formed from conductive materials such as metals or conductive polymers. Such a fabric structure can be expected to increase and retain flexibility after subsequent processing such as metal electroplating, and perhaps bonding ability of the ultimate interconnected cells as will be understood in light of the teachings contained hereafter. In the embodiment of Figures 39 and 40, the "holey" region takes the general form of a "buss" 221 extending in the Y-214 direction in communication with the individual fingers. However, as one will understand through the subsequent teachings, the invention requires only that conductive communication extend from the fingers to a region Wi intended to be electrically joined to the bottom conductive surface of an adjacent cell. The "holey" region Wi thus does not require overall electrical continuity in the "Y" direction as is characteristic of a "buss" form depicted in Figures 39 and 40.

[0213] Reference to Figure 40 shows that the material 220 applied to the "holey" interconnection region Wi is shown as the same as that applied to form the fingers 216. However, these materials 218 and 220 need not be identical. In this embodiment material 220 applied to the "holey" region extends through holes 202 and onto the opposite second surface 212 of article 214. The extension of material 220 through the holes 202 can be readily accomplished as a result of the relatively small thickness (Z dimension) of the sheetlike substrate 200. Techniques include two sided printing of material 220, through hole spray application, masked metallization or selective chemical deposition or mechanical means such as stapling, wire sewing or riveting. [0214] Figure 41 is a view similar to that of Figure 40 following an additional optional processing step. The article embodied in Figure 41 is designated by numeral 226 to reflect this additional processing. It is seen in Figures 41 that the additional processing has deposited highly conductive material 222 over the originally free surfaces of materials 218 and 220. Material 222 normally comprises metal-based material such as copper or nickel, tin or a conductive metal containing paste or ink. Typical deposition techniques such as printing, chemical or electrochemical metal deposition and masked deposition can be used for this additional optional process to produce the article 226. In a preferred embodiment, electrodeposition is chosen for its speed, ease, and cost effectiveness as taught above. It is understood that article 226 is another embodiment of "current collector stock".

[0215] It is seen in Figure 41 that highly conductive material 222 extends through holes to electrically join and form electrically conductive surfaces on opposite sides of article 226. While shown as a single layer in the Figure 41 embodiment, the highly conductive material can comprise multiple layers to achieve functional value. In particular, a layer of copper is often desirable for its high conductivity. Nickel is often desired for its adhesion characteristics, plateability and corrosion resistance. The exposed surface 229 of material 222 can be selected for corrosion resistance and bonding ability. It has been found very advantageous to form surface 229 with a material compatible with the conductive surface with which eventual contact is made. In preferred embodiments, electroless deposition or electrodeposition is used to form a suitable metallic surface. Specifically electrodeposition offers a wide choice of potentially suitable materials to form the top surface 229. Corrosion resistant materials such as nickel, chromium, tin, indium, silver, gold and platinum are readily electrodeposited may be chosen to form surface 229. When compatible, of course, surfaces comprising metals such as copper or zinc or alloys of copper or zinc may be considered. Alternatively, the surface 229 may comprise a conversion coating, such as a chromate coating, of a material such as copper or zinc. Further, it may be highly advantageous to choose a material, such as a conductive adhesive or metallic solder to form surface 229 which exhibits adhesive or bonding ability to a subsequently positioned abutting conductive surface. In this regard, electrodeposition offers a wide choice of materials to form surface 229. In particular, indium, tin or tin containing alloys are a possible choice of material to form the exposed surface 229 of material 222. These metals melt at relatively low temperatures less than about 275 degree Centigrade. Thus these metals may be desirable to promote ohmic joining, through soldering, to other components in subsequent processing such as lamination.

Alternatively, exposed surface 229 may comprise an electrically conductive adhesive. Selective deposition techniques such as brush plating or printing would allow the conductive materials of region Wi to differ from those of fingers 216. In addition to supplying electrical communication from surfaces 210 to 212, holes 202 also function to increase flexibility of "buss" 221 by relieving the "sandwiching" effect of continuous oppositely disposed layers. Holes 202 can clearly be the holes naturally present should substrate 200 in the region Wi be a fabric.

[0216] One method of combining the current collector stock 226 embodied in

Figure 41 with a cell stock 10 as embodied in Figures 1A and 2A is illustrated in Figure 42 and 43. In the Figure 43 structure, individual current collector stocks 226 are combined with cells 10a, 10b, 10c respectively to produce a series interconnected array. This may be accomplished via a process generally described as follows.

[0217] As embodied in Figure 42, individual current collector stock, such as 226, is combined with cells such as 10 by positioning of surface region "Wcc" of current collector stock 226 having free surface 210 in registration with the light incident surface 59 of cell 10. The article so produced is identified as article 227. Adhesion joining the two surfaces is accomplished by a suitable process. In particular, the material forming the remaining free surface 210 of article 226 (that portion of surface 210 not covered with conductive material 222) may be a sealing material chosen for adhesive affinity to surface 59 of cell 10 thereby promoting good adhesion between the collector stock 226 and cell surface 59 resulting from a laminating process such as that depicted in Figure 21. Such a laminating process brings the conductive material of fingers 216 into firm and effective contact with the window electrode 18 forming surface 59 of cell 10. This contact is ensured by the blanketing "hold down" afforded by the adhesive bonding adjacent the conductive fingers 216. Also, as mentioned above, the nature of the free surface of conductive material 222 may optionally be manipulated and chosen to further enhance ohmic joining and adhesion. It is envisioned that batch or continuous laminating would be suitable. The invention has been demonstrated using both roll laminators and batch vacuum laminators. Should the articles 226 and 10 be in a continuous form it will be understood that article 227 could be formed as a continuous "tabbed cell stock". The subsequent series arrangement of articles 227a, 227b, depicted in Figure 43 may employ strip portions of "tabbed cell stock" having a defined length. Alternatively continuous series interconnection of multiple strips of tabbed cell stock supplied from corresponding multiple rolls of tabbed cell stock is possible. [0218] Referring to Figure 43, it is seen that proper positioning allows the conductive material 222 extending over the second surface 212 of article 227b to be ohmicly adhered to the bottom surface 66 of cell 10a. This joining is accomplished by suitable electrical joining techniques such as soldering, riveting, spot welding or conductive adhesive application. The particular ohmic joining technique embodied in Figure 43 is through electrically conductive adhesive 42. A particularly suitable conductive adhesive is one comprising a carbon black filler in a polymer matrix possibly augmented with a more highly conductive metal filler. Such adhesive formulations are relatively inexpensive and can be produced as hot melt formulations. Despite the fact that adhesive formulations employing carbon black alone have relatively high intrinsic resistivities (of the order 1 ohm-cm.), the bonding in this embodiment is accomplished through a relatively thin adhesive layer and over a broad surface. Thus the resulting resistance losses are relatively limited. A hot melt conductive adhesive is very suitable for establishing the ohmic connection using a straightforward lamination process.

[0219] Figure 43 embodies multiple cells assembled in a series arrangement using the teachings of the instant invention. In Figure 43, "i" indicates the direction of net current flow and "hv" indicates the light incidence for the arrangement. It is noted that the arrangement of Figure 43 resembles a shingling arrangement of cells, but with an important distinction. The prior art shingling arrangements have included an overlapping of cells at a sacrifice of portions of very valuable cell surface. In the Figure 43 teaching, the benefits of the shingling interconnection concept are achieved without any loss of photovoltaic surface from shading by an overlapping cell. In addition, the Figure 43 arrangement retains a high degree of flexibility because there is no immediate overlap of the metal foil cell substrate.

[0220] Yet another form of the instant invention is embodied in Figures 44 through

56. Figure 44 is a top plan view of an article designated 230. Article 230 has width "X- 230" and length "Y-230". It is contemplated that "Y-230" may be considerably greater than "X-230" such that article 230 may be processed in continuous roll-to-roll fashion. However, such continuous processing is not a requirement.

[0221] Figure 45 is a sectional view taken substantially from the perspective of lines 45-45 of Figure 44. It is shown in Figure 45 that article 230 may comprise any number of layers such as those designated by numerals 232, 234, 236. The layers are intended to supply functional attributes to article 230 as has been discussed for prior embodiments. Article 230 is also shown to have thickness "Z-230". "Z-230" is much smaller than "X-230" of "Y-230" and thus article 230 can generally be characterized as being flexible and sheetlike. Article 230 is shown to have a first surface 238 and second surface 240. As will become clear in subsequent embodiments, it may be advantageous to form layer 232 forming surface 238 using a material having adhesive affinity to the bottom surface 66 of cell 10. In addition, it may be advantageous to have surface 240 formed by a material having adhesive affinity to surface 59 of cell 10.

[0222] Figure 46 is an alternate sectional embodiment depicting an article 230a.

The layers forming article 230a do not necessarily have to cover the entire expanse of article 230a.

[0223] Figure 47 is a simplified sectional view of the article 230 which will be used to simplify presentation of embodiments to follow. While Figure 47 presents article 230 as a single layer, it is emphasized that article 230 may comprise any number of layers.

[0224] Figure 48 is a top plan view of the initial article 230 following an additional processing step. The article embodied in Figure 48 is designated 244 to reflect this additional processing step. Figure 49 is a sectional view taken substantially from the perspective of lines 49-49 of Figure 48. Reference to Figures 48 and 49 show that the additional processing has produced holes 242 in the direction of "Y-244". The holes extend from the top surface 238 to the bottom surface 240 of article 244. Holes 242 may be produced by any number of techniques such as laser drilling or simple punching.

[0225] Figure 50 is a top plan view of the article 244 following an additional processing step. The article of Figure 50 is designated 250 to reflect this additional processing. Figure 51 is a sectional view taken substantially from the perspective of lines 51-51 of Figure 50. Reference to Figures 50 and 51 shows that material 251 has been applied to the first surface 238 in the form of "fingers" 252. Further, material 253 has been applied to second surface 240 in the form of "fingers" 254. In the embodiment, "fingers" 252 and 254 extend substantially perpendicular from a "buss-like" structure 256 extending in the direction "Y-250". As seen in Figure 51 , additional materials 251 and 253 extend through the holes 242. In the Figure 51 embodiment, materials 251 and 253 are shown as being the same. This is not necessarily a requirement and they may be different. Also, in the embodiment of Figures 50 and 51 , the buss-like structure 256 is shown as being formed by materials 251/253. This is not necessarily a requirement. Materials forming the "fingers" 252 and 254 and "buss" 256 may all be the same or they may differ in actual composition and be applied separately. Alternatively, fingers and busses may comprise a continuous material structure forming portions of both fingers and busses. Fingers and busses need not both be present in certain embodiments of the invention.

[0226] As in prior embodiments, "fingers" 252 and 254 and "buss" 256 may comprise electrically conductive material. Examples of such materials are metal wires and metal foils, conductive metal containing inks and pastes, patterned metals such as etched metal patterns or masked vacuum deposited metals, intrinsically conductive polymers, conductive inks and DER formulations. In a preferred embodiment, the "fingers and "busses" comprise material such as DER or an electrically conductive ink such as silver containing ink which will enhance or allow subsequent metal electrodeposition. "Fingers" 252 and 254 and "buss" 256 may also comprise non-conductive material which would assist accomplishing a subsequent deposition of conductive material in the pattern defined by the "fingers" and "busses". For example, "fingers" 252 and 254 or "buss" 256 could comprise a polymer which may be seeded to catalyze chemical deposition of a metal in a subsequent step. An example of such a material is ABS. "Fingers" 252 and 254 and "buss" 256 may also comprise materials selected to promote adhesion of a subsequently applied conductive material.

[0227] Figure 52 is a sectional view showing the article 250 following an additional optional processing step. The article of Figure 52 is designated 260 to reflect this additional processing. In a fashion like that described above for production of prior embodiments of current collector structures, additional conductive material 266 has been deposited by optional processing to produce the article 260 of Figure 52. The discussion involving processing to produce the articles of Figures 12-15, 20, 31 , and 41 is proper to describe the additional processing to produce the article 260 of Figure 52. In a preferred embodiment, conductive material 266 comprises material applied by electrodeposition. In addition, while shown in Figure 52 as a single continuous, monolithic layer, the additional conductive material may comprise multiple layers. As in prior embodiments, it may be advantageous to use a material such as a low melting point alloy or conductive adhesive to form exterior surface 268 of additional conductive material 266. Additional conductive material overlaying "fingers" 252 need not be the same as the additional conductive material overlaying "fingers" 254.

[0228] The sectional views of Figures 55 and 56 embody the use of article 250 or

260 to achieve a series connected structural array of photovoltaic cells 10. In Figure 55, an article designated as 270 has been formed by combining article 260 with cell 10 by laminating the bottom surface 240 of article 260 to the top conductive surface 59 of cell 10. In a preferred embodiment, exposed surface 240 (those regions not covered with "fingers" 254) is formed by a material having adhesive affinity to surface 59 and a secure and extensive adhesive bond forms between surfaces 240 and 59 during the heat and pressure exposure of the lamination process. Thus an adhesive "blanket" holds conductive material 266 of "fingers" 254 in secure ohmic contact with surface 59. As previously pointed out, low melting point alloys or conductive adhesives may also be considered to enhance this contact. It is understood that article 270 of Figure 55 is yet another embodiment of a "tabbed cell stock".

[0229] The sectional view of Figure 56 embodies multiple articles 270 arranged in a series interconnected array. The series connected array is designated by numeral 290 in Figure 56. In the Figure 56 embodiment, it is seen that "fingers" 252 positioned on surface 238 of article 270b have been brought into contact with the bottom surface 66 of cell 10 associated with article 270a. This contact is achieved by choosing material 232 forming free surface 238 of article 270b to have adhesive affinity for bottom conductive surface 66 of cell 10 of article 270a. Secure adhesive bonding is achieved during the heat and pressure exposure of a laminating process thereby resulting in a hold down of the "fingers" 252. The ohmic contact thus achieved can be enhanced using low melting point alloys or conductive adhesives as previously taught herein.

[0230] Thus, it is seen that continuous communication is achieved between the top surface of one cell and the bottom or rear surface of an adjacent cell. Importantly, the communication may achieved with a continuous, monolithic conductive structure. This avoids potential degradation of contact sometimes associated with multiple contact surfaces possible when using conductive adhesives. In addition, the Figure 56 embodiment clearly shows an advantageous "shingling" type structure that avoids any shielding of valuable photovoltaic cell surface. Finally, it is seen that the structural embodiment of Figure 56 includes complete encapsulation of cells 10.

[0231] The embodiments of Figures 50 through 52 show the "fingers" and

"busses" as essentially planar rectangular structures. Other geometrical forms are clearly possible. This is especially the case when considering structure for contacting the rear or bottom surface 66 of a photovoltaic cell 10. One embodiment of an alternate structure is depicted in Figures 53 and 54. Figure 53 is a top plan view while Figure 54 is a sectional view taken substantially from the perspective of lines 54-54 of Figure 53. In Figures 53 and 54, there is depicted an article 275 analogous to article 250 of Figure 50. The article 275 in Figures 53 and 54 comprises "fingers" 280 similar to "fingers" 254 of the Figure 50 embodiment. However, the pattern of material 251 forming the structure on the top surface 238a of article 275 is considerably different than the "fingers" 252 and "buss" 256 of the Figure 70 embodiment. In figure 53, material 251a is deposited in a mesh-like pattern having voids 276 leaving multiple regions of surface 238a exposed. Lamination of such a structure may result in improved surface area contact of the pattern compared to the finger structure of Figure 50. It is emphasized that since surface 238a of article 275 eventually contacts rear surface 66 of the photovoltaic cell, potential shading is not an issue and thus geometrical design of the exposed contacting surfaces 238a relative to the mating conductive surfaces 66 can be optimized without consideration to shading issues.

[0232] In the present specification lamination has been shown as a means of combining the collector grid or electrode structures with a conductive surface. However, one will recognize that other application methods to combine the grid or electrode with a conductive surface may be appropriate such as transfer application processing. For example, in the embodiments such as those of Figures 23 or 33, the substrate is shown to remain in its entirety as a component of the "tabbed cell stock" and final interconnected array. However, this is not a requirement. In other embodiments, all or a portion of substrate may be removed prior to or after a laminating process accomplishing positioning and attachment of "fingers" 84 and "busses" 86 to a conductive cell surface. In this case, a suitable release material (not shown) may be used to facilitate separation of the conductive collector electrode structure from a removed portion of substrate 70 during or following an application such as the lamination process depicted in Figure 21. Thus, in this case the removed portion of substrate 70 would serve as a surrogate or temporary support to initially manufacture and transfer the grid or electrode structure to the desired conductive surface. One example would be that situation where layer 72 of Figure 7 would remain with the final interconnected array while layers 74 and/or 76 would be removed.

[0233] Using a laminating approach to secure the conductive grid materials to a conductive surface involves some design and performance "tradeoffs". For example, if the electrical trace or path "finger" 84 comprises a wire form, it has the advantage of potentially reducing light shading of the surface (at equivalent current carrying capacity) in comparison to a substantially flat electrodeposited, printed or etched foil member. However, the relatively higher profile for the wire form must be addressed. It has been taught in the art that wire diameters as small as 50 micrometers (.002 inch) can be assembled into grid like arrangements. Thus when laid on a flat surface such a wire would project above the surface .002 inches. For purposes of this instant specification and claims, a structure projecting above a surface less than .002 inches will be defined as a low-profile structure. Often a low profile structure may be further characterized as having a substantially flat surface.

[0234] A potential cross sectional view of a wire form 84d after being laminated to a surface by the process such as that of Figure 21 is depicted in Figure 57. Figure 58 depicts a typical cross sectional view of an electrical trace 84e formed by printing, electrodeposition, chemical "electroless" plating, foil etching or stamping, masked vacuum deposition etc. It is seen in Figure 57 that being round the wire itself contacts the surface essentially along a line (normal to the paper in Figure 57). In addition, the wire form is embedded in the sealing material, but the sealing material forming surface 8Od of film 70 may have difficulty flowing completely around the wire, leaving voids as shown in Figure 57 at 99, possibly leading to insecure contact. Thus, the thickness of the sealing layer and lamination parameters and material choice become very important when using a round wire form. On the other hand, using a lower profile substantially flat conductive trace such as depicted in Figure 58 increases contact surface area compared to the line contact associated with a wire. The low profile form of Figure 58 is easily embedded into the sealing layer promoting broad surface contact and secure lamination but comes at the expense of increased light shading. The low profile, flat structure does require consideration of the thickness of the "flowable" sealing layer forming surface 8Oe relative to the thickness of the conductive trace. Excessive thickness of certain sealing layer materials might allow relaxation of the "blanket" pressure promoting contact of the surfaces 98 with a mating conductive surface such as 59. Insufficient thickness may lead to voids similar to those depicted for the wire forms of Figure 57. However, it has been found that sealing layer thicknesses for low profile traces such as embodied in Figure 58 ranging from .5 mil (.0005 inch) to 10 mil (.01 inch) all perform satisfactorily. Thus a wide range of thickness is possible, and the invention is not limited to sealing layer thicknesses within the stated tested range.

[0235] A low profile structure such as depicted in Figure 58 may be advantageous because it may allow minimizing sealing layer thickness and consequently reducing the total amount of functional groups present in the sealing layer. Such functional groups may adversely affect solar cell performance or integrity. For example, it may be advantageous to limit the thickness of a sealing layer such as EVA to 2 mils or less when using a CIS or CIGS photovoltaic material. [0236] Electrical contact between conductive grid "fingers" or "traces" 84 and a conductive surface (such as cell surface 59) may be further enhanced by coating a conductive adhesive formulation onto "fingers" 84 and possibly "busses" 86 prior to or during the lamination process such as taught in the embodiment of Figures 21. In a preferred embodiment, the conductive adhesive would be a "hot melt" material. A "hot melt" conductive adhesive would melt and flow at the temperatures involved in the laminating process 92 of Figure 21. In this way surface 98 is formed by a conductive adhesive resulting in secure adhesive and electrical joining of grid "fingers" 84 to a conductive surface such as top surface 59 following the lamination process. In addition, such a "flowable" conductive material may assist in reducing voids such as depicted in Figure 57 for a wire form. In addition, a "flowable" conductive adhesive may increase the contact area for a wire form 84d.

[0237] In the case of a low profile form such as depicted in Figure 58, the conductive adhesive may be applied by standard registered printing techniques. However, it is noted that a conductive adhesive coating for a low profile conductive trace may be very thin, of the order of 1-10 micron thick. Thus, the intrinsic resistivity of the conductive adhesive can be relatively high, perhaps up to or even exceeding about 100 ohm-cm. This fact allows reduced loading and increased choices for a conductive filler. Since the conductive adhesive does not require heavy filler loading (i.e. it may have a relatively high intrinsic resistivity as noted above) other unique application options exist.

[0238] For example, a suitable conductive "hot melt" adhesive may be deposited from solution onto the surface of the "fingers" and 'busses" by conventional paint electrodeposition techniques. Alternatively, should a condition be present wherein the exposed surface of fingers and busses be pristine (no oxide or tarnished surface), the well known characteristic of such a surface to "wet" with water based formulations may be employed to advantage. A freshly activated or freshly electroplated metal surface will be readily "wetted" by dipping in a water-based polymer containing fluid such as a latex emulsion containing a conductive filler such as carbon black. Application selectivity would be achieved because the exposed polymeric sealing surface 80 would not wet with the water based latex emulsion. The water based material would simply run off or could be blown off the sealing material using a conventional air knife. However, the water based film forming emulsion would cling to the freshly activated or electroplated metal surface. This approach is similar to applying an anti-tarnish or conversion dip coating to freshly electroplated metals such as copper and zinc. [0239] Alternatively, one may employ a low melting point metal-based material as a constituent of the material forming either or both surfaces 98 and 100 of "fingers" and "busses". In this case the low melting point metal-based material, or alloy, is caused to melt during the temperature exposure of the process 92 of Figure 21 (typically less than 600 degrees F) thereby increasing the contact area between the mating surfaces 98, 100 and a conductive surface such as 59. Such low melting point metal-based materials may be applied by electrodeposition or simple dipping to wet the underlying conductive trace. Suitable low melting point metals may be based on tin, such as tin-bismuth and tin-lead alloys. Such alloys are commonly referred to as "solders". In another preferred embodiment indium or indium containing alloys are chosen as the low melting point contact material at surfaces 98, 100. Indium melts at a low temperature, considerably below possible lamination temperatures. In addition, indium is known to bond to glass and ceramic materials when melted in contact with them. Given sufficient lamination pressures, only a very thin layer of indium or indium alloy would be required to take advantage of this bonding ability.

[0240] In yet another embodiment, one or more of the layers 84, 86, 88, 90 etc. may comprise a material having magnetic characteristics. Magnetic materials include nickel and iron. In this embodiment, either a magnetic material in the cell substrate or the material present in the finger/grid collector structure is caused to be permanently magnetized. The magnetic attraction between the "grid pattern" and magnetic component of the foil substrate of the photovoltaic cell (or visa versa) creates a permanent "pressure" contact.

[0241] In yet another embodiment, the "fingers" 84 and/or "busses" 86 comprise a magnetic component such as iron or nickel and a external magnetic field is used to maintain positioning of the fingers or busses during the lamination process depicted in Figure 21.

[0242] A number of methods are available to employ the current collecting and interconnection structures taught hereinabove with photovoltaic cell stock to achieve effective interconnection of multiple cells into arrays. A brief description of some possible methods follows. A first method envisions combining photovoltaic cell structure with current collecting electrodes while both components are in their originally prepared "bulk" form prior to subdivision to dimensions appropriate for individual cells. A expansive surface area of photovoltaic structure such as embodied in Figures 1 and 2 of the instant specification representing the cumulative area of multiple unit cells is produced. As a separate and distinct operation, an array comprising multiple current collector electrodes arranged on a common substrate, such as the array of electrodes taught in Figures 9 through 15 is produced. The bulk array of electrodes is then combined with the expansive surface of photovoltaic structure in a process such as the laminating process embodied in Figure 21. This process results in a bulk combination of photovoltaic structure and collector electrode. Appropriate subdividing of the bulk combination results in individual cells having a preattached current collector structure. Electrical access to the collector structure of individual cells may be achieved using through holes, as taught in conjunction with the embodiments of Figures 35 through 42. Alternatively, one may simply lift the collector structure away from the cell surface 59 at the edge of the unit photovoltaic cell to expose the collector electrode.

[0243] Another method of combining the collector electrodes and interconnect structures taught herein with photovoltaic cells involves a first step of manufacture of multiple individual current collecting structures or electrodes. A suitable method of manufacture is to produce a bulk continuous roll of electrodes using roll to roll processing. Examples of such manufacture are the processes and structures embodied in the discussion of Figures 9 through 15 of the instant specification. The bulk roll is then subdivided into individual current collector electrodes for combination with discrete units of cell stock. The combination produces discrete individual units of "tabbed" cell stock. In concept, this approach is appropriate for individual cells having known and defined surface dimensions, such as 6" x 6", 4" x 3", 2" x 8" and 2" x 16". Cells of such defined dimensions may be produced directly, such as with conventional single crystal silicon manufacture. Alternatively, cells of such dimension are produced by subdividing an expansive cell structure into smaller dimensions. The "tabbed" cell stock thereby produced could conceptually be packaged in cassette packaging. The discrete "tabbed" cells are then electrically interconnected into an array, optionally using automatic dispensing, positioning and electrical joining of multiple cells. The overhanging tabs of the individual "tabbed" cells facilitate such joining into an array as was taught in the embodiments of Figures 24, 34, 43, and 56 above

[0244] Alternate methods to achieve interconnected arrays according to the instant invention comprise first manufacturing multiple current collector structures in bulk roll to roll fashion. In this case the "current collector stock" would comprise electrically conductive current collecting structure on a supporting sheetlike web essentially continuous in the "Y" or "machine" direction. Furthermore, the conductive structure is possibly repetitive in the "X" direction, such as the arrangement depicted in Figures 9, 12 and 38 of the instant specification. In a separate operation, individual rolls of unit "cell stock" are produced, possibly by subdividing an expansive web of cell structure. The individual rolls of unit "cell stock" are envisioned to be continuous in the "Y" direction and having a defined width corresponding to the defined width of cells to be eventually arranged in interconnected array.

[0245] Having separately prepared rolls of "current collector stock" and unit "cell stock", multiple array assembly processes may be considered as follows. In one form of array assembly process, a roll of unit "current collector stock" is produced, possibly by subdividing a bulk roll of "current collector stock" to appropriate width for the unit roll. The rolls of unit "current collector stock" and unit "cell stock" are then combined in a continuous process to produce a roll of unit "tabbed stock". The "tabbed" stock therefore comprises cells, which may be extensive in the "Y" dimension, equipped with readily accessible contacting surfaces for either or both the top and bottom surfaces of the cell. The "tabbed" stock may be assembled into an interconnected array using a multiple of different processes. As examples, two such process paths are discussed according to (A) and (B) following.

[0246] Process Example (A): Multiple strips of "tabbed" stock are fed to a process such that an interconnected array of multiple cells is achieved continuously in the machine (original "Y") direction. This process would produce an interconnected array having series connections of cells whose number would correspond to the number of rolls of "tabbed" stock being fed. In this case the individual strips of "tabbed" stock would be arranged in appropriate overlapping fashion as dictated by the particular embodiment of "tabbed" stock. The multiple overlapping tabbed cells would be electrically joined appropriately using electrical joining means, surface mating through laminating or combinations thereof as has been taught above. Both the feed and exit of such an assembly process would be substantially in the original "Y" direction and the output of such a process would be essentially continuous in the original "Y" direction. The multiple interconnected cells could be rewound onto a roll for further processing.

[0247] Process Example (B): An alternative process is taught in conjunction with

Figures 59 and 60. Figure 59 is a top view of the process and Figure 60 is a perspective view. The process is embodied in Figures 59 and 60 using the "tabbed cell stock" 270 as shown in Figure 55. One will recognize that other forms of "tabbed cell stock" such as those shown in Figures 23, 33, 42, are also suitable. A single strip of "tabbed" cell stock 270 is unwound from roll 300 and cut to a predetermined length "Y-59". "Y-59" represents the width of the form factor of the eventual interconnected array. The strip of "tabbed cell stock" cut to length "Y-59" is then positioned. In the embodiment of Figures 59 and 60 the strip is securely positioned on vacuum belt 302. The strip is then "shuttled" in the original "x" direction of the "tabbed cell stock" a distance substantially the length of a repeat dimension among adjacent series connected cells. This repeat distance is indicated in Figures 56 and 59 as "X-10". A second strip of "tabbed cell stock" 270 is then unwound and appropriately positioned to properly overlap the first strip, as best shown in Figure 56. This second strip is cut to length "Y-59". The second strip is then slightly tacked to the first strip of "tabbed cell stock" using exposed substrate material, as that indicated at numeral 306 in Figure 56. The tacking may be accomplished quickly and simply at points spaced in the "Y-59" direction using heated probes to melt small regions of the sealing material forming the surface of the exposed substrate. This process of positioning and tacking is repeated multiple times. It is understood that methods other than tacking may be chosen to maintain positioning of the adjacent cells prior to lamination. Eventually, the repetitive structures are passed through a lamination step. In the embodiment of Figures 59 and 60, the lamination is accomplished using roll laminator 310. Thus the series connected structure 290 depicted in Figure 56 is achieved. The electrical joining may take many forms, depending somewhat on the structure of the individual "tabbed cell stock". For example, in the embodiment of Figures 24 and 25, joining may take the form of an electrically conductive adhesive, solder, etc. as previously taught. In the case of "tabbed" cell stock such as Figure 55, electrical joining may comprise a simple "blanket hold down" lamination such as embodied in Figure 56. It is seen that in the process depicted in Figures 59 and 60 the interconnected cell stock would exit the basic lamination assembly process in a fashion substantially perpendicular to the original "Y" direction of the "tabbed cell stock". The interconnected cells produced would therefore have a new predetermined width "Y-59" and the new length (in the original "X" direction) may be of extended dimension. The output in the new length dimension may be described as essentially continuous and thus the output of interconnected cells may be gathered on roll 320 as shown

[0248] It will be appreciated that using the processing as embodied in Figures 59 and 60, a large choice of final form factors for the interconnected array is possible. For example, dimension "Y-59" could conceivably and reasonably be quite large, for example 8 feet while dimension "X-59" may be virtually any desired dimension. To date, module sizes have been restricted by the practical problems of handling and interconnecting large numbers of small individual cells. The largest commercially available module known to the instant inventor is about 60 square feet. Using the instant invention, module sizes far in excess of 60 square feet are reasonable. Large modules suitable for combination with standard construction materials may be produced. For example, a module surface area of 4 ft. by 8 ft. (a standard dimension for plywood and other sheetlike construction materials) is readily produced using the processing of the instant invention. Alternatively, since the final modular array can be accumulated in roll form as shown in Figures 59 and 60, installation could be facilitated by the ability to simply "roll out" the array at the installation site. The ability to easily make modular arrays of very expansive surface and having wide choice of form factor greatly facilitates eventual installation and is a substantial improvement over existing options for modular array manufacture.

Example 1

[0249] A standard plastic laminating sheet from GBC Corp. 75 micrometer (.003 inch) thick was coated with DER in a pattern of repetitive fingers joined along one end with a busslike structure resulting in an article as embodied in Figures 16 through 19. The fingers were .020 inch wide, 1.625 inch long and were repetitively separated by .150 inch. The buss-like structure which contacted the fingers extended in a direction perpendicular to the fingers as shown in Figure 16. The buss-like structure had a width of .25 inch. Both the finger pattern and buss-like structure were printed simultaneously using the same DER ink and using silk screen printing. The DER printing pattern was applied to the laminating sheet surface formed by the sealing layer (i.e. that surface facing to the inside of the standard sealing pouch).

[0250] The finger/buss pattern thus produced on the lamination sheet was then electroplated with nickel in a standard Watts nickel bath at a current density of 50 amps, per sq. ft. Approximately 4 micrometers of nickel thickness was deposited to the overall pattern.

[0251] A photovoltaic cell having surface dimensions of 1.75 inch wide by 2.0625 inch long was used. This cell was a CIGS semiconductor type deposited on a .001 inch stainless steel substrate. A section of the laminating sheet containing the electroplated buss/finger pattern was then applied to the top, light incident side of the cell, with the electroplated grid finger extending in the width direction (1.75 inch dimension) of the cell. Care was taken to ensure that the buss region of the conductive electroplated metal did not overlap the cell surface. This resulted in a total cell surface of 3.61 sq. inch. (2.0625" X 1.75") with about 12 % shading from the grid, (i.e. about 88% open area for the cell). [0252] The electroplated "finger/buss" on the lamination film was applied to the photovoltaic cell using a standard Xerox office laminator. The resulting completed cell showed good appearance and connection.

[0253] The cell prepared as above was tested in direct sunlight for photovoltaic response. Testing was done at noon, Morgan Hill, CA. on April 8, 2006 in full sunlight. The cell recorded an open circuit voltage of .52 Volts. Also recorded was a "short circuit" current of .65 Amps. This indicates excellent power collection from the cell at high efficiency of collection.

Example 2

[0254] Individual thin film CIGS semiconductor cells comprising a stainless steel supporting substrate .001 inch thick were cut to dimensions of 7.5 inch length and 1.75 inch width.

[0255] In a separate operation, multiple laminating collector grids were prepared as follows. A .002 inch thick film of Surlyn material was applied to both sides of a .003 inch thick PET film to produce a starting laminating substrate as embodied in Figure 44. Holes having a .125 inch diameter were punched through the laminate to produce a structure as in Figure 48. A DER ink was then printed on opposite surfaces and through the holes to form a pattern of DER traces. The resulting structure resembled that depicted in Figure 51. The grid fingers 254 depicted in Figures 50 and 51 were .012 inch wide and 1.625 inch long and were spaced on centers .120 inch apart in the length direction. The grid fingers 252 were .062 inch wide and extended 1 inch and were spaced on centers .5 inch apart. The printed film was then electroplated to deposit approximately 2 micrometers nickel strike, 5 micrometers copper and a top flash coating of 1 micrometer nickel. This operation produced multiple sheets of laminating current collector stock having overall dimension of 7.5 inch length ("Y" dimension) and 4.25 in width ("X" dimension) as indicated in Figure 50. These individual current collector sheets were laminated to cells having dimension of 7.25 inches in length and 1.75 inches in width to produce tabbed cell stock as depicted in Figure 55. A standard Xerox office roll laminator was used to produce the tabbed cell stock. Six pieces of the tabbed cell stock were laminated together as depicted in Figure 56. A standard Xerox office roll laminator was used to produce the Figure 56 embodiment. The combined series interconnected array had a total surface area of 76.1 square inches. In full noon sunlight the 6 cell array had an open circuit voltage of 3.2 Volts and a short circuit current of 2.3 amperes. [0256] While many of the embodiments of the invention refer to "current collector" structure, one will appreciate that similar articles could be employed to collect and convey other electrical characteristics such as voltage.

[0257] One application of the modules made practical by the teachings above is expansive area photovoltaic energy farms or expansive area rooftop applications. The instant invention envisions facile installation of large arrays of modules having area dimensions suitable for covering expansive surface areas. In one embodiment, the instant teachings above are used to produce modules of large dimensions. Practical module widths may be 2 ft., 4 ft., 8 ft etc. Practical module lengths may be 2 ft., 4 ft., 10 ft., 50 ft, 100 ft., 500 ft., etc. The longer lengths can be characterized as "continuous" and be shipped and installed in a roll format. As taught above, such large modules can be produced in a flexible "sheetlike" form. In one embodiment, these sheetlike modules are adhered to a rigid supporting member such as a piece of plywood, polymeric sheet or a honeycomb structure. The sheetlike modules are produced having terminal bars at two opposite terminal ends of the module. These terminal bars are easily incorporated into the modules using the same continuous processes used in assembly of the bulk module. It is noted that in the hereinbefore teachings, the terminal bars may have oppositely facing conductive surface regions with electrical communication between them. This is an advantage for certain embodiments of the instant invention, in that an upward facing conductive surface for the terminal bars may facilitate electrical connections.

[0258] Referring now to Figures 63 through 65 of this instant specification, details of a module structure appropriate for embodiments of expansive area installations of the instant invention are presented. In Figure 63, a top plan view of a portion of photovoltaic module 410 is depicted. The Figure 63 depiction includes one terminal end 412 of a module. Positioned along the edge of the terminal end 412 is electrically conductive terminal bar 414. One realizes that a terminal bar such as the region indicated as 414 in Figure 63 would be present at the end of modular arrangements such as embodied in Figures 43 and 56. for example, a possible "terminal bar" region is shown at numeral 414 in Figure 42. One further understands that a terminal bar of opposite polarity would be positioned at the terminal end opposite terminal end 412 (not shown in Figure 63). In the embodiment of Figure 63, through holes 416 have been positioned within the terminal bar 414. Through holes such as those indicated by 416 may be used to achieve electrical communication between conductive surfaces on opposite sides of the terminal bar region. This feature expands installation design choices and may improve overall contact between the terminal bars and conductive attachment hardware. [0259] Continuing reference to Figure 63 shows photovoltaic cells 401 , 402, 403, etc. positioned in a repetitive arrangement. In the embodiment, the individual cells comprise thin film semiconductor material supported by a metal-based foil and modularized as taught above, for example as embodied in Figure 43 or 56. However, the installation concepts of the invention are not limited to such structure. Alternate photovoltaic cell structures known in the art and incorporated into expansive modules would be appropriate for practice of the invention. These alternate structures include thin film cells deposited on polymeric film substrates or superstrates and those interconnected monolithically or by known "shingling" techniques. It is however helpful that the expansive module be substantially complete prior field installation and be relatively lightweight, as will be understood in light of the discussion to follow.

[0260] On the top (light incident) surface 418 of the cells in the Figure 63 embodiment, a pattern of fingers 420 and busses 422 collect power for transport to an adjacent cell in series arrangement. The grid finger/ buss collector is but one of a number of means to accomplish power collection and transport from the top cell surface. Methods such as conductive through holes from the top surface to a backside electrode, monolithically integrated structures using polymeric substrates or superstrates, and known shingling techniques may also be considered to produce the expansive area installations of the invention.

[0261] Figure 64 is a sectional depiction from the perspective of lines 64-64 of

Figure 63. The Figure 64 embodiment shows a series connected arrangement of multiple photovoltaic cells 401 , 402, 403, etc. To promote clarity of presentation, the details of the series connections and cell structure are not shown in Figure 64. Also shown in Figure 64 is an optional rigid supporting structure 424. The rigid supporting structure 424 may comprise any number of material forms, such as rigid polymeric sheet, a honeycomb structure, expanded mesh, or even weatherable plywood. Supporting structure 424 may comprise a composite structure of more than one material. Structure 424 may also incorporate heat conveyance structure to assist in cooling the module. The flexible modules produced by the teachings above may be adhered to the rigid support 424 using standard techniques such as structural adhesives. In Figure 64, through hole 416 is seen to extend through terminal bar 414 and supporting structure 424. It is understood that support structure 424 may be omitted should the module 410 be attached directly to a surface such as a roof. Such a direct attachment is reasonable considering the expansive modular surfaces made possible with the aforementioned teachings. [0262] Figure 65 is a simplified top plan view of a typical module presenting an embodiment of appropriate overall structural features. In the Figure 65 embodiment, overall module surface dimensions are indicated to be 4 ft. width (Wm) by 8 ft. length (Lm). In the following, module dimensions of 4 ft. Wm by 8 ft. Lm will be used to teach and illustrate the various features and aspects of certain embodiments of the invention. However, one will realize that the invention is not limited to these dimensions. Module surface dimensions may be larger or smaller (i.e. 2 ft. by 4 ft., 4 ft. by 16 ft., 8 ft. by 4 ft., 8 ft. by 16 ft., 8 ft. by 100 ft., etc.) depending on specific requirements. Thus the overall module may be relatively large.

[0263] At opposite terminal ends of the module, defined by the module length dimension "Lm", are terminal bars 414 and 426. Mounting through holes 416 are positioned through the terminal bars 414, 426 and underlying support 424 as shown in Figure 64.

[0264] In the Figure 65 embodiment, the module is indicated to have a length (Lm) of 8 ft. The module comprises multiple cells having surface dimensions of width Wcell (actually in the defined length direction of the overall module) and length Lcell as shown. In the Figure 65 embodiment, the cell length (Lcell) is shown to be substantially equivalent to the module width (Wm). In addition, terminal bars 414, 426 are shown to span substantially the entire width (Wm) of the module.

[0265] Typically cell width (Wcell) may be from 0.2 inch to 12 inch depending on choices among many factors. For purposes of describing embodiments of the invention, the cell width (Wcell) may be considered to be 1.97 inch as shown in Figure 65. This means that the module 410 of Figure 65 comprises 48 individual cells interconnected in series, with terminal bars 414 and 426 of about 0.7 inch width at each terminal end of the module. Assuming an individual cell open circuit voltage of 0.5 volts (typical for example of a CIGS cell), the open circuit voltage for the module embodied in Figure 65 would be about 24 volts. This voltage is noteworthy in that it is insufficient to pose a significant electrical shock hazard, and further that the opposite polarity terminals are separated by 8 feet. Should higher voltages be permitted or desired, one very long module or multiple modules connected in series may be considered, employing mounting and connection structures taught herein for the individual modules. Alternatively, should higher voltage cells be employed (such as multiple junction a-silicon cells which may generate open circuit voltages in excess of 2 volts), the cell width (Wcell) may be increased accordingly to maintain a safe overall module voltage. At a ten percent module efficiency, the module of Figure 65 would generate about 290 Watts.

[0266] One realizes the module structures depicted in Figure 63 through 65 may be readily fabricated at a factory and shipped in bulk packaging form to an installation site.

[0267] Figure 66 is a top plan view of a portion of one form of field mounting structure, generally indicated by numeral 428. Figure 68 is a perspective view of the portion 428. In the structural and process embodiments herein described, the mounting structure may be pre-constructed at the site prior to combination with modules 410 depicted in Figure 65. For example, should a terrestrial installation be desired, appropriate land grading and support construction could be completed in advance of the arrival of the modules.

[0268] Figures 66 and 68 show that the mounting structure 428 comprises two parallel elongate rails 430 and 432. In this embodiment, rails 430 and 432 are oriented, spaced and have structure appropriate to readily receive modules 410. For example, in the embodiment of Figure 66 the rails have an open or "receiving" dimension (shown as 96.125 inch in the embodiment) slightly larger than a length dimension (Lm) of a module. The outline of a module such as that of Figure 65 is depicted in phantom by the dashed lines in Figure 66. The rails 430, 432 may normally extend a distance greater than the combined aggregate width (Wm) of a multiple of the expansive surface area photovoltaic modules.

[0269] Figure 67 is a sectional view taken substantially from the perspective of lines 67-67 of Figure 66 and shows the details of one form of structure for rails 430, 432. In the Figure 67 embodiment the rails comprises a 90 degree angle structure of an elongate form of metal such as aluminum. The angle forms a seat 434 to receive the photovoltaic module. Holes 436 through the metal rails are sized and spaced to mate with the holes 416 in modules 410. Holes 436 may have a smooth bore or be structured such as with a thread pattern to receive a threaded mounting bolt.

[0270] The rails 430, 432 comprise a material such as aluminum or copper or metal alloys which are relatively inexpensive, strong and have high conductivity. The rails can comprise more than one metal or alloy. Surface coatings or treatments or additional materials known in the art may be employed to prevent environmental corrosion and deterioration of contacts. As will be shown in the embodiments of Figures 69 through 72, the mounting rails 430, 432 may function also as power conduits or primary busses from a multiple of individual photovoltaic modules 410.

[0271] The rails may be supported above a base or ground level by piers or posts

440 emanating from the ground. Alternatively, they may be attached to additional structure such as a roof. The rails 430, 432 may be at different elevations so as to tilt the arrays at a given angle according to the latitude of the installation site.

[0272] Figure 69 shows the result of attaching multiple modules (3 in the Figure 69 embodiment) to the elongate rail structure. The rails have a structure which mates dimensionally with the sheetlike structure of the modules such that the sheetlike module 410 is easily positioned appropriately with respect to the rail structure. Electrical connection between the terminal bars 414, 426 disposed at the two opposite ends of the module 410 and the rails 430, 432 is simultaneously achieved through the mechanical joining of the module sheets to the rails. The terminal bars of a first polarity of the multiple modules are attached to a first rail and the terminal bars of the opposite polarity are attached to the second opposing rail. It is noted that in this embodiment the multiple modules are connected to rails such that each rail serves as a common manifold for conveyance of power associated with multiple modules and there is no need for coupling of components from the adjacent modules. Thus, current accumulates in the rails as they span multiple modules but the voltage is envisioned to remain substantially constant.

[0273] Figures 70 and 71 embody details of one form of mechanical joining which simultaneously accomplishes electrical communication between terminal bars 414, 426 and rails 432, 430. The Figures 70 and 71 show that the modules are quickly and easily secured to the angled rails using mechanical fasteners such as the metal bolts 446 shown extending through the oppositely disposed module terminal bars, the module support and the metal angle rails. Other conductive mechanical fasteners may be employed such as rivets and expansion bolts (toggle bolts for example) and metal anchors. Also, other hardware and materials (not shown) such as washers and conductive compounds known in the art may be considered to improve surface contact between the bolts 446, terminal bars 414, 426 and rails 432,430. One appreciates that materials used for the fasteners should be non-corrosive such as stainless steel in order to assure longevity of contact. It is noteworthy that no wires or metal ribbons are required to achieve this simultaneous mechanical and electrical joining. Thus there is no need for electrical leads such as unwieldy wires or ribbons emanating from the module. Further there is no need for processes such as soldering to achieve the mechanical and electrical mounting. The bolts shown in the Figures 69 through 72 embodiments are very robust, quick and simple to install and provide a low resistance connection resistant to breakage and environmental deterioration. In Figure 69, multiple bolts 446 at each module end (3 shown) minimize contact resistance between the module terminal bars 414, 426 and the angle rail material 432,430 and provide redundancy of contact. In this way the power generated in the expansive module is transferred to the supporting rails 432, 430. Thus module mounting and electrical connection to the rail "power conduit" is achieved easily and quickly without any separate wiring requirement. In addition, the mechanical mounting and electrical connection envisioned allows facile removal and replacement of a module should it become defective or future technology produces largely improved performance justifying such replacement.

[0274] Figure 72 embodies a structure similar to Figure 71 but including an optional additional component 450. Component 450 comprises a sheetlike transparent cover for the module and may comprise glass or a transparent polymer such as polycarbonate, acrylic, or PET. The purpose on the transparent sheet is to afford additional environmental protection to the thin film photovoltaic cells. For example, certain thin film semiconductors such as CIGS are susceptible to environmental deterioration and can be protected by such a transparent environmental cover. It is envisioned that protective cover sheet 450 may be installed after installation of the photovoltaic module by simply laying it over the top of the module. Alternatively, the cover 450 may be applied at the factory prior to shipment and site installation. It is further envisioned that a sealing member, such as depicted by numeral 452 in Figure 72, may be employed to fix the transparent sheet in position and provide edge sealing. It may be advantageous for such a sealing member 452 to be semi-permanent, such as would be the case for a conformable weather stripping material. In this way the module may be easily removed and repaired or replaced as necessary. One also will appreciate that a sealing member 452 may be appropriate even in the absence of sheet 450 in order to protect contact surfaces from environmental deterioration and provide edge protection to the module.

[0275] As shown in Figure 69, multiple sheetlike modules 410 are attached to the rails repetitively in a linear direction along the rails. Each of the modules produces substantially the same voltage, but the current increases each time the rails span an additional module. In this way the installation is a simple placement of the expansive surface modules relative the supporting rails and the mechanical fastening of the modules to the rails (using conductive, mechanical joining means such as nuts and bolts) allows current to flow from the individual module to the supporting rails, with the rails also serving as a conductive buss or power conduit of high current carrying capacity. The elongate rails lead to a collection point where the accumulated power is collected and optionally transferred to a larger master buss for additional transport or the power is converted from "high current/low voltage" to "high voltage/ low current" power to achieve more efficient transport.

[0276] (274) Referring now to Figure 73, another embodiment of an installation structure according the invention is shown in top plan view. This structural embodiment also comprises rails 43Oa₁ 432a. In the Figure 73 embodiment, rails 430a, 432a need not be electrically conductive as will be understood in light of the teachings to follow. Additional cross rails 460 span the separation between rails 430a, 432a. These cross rails 460 have an elongate structure as shown and in an embodiment may be electrically conductive. The repetitive distance between the elongate cross rails 460 is slightly greater than the length (Lm) of a module (for example 96.125 inch for a module of eight foot length). Cross rails 460 also comprise holes 436a which, as will be seen, are positioned to mate with complimentary holes extending through the terminal bars of modules to be eventually positioned on the Figure 73 structure. Finally, the rails are characterized as having a width dimension (Wm) slightly larger than the width of the eventual module. Thus the rails 430a, 432a, 460 form a convenient receptacle or frame within which a module may eventually be positioned.

[0277] Figure 74 is a perspective view of a portion of the Figure 73 structure. In

Figure 74 it is seen that the rail structure 430a, 432a, 460 may be supported on piers 440a above a base level as previously illustrated for the Figure 68 embodiment.

[0278] Figure 75 is a view in partial section taken substantially from the perspective of lines 75-75 of Figure 73, but following installation of modules 410. In this Figure 75 embodiment, elongate cross rail 460 comprises electrically conductive material, normally a metal. Two modules are generally indicated in Figure 75 by the numerals 410a, 410b and the individual series connected cells by the numerals 401a, 402a, etc. Figure 75 shows that cross rail 460 has the shape of an inverted "tee" having holes 436a on arms 449 and 462 of the "tee". The terminal bar 414a of module 410b is fastened to a first arm 449 of the "tee" form of cross rail 460 using conducting metal threaded bolts 446a and nuts 448a. The head 447a of bolt 446a contacts a top conductive surface of terminal bar 414a. Additional washers and conductive compounds may be used as appropriate to improve surface contact between fastener features and conductive surfaces. Application of the nut 448a securely fastens module 410b to the arm 449 and supplies electrical communication between terminal bar 414a and arm 449. A similar fastening arrangement secures and electrically connects the terminal bar 426a of module 410a to the second arm 462 of cross rail 460 using another bolt 446a. Since in this embodiment the cross rail 460 is conductive, electrical communication is established between terminal bar 414a of module 410b and opposite polarity terminal bar 426a of module 410a. The two modules are thereby simply, inexpensively and robustly connected in series.

[0279] Figure 76 shows an arrangement partially in section similar to Figure 75 but illustrating a different form of fastening and connection. In the Figure 76 embodiment, cross rail 460a is seen to be of cross section similar to that of cross rail 460 in Figure 75. However, in the Figure 76 embodiment, elongate cross rail 460a need not necessarily comprise conductive material. In Figure 76, first terminal bar 414b of module 41Od is secured to a first arm 449a of cross rail 460a using one end of a "U-bolt" type connector. In the embodiment, secure attachment of module 410d to rail 460a is achieved by threading of nut 448b such that it pulls flange 466 tightly against the bottom of arm 449a as shown. A similar attachment is made to terminal bar 426b of module 410c. Contact of the respective nuts 448b with the upper conductive surfaces of terminal bars 414b and 426b of modules 41Od and 410c respectively connect the two modules in series through the rigid conductive "U-bolt" fastener. Module mounting is rapid, inexpensive and simple.

[0280] Figure 77 shows another embodiment of a series connection among adjacent modules. In Figure 77 the "tee" shaped rails 460 or 460a of Figures 75 and 76 respectively are replaced by a simple flat rail in the form of a strap 460b. Modules 410e and 410f may have a slight separation between them as shown at 455 but are in close enough proximity to be described as adjacent. Electrically conductive rail 460b in the form of a conductive metal strap is positioned over the top of terminal bars 414c and 426c on the adjacent modules 410f and 41Oe respectively. Strap 460b has through holes positioned to mate with the through holes on terminal bars 426c and 414c of modules 41Oe and 410f respectively. Electrically conductive fasteners, in the Figure 77 embodiment "carriage" type threaded bolts 446b, then secure the strap rail to both terminal bars and thereby a secure and robust electrical connection between terminal bars 426c and 414c is achieved. Simultaneously, the two modules 41Oe and 41Of are affixed in adjacent positioning.

[0281] It is understood that the embodiments shown in figures 75 and 76 and 77 may be further augmented with protective transparent sheets such as that indicated by numeral 450 of Figure 72. [0282] Figure 78 is a top plan view of another structural embodiment of the inventive installations of the instant invention. Figure 79 is a sectional view taken substantially from the perspective of lines 79-79 of Figure 78. Reference to Figures 78 and 79 shows a structure comprising a pair of elongated rails 430b and 432b spanned by a rigid supporting sheet 468. Supporting sheet 468 may be chosen from any number of materials and forms, including honeycomb or expanded mesh forms. Sheet 468 may also be a composite structure of multiple materials and forms. The combination of rails 430b, 432b, and sheet 468 is seen to form an extended channel, which as will be seen has a width slightly larger than the width of the eventual applied module.

[0283] Continued reference to Figure 78 suggests that the structure is receptive to a single module having a relatively long length (Lm). Indeed, such a structure is intended to receive and support a module of extended length. While prior art modules have restricted surface dimensions due to fabrication limitations and materials of manufacture, the teachings and disclosures hereinbefore presented introduce materials and forms capable of practical production of modules having extended dimensions, particularly in the length direction. Technology is there taught to produce modules having a length limited only by the ability to properly accumulate them in a roll form. Modules having length in feet of two to three figures (i.e. 10 ft., 50 ft. 100 ft. 1000 ft.) are entirely reasonable using the teachings presented above. Modules having such extended length may be considered "continuous" and transported and installed in roll form. Thus, the dimension (Lm) in Figure 78 may be considered to be of such extended dimension. Width "Wm" in Figure 78 may correspond to a module width dimension which may be manageable from a handling and installation standpoint. By way of example, "Wm" may be less than 10 ft. (i.e. 4 ft., 8 ft.) but widths "Wm" greater than 10 ft. are certainly possible.

[0284] Figure 80 is a sectional view similar to Figure 79 following application of an extended length (continuous) form of photovoltaic module 41Og. It is envisioned that such a module would be conveyed to the installation site and simply rolled out following the outline of the channel frame formed by rails 430b, 432b and support 468 which is clearly shown in Figure 79. An appropriate structural adhesive (not shown in Figure 80) may be used to fix the module 41Og securely to sheet 468.

[0285] Figure 81 is a view similar to Figure 80 but after application of an optional transparent cover sheet 450a and sealing material 452a. As has previously been explained, sheet 450a and sealing material 452a may be useful in extending the life of certain environmentally sensitive photovoltaic materials. [0286] In the supporting structure embodiments shown herein, some embodiments depict "rail" members in the form of material having angled cross sections. While one will realize that such a cross section is not necessary to accomplish the structural and connectivity aspects of the invention, such a geometry forms a convenient recessed pocket or frame to readily receive the sheetlike forms being combined with the structures. In addition, the vertical wall portion of the angled rail structure offers a containment or attachment structure for appropriate edge protecting sealing materials.

CONCEPTUAL EXAMPLES [0287] Example 1

[0288] Modules of multiple interconnected cells comprising thin film CIGS supported by a metal foil are produced. Individual multi-cell modules are constructed according to the teachings associated with Figures 59 and 60 above. As noted, other methods of module construction may be chosen. Each individual cell has linear dimension of width 1.97 inches and length 48 inches (4 ft.). 48 of these cells are combined in series extending approximately 94.5 inches in the module length direction perpendicular to the 48 inch length of the cells. Such a modular assembly of cells is expected to produce electrical components of approximately 24 open circuit volts and 15 short circuit amperes. A terminal bar is included to contact the bottom electrode of the cell at one end of the 8 ft. module length. A second terminal bar is included to contact the top electrode of the cell at the opposite end of the 8 ft. length. The terminal bars are readily included according to the teachings above. The terminal bars need not be of extraordinary current carrying capacity because their function is only to convey current a relatively short distance and to serve as a convenient structure to interconnect to adjacent mating conductive structure. The individual modules may be adhered to an appropriate support structure as taught above.

[0289] In a separate operation, a terrestrial site is cleared and graded to form a landscape characterized by a combination of repetitive elongate hills adjoining elongate furrows. The linear direction of the elongate hills and furrows and the inclination angle from the base of a furrow to the peak of an adjoining hill is adjusted according to the latitude of the site, as those skillful in the art will appreciate. Mounting piers are situated to emanate from the ground at the top of the hills and base of the furrows. The mounting piers are positioned repetitively along the length of the hills and furrows. As an example, the piers may be positioned repetitively separated by about 4 to 8 feet, although this separation will be dictated somewhat by the strength of the eventual supporting structure spanning the distance between piers. Finally, a supporting structure, including the elongate rails such as the angled rails as described above, are attached to the piers extending along the length of the hills and furrows. The supporting structure need not be excessively robust, since the modules are relatively light. Should rail strength or current carrying capacity be of concern, other structural forms for the rails, such as box beam structures or increased cross sections, may be employed. Indeed, increased rail cross section may become appropriate as rail length increases.

[0290] Installation proceeds by repetitive placement and securing multiple module sheets along the length of the rails. The thin film modules are relatively light weight, even at expansive surface areas. For example, it is estimated that using construction as depicted in Figures 63 through 65, the 4 ft. X 8 ft. module of this example 1 would weigh less than 100 pounds. Thus easy and rapid mounting may be achieved by a 2 man team.

[0291] Should the mounting of the modules be in a parallel arrangement such as depicted in Figures 66 through 72, the elongate rails are constructed of conductive material such as aluminum or copper. Expected current increases in increments with the placement of each individual module but the expected voltage stays substantially constant along the length of the rails. The expected voltage from the 4 ft. by 8 ft. conceptual module is a maximum of about 24 volts, not enough to pose an electrical shock hazard. In addition, the oppositely charged rails are separated by 8 ft. Thus the oppositely disposed rails need not be heavily insulated.

[0292] A typical length for the rails may be greater than 10 ft. (i.e. 50 ft., 100 ft.,

200 ft., 300 ft..) As the expected current increases at greater length, the cross sectional area of the supporting rails may also be increased to accommodate the increasing current without undue resistive power losses. The rails thus serve as the conduit to convey photogenerated power from the multiple modules in parallel connection to a defined location for further treatment.

[0293] Should the modules be arranged in series, as depicted in the embodiments of Figures 73 through 76, voltage will increase along the length of the mounting structure but the current will remain substantially constant. In the case of the example modules (4 ft. X 8 ft. with cell widths of 1.97 inches and length of 48 inches, the current will remain at about 15 amperes as the power is collected through the multiple modules mounted in series. However, open circuit voltage will increase by about 24 volts as the power traverses each 8 ft. length of module. For a 104 ft. accumulated length of modules, the open circuit voltage will have accumulated to about 312 volts. Thus, in this case precautions must be observed regarding electrical shock danger. [0294] Example 2

[0295] In this example, site preparation is generally similar to that of Example 1 and structures are constructed according to the embodiment of Figure 79. Modules are manufactured and shipped to the installation site in the form of rolls of extended length. For example, a continuous roll of CIGS cells interconnected in series to form a single module is produced. Individual cells have a width dimension of 1.97 inches and length of 48 inches. The module is 100 ft. in length and has terminal bars at each end of the 100 ft. length. There are 608 series connected cells and the terminal bars are about 1 inch wide and extend across substantially the entire 48 inch width of the module. The modules are accumulated in rolls each of which comprises a 100 ft. module as described.

[0296] The rolls are shipped to the installation site. There, workers position one end at the start of an extended channel such as depicted in Figure 79. Such a 100 ft. roll of thin film module on a .001 inch metal foil substrate is estimated to weigh less than 40 pounds so that the installation could proceed with as little as a two man crew. Electrical connections to a buss bar mounted on the channel's end may be made using the electrically conductive fasteners and techniques such as hereinbefore discussed in reference to Figures 69 - 72, and 75 - 76. The module is unrolled using the channel as a guide, optionally using a structural adhesive to fix the module to the substrate. Finally, electrical connections to a buss bar at the opposite end of the structure may be made using the electrical and structural fasteners as herein taught.

[0297] The extended length module has a total active surface area of 400 square feet. It would be expected to generate approximately 3600 peak watts. Output current would be only about 15 amperes so that conductors need not be overly robust. Closed circuit voltage would be about 310 volts so that safety precautions and security concerns would have to be addressed.

[0298] In a comparison of the conceptual examples, the parallel mounting arrangement presented in Figures 66 through 72 has the advantage of low shock hazard, easy installation and replacement. However, this arrangement requires attention to conductor cross sections to minimize resistive losses from high currents. The series arrangement presented in Figures 73 through 76 has the advantage of low currents and therefore low costs of conductors. This arrangement also is characterized by relatively facile installation and replacement. However, this arrangement is characterized by high voltage accumulation and resulting shock potential. Finally, the extended length module arrangement of Figures 78 through 81 is likely the simplest installation requiring a minimum of interconnections and facile module shipping and placement. However, this arrangement produces high voltage buildup and inability to easily replace defective cells or portions of modules.

[0299] Finally it should be clear that while the mounting structures illustrate in the embodiments accomplish supporting modules above a base surface such as the ground (earth), the installation principles taught herein are equally applicable should one use a roof or other surface to support the module.

[0300] An additional embodiment of the instant invention is presented in Figure

82. In the Figure 82 arrangement one of the mounting rails 430 is mounted on a pivoting support 480. The opposite rail 432 is also mounted to a pivoting support 482. Pivoting support 482 is further mounted to a jacking device 484 as shown. The jacking device 484 may comprise any number of means, such as motorized jack screw or even a hydraulic cylinder. The jacking device 484 provides adjustable extension of arm 486 which accomplishes rotation of the mounted module along an arc generally indicated by double ended arrow 488.

Thus, the multiple modules mounted on rails may be conveniently tilted appropriately according to positional latitude or season. Since the modules are relatively large yet lightweight this tilting mechanism may be accomplished with a minimum of complexity.

[0301] Although the present invention has been described in conjunction with preferred embodiments, it is to be understood that modifications, alternatives and equivalents may be included without departing from the spirit and scope of the inventions, as those skilled in the art will readily understand. Such modifications, alternatives and equivalents are considered to be within the purview and scope of the invention and appended claims.

Claims

WHAT IS CLAIMED IS:

1. An interconnecting structure to achieve series interconnections among multiple photovoltaic cells, said interconnecting structure comprising a first pattern of electrically conductive material extending over a first surface of an insulating sheetlike form, and a second pattern of electrically conductive material extending over a second surface of said sheetlike form, said first surface comprising a sealing material having adhesive affinity for an electrically conductive top light incident surface of a first photovoltaic cell, said second surface comprising a material having adhesive affinity for a conductive bottom surface of a second photovoltaic cell, said first and second patterns comprising a monolithic conductive material extending through holes in said form from said first pattern to said second pattern.

2. In combination, photovoltaic cell structure and an interconnecting structure, said combination characterized as having,

- a first unit of photovoltaic cell structure, said unit comprising a top light incident cell surface and an electrically conductive bottom cell surface,

- an interconnecting structure comprising a first pattern of electrically conductive material extending over a first surface of an insulating sheetlike form, said first surface comprising a sealing material having adhesive affinity for said top light incident surface,

- said interconnecting structure further comprising and a second pattern of electrically conductive material extending over a second surface of said insulating sheetlike form, said second surface comprising a sealing material having adhesive affinity for a said bottom cell surface,

- said first and second patterns comprising a monolithic conductive material extending through holes in said form from said first pattern to said second pattern,

- said combination being characterized as having a portion of said first surface being adhesively bonded to the top surface of said first unit of photovoltaic cell structure.

3. The combination of claim 2 further comprising a second unit of photovoltaic cell structure, and having a portion of said second surface of said insulting sheetlike form adhesively bonded to a said bottom surface of said second unit.

4. A unit of tabbed photovoltaic cell stock, said unit comprising, a. a first photovoltaic cell having a width dimension and a length dimension, said width dimension defining first and second terminal edges of said cell, said cell having a top light incident surface and a bottom surface, b. a first interconnecting electrode having a first pattern of electrically conductive material extending over a surface of an insulating substrate, and said top surface said cell positioned relative to said first pattern such that said first pattern is brought into contact with said top surface and said first pattern of electrically conductive material further extends outside a first terminal edge of said cell to form a top surface tab, c. a second interconnecting electrode having a second pattern of electrically conductive material extending over a surface of an insulating substrate, and said bottom surface of said cell being positioned relative to said second pattern such that said pattern is brought into contact with said bottom surface and said electrically conductive material further extends outside a second terminal edge of said cell to form a bottom surface tab.

5. A process for production of an interconnected array of photovoltaic cells, said process comprising the steps of. a. Providing a feed source of tabbed cell stock having a length and a width substantially perpendicular to said length, b. positioning a first predetermined length of said tabbed cell stock, c. shuttling the first length a predetermined distance in the width direction, d. combining a second predetermined length of tabbed cell stock with said first length by positioning said second length relative to said first length such that electrical communication may be established between the top tab portion of one tabbed cell and the bottom electrode of an adjacent tabbed cell, e. shuttling the combination resulting from step "d" said predetermined distance in the width direction, f. repeating steps "d" and "e" to produce a continuous repetitive positioning of arranged cells in the width direction,

6. The process of claim 5 further comprising the step of exposing the arrangement resulting from step "f of claim 5 to heat and pressure.

7. The process of claim 6 wherein said heat and pressure are part of a laminating process.

8. The process of claim 7 wherein said laminating process is a roll laminating process.

9. A photovoltaic energy installation, said installation comprising a structure positioned and adapted to mate with a first photovoltaic module,

- said photovoltaic module comprising multiple interconnected photovoltaic cells and further comprising terminal bars having opposite polarity,

- said structure comprising one or more rails, a first of said rails comprising an elongate form of electrically conducting metal,

- said installation characterized as having a first electrical connection between a first of said terminal bars and said first of said rails and,

- said first connection being achieved absent the use of flexible metallic leads extending from a surface of said module.