Novel Interconnection Process for Lightweight Flexible Photovoltaic Modules

In traditional monolithic interconnection processes for the manufacture of solar cells, one or more of the interconnection steps is performed before the deposition of the thin-film semiconductor material. In this project, the manufacturing process will be improved by performing all series interconnection steps after the thin film solar cell is fabricated. The process uses ink-jet and laser processing for the interconnection, and when fully developed, will be substantially automated. Phase I involved the further development of a patent-pending concept for the series interconnection of thin film solar cells that have been pre-fabricated on plastic or other insulating substrates. In Phase II, the process will be designed for compatibility with low-cost, continuous, roll-to-roll photovoltaic manufacturing processes. Commercial Applications and Other Benefits as described by the awardee: The new process would allow solar cell interconnections at a single station near the end of the production line. The technology also would allow manufacturers to ship solar cells to a different location for interconnection and module assembly, if required.