Structured connectors for interconnecting device components

Abstract

The present disclosure provides a structured connector for positioning on a surface of a device component and electrically coupling to the surface of the device component. The connector has a bottom portion for contacting the surface of the device component and includes a conductive material. In addition, the connector has at least one light-diverting surface portion, the at least one light-diverting surface portion being oriented relative to the surface of the device component so that, in use, light irradiated at a direction of normal incidence relative to the surface of the device component is received by the at least one light-diverting surface portion so that the received light is diverted toward an exposed adjacent surface of the device component. In addition, the connector has at least one light-scattering surface portion, the at least one light-scattering surface portion being oriented relative to the surface of the device component so that, in use, light irradiated at a direction of normal incidence relative to the surface of the device component is received by the at least one light-scattering surface portion so that the received light is scattered in a direction away from the device component.

Description

Technical Field

[0001] The present invention relates to a structured connector for interconnecting device components, and particularly, but not exclusively, to a structured conductor for connecting or interconnecting device components within a device structure. Background Art

[0002] Photovoltaic (solar) modules typically include multiple photovoltaic (solar) cells interconnected by means of conductive interconnectors that enable the collection and conduction of electrical current generated by the respective solar cells due to the absorption of solar energy. Each solar cell typically has electrical contacts or metal electrodes comprising an array of metal fingers and a plurality of busbars oriented perpendicular to the metal fingers. One or more flat interconnect ribbons having a rectangular cross-section are then used to electrically connect adjacent cells in a series-connected string of solar cells by bonding them to the front surface busbar of one cell and the rear busbar of an adjacent solar cell.

[0003] In a variation of this interconnection method, the metal electrodes of the solar cells may include only metal fingers or may include an array of metal fingers and isolated metal tabs. In this case, a round metal wire coated with an adhesive material is used to achieve interconnection between adjacent solar cells. The bonding between the wire and the solar cell electrode can be achieved by applying local heating (e.g., welding) at locations that coincide with the metal tabs of the solar cell electrode or during lamination. Examples of these interconnection methods include Schmidt's MultiBB and Meyer Burger's SmartWire Interconnection Scheme.

[0004] Using these solar cell interconnection methods, incident light impinging on the solar cell's metal electrodes and interconnects can be reflected off the solar cell and out of the module, reducing the current that can be generated by the module. One solution to this shading problem of the metal electrodes and interconnects is to place both polarities of electrical contacts on the back surface of the solar cell so that shading does not limit the electrical performance of the individual solar cells in the module. However, modules that include back-contact solar cells require photovoltaic materials with long electrical carrier lifetimes and require more complex manufacturing processes. These two factors make back-contact photovoltaic modules more expensive to manufacture.

[0005] In the aforementioned existing solar cell interconnection methods for solar cells having electrodes on both surfaces, the interconnector is a flat ribbon with a rectangular cross-section or a wire with a circular cross-section. The cross-sectional shape of the interconnector can present several disadvantages, particularly in terms of reflection losses of incident light that would otherwise be collected by the solar cell (resulting in reduced current), resistance losses (which can result in reduced power), and increased thermomechanical stress in the underlying photovoltaic material (which can reduce module durability).

[0006] Improvements are needed in the area of ​​solar cell interconnects. Summary of the Invention

[0007] In a first aspect of the present invention, there is provided a structured connector for positioning on and electrically coupling to a surface of a device component, the structured connector having a bottom portion for contacting the surface of the device component, the structured connector being formed of a conductive material and comprising:

[0008] at least one light-diverting surface portion, the at least one light-diverting surface portion being oriented relative to a surface of the device component such that, in use, light impinging at a direction of normal incidence relative to the surface of the device component is received by the at least one light-diverting surface portion such that the received light is diverted towards an exposed adjacent surface of the device component, and

[0009] - at least one light scattering surface portion, which is oriented relative to the surface of the device component so that, in use, light irradiated at a direction of normal incidence relative to the surface of the device component is received by the at least one light scattering surface portion so that the received light is scattered in a direction away from the device component.

[0010] Throughout this specification, the term "structured" is used to denote a non-circular cross-sectional shape.

[0011] In use, when the structured connector is positioned on and electrically coupled to a surface of a device component, a cover sheet (such as a glass cover sheet or a polymer cover sheet) can be positioned over the device component and the structured connector so that at least a portion of light scattered away from the device component is reflected at the cover sheet back onto an adjacent exposed surface of the device component.

[0012] When the structured connector is positioned on a surface of a device component, the at least one light redirecting surface portion may be oriented at an acute internal angle relative to the surface of the device component.

[0013] Acute interior angles may range from 45 degrees to 90 degrees.

[0014] In one embodiment, when the structured connector is positioned on a surface of a device component, the at least one light scattering surface portion is oriented at an acute internal angle relative to the surface of the device component.

[0015] Acute interior angles may range from 0 degrees to 45 degrees.

[0016] In one embodiment, the at least one light redirecting surface portion comprises at least one flat light redirecting surface portion.

[0017] In one embodiment, the at least one light scattering surface portion comprises at least one flat light scattering surface portion.

[0018] In one embodiment, the at least one light turning surface portion is positioned at a respective side portion of the structural connector.

[0019] In one embodiment, the structured connector includes at least two light redirecting surface portions, each of the at least two light redirecting surface portions being oriented relative to a surface of the device component such that, in use, light irradiated at a direction of normal incidence relative to the surface of the device component is received by the light redirecting surface portion such that the received light is redirected toward an exposed adjacent surface of the device component.

[0020] The at least one light scattering surface portion may be positioned at a top portion of the structural connector.

[0021] The structured connector may include at least two light scattering surface portions, each of the at least two light scattering surface portions being oriented relative to a surface of the device component so that, in use, light irradiated in a direction of normal incidence relative to the surface of the device component is received by the light scattering surface portion so that the received light is scattered in a direction away from the device component.

[0022] In one embodiment, the at least two light scattering surface portions form at least one recess along the structural connector at a top portion of the structural connector, the at least one recess being positioned between opposing side portions of the structural connector.

[0023] The or each recess may be configured to form a v-shaped groove along the structured connector.

[0024] In one embodiment, the structured connector includes a plurality of light scattering surface portions that form a plurality of adjacent and parallel recesses at a top portion of the structured connector, the plurality of adjacent and parallel recesses being positioned between opposite side portions of the structured connector and configured to form adjacent v-grooves along the structured connector.

[0025] Each light redirecting surface portion may intersect a corresponding light scattering surface portion.

[0026] In one embodiment, the or each light redirecting surface portion defines a height hi of the structured connector in the range of 0.1 mm to about 0.5 mm.

[0027] The structural connector may include upper opposing side portions and lower opposing side portions.

[0028] Each of the upper opposing side portions may include a respective light turning surface portion and may intersect a respective one of the lower opposing side portions.

[0029] When the structural connector is positioned on a surface of an equipment component, the lower opposing side portions may be oriented substantially perpendicular to the surface of the equipment component.

[0030] In one embodiment, the lower opposing side portions and the upper opposing side portions define a height h2 of the structural connector, h2 being in the range of 0 mm to about 0.5 mm.

[0031] The lower opposing side portions may each include at least one recess that is substantially identical to the at least one recess formed by the at least two light scattering surface portions at the top portion of the structural connector.

[0032] The structural connector may have an axis and a shape in a cross-sectional plane perpendicular to the axis, the shape having three-fold rotational symmetry.

[0033] In one embodiment, the device component is a solar cell and the structural connector is a solar cell structural connector.

[0034] The structured connector may be formed from, or may include, a relatively highly conductive material, such as copper, aluminum, or another suitable material.

[0035] According to a second aspect of the present invention, there is provided a contact sheet for contacting a device component, the contact sheet comprising a polymer material sheet and a structured connector embedded therein with a surface portion of the structured connector being exposed, the structured connector provided according to the first aspect of the present invention.

[0036] The structured connector may comprise a coating arranged to form a bond with the conductive surface area of ​​the device component when activated (eg by heat treatment).

[0037] The contact sheet may be a first contact sheet for contacting electrical contacts on a first surface of the device component, and a second contact sheet may be provided for contacting electrical contacts on a second surface of the device component opposite the first surface.

[0038] According to a third aspect of the invention, there is provided a device structure comprising a device component having electrical contacts on a front surface and a rear surface and being sandwiched between a first contact sheet and a second contact sheet, each contact sheet comprising a polymer material and having one or more of the structured connectors according to the first aspect of the invention at least partially embedded therein, the device structure being arranged such that the structured connectors are electrically coupled to the electrical contacts of the device component.

[0039] According to a fourth aspect of the present invention, there is provided a device structure comprising at least two device components, the at least two device components having electrical contacts on a front surface and a rear surface and being sandwiched between a first contact sheet and a second contact sheet, each contact sheet comprising a polymer material and having one or more of the structured connectors according to the first aspect of the present invention at least partially embedded therein, the device structure being arranged such that the structured connectors are electrically coupled to the electrical contacts of the at least two device components and interconnect adjacent ones of the at least two device components.

[0040] In one embodiment, the device component is a solar cell and the device structure is a photovoltaic module. BRIEF DESCRIPTION OF THE DRAWINGS

[0041] Although any other forms may fall within the scope of the present disclosure as set forth in this summary, specific embodiments will now be described, by way of example only, with reference to the accompanying drawings, in which:

[0042] Figure 1 (a) is a schematic diagram illustrating a perspective view of a known structure of a solar cell;

[0043] Figure 1 (b) is a schematic diagram depicting a cross-sectional view of a known configuration for connecting adjacent solar cells in a photovoltaic module using existing solar cell connectors;

[0044] Figure 2 is a graph showing the potential gain in current as a function of light incident angle for connectors employing light scattering tape (LSR) and light redirecting tape (LDR);

[0045] Figure 3 (a)-(b) are schematic diagrams depicting cross-sectional views of a structured connector provided according to an embodiment of the present invention;

[0046] Figure 4 is shown with Figure 2 Compared with LSR and LDR, according to Figure 3 Embodiments of the present invention provide a graph of potential gain of current of a structured connector as a function of light incident angle;

[0047] Figure 5 (a) and Figure 5 (c) is a schematic diagram depicting a cross-sectional elevation view of a structured connector provided according to another embodiment of the present invention;

[0048] Figure 5 (b) and Figure 5 (d) is a description Figure 5 (a) and Figure 5 (c) Schematic diagram of the top view of the structured connector;

[0049] Figure 6 is a schematic diagram depicting a cross-sectional elevation view of a structured connector provided according to another embodiment of the present invention;

[0050] Figure 7 (a)-(c) are schematic diagrams depicting cross-sectional elevation views of various processes for connecting adjacent solar cells in a photovoltaic module according to embodiments of the present invention;

[0051] Figure 8 (a)-(d) are diagrams illustrating the process for applying the coating material to the Figure 3 Schematic diagram of various coating processes on structured connectors;

[0052] Figure 9 is a flow chart of a method of forming a device structure according to one aspect of the present invention;

[0053] Figure 10 It is depicted in perspective exploded diagram including the use of Figure 9 A schematic diagram of an element of a photovoltaic module formed according to an embodiment of the present invention;

[0054] Figure 11 is a flow chart of a method of forming a photovoltaic module according to an embodiment of the present invention;

[0055] Figure 12 is a flow chart of a method for embedding a structured connector into the polymer material of a contact sheet of a device structure according to an embodiment of the present invention;

[0056] Figure 13 (a)-(c) to Figure 15 (a)-(c) are schematic perspective and cross-sectional views of a known connector and an apparatus for embedding a corresponding connector in the polymer material of a contact sheet according to an embodiment of the present invention;

[0057] Figure 16 (a)-(c) are schematic perspective and cross-sectional views of a structured connector according to an embodiment of the present invention and an apparatus for embedding the structured connector in the polymer material of a contact sheet;

[0058] Figure 17 (a)-(c) are schematic diagrams illustrating an apparatus and method for embedding a structured connector in a polymer material of a contact sheet according to an embodiment of the present invention;

[0059] Figure 18 (a) is a schematic diagram depicting a cross-sectional elevation view of a known connector;

[0060] Figure 18 (b) is a schematic diagram depicting a cross-sectional elevation view of a structured connector provided according to another embodiment of the present invention;

[0061] Figure 19 (a)-(c) are based on Figure 18 (b) Schematic perspective and cross-sectional views of a structured connector and an apparatus according to an embodiment of the present invention for embedding the structured connector in the polymer material of a contact sheet;

[0062] Figure 20 (a)-(c) to Figure 21 (a)-(c) are schematic perspective views and cross-sectional views of a structured connector according to further embodiments of the present invention and of an apparatus for embedding a corresponding structured connector in the polymer material of a contact sheet;

[0063] Figure 22 (a)-(b) are schematic diagrams of cross-sectional elevation views of a structured connector provided according to another embodiment of the present invention; and

[0064] Figure 23 (a)-(c) are schematic diagrams depicting cross-sectional elevation views of a structured connector provided according to another embodiment of the present invention. DETAILED DESCRIPTION

[0065] Thus, embodiments of the present invention are generally directed to structured connectors, i.e., connectors having a non-circular cross-sectional shape, for positioning on and electrically coupling to a surface of a device component, such as a solar cell, whereby the structured connector also allows for connection of device components, such as solar cells, within a device structure, such as a photovoltaic module.

[0066] Additionally, embodiments of methods for forming a device structure will be described that allow for interconnection of device components within the device structure via structured connectors provided according to embodiments of the present invention.

[0067] In the following description, embodiments of the structural connector will be described particularly with respect to a solar cell structural connector for interconnecting solar cells within a photovoltaic module. Embodiments of the structural connector will also be described with respect to a method of forming a photovoltaic module.

[0068] However, it should be understood that the embodiments of the present invention are not limited to device components as solar cells and device structures as photovoltaic modules. Application to other device components and structures (such as optical device components and structures) or any electrical or electronic device components and structures is also considered to be within the scope of the present invention.

[0069] Furthermore, it should be understood that although embodiments of the present invention are described with reference to silicon solar cells and silicon photovoltaic modules, solar cells and modules comprising other photovoltaic materials are also considered to be within the scope of the present invention.

[0070] refer to Figures 1 to 11 , embodiments of structured connectors for interconnecting device components, such as solar cells, within a device structure, such as a photovoltaic module, will now be described.

[0071] Figure 1 (a) shows a known structure of a solar cell 100, and Figure 1 (b) shows a known configuration 110 for interconnecting adjacent solar cells of a photovoltaic module using existing solar cell connectors.

[0072] The solar cell 100 generally has a front surface 120 and a rear surface 130, each of which includes electrical contacts or metal fingers 140, 140'. A solar cell connector is a conductive element that is generally arranged to connect the electrical contacts 140 on the front surface 120 of one solar cell, such as the solar cell 100, to the electrical contacts 140' on the rear surface 130 of another adjacent solar cell 100'. The connection structure 110 shows the interconnection of adjacent solar cells 150, 150', 150" using solar cell connectors 155, 155'.

[0073] Existing solar cell connectors can have various cross-sectional shapes. For example, the most common designs of existing solar cell connectors include flat ribbons with rectangular cross-sections or wires with circular cross-sections.

[0074] In use, when the solar cell connectors are positioned on and electrically coupled to the respective surfaces of the solar cells, first the sealant sheet and then the cover sheet comprising a glass material and / or a polymer material may be positioned over the solar cells and connectors to form a photovoltaic module.

[0075] Flat ribbons with a rectangular cross-sectional shape have the following disadvantage: when the ribbon is positioned on and electrically coupled to the surface of a solar cell, with the bottom portion of the ribbon contacting the surface of the solar cell, light received by the top surface of the ribbon at a normal angle of incidence (relative to the surface of the solar cell) in use is typically reflected directly back into the cover sheet within the escape cone of the cover sheet, resulting in high optical losses and thus affecting the generation of current and the power enhancement of the photovoltaic module. However, such optical losses are balanced by a larger contact area, which can reduce the resistance of the current flowing from the solar cell into the connector. The low aspect ratio of the connector with a rectangular cross-sectional shape also serves to minimize stress in the silicon wafer of the solar cell. High stress can lead to the formation of microcracks in the silicon wafer, which reduces the durability and therefore the lifetime of the photovoltaic module. With the trend to reduce the thickness of silicon wafers to reduce material costs, it is becoming increasingly important to reduce the stress in the silicon wafer caused by the shape of the connector.

[0076] A connector having a circular cross-sectional shape allows, when positioned on and electrically coupled to the surface of a solar cell, a substantial portion of the normally incident light, during use, to be deflected or scattered back toward the surface of the solar cell, which reduces the effective optical width. However, a portion of the normally incident light is also directly reflected back toward the sealant sheet and / or the glass and / or polymer cover sheet within the defined escape cone of the glass and / or polymer cover sheet, resulting in optical losses. Furthermore, the contact area provided by such a circular or round connector on the electrical contacts of the solar cell is relatively small, which can lead to poor adhesion of the connector to the electrical contacts and result in high resistivity and high resistive losses.

[0077] The aforementioned limitations of connectors having corresponding rectangular and circular cross-sectional shapes can be addressed by using connectors that are specifically constructed to improve optical performance, allow sufficient contact area for low-resistance interconnection, and minimize the thermo-mechanical stresses generated in the module's silicon wafer.

[0078] The first design approach is to use a light scattering ribbon (LSR) connector, which has a scattering pattern on one surface of the connector, which has a substantially rectangular cross-sectional shape with a low aspect ratio. An example of an LSR connector is a series of relatively flat V-grooves aligned along the ribbon surface.

[0079] When positioned on and electrically coupled to the surface of a solar cell (the bottom portion of the LSR contacts the surface of the solar cell), the LSR allows light incident at normal incidence relative to the surface of the solar cell and received by the top surface portion of the LSR to be scattered toward the sealant sheet and / or glass and / or polymer cover sheet at angles beyond the escape cone, so that the light is then internally reflected back to the exposed surface of the solar cell.

[0080] Another approach is to use a light-diverting tape (LDR) structured connector. When positioned on the surface of a solar cell and electrically coupled to the surface of the solar cell (the bottom portion of the LDR contacts the surface of the solar cell), the LDR allows light incident at normal incidence relative to the surface of the solar cell and received by the side surface portion of the LDR in use to be diverted directly toward the exposed surface of the solar cell. An example of an LDR connector is a connector with a triangular cross-section, in which light can be diverted from each of two faces of the connector, while the third face is in electrical contact with the solar cell.

[0081] LSR and LDR are examples of structured connectors that typically allow all normally incident light to be redirected to the exposed surface of the solar cell, which is advantageous for evaluating and determining the power enhancement of photovoltaic modules under standard test conditions. However, in actual use, photovoltaic modules receive solar radiation from varying angles of incidence, and the performance of the solar cell connector under such varying angles of incidence often determines the power yield of the photovoltaic module.

[0082] refer to Figure 2 Graph 200 shows curves 210 and 220 of the potential gain of current as a function of the angle of incidence of light relative to the solar cell surface, obtained for an LSR and an LDR, respectively. It is observed that while the LSR and LDR provide similar gain from an angle of incidence of 0° (normal incidence relative to the solar cell surface) to approximately 30°, the potential gain of current decreases for both the LSR and LDR as the angle of incidence subsequently increases. Specifically, the current gain of the LSR begins to decrease from an angle of incidence of approximately 28°, at which light received at the surface of the V-groove at the top portion of the connector is reflected at an angle close to the escape cone of the glass and / or polymer cover sheet. The current gain of the LDR begins to decrease from an angle of incidence of approximately 49°, at which light received at the side surfaces of the triangular connector can be diverted in a direction parallel to the solar cell surface or returned toward the glass and / or polymer cover sheet at an angle close to the escape cone.

[0083] However, in addition to being relatively efficient in terms of current gain over a relatively wide range of angles of incidence (from 0° to approximately 49°), the LDR has a relatively small conductive cross-sectional area, which is approximately 50% smaller than the conductive cross-sectional area provided by a connector having a rectangular cross-sectional shape of the same width and height as the LDR, and approximately 50% smaller than the conductive cross-sectional area provided by a connector having a circular cross-sectional shape. Therefore, compared to other known structured connectors, the LDR may result in higher resistive losses and reduce electrical efficiency. The LDR may further require to be larger in order to reduce such resistive losses, however, this will result in a greater height and may cause higher stress in the sealant sheet and / or glass and / or polymer cover sheet during the lamination process (for packaging the solar cell and connector, and forming the photovoltaic module), and may also result in increased internal stress in the solar cell.

[0084] Embodiments of the present invention generally seek to provide a structured connector having a structure that allows for improved current gain of the connector as a function of the angle of incidence of light received at a surface of the connector relative to the surface of a corresponding device component, while improving the conductivity of the connector and reducing stresses that enter the device component and, in the case of a solar cell, into the sealant sheet and / or glass and / or polymer cover sheet due to the packaging process.

[0085] Figure 3 (a)-(b) show cross-sectional views of a structured connector 300 provided according to an embodiment of the present invention, which is used to be positioned on a surface of a device component such as a solar cell and electrically coupled to the surface. Figure 3 As shown in (a)-(b), it is positioned on and electrically coupled to the surface 310 of a device component 320. The structured connector 300 has a bottom portion 330 for contacting the surface 310 of the device component 320, is formed of a conductive material and includes:

[0086] i) at least one light redirecting surface portion, such as n light redirecting surface portion 340, oriented relative to surface 310 of device component 320 such that, in use, light impinging at a direction of normal incidence relative to surface 310 of device component 320 is received by the at least one light redirecting surface portion such that the received light is redirected towards an exposed adjacent surface 310′ of device component 320, and

[0087] ii) at least one light scattering surface portion, such as light scattering surface portion 375, which is oriented relative to the surface 310 of the device part 320 so that, in use, light incident at a direction of normal incidence relative to the surface 310 is received by the at least one light scattering surface portion so that the received light is scattered in a direction away from the device part 320.

[0088] Specifically, according to Figure 3 (a) and Figure 3 In the specific embodiment shown in (b), the structured connector 300 has a non-circular cross-sectional shape and, when positioned and electrically coupled to the surface 310 of the device component 320, has two flat light redirecting surface portions 340, 345 oriented relative to the surface 310 of the device component 320 such that, in use, light 385 incident at normal incidence relative to the surface 310 is received by the flat light redirecting surface portions 340, 345 and redirected directly toward the exposed adjacent surface 310' (redirected light 385"). The connector 300 also has two flat light redirecting surface portions 340, 345. Scattering surface portions 375, 375', the two flat light scattering surface portions being oriented relative to surface 310 of device component 320 such that, in use, light 385 incident at normal incidence relative to surface 310 is received by flat light scattering surface portions 375, 375' and scattered in a direction away from device component 320 (scattered light 385'). In one embodiment, device component 320 and structural connector 300 are covered by and / or encapsulated between glass and / or polymer cover sheets, such as Figure 3 (a) and Figure 3 (b) The cover sheet 305 is shown. In use, light 385 received by the light scattering surface portions 375, 375' is scattered away from the device component 320 towards the surface of the glass (and / or polymer) cover sheet 305, where the light 385 is internally reflected back to the adjacent surface 310' of the device component 320.

[0089] It should be understood that the term "flat" used throughout the specification should not be interpreted in a strict sense, and the light redirecting surface portion and the light scattering surface portion can be substantially flat, that is, flat to a certain extent to achieve the light scattering and light redirecting effects according to the embodiments of the present invention.

[0090] In a specific embodiment of the invention, the device component 320 is and will now be referred to as a solar cell, and the structured connector 300 is and will now be referred to indiscriminately as a 'structured solar cell connector', a 'structured connector' and / or a 'structured wire'.

[0091] like Figure 3As shown in FIG. 5( b ), each of the light redirecting surface portions 340, 345 is positioned at a respective one of the opposing side portions 350, 355 of the structural connector 300 and is oriented at an acute internal angle b1′ relative to the surface 310 of the solar cell 320 or a plane parallel to the surface 310 of the solar cell 320 when the structural connector 300 is positioned on the surface 310. The acute internal angle b1′ is typically in the range of 45 degrees to 90 degrees.

[0092] In addition, if Figure 3 As shown in FIG. 5( b ), each of the light scattering surface portions 375, 375′ is positioned at the top portion 360 of the structural connector 300 and is oriented at an acute internal angle b2 relative to the surface 310 of the solar cell 320 or a plane parallel to the surface of the solar cell when the structural connector 300 is positioned on the surface 310. The acute internal angle b2 is typically in the range of 0 to 45 degrees.

[0093] Although the values ​​of angles b1′ and b2 can be varied to achieve given steering and scattering properties, the inventors have found based on computer simulations that the optimal value of b1′ is 60° and the optimal value of b2 is 30° to achieve optimal scattering and steering properties and optimal current gain for the structured connector 300 .

[0094] The two light scattering surface portions 375 , 375 ′ form a recess 370 at the top portion 360 that extends along the structured connector 300 and is positioned between the opposing side portions 350 , 355 .

[0095] In this embodiment, the recess 370 is specifically configured such that the flat light scattering surface portions 375, 375' form a V-shaped groove extending along the structured connector 300 at the top portion 360, wherein the flat light scattering surface portions 375, 375' intersect at the bottom 380 of the recess 370. Figure 3 (a) and Figure 3 As shown in (b), the flat light redirecting surface portion 340 intersects with the flat light scattering surface portion 375, and the flat light redirecting surface portion 345 intersects with the flat light scattering surface portion 375'.

[0096] like Figure 3As shown in (a)-(b), structural connector 300 includes opposing side portions 350, 355 constituting upper opposing side portions, and opposing side portions 350', 355' constituting lower opposing side portions. When lower side portion 350' intersects upper side portion 350 and lower side portion 355' intersects upper side portion 355, the lower opposing side portions intersect with the corresponding upper side portions. Structural connector 300 is arranged such that, when positioned on surface 310 of solar cell 320, lower opposing side portions 350', 355' are oriented substantially perpendicular to surface 310 of solar cell 320.

[0097] Thus, structural connector 300 includes a base portion 390 having a rectangular (or substantially rectangular) cross-sectional shape formed by lower opposing side portions 350', 355' and bottom portion 330, and an upper portion 395 formed by upper opposing side portions 350, 355 and top portion 360. Upper portion 395 generally has a triangular (or substantially triangular) cross-sectional shape with the top vertex of the triangular shape being cut off by a v-shaped groove opening, thereby forming a recess 370 in top portion 360. In this embodiment, upper portion 395 defines a height h1 of the connector relative to the top surface of base portion 390, which is in the range of about 0.1 mm to about 0.5 mm. Base portion 390 defines a height h2' relative to surface 310 of solar cell 320, which is in the range of about 0 mm to 0.5 mm. In particular, heights h1 and h2' can be varied to achieve specific light scattering and light redirecting properties for structural connector 300. The height h1 of the upper portion 395 determines in particular the amount of light scattering and light redirection (due to (i) the obtuse external angle of the flat light redirecting surface portions 340, 345 relative to the surface 310 of the solar cell 320, and (ii) the acute internal angle of the flat light scattering surface portions 375, 375' relative to each other), and therefore has an impact on the optical performance of the connector 300.

[0098] In addition, the inventors have found that the optimal height h2' is approximately 0.2mm, while the optimal height h1 is approximately half the height of the LDR, which is typically approximately 0.4mm. The heights h1 and h2' of the base 390 and upper portion 395, respectively, define the total height h2 of the structural connector 300, which is in the range of 0.1mm to 0.8mm. This total height affects the stress applied to the solar cell 320 and the encapsulation glass (and / or polymer) cover sheet during the manufacturing process of the photovoltaic module. The cross-sectional area of ​​the structural connector 300 also affects the conductivity of the structural connector 300. Specifically, the structural connector 300 is configured to have a cross-sectional area similar to that of the LDR, but has a larger height than the LDR, which allows for reducing the stress applied to the solar cell 320 during the manufacturing process of the photovoltaic module.

[0099] Figure 4 A graph 400 is shown, which illustrates a curve 420 showing the potential gain in current achieved for the structured solar cell connector 300 as a function of the angle of incidence of light (relative to the surface of the solar cell), compared to known solar cell connectors LSR and LDR (current gain curves 440 and 460). It can be observed that at approximately normal incidence, the structured connector 300 behaves similarly to the LSR and LDR, and as the angle of incidence increases, the structured connector 300 allows for current gain values ​​to be achieved that are between the respective current gain values ​​achieved for the LSR and LDR. In particular, for angles of incidence between 60° and 90°, the structured connector 300 behaves similarly to the LDR. Thus, the structured connector 300 of the present invention allows for maintaining optical and electrical performance similar to that of the LDR, while the adjustable height of the structured connector 300 also enables reduced stress on the solar cell during the manufacture of the photovoltaic module. Thus, the structured connector 300 according to embodiments of the present invention allows for a balanced, optimized performance in terms of balancing power enhancement efficiency and stress applied to the solar cell and the encapsulant sheet and / or glass / polymer cover sheet.

[0100] Figure 5 (a)-(d) show cross-sectional elevation views of structured connectors provided according to further embodiments of the present invention.

[0101] Specifically, Figure 5 (a) shows a cross-sectional elevation view of a solar cell structural connector 500 for positioning on and electrically coupling to a surface of a solar cell (not shown), similar to structural connector 300, structural connector 500 having a bottom portion 510 for contacting the surface of the solar cell. Structural connector 500 is formed of a conductive material. Figure 5 (b) shows a corresponding top view of the structured connector 500 .

[0102] The structured connector 500 includes two light-diverting surface portions 520, 530 that can be planar and, when the structured connector 500 is positioned on the surface of a solar cell, each light-diverting surface portion is oriented at an acute internal angle b3' relative to the surface of the solar cell. The structured connector 500 also includes a plurality of light-scattering surface portions 575, 575', 576, 576', 577, 577' at a top portion 560 located between the light-diverting surface portions 520, 530. Each light-scattering surface portion 575, 575', 576, 576', 577, 577' can be planar and oriented at an acute internal angle b3' relative to the surface of the solar cell. The plurality of light-scattering surface portions 575, 575', 576, 576', 577, 577' form a plurality of adjacent and parallel recesses 570 at the top portion 560 of the structured connector 500 that extend along the structured connector 500. The plurality of light scattering surface portions are arranged such that adjacent and parallel recesses 570 form adjacent and parallel v-shaped grooves along the structured connector 500 at the top portion 560 .

[0103] Similar to structural connector 300, light redirecting surface portions 520, 530 can be oriented at an acute internal angle b3' relative to the surface of the solar cell in the range of 45 to 90 degrees. The light scattering surface portions of structural connector 500 have obtuse angles relative to each other, and when structural connector 500 is positioned on the surface of the solar cell, each of the light scattering surface portions has an acute internal angle b4 relative to the surface of the solar cell or a plane parallel to the surface of the solar cell in the range of 0 to 45 degrees.

[0104] Furthermore, the structured connector 500 has a base portion 580 having a rectangular cross-section formed by lower opposing side portions 540, 550 and a bottom portion 510, and an upper portion 590 formed by upper opposing side portions or light-diverting surface portions 520, 530 and a top portion 560. The base portion 580 has a height h4, and the upper portion 590 has a height h3.

[0105] Figure 5 (c) shows a cross-sectional elevation view of a solar cell structured connector 500' for positioning on and electrically coupling to a surface of a solar cell (not shown), and Figure 5 (d) shows a corresponding top view of the structured connector 500 .

[0106] The structural connector 500' has substantially the same features as those defining the structural connector 500, however, while adjacent and parallel recesses or v-grooves 570 are arranged parallel to one another and extend in a direction parallel to the longitudinal direction of the structural connector 500, in an alternative embodiment of the structural connector 500', adjacent v-grooves 570 extend parallel to one another and are respectively oriented at an angle b5 relative to a plane extending in the longitudinal direction of the structural connector 500' perpendicular to the surface of the solar cell when the structural connector 500' is positioned on the surface of the solar cell.

[0107] For both structured connectors 500, 500', the multiple recesses at the top portion and base portion of the structured connector allow for an increase in the cross-sectional area of ​​the connector compared to known LDRs and compared to structured connector 300, which allows for significantly enhanced conductivity of the structured connectors 500, 500' while maintaining relatively optimal optical performance compared to other existing solar cell connectors.

[0108] Figure 6 A structured solar cell connector 600 according to another embodiment of the present invention is shown.

[0109] In this embodiment, the structured connector 600 has a structure that exhibits some features substantially similar to those of the structured connector 300. The structured connector 600 has a non-circular cross-sectional shape and has light-scattering surface portions 680, 680', which may be flat, and defines a recess or v-groove 610 at the top portion of the structured connector 600 between the light-diverting surface portions 620, 630. The light-diverting surface portions 620, 630 define an upper side portion. However, compared to the structured connector 300, the lower side portions 640, 650 are trimmed to define recesses or v-grooves 660, 670 that are substantially identical to the v-groove 610. The structured connector 600 has an axis x oriented along the longitudinal direction of the structured connector 600, and the recesses 610, 660, 670 are arranged such that the cross-sectional shape of the structured connector 600 in a plane perpendicular to the axis x has three-fold rotational symmetry.

[0110] The structural connector 600 may alternatively initially have a triangular cross-sectional shape in a plane perpendicular to the axis x, wherein the corresponding cross-sectional shape is an equilateral triangle (having an angle b6 of 60° at each corner), and wherein three substantially identical v-shaped grooves or recesses 610, 660, and 670 are formed at three corners of the equilateral triangle such that the cross-sectional shape of the structural connector 600 in a plane perpendicular to the axis x has three-fold rotational symmetry.

[0111] Structured connector 600 has a height h5, and each of planar light scattering surface portions 680, 680' is oriented at an angle b7 relative to a plane parallel to the bottom of the corresponding v-groove. Height h5 and angle b7 can be varied to achieve specific light scattering and light redirecting properties.

[0112] The structured connector provided according to embodiments of the present invention generally comprises a material having a relatively high electrical conductivity and may comprise a metal element such as copper, silver, aluminum, or an alloy of metal elements. The structured connector may alternatively or concurrently comprise other highly conductive materials and may, for example, comprise a conductive polymer.

[0113] For the manufacture of photovoltaic modules, various methods of interconnecting solar cells within a photovoltaic module may be used.

[0114] For example, as is known in the art, a 'solar strap and string' approach can be used. In this example, the connector is positioned so that the connector is placed in contact with the electrical contacts on the front surface of the first solar cell, and the second solar cell is then positioned adjacent to the first solar cell, with the rear surface of the second solar cell placed on top of the connector so that the connector contacts the electrical contacts on the rear surface of the second solar cell. Thus, the connector connects the electrical contacts on the front surface of the first solar cell to the electrical contacts on the rear surface of the second solar cell. Figure 7 (a) shows an example of such a method 700 for interconnecting solar cells. Connectors 710 and 720 (each corresponding to a connector such as structured connector 300, 500, or 600) are positioned relative to adjacent solar cells 730, 730', and 730" in the manner described above, i.e., where connector 710 connects the electrical contacts on the front surface of solar cell 730 to the electrical contacts on the rear surface of adjacent solar cell 730', and connector 720 connects the electrical contacts on the front surface of solar cell 730' to the electrical contacts on the rear surface of adjacent solar cell 730".

[0115] refer to Figure 7 (b) and Figure 7 (c), Other alternative methods of connecting solar cells may include the following methods.

[0116] First go to Figure 7(b) The connector can be designed and manufactured to have two structured profiles along the connector, wherein each of the two profiles extends along half of the length of the connector. The length of the connector is determined to be suitable for connecting two solar cells 740, 740'. More specifically, the connector has (i) a first profile 750 according to one of the structures of connector 300, 500 or 600, the first profile 750 being positioned on the front surface of the solar cell 740, and (ii) a second profile 760 corresponding to a "flat ribbon", the second profile 760 being positioned on the rear surface of the solar cell 740', whereby the electrical contacts on the front surface of the solar cell 740 are connected to the electrical contacts on the rear surface of the adjacent solar cell 740'.

[0117] In another example, reference Figure 7 (c) Two sets of connectors can be used to achieve the connection of two solar cells 765, 765'. A first set of connectors is provided, wherein the connectors have a first profile 770 according to one of the structured connectors 300, 500, or 600, and wherein the first profile 770 is positioned on the front surface of the solar cell 765. A second set of connectors is provided, wherein the connectors have a second profile 780 corresponding to a flat ribbon having a rectangular cross-sectional shape, and wherein the second profile 780 is positioned on the rear surface of the solar cell 765'. Each of the first set of connectors and each of the second set of connectors has a length that is longer than the width of the solar cell where the connector is positioned, so that the corresponding connectors overlap between the two solar cells 765, 765' at the 'inter-cell region'. During the formation of the photovoltaic module, the corresponding first and second connectors can be connected together in the 'inter-cell region' so that the electrical contacts on the front surface of the solar cell 765 are connected to the electrical contacts on the rear surface of the adjacent solar cell 765', and the current generated by the solar cell can be conducted.

[0118] Solar cell connectors, such as structured connectors 300, 500, 600, may be coated with a coating material before contacting the electrical contacts of a solar cell in order to improve optical and soldering properties.

[0119] Figure 8 (a)-(d) illustrate various coating processes that can be used to coat at least a surface portion of a structured connector provided according to an embodiment of the present invention with a material such as a low melting point metal alloy (solder, conductive film or ECA tape) depending on the desired connection properties. Figure 8 In (a)-(d), a structural connector 800 is shown, however it should be understood that the coating can also be applied to the surface of the structural connectors 300, 500 and 600 and any structural connector provided according to other embodiments of the present invention in a similar manner to achieve the same effect.

[0120] In particular, the layout and thickness of the coating material can be varied. For example, Figure 8 As shown in FIG. 8( a ), the coating material 810 may be applied to all surfaces of the structured connector 800 at a thickness of t1 to achieve improved reflection and welding properties. Alternatively, the coating material 810 may be applied partially to selected surfaces, such as only the bottom portion 830 of the structured connector 800, at a thickness of t2. Figure 8 In yet another alternative embodiment, the coating material 810 may be applied to different surfaces of the structured connector 800 at different thicknesses. For example, Figure 8 As shown in (c), a layer 840 of coating material 810 having a thickness t4 may be applied to the bottom portion 830 of the structural connector 800, and a thinner layer 850 of coating material 810 having a thickness t3 may be applied to the top portion 860 of the structural connector 800. Figure 8 As shown in (d), another embodiment includes coating respective surfaces of the connector with layers of two or more different coating materials having desired thicknesses. For example, the top portion 860 is coated with a layer of a first given coating material 880 having a first given thickness t5, and the bottom portion 830 of the structured connector 800 is coated with a layer of a second given coating material 870 having a second given thickness t6.

[0121] According to another embodiment of the present invention and as will be referred to Figures 9 to 21 As further described, a structured connector (such as structured solar cell connector 300, 500, or 600) can be embedded in the polymer material of a contact sheet in a manner such that a surface portion of the structured connector is exposed before being connected to the electrical contacts of a solar cell for forming a photovoltaic module. In this embodiment, the structured connector can be embedded in the polymer material of the contact sheet before and / or after forming the polymer contact sheet. Figure 8 Various coating processes shown in (a)-(d) apply coating materials to the structured connector.

[0122] For example, the surface portion of the structured connector embedded in the polymer material can be coated to form a reflective surface, wherein the surface portion of the structured connector surrounded by the polymer material can be coated with a reflective coating such as Ag, Al, or Sn solder and highly reflective metal films, multilayer dielectric films, metal foils, or silver-coated reflective cloth. The reflective coating can be applied by air knife, rolling or calendaring, PVD (sputtering, PLD, ALD), CVD, electroplating, hot-dip galvanizing, spraying, and metal foil with an adhesive. The exposed surface portion of the structured connector when embedded in the polymer material of the contact sheet can then be coated with a low-melting-point solder, conductive film, or ECA tape, which can be bonded to other materials, such as metal fingers on a solar cell. The metal fingers or conductive areas on the front and back surfaces of the solar cell can alternatively or additionally be coated with a low-melting-point solder, conductive film, or ECA tape.

[0123] Similar to reflective coatings, low melting point solders can be applied by air knife, rolling or calendaring, electroplating, hot dip galvanizing, spraying, or via drag soldering (dragging a heated soldering iron tip with molten solder from a solder wire). Commercial ECA tapes or conductive films can be applied directly.

[0124] refer to Figure 9 , a flow chart of a method 900 for forming a device structure, such as a photovoltaic module, is shown. At step 910, method 900 includes providing at least one device component, such as a solar cell, having a front surface and a back surface, each of the front surface and the back surface including at least one conductive region. At step 930, method 900 includes providing at least one contact sheet comprising a polymer material and at least one structured conductive element embedded in the polymer material such that a surface portion of the at least one structured conductive element is exposed.

[0125] In embodiments of method 900 , the at least one structured conductive element generally corresponds to at least one structured connector, such as structured connector 300 , 500 , or 600 , or any other structured connector provided according to embodiments of the present invention.

[0126] At step 950 , method 900 includes applying an adhesive material to either or both of the exposed surface portion and at least one of the conductive regions of the front and back surfaces of the at least one device component or solar cell.

[0127] At step 970 , method 900 includes positioning the at least one contact sheet relative to the at least one device component or solar cell such that the bonding material is located between the at least one conductive region of the one or more device components or solar cells and the exposed surface portion of the at least one structured conductive element or connector.

[0128] At step 990 , method 900 includes activating the bonding material such that a bond and a conductive coupling are formed between the at least one conductive region and the exposed surface portion.

[0129] In a particular embodiment, activating the adhesive material comprises applying heat and pressure to the at least one contact sheet, such as laminating the at least one contact sheet in contact with the front sheet of the solar cells and photovoltaic module.

[0130] In the case of solar cell and photovoltaic module formation, activation of the adhesive material causes the at least one structured conductive element to be electrically coupled to the at least one electrically conductive region and enables conduction of electrical current generated by the at least one solar cell.

[0131] Now refer to Figure 10 and Figure 11 Specific embodiments of method 900 are described in more detail with respect to the formation of photovoltaic modules.

[0132] Figure 10 A schematic diagram depicting elements of a photovoltaic module 1000 formed according to an embodiment of method 900 is shown in a perspective exploded view. Two adjacent solar cells 1030, 1030' are provided, each of which has a front surface and a back surface coated with a surface dielectric layer that serves as an anti-reflective coating (ARC) layer. Conductive electrodes are present on each of the front and back surfaces of solar cells 1030 and 1030', the conductive electrodes comprising an array of linear conductive fingers 1032 and 1034, respectively.

[0133] The conductive electrodes on the solar cells 1030 and 1030' can be formed by screen printing a metal paste, such as silver, onto the surface dielectric layer of the solar cells 1030, 1030'. The solar cells are then typically "fired" by passing through a high-temperature belt furnace, where they are subjected to temperatures ranging from 700°C to 850°C for several seconds. This process allows the screen-printed metal electrodes, including the metal fingers 1032, 1034, to penetrate the dielectric layer and make intimate contact with the underlying solar cell.

[0134] Alternatively, conductive electrodes including fingers 1032, 1034 can be formed on solar cells 1030, 1030' by first using a laser to ablate a dielectric layer to form thin linear openings, and then depositing a metal stack onto the exposed areas of solar cells 1030, 1030', preferably comprising a nickel layer, a copper layer, and a capping layer of silver or tin. Deposition of the metal stack can be achieved by electroless plating, by using a light-induced current from the respective solar cells 1030, 1030', or by applying an external bias or current to the other surface of the cell to forward bias any semiconductor junction in the solar cell. The silver capping layer in embodiments of the present invention should have a thickness of at least 80 nm, and preferably greater than 100 nm, to provide adequate coating of the underlying copper.

[0135] When tin is used as the cover layer, the preferred layer thickness is greater than 1 μm, and more preferably greater than 2 μm. The cover layer can be applied using the electroplating process described above for nickel and copper. Alternatively, a thinner cover layer can be formed by immersion plating or displacement plating, in which the surface layer of copper is electrochemically replaced by a thin layer of the cover metal.

[0136] In such Figure 10 In the illustrated embodiment, the solar cells 1030, 1030' are bifacial solar cells 1030, 1030' to form a bifacial photovoltaic module 1000. Bifacial modules can offer numerous benefits due to their ability to convert light from both surfaces of the solar cell into electricity. For example, they offer advantages in highly reflective environments because light incident on the ground or background can be reflected into the module via its rear surface, resulting in energy conversion efficiency enhanced by the albedo factor, which can be as high as 30% for highly reflective surfaces.

[0137] However, it should be understood that embodiments of the present invention are not limited to bifacial solar cells and bifacial photovoltaic modules, and may also be applied to monofacial solar cells.

[0138] Furthermore, it should be understood that although the present embodiment is described with respect to a photovoltaic module including two solar cells, a photovoltaic module formed according to method 900 may include an array of adjacent individual solar cells.

[0139] Two contact sheets 1020 and 1040 are also provided to form a bifacial photovoltaic module, for which current is extracted from both surfaces of solar cells 1030 and 1030'. Each of the contact sheets 1020, 1040 comprises a polymer material and a plurality of structured conductive elements or connectors 1025, 1045. The structured connectors 1025, 1045 are embedded in the polymer material in such a way that a surface portion of each of the connectors 1025, 1045 is exposed.

[0140] It should be understood that the method 900 of forming a device structure may also be performed using known connectors, such as connectors (wires) having a circular cross-sectional shape or ribbons or LSRs and LDRs having a rectangular cross-sectional shape.

[0141] As previously mentioned, preferably, the structured connector comprises one or more metal elements. However, alternative materials (e.g., conductive polymers) may also be used. Connectors 1025 and connectors 1045 are equally spaced apart on the respective contact sheets 1020, 1040 to form a corresponding connector pattern on at least one surface of the respective contact sheets 1020, 1040.

[0142] Adhesive material is then applied to the exposed surface portions of structural connector 1025 and to the exposed surface portions of structural connector 1045. Alternatively, or concurrently, adhesive material may be applied to conductive fingers 1032 on the front and / or back surfaces of solar cell 1030 and / or to conductive fingers 1034 on the front and / or back surfaces of solar cell 1030′.

[0143] To form photovoltaic module 1000 according to method 900, solar cells 1030, 1030' are positioned between contact sheets 1020, 1040 such that contact sheet 1040 (hereinafter referred to as front contact sheet 1040) faces the front surfaces of solar cells 1030, 1030', and contact sheet 1020 (hereinafter referred to as rear contact sheet 1020) faces the rear surfaces of solar cells 1030, 1030'. More specifically, exposed surface portions of structural connectors 1045 face the front surfaces of solar cells 1030, 1030', and exposed surface portions of structural connectors 1025 face the rear surfaces of solar cells 1030, 1030'. In this embodiment, when solar cells 1030, 1030' are positioned between back contact sheet 1020 and front contact sheet 1040, structured connectors 1025, 1045 are oriented perpendicular to the linear conductive fingers 1032, 1034, respectively, of the adjacent solar cells. Depending on the different conductivities of the electron and hole collection layers of solar cells 1030, 1030', the spacing of linear conductive fingers 1032, 1034 can be different on the front and back surfaces of the solar cells. However, the spacing and thickness of linear fingers 1032 and 1034 on solar cells 1030, 1030' can be adjusted to limit power losses due to series resistance. This optimization process depends on the conductivity of the underlying solar cell contact layer, the resistivity of the material (e.g., metal) used for the conductive fingers 1032 and 1034, the cross-sectional area of ​​the fingers, and the distance that the collected current must travel in the fingers before being collected in the connectors 1025, 1045 of the contact sheets 1020, 1040. In this particular embodiment, the photovoltaic module 1000 is arranged so that the distance that the current must flow along the conductive fingers 1032, 1034 before being delivered to the corresponding structural connectors 1025, 1045 is equal to half the spacing between the structural connectors 1025, 1045.

[0144] Furthermore, the front contact sheet 1040 and the back contact sheet 1020 are positioned relative to the solar cells 1030, 1030' such that the applied adhesive material is located between the conductive fingers 1032 and the corresponding exposed surface portions of the structured connectors 1025, 1045, and between the conductive fingers 1034 and the corresponding exposed surface portions of the structured connectors 1025, 1045. The adhesive material is then activated by heating the polymer material of the contact sheets 1020, 1040 under applied pressure, thereby forming a bond between the pattern of connectors 1025, 1045 and the corresponding conductive fingers 1032, 1034 of the solar cells 1030, 1030'. According to an embodiment of the present invention, the bonding electrically couples each of the structured connectors 1025, 1045 to at least one of the conductive fingers 1032, 1034, respectively.

[0145] like Figure 10 As shown, front contact sheet 1040 also includes an interconnecting sheet 1028, which is also embedded in the polymer material in a manner such that at least a surface portion of interconnecting sheet 1028 is exposed. Each structured connector 1025 of the connector pattern is electrically coupled to interconnecting sheet 1028. Similarly, back contact sheet 1020 includes a similar interconnecting sheet 1048, which is also embedded in the polymer material in a manner such that at least a surface portion of interconnecting sheet 1048 is exposed. Each structured connector 1045 of the metal pattern is coupled to interconnecting sheet 1048. During the manufacture of photovoltaic module 1000, adhesive material is also applied to interconnecting sheet 1048 and / or interconnecting sheet 1028, and front contact sheet 1040 and back contact sheet 1020 are positioned relative to solar cells 1030, 1030' such that interconnecting sheets 1028, 1048 are preferably aligned relative to each other, and the applied adhesive material is located between interconnecting sheets 1028, 1048. When the bonding material is activated by heating the polymer material of the contact sheets 1020, 1040 and applying pressure, a bond is formed between the interconnecting sheets 1028, 1048, whereby the connector 1025 is connected to the connector 1045, and the conductive fingers 1032 of the rear surface of the solar cell 1030 are connected to the conductive fingers 1034 of the front surface of the solar cell 1030', so that the solar cells 1030, 1030' are connected in series and the current generated by the solar cells 1030, 1030' is allowed to be conducted between the solar cells 1030, 1030'.

[0146] Although the interconnecting elements 1028, 1048 are shown as continuous linear tabs, it should be understood that the interconnecting elements 1028, 1048 may alternatively comprise an array of tabs or elements.

[0147] In an alternative arrangement, the interconnecting sheets 1028 and 1048 are not embedded in the polymer sheets 1020 and 1040, but rather separate interconnecting sheets are precisely placed over the ends of the connectors 1025 of the sheet 1020 and, during the activation process, the interconnecting sheets bond to both the ends of the connectors 1025 of the polymer sheet 1020 and the beginnings of the connectors 1045 of the polymer sheet 1040.

[0148] In another alternative embodiment, the structural connector 1025 and the structural connector 1045 can be arranged so that when the contact sheets 1020, 1040 are positioned relative to adjacent solar cells 1030, 1030', the structural connectors 1025 and 1045 overlap. In this embodiment, an adhesive material is applied to at least a portion of the portion of the structural connector 1025 that faces the structural connector 1045 and / or to a portion of the portion of the structural connector 1045 that faces the structural connector 1025, such that when the adhesive material is activated, a bond is formed between the overlapping structural connectors 1025 and 1045.

[0149] exist Figure 10 In the example described in , cover sheets 1010 and 1050, which may comprise glass or a polymer material, are additionally positioned to cover contact sheets 1020 and 1040, respectively, and the entire photovoltaic module assembly is then laminated at a lamination temperature between 130° C. and 170° C., more preferably 150° C., for 8 to 15 minutes. The lamination pressure is between 400 mbar and 900 mbar, more preferably between 500 mbar and 700 mbar. During this lamination step, the adhesive material is activated, forming a bond between the connectors 1025 and 1045 and the respective conductive fingers 1032 and 1034 of the solar cells 1030 and 1030′. As the polymer material softens upon heating, the contact sheets 1020 and 1040 further encapsulate or encapsulate the solar cells 1030 and 1030′. The lamination step can be performed, for example, for about 10 minutes to encapsulate the solar cells 1030, 1030' and seal the photovoltaic module 1000 to prevent moisture from entering during field operation. Thus, the back contact sheet 1020 and the front contact sheet 1040 encapsulate the solar cells 1030, 1030' in the module 1000 and may be referred to hereinafter as the back encapsulating polymer contact sheet 1020 and the front encapsulating polymer contact sheet 1040.

[0150] The bonding material may comprise a metal alloy or conductive adhesive (ECA) paste or tape that melts at a temperature below the lamination temperature (ie, below 160°C). For example, the bonding material may comprise Sn, which has a melting point of 138°C. 58 Bi 42solder alloy, DowCorning PV-5802 silicone-based ECA, or Adhesive Research's EL-9032 ECA tape.

[0151] It should be understood that although the structured connectors 1025, 1045 have been described as being arranged in a pattern and aligned in a direction perpendicular to the direction of the conductive fingers 1032, 1034, respectively, any other configurations, arrangements, and orientations that further allow for electrically coupling the structured connectors and corresponding conductive fingers are contemplated.

[0152] Furthermore, it should be understood that while the solar cells 1030, 1030' have been described as including a plurality of conductive fingers 1032, 1034 on their respective front and back surfaces, the solar cells may alternatively be coated with a conductive oxide that is preferably substantially transparent and forms a low resistance electrical contact with the structured connectors 1025 and 1045 of the contact sheets 1020, 1040 during lamination.

[0153] refer to Figure 11 , shows a flow chart of a general manufacturing process 1100 for manufacturing a photovoltaic module assembly, such as photovoltaic module 1000, according to an embodiment of method 900. In a first step 1110, a backsheet, such as cover sheet 1110, is applied. The backsheet can be a lightweight, opaque composite material for monofacial modules. Alternatively, glass materials or transparent polymer materials can be used for bifacial modules. Preferably, 'solar glass' with integrated anti-reflection and light-scattering capabilities is used.

[0154] Then, at step 1120, an encapsulating polymer contact sheet such as contact sheet 1020 is positioned on the back sheet, the encapsulating polymer contact sheet comprising a polymer material and a polymer material as described in method 900 ( Figure 9 ) and the conductive connectors 1025 embedded therein and coated with bonding material. For example, the contact sheet can be extended from a roll onto the backing sheet and then cut to size once aligned on the backing sheet, or the contact sheet can simply be laid down as a pre-cut sheet. An optical alignment system is used to align the surface of the polymer contact sheet with the backing sheet using alignment marks provided on the surface of the layout assembly, with the exposed surface portion of the conductive metal pattern facing upward in preparation for bonding to the solar cells of the photovoltaic module.

[0155] At step 1130, solar cells (such as solar cells 1030, 1030') are arranged in a layout pattern on the encapsulating polymer contact sheet using "pick and place" automation. Preferably, the layout placement accuracy is 10 μm ± 3 μm, and more preferably 10 μm ± 1 μm, however, if higher process throughput is required, placement accuracy can be sacrificed for faster placement.

[0156] Once all solar cells have been laid out, a second encapsulating polymer contact sheet, such as contact sheet 1040, is positioned over the solar cells at step 1140. If electrical contact is required on both the front and back surfaces of the solar cells, such as for bifacial solar cells, the second encapsulating polymer contact sheet also includes conductive connectors embedded in a polymer material and coated with an adhesive material. A front sheet is then laid over the second contact sheet at step 1150. The front sheet can comprise glass or a substantially transparent, transparent polymer material.

[0157] The entire assembly is then moved to a laminator where it is laminated at step 1160. The lamination process can be customized based on the type of encapsulating polymer material used and the type of bonding material used to coat the conductive structural connectors of the contact sheet and / or the conductive areas (e.g., metal fingers) of the solar cell. For example, electroplated and printed metal alloys may require different bonding conditions, and the lamination process must therefore be adjusted to these requirements. Additionally, if an ECA is used, the lamination process may also need to be adapted to the ECA's bonding requirements.

[0158] After lamination, the frame and module electronics, typically housed within one or more junction boxes, are added to the photovoltaic module assembly at step 1170 to complete the fabrication of the photovoltaic module.

[0159] Thus, an embodiment of method 900 of forming a photovoltaic module can be simply performed by a photovoltaic module manufacturer by: (i) purchasing a pre-made polymer contact sheet (i.e., a contact sheet including at least one structured conductive element or connector embedded therein); and (ii) performing a photovoltaic module layout process according to method 900 using automated solar cell placement technology.

[0160] Furthermore, embodiments of method 900 for forming a photovoltaic module eliminate the need to perform wire handling processes as part of the final product manufacturing line, which further allows for simplification of the process for interconnecting solar cells in a photovoltaic module and further allows for simplification of the photovoltaic module manufacturing process.

[0161] While a process for forming a bifacial photovoltaic module has been described, it will be understood that the same process can be used to interconnect monofacial solar cells comprising a fully metallized rear surface, provided that the fully metallized rear surface of the solar cell can adequately bond to the bonding material on the polymer contact sheet. For example, if the rear surface of the solar cell comprises screen-printed and "fired" aluminum, that surface may need to include a bonding area comprising another metal, such as silver, or be pretreated before bonding can be achieved. Options for such pretreatment include zincating and using tin pad technology, such as that commercialized by Schmid. Another option, made possible by the pattern flexibility and high conductivity of the rear aluminum electrode, is to have different conductive patterns (e.g., fewer connectors) bonded to the front and rear surfaces of the solar cell. Because the rear aluminum electrode is very conductive and opaque, fewer, wider connectors can be used in the polymer contact sheet, with bonding achieved using an ECA.

[0162] It should also be clear from the above description that the interconnection process can also be applied to interdigitated back contact (IBC) cells. For example, it can be used to implement a cell interconnection method for IBC cells, which are metallized as described in Z. Li et al., "Electrical and optical analysis of polymer rear insulation layers for back contact cells" (published in Energy Procedia, 77, 744-751) and U. Romer et al., "Decoupling the metal layer of back contact solar cells - optical and electrical benefits" (published in Energy Procedia, 77, 744-751).

[0163] The structured connectors 1025, 1045 embedded in the polymer material of the contact sheets 1020, 1040 may have a polygonal cross-sectional shape, such as the cross-sectional shape of the connectors 300, 500 or 600, and may be specifically formed to have a non-circular cross-sectional shape that allows for the desired optical and current carrying properties to be achieved, which will be referred to in detail. Figure 18 (b) to Figure 23 Describe in more detail.

[0164] refer to Figures 12 to 17A method for embedding a connector in a polymer material to form a contact sheet will now be described. The connector can be provided in the form of a known connector, such as a connector having a rectangular, circular, or triangular cross-sectional shape, as well as in the form of a structured connector, such as structured connectors 300, 500, or 600 provided according to embodiments of the present invention.

[0165] exist Figure 12 An embedding method 1200 according to an embodiment of the present invention is shown in a flow chart of FIG. In step 1220, a connector or metal wire having a given cross-sectional shape is formed by extruding or drawing the wire through a series of dies having the desired size and shape and then annealing the obtained wire to soften it.

[0166] Portions of the surface of the connector or metal wire are preferably coated (at step 1240) to form a reflective surface that can improve light redirection in the photovoltaic module. Figure 8 (a)-(d) describe possible coating methods. Then optionally, a groove or a recessed portion that helps to embed the metal wire is formed in the polymer material, and the groove or recessed portion is aligned with the desired position of the connector. Then in step 1260, the connector is placed in the corresponding groove or recessed portion to form the contact sheet, thus embedding the connector in the polymer material and exposing the corresponding surface portion of the connector. Grooves can be formed by laser ablation or using a heated stamping press that locally melts the polymer and deforms the polymer. It should be understood that the contact sheet 1020, 1040 can be alternatively provided with a groove or recessed portion that has been formed in the polymer material, and the groove or recessed portion is arranged to receive the connector or structured wire.

[0167] Alternatively, the connectors may be placed on the polymer material and directly embedded by laminating the assembly of the connectors and polymer material at a temperature between 75° C. and 85° C., and more preferably at 80° C., for 5-15 minutes, and more preferably 10 minutes, at step 1260. Although the placement accuracy of the connectors may be limited by this method due to possible movement of the connectors between placement and lamination, this low-cost embedding method may be suitable when a small number of connectors are required and / or a lower alignment accuracy is required.

[0168] Improved control over the alignment and orientation of the connector in the polymer material can be achieved by placing and holding the connector in the thermally conductive embedding tool by vacuum suction. The connector is then embedded in the polymer material by applying localized heat. Figures 13 to 18 The process is described in more detail for different cross-sectional geometries of connectors.

[0169] Finally, the exposed surface portion of the embedded connector is coated with an adhesive material in preparation for photovoltaic module fabrication in step 1280. The adhesive material is preferably solder and is applied by localized heating, which also melts the polymer material near the connector and serves to cause the polymer to flow around the connector, whereby upon cooling, the connector is embedded in the polymer material and forms a contact sheet.

[0170] Figures 13 to 15 Depicted is a single connector insertion tool for a variety of known connector cross-sectional shapes or geometries. Figure 3 The embodiment described in Figure 16 (a)-(c) depict a single connector insertion tool for a structured connector having a cross-sectional shape or geometry according to a specific embodiment of the present invention. Figures 13 to 16 In each of the figures, Figure (a) shows a cross-section of the connector held in the embedding tool and aligned with the vacuum line; Figure (b) shows a 3D perspective view of the embedding tool holding the connector; and Figure (c) shows a cross-sectional view of the connector and the embedding tool in a plane perpendicular to the longitudinal direction of the connector and the embedding tool.

[0171] Specifically, in Figure 13 、 Figure 14 and Figure 15 , connectors 1320, 1440, and 1550 represent known connectors having triangular, circular, and rectangular cross-sectional shapes, respectively. The limitations of these cross-sectional geometries have been described previously.

[0172] Figure 16 (a)-(c) show a connector 1660 having a ridge-like cross-sectional shape, which is partially similar to Figure 3 The structure of the connector 300 shown. This ridge-like structure provides the above reference Figures 3 to 6 The light-redirecting and light-scattering surfaces, as described above, advantageously allow for reduced stress on the respective solar cells and further enable more efficient reflection of light onto the respective solar cells. Additionally, the greater height of the mountain-like structures described with reference to connectors 300 and 1660 (compared to LDRs) further allows for reduced stress on the polymer material, which can contribute to significantly improved overall performance of the photovoltaic module.

[0173] like Figures 13 to 16 As shown, the embedding tool has a groove or recessed portion that is arranged to maintain a flat bottom surface of the connector and ensure that the connector is aligned to have a top surface portion and side surface portions that are to be embedded in the polymer material and are designed for effective light capture in the photovoltaic module, correctly oriented relative to the polymer material.

[0174] Figure 17 (a)-(c) then illustrate a specific embodiment of method 900 in which a metallized polymer contact sheet (also referred to herein as 'sealant' or 'metallized sealant') is formed by embedding a piece of structured connector into a polymer material using embedding tool 1700 .

[0175] The embedding tool 1700 is adapted to receive and hold a connector 1720 having a ridge structure (similar to the connector 1660). The connector 1720 is placed in the embedding tool 1700 and held in place by vacuum suction so that the ridge surface structure is exposed. The embedding tool 1700 having the connector 1720 is then heat pressed onto the polymer material 1780, wherein the polymer material 1780 flows around the exposed surface structure of the structured connector 1720 and adheres thereto. The vacuum holding the connector 1720 in the embedding tool 1700 is then released, and the tool 1700 is separated from the connector 1720, as shown in FIG. Figure 17 (c) whereby, as the polymer material 1780 cools, the structured connector 1720 is embedded in the polymer material 1780, exposing the surface portion 1740 of the connector 1720 and forming a contact sheet.

[0176] Figure 18 (a) shows a cross-sectional front view of a known LDR connector 1800 having a triangular cross-sectional shape and embedded in a polymer material 1810 to form a contact sheet 1820 as described above. The arrows represent the forces applied to the opposite side portions 1825, 1825' of the connector 1800 when the connector 1800 is embedded in and partially surrounded by the polymer material 1810. The polymer material 1810 exerts pressure on the side portions 1825, 1825', causing the LDR connector 1800 to be "pushed" out of the polymer material 1810, which affects the process of securing the connector 1800 within the polymer material 1810.

[0177] Another embodiment of the present invention provides a structured connector having a structure that allows for facilitating securing of the connector within the polymer material 1810 when forming the contact sheet 1820 .

[0178] Specifically, a structured connector is provided that has a non-circular cross-sectional shape and includes at least one protrusion and / or at least one recess, wherein the at least one protrusion and / or at least one recess has an anchoring function when the connector is embedded in a polymer material. The non-circular cross-sectional shape of the connector can be a polygonal cross-sectional shape. However, it should be understood that embodiments of the present invention are not limited to structured conductive elements or connectors having polygonal cross-sectional shapes, and conductive elements or connectors of any shape that is not circular (including non-polygonal and polygonal cross-sectional shapes) are considered to be within the scope of the present invention.

[0179] The at least one protrusion and / or the at least one recess are arranged such that, when the connector is embedded in the polymer material, the polymer material at least partially surrounds the at least one protrusion and / or at least partially fills the at least one recess. The presence of the at least one protrusion and / or the at least one recess facilitates securing the respective connector within the polymer material of the contact sheet.

[0180] Figure 18 (b) shows a cross-sectional elevational view of a structured connector 1830 embedded in a polymer material 1810 to form a contact sheet 1820 as described above. Arrows indicate the forces applied to opposite side portions of the structured connector 1830 when the structured connector 1830 is embedded in and partially surrounded by the polymer material 1810. The structured connector 1830, for positioning on and electrically coupling to the surface of a solar cell (not shown), initially has a triangular cross-sectional shape similar to that of connector 1800 and has recesses 1840, 1845 in opposite side portions 1825, 1825', the recesses defining protrusions 1850, 1855 at the opposite side portions 1825, 1825'. Thus, the structural connector 1830 is arranged such that when the structural connector 1830 is embedded in the polymer material 1810 of the polymer contact sheet 1820, the polymer material 1810 at least partially fills the recesses or spaces 1840, 1845 between the protrusions 1850, 1855, and the recesses 1840, 1845 and / or the protrusions 1850, 1855 have an anchoring function as indicated by the direction of arrow 1870, which helps to secure the connector 1830 within the polymer material of the polymer contact sheet. The top of the structural connector 1830, including the protrusions 1850, 1855, has a height h6, and the structural connector 1830 has an overall height h7, which can be varied to achieve a given embedding of the structural connector 2030 in the polymer material 2010.

[0181] More specifically, the structured connector 2030 has a cross-sectional shape corresponding to the profile of two overlapping triangular portions 2060 , 2065 , each having an axis x1 , x2 and oriented such that the axis x1 of the triangular portion 2060 coincides with the axis x2 of the other triangular portion 2065 .

[0182] Figure 19 (a)-(c) to Figure 21 (a)-(c) depict a single connector embedding tool for a structural connector having a non-circular cross-sectional shape and provided with recesses and / or protrusions having an anchoring function for facilitating adhesion of the structural connector to the polymer material when the structural connector is embedded in the polymer material, as shown in reference Figure 18 (b) As described with respect to connector 1830. Similar to Figures 13 to 16 , Figure 19 (a) Figure 20 (a) and Figure 21 (a) each shows a cross section of a connector held in the insertion tool and aligned with the vacuum line; Figure 19 (b) Figure 20 (b) and Figure 21 (b) shows a 3D perspective view of the embedding tool holding the connector; and Figure 19 (c) Figure 20 (c) and Figure 21 (c) shows a cross-sectional view of the connector and the embedding tool in a plane perpendicular to the longitudinal direction of the connector and the embedding tool. Figure 19 (a)-(c) specifically depict a single connector insertion tool 1950 for a structured connector 1970 having the same Figure 18 (b) depicts a connector 1830 having substantially the same cross-sectional shape / geometry. Figures 20 to 21 Depicted are additional connectors 2080, 2190 held in grooves of a connector embedding tool (such as embedding tool 1950), the connectors 2080, 2190 having respective non-circular cross-sectional shapes with recesses and / or protrusions in side, top, and / or bottom surface portions to provide anchor points when the respective connectors 2080, 2190 are embedded into the polymer material of a contact sheet (not shown), and to assist in securing the respective structured connector within the polymer material of the contact sheet for forming a device structure, such as, for example, a photovoltaic module. As described above with reference to Figure 18As described in (b), when the corresponding connectors 2080, 2190 are embedded in the polymer material, the polymer material will at least partially fill the recesses or spaces between the protrusions and at least partially surround the protrusions, which will help to fix the structured connectors 2080, 2190 within the polymer material of the contact sheet.

[0183] In the context of solar cell and photovoltaic module formation, similar to existing connector-based interconnect processes, embodiments of the present invention do not require bus bar regions to be formed on the front and rear surfaces of the solar cell, thereby enabling higher cell voltages to be achieved. However, embodiments of the present invention provide the additional benefit that the material costs for forming device structures (such as photovoltaic modules) can be significantly reduced. In addition, the embedding method 1200, for example using an embedding tool, provides greater flexibility in connector cross-sectional shapes, where enhanced light capture can be achieved by incorporating light structuring features and reflective coatings. Additionally, the use of specially designed connector geometries (ridge structures or providing as shown in reference 1200) can provide greater flexibility in connector cross-sectional shapes compared to when using connectors having, for example, a circular cross-sectional shape (such as employed in the multiBB technology described above). Figure 18 (b) to Figure 21 The structure of the anchor portion described) can also reduce stress that can develop in the underlying solar cells that are interconnected in the photovoltaic module.

[0184] The polymeric material used for application to embodiments of the present invention may preferably comprise a highly water-resistant material such as POE, thermoplastic polyolefin (TPO), silicone (such as Dow Corning Sylgard 184), ionomer-based sealants (such as DuPont's PV5400 and PV8400), or ethylene vinyl acetate (EVA).

[0185] Furthermore, it should be noted that in addition to the encapsulation of solar cells, the contact sheet comprising polymer material and structured connectors or conductive elements embedded therein can also be used for other applications and can, for example, be used to form electrical or electronic circuits or sensor or antenna elements.

[0186] The inventors have further discovered that a structured connector including additional recesses and / or protrusions having an anchoring function when embedded in a polymer material (compared to structured connectors 1830 and 2080) can further allow for: (i) improving the reliability of embedding between the structured connector and a polymer material (such as polymer material 1810), and (ii) providing improved adhesion of the structured connector to polymer material 1810. Figure 22 (a) and Figure 22(b) shows a cross-sectional elevation view of a structural connector 2200 and 2210 provided according to another embodiment of the present invention. Each of the connectors 2200 and 2210 has a cross-sectional shape corresponding to the outline of three overlapping triangular portions 2215, 2220, 2225 and 2215', 2220', 2225', respectively. Each triangular portion has an axis x1, x2, x3 and x1', x2', x3', respectively, and is oriented such that: (i) the axis x1 of the triangular portion 2215 coincides with the respective axes x2 and x3 of the triangular portions 2220 and 2225, and (ii) the axis x1' of the triangular portion 2215' coincides with the respective axes x2' and x3' of the triangular portions 2220' and 2225'.

[0187] The inventors have also found that forming a contact sheet in which one or more connectors are embedded can be further facilitated by providing a structured connector comprising at least one recess and / or protrusion having an anchoring function in each of the opposing side portions and the bottom portion, the recess and / or protrusion or each recess and / or protrusion in the bottom portion being substantially identical to the recess and / or protrusion or each recess and / or protrusion in each of the opposing side portions and the bottom portion.

[0188] Figure 23 (a)-(c) show cross-sectional elevation views of structural connectors 2300, 2310, and 2320. Structural connector 2300 includes two substantially identical recesses 2305, 2305' in each of opposing side portions 2315, 2315' and a bottom portion 2325. The substantially identical recesses 2305, 2305' are slots having sidewalls 2330, 2335 that are parallel to one another. Structural connector 2300 has an axis x, and the recesses 2305, 2305' in the opposing side portions 2315, 2315' and the bottom portion 2325 are arranged such that the shape of structural connector 2300 in a cross-sectional plane perpendicular to axis x has three-fold rotational symmetry.

[0189] The structural connector 2310 includes a recess 2340 in each of the opposing side portions 2345, 2345' and the bottom portion 2350, with the recess 2340 being substantially identical in each of the portions 2345, 2345', and 2350. The recess 2340 represents an 'arbitrary' slot in which the side walls of the slot are not parallel to one another, such that corresponding protrusions 2355, 2355' are defined on each of the opposing side portions 2345, 2345' and the bottom portion 2350. In the same manner as the structural connector 2300, the structural connector 2310 has an axis x', and the recesses 2340 and protrusions 2355, 2355' are arranged on the opposing side portions 2315, 2315' and the bottom portion 2325 such that the shape of the structural connector 2310 in a cross-sectional plane perpendicular to the axis x' has three-fold rotational symmetry.

[0190] Connector 2320 includes a recess 2360 in each of opposing side portions 2365, 2365' and bottom portion 2370, with recess 2360 being substantially identical in each of portions 2365, 2365', and 2370. Recess 2360 represents a substantially rectangular slot in which the side walls of the slot are parallel to one another. In the same manner as structural connectors 2300 and 2310, connector 2320 has an axis x", and recesses 2360 are arranged on opposing side portions 2365, 2365' and bottom portion 2370 such that the shape of structural connector 2320 in a cross-sectional plane perpendicular to axis x" has three-fold rotational symmetry.

[0191] like Figure 23 As shown in (b) by light ray 2380, in use, when the structured connector is positioned on a solar cell, 'arbitrary' slots such as slot 2340 having non-parallel sidewalls can cause light incident at normal incidence relative to the surface of the solar cell to be trapped in the area surrounding the protrusions 2355, 2355', or even reflected back into the glass (and / or polymer) sheet within its escape cone. However, as Figure 23 As shown in (c), the slots with parallel sidewalls allow light incident at normal incidence relative to the solar cell surface to be reflected in a direction outside the region surrounding the slots that is the same as when there are no slots (i.e., in the embodiment of the triangular connector). Thus, the structured connector 2320 allows for improved embedding and anchoring in the polymer material to form the contact sheet, as well as maintaining optimal optical and electrical performance. In addition, Figure 23 The angle b8 shown in (c) should be equal to or greater than the base angle b9 of the structural connector 2320 in order to provide a minimum aspect ratio for the structural connector 2320 .

[0192] It should be understood that it is also contemplated that the opposing side portions and / or the bottom portion of the structural connector may include more than two recesses and may have any other shape suitable for achieving a given optical performance.

[0193] When embedded in the polymer material of the contact sheet and coupled to the electrical contacts of the solar cell to form a photovoltaic module, the Figures 16 to 23 The described structured connectors, formed contact sheets, and solar cells may then be further encapsulated in glass and / or polymer cover sheets to form photovoltaic modules.

[0194] Additionally, it should be noted that the structural connectors described herein according to specific embodiments of the present invention may alternatively not be embedded in the polymer material of the contact sheet. The solar cells and structural connectors can then be simply encapsulated in a glass and / or polymer cover sheet. For example, the structural connectors can also be used to manufacture photovoltaic modules using various known methods for connecting solar cells within a photovoltaic module, such as the 'solar strap and string' method.

[0195] In the following claims and in the foregoing description of the invention, except where the context requires otherwise by express language or necessary implication, the word "comprise" or variations such as "comprises" and "comprising" are used in an inclusive sense to specify the presence of the described features in various embodiments of the invention.

[0196] Modifications and variations that are obvious to those skilled in the art are intended to be within the scope of the present invention.

[0197] It will also be understood that, if any prior art publication is referred to herein, this reference does not constitute an admission that the publication forms part of the common general knowledge in the art, in Australia or any other country.

Claims

1. A structured connector for positioning on a surface of a device component and electrically coupling to the surface of the device component, the connector having a bottom portion for contacting the surface of the device component, the structured connector comprising: Conductive materials; at least one light-diverting surface portion, the at least one light-diverting surface portion being oriented relative to the surface of the device component such that, in use, light impinging at a direction of normal incidence relative to the surface of the device component is received by the at least one light-diverting surface portion such that the received light is diverted towards an exposed adjacent surface of the device component, and at least one light scattering surface portion, the at least one light scattering surface portion being oriented relative to the surface of the device component such that, in use, light incident at normal incidence relative to the surface of the device component is received by the at least one light scattering surface portion such that the received light is scattered in a direction away from the device component; wherein when the structured connector is positioned on the surface of the device component, the at least one light redirecting surface portion is oriented at an acute internal angle relative to the surface of the device component, the acute internal angle being in the range of 45 degrees to 90 degrees; wherein when the structured connector is positioned on the surface of the device component, the at least one light scattering surface portion is oriented at an acute internal angle relative to the surface of the device component, the acute internal angle being in the range of 0 degrees to 45 degrees; wherein the or each light diverting surface portion defines a height h1 of the connector, h1 being in the range of 0.1 mm to 0.5 mm; The structural connector includes an upper opposing side portion and a lower opposing side portion; the lower opposing side portion and the upper opposing side portion define a height h2 of the connector, h2 being in the range of 0.1 mm to 0.8 mm; The structured connector has an axis and a shape in a cross-sectional plane perpendicular to the axis, the shape having three-fold rotational symmetry.

2. The structured connector of claim 1, wherein the at least one light-diverting surface portion comprises at least one planar light-diverting surface portion.

3. The structured connector of claim 1, wherein the at least one light scattering surface portion comprises at least one flat light scattering surface portion.

4. The structured connector of claim 1 , wherein the at least one light turning surface portion is positioned at a respective side portion of the connector.

5. A structured connector as claimed in claim 1 , wherein the structured connector comprises at least two light redirecting surface portions, each of the at least two light redirecting surface portions being oriented relative to the surface of the device component such that, in use, light impinging at a direction of normal incidence relative to the surface of the device component is received by the light redirecting surface portion such that the received light is redirected towards an exposed adjacent surface of the device component.

6. The structured connector of claim 1, wherein the at least one light scattering surface portion is positioned at a top portion of the structured connector.

7. A structured connector as claimed in claim 6, wherein the structured connector comprises at least two light scattering surface portions, each of the at least two light scattering surface portions being oriented relative to the surface of the device component such that, in use, light incident at normal incidence relative to the surface of the device component is received by the light scattering surface portion such that the received light is scattered in a direction away from the device component.

8. The structured connector of claim 7, wherein the at least two light scattering surface portions form at least one recess along the structured connector at the top portion of the connector, the at least one recess being positioned between opposing side portions of the structured connector.

9. The structured connector of claim 8, wherein each recess is configured to form a v-shaped groove along the structured connector.

10. The structured connector of claim 1 , wherein the structured connector includes a plurality of light scattering surface portions that form a plurality of adjacent and parallel recesses at a top portion of the structured connector, the plurality of adjacent and parallel recesses being positioned between opposing side portions of the structured connector and configured to form adjacent v-shaped grooves along the structured connector.

11. A structured connector as claimed in claim 1 , wherein the or each light diverting surface portion intersects a respective light scattering surface portion.

12. The structured connector of claim 1, wherein each of the upper opposing side portions includes a respective light turning surface portion and intersects a respective one of the lower opposing side portions.

13. The structured connector of claim 1, wherein the lower opposing side portions are oriented perpendicular to the surface of the equipment component when the structured connector is positioned on the surface of the equipment component.

14. The structured connector of claim 8 or 9, wherein each of the lower opposing side portions comprises at least one recess that is identical to the at least one recess formed by the at least two light scattering surface portions at the top portion of the structured connector.

15. The structural connector of claim 1, wherein the device component is a solar cell and the structural connector is a solar cell structural connector.

16. A contact sheet for contacting a device component, the contact sheet comprising a sheet of polymer material and a structured connector embedded therein in such a way that a surface portion of the structured connector is exposed, the structured connector being provided according to any one of the preceding claims.

17. The contact sheet of claim 16, wherein the structured connector comprises a coating arranged to form a bond with the conductive surface area of ​​the device component when activated.

18. A device structure comprising a device component having electrical contacts on a front surface and a rear surface and sandwiched between a first contact sheet and a second contact sheet, each contact sheet comprising a polymer material and having one or more of the structured connectors according to any one of claims 1 to 15 embedded therein, the device structure being arranged such that the structured connectors are electrically coupled to the electrical contacts of the device component.

19. A device structure comprising at least two device components, the at least two device components having electrical contacts on a front surface and a rear surface and being sandwiched between a first contact sheet and a second contact sheet, each contact sheet comprising a polymer material and having one or more of the structured connectors according to any one of claims 1 to 15 embedded therein, the device structure being arranged such that the structured connectors are electrically coupled to the electrical contacts of the at least two device components and interconnect adjacent ones of the at least two device components.

20. The device structure of claim 18 or 19, wherein each device component is a solar cell and the device structure is a photovoltaic module.

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