Photovoltaic devices and methods of making the same

Abstract

To provide photovoltaic devices and methods of making the same.SOLUTION: A photovoltaic device comprises: a plurality of electrically connected photovoltaic cells, where the photovoltaic cells comprise a conducting layer having a first surface and a second surface, the first surface facing an absorber layer; an insulating material disposed on the second surface over at least one of the photovoltaic cells; a conductive member on the insulating material, where the insulating material is configured to electrically insulate the conductive member from the second surface; a bus member electrically coupled to the one of the photovoltaic cells and to the conductive member; and an edge seal comprising a sealant material extending over at least a portion of the one of the photovoltaic cells; where the bus member is disposed between the edge seal and the plurality of photovoltaic cells.SELECTED DRAWING: Figure 11E

Description

[Technical Field]

[0001]

[0001] Photovoltaic devices generate power by converting light into electricity using semiconductor materials that exhibit the photovoltaic effect. Photovoltaic devices include several layers that are divided into multiple photovoltaic cells. Each photovoltaic cell can convert a light source, such as sunlight, into electricity and can be connected in series with one or more adjacent cells. Thus, the current generated by the adjacent cells can flow through each of the photovoltaic cells. [Background technology]

[0002]

[0002] Improving contact between current collecting portions of a photovoltaic device is important for the efficient and durable operation of the device. Summary of the Invention

[0003] For example, the electrical bond between the conductive members and the bus members is a critical current collecting contact for maintaining the functionality of the photovoltaic device. If the bond is damaged or fails, an open circuit can be created, rendering the photovoltaic device inoperable. Therefore, the industry continually needs improved, more robust, and more reliable electrical contact between the conductive members and the bus members that can enhance the performance of photovoltaic devices. [Brief explanation of the drawings]

[0004] [Figure 1]

[0003] FIG. 1 is a schematic diagram illustrating a photovoltaic device according to one or more embodiments shown and described herein. [Figure 2] 2 is a schematic cross-sectional view of the photovoltaic device of FIG. 1 taken along line 2-2 according to one or more embodiments shown and described herein. [Figure 3]

[0005] 1A and 1B illustrate a schematic diagram of a substrate according to one or more embodiments shown and described herein. [Figure 4]

[0006] FIG. 1 illustrates a schematic diagram of a photovoltaic device according to one or more embodiments shown and described herein. [Figure 5]

[0007] 5A-5C are schematic cross-sectional views of the photovoltaic device of FIG. 1 according to one or more embodiments shown and described herein. [Figure 6]

[0008] FIG. 1 illustrates a schematic diagram of a photovoltaic device according to one or more embodiments shown and described herein. [Figure 7]

[0009] 7 shows a view of the photovoltaic device of FIG. 6 along line 7-7, and is a schematic illustration of a T-shaped contact between current collecting portions of a photovoltaic device according to one or more embodiments shown and described herein. FIG. [Figure 8]

[0010] FIG. 1A is a diagram illustrating a backside view of a photovoltaic device. [Figure 9A]

[0011] 1A-1D illustrate schematic diagrams of a photovoltaic device according to one or more embodiments shown and described herein during successive steps of a manufacturing process. [Figure 9B] 1A-1D illustrate schematic diagrams of a photovoltaic device according to one or more embodiments shown and described herein during successive steps of a manufacturing process. [Figure 9C] 1A-1D illustrate schematic diagrams of a photovoltaic device according to one or more embodiments shown and described herein during successive steps of a manufacturing process. [Figure 9D] 1A-1D illustrate schematic diagrams of a photovoltaic device according to one or more embodiments shown and described herein during successive steps of a manufacturing process. [Figure 9E] 1A-1D illustrate schematic diagrams of a photovoltaic device according to one or more embodiments shown and described herein during successive steps of a manufacturing process. [Figure 10A]

[0012] 1A-1D illustrate schematic diagrams of a photovoltaic device according to one or more embodiments shown and described herein during successive steps of a manufacturing process. [Figure 10B] 1A-1D illustrate schematic diagrams of a photovoltaic device according to one or more embodiments shown and described herein during successive steps of a manufacturing process. [Figure 10C] 1A-1D illustrate schematic diagrams of a photovoltaic device according to one or more embodiments shown and described herein during successive steps of a manufacturing process. [Figure 10D] 1A-1D illustrate schematic diagrams of a photovoltaic device according to one or more embodiments shown and described herein during successive steps of a manufacturing process. [Figure 10E] 1A-1D illustrate schematic diagrams of a photovoltaic device according to one or more embodiments shown and described herein during successive steps of a manufacturing process. [Figure 11A]

[0013] 1A-1D illustrate schematic diagrams of a photovoltaic device according to one or more embodiments shown and described herein during successive steps of a manufacturing process. [Figure 11B] 1A-1D illustrate schematic diagrams of a photovoltaic device according to one or more embodiments shown and described herein during successive steps of a manufacturing process. [Figure 11C] 1A-1D illustrate schematic diagrams of a photovoltaic device according to one or more embodiments shown and described herein during successive steps of a manufacturing process. [Figure 11D] 1A-1D illustrate schematic diagrams of a photovoltaic device according to one or more embodiments shown and described herein during successive steps of a manufacturing process. [Figure 11E] 1A-1D illustrate schematic diagrams of a photovoltaic device according to one or more embodiments shown and described herein during successive steps of a manufacturing process. [Figure 12A]

[0014] 1A-1D illustrate schematic diagrams of a photovoltaic device according to one or more embodiments shown and described herein during successive steps of a manufacturing process. [Figure 12B]1A-1D illustrate schematic diagrams of a photovoltaic device according to one or more embodiments shown and described herein during successive steps of a manufacturing process. [Figure 12C] 1A-1D illustrate schematic diagrams of a photovoltaic device according to one or more embodiments shown and described herein during successive steps of a manufacturing process. [Figure 12D] 1A-1D illustrate schematic diagrams of a photovoltaic device according to one or more embodiments shown and described herein during successive steps of a manufacturing process. [Figure 12E] 1A-1D illustrate schematic diagrams of a photovoltaic device according to one or more embodiments shown and described herein during successive steps of a manufacturing process. [Figure 12F] 1A-1D illustrate schematic diagrams of a photovoltaic device according to one or more embodiments shown and described herein during successive steps of a manufacturing process. [Figure 13A]

[0015] 1A-1D illustrate schematic diagrams of a photovoltaic device according to one or more embodiments shown and described herein during successive steps of a manufacturing process. [Figure 13B] 1A-1D illustrate schematic diagrams of a photovoltaic device according to one or more embodiments shown and described herein during successive steps of a manufacturing process. [Figure 13C] 1A-1D illustrate schematic diagrams of a photovoltaic device according to one or more embodiments shown and described herein during successive steps of a manufacturing process. [Figure 13D] 1A-1D illustrate schematic diagrams of a photovoltaic device according to one or more embodiments shown and described herein during successive steps of a manufacturing process. [Figure 13E] 1A-1D illustrate schematic diagrams of a photovoltaic device according to one or more embodiments shown and described herein during successive steps of a manufacturing process. [Figure 13F] 1A-1D illustrate schematic diagrams of a photovoltaic device according to one or more embodiments shown and described herein during successive steps of a manufacturing process. [Figure 14A]

[0016] 1A-1D illustrate schematic diagrams of a photovoltaic device according to one or more embodiments shown and described herein during successive steps of a manufacturing process. [Figure 14B] 1A-1D illustrate schematic diagrams of a photovoltaic device according to one or more embodiments shown and described herein during successive steps of a manufacturing process. [Figure 14C] 1A-1D illustrate schematic diagrams of a photovoltaic device according to one or more embodiments shown and described herein during successive steps of a manufacturing process. [Figure 14D] 1A-1D illustrate schematic diagrams of a photovoltaic device according to one or more embodiments shown and described herein during successive steps of a manufacturing process. [Figure 14E] 1A-1D illustrate schematic diagrams of a photovoltaic device according to one or more embodiments shown and described herein during successive steps of a manufacturing process. DETAILED DESCRIPTION OF THE INVENTION

[0005]

[0017] Photovoltaic devices can be formed by depositing various semiconductor materials and electrode layers as thin (generally recognized in the art as less than 10 microns) film layers on a glass substrate. The substrate then undergoes various processing steps, including laser scribing processes, to define and separate individual photovoltaic cells, define peripheral edge zones around the photovoltaic cells, and connect the photovoltaic cells in series. These steps can result in the creation of multiple individual photovoltaic cells defined within the physical edge of the substrate.

[0006]

[0018] One method for collecting current from a photovoltaic device is to attach insulating material (e.g., insulating tape) longitudinally along the device across the photovoltaic cells. Conductive members (e.g., conductive foil tape or ribbon) can then be aligned and attached to the insulating material. Bus members (e.g., bus bars in the form of adhesive bus tape) can then be aligned with the first and last cells, respectively, and attached to the opposite longitudinal ends of the device. The bus members can cross and attach to the conductive members to collect current from the cells and transfer the current to the conductive members. The conductive members can be separated in a connection box, with leads connected to the separated ends of the conductive members. The leads can provide a means for connecting the photovoltaic device to a load, other cells, a grid, etc.

[0007]

[0019] This technology improves the reliability and durability of the current collection portion of a photovoltaic device, thereby improving the performance of the device. For example, current from a photovoltaic device can be collected by attaching an insulating material (e.g., insulating tape) longitudinally along the device across the photovoltaic cells and then aligning and attaching a conductive member (e.g., conductive foil tape or ribbon) to the insulating material. Bus members (e.g., bus bars in the form of adhesive bus tape) can then be attached to the opposite longitudinal ends of the photovoltaic device, aligned with the first and last cells, respectively. In certain configurations, the bus members can cross and attach to the conductive members, collect current from the cells, and transfer the current to the conductive members. When the bus members cross near the ends of the conductive members, the connection can be described as a T-junction or T-connection. The T-connection is where current from the photovoltaic device can accumulate; therefore, low and stable contact resistance at this location can be important for maintaining good device performance. However, during various manufacturing steps, the bus members may be physically displaced by manufacturing-related forces, and therefore it is advantageous to protect the bus members during manufacturing.

[0008]

[0020] Referring now to FIG. 1 , one embodiment of a photovoltaic device 100 is illustrated schematically. The photovoltaic device 100 may be configured to receive light and convert the light into an electrical signal; for example, photons may be absorbed from the light and converted to an electrical signal via the photovoltaic effect. Thus, the photovoltaic device 100 may define an energy side 102 configured to be exposed to a light source, such as the sun. The photovoltaic device 100 may further define an opposite side 104 offset from the energy side 102, such as by multiple material layers. It should be noted that the term “light” may refer to various wavelengths of the electromagnetic spectrum, such as, but not limited to, wavelengths in the ultraviolet (UV), infrared (IR), and visible portions of the electromagnetic spectrum. As used herein, “sunlight” refers to light emitted by the sun.

[0009]

[0021] The photovoltaic device 100 can include multiple layers disposed between an energy side 102 and an opposing side 104. As used herein, the term "layer" refers to a layer that is formed on a surface of a substrate. The term "layer" refers to a thickness of material disposed on a surface. Each layer can cover all or any portion of the surface. In some embodiments, a layer of a photovoltaic device 100 can be divided into a number of side-by-side photovoltaic cells 200. For example, the photovoltaic device 100 can be scribed according to a plurality of serial scribes 202 and a plurality of parallel scribes 204. The serial scribes 202 can extend along the length Y of the photovoltaic device 100 and define the boundaries of the photovoltaic cells 200 along the length Y of the photovoltaic device 100. The serial scribes 202 can be configured to serially connect neighboring cells of the photovoltaic cells 200 along the width X of the photovoltaic device 100. The serial scribes 202 can form monolithic interconnections of neighboring cells, i.e., cells adjacent to the serial scribes 202. The parallel scribes 204 extend along the width X of the photovoltaic device 100 and can demarcate the photovoltaic cells 200 along the width X of the photovoltaic device 100. Under operation, current 205 can flow primarily along the width X through the photovoltaic cells 200 connected in series by the serial scribes 202. Under operation, the parallel scribes 204 can limit the ability of the current 205 to flow along the length Y. The parallel scribes 204 are optional and can be configured to separate the serially connected photovoltaic cells 200 into groups 206 arranged along the length Y. Thus, the serial scribes 202 and the parallel scribes 204 can demarcate a number of photovoltaic cells 200 side by side.

[0010]

[0022] 1 , the parallel scribes 204 can electrically isolate groups 206 of photovoltaic cells 200 that are connected in series. In some embodiments, the groups 206 of photovoltaic cells 200 can be connected in parallel, such as via electrical bussing. Optionally, the number of parallel scribes 204 can be configured to limit the maximum current generated by each group 206 of photovoltaic cells 200. In some embodiments, the maximum current generated by each group 206 can be about 200 milliamps (mA) or less, such as about 100 mA or less in one embodiment, about 75 mA or less in another embodiment, or about 50 mA or less in further embodiments.

[0011]

[0023] 1 and 2 collectively, the layers of the photovoltaic device 100 may include a substrate 110 configured to facilitate the transmission of light into the photovoltaic device 100. The substrate 110 may be disposed on the energy side 102 of the photovoltaic device 100. Referring now to FIGS. 2 and 3 , the substrate 110 may have a first surface 112 that substantially faces the energy side 102 of the photovoltaic device 100 and a second surface 114 that substantially faces the opposite side 104 of the photovoltaic device 100. One or more material layers may be disposed between the first surface 112 and the second surface 114 of the substrate 110.

[0012]

[0024] The substrate 110 can include a transparent layer 120 having a first surface 122 substantially facing the energy side 102 of the photovoltaic device 100 and a second surface 124 substantially facing the opposite side 104 of the photovoltaic device 100. In some embodiments, the second surface 124 of the transparent layer 120 can form the second surface 114 of the substrate 110. The transparent layer 120 can be formed from a substantially transparent material, such as glass. Suitable glasses can include soda-lime glass or any glass with a low iron content. The transparent layer 120 can have a suitable transmittance, including from about 250 nm to about 1300 nm in some embodiments, or from about 250 nm to about 950 nm in other embodiments. The transparent layer 120 can also have any suitable transmittance, including, for example, greater than about 50% in one embodiment, greater than about 60% in another embodiment, greater than about 70% in yet another embodiment, greater than about 80% in a further embodiment, or greater than about 85% in yet still further embodiments. In one embodiment, the transparent layer 120 may be formed from glass having a transmittance of about 90% or greater. Optionally, the substrate 110 may be formed from a first surface 12 2. The coating 126 may be configured to interact with light or to improve the durability of the substrate 110, such as, but not limited to, an anti-reflective coating, an anti-fouling coating, or a combination thereof.

[0013]

[0025] 2 , the photovoltaic device 100 may include a barrier layer 130 configured to mitigate diffusion of contaminants (e.g., sodium) from the substrate 110, which can result in degradation or delamination. The barrier layer 130 may have a first surface 132 that substantially faces the energy side 102 of the photovoltaic device 100 and a second surface 134 that substantially faces the opposite side 104 of the photovoltaic device 100. In some embodiments, the barrier layer 130 may be provided adjacent to the substrate 110. For example, the first surface 132 of the barrier layer 130 may be provided on the second surface 114 of the substrate 100. As used herein, the phrase “adjacent to” means that two layers are disposed contiguously, without any intervening material between at least a portion of the layers.

[0014]

[0026] Generally, the barrier layer 130 can be substantially transparent, thermally stable, have a low pinhole count, a high sodium blocking capacity, and good adhesion properties. Alternatively or additionally, the barrier layer 130 can be configured to provide color suppression to light. The barrier layer 130 can include one or more layers of a suitable material, including, but not limited to, tin oxide, silicon dioxide, aluminum-doped silicon oxide, silicon oxide, silicon nitride, or aluminum oxide. The barrier layer 130 can have a suitable thickness, bounded by the first surface 132 and the second surface 134, including, for example, greater than about 100 Å in one embodiment, greater than about 150 Å in another embodiment, or less than about 200 Å in a further embodiment.

[0015]

[0027] Still referring to FIG. 2 , the photovoltaic device 100 may include a transparent conductive oxide (TCO) layer 140 configured to provide electrical contact for transporting charge carriers generated by the photovoltaic device 100. The TCO layer 140 may have a first surface 142 substantially facing the energy side 102 of the photovoltaic device 100 and a second surface 144 substantially facing the opposite side 104 of the photovoltaic device 100. In some embodiments, the TCO layer 140 may be provided adjacent to the barrier layer 130. For example, the first surface 142 of the TCO layer 140 may be provided on the second surface 134 of the barrier layer 130. Generally, the TCO layer 140 may be formed from one or more layers of n-type semiconductor material that is substantially transparent and has a wide bandgap. Specifically, the wide bandgap may have a larger energy value compared to the energy of the light photons, thereby reducing undesired light absorption. The TCO layer 140 may include one or more layers of suitable materials, including, but not limited to, tin dioxide, doped tin dioxide (e.g., F—SnO 2 ), indium tin oxide, or cadmium stannate.

[0016]

[0028] The photovoltaic device 100 may include a buffer layer 150 configured to provide an insulating layer between the TCO layer 140 and an adjacent semiconductor layer. The buffer layer 150 may have a first surface 152 substantially facing the energy side 102 of the photovoltaic device 100 and a second surface 154 substantially facing the opposite side 104 of the photovoltaic device 100. In some embodiments, the buffer layer 150 may be provided adjacent to the TCO layer 140. For example, the first surface 152 of the buffer layer 150 may be provided on the second surface 144 of the TCO layer 140. The buffer layer 140 may be formed of a material such as, but not limited to, intrinsic tin dioxide, zinc magnesium oxide (e.g., Zn 1-x Mg x a TCO layer 140 comprising silicon dioxide (SnO), aluminum oxide (AlO), aluminum nitride (AlN), zinc tin oxide, zinc oxide, tin silicon oxide, or any combination thereof; In some embodiments, the material of buffer layer 140 may be configured to substantially match the bandgap of an adjacent semiconductor layer (e.g., an absorber). Buffer layer 150 may have a suitable thickness between first surface 152 and second surface 154, including, for example, greater than about 100 Å in one embodiment, between about 100 Å and about 800 Å in another embodiment, or between about 150 Å and about 600 Å in further embodiments.

[0017]

[0029] Still referring to FIG. 2 , the photovoltaic device 100 can include an absorber layer 160 configured to cooperate with another layer to form a p-n junction within the photovoltaic device 100. Thus, absorbed photons of light liberate electron-hole pairs, generating a flow of carriers, which can generate electrical power. The absorber layer 160 can have a first surface 162 that substantially faces the energy side 102 of the photovoltaic device 100 and a second surface 164 that substantially faces the opposite side 104 of the photovoltaic device 100. A thickness of the absorber layer 160 can be defined between the first surface 162 and the second surface 164. The thickness of the absorber layer 160 can be between about 0.5 μm and about 10 μm, such as between about 1 μm and about 7 μm in one embodiment, or between about 1.5 μm and about 4 μm in another embodiment.

[0018]

[0030] According to embodiments described herein, the absorber layer 160 may be formed from a p-type semiconductor material having an excess of positive charge carriers, i.e., holes or acceptors. The absorber layer 160 may include any suitable p-type semiconductor material, such as a II-VI semiconductor. Specific examples include, but are not limited to, semiconductor materials containing cadmium, tellurium, selenium, or any combination thereof. Suitable examples include, but are not limited to, ternaries of cadmium, selenium, and tellurium (e.g., CdSe x Te 1-x), or compounds containing cadmium, selenium, tellurium, and one or more additional elements. The absorber layer 160 can further include one or more dopants. A photovoltaic device can include multiple absorber materials.

[0019]

[0031] In embodiments in which the absorber layer 160 comprises tellurium and cadmium, the atomic percent of tellurium may be greater than or equal to about 25 atomic percent and less than or equal to about 50 atomic percent, such as greater than about 30 atomic percent and less than about 50 atomic percent in one embodiment, greater than about 40 atomic percent and less than about 50 atomic percent in a further embodiment, or greater than about 47 atomic percent and less than about 50 atomic percent in yet another embodiment. Alternatively or additionally, the atomic percent of tellurium in the absorber layer 160 may be greater than about 45 atomic percent, such as greater than about 49% in one embodiment. It should be noted that the atomic percentages described herein represent the absorber layer 160 as a whole, and that the atomic percentage of material at a particular location within the absorber layer 160 may vary with thickness compared to the overall composition of the absorber layer 160.

[0020]

[0032] In embodiments in which absorber layer 160 comprises selenium and tellurium, the atomic percent of selenium in absorber layer 160 can be greater than about 0 atomic percent and less than about 25 atomic percent, such as greater than about 1 atomic percent and less than about 20 atomic percent in one embodiment, greater than about 1 atomic percent and less than about 15 atomic percent in another embodiment, or greater than about 1 atomic percent and less than about 8 atomic percent in a further embodiment. Note that the concentration of tellurium, selenium, or both can vary with the thickness of absorber layer 160. For example, if absorber layer 160 comprises a compound comprising selenium with a mole fraction of x and tellurium with a mole fraction of 1-x (Se x Te 1-x ), x may vary in the absorber layer 160 with distance from the first surface 162 of the absorber layer 160.

[0021]

[0033] Still referring to FIG. 2, the absorber layer 160 manipulates the charge carrier concentration. In some embodiments, the absorber layer 160 may be doped with a group I or group V dopant, such as, for example, copper, arsenic, phosphorus, antimony, or a combination thereof. The total density of the dopant within the absorber layer 160 may be controlled. Alternatively or additionally, the amount of dopant may vary with distance from the first surface 162 of the absorber layer 160. In some embodiments, the dopant is introduced during a passivation step of the fabrication process. Passivation may include, for example, treatment with CdCl or other halide compounds, and the resulting dopant may include chlorine or other halogens. Additionally, the amount of the selected dopant may vary with distance from the first surface 162 of the absorber layer 160.

[0022]

[0034] According to embodiments provided herein, a p-n junction may be formed by providing an absorber layer 160 sufficiently close to a portion of the photovoltaic device 100 that has an excess of negative charge carriers, i.e., electrons or donors. In some embodiments, the absorber layer 160 may be provided adjacent to an n-type semiconductor material. Alternatively, one or more intervening layers may be provided between the absorber layer 160 and the n-type semiconductor material. In some embodiments, the absorber layer 160 may be provided adjacent to the buffer layer 150. For example, the first surface 162 of the absorber layer 160 may be provided on the second surface 154 of the buffer layer 150.

[0023]

[0035] Referring now to FIG. 4 , in some embodiments, the photovoltaic device 210 can include a window layer 170 comprising an n-type semiconductor material. The absorber layer 160 can be formed adjacent to the window layer 170. The window layer 170 can have a first surface 172 substantially facing the energy side 102 of the photovoltaic device 100 and a second surface 174 substantially facing the opposite side 104 of the photovoltaic device 100. In some embodiments, the window layer 170 can be positioned between the absorber layer 160 and the TCO layer 20. In one embodiment, the window layer 170 can be positioned between the absorber layer 160 and the buffer layer 150. The window layer 170 can include a suitable material, including, for example, cadmium sulfide, zinc sulfide, cadmium zinc sulfide, zinc magnesium oxide, or any combination thereof. The material of the window layer 170 can include a dopant.

[0024]

[0036] 2 and 4 collectively, the photovoltaic device 100, 210 may include a back contact layer 180 configured to mitigate undesired dopant changes and to be in electrical contact with the absorber layer 160. The back contact layer 180 may have a first surface 182 substantially facing the energy side 102 of the photovoltaic device 100 and a second surface 184 substantially facing the opposite side 104 of the photovoltaic device 100. A thickness of the back contact layer 180 may be defined between the first surface 182 and the second surface 184. The thickness of the back contact layer 180 may be between about 5 nm and about 200 nm, such as between about 10 nm and about 50 nm in one embodiment.

[0025]

[0037] In some embodiments, the back contact layer 180 may be disposed adjacent to the absorber layer 160. For example, the first surface 182 of the back contact layer 180 may be disposed on the second surface 164 of the absorber layer 160. In some embodiments, the back contact layer 180 may include a binary or ternary combination of materials from Groups I, II, and VI, such as one or more layers including zinc, copper, cadmium, tellurium in various compositions, etc. Further exemplary materials include, but are not limited to, zinc telluride doped with copper telluride or zinc telluride alloyed with copper telluride.

[0026]

[0038] The photovoltaic device 100 can include a conductive layer 190 configured to be in electrical contact with the absorber layer 160. The conductive layer 190 can have a first surface 192 that substantially faces the energy side 102 of the photovoltaic device 100 and a second surface 194 that substantially faces the opposite side 104 of the photovoltaic device 100. In some embodiments, In some embodiments, conductive layer 190 may be provided adjacent back contact layer 180. For example, first surface 192 of conductive layer 190 may be provided on second surface 184 of back contact layer 180. Conductive layer 190 may include a suitable conductive material such as, for example, one or more layers of a nitrogen-containing metal, silver, nickel, copper, aluminum, titanium, palladium, chromium, molybdenum, gold, etc. Suitable examples of nitrogen-containing metal layers may include aluminum nitride, nickel nitride, titanium nitride, tungsten nitride, selenium nitride, tantalum nitride, or vanadium nitride.

[0027]

[0039] The photovoltaic device 100, 210 may include a back support 196 configured to cooperate with the substrate 110 to form a housing for the photovoltaic device 100. The back support 196 may be disposed on the opposite side 102 of the photovoltaic device 100. For example, the back support 196 may be formed adjacent to the conductive layer 190. The back support 196 may comprise any suitable material, including, for example, glass (e.g., soda-lime glass). In some embodiments, an encapsulation layer may also function as the back support 196.

[0028]

[0040] 2, 4, and 5 collectively, fabrication of photovoltaic devices 100, 210 generally involves sequentially disposing functional layers or layer precursors into a "stack" of layers by one or more thin film deposition processes, including, but not limited to, sputtering, spraying, evaporation, molecular beam deposition, pyrolysis, confined space sublimation (CSS), pulsed laser deposition (PLD), chemical vapor deposition (CVD), electrochemical deposition (ECD), atomic layer deposition (ALD), or vapor transport deposition (VTD). In some embodiments, VTD may be preferred for throughput quality. Fabrication may further include annealing and passivating steps.

[0029]

[0041] Fabrication of the photovoltaic device 100, 210 can further include selective removal, i.e., scribing, of certain layers of the stack of layers to divide the photovoltaic device 100, 210 into multiple photovoltaic cells 200. For example, the serial scribe 202 can include a first separation scribe 212 (also referred to as a P1 scribe), a series connection scribe 214 (also referred to as a P2 scribe), and a second separation scribe 216 (also referred to as a P3 scribe). The first separation scribe 212 can be formed to ensure that the TCO layer 140 is electrically isolated between the cells 200. Specifically, the first separation scribe 212 can be formed through the TCO layer 140, buffer layer 150, and absorber layer 160 of the photovoltaic device 100, or through the TCO layer 140, buffer layer 150, window layer 170, and absorber layer 160 of the photovoltaic device 210. The first isolation scribe 212 that borders the reverse-operating cell 208 may be filled with a dielectric material 198 .

[0030]

[0042] 2 and 4 , the series connection scribe 214 may be formed to electrically connect the photovoltaic cells 200 in series. For example, the series connection scribe 214 may be utilized to provide a conductive path from the conductive layer 190 of one of the photovoltaic cells 200 to the TCO layer 140 of another of the photovoltaic cells 200. The series connection scribe 214 may be formed through the absorber layer 160 and back contact layer 180 of the photovoltaic device 100, or through the window layer 170, absorber layer 160, and back contact layer 180 of the photovoltaic device 210. Optionally, the series connection scribe 214 may be formed through some or all of the buffer layer 150. Thus, the series connection scribe 214 may be formed after the back contact layer 180 is deposited. The series connection scribe 214 may then be filled with a conductive material, such as, but not limited to, the material of the conductive layer 190. In some embodiments, the conductive material may be more conductive under reverse bias compared to forward bias.

[0031]

[0043] A second separation scribe 216 may be formed to separate the back contact 190 into individual cells 200. The second separation scribe 216 may be formed through at least a portion of the conductive layer 190, the back contact layer 180, and the absorber layer 160. The second separation scribe 216 may be filled with a dielectric material 218.

[0032]

[0044] 1 and 5 collectively, parallel scribes 204 (also referred to as P4 scribes) may be formed to separate groups 206 of cells 200 from one another. In some embodiments, each group 206 may include a number of photovoltaic cells 200 connected in series, such as via series connection scribes 214. The parallel scribes 204 may be formed through the conductive layer 190, the back contact layer 180, the absorber layer 160, the buffer layer 150, the TCO layer 140, the barrier layer 130, and the window layer 170 (if present). According to embodiments provided herein, each of the parallel scribes 204, the first separation scribe 212, the series connection scribe 214, and the second separation scribe 216 may be formed by laser cutting or laser scribing. In some embodiments, the parallel scribes 204 may be filled with a dielectric material.

[0033]

[0045] 5-7, one embodiment of a photovoltaic device 100, 210 is shown. A plurality of photovoltaic cells 200 are formed on the substrate 110, each of the photovoltaic cells 200 including an absorber layer 160 and a conductive layer 190, the conductive layer 190 having a first surface 192 and a second surface 194, the first surface 192 of the conductive layer 190 facing the absorber layer 160. A bus member 224 is electrically coupled to the second surface 194 of the conductive layer 190 of at least one of the plurality of photovoltaic cells 200, the bus member 224 operable to collect current generated by the plurality of photovoltaic cells 200. A conductive member 226 is provided, the conductive member 226 having a portion 228 adjacent to a portion 230 of the bus member 224 to define a connection area 232 between the conductive member 226 and the bus member 224. The conductive members 226 extend from the connection region 232 across a portion of the plurality of photovoltaic cells 200. An insulating material 234 electrically insulates the conductive members 226 from the second surface 194 of the conductive layer 190 of the portion of the plurality of photovoltaic cells 200. A conductive adhesive layer is disposed between the bus member 224 and the conductive members 226 in the connection region 232. The conductive adhesive layer in the connection region 232 provides direct contact between the bus member 224 and the conductive members 226.

[0034]

[0046] 7 , it can be seen that a portion 228 of conductive member 226 adjacent a portion 230 of bus member 224, which defines a connection region 232 between conductive member 226 and bus member 224, is provided by overlapping portion 230 of bus member 224 with portion 228 of conductive member 226. It can further be seen that bus member 224 can intersect conductive member 226 at connection region 232. In this manner, bus member 224 can be electrically coupled to second surfaces 194 of conductive layers 190 of one or more photovoltaic cells 200 on each side of conductive member 226, such that bus member 224 is operable to collect current generated by photovoltaic cells 200 on each side of conductive member 226.

[0035]

[0047] After the layer stack with scribes is formed, bus connections can be added as described above and in detail below, and the photovoltaic device can be assembled. An encapsulation layer can be applied to seal the semiconductor layers against rain, snow, and other measurement elements. Next, referring to FIG. 8 , the substrate 110 and back support 196 can be laminated together to encapsulate the photovoltaic cell 200. The substrate 110 has a width and a length, and the back support 196 can have substantially the same width and length as the substrate 110. Each of the substrate 110 and back support 196 can be made of a suitable protective material, such as, for example, borosilicate glass, float glass, soda-lime glass, carbon fiber, or polycarbonate. The back support 196 may include a protective material. Alternatively, the back support 196 may be any suitable material, such as a polymer-based backsheet. The back support 196 and substrate 110 may protect the various layers of the photovoltaic device 100 from exposure to moisture and other environmental hazards. FIG. 8 shows a perspective view of the back of an example of a completed module. The module assembly 400 may include the layers described and shown in FIGS. 1-5 , as well as bussing, encapsulation, and electrical connectors. The photovoltaic module assembly 400 may be configured to connect to a load with an electrical connector that passes through a connection box 440. The electrical connector may include a first cable 415 with a first terminal 410 and a second cable 425 with a second terminal 420. The module assembly 400 may further include a support frame, bracket, or mount 430.

[0036]

[0048] 5-7 and 9-14, bus connections can be added in a variety of ways and configurations. Bus members 224 can be metal strips that can be added to the front and back of the photovoltaic device 100 to conduct the DC current generated by the photovoltaic cells 200. Typically, two bus members 224 can be added to the photovoltaic device 100 to conduct the DC current generated by the photovoltaic cells 200, as described below and shown in FIG. 6. The bus members 224 can also be referred to as bus bars, bus conductors, common conductors, photovoltaic ribbons, or buses. Each bus member 224 can function, for example, as one of the common positive and negative conductors electrically connected to the first cell 200 in the series or the last cell 200 in the series.

[0037]

[0049] 9-14 show a bus connection configuration near the peripheral edge 340, it will be understood that the photovoltaic device 100 can have an opposite second peripheral edge and a corresponding bus connection configuration near the second peripheral edge. In such an embodiment, the bus member 224 near the peripheral edge 340 can function as a positive bus, and the second bus member near the second peripheral edge can function as a negative bus. For example, referring now to FIG. 6, the photovoltaic device 100 can have a first peripheral edge 340a on the first side 207 with a first bus member 224a extending along a length Y and a first conductive member 226a extending along a width X, and a second peripheral edge 340b on the opposite second side 209 with a second bus member 224b extending along a length Y and a second conductive member 226b extending along a width X. The photovoltaic device 100 can have a first side edge 306 and a second side edge 308 extending along a width X on opposite sides of a length Y, and each of the first side edge 306 and the second side edge 308 can include a dead area similar to the respective peripheral edges 340a, 340b. However, for ease of illustration and description, only one peripheral edge 340 and one set of bus members 224 and conductive members 226 are shown and referred to in FIGS. 9-14. FIGS. 9-14 show one set of bus connection components, which can be replicated on the opposite side of the photovoltaic device 100. Thus, for example, when referring to FIGS. 9-14, it will be understood that the first photovoltaic cell 200a can alternatively be the last photovoltaic cell.

[0038]

[0050] 9A-9E, a photovoltaic device 100 is shown at certain sequential stages in the manufacturing process. The photovoltaic cells 200 can include a first cell 200a that is closest to a dead area 301 of the photovoltaic cells 200, the dead area 301 being formed by a suitable ablation method in a region of the photovoltaic device 100 extending inward from a peripheral edge 340 of the photovoltaic device 100. The first photovoltaic cell 200a is the photovoltaic cell 200 that is closest to the peripheral edge 340 of the photovoltaic device 100. In this embodiment, the first photovoltaic cell 200a is larger than each of the neighboring photovoltaic cells 200b, 200c, and 200d, as described in more detail below. The photovoltaic cells 200 are separated by parallel scribes 204.

[0039]

[0051] 9A , an insulating material 234 may be added over the photovoltaic cells 200, extending over at least a portion of the first photovoltaic cell 200a. The insulating material 234 extends over multiple photovoltaic cells 200. While FIG. 9A shows the first photovoltaic cell 200a, the second photovoltaic cell 200b, the third photovoltaic cell 200c, and the fourth photovoltaic cell 200d, it will be understood that the insulating material 234 may be added over any number of photovoltaic cells 200. Furthermore, the insulating material 234 need not extend over the entire first photovoltaic cell 200a. Rather, as seen in FIG. 9A , the insulating material 234 may extend over only a portion of the first cell 200a, in which case the insulating material 234 does not contact the dead area 301.

[0040]

[0052] The insulating material 234 can be, for example, double-sided tape. However, other electrically insulating materials are possible. The insulating material 234 can electrically insulate the conductive member 226 from the second surface 194 of the conductive layer 190 of the photovoltaic cell 200 that it contacts, and can also hold the conductive member 226 in place.

[0041]

[0053] 9B, conductive member 226 may be added on top of insulating material 234 such that conductive member 226 does not directly contact photovoltaic cell 200. Rather, conductive member 226 may directly contact insulating material 234. In this manner, insulating material 234 may electrically insulate conductive member 226 from photovoltaic cell 200. Conductive member 226 may be any conductive material, such as, but not limited to, a metal.

[0042]

[0054] 9C , a bus member 224 may be added over the conductive member 226 so as to extend across the first photovoltaic cell 200a and overlap the conductive member 226. The bus member 224 may be electrically coupled to the second surface 194 of the conductive layer 190 of the first photovoltaic cell 200a such that the bus member 224 is operable to collect current generated by the plurality of photovoltaic cells 200. The bus member 224 may directly contact the first photovoltaic cell 200a, or the bus member 224 may alternatively be coupled to the first photovoltaic cell 200a through a conductive material or conductive adhesive. Referring to FIG. 6 , the bus member 224 may extend along a length Y from a location near the blind area on the first side edge 306 of the photovoltaic device 100 to a location near the blind area on the second side edge 308 of the photovoltaic device 100. The bus member 224 can have a width W that extends entirely over the conductive member 226 and over the first photovoltaic cell 200a. As described above, the bus member 224 can be connected to the conductive member 226 by a conductive adhesive layer. In other embodiments, the bus member 224 can be in direct contact with the conductive member 226. The bus member 224 is operable to carry the generated photocurrent from the cell 200 to the conductive member 226. The conductive member 226 can, in turn, be operable to carry the photocurrent to the connection box 440.

[0043]

[0055] 9C, the overlap of bus members 224 onto conductive members 226 forms a configuration known as a T-connection 312. Bus members 224 may intersect conductive members 226 substantially orthogonally. However, the overlap of bus members 224 onto conductive members 226 need not be substantially orthogonal.

[0044]

[0056] 9D , an edge seal 320 may be added over a portion of the photovoltaic device 100 after adding the bus member 224. The edge seal 320 may extend along a length Y from a location near the dead area on the first side edge 306 to a location near the dead area on the second side edge 308, and may be at or near the peripheral edge 340 of the photovoltaic device 100. The edge seal 320 may cover a portion of the first photovoltaic cell 200a. A portion of the dead area 301 may be at or near the peripheral edge 340 of the photovoltaic device 100. 9D , edge seal 320 does not cover bus member 224. Thus, in this embodiment, edge seal 320 does not cover T-connection 312.

[0045]

[0057] The edge seal 320 can protect the photovoltaic device 100 from moisture intrusion, foreign objects, and other environmental hazards. The edge seal 320 can also function as an adhesive that bonds the device 100 together. Polyisobutylene (PIB), also known as butyl rubber, is a possible sealant material for the edge seal 320, but other examples of edge seal materials include, but are not limited to, opaque polymeric compounds. The edge seal material can also be dyed any desired color and can include any colorant. The edge seal material that forms the edge seal 320 can be applied in liquid hot melt form, in tape form, or by any other known technique. Liquid hot melt edge seal material can cool to a solid state when the substrate 110 and back support 196 are combined during manufacturing. Cured edge seal material can be applied in liquid hot melt form during manufacturing using a hot melt process, which can include, for example, a hot melt dispensing device. The hot melt dispensing device can dispense the liquid edge seal material through an applicator attached to a hose, which in turn delivers the liquid edge seal material from a dispensing pump connected to an edge seal material container. The edge seal material can further include a desiccant material.

[0046]

[0058] Next, referring to FIG. 9E , an intermediate layer 314 may be added to the photovoltaic device 100. The intermediate layer 314 may extend along the length Y from a location near the blind area on the first side edge 306 to a location near the blind area on the second side edge 308 of the photovoltaic device 100. The intermediate layer 314 may be applied to extend over a portion of the first photovoltaic cell 200a, completely covering the bus member 224 from a location near the blind area on the first side edge 306 to a location near the blind area on the second side edge 308. In this manner, the bus member 224 is protected by the intermediate layer 314 during subsequent manufacturing processes and is therefore less susceptible to movement due to forces associated with subsequent manufacturing steps. Portions of the first photovoltaic cell 200a, the insulating member 234, and the conductive member 226 may remain uncovered by both the intermediate layer 314 and the edge seal 320.

[0047]

[0059] The interlayer 314 can serve multiple functions. First, the interlayer 314 can act as a moisture barrier between the back support 196 and the plurality of photovoltaic cells 200. By being a moisture barrier, the interlayer 314 can prevent moisture-induced corrosion from occurring within the photovoltaic device 100. Consequently, this can improve the expected useful life of the device. Second, the interlayer 314 can act as an electrical insulator between the conductive core of the photovoltaic device 100 and any accessible points outside the photovoltaic device 100. For example, the interlayer 314 can limit or prevent leakage current from passing from the back contact of the photovoltaic device 100 to the back support 196. Third, the interlayer 314 can act as a bonding agent that attaches the back support 196 to the rest of the photovoltaic device 100. During manufacturing, the lamination process can heat the interlayer 314 under vacuum to allow the material to infiltrate adjacent bonding surfaces and, in some cases, initiate a cross-linking reaction. This process can promote bonding between the intermediate layer 314 and the back support 196, as well as bonding between the intermediate layer 314 and the conductive layer 190. Therefore, the intermediate layer 314 can function as a bonding agent within the photovoltaic device 100.

[0048]

[0060] The intermediate layer 314 can include any suitable material, such as, for example, ethylene (EVA), polyvinyl butyral (PVB), polydimethylsiloxane (PDMS), polyisobutylene (PIB), polyolefin, thermoplastic polyurethane (TPU), polyurethane, epoxy, silicone, ionomer, or a combination thereof. In some embodiments, the intermediate layer 314 can include a base material and a filler material. The base material can be any of ethylene (EVA), polyvinyl butyral (PVB), polydimethylsiloxane (PDMS), polyisobutylene (PIB), polyolefin, thermoplastic polyurethane (TPU), polyurethane, epoxy, silicone, ionomer, or a combination thereof. The filler material can include a flame retardant material, a desiccant material, a pigment, an inert material, or any combination thereof.

[0049]

[0061] 9A-9E can include a first photovoltaic cell 200a that is larger in size than neighboring photovoltaic cells 200b, 200c, and 200d. Specifically, first photovoltaic cell 200a can extend a distance d1 that is greater than each of distances d2, d3, and d4 of second, third, and fourth photovoltaic cells 200b, 200c, and 200d. This allows bus member 224 to be covered with intermediate layer 314 without sacrificing edge seal width, which is important for preventing moisture ingress from the environment. If the first photovoltaic cell 200a is not larger than the other photovoltaic cells 200b, 200c, and 200d, the interlayer 314 and the edge seal 320 may extend over each other during the manufacturing process unless the width of the edge seal 320 is reduced, both of which would reduce the effectiveness of the edge seal 320 as a moisture barrier. Furthermore, if the first photovoltaic cell 200a is not larger than the other photovoltaic cells 200b, 200c, and 200d, the interlayer 314 would have to be deposited over a larger area of ​​the photovoltaic device 100 (hence requiring a larger amount of interlayer material) to reach and cover the bus member 224 that extends across and is electrically coupled to the first photovoltaic cell 200a to collect the current generated from all of the series-connected power cells 200. Thus, as seen in FIG. 9E , the interlayer 314 can cover the bus member 224 and, in doing so, can cover a portion of the first photovoltaic cell 200a. As a result, the intermediate layer 314 can protect the bus member 224 during subsequent manufacturing steps that might otherwise require the bus member 224 to be physically removed. However, because the photovoltaic cells 200 are connected in series, a larger cell size for the first photovoltaic cell 200a does not result in a larger current passing from the photovoltaic cell 200 through the bus member 224. Therefore, improved device efficiency can be achieved with a bus connection configuration that reduces the size of the first photovoltaic cell 200a while still protecting the bus member 224.Provided herein is a photovoltaic device having a bus connection configuration that allows for a reduction in first photovoltaic cell size while still protecting the bus member 224 during manufacturing, thus achieving higher device efficiency.

[0050]

[0062] 10A-10E, a photovoltaic device 100 is shown at specific sequential steps in the manufacturing process. As seen in FIG. 10A, a dead area 301 abutting a peripheral edge 340 of the photovoltaic device 100 can be created by an appropriate ablation method. The photovoltaic device 100 can include a first photovoltaic cell 200a, a second photovoltaic cell 200b, a third photovoltaic cell 200c, and a fourth photovoltaic cell 200d adjacent to the dead area 301, separated by serial scribes 202. While four photovoltaic cells 200 are shown for illustrative purposes, it will be understood that the number of photovoltaic cells 200 is not particularly limited. In this embodiment, the first photovoltaic cell 200a has a smaller size compared to that of the embodiment shown in FIGS. 9A-9E. The distance d1 over which the first photovoltaic cell 200a extends may still be greater than each of the distances d2, d3, d4 over which the neighboring photovoltaic cells 200d, 200c, and 200d extend, but the distance d1 over which the first photovoltaic cell 200a extends may be greater than the distances d2, d3, d4 over which the neighboring photovoltaic cells 200d, 200c, and 200d extend, as shown in FIGS. 9A-9E. It may be smaller than the distance d1 that the first photovoltaic cell 200a extends in the embodiment.

[0051]

[0063] 10A, insulating material 234 can be added over the photovoltaic cells 200 in the same manner as previously described. The insulating material 234 can cover any number of photovoltaic cells 200, provided that the insulating material 234 extends over at least a portion of the first photovoltaic cell 200a. The insulating material 234 can extend to the dead area 301, but the insulating material 234 does not have to extend to the dead area 301.

[0052]

[0064] 10B, conductive member 226 may be deposited on insulating material 234. Conductive member 226 should not directly contact photovoltaic cell 200, but may directly contact insulating material 234. In this manner, insulating material 234 may function to electrically insulate conductive member 226 from second surface 194 of conductive layer 190 of photovoltaic cell 200. Insulating material 234 may also hold conductive member 226 in place during subsequent manufacturing steps.

[0053]

[0065] 10C , a bus member 224 may be added over the conductive member 226, the insulating material 234, and the first photovoltaic cell 200a. The bus member 244 may extend along a length Y from a location near the blind area on the first side edge 306 of the photovoltaic device 100 to a location near the blind area on the second side edge 308 of the photovoltaic device 100. The bus member 224 may have a width W that extends entirely over the conductive member 226 and over the first photovoltaic cell 200a. A T-connection 312 is formed by the bus member 224 overlapping the conductive member 226 and may be substantially orthogonal (and thus resemble a “T” shape). However, the portion of the bus member 224 that extends over the conductive member 226 need not be substantially orthogonal.

[0054]

[0066] 10D , an edge seal 320 may be added over the dead area 301 and the T-connection 312 from a location near the dead area on the first side edge 306 to a location near the dead area on the second side edge 308 to completely cover the T-connection 312. The edge seal 320 need not extend all the way to the peripheral edge 340. Rather, a portion of the dead area 301 may remain uncovered by the edge seal 320. However, in some embodiments, the edge seal 320 may extend all the way to the peripheral edge 340, leaving no dead area 301 uncovered by the edge seal 320. Advantageously, in the embodiment shown in FIG. 10D , the edge seal 320 completely covers the bus member 224 during subsequent manufacturing steps (such as a lamination process), thereby protecting the bus member 224 during subsequent manufacturing steps.

[0055]

[0067] 10E, an intermediate layer 314 may be added over photovoltaic cells 200b, 200c, and 200d and a portion of first photovoltaic cell 200a. Two regions 316a, 316b of first photovoltaic cell 200a on opposite sides of insulating material 234 may remain uncovered by edge seal 320 and uncovered by intermediate layer 314. Similarly, region 318 of conductive member 226 and two regions 322a, 322b of insulating material 234 may remain uncovered by edge seal 320 and uncovered by intermediate layer 314. In this embodiment, because edge seal 320 covers bus members 224, intermediate layer 314 is not used to cover bus members 224. Therefore, less intermediate layer material may be used than if intermediate layer 314 had to cover bus members 224.

[0056]

[0068] 10C, the bus members 224 may be deposited over the conductive members 226 and insulating material 234 in areas closer to the peripheral edge 340 of the photovoltaic device 100 than in the embodiment shown in FIGS. In this embodiment, the bus members 224 (and T-connections 312) are completely covered by the edge seal 320 instead of the interlayer 314, and therefore the amount of interlayer material required to cover the bus members 224 is not a factor in determining the positioning of the bus members 224. As a result, the first photovoltaic cell 200a can be smaller than that of the embodiment shown in FIGS. 9A-9E because the interlayer 314 does not need to reach the bus members 224 and therefore does not need to use an undesirable amount of interlayer material. Because this embodiment allows the T-connections 312 to be closer to the peripheral edge 340 while still being covered and protected during subsequent manufacturing steps, the distance d1 over which the first photovoltaic cell 200a extends can be reduced so that it is closer in size to the distance d2 over which the second photovoltaic cell 200b extends, or the distance over which neighboring photovoltaic cells 200c, 200d extend. In this manner, the overall efficiency of the photovoltaic device 100 can be improved.

[0057]

[0069] 11A-11E, an alternative embodiment of photovoltaic device 100 is shown at a particular sequential step in the manufacturing process. In this embodiment, T-connection 312 is covered by edge seal 320, but less edge seal material is used compared to the embodiment shown in FIGS. 10A-10E.

[0058]

[0070] 11A, an insulating material 234 may be added over the photovoltaic cells 200 in the same manner as described above, extending over at least a portion of the first photovoltaic cell 200a. A dead area 301 may be created adjacent a peripheral edge 340 of the photovoltaic device 100 by a suitable ablation method. The dead area 301 may extend along a length Y from a first side edge 306 to a second side edge 308. The first photovoltaic cell 200a is adjacent to the dead area 301.

[0059]

[0071] 11B, a conductive member 226 may be added over the insulating material 234 as previously described. The conductive member 226 may be positioned over at least a portion of the first photovoltaic cell 200a. The conductive member 226 may extend over the plurality of photovoltaic cells 200. The conductive member 226 may contact the dead area 301. In other embodiments, the conductive member 226 and the dead area 301 do not contact each other.

[0060]

[0072] 11C , a bus member 224 can be added on top of the conductive member 226 to form a T-connection 312 in which the bus member 224 overlaps the conductive member 226. The bus member 224 can extend from a location near the blind area on the first side edge 306 of the photovoltaic device 100 to a location near the blind area on the second side edge 308. The bus member 224 can have a width W that extends entirely over the conductive member 226 and over the first photovoltaic cell 200a. The bus member 224 can be electrically coupled to the first photovoltaic cell 200a and to the conductive member 226. The bus member 224 can directly contact the first photovoltaic cell 200a or, alternatively, can be electrically coupled to the first photovoltaic cell 200a via a conductive metal or a conductive adhesive. The bus member 224 can directly contact the conductive member 226 or, alternatively, can be electrically coupled to the conductive member 226 by a conductive adhesive.

[0061]

[0073] 11D , the edge seal 320 may be formed with a shape that includes a tab 324 that extends over the T-connection 312. The edge seal 320 may be positioned along or near the peripheral edge 340, but need not extend all the way to the peripheral edge 340. Rather, as seen in FIG. 11D , a portion of the dead area 301 may remain uncovered by the edge seal 340. A portion of the edge seal 320 may extend along the length Y from a location near the dead area on the first side edge 306 to a location near the dead area on the second side edge 308, while the tab 324 then does not extend to the same extent along the length Y. Rather, the tab 324 may be longer than the length l1 of the remaining edge seal 320. The edge seal 320 may have a shorter length l2. The edge seal 320 may include side portions 360, 362 that extend from the region 321 of the edge seal 320 having the longer length l1 to the tab 324 having the shorter length l2. The side portions 360, 362 may be angular, as seen in FIG. 11D , or alternatively, may be substantially parallel to the first side edge 306 and the second side edge 308.

[0062]

[0074] The tab 324 of the edge seal 320 can extend to a position over the serial scribe line 202 separating the first photovoltaic cell 200a from the second photovoltaic cell 200b. The remaining portion of the edge seal 320 between the tab 324 and the peripheral edge 340 can cover only a portion of the first photovoltaic cell 200a. In this embodiment, the edge seal 320 is defined by a region 321 from the first side edge 320 to a side portion 360 having a first length l1 and extending inward from the peripheral edge 340 to the serial scribe line 202, and then the tab 324 having a second length l2 from the side portion 360 above the T-connection 312 to a side portion 362 that extends back to the region 321 having the first length l1. The edge seal 320 can have a first length l1 above the blind area 301 and a second length l2 above the T-connection 312, where the first length l1 is greater than the second length l2.

[0063]

[0075] 11D , tab 324 can extend over bus member 224 from a first side edge 350 of insulating material 234 to a second side edge 352 of insulating material 234. In other embodiments, tab 324 can extend over bus member 224 from a first side edge 354 of conductive member 226 to a second side edge 356 of conductive member 226. Tab 324 can extend over serial scribe lines 202 and can extend to the side of insulating material 234 over some portions of first photovoltaic cell 200a. However, this is not required.

[0064]

[0076] Advantageously, as seen in Figures 11D-11E, the T-connection 312 may be covered by an edge seal 320. However, the edge seal 320 does not cover the entire bus member 224 across the length Y of the photovoltaic device 100. Rather, the bus member 224 remains uncovered by the edge seal 320 at a portion 225a, 225b on each side of the T-connection 312.

[0065]

[0077] Next, referring to FIG. 11E , the intermediate layer 314 may be added as previously described. After the intermediate layer 314 is added, portions 225 a, 225 b of the bus member 224 may not be covered by the intermediate layer 314, and therefore may not be covered by both the edge seal 320 and the intermediate layer 314. Moreover, the area of ​​the first photovoltaic cell 200 a on the opposite side of the T-connection 312 may also not be covered by the edge seal 320 and may not be covered by the intermediate layer 314. In any case, because the bus member 224 is covered by the edge seal 320 where it overlaps the conductive member 226, the T-connection 312 is more robust and protected during subsequent manufacturing steps. Advantageously, this embodiment does not require as much material to form the edge seal 320 as the embodiment shown in FIGS. 10A-10E . This embodiment also allows for a reduction in the size of the first photovoltaic cell 200 a since the intermediate layer 314 is not used to cover and protect the T-connection 312 .

[0066]

[0078] 12A-12F, alternative embodiments of a photovoltaic device 100 are shown at specific sequential steps in the manufacturing process. As shown in FIGS. 12A-12B, an insulating material 234 may be added over the photovoltaic cell 200, and a conductive member 226 may be added over the insulating material 234, as previously described. A dead zone 301 may extend inward from a peripheral edge 340 of the photovoltaic device 100, and may be removed by an appropriate ablation method. The insulating material 234 has a peripheral edge 334 that may be on the first photovoltaic cell 200a and near the dead area 301. In other embodiments, the peripheral edge 334 of the insulating material 234 may be on the dead area 301. The conductive member 226 has a peripheral edge 358 that may be opposite the peripheral edge 334 from the dead area 301, but still on the first photovoltaic cell 200a.

[0067]

[0079] 12C , a bridge 332 may be formed on the insulating material 234 and the conductive member 226. The bridge 332 may cover a peripheral edge 358 of the conductive member 226 and may extend over an adjacent portion of the insulating material 234. The bridge 332 may extend over a peripheral edge 334 of the insulating material 234. The bridge 332 may be formed, for example, from a wide conductive metal with a conductive adhesive and may function to bridge the bus member 224 and the conductive member 226. In some embodiments, the bridge 332 is a multi-layer structure comprised of one or more conductive metal layers and one or more conductive adhesive layers. In some embodiments, the bridge 332 is a multi-layer structure comprised of a liner, one or more layers of conductive metal, and one or more layers of conductive adhesive. In some embodiments, the bridge 332 is a multi-layer structure comprised of two or more conductive metal layers and two or more conductive adhesive layers.

[0068]

[0080] Next, referring to FIG. 12D , a bus member 224 may be added on top of the bridge 332. The bus member 224 may extend along a length Y from a location near the dead zone on the first side edge 306 of the photovoltaic device 100 to a location near the dead zone on the second side edge 308. The bus member 224 may have a width W that completely spans the first photovoltaic cell 200a. The bus member 224 may be electrically coupled to the first photovoltaic cell 200a, for example, by directly contacting the first photovoltaic cell 200a or via a conductive metal or conductive adhesive. Additionally, the bus member 224 may be in direct contact with the bridge 332. The bridge 332 may be disposed between the conductive member 226 and the bus member 224. The bridge 332 may be configured to electrically couple the conductive member 226 to the bus member 224. The bridge 332 may function to enhance the conduction of electrical current between the bus member 224 and the conductive member 226.

[0069]

[0081] 12E , an edge seal 320 may be formed over the bus member 224 and a portion of the bridge 332 and insulating material 224. The edge seal 340 may cover the entire bus member 224. The edge seal 320 may extend from a location near the dead area on the first side edge 306 of the photovoltaic device 100 to a location near the dead area on the second side edge 308. The edge seal 320 may leave a portion of the dead area 301 uncovered at or near the peripheral edge 340 of the photovoltaic device 100. In an alternative embodiment, the edge seal 320 may extend to the peripheral edge 340 so that the dead area 301 is not left uncovered by the edge seal 320.

[0070]

[0082] 12F , intermediate layer 314 may be formed to leave exposed areas 336 of bridge 332 and exposed areas 338a, 338b of insulating material 234, such areas 336, 338a, 338b uncovered by edge seal 320 and uncovered by intermediate layer 314. Additionally, conductive members 226 may be partially covered by bridge 332 and partially covered by intermediate layer 314. In this embodiment, bus members 224 are completely covered by edge seal 320 and, therefore, may be protected by edge seal 320 during subsequent manufacturing steps. Thus, advantageously, this embodiment also allows for a reduction in the size of first photovoltaic cell 200a, since intermediate layer 314 is not used to protect bus members 224.

[0071]

[0083] 13A-13E, an alternative embodiment is shown in which bridge 332 is formed on bus member 224 rather than between bus member 224 and conductive member 226. As shown in FIGS. 13A-13B, insulating material 234 and then conductive member 226 may be applied over photovoltaic cell 200 as previously described. Insulating material 234 may extend over at least a portion of first photovoltaic cell 200a. A dead zone 301 extending inward from a peripheral edge 340 of photovoltaic device 100 may be formed by a suitable ablation method.

[0072]

[0084] 13C, a bus member 224 may be applied over the conductive member 226 and over the first photovoltaic cell 200a in a similar manner, extending along a length Y from a location near the dead zone on the first side edge 306 of the photovoltaic cell 100 to a location near the dead zone on the second side edge 308. The bus member 224 may have a width W that resides entirely over the first photovoltaic cell 200a. The bus member 224 may be electrically coupled to the first photovoltaic cell 200a by direct contact or via a conductive metal or conductive adhesive, for example. However, in this embodiment, in contrast to the embodiment shown in FIGS. 12A-12F, the bus member 224 is applied before the bridge 332.

[0073]

[0085] 13D , a bridge 332 may be applied over the bus member 224 and extended into place at the peripheral edge 358 of the conductive member 226 and the peripheral edge 334 of the insulating material 234. As in the previous embodiment, the bridge 332 may be formed from a wide conductive metal with a conductive adhesive and may function to bridge the bus member 224 and the conductive member 226. In some embodiments, the bridge 332 is a multi-layer structure comprised of one or more conductive metal layers and one or more conductive adhesive layers. In some embodiments, the bridge 332 is a multi-layer structure comprised of a liner, one or more layers of conductive metal, and one or more layers of conductive adhesive. In some embodiments, the bridge 332 is a multi-layer structure comprised of two or more conductive metal layers and two or more conductive adhesive layers. However, in contrast to the previous embodiment, the bridge 332 may be disposed over the bus member 224 and the conductive member 226 such that a portion of the bus member 224 is disposed between the insulating material 234 and the bridge 332 and a portion of the conductive member 226 is disposed between the insulating material 234 and the bridge 332. The bus member 224 may not directly contact the conductive member 226, but is electrically coupled to the conductive member 226 through the bridge 332. In this embodiment, the bus member 224 is conductive on both sides to facilitate electrical communication. That is, the bus member 224 may include a first surface comprising a conductive material and facing the first photovoltaic cell 200a, and a second surface comprising a conductive material and facing the bridge 332.

[0074]

[0086] 13E-13F, the application of the edge seal 320 and intermediate layer 314 can be the same as previously described. The edge seal 320 can extend along the length Y from a location near the dead area on the first side edge 306 to a location near the dead area on the second side edge 308, leaving uncovered a portion of the dead area 301 adjacent the peripheral edge 340 of the photovoltaic device 100. Alternatively, the edge seal 320 can extend to the peripheral edge 340 such that no part of the dead area 301 remains uncovered by the edge seal 320. The edge seal 320 can extend along the width X to cover the exposed portions of the bus members 224 that are not covered by the bridges 332. Thus, in this embodiment, the bridges 332 and edge seal 320 can protect the bus members 224 during subsequent manufacturing steps.

[0075]

[0087] The intermediate layer 314 extends along a length Y from a location near the dead zone on the first side edge 306 of the photovoltaic device 100 to a location near the dead zone on the second side edge 308. The intermediate layer 314 can cover the portions of the bridge 332, the conductive members 226, and the insulating material 234 that are not covered by the edge seal 320. Thus, in this embodiment, the bus members 224 are again completely covered by the edge seal 320 and can therefore be protected by the edge seal 320 during subsequent manufacturing steps. Therefore, this embodiment advantageously allows for a reduction in the size of the first photovoltaic cell 200a because the intermediate layer 314 is not used to cover and protect the bus members 224.

[0076]

[0088] 14A-14E, alternative embodiments of photovoltaic device 100 are shown at particular sequential stages in the manufacturing process. As shown in FIGS. 14A-14B, insulating material 234 and then conductive members 226 may be added over photovoltaic cell 200 as previously described. Insulating material 234 and conductive members 226 may extend over at least a portion of first photovoltaic cell 200a. Dead zone 301 may be formed adjacent peripheral edge 340 of photovoltaic device 100 by a suitable ablation method.

[0077]

[0089] 14C , patches 342 may be added over the insulating material 234 and the conductive member 226. The patches 342 may be composed of a conductive material and may be printed on the photovoltaic device 100. However, the patches 342 do not need to be printed conductors. The patches 342 may function to enhance the conduction of electricity generated from the photovoltaic cell 200 to the bus member 224.

[0078]

[0090] 14C, patch 342 may include an upper portion 344 and a lower portion 346. Lower portion 346 may have a width W of conductive member 226. C , but the overall width W of the insulating material 234 I , and the upper portion 344 may not be wide enough to cover the entire width W of the insulating material 234. I The patch 342 may be wide enough to extend across the first photovoltaic cell 200a for a distance greater than 1 / 2 . The upper portion 344 may not cover the insulating material 234 or the conductive member 226. The lower portion 346 may cover a segment of the conductive member 226 across the entire width WC of the conductive member 226, as well as the periphery of the insulating material 234. The patch 342 may cover a peripheral edge 334 of the insulating material 234 and a peripheral edge 358 of the conductive member 226, and the upper portion 344 may extend beyond the peripheral edge 334 of the insulating material 234 toward the dead zone 301 and toward an edge 306 on a first side of the photovoltaic device 100 and / or an edge 308 on a second side of the photovoltaic device 100.

[0079]

[0091] 14D , a bus member 224 may be added across the top portion 344 of the patch 342, extending along a length Y from a location near the blind area on the first side edge 306 of the photovoltaic device 100 to a location near the blind area on the second side edge 308. The bus member 224 may have a width W that completely covers the first photovoltaic cell 200a. The bus member 224 may be electrically coupled to the first photovoltaic cell 200a by direct contact or via a conductive metal or conductive adhesive, for example. The bus member 224 may be electrically coupled to the conductive member 226 through the patch 342.

[0080]

[0092] 14E, edge seal 320 and intermediate layer 314 may be added as previously described and extend along length Y from a location near the dead zone on first side edge 306 to a location near the dead zone on second side edge 308 of photovoltaic device 100. Edge seal 320 may completely cover bus member 224, thus protecting bus member 224 during subsequent manufacturing steps. Areas 348a, 348b of insulating material 234 on each side of patch 342 and area 351 of patch 342 remain uncovered by edge seal 320 and uncovered by intermediate layer 314. However, the bus member 224 may be completely covered by the edge seal 320. Therefore, this embodiment also allows for a reduction in the size of the first photovoltaic cell 200a because the intermediate layer 314 is not used to cover and protect the bus member 224 during subsequent manufacturing steps. Moreover, the patch 342 can further provide robustness to the bus member 224 while enhancing electrical conduction from the photovoltaic cell 200 through the bus member 224 to the conductive member 226.

[0081]

[0093] Advantageously, the photovoltaic devices 100 described herein can have a bussing configuration that reduces dead area losses from the end cells to nearly zero, thereby improving device efficiency. Moreover, the photovoltaic devices 100 described herein can have a bussing configuration that allows for low and stable contact resistance of the T-connections 312, which is important for good device performance.

[0082]

[0094] The bus connection components described herein, such as insulating material 234, conductive members 226, bridges 332, patches 342, edge seals 320, and intermediate layers 314, can each be deposited in any suitable manner and added sequentially in a conveyorized system using one or more stations or chambers. Some components, such as patches 342, can be printed onto photovoltaic device 100. However, patches 342 need not be printed and may be applied by other methods.

[0083]

[0095] According to embodiments described herein, a photovoltaic device can include a bus member that is completely covered under an edge seal. The edge seal can protect the bus member during certain manufacturing steps. According to embodiments described herein, a photovoltaic device can include a bus member that overlaps a conductive member to define a T-connection, where the T-connection is completely covered under the edge seal. However, in some embodiments, at least a portion of the bus member is not covered by the edge seal, but the portion of the bus member that overlaps the conductive member (i.e., the T-connection) is covered by the edge seal. For example, in some embodiments, two portions of the bus member on opposite sides of the T-connection are not covered by the edge seal. By "covered," it is meant that the bus member, or a portion thereof, is disposed between the edge seal and the photovoltaic cell.

[0084]

[0096] According to embodiments described herein, a photovoltaic device can include a patch of conductive material that overcomes the tolerances of a T-connection defined by the overlap of a bus member over a conductive member, improving robustness.

[0085]

[0097] According to embodiments described herein, a photovoltaic device can include a bridge comprised of a conductive metal and a conductive adhesive that electrically couples the bus member to the conductive member. According to embodiments described herein, the bridge can be a multi-layer structure comprised of two or more layers of conductive metal and two or more layers of conductive adhesive. According to embodiments described herein, the bridge can be a multi-layer structure comprised of one or more layers of conductive metal and one or more layers of conductive adhesive. According to embodiments described herein, the bridge can be a multi-layer structure comprised of a liner, one or more layers of conductive metal, and one or more layers of conductive adhesive.

[0086]

[0098] According to embodiments described herein, a photovoltaic device having a bus member disposed between an edge seal and a plurality of photovoltaic cells can further include a bridge comprising a conductive adhesive electrically coupling the bus member to the conductive member. In certain embodiments, the bridge is disposed between the insulating material and the bus member. In certain embodiments, the bridge is disposed between the bus member and the edge seal.

[0087]

[0099] According to embodiments described herein, a photovoltaic device having a bus member disposed between an edge seal and a plurality of photovoltaic cells can further include a conductive patch disposed between the conductive member and the bus member.

[0088]

[0100] According to embodiments described herein, a bridge or Photovoltaic devices having patches can also have bus members that are not completely covered by the edge seal. Rather, the bus members can include one or more portions that are not disposed between the edge seal and the photovoltaic cells.

[0089]

[0101] According to embodiments described herein, a bridge or The photovoltaic device having the patch can also have an edge seal having a first length and a second length, the first length and the second length being different, and a side portion connecting the first length of edge seal material and the second length of edge seal material.

[0090]

[0102] According to embodiments described herein, a bridge or The photovoltaic device having the patch may further include an edge seal disposed over the T-connection defined by the overlap of the bus member over the conductive member, but not over at least a portion of the bus member. In an alternative embodiment, the edge seal is disposed over the entire bus member.

[0091]

[0103] According to embodiments described herein, the photovoltaic device may include a liner, a metal, and a conductive adhesive. Such bus members can be used in photovoltaic devices having patches or bridges as described herein. Such bus members can also be used in photovoltaic devices having an edge seal that covers some or all of the bus member.

[0092]

[0104] According to embodiments described herein, the photovoltaic device includes a first electrode above the dead area. The photovoltaic device may include an edge seal having one length and a second length above the T-connection defined by the overlap of the bus member over the conductive member, where the first length is greater than the second length. In some embodiments, the bus member of such a photovoltaic device includes two portions not covered by the edge seal. In some embodiments, the photovoltaic device further includes a bridge as described herein. In some embodiments, the photovoltaic device further includes a patch as described herein.

[0093]

[0105] Certain embodiments of the devices and methods disclosed herein are described in the examples above. It should be understood that these examples, while indicating particular embodiments, are given by way of illustration only. From the above discussion and these examples, one skilled in the art can ascertain the essential features of the present disclosure and can make various changes and modifications to adapt the devices and methods described herein to various uses and conditions without departing from the spirit and scope of the present disclosure. Various modifications may be made, and equivalents may be substituted for elements thereof without departing from the essential scope of the present disclosure. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the present disclosure without departing from the essential scope of the present disclosure. [Mode of the invention] [1] a plurality of electrically connected photovoltaic cells, each of the photovoltaic cells including a conductive layer having a first surface and a second surface, the first surface facing an absorber layer; an insulating material disposed on the second surface over at least one of the photovoltaic cells; a conductive member on the insulating material, the insulating material configured to electrically insulate the conductive member from the second surface; a bus member electrically coupled to one of the plurality of photovoltaic cells and to the conductive member; an edge seal including a sealant material extending over at least a portion of said one of said plurality of photovoltaic cells; 1. A photovoltaic device comprising: the bus member is disposed between the edge seal and the plurality of photovoltaic cells. Photovoltaic devices. [2] the bus members overlap the conductive members to define a T-connection; the T-connection is disposed between the edge seal and the plurality of photovoltaic cells; 2. The photovoltaic device of claim 1, wherein at least a portion of the bus member is not present between the edge seal and the plurality of photovoltaic cells. [3] 3. The photovoltaic device of claim 2, wherein the two portions of the bus member are not present between the edge seal and the plurality of photovoltaic cells. [4] 10. The photovoltaic device of 1, further comprising an intermediate layer disposed on at least some of the plurality of photovoltaic cells. [5] 2. The photovoltaic device of claim 1, wherein the bus member resides entirely between the edge seal and the plurality of photovoltaic cells. [6] 2. The photovoltaic device of claim 1, wherein the bus member is between the edge seal and the conductive member. [7] 7. The photovoltaic device of 6, wherein the conductive member is between the bus member and the insulating material. [8] 2. The photovoltaic device of claim 1, further comprising a bridge formed on the conductive member and the insulating material, the bridge comprising a conductive adhesive and electrically coupling the conductive member to the bus member. [9] 9. The photovoltaic device of claim 8, wherein a first portion of the bridge is disposed under the edge seal, a second portion of the bridge is not covered by the edge seal and is not covered by the intermediate layer, and a third portion of the bridge is disposed under the intermediate layer.

[10] 9. The photovoltaic device of claim 8, wherein the bridge comprises a multi-layer structure including a liner, one or more layers of conductive metal, and one or more layers of the conductive adhesive.

[11] 9. The photovoltaic device of claim 8, wherein the bridge comprises a multi-layer structure including two or more layers of conductive metal and two or more layers of the conductive adhesive.

[12] 9. The photovoltaic device of claim 8, wherein the bridge comprises a multi-layer structure including one or more conductive metal layers and one or more conductive adhesive layers.

[13] a plurality of electrically connected photovoltaic cells, the photovoltaic cells having a first surface and a second surface; a conductive layer having a first surface facing the absorber layer; an insulating material disposed on the second surface over at least one of the photovoltaic cells; a conductive member on the insulating material, the insulating material configured to electrically insulate the conductive member from the second surface; a bridge on the insulating material and the conductive member, the bridge including a conductive metal and a conductive adhesive; a bus member electrically coupled to one of the plurality of photovoltaic cells and to the conductive member, the bridge electrically coupling the bus member to the conductive member; 1. A photovoltaic device comprising:

[14] an edge seal including a sealant material extending over at least a portion of said one of said plurality of photovoltaic cells; further comprising 14. The photovoltaic device of claim 13, wherein the bus member is disposed between the edge seal and the photovoltaic cell.

[15] 15. The photovoltaic device of claim 14, wherein the bridge is disposed between the edge seal and the bus member.

[16] 14. The photovoltaic device of claim 13, wherein the bridge is disposed between the bus member and the insulating material.

[17] 14. The photovoltaic device of claim 13, wherein the bus member is directly on the bridge and adjacent to the conductive member.

[18] 14. The photovoltaic device of claim 13, wherein the bridge comprises a multi-layer structure including a liner, one or more metal layers, and one or more conductive adhesive layers.

[19] 14. The photovoltaic device of claim 13, wherein the bridge comprises a multi-layer structure comprised of two or more layers of conductive metal and two or more layers of conductive adhesive.

[20] 14. The photovoltaic device of claim 13, wherein the bridge comprises a multi-layer structure including one or more conductive metal layers and one or more conductive adhesive layers. [twenty one] 14. The photovoltaic device of claim 13, wherein the bus member has a first surface comprising a conductive material facing the one of the plurality of photovoltaic cells, and a second surface comprising a conductive material facing the bridge. [twenty two] 14. The photovoltaic device of claim 13, wherein the bridge is disposed between the conductive member and the bus member. [twenty three] a plurality of electrically connected photovoltaic cells, each of the photovoltaic cells including a conductive layer having a first surface and a second surface, the first surface facing an absorber layer; an insulating material disposed on the second surface over at least one of the photovoltaic cells; a conductive member on the insulating material, the insulating material configured to electrically insulate the conductive member from the second surface; a patch comprising conductive material on a peripheral edge of the conductive member and a peripheral edge of the insulating material; a bus member on the one of the plurality of photovoltaic cells and the patch, the bus member electrically coupled to the one of the plurality of photovoltaic cells, and the patch electrically coupling the bus member to the conductive member; an edge seal including a sealant material extending over at least a portion of the one of the plurality of photovoltaic cells; 1. A photovoltaic device comprising: The photovoltaic device, wherein the bus member is disposed between the edge seal and the patch. [twenty four] 24. The photovoltaic device of claim 23, wherein the patch is a printed conductor. [twenty five] 24. The photovoltaic device of claim 23, wherein the patch includes an upper portion and a lower portion, the upper portion contacting the one of the plurality of photovoltaic cells.

[26] 26. The photovoltaic device of claim 25, wherein the top portion is disposed between the bus member and the plurality of photovoltaic cells.

[27] 26. The photovoltaic device of claim 25, further comprising an intermediate layer extending over at least a portion of the plurality of photovoltaic cells, the lower portion being at least partially disposed between the intermediate layer and the conductive member.

[28] a plurality of electrically connected photovoltaic cells, each of the photovoltaic cells including a conductive layer having a first surface and a second surface, the first surface facing an absorber layer; an insulating material disposed on the second surface over at least one of the photovoltaic cells; a conductive member on the insulating material, the insulating material configured to electrically insulate the conductive member from the second surface; a bus member electrically coupled to the one of the plurality of photovoltaic cells and to the conductive member, the bus member extending over the conductive member to define a T-connection; an edge seal including a sealant material extending over the T-connection 1. A photovoltaic device comprising:

[29] 29. The photovoltaic device of 28, further comprising an intermediate layer disposed over at least some of the plurality of photovoltaic cells.

[30] 29. The photovoltaic device of claim 28, further comprising a dead area abutting a peripheral edge of the photovoltaic device, the edge seal comprising a first length over the dead area and a second length over the T-connection, the first length being greater than the second length.

[31] 29. The photovoltaic device of claim 28, wherein the bus member includes two portions not covered by the edge seal.

[32] 32. The photovoltaic device of any of 1 to 31, wherein the intermediate layer comprises ethylene (EVA), polyvinyl butyral (PVB), polydimethylsiloxane (PDMS), polyisobutylene (PIB), polyolefin, thermoplastic polyurethane (TPU), polyurethane, epoxy, silicone, ionomer, or a combination thereof.

[33] The intermediate layer includes a base material and a filler material, and the base material is selected from the group consisting of ethylene (EVA), polyvinyl butyral (PVB), polydimethylsiloxane (PDMS), polyisobutylene (PIB), polyolefin, thermoplastic polyurethane (TPU), polyurethane. 33. The photovoltaic device of any of 1 to 32, wherein the filler material comprises a flame retardant material, a desiccant material, a pigment, an inert material, or any combination thereof.

[34] 34. The photovoltaic device of any of 1 to 33, wherein the sealant material comprises polyisobutylene (PIB), a desiccant material, or a combination thereof.

[35] 35. The photovoltaic device of any of 1 to 34, wherein the absorber layer comprises cadmium, tellurium, and selenium.

[36] 37. The photovoltaic device of any one of 1 to 35, wherein the insulating material comprises double-sided tape. 37. A photovoltaic device according to any one of 1 to 36, wherein the conductive member comprises a lead foil.

[38] 38. A photovoltaic device according to any one of 1 to 37, wherein the plurality of electrically connected photovoltaic cells are disposed between a substrate and a back support, the substrate defining an upper outer surface of the photovoltaic device and the back support defining a lower outer surface of the photovoltaic device.

[39] 39. The photovoltaic device of any of 1 to 38, wherein the photovoltaic cell defines a first side edge of the photovoltaic device and a second side edge of the photovoltaic device, the photovoltaic device has a peripheral edge extending between the first side edge and the second side edge, and the bus member extends from a location near a blind area on the first side edge to a location near a blind area on the second side edge.

[40] 40. A photovoltaic device according to any one of 1 to 39, wherein the photovoltaic cell defines a first side edge of the photovoltaic device and a second side edge of the photovoltaic device, the photovoltaic device has a peripheral edge extending between the first side edge and the second side edge, and the edge seal extends from a location near the blind area of ​​the first side edge to a location near the blind area of ​​the second side edge.

[41] 41. A photovoltaic device according to any one of 1 to 40, wherein the photovoltaic cells define a first side edge of the photovoltaic device and a second side edge of the photovoltaic device, the photovoltaic device having a peripheral edge extending between the first side edge and the second side edge, and a blind area not including photovoltaic cells extending from the peripheral edge.

[42] 42. The photovoltaic device of any of 1 to 41, wherein the bus member comprises a multilayer structure including a liner, a metal, and a conductive adhesive.

Claims

1. a plurality of electrically connected photovoltaic cells, wherein the photovoltaic cells include a conductive layer having a first surface and a second surface, the first surface facing an absorber layer; an insulating material disposed on the second surface over at least one of the photovoltaic cells; a conductive member on the insulating material, wherein the insulating material is configured to electrically insulate the conductive member from the second surface; a bus member electrically coupled to one of the plurality of photovoltaic cells and to the conductive member; and Edge seal containing sealant material 1. A photovoltaic device comprising: the bus member is between the edge seal and the conductive member; the bus members overlap the conductive members to define a T-connection; and at least a portion of the bus member is not between the edge seal and the plurality of photovoltaic cells; Photovoltaic devices.

2. The photovoltaic device of claim 1 , wherein the conductive member is between the bus member and the insulating material.

3. The photovoltaic device of claim 1 , further comprising an intermediate layer disposed over at least some of the plurality of photovoltaic cells.

4. 10. The photovoltaic device of claim 1, further comprising a dead area abutting a peripheral edge of the photovoltaic device, the edge seal comprising a first length over the dead area and a second length over the T-connection, the first length being greater than the second length.

5. The photovoltaic device of claim 1 , wherein a layer of conductive adhesive is disposed between the bus member and the conductive member.

6. 4. The photovoltaic device of claim 3, wherein the intermediate layer comprises ethylene (EVA), polyvinyl butyral (PVB), polydimethylsiloxane (PDMS), polyisobutylene (PIB), polyolefin, thermoplastic polyurethane (TPU), polyurethane, epoxy, silicone, ionomer, or a combination thereof.

7. 4. The photovoltaic device of claim 3, wherein the intermediate layer comprises a base material and a filler material, the base material comprising ethylene (EVA), polyvinyl butyral (PVB), polydimethylsiloxane (PDMS), polyisobutylene (PIB), polyolefin, thermoplastic polyurethane (TPU), polyurethane, epoxy, silicone, ionomer, or a combination thereof, and the filler material comprises a flame retardant material, a desiccant material, a pigment, an inert material, or any combination thereof.

8. The photovoltaic device of claim 1 , wherein the sealant material comprises polyisobutylene (PIB), a desiccant material, or a combination thereof.

9. The photovoltaic device of claim 1 , wherein the absorber layer comprises cadmium, tellurium, and selenium.

10. The photovoltaic device of claim 1 , wherein the insulating material comprises double-sided tape.

11. The photovoltaic device of claim 1 , wherein the conductive member comprises a lead foil.

12. 12. The photovoltaic device of claim 1, wherein the plurality of electrically connected photovoltaic cells are disposed between a substrate and a back support, the substrate defining an upper outer surface of the photovoltaic device, and the back support defining a lower outer surface of the photovoltaic device.

13. 13. The photovoltaic device of claim 1, wherein the photovoltaic cell defines a first side edge of the photovoltaic device and a second side edge of the photovoltaic device, the photovoltaic device has a peripheral edge extending between the first side edge and the second side edge, and the bus member extends from a location near a blind area on the first side edge to a location near a blind area on the second side edge.

Images