Patent ID: 9685568
Date: 2017-06-20
CPC Classifications: H01L,H02S,Y02E

Claim:
1. A method of fabricating a photovoltaic module, the method comprising the steps of: i) providing a plurality of photovoltaic cells, wherein each cell comprises a first free-standing metallic article electrically coupled to a top surface of a semiconductor substrate and a second free-standing metallic article electrically coupled to a bottom surface of the semiconductor substrate, wherein the first free-standing metallic article of each photovoltaic cell is a unitary piece comprising a plurality of gridlines that are integrally formed with a cell interconnection element; ii) electrically coupling the plurality of the photovoltaic cells in series to form a series of cells, wherein the cell interconnection element of each photovoltaic cell is electrically coupled to the second free-standing metallic article of an adjacent photovoltaic cell, and wherein a cell interconnection element of an initial cell in the series of cells serves as a first contact end for the series of cells, and a cell interconnection element for a final cell in the series cells serves as a second contact end for the series of cells; iii) providing a flexible circuit comprising: a junction box contact region; a first electrical conduit comprising a first contact tab and a first junction box contact pad, the first junction box contact pad being in the junction box contact region; a second electrical conduit comprising a second contact tab and a second junction box contact pad, the second junction box contact pad being in the junction box contact region; and a flexible support sheet, wherein the first and second electrical conduits are mounted on the support sheet in the junction box contact region; iv) electrically coupling the first contact tab of the flexible circuit to the first contact end of the series of cells, and the second contact tab of the flexible circuit to the second contact end of the series of cells; and v) electrically coupling the junction box contact region of the flexible circuit to a junction box of the photovoltaic module.