Abstract:
A solar module (and its fabrication method) is presented where a supporting substrate comprises a network of finger traces connected to bus bars. Photo-active layer portions and upper electrode layer portions are deposited on the substrate thereby forming a network of cells. The cells are connected in series by connecting the bus bar of one cell to the upper electrode layer of the adjacent cell, and the bus bars of two adjacent cells are coupled through a bypass element for protecting the cell array.

Description:
BACKGROUND OF THE INVENTION 
       [0001]    1. Field of the Invention 
         [0002]    The present invention relates to a photovoltaic device. 
         [0003]    The present invention further relates to a method of manufacturing a photovoltaic device. 
         [0004]    2. Related Art 
         [0005]    Most organic photovoltaic (OPV) devices are produced in an electrical series configuration. In this way Ohmic losses in the poor conducting transparent electrode and other current conductors is reduced. However, local shading of the one or more of the cells in this series arrangement (due to tree and chimney shading, bird poop, leaves sticking to the surface of the photo voltaic device etc.) gives rise to severe power losses. The shaded cells, do not conduct current very well. Moreover, the shadowed cell or cells may become reversed biased because of the voltage generated by the unshadowed cells. Reverse biasing of a cell can cause degradation in cell performance or even complete cell failure. A way to overcome this problem is the use of bypass elements such as bypass diodes or more sophisticated bypass circuitry. US2007089779A discloses a system comprising a photovoltaic cell and a diode. The photovoltaic cell comprises a first hole carrier layer, a first hole blocking layer, and a photoactive layer between the first hole carrier layer and the first hole blocking layer. The diode comprises a second hole carrier layer and a second hole blocking layer. Therein the first hole carrier layer is electrically connected with the second hole blocking layer, and the second hole carrier layer is electrically connected with the first hole blocking layer. It is a disadvantage of the known system that it is restricted to a bypass diode as the bypass element. 
       SUMMARY OF THE INVENTION 
       [0006]    According to a first aspect of the present invention a photovoltaic device is provided comprising a stack of layers including a first electrode layer, a second electrode layer, and a photo-active layer arranged between the first electrode layer and the second electrode layer. The first electrode layer comprises an electric support layer. The electric support layer comprises a first structure of electrically conductive electrode lines. The electric support layer comprises a second structure of electrically conductive collector lines that are relatively wide with respect to the electrode lines. More in particular the electrode lines typically have a width in the range of 15 to 150 microns and the collector lines typically have a width of at least 150 microns, for example of 500 microns. The electrode lines and collector lines are arranged in the plane of the electric support layer. The photovoltaic device has a plurality of photovoltaic modules that each comprise a respective lateral portion of the stack of layers. Each lateral portion comprises a first electrode layer portion of the first electrode layer, a second electrode layer portion of the second electrode layer, a photo-active layer portion of the photo-active layer. Each first electrode layer portion comprises a respective electric support layer portion of the electric support layer. The photovoltaic modules are arranged in a series connection wherein mutually subsequent photovoltaic modules are coupled by an electric connection from an electric connection from a collector line ( 44 A) of a first electrode layer portion of a first one of said mutually subsequent photovoltaic modules to a second electrode layer portion of a second one of said mutually subsequent photovoltaic modules. At least one conditional electric bypass element is mounted against the electric support layer. The conditional electric bypass element has a first and a second terminal that are each connected to a respective collector line of mutually different, neighbouring electric support layer portions. The conditional electric bypass element has a conditionally electrically conductive channel between said first and said second terminal. The at least one conditional electric bypass element forms a shunt for at least one of the photovoltaic modules or a set of modules. Preferably each of the photovoltaic modules is provided with a respective conditional electric bypass element. 
         [0007]    In the photovoltaic device according to the first aspect of the invention the electric support layer serves both as an electrode and collector for collecting current from the electrode. The collector lines of the electric support layer additionally serve as a connection facility for electrically and mechanically connecting the conditional electric bypass elements. Therewith the photovoltaic device according to the first aspect of the invention can be economically partitioned to a smaller granularity. For example the photovoltaic modules may have a size of a few square cm each. This is advantageous in that it is avoided that large areas of the photovoltaic device have to be bypassed in case only a small portion thereof is dysfunctional. 
         [0008]    The arrangement of electrode lines in the plane of the electric support layer may be formed as a grid or mesh, but may alternatively comprise a plurality of mutually parallel lines. The arrangement on the one hand provides for a good transparency, as light can pass unhindered between the electrode lines from the environment to the photo-active layer. Therewith the electrode lines themselves do not need to be transparent, so that a material can be selected therefore that in the first place has a relatively high conductivity, e.g. a metal such as aluminum or copper. If desired an additional transparent electrode layer, may be applied between this electric support layer and the photo-active layer. As the electric support layer already provides for a good lateral electric conduction the requirements for electric conductivity of this additional transparent electrode layer are modest, so that a material can be selected that in the first place has a good transparency. An inorganic layer, such as an indium tin oxide (ITO) layer may be used for this purpose, but alternatively an organic layer, such as a PEDOT layer may be used. Preferably the additional transparent electrode layer has a transparency of at least 50% for a wavelength range for which the photovoltaic device is designed, which is typically the wavelength range of visible radiation. Even more preferably the transparency is at least 90%. The bypass elements can be manufactured in a separate process, and may if required be manufactured according to another technology. For example these bypass elements may be manufactured with a compact, silicon based process. 
         [0009]    In an embodiment of the photovoltaic device according to the first aspect the conditional electric bypass element is a diode. However, more preferably the conditional electric bypass element comprises a switching element. A switching element usually has a negligible electrical resistance in its conductive state. The switching element, e.g. a transistor may be controlled by an external signal, but preferably the conditional electric bypass element further comprises a controller for controlling the switching element and that is electrically powered from the first and the second terminal of the bypass element. In this way external control lines to the switching element are obviated. Suitable circuitry for this purpose is known for example from US20090184746A1, US20080198523A1 and DE10200501223B4. 
         [0010]    According to a second aspect of the present invention a method of manufacturing a photovoltaic device is provided. In a method according to the second aspect of the invention a first electrode layer at least comprising an electric support layer of an electrically conductive material is provided that comprises a first structure of electrode lines and second structure of collector lines that are relatively wide with respect to the electrode lines. Both the electrode lines and the collector lines are arranged in the plane of the electric support layer. The first electrode layer is partitioned into a plurality of mutually insulated lateral portions. 
         [0011]    At least one conditional electric bypass element is mounted at the electric support layer. The conditional electric bypass element has a first and a second electric terminal each in electric contact with a respective collector line of a first and a second mutually neighbouring portion of said electric support layer. The conditional electric bypass element has a conditionally electrically conductive channel between said first and said second terminal. 
         [0012]    Optionally additional transparent electrode layer portions of an electrically conducting transparent material are applied on respective lateral portions of the electric support layer structure. The optional step of applying additional electrode layer portions may take place either before or after the step of mounting the at least one conditional electric bypass element. 
         [0013]    The method according to the second aspect of the invention further comprises applying respective photo-voltaic layer portions on the first electrode layer portions and subsequently applying respective second electrode layer portions on the photo-voltaic layer portions. Therewith photovoltaic modules are formed each comprising a lateral portion of the first electrode layer including the portion of the electric support layer, comprising the photovoltaic layer and comprising the second electrode layer. Electric connections between each second electrode layer portion and neighboring first electrode layer portion are formed to provide for an electric series connection of the photovoltaic modules. Advantageously these electric connections are formed by applying the second electrode layer portion so that they extend over a free portion of a collector line of their neighboring first electrode layer portion. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0014]    These and other aspects are described in more detail with reference to the drawing. 
         Therein: 
         [0015]      FIG. 1  shows a first embodiment of a photo-voltaic device comprising a plurality of serially arranged photo-voltaic modules, 
           [0016]      FIG. 2  shows a second embodiment of a photo-voltaic device comprising a plurality of serially arranged photo-voltaic modules, 
           [0017]      FIG. 3  shows a partial cross-section according to III-III in  FIG. 1 , 
           [0018]      FIG. 3A  shows a detail according to MA in  FIG. 3 , 
           [0019]      FIG. 4  shows a cross-section according to IV-IV in  FIG. 3 , 
           [0020]      FIG. 5  schematically shows a conditional electric bypass element in a cross-section according to V-V of  FIG. 4 , 
           [0021]      FIG. 6A-6C  show examples of an electric support layer in photo-voltaic devices according to the first aspect of the invention, 
           [0022]      FIG. 7  shows an electronic replacement scheme for a photo-voltaic device according to the first aspect of the invention, 
           [0023]      FIG. 7A  shows a first example of a conditional electric bypass element, 
           [0024]      FIG. 7B  shows a second example of a conditional electric bypass element, 
           [0025]      FIG. 7C  shows a third example of a conditional electric bypass element, 
           [0026]      FIG. 7D  shows a fourth example of a conditional electric bypass element, 
           [0027]      FIG. 7E  shows an embodiment wherein a conditional electric bypass element bridges more than one photovoltaic module, 
           [0028]      FIG. 7F  shows an electronic replacement scheme for this embodiment, 
           [0029]      FIG. 8  illustrates operation of a photo-voltaic device according to the present invention comprising a conditional electric bypass element in  FIG. 7D , 
           [0030]      FIG. 9  shows a fifth example of a conditional electric bypass element, 
           [0031]      FIG. 10A to 10M  illustrate a first embodiment of the method in more detail, 
           [0032]      FIG. 11A-11H  illustrate a second embodiment of the method in more detail, 
           [0033]      FIG. 11I  illustrates an alternative for carrying out a step of this second method, 
           [0034]      FIG. 12A-12E  illustrate steps of a third embodiment of the method in more detail, 
           [0035]      FIG. 13  shows an example of a photo-voltaic device obtainable with this method. 
       
    
    
     DETAILED DESCRIPTION OF EMBODIMENTS 
       [0036]    In the following detailed description numerous specific details are set forth in order to provide a thorough understanding of the present invention. However, it will be understood by one skilled in the art that the present invention may be practiced without these specific details. In other instances, well known methods, procedures, and components have not been described in detail so as not to obscure aspects of the present invention. 
         [0037]    The invention is described more fully hereinafter with reference to the accompanying drawings, in which embodiments of the invention are shown. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. In the drawings, the size and relative sizes of layers and regions may be exaggerated for clarity. Embodiments of the invention are described herein with reference to cross-section illustrations that are schematic illustrations of idealized embodiments (and intermediate structures) of the invention. As such, variations from the shapes of the illustrations as a result, for example, of manufacturing techniques and/or tolerances, are to be expected. Thus, embodiments of the invention should not be construed as limited to the particular shapes of regions illustrated herein but are to include deviations in shapes that result, for example, from manufacturing. Thus, the regions illustrated in the figures are schematic in nature and their shapes are not intended to illustrate the actual shape of a region of a device and are not intended to limit the scope of the invention. 
         [0038]    It will be understood that when an element or layer is referred to as being “on”, “connected to” or “coupled to” another element or layer, it can be directly on, connected or coupled to the other element or layer or intervening elements or layers may be present. In contrast, when an element is referred to as being “directly on,” “directly connected to” or “directly coupled to” another element or layer, there are no intervening elements or layers present. Like numbers refer to like elements throughout. As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items. 
         [0039]    It will be understood that, although the terms first, second, third etc. may be used herein to describe various elements, components, regions, layers and/or sections, these elements, components, regions, layers and/or sections should not be limited by these terms. These terms are only used to distinguish one element, component, region, layer or section from another region, layer or section. Thus, a first element, component, region, layer or section discussed below could be termed a second element, component, region, layer or section without departing from the teachings of the present invention. 
         [0040]    Spatially relative terms, such as “beneath”, “below”, “lower”, “above”, “upper” and the like, may be used herein for ease of description to describe one element or feature&#39;s relationship to another element(s) or feature(s) as illustrated in the figures. It will be understood that the spatially relative terms are intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as “below” or “beneath” other elements or features would then be oriented “above” the other elements or features. Thus, the exemplary term “below” can encompass both an orientation of above and below. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly. 
         [0041]    Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. It will be further understood that terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein. In case of conflict, the present specification, including definitions, will control. In addition, the materials, methods, and examples are illustrative only and not intended to be limiting. 
         [0042]    Like reference symbols in the various drawings indicate like elements. 
         [0043]      FIG. 1  schematically shows a photovoltaic device having a plurality of photovoltaic modules A-F. The modules are serially arranged in the alphabetical order indicated in  FIG. 1 . In this case the photovoltaic modules are rectangular and are arranged in a single row. Subsequent ones of the modules are arranged with their long sides neighboring each other.  FIG. 2  shows another embodiment of a photovoltaic device having a plurality of photovoltaic modules A-I, wherein the modules are arranged in a two-dimensional pattern. The modules are electrically serially arranged in the alphabetical order indicated in  FIG. 2 . 
         [0044]      FIG. 3  shows a cross-section according to III-III in  FIG. 1 . As shown in  FIG. 3 , the photovoltaic device comprises a stack of layers that includes a first electrode layer  40 , a second electrode layer  60 , a photo-active layer  50  arranged between the first electrode layer  40  and the second electrode layer  60 . Other functional layers may be present between those layers. For example a hole carrier layer may be arranged between the first electrode layer  40  and the photo-active layer  50 , and a hole blocking layer may be arranged between the second electrode layer  60  and the photo-active layer  50 . The photo-voltaic layer  50  may comprise sub-layers, for example two or more sub-layers that sensible to mutually different wavelength ranges. As shown in  FIG. 3A , the first electrode layer  40  comprises an electric support layer  41  as a first sub-layer and additionally a transparent electrode layer  43  as a second sub-layer arranged against the electric support layer  41 .  FIG. 4  shows a cross-section IV-IV as indicated in  FIG. 3  through the electric support layer  41 . As shown in  FIG. 4  the electric support layer comprises a first structure of electrode lines  42 A,  42 B here arranged in a hexagonal grid and a second structure of electrically conductive collector lines  44 A,  44 B. The collector lines are relatively wide with respect to said electrode lines. The electrode lines  42 A,  42 B and the collector lines  44 A,  44 B are arranged in the plane of the electric support layer  41 . The electric support layer  41  can be on the substrate or embedded in an electrically insulating, transparent layer  20  on the substrate or on or in the substrate itself. The transparent electrode layer  43  is arranged at a side of the electric support layer  41  facing the photo-active layer  50 . As shown in  FIG. 3  the photovoltaic modules A, B each comprise a respective lateral portion of the above-mentioned stack of layers  40 ,  50 ,  60 . More in particular the lateral portions of the stack comprises a first electrode layer portion  40 A,  40 B of the first electrode layer  40 , a second electrode layer portion  60 A,  60 B of the second electrode layer  60 , and a photo-active layer portion  50 A,  50 B of the photo-active layer  50 .  FIG. 3A  shows that in this case the first electrode layer portions  40 A,  40 B each comprise a first sub-layer portion, formed by the respective electric support layer portions  41 A,  41 B and a second sub-layer portion  43 B. As shown in  FIG. 3 , the photovoltaic modules A, B are arranged in a series connection, in that mutually subsequent photovoltaic modules A, B are coupled by an electric connection from collector line  44 A of a first electric support layer portion  41 A of a first one of the mutually subsequent photovoltaic modules A to a second electrode layer portion  60 B of a second one B of the mutually subsequent photovoltaic modules. The wording “transparent” is intended to mean that the layer  20  transmits at least 50% of radiation for a wavelength range for which the photovoltaic device is designed, which is typically the wavelength range of visible radiation. Even more preferably at least 90% of this radiation is transmitted. 
         [0045]    Here the electrode lines  42 A,  42 B are arranged according to a hexagonal pattern, however various alternative patterns are possible as shown in  FIG. 6A-C . At least one conditional electric bypass element  30  is mounted against the electric support layer  41 . The conditional electric bypass element  30  has a first and a second terminal  31 ,  32  that are each connected to a collector line  44 A,  44 B of a respective one of the neighbouring electric support layer portions  41 A,  41 B.  FIG. 5  shows a cross-section according to V-V in  FIG. 4 . The conditional electric bypass element  30 , shown in more detail in  FIG. 5  has a conditionally electrically conductive channel  33  between said first and said second terminal  31 ,  32 . Typically the conditional electric bypass element  30  is formed by a silicon based chip. Various methods are available to the person skilled in the art to provide for a mechanical and electrical connection between the element  30  and the electric support layer  41 . For example a direct wire bonding may be provided. Alternatively gold or solder bumps may be used for providing the connections with the electric support layer  41 . Instead of directly mounting the conditional electric bypass element  30  on the electric support layer  41 , an interposer may be used. The conditional electric bypass element  30  may be mounted on the interposer, for example with bumps, and the interposer can subsequently be connected to the electric support layer  41  by soldering, gluing or crimping. 
         [0046]      FIG. 6A  shows an alternative arrangement for an electric support layer  41 A+B. Therein the electrode lines  42 A+B are arranged in circular patterns.  FIG. 6B  shows an arrangement wherein the electrode lines  42 A,  42 B are arranged in a rectangular grid.  FIG. 6C  shows an arrangement wherein the electrode lines  42 A,  42 B are arranged as a set of parallel lines. As shown in  FIG. 6C , the collector lines  44 A,  44 B may enclose each lateral portion  41 A,  41 B of the electric support layer  41  therewith obtaining an optimal electrical contact between the first structure of electrode lines  42 A,  42 B and the second structure of collector lines  44 A,  44 B respectively. However, alternatively the collector lines may be arranged along a part of the circumference. In an other alternative embodiment the collector lines of an electric support layer portion may be arranged within the structure of the electrode lines. The collector lines  44 A,  44 B may have a width that is substantially greater than the width of the electrode lines  42 . 
         [0047]    Suitable materials for use in the various layers in the photovoltaic device are well-known as such, and are for example disclosed in the cited EP patent publication. 
         [0048]    By way of example  FIG. 7  schematically shows an arrangement for a photovoltaic device having four modules A-D, of which module B is not functioning Each of the modules A-D has a conditional electric bypass element  30 A- 30 D. In this case the corresponding conditional electric bypass element  30 B becomes electrically conducting, so that the current path Ip is diverted via this bypass element  30 B. In an embodiment shown in  FIG. 7A  of the photovoltaic device according to the first aspect the conditionally electrically conductive channel  35  is a diode that is arranged in a normally blocking direction, i.e. blocking when its corresponding photo-voltaic module properly functions.  FIG. 7B  shows a second embodiment wherein the conditionally electrically conductive channel  35  is a switching element  35 . The switching element may be coupled to an external controller.  FIG. 7C  shows a still further embodiment, wherein said conditional electric bypass element  30  further comprises a controller  36  for controlling the switching element  35  and that is electrically powered from the first and the second terminal  31 ,  32  of the bypass element  30 . The controller  36  is shown in more detail in  FIG. 7D . The controller  36  has a control module  361  and a power supply module  362 . The control module  361  controls the switching element  35  dependent on voltages sensed on the terminals  31 ,  32 . The power supply module  362  has inputs coupled to the terminals  31 ,  32  of the bypass element  30  and provides a regulated voltage supply V to the control module  361 . In order to provide the regulated voltage supply the power supply module  362  may use technologies known as such, e.g. rectifier elements such as diodes, storage elements such as a battery or a capacitor. Also more complicated voltage regulation means, such as voltage conversion means, such as a switched mode power supply may be incorporated in this module. 
         [0049]    It is not necessary that each photovoltaic module is bridged by a conditional electric bypass element. Alternatively a set of serially arranged photovoltaic modules may be bridged by a conditional electric bypass element. In the embodiment as shown in  FIG. 7E  a first pair of photovoltaic modules A,B has a conditional electric bypass element  30 AB, and a second pair of photovoltaic modules C,D has a conditional electric bypass element  30 CD. The photovoltaic modules A-D each have a respective lateral portion  41 A, . . .  41 D of the electric support layer with electrode lines  42 A, . . .  42 D and with collector lines  44 A, . . .  44 D. The pair of serially arranged modules A, B is coupled to a main collector line  44 AB, the pair of serially arranged modules C, D is coupled to a main collector line  44 CD.  FIG. 7F  shows the electrical replacement scheme for this arrangement. By way of example a situation is shown wherein photovoltaic module B is dysfunctional. In this case conditional electric bypass element  30 AB becomes electrically conducting. 
         [0050]      FIG. 8  illustrates an operation of an embodiment of the photovoltaic device comprising a bypass element  30  as shown in  FIG. 7D . During a time period t 0  to t 1 , no input radiation is impingent upon photovoltaic device. Accordingly, the input voltage Vin, i.e. the voltage of terminal  32  relative to terminal  31  is 0V. During a subsequent time period t 1 -t 2  the photovoltaic device receives solar radiation and the photovoltaic module corresponding to the bypass element  30 , denoted as monitored photovoltaic module normally functions. Accordingly a positive voltage is generated that exceeds a first threshold voltage V 1 . The control module  361  responds to this condition by blocking the switching element  35 . In a subsequent time period t 2  to t 3 , the monitored photovoltaic module is obscured, e.g. by a shadow of a tree, while other photovoltaic modules in the photo voltaic device function normally. This has the effect that the control module  361  senses a voltage below a second threshold voltage V 2 . The control module  361  responds to this condition by setting the switching element  35  in a conductive state. Therewith a small rest voltage may remain to enable detection of the prevailing condition of the monitored photovoltaic module. In a subsequent time-period from t 3  to t 4  the obscuration of the monitored photovoltaic module is cancelled, resulting in a normal functioning of said module. Therewith the voltage Vin observed by the control module  361  again exceeds the first threshold voltage V 1 , causing the control module  361  to block the switching element  35 . In subsequent time period t 4  to t 5  subsequently the monitored photovoltaic element is obscured, causing the control module  361  to set the switching element  35  in a conductive state. In the time period from t 5  to t 6  again no input radiation is impingent upon photovoltaic device. Accordingly, the input voltage Vin, i.e. the voltage of terminal  32  relative to terminal  31  is 0V. In this condition the control module  361  typically maintains the switching element  35  in a blocked state. 
         [0051]    As a fail save facility the switching element  35  may be bridged by a diode  351 . 
         [0052]    As shown in  FIG. 9 , the bypass element  30  may comprise an additional bypass channel  352  that is controlled by a second control module  363 . The second control module  363  may be coupled to the first control module  361  and receive an input signal Sc indicative for the detected condition. The input signal Sc may indicate one of the following conditions. 
         [0053]    A first signal value indicative for a first condition that none of the photovoltaic modules of the photovoltaic device is operational (when no solar radiation is received). 
         [0054]    A second signal value indicative for a second condition that the monitored photovoltaic module functions normally. 
         [0055]    A third signal value indicative for a third condition that other photovoltaic module function normally but that the monitored photovoltaic module does not functions normally. 
         [0000]    The second control module  363  may be provided with means that statistically analyse the occurrence of the various conditions and that dependent on this analysis cause setting the additional bypass channel  352  from a normally blocked state into a permanently conductive state. For example the additional bypass channel  352  maybe set into a permanently conductive state if it is detected that the second condition has not been detected since a time exceeding a threshold time interval. During maintenance it may appear the monitored photovoltaic module was only temporarily malfunctioning, e.g. by dirt present on the monitored photovoltaic module. In order to enable resumption of normal operation of the monitored photovoltaic module in this case a tool may be provided that is capable of generating a normally not occurring illumination sequence, for example a light pulse train. The control module  36  may have a reset facility that detects this light sequence. The reset facility may for example be a section in the second control module  363  that detects a rapid alternation between the first and the second condition. 
         [0056]    As in the embodiment shown in  FIG. 7D  a fail save facility may be present. 
         [0057]    According to the second aspect of the invention a photovoltaic device according to the first aspect of the invention is manufactured by the following steps. 
         [0058]    In a step S 1  a first electrode layer is provided that comprises an electric support layer of an electrically conductive material and that comprises a first structure of electrically conductive electrode lines arranged in the plane of said electric support layer. The electric support layer comprises a second structure of collector lines also arranged in the plane of said electric support layer and having a width greater than the width of the electrode lines. The electric support layer comprises a plurality of lateral portions that are mutually isolated from each other. 
         [0059]    In a step S 2  at least one conditional electric bypass element is mounted at said electric support layer. The conditional electric bypass element has a first electric terminal that is brought into electric contact with a collector line of a first one of a first and a second mutually neighbouring portion of the electric support layer. The conditional electric bypass element has a second electric terminal that is brought into electric contact with a collector line of a second one of the first and the second mutually neighbouring portion of the electric support layer. The conditional electric bypass element has a conditionally electrically conductive channel between said first and said second terminal. 
         [0060]    In a step S 3  respective first electrode layer portions of an electrically conducting transparent material are applied on said plurality of lateral portions of the electric support layer structure. 
         [0061]    In a step S 4  respective photo-voltaic layer portions are applied on the second electrode layer portions. 
         [0062]    In a step S 5  respective second electrode layer portions are applied on the photo-voltaic layer portions. Therewith an electric connection is formed between each second electrode layer portion and a collector line of a neighbouring first electrode layer portion. It is noted that a layer may be formed as a stack of sublayers. 
         [0063]    It is not necessary that the steps are carried out in the order presented here. It is alternatively possible that first the photovoltaic cell is manufactured according steps S 1 , S 3 , S 4  and S 5  and that subsequently step S 2  is carried out wherein the conditional electric bypass element is mounted at said electric support layer. In another embodiment wherein the at least one conditional bypass element is integrated in a foil below the photovoltaic cell, step S 2  may be the first step and followed by steps S 1 , S 3 , S 4  and S 5 . 
         [0064]    Embodiments of methods according to the second aspect of the invention are now described in more detail. 
         [0065]      FIG. 10  shows a first embodiment of a method according to the second aspect. In this embodiment the first step S 1  comprises four substeps S 101 , S 102 , S 103 , S 104  shown in  FIG. 10A-10E . 
         [0066]    More in particular the first step S 1  of providing a first electrode  40  comprises a first substep S 101 , shown in  FIG. 10A  wherein a first, metal substrate  10  is provided. 
         [0067]    As shown in  FIG. 10B , in a second substep S 102  of step S 1  a first main surface  11  of the metal substrate is patterned. Therewith protruding  12  and recessed portions  13  are created in said first main surface  11 . 
         [0068]    As shown in  FIG. 10C , in a third substep S 103  an electrically insulating, transparent support layer  20  is deposited at the first main surface  11  of the metal substrate  10 . 
         [0069]    As shown in  FIGS. 10D and 10E  in a fourth substep S 104  material is removed from the metal substrate at a second main surface  15  of the metal substrate opposite its first main surface  11 .  FIG. 10E  shows a top-view according to XIE in  FIG. 10D .  FIG. 10D  is a cross-section according to D-D in  FIG. 10E . Therewith the electrically insulating, transparent support layer  20  is revealed where the recessed portions  13  are disappeared due to the removal of material from the metal substrate  10 . Therewith an electric support layer  41  is formed that comprises a structure of electrically conductive electrode lines  42 A,  42 B arranged in the plane of said electric support layer and that is embedded in the electrically insulating, transparent support layer  20 . The electric support layer  41  forms an electrode  40 . More details of such methods for providing a first electrode  40  are presented in WO2011/016724. 
         [0070]    The pattern of protruding  12  and recessed portions  13  is created during the second substep S 102  so that the electric support layer  41  comprises a plurality of lateral portions  41 A,  41 B, that are electrically insulated from each other. I.e. between each two regions that will result in a lateral portion the pattern of protruding  12  and recessed portions  13  is interrupted by a boundary zone having no protruding portions. Each of the electric support layer portions  41 A,  41 B comprises a first structure with electrode lines  42 A,  42 B and a second structure with collector lines  44 A,  44 B. The first structure and the second structure of each electric support layer portion  41 A,  41 B are electrically connected to each other. 
         [0071]      FIG. 10F  and  FIG. 10G , respectively show in a cross-section and in a top-view according to XIG in  FIG. 10F  the second step S 2 .  FIG. 10F  shows a cross-section according to F-F in  FIG. 10G . In step S 2  the at least one conditional electric bypass element  30  is mounted at said electric support layer  41 . As can be seen in  FIG. 10F , the first electric terminal  31  of the conditional electric bypass element  30  is brought into electric contact with a collector line  44 A of a first one  41 A of the mutually neighbouring portions  41 A,  41 B of the electric support layer  41 . The second electric terminal  32  of the conditional electric bypass element  30  is brought into electric contact with a collector line  44 A of a second one  41 B of the mutually neighbouring portions  41 A,  41 B of the electric support layer  41 . 
         [0072]    Steps S 3 , S 4  and S 5  are shown in cross-section in  FIGS. 10H ,  10 J and  10 L respectively and in top-view in  FIG. 10I ,  10 K,  10 M respectively.  FIGS. 10H ,  10 J and  10 J are cross-section according to H-H in  FIG. 10I , according to J-J in  FIG. 10K  and according to L-L in  FIG. 10M . The direction of the top-views corresponds to the directions defined for the top-views of  FIGS. 10E and 10G . 
         [0073]      FIGS. 10H and 10I  show the result of the third step S 3  wherein respective electrically conductive transparent layer portions  43 A,  43 B of an electrically conducting transparent material, such as indium tin oxide (ITO) or PEDOT are applied on said plurality of lateral portions  41 A,  41 B of the electric support layer structure  41 . Lateral portion  41 A of the support layer structure  41  and electrically conductive transparent layer portion  43 A together form a lateral portion  40 A of the electrode layer  40 . Lateral portion  41 B of the support layer structure  41  and electrically conductive transparent layer portion  43 B together form a lateral portion  40 B of the electrode layer  40 . 
         [0074]      FIGS. 10J and 10K  show the result of the fourth step S 4  wherein respective photo-voltaic layer portions  50 A,  50 B are applied on the electrically conductive transparent layer portions  43 A,  43 B. Alternatively the photo-voltaic layer portions  50 A,  50 B may be applied directly on the lateral portions  41 A,  41 B of the electric support layer structure  41 . 
         [0075]      FIGS. 10L and 10M  show the result of the fifth step S 5  wherein respective second electrode layer portions  60 A,  60 B are applied on the photo-voltaic layer portions  50 A,  50 B. The second electrode layer portion  60 B extends beyond its corresponding photo-voltaic layer portion  50 B over a collector line  44 A of a lateral portion  41 A of the support layer  41 , which lateral portion  41 A is part of the neighbouring first electrode layer portion  40 A. Therewith an electric connection is formed between the second electrode layer portion  60 B of the second photo-voltaic module B and the first electrode portion  40 A of the first photo-voltaic module A. In this case the second electrode layer portion  60 B extends directly over the collector line  44 A of the lateral portion  41 A of the electric support layer structure  41  of module A. Alternatively the electric connection may be formed via an intermediate layer or combination of layers. For example, the electric connection between the second electrode layer portion  60 B and the first electrode layer portion  40 A may be formed via the transparent layer  43 A of that first electrode layer portion  40 A. Although for clarity an electrical connection is only shown between one second electrode layer portion  60 B and one first electrode layer portion  40 A it will be clear that in practice the photovoltaic device may have a larger plurality of photovoltaic modules that are serially arranged in this way, for example as shown in  FIG. 1  or  2 . 
         [0076]      FIG. 11A-11H  show a second embodiment of a method according to the second aspect of the invention. In this embodiment the step S 1  of providing a first electrode  40  comprising an electric support layer  41  comprising the substeps S 111 , S 112 , S 113  and S 114  as described in more detail below. 
         [0077]    According to a first one S 111  of these substeps a substrate  10  is provided as shown in  FIG. 11A . Any material may be used for this substrate  10  provided that it can be removed relatively easily later in the process, e.g. by etching, solving or peeling. It is further preferable, but not necessary that the material is flexible, so that it can be handled in a roll process. Typically a foil is used having a thickness H in the range of 50 μm to 0.5 mm. The foil is for example a metal foil, such as an aluminum foil or a copper foil. 
         [0078]      FIG. 11B  shows a second one S 112  of these substeps, wherein an electric support layer  41 , having electric support layer portions is deposited on a first main side  11  of the substrate. For clarity only the collector lines  44 A,  44 B of these electric support layer portions are shown. The electric support layer  41  may be deposited in any manner, for example by printing, by a vapor deposition process or by electroplating. The electric support layer  41  forms a first electrode layer  40 , with first electrode layer portions  40 A,  40 B. 
         [0079]    The substrate  10  is temporary, in that it is removed S 114  after the electric support layer  41  is embedded S 113  in a transparent layer  20 . 
         [0080]    More in particular  FIG. 11D  shows the result of substep S 113 , wherein the electric support layer  41  is embedded in a transparent layer  20 . The substep of embedding in a transparent layer may comprise depositing one or more layers on the electric support layer  41 . It is for example possible to deposit a single layer on the electric support layer, e.g. by spin-coating. Alternatively a stack of sub-layers may be deposited as the transparent layer  20 . The stack may for example be a barrier stack comprising inorganic layers and organic layers that alternate each other or inorganic layers of a different type that alternate each other.  FIG. 11E  shows the result of the substep S 114 , wherein the substrate is removed from transparent layer  20  with the electric support layer  41  embedded therein. In the embodiment shown, the step of mounting S 2  ( FIG. 11C ) the conditional electric bypass element  30  at the electric support layer  41  is carried out after the substep of depositing S 112  the electric support layer  41  at a first main side of the substrate  5 , and before the substep of embedding S 113  the electric support layer  41  in a transparent layer  20 . 
         [0081]    More details of such methods for providing a first electrode  40  are presented in WO2011/016725. 
         [0082]    After the temporary substrate  5  is removed, steps S 3  and S 4  are carried out.  FIG. 11F  shows the result of these steps. In step S 3  respective mutually separate lateral portions  43 A,  43 B of a layer of an electrically conducting transparent material are applied on the plurality of lateral portions  41 A,  41 B of the electric support layer structure  41 . In step S 4  respective photo-voltaic layer portions  50 A,  50 B are applied on these lateral portions  43 A,  43 B of the layer  43 . Then, as shown in  FIG. 11G  respective second electrode layer portions  60 A,  60 B are applied, step S 5 , on the photo-voltaic layer portions  50 A,  50 B. Second electrode layer portion  60 B extends beyond its corresponding photo-voltaic layer portions  50 B over a free portion of the first electrode layer portion of the neighboring photovoltaic module. In this case second electrode layer portion  60 B extends directly over the collector line  44 A of the lateral portion  41 A of the electric support layer structure  41 , so that an electrical connection is formed between the second electrode layer portion  60 B and the first electrode layer portion comprising the lateral portion  41 A of the neighboring module. In the embodiment of the method shown, a barrier layer  70  is deposited. The barrier layer  70  may comprise a stack of sublayers analogously as described for the layer  20 . 
         [0083]      FIG. 11I  shows that alternatively, the step of mounting S 2  the at least one conditional electric bypass element  30  at said electric support layer  41  may be carried out after the substep of removing S 114  the substrate  10  from the embedded electric support layer structure  41 . In that case step S 2  may be succeeded by step S 3 , S 4 , S 5 , similarly as shown in  FIGS. 11F and 11G . 
         [0084]    It is alternatively also possible that the step of mounting S 2  the at least one conditional electric bypass element  30  at the electric support layer  41  is postponed until one or more of the steps S 3 , S 4 , and S 5  are carried out, provided that a free area portion of the electric support layer structure  41  where the conditional electric bypass element  30  can be mounted with its terminals in electrical contact with the electric support layer portion  41 A,  41 B. Alternatively the electrical contact between the terminals of the conditional electric bypass element  30  and the respective electric support layer portion  41 A,  41 B may be made via respective transparent electrically conductive layer portions at the electric support layer portions  41 A,  41 B. 
         [0085]      FIG. 12A to 12C  show an alternative way of carrying out the step S 1  of providing a first electrode  40  having an electric support layer  41 .  FIG. 12A  shows the result of a first and a second substep. The first substep S 121  comprises providing a first inorganic layer  21  on a transparent substrate  4 . The second substep S 122  comprises providing a first organic decoupling layer  22  on the first inorganic layer  21 . Subsequently, as shown in  FIG. 12B  a substep S 123  is carried out wherein at least one trench  13  is formed in the organic decoupling layer. 
         [0086]    In order to form the at least one trench  13  in the organic decoupling layer for example soft lithography (embossing PDMS rubber stamp into a partially reacted organic layer) may be applied. In this way trenches  13  are formed that can have an aspect ratio of up to 10. The aspect ratio is considered here the dept D 3  of the trenches divided by their smallest lateral dimension. 
         [0087]    Further the organic decoupling layer is fully cured after imprinting e.g. by polymerization using a heat-treatment or UV-radiation. 
         [0088]    The trenches  13  may be treated such that no organics remain in bottom of the trench on top of the first inorganic barrier layer  21 . A plasma etch might be used for this cleaning. Remaining organic material could form a diffusion path for moisture. 
         [0089]    Subsequently, in substep S 124  a second inorganic layer  23  is provided, as shown in  FIG. 12C . 
         [0090]    An inline vacuum or air based roll-to-roll web coating system known as such may be used to apply the organic  22  and inorganic layers  21 ,  23 . The coating system consists of multiple sections combining an unwind, a rewind and in between a multiple of process chambers dedicated for example to pre-treat a substrate surface, or coat a substrate surface with an inorganic layer, or coat a substrate surface with an organic layer, or coat a substrate surface with a patterned organic layer, or cure an organic coated surface. 
         [0091]    The inorganic layers  21 ,  23  may be applied by all kinds of physical vapor deposition methods such as thermal evaporation, e-beam evaporation, sputtering, magnetron sputtering, reactive sputtering, reactive evaporation, etc. and all kinds of chemical vapor deposition methods such as thermal chemical vapor deposition (CVD), photo assisted chemical vapor deposition (PACVD), plasma enhanced chemical vapor deposition (PECVD), etc. 
         [0092]    The organic layers  22  may be applied by all kinds of coatings techniques, such spin coating, slot-die coating, kiss-coating, hot-melt coating, spray coating, etc. and all kinds of printing techniques, such as inkjet printing, gravure printing, flexographic printing, screen printing, rotary screen printing, etc. 
         [0093]    After deposition of the second inorganic layer  23  substep S 125  is carried out wherein an electrically conductive material is deposited in the at least one trench  13 , as shown in  FIG. 12D . The electrically conductive material forms an electric support layer structure  41  having electric support layer portions  41 A,  41 B. In case the at least one trench  13  is formed by a single trench mutually disconnected electric support layer portions  41 A,  41 B may be formed by depositing the electrically conductive material in respective portions of the single trench. Alternatively separate trenches may be provided for each of the electric support layer portions  41 A,  41 B to be formed. 
         [0094]    To mitigate that the conductive material spreads out at the surface, the top surface is made hydrophobic and the trenches are made hydrophilic. The trenches  13  (see  FIG. 12B ) may be filled in a single step, for example by sputtering, or by vapor deposition, such as MOCVD, and combining this with the step of polishing or etching. Preferably the trenches  13  are filled with a two-stage process. For example the trenches  13  can be filled with an evaporated metal (e.g. Al as described in EP 1 693 481 A1) or with solution based metals (e.g. Ag, Au, Cu) and an extra baking step (bellow 150 C). The next process is to fill completely the trenches  13  in order to compensate for shrinkage of the material in the trenches. The electrically conductive material applied during the second step may be the same, but may alternatively be a different material. The metals Ag, Au, and Cu for example have a high reflectivity and therewith preferred as the second electrically conductive material. During this process attention should be paid to the structure design such that the contact area for an electrically conductive layer of a functional component that is to be assembled with the electrical transport component does not come in direct contact with another conductive layer of the functional component, in order to prevent shortcuts. In an alternative method the electrically conductive material is applied in a single step. 
         [0095]    More details of such methods for providing a first electrode  40  are presented in WO2010/016763. 
         [0096]    Next the at least one conditional electric bypass element  30  is mounted (S 2 ) at the electric support layer as shown in  FIG. 12E . Subsequently, steps S 3  to S 5  may be performed analogously as was described with reference to  FIG. 10J  to  FIG. 10M , therewith obtaining a photovoltaic device according to the first aspect of the invention, as shown in  FIG. 13 . 
         [0097]    Alternatively, the photo-voltaic device may be completed according to a different procedure. For example, the photo-active layer portions  50 A,  50 B may be directly applied at the electric support layer portions  41 A,  41 B. 
         [0098]    As used herein, the terms “comprises,” “comprising,” “includes,” “including,” “has,” “having” or any other variation thereof, are intended to cover a non-exclusive inclusion. For example, a process, method, article, or apparatus that comprises a list of elements is not necessarily limited to only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus. Further, unless expressly stated to the contrary, “or” refers to an inclusive or and not to an exclusive or. For example, a condition A or B is satisfied by any one of the following: A is true (or present) and B is false (or not present), A is false (or not present) and B is true (or present), and both A and B are true (or present). 
         [0099]    Also, use of the “a” or “an” are employed to describe elements and components of the invention. This is done merely for convenience and to give a general sense of the invention. This description should be read to include one or at least one and the singular also includes the plural unless it is obvious that it is meant otherwise.