Patent ID: 8082672

Claim:
A method of forming patterns on a thin film photovoltaic structure comprising: providing a soda lime glass substrate having a first molybdenum layer and a second molybdenum layer overlying the first molybdenum layer, the first molybdenum layer being tensile stress and the second molybdenum layer being in compressive stress to suppress formation of voids in the molybdenum layers; forming the absorber layer which includes copper over the second molybdenum layer; at the time the absorber layer is formed, also forming an interface layer between the second molybdenum layer and the absorber layer, the interface layer including a graded composition of a combination of molybdenum and material from an absorber layer, and having a thickness of at least about 100 Angstroms; depositing a window layer including cadmium disposed over the absorber layer; supporting the substrate with the window layer exposed; applying a scribe device having a tip with pressure against the window layer; and moving the scribe device at about 0.25 meter per second relative to the substrate to form a scribe region pattern between about 30 and 100 microns in width on at least the window layer while maintaining the molybdenum layer free from the pattern of the scribe device.