A string-forming system is described. The string-forming system may include at least a first cell-lifting mechanism and a second cell-lifting mechanism that can automatically arrange a set of strips of a photovoltaic structure into a cascaded formation. During operation, a controller can cause the first cell-lifting mechanism to lift a first strip from a first platform, and can cause the second cell-lifting mechanism to lift, from the first platform, a second strip that may follow the first strip on the first platform. The controller may then activate a first shifting actuator of the first cell-lifting mechanism or a second shifting actuator of the second cell-lifting mechanism to place a leading edge of the second strip above a trailing edge of the first strip.

A photovoltaic module, and method of making, is disclosed in which a flexible circuit is electrically coupled to a plurality of photovoltaic cells, where the photovoltaic cells are electrically coupled in series to form a series of cells. Each photovoltaic cell has free-standing metallic articles coupled to the top and bottom surfaces of a semiconductor substrate. A cell interconnection element of each photovoltaic cell is electrically coupled to a free-standing metallic article of an adjacent photovoltaic cell, where the interconnection elements of the initial and final cells in the series serve as contact ends for the series of cells. Contact tabs of the flexible circuit are electrically coupled to the contact ends of the series of cells, and a junction box is electrically coupled to a junction box contact region of the flexible circuit.

Solar cell including: a semiconductor substrate of a first conductivity type having a region of the first conductivity type and region of a second conductivity type on the back side; a first finger electrode composed of a first contact portion and first current collector, a second finger electrode composed of a second contact portion and second current collector, a first bus bar electrode, a second bus bar electrode on the backside; an insulator film disposed at least in the area just under the first bus bar electrode and second bus bar electrode; wherein the electrical contact between the first current collector and first bus bar electrode as well as electrical contact between the second current collector and the second bus bar electrode are made on the insulator film; and first contact portion and the second contact portion are in a continuous line shape at least just under the insulator film.

A solar module that includes multiple series-connected sub-circuits is provided. Each sub-circuit may include multiple solar cell strings coupled in parallel. The sub-circuits may be coupled to a junction box that includes bypass diodes. Each of the sub-circuits may be coupled in parallel with a respective bypass diode in the junction box. The sub-circuits may be coupled to the junction box via interconnect buses. The interconnect buses may be routed to an entry point from only one side the junction box to improve manufacturability. The interconnect buses may also include one or more bends to provide strain relief during normal operation of the solar module and during thermal cycling events.

Methods are disclosed for assembling PV modules using connectors that have strain relief elements. Strings can be inspected individually and dimensional information can be obtained to layup the strings into a PV module in a specific manner. Portions of the strings can be soldered using elevators to lift connectors into place, and then applying heat to both sides of the connector.

A photovoltaic module can be constructed from one or more strings, with each of the strings being constructed from a plurality of cascaded solar cells. A connector can electrically connect the strings to one another. The connector can include strain relief connectors that extend between the connector and the strings to help reduce effects caused by thermal expansion.

Methods for fabricating busbar and finger metallization over TCO are disclosed. Rather than using expensive and relatively resistive silver paste, a high conductivity and relatively low cost copper is used. Methods for enabling the use of copper as busbar and fingers over a TCO are disclosed, providing good adhesion while preventing migration of the copper into the TCO. Also, provisions are made for easy soldering contacts to the copper busbars.

A bifacial photovoltaic module with at least one bifacial solar cell is provided. The at least one bifacial solar cell includes a substrate with a front-side and a rear-side. The front-side is the light incident side and the rear-side has rear-side contact structure. The rear-side contact structure includes a plurality of electrically conductive contact fingers, which have a first metal, a plurality of solder pads electrically connected to the contact fingers. The solder pads have a top. The solder pads have a second metal, which is different from the first metal. The rear-side contact structure further includes several cell connectors electrically connected to the solder pads. The top of the solder pads is free from the contact fingers in an area along one direction. The cell connectors are disposed planar on or above this area.

A solar module comprising a plurality of solar cell strings arranged side-by-side, each solar cell string having positive and negative terminals at opposite ends thereof, the plurality of solar cell strings comprising: a first group of adjacent solar cell strings, each oriented such that their positive terminals are disposed towards a first end of the solar module; and a second group of adjacent solar cell strings, each oriented such that their positive terminals are disposed towards a second end of the solar module opposite the first end, the positive terminals of the second group of solar cell strings electrically connected to the negative terminals of the first group of solar cell strings.

Solar cells, electrodes of solar cells, and methods of forming thereof are provided in this disclosure. In an implementation, an electrode includes a bus electrode and a collector electrode intersecting with each other, where a width of the collector electrode ranges from 5 m to 30 m. A resistivity of each of the collector electrode and the bus electrode is less than or equal to 310.sup.6 .Math.cm.