A layer stack for thin-film photovoltaic modules includes a back electrode, an absorber, a buffer/i-layer, a front electrode and an interlayer which are sequentially stacked on a corresponding substrate from bottom up by vacuum coating deposition. The layer stack is divided by P1, P2 and P3 structure lines respectively. A conductive metal grid is embedded in the layer stack, and the metal grid is deposited on the buffer/i-layer before or after the P2 structure line. According to the present invention, the conductive metal grid is embedded in the layer stack, and the metal grid is deposited on the buffer/i-layer before or after the P2 structure line, thereby forming an embedded grid, and thus, the front electrode and the interlayer can be deposited without breaking vacuum in the process sequence. The embedded grid reduces capital expenditure and operating cost.

A solar module and a method of manufacturing the same. The solar module has a plurality of solar cell arrays, a cross-connector and an encapsulation. Each of the solar cell arrays includes solar cell substrates with contact structures and an interconnection structure that includes a plurality of round or rounded wires. Some of the wires have a flatter cross-section in a flattened region than the same wires in a non-flattened region adjacent to the flattened region and/or than other wires. The flattened region is located at and/or near an edge of a terminal solar cell substrate adjacent to a portion of the contacting surface of a rear side of the solar cell substrate. At least two strings of solar cell arrays are arranged side by side and interconnected by means of the cross-connector.