Abstract: A system for fabricating a photovoltaic module is provided. During operation, the system can obtain a plurality of photovoltaic structures. A respective photovoltaic structure can include first and second metallic grids on first and second surfaces, respectively. The system can then encapsulates the photovoltaic structures between a first cover and a second cover using an encapsulant having a moisture vapor transmission rate (MVTR) less than a predetermined value, thereby preventing oxidation and corrosion of the metallic grids during the service life of the photovoltaic module.

Abstract: One embodiment of the present invention provides a photovoltaic module. The photovoltaic module includes a front-side cover, a back-side cover, and a plurality of photovoltaic strings situated between the front- and back-side covers. A respective photovoltaic string includes a plurality of gridless photovoltaic cells sharing one or more metallic grids while coupled in series. The photovoltaic strings are in turn coupled in parallel to form the photovoltaic module.

Abstract: A system and method for fabricating a photovoltaic structure is provided. During fabrication, the system can apply a wax coating on at least one surface of a multilayer photovoltaic structure, the surface of the multilayer photovoltaic structure being electrically conductive. The system can then pattern the wax coating using one or more laser beams. The patterned wax coating includes a plurality of openings that expose portions of the electrically conductive surface of the multilayer photovoltaic structure.

Abstract: Systems and methods for fabricating a photovoltaic structure are provided. During fabrication, a patterned mask is formed on a first surface of a multilayer body of the photovoltaic structure, with openings of the mask corresponding to grid line locations of a first grid. Subsequently, a core layer of the first grid is deposited in the openings of the patterned mask, and a protective layer is deposited on an exposed surface of the core layer. The patterned mask is then removed to expose the sidewalls of the core layer. Heat is applied to the protective layer such that the protective layer reflows to cover both the exposed surface and sidewalls of the core layer.

Abstract: A photovoltaic structure can include two or more sets of parallel conductive fingers on a top surface and a bottom surface, such that the fingers can collect an electric current from the underlying photovoltaic structure. A scribing system can scribe a groove of a predetermined depth near and perpendicular to the plurality of fingers of the photovoltaic structure, and the photovoltaic structure can be cleaved along the groove to produce multiple strips that each can include a set of parallel fingers. An adhesive dispense system may deposit a band of conductive adhesive that can overlap a set of parallel fingers on each strip, and the strips may be overlapped over the conductive adhesive to form a string of cascaded strips. An adhesive-curing system can include an oven that may cure the conductive adhesive on one or more strips of the string at a time.

Abstract: Systems and methods for fabricating a photovoltaic structure are provided. During fabrication, a patterned mask is formed on a first surface of a multilayer body of the photovoltaic structure, with openings of the mask corresponding to grid line locations of a first grid. Subsequently, a core layer of the first grid is deposited in the openings of the patterned mask, and a protective layer is deposited on an exposed surface of the core layer. The patterned mask is then removed to expose the sidewalls of the core layer. Heat is applied to the protective layer such that the protective layer reflows to cover both the exposed surface and sidewalls of the core layer.