Abstract: A method including singulating a solar cell to form a plurality of strips, the singulation exposes unpassivated portions of the solar cell. The method further includes sorting the strips to ensure that similar shaped strips are grouped together, and re-passivating the plurality of strips, wherein the re-passivation eliminates active recombination centers. The method further includes aligning the re-passivated strips in an overlapping pattern, depositing electrically conductive adhesive (ECA) between the overlapped portions of the re-passivated strips, wherein the ECA adheres adjacent re-passivated strips to one another and electrically connects the re-passivated strips to form a string, electrically connecting a plurality of strings in parallel to form a string set, electrically connecting at least two string sets in series, and encapsulating the electrically connected string sets.

Abstract: The present disclosure describes methods of forming a colored conductive ribbon for a solar module which includes combining a conductive ribbon with a channeled ribbon holder, applying a color coating to at least the conductive ribbon within the channel, curing the color coating on the conductive ribbon, and separating the conductive ribbon from the channeled holder.

Abstract: The present disclosure describes methods of forming solar modules including a shingled array of strips of solar cells and methods of bonding the strips of shingled solar cells.

Abstract: A solar cell is provided including a substrate having a front and back side, a metallization pattern deposited on the front side, the metallization pattern including a plurality of front side bus bars each including fingers extending therefrom, and a plurality of back side bus bars deposited on the back side. On the front side, one front side bus bar is formed along an edge of the front side of the substrate, and a remainder of the front side bus bars are unequally spaced across the substrate. On the back side of the substrate, only one back side bus bar is formed along an edge of the back side of the substrate, and a remainder of the back side bus bars are unequally spaced across the substrate.

Abstract: The present disclosure describes a method of forming a solar sub-assembly including etching a solar cell, singulating the solar cell to form a plurality of strips, each strip including at least a bus bar, screen printing electrically conductive adhesive (ECA) onto at least one edge of the singulated strips of the solar cell, and shingling the singulated strips such that the ECA bonds one of the plurality of strips to another to form a string.