Abstract: A method of removing a plurality of portions of a black layer of an electrical conduit for a photovoltaic cell is disclosed. The method includes providing a mandrel having the electrical conduit electroformed in the mandrel. The electrical conduit is formed in a preformed pattern on an outer surface of the mandrel. The electrical conduit has the black layer with a black layer thickness on a side opposite of the outer surface of the mandrel. A beam of a laser is controlled toward the black layer of the electrical conduit. The beam is characterized by laser parameters. The beam of the laser removes the plurality of portions of the black layer on the electrical conduit. Each removed portion of the plurality of portions of the black layer has a thickness equal to the black layer thickness, and a portion area of 5 mm2 to 20 mm2.

Abstract: A method includes providing an electrically conductive mandrel having an outer surface layer comprising a preformed pattern. The metallic article is electroformed. The metallic article includes a plurality of electroformed elements formed in the preformed pattern on the outer surface layer of the mandrel. The plurality of electroformed elements have a first side adjacent to the outer surface layer of the mandrel and a second side. The metallic article is separated from the mandrel. The plurality of electroformed elements are interconnected such that the metallic article forms a unitary, free-standing piece. A solution is applied to create a blackening of the first side of the plurality of electroformed elements.

Abstract: A method includes providing a mandrel having an electrical conduit electroformed in the mandrel. The second side of the electrical conduit is blackened while in the mandrel to create a black layer on the electrical conduit. The mandrel is aligned in a flatness fixture such that the mandrel is substantially flat. The mandrel remains flat and in a fixed relationship to the flatness fixture throughout the method. A beam of a laser is controlled toward the black layer. The beam has laser parameters including a power output, a frequency and a mark speed, and selected by setting the power output and the mark speed then determining the frequency. The beam removes a plurality of the portions of the black layer. Each removed portion of the plurality of the portions has a thickness equal to the black layer thickness, and a portion area of 9 mm2 to 18 mm2.

Abstract: A method includes providing a mandrel having an electrical conduit electroformed in the mandrel. The second side of the electrical conduit is blackened while in the mandrel to create a black layer on the electrical conduit. The mandrel is aligned in a flatness fixture such that the mandrel is substantially flat. The mandrel remains flat and in a fixed relationship to the flatness fixture throughout the method. A beam of a laser is controlled toward the black layer. The beam has laser parameters including a power output, a frequency and a mark speed, and selected by setting the power output and the mark speed then determining the frequency. The beam removes a plurality of the portions of the black layer. Each removed portion of the plurality of the portions has a thickness equal to the black layer thickness, and a portion area of 9 mm2 to 18 mm2.

Abstract: In embodiments, a photovoltaic cell has an expanded metal article configured as a mesh, a semiconductor material, and a front metallic article. The expanded metal article has a plurality of first segments intersecting a plurality of second segments thereby forming a plurality of openings, and has a plurality of cuts in the mesh. The expanded metal article is electrically coupled to a back surface of the semiconductor material. The front metallic article has a plurality of electroformed elements interconnected to form a unitary, free-standing piece comprising a continuous grid. The continuous grid of the front metallic article is electrically coupled to a front surface of the semiconductor material. The plurality of cuts of the expanded metal article is arranged on the photovoltaic cell to relieve stresses induced by the front metallic article on the front surface of the semiconductor material.

Abstract: A method includes providing an electrically conductive mandrel having an outer surface layer comprising a preformed pattern. The metallic article is electroformed. The metallic article includes a plurality of electroformed elements formed in the preformed pattern on the outer surface layer of the mandrel. The plurality of electroformed elements have a first side adjacent to the outer surface layer of the mandrel and a second side. The metallic article is separated from the mandrel. The plurality of electroformed elements are interconnected such that the metallic article forms a unitary, free-standing piece. A solution is applied to create a blackening of the first side of the plurality of electroformed elements.

Abstract: A method includes providing an electrically conductive mandrel having an outer surface layer comprising a preformed pattern. The metallic article is electroformed. The metallic article includes a plurality of electroformed elements formed in the preformed pattern on the outer surface layer of the mandrel. The plurality of electroformed elements have a first side adjacent to the outer surface layer of the mandrel and a second side. A solder is plated on the second side of the plurality of electroformed elements while on the mandrel. The metallic article is separated from the mandrel. The plurality of electroformed elements are interconnected such that the metallic article forms a unitary, free-standing piece. A solution is applied to create a blackening of the first side of the plurality of electroformed elements. The solder on the second side of the plurality of electroformed elements is not blackened.

Abstract: In embodiments, a photovoltaic cell has an expanded metal article configured as a mesh, a semiconductor material, and a front metallic article. The expanded metal article has a plurality of first segments intersecting a plurality of second segments thereby forming a plurality of openings, and has a plurality of cuts in the mesh. The expanded metal article is electrically coupled to a back surface of the semiconductor material. The front metallic article has a plurality of electroformed elements interconnected to form a unitary, free-standing piece comprising a continuous grid. The continuous grid of the front metallic article is electrically coupled to a front surface of the semiconductor material. The plurality of cuts of the expanded metal article is arranged on the photovoltaic cell to relieve stresses induced by the front metallic article on the front surface of the semiconductor material.

Abstract: Methods include providing an expanded metal article configured as a mesh. The expanded metal article has a plurality of cuts in the mesh and has a surface comprising a plurality of solder pads. A semiconductor material is provided, having a back surface comprising a plurality of silver pads. A front surface of the semiconductor material serves as a light-incident surface of the photovoltaic cell. A front metallic article is provided, the front metallic article comprising a plurality of electroformed elements interconnected to form a unitary, free-standing piece comprising a continuous grid. The continuous grid of the front metallic article is electrically coupled with the front surface of the semiconductor material. The plurality of cuts of the expanded metal article is arranged to relieve stresses induced by the front metallic article on the front surface of the semiconductor material.

Abstract: A method includes providing an electrically conductive mandrel having an outer surface layer comprising a preformed pattern. The metallic article is electroformed. The metallic article includes a plurality of electroformed elements formed in the preformed pattern on the outer surface layer of the mandrel. The plurality of electroformed elements have a first side adjacent to the outer surface layer of the mandrel and a second side. A solder is plated on the second side of the plurality of electroformed elements while on the mandrel. The metallic article is separated from the mandrel. The plurality of electroformed elements are interconnected such that the metallic article forms a unitary, free-standing piece. A solution is applied to create a blackening of the first side of the plurality of electroformed elements. The solder on the second side of the plurality of electroformed elements is not blackened.

Abstract: A metallic article for a photovoltaic cell is disclosed. The metallic article includes a first region having a plurality of electroformed elements that are configured to serve as an electrical conduit for a light-incident surface of the photovoltaic cell. A cell-to-cell interconnect is integral with the first region. The cell-to-cell interconnect is configured to extend beyond the light-incident surface and to directly couple the metallic article to a neighboring photovoltaic cell. The cell-to-cell interconnect includes a plurality of electroformed, curved appendages. Each appendage has a first end coupled to an edge of the first region and a second end opposite the first end and away from the edge. The appendages are spaced apart from each other. The metallic article is a unitary, free-standing piece.

Abstract: A bonding apparatus includes a heat source, a first plate, a second plate, and an actuation mechanism. The first plate is coupled to the heat source. The first and second plates are thermally conductive and configured to cover an entire solar cell. The actuation mechanism moves the bonding apparatus between an open position and a closed position. In the closed position, the first plate and the second plate contact opposite surfaces of the solar cell. The second plate is configured to dissipate heat such that the second plate has a lower temperature than the first plate when in the closed position. The first plate and the second plate apply a force to the solar cell, the force at a first end of the solar cell being different than at a second end of the solar cell when the bonding apparatus is in or moving to the closed position.

Abstract: Methods include providing an expanded metal article configured as a mesh. The expanded metal article has a plurality of cuts in the mesh and has a surface comprising a plurality of solder pads. A semiconductor material is provided, having a back surface comprising a plurality of silver pads. A front surface of the semiconductor material serves as a light-incident surface of the photovoltaic cell. A front metallic article is provided, the front metallic article comprising a plurality of electroformed elements interconnected to form a unitary, free-standing piece comprising a continuous grid. The continuous grid of the front metallic article is electrically coupled with the front surface of the semiconductor material. The plurality of cuts of the expanded metal article is arranged to relieve stresses induced by the front metallic article on the front surface of the semiconductor material.

Abstract: A method comprises providing an expanded metal article having a plurality of first segments intersecting a plurality of second segments thereby forming a plurality of openings. The expanded metal article has a surface comprising a plurality of solder pads. A semiconductor material with a top surface and a bottom surface is provided, the bottom surface having a plurality of silver pads and the top surface serving as a light-incident surface of the photovoltaic cell. At a plurality of soldering locations, a majority of the plurality of solder pads on the surface of the expanded metal article is electrically coupled with the plurality of silver pads on the bottom surface of the semiconductor material. Also disclosed is a photovoltaic cell resulting from this method.

Abstract: A bonding apparatus includes a heat source, a first plate, a second plate, and an actuation mechanism. The first plate is coupled to the heat source. The first and second plates are thermally conductive and configured to cover an entire solar cell. The actuation mechanism moves the bonding apparatus between an open position and a closed position. In the closed position, the first plate and the second plate contact opposite surfaces of the solar cell. The second plate is configured to dissipate heat such that the second plate has a lower temperature than the first plate when in the closed position. The first plate and the second plate apply a force to the solar cell, the force at a first end of the solar cell being different than at a second end of the solar cell when the bonding apparatus is in or moving to the closed position.

Abstract: A metallic article for a photovoltaic cell is disclosed. The metallic article includes a first region having a plurality of electroformed elements that are configured to serve as an electrical conduit for a light-incident surface of the photovoltaic cell. A cell-to-cell interconnect is integral with the first region. The cell-to-cell interconnect is configured to extend beyond the light-incident surface and to directly couple the metallic article to a neighboring photovoltaic cell. The cell-to-cell interconnect includes a plurality of electroformed, curved appendages. Each appendage has a first end coupled to an edge of the first region and a second end opposite the first end and away from the edge. The appendages are spaced apart from each other. The metallic article is a unitary, free-standing piece.

Abstract: A photovoltaic module has a flexible backing substrate, a plurality of photovoltaic cells, and an electrical conduit. The photovoltaic cells are mounted on the backing substrate. Each photovoltaic cell has a metallic article, the metallic article including a plurality of electroformed elements comprising a cell interconnection element integral with a continuous grid having a plurality of first elements intersecting a plurality of second elements. The electroformed elements are interconnected and integral, with the continuous grid in contact with the light-incident surface of the photovoltaic cell. The cell interconnection element extends beyond the light-incident surface and couples the continuous grid to a neighboring photovoltaic cell. The electrical conduit has a flexible strip of electrically conductive material.

Abstract: An integrated circuit (IC) combines a first IC chip (die) having a first on-chip interconnect structure and a second IC chip having a second on-chip interconnect structure on a reconstructed wafer base. The second IC chip is edge-bonded to the first IC chip with oxide-to-oxide edge bonding. A chip-to-chip interconnect structure electrically couples the first IC chip and the second IC chip.

Abstract: A method comprises providing an expanded metal article having a plurality of first segments intersecting a plurality of second segments thereby forming a plurality of openings. The expanded metal article has a surface comprising a plurality of solder pads. A semiconductor material with a top surface and a bottom surface is provided, the bottom surface having a plurality of silver pads and the top surface serving as a light-incident surface of the photovoltaic cell. At a plurality of soldering locations, a majority of the plurality of solder pads on the surface of the expanded metal article is electrically coupled with the plurality of silver pads on the bottom surface of the semiconductor material. Also disclosed is a photovoltaic cell resulting from this method.

Abstract: Methods include providing a metallic article that is configured to serve as an electrical conduit within a photovoltaic cell. The processes further include providing a semiconductor substrate that includes a coating at a top surface of the semiconductor substrate, where the coating is a dielectric anti-reflective coating, a transparent conductive oxide or an amorphous silicon. The metallic article is coupled to the top surface of the semiconductor substrate, including soldering a first surface of the metallic article to the top surface of the semiconductor substrate using an active solder.