Foil-based interconnect for rear-contact solar cells

1. A rear-contact solar cell interconnect assembly comprising:

a first rear-contact solar cell comprising a first polarity contact and a second polarity contact,

a second rear-contact solar cell comprising a third polarity contact and a fourth polarity contact,

a first interconnect comprising a first conductive foil having a first conductive foil opening,

the first interconnect further comprising a first insulating layer having a first insulating layer opening aligned with the first conductive foil opening; and

a second interconnect comprising a second conductive foil and a second insulating layer,

wherein the first interconnect is disposed between the first rear-contact solar cell and the second interconnect,

wherein the first conductive foil of the first interconnect faces the first rear-contact solar cell, and

wherein the second conductive foil of the second interconnect faces the first insulating layer of the first interconnect;

a first electrical connection extending between the first conductive foil and the first polarity contact of the first rear-contact solar cell;

a second electrical connection extending between the second conductive foil and the second polarity contact of the first rear-contact solar cell, the second electrical connection protruding through the first conductive foil opening of the first conductive foil and the first insulating layer opening of the first insulating layer; and

a third electrical connection extending between the second conductive foil and the third polarity contact of the second rear-contact solar cell.

2. The rear-contact solar cell interconnect assembly recited in claim 1 , wherein a width of the first conductive foil opening of the first conductive foil is at least 25% larger than a critical feature size of the second electrical connection protruding through the first conductive foil opening of the first conductive foil.

3. The rear-contact solar cell interconnect assembly recited in claim 1 , wherein the first insulating layer opening is smaller than the first conductive foil opening such that the first insulating layer extends over a portion of the first conductive foil opening of the first conductive foil.

4. The rear-contact solar cell interconnect assembly recited in claim 1 , wherein the first conductive foil comprises one or more materials selected from the group consisting of aluminum, copper, steel, titanium, molybdenum, and tungsten.

5. The rear-contact solar cell interconnect assembly recited in claim 1 , wherein a thickness of the first conductive foil is approximately between 10 micrometers and 200 micrometers.

6. The rear-contact solar cell interconnect assembly recited in claim 1 , wherein the first rear-contact solar cell comprises silicon.

7. The rear-contact solar cell interconnect assembly recited in claim 1 , wherein the second electrical connection comprises a material selected from the group consisting of a solder, a conductive ink, an isotropic electrically conductive adhesive, and a anisotropic electrically conductive adhesive.

8. A rear-contact solar cell interconnect assembly comprising:

a first interconnect comprising a first conductive foil having a first conductive foil opening,

the first interconnect further comprising a first insulating layer having a first insulating layer opening aligned with the first conductive foil opening,

wherein the first insulating layer is mechanically coupled to a back surface of the first conductive foil; and

a second interconnect comprising a second conductive foil and a second insulating layer,

wherein the second conductive foil of the second interconnect faces the first insulating layer of the first interconnect, and

wherein a portion of the second conductive foil is mechanically coupled to a portion of the first insulating layer;

wherein the first conductive foil and the first insulating layer are arranged to be mechanically coupled to a first rear-contact solar cell,

wherein the second conductive foil and the second insulating layer are arranged to be mechanically coupled to a second rear-contact solar cell,

wherein the first conductive foil is arranged to be electrically connected to a first polarity contact on a rear side of the first rear-contact solar cell using a first electrical connection,

wherein the second conductive foil is arranged to be electrically connected to a second polarity contact on the rear side of the first rear-contact solar cell using a second electrical connection protruding through the first conductive foil opening of the first conductive foil and the first insulating layer opening of the first insulating layer, and

wherein the second conductive foil is arranged to be electrically connected to a third polarity contact on a rear side of the second rear-contact cell using a third electrical connection.

9. The rear-contact solar cell interconnect assembly recited in claim 8 , further comprising a backsheet mechanically supporting the first conductive foil, the first insulating layer, the second conductive foil, and the second insulating layer.

10. The rear-contact solar cell interconnect assembly recited in claim 8 , wherein the first conductive foil comprises a surface finish, wherein the surface finish comprises a material selected from the group consisting of tin, lead, nickel, silver, palladium, gold, indium, and alloys thereof.

11. The rear-contact solar cell interconnect assembly recited in claim 8 , further comprising an adhesive layer disposed between the first interconnect and the second interconnect, wherein the adhesive layer directly interfaces the first insulating layer of the first interconnect and the second conductive layer of the second interconnect, and wherein the adhesive layer mechanically couples the portion of the second conductive foil and the portion of the first insulating layer.

12. The rear-contact solar cell interconnect assembly recited in claim 8 , further comprising an insulating sidewall coating disposed on at least a sidewall of the first conductive foil opening of the first conductive foil for electrically insulating the second electrical connection from the first conductive foil.

13. The rear-contact solar cell interconnect assembly recited in claim 8 , further comprising an adhesive layer disposed on a surface of the first conductive foil facing away from the first insulating layer.

14. The rear-contact solar cell interconnect assembly recited in claim 8 , wherein the first insulating layer comprises polyethylene terephthalate.

15. A method for fabricating a rear-contact solar cell interconnect assembly, the method comprising:

providing a first interconnect comprising a first conductive foil having a first conductive foil opening,

the first interconnect further comprising a first insulating layer having a first insulating layer opening aligned with the first conductive foil opening,

wherein the first insulating layer is mechanically coupled to a back surface of the first conductive foil;

providing a second interconnect comprising a second conductive foil and a second insulating layer; and

mechanically coupling a portion of the first insulating layer to a portion of the second conductive foil,

wherein the first interconnect is arranged to be mechanically coupled to a first rear-contact solar cell,

wherein the second interconnect is arranged to be mechanically coupled to a second rear-contact solar cell,

wherein the first conductive foil is arranged to be electrically connected to a first polarity contact on a rear side of the first rear-contact solar cell using a first electrical connection,

wherein the second conductive foil is arranged to be electrically connected to a second polarity contact on the rear side of the first rear-contact solar cell using a second electrical connection protruding through the first conductive foil opening of the first conductive foil and the first insulating layer opening of the first insulating layer, and

wherein the second conductive foil is arranged to be electrically connected to a third polarity contact on a rear side of the second rear-contact cell using a third electrical connection.

16. The method of claim 15 , further comprising

forming the first electrical connection extending between the first conductive foil and the first polarity contact of the first solar rear-contact cell,

forming the second electrical connection extending between the second conductive foil and the second polarity contact of the first solar rear-contact cell,

the second electrical connection protruding through the first conductive foil opening of the first conductive foil and the first insulating layer opening of the first insulating layer, and

mechanically coupling the first interconnect to the first rear-contact cell.

17. The method of claim 15 , further comprising forming the third electrical connection extending between the second conductive foil and the third polarity contact of the second rear-contact solar cell and mechanically coupling the second interconnect to the second rear-contact cell.

18. The method of claim 15 , further comprising forming the first conductive foil opening and the first insulating layer opening using a process selected from the group consisting of rotary die punching and laser cutting.

19. The method of claim 15 , further comprising forming the first conductive foil opening and the first insulating layer opening in the same operation.

20. The method of claim 15 , further comprising, prior to coupling the portion of the first insulating layer to the portion of the second conductive foil, forming an adhesive layer on a surface the first insulating layer facing away from the first conductive foil.

21. The method of claim 15 , wherein mechanically coupling the portion of the first insulating layer to the portion of the second conductive foil comprises aligning the first interconnect with respect to the second interconnect using a roll-to-roll technique such that an overlap between the portion of the first insulating layer and the portion of the second conductive foil is formed in a cross-web direction.

22. The method of claim 15 , wherein mechanically coupling the portion of the first insulating layer to the portion of the second conductive foil comprises forming an overlap between the portion of the first insulating layer and the portion of the second conductive foil in a direction of a web.