Integrated back-sheet assembly for photovoltaic module

1. A process for forming a back-sheet assembly for a photovoltaic module having multiple solar cells with back-side electrical contacts, comprising:

providing a substrate having a back surface and a front surface;

adhering an electrically conductive metal circuit to the front surface of said substrate;

adhering a plurality of discrete release pads to the electrically conductive metal circuit in a pattern, wherein said plurality of discrete release pads are comprised of an electrically conductive polymeric material and said plurality of discrete release pads do not touch each other;

adhering an insulating layer to said electrically conductive metal circuit over said electrically conductive metal circuit and said plurality of discrete release pads, wherein the peel strength between said plurality of discrete release pads and said electrically conductive metal circuit is greater than the peel strength between said plurality of discrete release pads and the insulating layer;

cutting said insulating layer to form a plurality of discrete cut sections in said insulating layer in a pattern corresponding to the pattern in which the plurality of discrete release pads are adhered to the electrically conductive metal circuit, each of said plurality of discrete cut sections in said insulating layer being disposed over a corresponding one of said plurality of discrete release pads;

removing said plurality of discrete cut sections in said insulating layer from said insulating layer, wherein the removing the plurality of discrete cut sections of the insulating layer over said plurality of discrete release pads leaves a plurality of openings in said insulating layer in a pattern corresponding to the pattern in which the plurality of discrete release pads are adhered to the electrically conductive metal circuit; and

filling said plurality of openings in said insulating layer with an electrically conductive material such that the electrically conductive material in each opening of said plurality of openings in the insulating layer is in electrical contact with the electrically conductive metal circuit through the electrically conductive polymeric material of each corresponding discrete release pad of said plurality of discrete release pad.

2. The process of claim 1 wherein said plurality of discrete release pads are screen printed on said electrically conductive metal circuit.

3. The process of claim 1 wherein said plurality of discrete release pads are formed by casting, extruding or laminating a polymer layer on said electrically conductive metal circuit, cutting the polymer layer to form said plurality of discrete release pads in said polymer layer and polymer layer portions between and around said plurality of discrete release pads, and removing said polymer layer portions between and around said plurality of discrete release pads.

4. The process of claim 1 wherein said insulating layer comprises a polymer insulating layer.

5. The process of claim 4 wherein said polymer insulating layer is extruded, laminated or cast on said electrically conductive metal circuit.

6. The process of claim 4 wherein said insulating layer comprises at least two layers.

7. The process of claim 6 wherein said at least two layers comprise an interlayer dielectric adhered to said electrically conductive metal circuit and an encapsulant layer adhered to said interlayer dielectric.

8. The process of claim 1 wherein the cutting of said insulating layer to form the plurality of discrete cut sections is done by die cutting, laser cutting, or calendering.

9. The process of claim 1 wherein in the step of filling said plurality of openings in said insulating layer with said electrically conductive material, the electrically conductive material comprises a plurality of electrically conductive solid objects that are inserted into corresponding openings in said insulating layer.

10. The process of claim 1 wherein in the step of filling said plurality of openings in said insulating layer with said electrically conductive material, the electrically conductive material is an electrically conductive adhesive in the form of a liquid, a melt or a powder.

11. The process of claim 10 wherein said electrically conductive adhesive is a polymer filled with conductive metal particles.

12. The process of claim 1 wherein said electrically conductive metal circuit comprises a plurality of electrically conductive circuits formed from an electrically conductive metal foil.

13. A process for forming a back-contact photovoltaic module, comprising:

providing said back-sheet assembly of claim 1 ;

providing a plurality of back-contact solar cells having a light receiving side and an opposite back side, said plurality of back-contact solar cells each having a plurality of electrical contacts on the opposite back side in a pattern corresponding to the pattern of the plurality of openings in the insulating layer that are filled with the electrically conductive material; and

adhering the opposite back side of the plurality of back-contact solar cells to the insulating layer such that the plurality of electrical contacts on the back side of the plurality of back-contact solar cells are in electrical contact with the electrically conductive metal circuit through the electrically conductive material in the plurality of openings in said insulating layer.