Photovoltaic cell having a coupled expanded metal article

1. A method for forming a photovoltaic cell, the method comprising:

a) providing an expanded metal article comprising a plurality of first segments intersecting a plurality of second segments thereby forming a plurality of openings, the expanded metal article having a surface comprising a plurality of solder pads;

b) providing a metal cutting assembly, the metal cutting assembly comprising a cutting tool, a receiving plate, and a holding plate, the holding plate stacked between the cutting tool and the receiving plate, wherein the cutting tool comprises a plurality of cutting elements facing the holding plate;

c) after the step (a) of providing the expanded metal article, inserting the expanded metal article between the holding plate and the receiving plate;

d) moving the cutting tool toward the holding plate and the receiving plate such that the plurality of cutting elements penetrates through the holding plate and the receiving plate and forms a plurality of cuts in the expanded metal article;

e) providing a semiconductor material having a bottom surface comprising a plurality of silver pads, wherein a top surface of the semiconductor material serves as a light-incident surface of the photovoltaic cell; and

f) electrically coupling, at a plurality of soldering locations, a majority of the plurality of solder pads on the surface of the expanded metal article with the plurality of silver pads on the bottom surface of the semiconductor material.

2. The method of claim 1 , wherein the expanded metal article spans the bottom surface of the semiconductor material.

3. The method of claim 1 , wherein each opening in the plurality of openings is diamond shaped, each opening having a width from 3 mm to 7 mm, and a length from 10 mm to 15 mm.

4. The method of claim 1 , wherein each of the first segments and each of the second segments have a width from 1 mm to 5 mm.

5. The method of claim 1 , wherein the expanded metal article has a thickness from 75 microns to 150 microns.

6. The method of claim 1 , wherein the photovoltaic cell has a percent open area greater than 80%.

7. The method of claim 1 , wherein the expanded metal article comprises an interconnection element that extends beyond the bottom surface of the semiconductor material.

8. The method of claim 1 , wherein the method further comprises electrically coupling a free-standing metallic article with the top surface of the semiconductor material to form the photovoltaic cell, wherein the metallic article comprises a plurality of electroformed elements interconnected to form a unitary, free-standing piece comprising gridlines.

9. The method of claim 1 , wherein at least one cut in the plurality of cuts is within a region between neighboring soldering locations of the plurality of soldering locations.

10. The method of claim 1 , wherein each cut in the plurality of cuts creates a discontinuity in the expanded metal article.

11. The method of claim 1 , wherein the plurality of cuts is arranged as an array having array dimensions configured to accommodate a difference in coefficient of thermal expansion between the expanded metal article and the semiconductor material.

12. The method of claim 1 , wherein:

the method further comprises electrically coupling a free-standing metallic article with the top surface of the semiconductor material to form the photovoltaic cell, wherein the metallic article comprises a plurality of electroformed elements interconnected to form a unitary, free-standing piece comprising gridlines; and

the plurality of cuts is arranged to relieve mechanical stresses induced by the metallic article on the top surface of the semiconductor material.

13. A method for forming a photovoltaic cell, the method comprising:

a) providing an expanded metal article comprising a plurality of first segments intersecting a plurality of second segments thereby forming a plurality of openings, wherein the expanded metal article further comprises a plurality of cuts, each cut in the plurality of cuts creating a discontinuity in the expanded metal article;

b) providing a metal cutting assembly, the metal cutting assembly comprising a cutting tool, a receiving plate, and a holding plate, the holding plate stacked between the cutting tool and the receiving plate, wherein the cutting tool comprises a plurality of cutting elements facing the holding plate;

c) after the step (a) of providing the expanded metal article, inserting the expanded metal article between the holding plate and the receiving plate;

d) moving the cutting tool toward the holding plate and the receiving plate such that the plurality of cutting elements penetrates through the holding plate and the receiving plate and forms the plurality of cuts in the expanded metal article;

e) providing a semiconductor material having a bottom surface comprising a plurality of silver pads, wherein a top surface of the semiconductor material serves as a light-incident surface of the photovoltaic cell; and

f) electrically coupling the expanded metal article at a plurality of soldering locations to the plurality of silver pads on the bottom surface of the semiconductor material, to form the photovoltaic cell.

14. The method of claim 13 , wherein:

the expanded metal article comprises a solder coating; and

the electrically coupling of step (f) comprises soldering the expanded metal article to the plurality of silver pads with an applied solder that is placed onto the solder coating.

15. The method of claim 13 , wherein at least one cut in the plurality of cuts is within a region between neighboring soldering locations of the plurality of soldering locations.

16. The method of claim 13 , wherein the plurality of cuts is arranged as an array having array dimensions configured to accommodate a difference in coefficient of thermal expansion between the expanded metal article and the semiconductor material.