Conductive foil based metallization of solar cells

1. A system for electrically coupling solar cells, the system comprising:

a first separation unit for forming a first cut portion and a second cut portion from a conductive foil;

a bonding unit for bonding the first cut portion to a first doped region of a first semiconductor substrate and for bonding the second cut portion to a first doped region of a second semiconductor substrate; and

an aligner to align the first cut portion with the first doped region of the first semiconductor substrate and to align the second cut portion with the first doped region of the second semiconductor substrate, wherein the aligner has a plurality of slots, and wherein the aligner comprises a cover plate for inhibiting misalignment of the first cut portion and the second cut portion.

2. The system of claim 1 , wherein the aligner is to align the first cut portion to the first doped region on a front side of the first semiconductor substrate and to align the second cut portion to the first doped region on a front side of the second semiconductor substrate.

3. The system of claim 1 , wherein the aligner is to align the first cut portion to the first doped region on a back side of the first semiconductor substrate and to align the second cut portion to the first doped region on a back side of the second semiconductor substrate.

4. The system of claim 1 , wherein the first separation unit is for forming a third, additional, cut portion from the conductive foil, the bonding unit for bonding the third cut portion to a second doped region of the first semiconductor substrate, and wherein the aligner is to align the third cut portion to the second doped region of the first semiconductor substrate.

5. The system of claim 1 , wherein the separation unit comprises a knife, saw or a laser.

6. The system of claim 1 , wherein the bonding unit comprises a thermocompression roller, a laser welder or an ultrasonic bonding apparatus.

7. The system of claim 1 , wherein the aligner comprises the cover plate for inhibiting misalignment of the first cut portion and the second cut portion during a bonding process.

8. The system of claim 1 , wherein the aligner comprises the cover plate for inhibiting movement of the first cut portion and the second cut portion to adjacent slots of the plurality of slots.

9. A system for electrically coupling solar cells, the system comprising:

a first separation unit for forming a plurality cut portions from a conductive foil;

a bonding unit for bonding the plurality cut portions to doped regions of a first and second semiconductor substrates; and

an aligner to align the plurality cut portions with the first and second semiconductor substrates, wherein the first and second semiconductor substrates are electrically connected by the plurality of cut portions and the aligner has a plurality of slots, wherein the aligner comprises a cover plate for inhibiting misalignment of the plurality of cut portions.

10. The system of claim 9 , wherein the aligner is to align the plurality of cut portions with doped regions on a front side of the first and second semiconductor substrates.

11. The system of claim 9 , wherein the aligner is to align the plurality of cut portions with doped regions on a back side of the first and second semiconductor substrates.

12. The system of claim 9 , wherein the separation unit comprises a knife, saw or a laser.

13. The system of claim 9 , wherein the bonding unit comprises a thermocompression roller, a laser welder or an ultrasonic bonding apparatus.

14. The system of claim 9 , wherein the aligner comprises the cover plate for inhibiting misalignment of the plurality of cut portions during a bonding process.

15. A method of fabricating a solar cell, the method comprising:

forming a plurality of cut portions from a conductive foil;

aligning the plurality of cut portions to doped regions of a first semiconductor substrate and second semiconductor substrates, wherein the plurality of cut portions are aligned substantially parallel to the doped regions, wherein aligning the plurality of cut portions to the doped regions of the first and second semiconductor substrates comprises placing the plurality of cut portions in an aligner having a plurality of slots, wherein the aligner comprises a cover plate for inhibiting misalignment of the plurality of cut portions; and

bonding the plurality of cut portions to the doped regions of the first and second semiconductor regions, wherein the first and second semiconductor regions are electrically connected by the plurality of cut portions.

16. The method of claim 15 , further comprising, prior to forming the plurality of cut portions from the conductive foil, conveying the conductive foil from a first location to a second location, wherein the conveying positions the conductive foil over the first and second semiconductor substrates.

17. The method of claim 15 wherein aligning the plurality of cut portions to the doped regions of the first and second semiconductor substrates comprises aligning the plurality of cut portions to doped regions located on a back side or a front side of the first and second semiconductor substrates.

18. The method of claim 15 wherein aligning the plurality of cut portions to the doped regions of the first and second semiconductor substrates comprises aligning the plurality of cut portions to a N-type or P-type doped regions of the first and second semiconductor substrates.

19. The method of claim 15 wherein bonding the plurality of cut portions comprises performing a laser welding process, thermocompression process or an ultrasonic bonding process.

20. The method of claim 15 wherein aligning the plurality of cut portions to the doped regions of the first and second semiconductor regions comprises spreading the plurality of cut portions to align to the plurality of cut portions to the doped regions of the first and second semiconductor substrates.