Patterned thin foil

Abstract

An adhesive may be applied to a surface of a reusable carrier. Metal foil may be attached to the adhesive to couple the metal foil to the surface of the reusable carrier. The metal foil may be patterned without damaging the reusable carrier. A semiconductor structure (e.g., a solar cell) may be attached to the patterned metal foil. The reusable carrier may then be removed. In some embodiments, the semiconductor structure may be encapsulated using an encapsulant, with the adhesive being compatible with the encapsulant.

What is claimed is: 
     
         1 . A solar module comprising:
 a first solar cell and a second solar cell;   a metal foil comprising a first surface and an opposing second surface, the first and second solar cells being electrically connected to the first surface of the metal foil; and   an adhesive layer on the second surface of the metal foil.   
     
     
         2 . The solar module of  claim 1 , further comprising an encapsulant that encapsulates at least the first solar cell, the second solar cell, the metal foil, and the adhesive layer. 
     
     
         3 . The solar module of  claim 2 , further comprising:
 a cover layer on a surface of the encapsulant on front sides of the first and second solar cells; and   a backsheet on a surface of the encapsulant on backsides of the first and second solar cells.   
     
     
         4 . The solar module of  claim 3 , wherein the cover layer comprises glass. 
     
     
         5 . The solar module of  claim 3 , wherein the cover layer comprises colored glass. 
     
     
         6 . The solar module of  claim 3 , wherein the cover layer has different colors on different areas of the cover layer. 
     
     
         7 . The solar module of  claim 2 , wherein the layer of adhesive is optically transparent to an attachment laser. 
     
     
         8 . The solar module of  claim 2 , wherein the adhesive layer is opaque to a patterning laser. 
     
     
         9 . The solar module of  claim 1 , wherein the metal foil includes regions not covered by any solar cell in the solar module. 
     
     
         10 . A solar module comprising:
 a plurality of solar cells;   a metal foil that interconnects the plurality of solar cells;   an adhesive layer on a side of the metal foil that is away from the plurality of solar cells;   an encapsulant that encapsulates the plurality of solar cells, the metal foil, and the adhesive layer; and   a cover layer on front sides of the plurality of solar cells.   
     
     
         11 . The solar module of  claim 10 , wherein the cover layer is colored. 
     
     
         12 . The solar module of  claim 10 , wherein the cover layer has different colors on different areas of the cover layer. 
     
     
         13 . The solar module of  claim 10 , wherein the cover layer comprises glass. 
     
     
         14 . The solar module of  claim 10 , wherein the adhesive layer is opaque to a patterning laser. 
     
     
         15 . The solar module of  claim 10 , wherein the adhesive layer is optically transparent to an attachment laser. 
     
     
         16 . A solar module comprising:
 a cover layer;   a backsheet; and   an encapsulant between the cover layer and the backsheet, the encapsulant encapsulating a plurality of solar cells, a metal foil, and an adhesive layer that is on surface of the metal foil.   
     
     
         17 . The solar module of  claim 16 , wherein the cover layer is colored. 
     
     
         18 . The solar module of  claim 16 , wherein the cover layer has different colors on different areas of the cover layer. 
     
     
         19 . The solar module of  claim 16 , wherein the metal foil is optically transparent to a laser. 
     
     
         20 . The solar module of  claim 16 , wherein the metal foil has regions that are not covered by any solar cell in the solar cell module.