Small gauge wire solar cell interconnect

Abstract

Disclosed are wire assemblies for solar cells. One wire assembly includes a first polymer film and a second polymer film overlaying the first polymer film. The second polymer film has a wire embedded in it such that a surface of the wire that is facing away from the first polymer film is exposed. The gauge of the wire is about 36 to 46 gauge. The thickness of the second polymer film is about ¼ to ½ the diameter of the wire and about 0.5 to 1.5 mils.

1 . A wire assembly for a solar cell, comprising:
 a wire;   a top decal that includes a first polymer film, a second polymer film, and a third polymer film; and   a bottom decal that includes a fourth polymer film, a fifth polymer film, and a sixth polymer film, wherein:
 the second polymer film is interposed between the first polymer film and the third polymer film, and is in direct contact with the first polymer film, 
 the fifth polymer film is interposed between the fourth polymer film and the sixth polymer film, and is in direct contact with the fourth polymer film, 
 a first portion of a first side of the wire is embedded in the third polymer film such that a second portion of the first side of the wire is positioned outside the first decal, 
 a third portion of a second side of the wire is embedded in the sixth polymer film such that a fourth portion of the second side of the wire is positioned outside the second decal, 
 the first polymer film, the second polymer film, and the third polymer film each have a first length and a first width that is the same, and 
 the fourth polymer film, the fifth polymer film, and the sixth polymer film each have a second length and a second width that is the same. 
   
     
     
         2 . The wire assembly of  claim 1 , wherein the first portion of the first side of the wire and the third portion of the second side of the wire partially overlap. 
     
     
         3 . The wire assembly of  claim 1 , wherein the first portion of the first side of the wire and the third portion of the second side of the wire do not overlap. 
     
     
         4 . The wire assembly of  claim 1 , wherein the first width is different than the second width. 
     
     
         5 . The wire assembly of  claim 1 , wherein the first width is greater than the second width. 
     
     
         6 . The wire assembly of  claim 1 , wherein:
 the first width is the same as the second width, and   the first length is the same as the second length.   
     
     
         7 . The wire assembly of  claim 1 , wherein the wire is not embedded in the second polymer film or the fifth polymer film. 
     
     
         8 . The wire assembly of  claim 7 , wherein the second polymer film is in contact with the wire. 
     
     
         9 . The wire assembly of  claim 7 , wherein the fifth polymer film is in contact with the wire. 
     
     
         10 . The wire assembly of  claim 1 , wherein:
 an adhesive is interposed between the second polymer film and the third polymer film, and   an adhesive is interposed between the fifth polymer film and the sixth polymer film.   
     
     
         11 . The wire assembly of  claim 1 , wherein:
 a first thickness of the third polymer film is about ¼ to ½ a diameter of the wire, and   a second thickness of the sixth polymer film is about ¼ to ½ the diameter of the wire.   
     
     
         12 . The wire assembly of  claim 1 , wherein a gauge of the wire is about 36 to 46 gauge. 
     
     
         13 . The wire assembly of  claim 1 , wherein the wire is arranged in a serpentine pattern. 
     
     
         14 . The wire assembly of  claim 1 , wherein:
 the first polymer film and the fourth polymer film are comprised of the same materials,   the second polymer film and the fifth polymer film are comprised of the same materials, and   the third polymer film and the sixth polymer film are comprised of the same materials.   
     
     
         15 . The wire assembly of  claim 1 , wherein:
 the first polymer film and the third polymer film are comprised of the same materials, and   the fourth polymer film and the sixth polymer film are comprised of the same materials.   
     
     
         16 . The wire assembly of  claim 1 , wherein:
 the third polymer film comprises a first thermoplastic polymer film,   the second polymer film comprises a second thermoplastic polymer film, and   a melting temperature of the second thermoplastic polymer film is greater than a melting temperature of the first thermoplastic polymer film.   
     
     
         17 . The wire assembly of  claim 1 , wherein the third polymer film and the sixth polymer film each comprise a material selected from the group consisting of: a low density polymer with ionomer functionality, a thermoset, a pressure sensitive adhesive, poly(ethylene-co-methacrylic acid), and a first thermoplastic polymer film. 
     
     
         18 . The wire assembly of  claim 1 , wherein the first polymer film, the second polymer film, and the third polymer film are transparent. 
     
     
         19 . A wire assembly for a solar cell, comprising:
 a wire;   a decal that includes a first polymer film, a second polymer film, and a third polymer film, wherein:
 the second polymer film is interposed between the first polymer film and the third polymer film, and is in direct contact with the first polymer film, 
 a first portion of the wire is embedded in the third polymer film such that a second portion of the first side of the wire is positioned outside the decal, and 
 the first polymer film, the second polymer film, and the third polymer film each have a first length and a first width that is the same.