Solar cell separation with edge coating

Abstract

A groove is cut along a line between adjacent solar cells of a wafer. A coating powder is processed to form a coating layer on the surface of the groove. The solar cells are thereafter physically separated from each other along the groove, with the coating layer serving as an edge coat. The solar cells are electrically connected in series and packaged in a solar module.

1 .- 20 . (canceled) 
     
     
         21 . An edge coated solar cell comprising:
 a solar cell having a laser etched beveled edge,
 wherein the beveled edge has an upper surface, the upper surface comprising a melted coating powder on the upper surface of the beveled edge, the melted coating powder forming a coating layer on the upper surface of the beveled edge. 
   
     
     
         22 . The coated solar cell of  claim 21  wherein the coating powder prior to melting has a particle size that is less than 10 μm. 
     
     
         23 . The coated solar cell of  claim 21  wherein the coating powder comprises aluminum or boron. 
     
     
         24 . The coated solar cell of  claim 21  wherein the coating powder comprises silicon dioxide or boric oxide. 
     
     
         25 . The coated solar cell of  claim 21  wherein the solar cell comprises a wafer comprising a monocrystalline silicon. 
     
     
         26 . A solar module comprising:
 a first solar cell having a first edge and a second edge;   a second solar cell having a first edge and a second edge, the first edge of the second solar cell spanning across a light-receiving surface of the first solar cell,   the first edge of the first solar cell spanning across a back surface of the second solar cell;   a coating layer on the first edge of the first solar cell and on the first edge of the second solar cell, the coating layer providing passivation to the first edge of the first solar cell and to the first edge of the second solar cell; and   an encapsulant that encapsulates at least the first and second solar cells,   wherein the first and second solar cells are electrically connected in series.   
     
     
         27 . The solar module of  claim 26 , wherein the coating layer comprises aluminum or boron. 
     
     
         28 . The solar module of  claim 26 , wherein the coating layer comprises silicon dioxide or boric oxide. 
     
     
         29 . The solar module of  claim 26 , further comprising:
 a transparent layer on the light-receiving surface of the first solar cell; and   a backsheet on the back surface of the second solar cell; and   a frame that provides mechanical support to the solar module.   
     
     
         30 . A plurality of solar cells comprising:
 a wafer comprising a first solar cell and a second solar cell;   a laser cut groove on the wafer and positioned between the first solar cell and the second solar cell; and   a melted coating powder positioned in the laser cut groove of the wafer, the melted coating powder coating a layer on a surface of the groove on the wafer.   
     
     
         31 . The plurality of solar cells of  claim 30  wherein the laser cut groove has a “V” shape. 
     
     
         32 . The plurality of solar cells of  claim 30  wherein when the first solar cell and the second solar cell are separated from each other along the laser cut groove, the melted coating powder forms a coating layer on an edge surface of the first solar cell, the edge surface extending from a top surface of the first solar cell to a bottom surface of the first solar cell, the coating layer extending from the top surface of the first solar cell to the bottom surface of the first solar cell. 
     
     
         33 . The plurality of solar cells of  claim 30  wherein the coating powder prior to melting has a particle size that is less than 10 μm. 
     
     
         34 . The plurality of solar cells of  claim 30 , wherein the coating powder comprises aluminum or boron. 
     
     
         35 . The plurality of solar cells of  claim 30 , wherein the coating powder comprises silicon dioxide or boric oxide. 
     
     
         36 . The plurality of solar cells of  claim 30 , wherein the wafer comprises a monocrystalline silicon.