Manufacturing of optoelectronic devices

Abstract

A method for manufacturing optoelectronic devices is disclosed. A layered structure may be formed with a plurality of layers including a bottom electrode layer, a top electrode layer, and one or more active layers between the top and bottom electrode layers. The layered structure is divided into one or more separate device module sections by cutting through one or more of the layers of the layered structure. At least one of the layers is an unpatterned layer at the time of cutting. Each of the resulting device module sections generally includes a portion of the active layer disposed between portions of the top and bottom electrode layers. An edge of a device section may optionally be protected against undesired electrical contact between two or more of the bottom electrode, top electrode and active layer portions. Two or more device module sections may be assembled into a device and connected in series by electrically connecting the bottom electrode layer portion of one device section to the top electrode layer portion of another device module section.

1 - 11 . (canceled) 
     
     
         12 . A method of manufacturing a photovoltaic module comprising; coating at least an illuminating surface of solar cells with a moisture barrier film to form solar cells with moisture-resistance; electrically interconnecting any two of the solar cells using a conductor between at least one of the terminals of each of the any two solar cells to form a circuit, and encapsulating the circuit in a package. 
     
     
         13 . The method according to  claim 12  wherein the step of coating coats substantially all surfaces of the solar cells including the illuminating surface and the back surface, with the moisture barrier film, and wherein the step of electrically interconnecting includes the step of forming an opening in the moisture barrier film so that the conductor can form the electrical interconnection at the at least one of the terminals of each of the at least two solar cells. 
     
     
         14 . The method according to  claim 13  wherein the moisture barrier film is substantially transparent to solar light. 
     
     
         15 . The method according to  claim 14  wherein the moisture barrier film comprises at least one of polyethylene, polypropylene, polystyrene, poly(ethylene terephthalate), polyimide, parylene, benzocyclobutene, polychlorotrifluoroethylene, silicon oxide, aluminum oxide, silicon nitride, aluminum nitride, silicon oxy-nitride, aluminum oxy-nitride, amorphous or polycrystalline silicon carbide, transparent ceramics, and carbon doped oxide. 
     
     
         16 . The method according to  claim 13  wherein the step of encapsulation comprises embedding the circuit within a structure that includes a top film, a flexible encapsulant and a backing material. 
     
     
         17 . The method according to  claim 12  wherein the step of encapsulation comprises embedding the circuit within a structure that includes a top film, a flexible encapsulant and a backing material. 
     
     
         18 . The method according to  claim 12  wherein the moisture barrier film is substantially transparent to solar light. 
     
     
         19 . The method according to  claim 18  wherein the moisture barrier film comprises at least one of polyethylene, polypropylene, polystyrene, poly(ethylene terephthalate), polyimide, parylene, benzocyclobutene, polychlorotrifluoroethylene, silicon oxide, aluminum oxide, silicon nitride, aluminum nitride, silicon oxy-nitride, aluminum oxy-nitride, amorphous or polycrystalline silicon carbide, transparent ceramics, and carbon doped oxide. 
     
     
         20 . The method according to  claim 12  wherein the step of electrically interconnecting interconnects a chain of at least three solar cells, such that each solar cell is electrically connected to at least one other solar cell. 
     
     
         21 . A photovoltaic module comprising; at least two solar cells, each of the at least two solar cells having a top illuminating surface and two terminals; an electrical conductor that electrically interconnects the at least two solar cells with a conductor between at least one of the terminals of each of the at least two solar cells, and a moisture barrier film that coats at least an entire side of the circuit that corresponds to and includes the top illuminating surface of the at least two solar cells to form a moisture-resistant surface on the circuit. 
     
     
         22 . The module according to  claim 21  wherein the moisture-barrier film fully encapsulates the circuit. 
     
     
         23 . The module according to  claim 22  wherein the moisture barrier film is coated conformally. 
     
     
         24 . The module according to  claim 23  further including a structure in which the circuit that contains the top illuminating surface is embedded, the structure including a top film, a flexible encapsulant and a backing material. 
     
     
         25 . The module according to  claim 22  wherein the moisture barrier film is substantially transparent to solar light. 
     
     
         26 . The module according to  claim 25  wherein the moisture barrier film comprises at least one of polyethylene, polypropylene, polystyrene, poly(ethylene terephthalate), polyimide, parylene, benzocyclobutene, polychlorotrifluoroethylene, silicon oxide, aluminum oxide, silicon nitride, aluminum nitride, silicon oxy-nitride, aluminum oxy-nitride, amorphous or polycrystalline silicon carbide, transparent ceramics, and carbon doped oxide. 
     
     
         27 . The module according to  claim 21  wherein the moisture barrier film is coated conformally. 
     
     
         28 . The module according to  claim 27  further including a structure in which the circuit that contains the top illuminating surface is embedded, the structure including a top film, a flexible encapsulant and a backing material. 
     
     
         29 . The module according to  claim 21  wherein the moisture barrier film is substantially transparent to solar light. 
     
     
         30 . The module according to  claim 29  wherein the moisture barrier film comprises at least one of polyethylene, polypropylene, polystyrene, poly(ethylene terephthalate), polyimide, parylene, benzocyclobutene, polychlorotrifluoroethylene, silicon oxide, aluminum oxide, silicon nitride, aluminum nitride, silicon oxy-nitride, aluminum oxy-nitride, amorphous or polycrystalline silicon carbide, transparent ceramics, and carbon doped oxide. 
     
     
         31 . The module according to  claim 21  wherein at least three solar cells are interconnected in a chain, such that each solar cell is electrically connected to at least one other solar cell. 
     
     
         32 - 40 . (canceled)