Adaptable free-standing metallic article for semiconductors

摘要

A free-standing metallic article, and method of making, is disclosed in which the metallic article is electroformed on an electrically conductive mandrel. The metallic article has a plurality of electroformed elements that are configured to serve as an electrical conduit for a photovoltaic cell. A first electroformed element has at least one of: a) a non-uniform width along a first length of the first element, b) a change in conduit direction along the first length of the first element, c) an expansion segment along the first length of the first element, d) a first width that is different from a second width of a second element in the plurality of electroformed elements, e) a first height that is different from a second height of the second element in the plurality of electroformed elements, and f) a top surface that is textured.

主权项

1. A method of forming an electrical component for a photovoltaic cell, the method comprising:
electroforming a metallic article on an electrically conductive mandrel, wherein the electrically conductive mandrel has an outer surface comprising at least one preformed pattern, wherein the metallic article comprises a plurality of electroformed elements formed by the preformed pattern; and separating the metallic article from the electrically conductive mandrel, wherein the plurality of electroformed elements are interconnected such that the metallic article forms a unitary, free-standing piece when separated from the electrically conductive mandrel; wherein the plurality of electroformed elements are configured to serve as an electrical conduit for a light-incident surface of the photovoltaic cell; wherein the plurality of electroformed elements comprises a first element configured with a first expansion segment along at least a portion of a first length of the first element, the first expansion segment having dimensions chosen to accommodate a difference in coefficient of thermal expansion between the metallic article and a semiconductor substrate of the photovoltaic cell, wherein the first expansion segment is configured as a wave pattern; and wherein the first element further comprises a plurality of bonding areas, the first expansion segment being between the bonding areas.