Solar module with optimized interconnection and method of manufacturing the same

A solar module comprising:

• a plurality of solar cell arrays,
• a cross-connector, and
• an encapsulation,
• wherein each solar cell array of the plurality of solar cell arrays comprises:
• a plurality of planar solar cell substrates, and
• an interconnection structure,
• wherein each planar solar cell substrate of the plurality of solar cell substrates has contact structures for conducting away current generated in a respective planar solar cell substrate of the plurality of planar solar cell substrates upon illumination of the respective planar solar cell substrate,
• wherein the interconnection structure comprises a plurality of wires contacting the contact structures on at least one planar solar cell substrate of the plurality of planar solar cell substrates at contact locations,
• wherein a first plurality of wires of the plurality of wires electrically connects respective contact structures on one planar solar cell substrate of the plurality of planar solar cell substrates to contact structures on one neighboring planar solar cell substrate of the plurality of planar solar cell substrates, so that the plurality of solar cell substrates is connected in series to form a string by means of the first plurality of wires,
• the first plurality of wires is electrically connected to contact structures on a terminal solar cell substrate of the plurality of planar solar cell substrates which is terminal in the string of the plurality of solar cell substrates connected in series,
• wherein a second plurality of wires of the plurality of wires is located only on a surface of the terminal solar cell substrate, and each wire of the second plurality of wires contains both a flattened region and a non-flattened region, the flattened region of each wire of the second plurality of wires has a flatter cross-section than the non-flattened region, the flattened region of each wire of the second plurality of wires has a flatter cross-section than each wire of the first plurality of wires,
• wherein the flattened region in each wire of the second plurality of wires is located at or near an edge of the terminal solar cell substrate adjacent to a portion of a contacting surface of a rear side of the terminal solar cell substrate in which contact is made between the rear side of the terminal solar cell substrate and the flattened region in each wire of the second plurality of wires,
• wherein the non-flattened region in each wire of the second plurality of wires has a rounded cross-section with a circumferential surface which is curved,
• wherein at least two strings, each string formed by means of the first plurality of wires of each solar cell array of the plurality of solar cell arrays, are arranged side by side,
• wherein two strings of the at least two strings are interconnected by means of the cross-connector,
• and wherein the cross-connector overlaps the second plurality of wires of the respective terminal solar cell substrates of each string of the two strings of solar cell arrays respectively in the flattened region with the cross-connector being arranged in an orthogonal direction to the contacting surface of the rear side of the respective terminal solar cell substrate,
• said cross-connector directly contacting the flattened region of each wire of the second plurality of wires of the respective terminal solar cell substrates of each string of the two strings, wherein the encapsulation encapsulates the plurality of solar cell arrays and the cross-connector.