Finger pattern formation for thin film solar cells

A roll to roll system for forming a metallic pattern comprising:

• a first process station for forming a solar cell structure, including a transparent conductive layer over a transparent top layer as a portion of a continuously fed roll-to-roll solar cell structure is advanced through the first process station;
• an assembly to hold and move a conductive foil over the continuously fed roll-to-roll solar cell structure;
• an embosser station having an embosser with raised surfaces to attach a section of the conductive foil to the transparent conductive layer by pressing raised features of the embosser against the metallic foil so that pressure and heat are simultaneously applied to a portion of the metallic foil interposed between the raised features and the transparent conductive layer, wherein the raised features are shaped in the form of the metallic pattern;
• and
• a moving assembly for holding and moving the continuously fed roll-to-roll solar cell structure through the first process station and the embosser station, wherein subsequent portions of the continuously fed roll-to-roll solar cell structure is unwrapped and fed from a supply roll, and the portions with attached metallic pattern are received and wrapped around a receiving roll.