Thin film photovoltaic module manufacturing methods and structures

A method of manufacturing a solar module, comprising:

• providing a front protective layer having a front surface and a back surface, wherein the front protective layer is transparent;
• placing a first encapsulant layer over the back surface of the front protective layer;
• placing a solar cell string over the first encapsulant layer, wherein the solar cell string includes a plurality of solar cells, each solar cell having a light receiving side and a back side, wherein the back side comprises a conductive substrate and wherein the plurality of solar cells are electrically interconnected in series using conductive leads which connect the light receiving side of one solar cell to the back side of an adjacent solar cell, and wherein the light receiving side of the solar cells face the first encapsulant layer;
• attaching a bypass diode device to the solar cell string, the bypass diode device including a first conductive strip and a second conductive strip each attached at one end to respective first and second leads of a bypass diode, wherein the bypass diode is electrically connected to a first conductive substrate of a first solar cell and a second conductive substrate of a second solar cell of the plurality of solar cells by the first conductive strip and the second conductive strip, respectively;
• placing a second encapsulant layer over the bypass diode device and the conductive substrates of the plurality of solar cells;
• placing a back protective sheet over the second encapsulant layer and sealing a peripheral gap between the periphery of the front protective sheet and the back protective sheet with a moisture barrier edge sealant, and thereby forming a pre-module structure;
• and
• subjecting the pre-module structure to heat and pressure to form the solar module.