Abstract:
System and method of providing a photovoltaic (PV) cell (200) having a cushion layer (260, 411, 412) to alleviate stress impact between a front metal contact (220) and a thin film PV layer (230). The cushion layer is made of a nonconductive material and has a plurality of vias (420) filled with a conductive material (430) to provide electrical continuity between the bus bar and the PV layer. The cushion layer may be made of a flexible material preferably with rigidity that matches the substrate. Thus, the cushion layer can effectively protect the PV layer from physical damage due to tactile contact with the front metal contact.