NOVELTY - Forming a solar module, comprises: providing a substrate (220) member having a surface (211) region; forming a photovoltaic film (210) overlying the surface region; forming a barrier layer (230) overlying and enclosing the photovoltaic film on the top and side surfaces; forming a powder coating overlying the barrier layer and enclosing the photovoltaic film to protect the photovoltaic film; performing a thermal treatment process to cure the powder coating; and sealing with an encapsulating material over the powder coating.    USE - The method is useful for forming a solar module.    ADVANTAGE - The method: is easy to process and provides large scale manufacturing of solar module, which provides higher efficiencies ( greater than or equal to 20%) in converting sunlight into electrical power using a multiple junction design and method; provides powder coating and thermal treatment process that is compatible with conventional technology without modifications to conventional equipment and processes; reduces both processing cost and material cost associated with the solar module packaging; and can utilizes any combination of suitable single junction solar cell designs to form the top and lower cells.    DETAILED DESCRIPTION - Forming a solar module, comprises: providing a substrate (210) member having a surface (211) region; forming a photovoltaic film (210) overlying the surface region, where the photovoltaic film comprises at least one layer of N-type photosensitive semiconductor material alternatively and respectively overlying at least one layer of P-type photosensitive semiconductor material; forming a barrier layer (230) overlying and enclosing the photovoltaic film on the top and side surfaces; forming a powder coating overlying the barrier layer and enclosing the photovoltaic film to protect the photovoltaic film, where the powder coating consists of a tetrafluorooxetane fluorine-doped tin oxide; performing a thermal treatment process to cure the powder coating; and sealing with an encapsulating material (270) over the powder coating, where the barrier layer comprises silicon nitride, silicon dioxide, titanium nitride or tetrafluorooxetane.    DESCRIPTION OF DRAWING(S) - The figure shows process of forming a solar module using a power coating.    Photovoltaic film (210)    Surface (211)    Substrate (220)    Barrier layer (230)    Encapsulating material (270)