SunPower Patent Applications

Photovoltaic Panel Having a Distributed Support Frame

Granted: January 13, 2022
Application Number: 20220014144
A photovoltaic panel having a photovoltaic module supported by a distributed support frame is described. The distributed support frame may include a support member extending over a back surface of the photovoltaic module. For example, one or more support members may extend laterally from a support hub mounted on the back surface. The distributed support frame may reduce a span length of the photovoltaic module between support locations, and thus, may reduce a likelihood that a module…

CLAMPS FOR SOLAR SYSTEM

Granted: December 30, 2021
Application Number: 20210408960
A solar power system can include a rail and a solar module disposed on the rail. A clamp assembly can couple the solar module to the rail. The clamp assembly can have a clamped configuration in which the solar module is secured to the rail and an unclamped configuration. The clamp assembly can comprise an upper clamp member, a lower clamp member coupled to the rail, and a stabilization member mechanically engaging the upper clamp member and the lower clamp member. The stabilization…

COMPOSITE MASKING BETWEEN SOLAR CELLS

Granted: December 9, 2021
Application Number: 20210384363
Composite making regions are provided. These masking regions can include layers or other areas of different transparency where a first region has a first transparency and a second region has a different transparency. Masking regions can be positioned between adjacent photovoltaic cells of photovoltaic arrays.

SYSTEM AND METHOD FOR SHINGLING WAFER STRIPS CONNECTED IN PARALLEL

Granted: November 4, 2021
Application Number: 20210343888
A solar device includes a first string of first solar wafers, wherein a plurality of the first solar wafers each overlap with at least one vertically adjacent solar wafer from the first string. Additionally, the solar device includes a second string of second solar wafers, wherein a plurality of the second solar wafers each overlap with at least one vertically adjacent solar wafer from the second string, wherein a plurality of the first solar wafers overlap with one or more of the…

WATER SEALING SURFACE ATTACHMENT

Granted: October 7, 2021
Application Number: 20210310513
A mounting assembly for securing fixtures to a mounting structure may include a first fastener, a washer, a mounting bracket, and second fastener. The first fastener may be coupled to the mounting structure through a mounting aperture. The washer may be disposed around shaft of the first fastener between a head of the first fastener and the mounting surface. The mounting bracket may be disposed on top of the first fastener. The second fastener may be disposed through the mounting bracket…

ELECTRICALLY CONDUCTIVE ADHESIVES FOR SOLAR CELL MODULES

Granted: September 23, 2021
Application Number: 20210296520
A solar module includes at least one first solar cell and at least one second solar cell, each including: a substrate including a first semiconductor region of a first conductivity type and a second semiconductor region of a second conductivity type different from the first conductivity type; a first metallization pattern providing electrical contact to the first semiconductor region of the first conductivity type; and a second metallization pattern providing electrical contact to the…

CURRENT CYCLICAL TESTING FOR PV ELECTRICAL CONNECTIONS

Granted: September 9, 2021
Application Number: 20210281215
Cyclical testing of electrically conductive bonding (ECB) is provided. Cyclical testing comprises high current flows using multiples of max operating currents and monitoring sensors with periods of no current to accelerate testing of electrical connections employing ECBs.

SPACER FORMATION IN A SOLAR CELL USING OXYGEN ION IMPLANTATION

Granted: September 9, 2021
Application Number: 20210280726
A solar cell is disclosed. The solar cell has a front side facing the sun during normal operation, and a back side facing away from the sun. The solar cell comprises a silicon substrate, a first polysilicon layer with a region of doped polysilicon on the back side of the substrate. The solar cell also comprises a second polysilicon layer with a second region of doped polysilicon on the back side of the silicon substrate. The second polysilicon layer at least partially covers the region…

SOLAR PANEL SYSTEM GENERATION

Granted: August 26, 2021
Application Number: 20210264071
A solar panel system proposal system includes a remote device configured to display various steps of the solar panel system proposal process and receive input from a user. The user input received from the user allows the user, via the solar panel system proposal system, to create one or more solar panel system layout designs, compare savings for different solar panel system layout designs, select a solar panel system layout design from the one or more solar panel system layout designs,…

SOLAR POWER SYSTEM COMMISSIONING

Granted: August 19, 2021
Application Number: 20210257968
Commissioning a solar power monitoring system includes imaging a plurality of labels, wherein each label of the plurality of labels is associated with an electronic component. Further, commissioning the solar power monitoring system includes discovering each electronic component at the same time based on the imaging of the plurality of labels, displaying a list of the discovered electronic components, and commissioning a solar power monitoring system including the discovered electronic…

SOLAR MODULE SKIRT ASSEMBLY

Granted: August 12, 2021
Application Number: 20210249990
A solar module skirt assembly includes a skirt that is attached to a frame of a solar module, and a clip to attach the skirt to the solar module. The clip includes a first portion to attach to a frame of the solar module and to the skirt, a second portion to hold a portion of the frame of the solar module and a portion of the skirt, and a fastener to affix the clip to the frame of the solar module and the portion of the skirt.

PHOTOVOLTAIC CELL AND LAMINATE METALLIZATION

Granted: July 29, 2021
Application Number: 20210234054
A photovoltaic laminate is disclosed. Embodiments include placing a first encapsulant on a substantially transparent layer that includes a front side of a photovoltaic laminate. Embodiments also include placing a first solar cell on the first encapsulant. Embodiments include placing a metal foil on the first solar cell, where the metal foil uniformly contacts a back side of the first solar cell. Embodiments include forming a metal bond that couples the metal foil to the first solar cell.…

ELECTRICAL PATHWAY INTERMITTENT FAULT DETECTION

Granted: June 24, 2021
Application Number: 20210194425
Testing to detect intermittent electrical pathways is described. Applied currents may be reversed to fully test all components of a workpiece. Various testing methodologies may be employed. These methodologies may include Time Domain Reflectometry (TDR), mechanical agitation, dark current/voltage testing, (dark IV), i.e., electrical testing of a workpiece using applied electricity, and thermographic imaging, e.g., infra-red thermal imaging. The sensed voltage during agitation may be…

SINGLE-WALLED CONNECTING KEY FRAMESETS

Granted: June 17, 2021
Application Number: 20210180831
Frames and processes of manufacture using single-wall frame sections coupled to other single-wall frame sections or double-wall frame sections using a connecting key are provided. The connecting key can be metallic, polymer, ceramic, a laminate, and combinations thereof.

METAL-FOIL-ASSISTED FABRICATION OF THIN-SILICON SOLAR CELL

Granted: June 10, 2021
Application Number: 20210175375
One embodiment relates to a method of fabricating a solar cell. A silicon lamina is cleaved from the silicon substrate. The backside of the silicon lamina includes the P-type and N-type doped regions. A metal foil is attached to the backside of the silicon lamina. The metal foil may be used advantageously as a built-in carrier for handling the silicon lamina during processing of a frontside of the silicon lamina. Another embodiment relates to a solar cell that includes a silicon lamina…

PHOTOVOLTAIC FRAME WITH LAMINATE RECEIVER

Granted: May 27, 2021
Application Number: 20210159850
Photovoltaic (PV) frames, PV frame systems, methods of PV manufacture, articles of PV manufacture, and processes involving PVs are provided. These frames may employ a laminate receiver configured to receive a surface of a PV laminate and support that PV laminate upon installation of a PV system.

SOLAR POWER GENERATION ASSEMBLY AND METHOD FOR PROVIDING SAME

Granted: May 20, 2021
Application Number: 20210152119
The present invention relates to a solar power generation assembly and method for providing same involving an array of solar generating modules on a dual-incline structure, which can achieve high energy yields over a wide range of azimuths/orientations. The assembly consists of canopy wings providing for the dual-incline structure, where, depending on specifications, the canopy wings can differ in length, width, angle of inclination, structural material and solar module or other material…

HYBRID DENSE SOLAR CELLS AND INTERCONNECTS FOR SOLAR MODULES AND RELATED METHODS OF MANUFACTURE

Granted: May 13, 2021
Application Number: 20210143290
A solar module includes at least one first solar cell and at least one second solar cell, each solar cell including a top side and bottom side, a bus bar, and a plurality of wires, disposed on the top side, extending from and electrically connected to the bus bar. The first solar cell overlaps a region of the second solar cell to electrically connect to the second solar cell and to form a shingled arrangement, and in the second solar cell, the plurality of wires connect to the bus bar…

SYSTEMS AND APPARATUSES FOR CARPORT WITH INTEGRATED PRECIPITATION AND CABLE MANAGEMENT

Granted: May 13, 2021
Application Number: 20210140187
A solar power generation assembly includes a vertical support column; a canopy including a plurality of solar modules for solar power generation; a first brace and a second brace on a first side of the support column to support the canopy; a third brace and a fourth brace on a second side of the support column to support the canopy; and a gutter system integrated into the canopy and directing precipitation along one or more of the second brace and the fourth brace to the support column.…

SYSTEMS AND METHOD FOR DETERMINING SOLAR PANEL PLACEMENT AND ENERGY OUTPUT

Granted: April 22, 2021
Application Number: 20210117587
Determining solar panel placement enables sales representatives and homeowners to modify a solar power system by adding or removing solar panels or arrays of solar panels, or changing module type. The user sees the corresponding solar energy production update instantly in a user interface. Determining solar panel placement includes receiving data corresponding to an installation location. A maximum solar panel design is determined based on the installation location. Energy production is…