SunPower Patent Grants

Regulation of powertrain converter circuit

Granted: November 15, 2016
Patent Number: 9496794
Regulation of powertrain converter circuits is provided. The power conversion may include converting between direct current and alternating current and the regulation may include reduction of distortion on switching start up and zero-crossings. Solid-state implementations, code implementations, and mixed implementations are provided.

Shingled solar cell module

Granted: November 1, 2016
Patent Number: 9484484
A high efficiency configuration for a solar cell module comprises solar cells arranged in a shingled manner to form super cells, which may be arranged to efficiently use the area of the solar module, reduce series resistance, and increase module efficiency.

Support for solar energy collectors

Granted: November 1, 2016
Patent Number: 9482449
A solar energy collection system can include support devices configured to accommodate misalignment of components during assembly. For example, the system can include piles fixed to the earth and an adjustable bearing assembly at the upper end of the pile. The adjustable bearing assembly can include at least one of a vertical adjustment device, a lateral adjustment device and an angular adjustment device. The solar energy collection system can also include a plurality of solar energy…

Device and method for global maximum power point tracking

Granted: October 25, 2016
Patent Number: 9477247
A device, system, and method for global maximum power point tracking comprises monitoring an output power of a DC power source while executing a maximum power point tracking algorithm and adjusting a maximum power point tracking command signal in response to the output power being less than a reference output power. The command signal is adjusted until the output power exceeds a previous output power by a reference amount. The command signal may be a voltage command signal, a current…

Device for shunting current from photovoltaic circuit near the open circuit voltage and/or disconnecting solar module of a solar system

Granted: October 18, 2016
Patent Number: 9472691
Devices for reducing the open circuit voltages of solar systems are described. In one embodiment, a solar system includes a string of a plurality of solar modules having an open circuit voltage. The solar system also includes a device for reducing the open circuit voltage of the string of the plurality of solar modules during an open circuit configuration.

Optoelectronic device with heat spreader unit

Granted: October 11, 2016
Patent Number: 9466748
A solar module includes a solar cell, a heat spreader layer disposed above the solar cell, and a cell interconnect disposed above the solar cell. From a top-down perspective, the heat spreader layer at least partially surrounds an exposed portion of the cell interconnect.

Technologies for interleaved control of an inverter array

Granted: October 11, 2016
Patent Number: 9467063
An apparatus to deliver an alternating current (AC) power may include a controller having a processor and a memory. The apparatus may also include a plurality of power inverters in communication with the controller. Each power inverter may be configured to convert direct-current (DC) power into the (AC) power. Each of the plurality of power inverters may be configured to be controlled by the controller to generate AC power below at least one predetermined operating threshold. The…

Grain growth for solar cells

Granted: October 11, 2016
Patent Number: 9466754
A solar cell can include a silicon layer formed over a silicon substrate. The silicon layer can have a P-type doped region and an N-type doped region. Portions of the silicon layer can have a grain size larger than other portions of the silicon layer. For example, larger grains of the silicon layer formed within a depletion region between P-type and N-type doped regions can minimize recombination loss at the P-type and N-type doped region boundaries and improve solar cell efficiency.

Module assembly for thin solar cells

Granted: October 11, 2016
Patent Number: 9466752
Solar cells are packaged by placing the solar cells between sheets of encapsulants. The encapsulants are exposed to ultraviolet (UV) light to cure the encapsulants and bond the encapsulants together to encapsulate the solar cells. The UV curing steps may be performed to bond one of the encapsulants to a transparent top cover and the solar cells, and to bond the other encapsulant to the solar cells and a backsheet. A protective package that includes the transparent top cover, encapsulated…

Hybrid polysilicon heterojunction back contact cell

Granted: October 11, 2016
Patent Number: 9466750
A method for manufacturing high efficiency solar cells is disclosed. The method comprises providing a thin dielectric layer and a doped polysilicon layer on the back side of a silicon substrate. Subsequently, a high quality oxide layer and a wide band gap doped semiconductor layer can both be formed on the back and front sides of the silicon substrate. A metallization process to plate metal fingers onto the doped polysilicon layer through contact openings can then be performed. The…

Thick damage buffer for foil-based metallization of solar cells

Granted: October 4, 2016
Patent Number: 9461192
Approaches for the foil-based metallization of solar cells and the resulting solar cells are described. A method involves patterning a first surface of a metal foil to provide a plurality of alternating grooves and ridges in the metal foil. Non-conductive material regions are formed in the grooves in the metal foil. The metal foil is located above a plurality of alternating N-type and P-type semiconductor regions disposed in or above a substrate to provide the non-conductive material…

Support for solar energy collectors

Granted: September 27, 2016
Patent Number: 9455664
A solar energy collection system can include support devices made with bearings formed from sheet material. These bearings can be optionally formed so as to provide tool-less connections to their associated bearing housings. The bearings can be formed with an open configuration allowing a shaft to be inserted into an open bite of the bearing. Optionally, the bearing can be made from an ultrahigh molecular weight polyethylene plastic material. Additionally, two open-type bearing…

Variable tilt tracker for photovoltaic arrays

Granted: September 27, 2016
Patent Number: 9455661
A solar tracking system is disclosed. The tracking system includes a tube rotatable around its end-to-end axis. A first support is coupled to the tube at a first location of the tube, and is coupled with a first base. A second support is coupled to the tube at a second location of the tube, and is coupled with a second base. A translation mechanism is coupled with the tube and provided to change the position of the first support relative to the second support.

Solar panel

Granted: September 27, 2016
Patent Number: D767484

Frame-mounted wire management device

Granted: September 20, 2016
Patent Number: 9450130
A wire management device is disclosed. The device comprises a clip comprising an upper planar member and a lower planar member, each planar member having an inner and outer surface, wherein the inner surface of the upper planar member includes a post extending toward the inner surface of the lower planar member, a stem extending from the outer surface of the lower planar member, the stem including two outwardly-extending flanges, each of the first and second outwardly-extending flanges…

Alignment for metallization

Granted: September 20, 2016
Patent Number: 9450113
Forming a metal layer on a solar cell. Forming a metal layer can include placing a patterned metal foil on the solar cell, where the patterned metal foil includes a positive busbar, a negative busbar, a positive contact finger extending from the positive busbar, a negative contact finger extending from the negative busbar, and a metal strip, and one or more tabs. The positive and negative busbars and the positive and negative contact fingers can be connected to one another by the metal…

Chucks for supporting solar cell in hot spot testing

Granted: September 6, 2016
Patent Number: 9435848
In an embodiment, a chuck to support a solar cell in hot spot testing is provided. This embodiment of the chuck comprises a base portion and a support portion disposed above the base portion. The support portion is configured to support the solar cell above the base portion and to define a cavity between a bottom surface of the solar cell and the base portion that thermally separates a portion of the bottom surface of the solar cell from the base portion.

Methods for wet chemistry polishing for improved low viscosity printing in solar cell fabrication

Granted: September 6, 2016
Patent Number: 9437757
A method of fabricating a solar cell is disclosed. The method includes forming a polished surface on a silicon substrate and forming a first flowable matrix in an interdigitated pattern on the polished surface, where the polished surface allows the first flowable matrix to form an interdigitated pattern comprising features of uniform thickness and width. In an embodiment, the method includes forming the silicon substrate using a method such as, but not limited to, of diamond wire or…

Metallization of solar cells using metal foils

Granted: September 6, 2016
Patent Number: 9437756
A solar cell structure includes P-type and N-type doped regions. A dielectric spacer is formed on a surface of the solar cell structure. A metal layer is formed on the dielectric spacer and on the surface of the solar cell structure that is exposed by the dielectric spacer. A metal foil is placed on the metal layer. A laser beam is used to weld the metal foil to the metal layer. A laser beam is also used to pattern the metal foil. The laser beam ablates portions of the metal foil and the…

Front contact solar cell with formed electrically conducting layers on the front side and backside

Granted: September 6, 2016
Patent Number: 9437755
A bipolar solar cell includes a backside junction formed by a silicon substrate and a first doped layer of a first dopant type on the backside of the solar cell. A second doped layer of a second dopant type makes an electrical connection to the substrate from the front side of the solar cell. A first metal contact of a first electrical polarity electrically connects to the first doped layer on the backside of the solar cell, and a second metal contact of a second electrical polarity…