SunPower Patent Grants

Shingled solar cell module

Granted: May 31, 2016
Patent Number: 9356184
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.

Power point tracking

Granted: May 17, 2016
Patent Number: 9342088
A local power converter may include a controller to manipulate the operating point of a local power converter to cause the power point tracking feature of a central power converter to operate at a point determined by the controller. In some embodiments, the controller can manipulate the operating point of the local power converter by alternating between at least two modes. In some other embodiments, the controller can manipulate the operating point of the local power converter to provide…

Solar cells with tunnel dielectrics

Granted: May 10, 2016
Patent Number: 9337369
A solar cell can have a first dielectric formed over a first doped region of a silicon substrate. The solar cell can have a second dielectric formed over a second doped region of the silicon substrate, where the first dielectric is a different type of dielectric than the second dielectric. A doped semiconductor can be formed over the first and second dielectric. A positive-type metal and a negative-type metal can be formed over the doped semiconductor.

Edgeless pulse plating and metal cleaning methods for solar cells

Granted: May 3, 2016
Patent Number: 9328427
A method for plating metal to a solar cell is disclosed. The method includes plating a metal layer only on the surface of solar cell without plating metal along the solar cell edges by conducting a first current in a first direction in an electroplating bath, ejecting metal from the metal layer by conducting a second current in a second direction and plating additional metal to the metal layer by conducting a third current in the first direction. The first, second and third current can…

Opposing row linear concentrator architecture

Granted: April 26, 2016
Patent Number: 9322963
A solar concentrator assembly is disclosed. The solar concentrator assembly comprises a first reflective device having a first reflective front side and a first rear side, a second reflective device having a second reflective front side and a second rear side, the second reflective device positioned such that the first reflective front side faces the second rear side, and a support assembly coupled to and supporting the first and second reflective devices, the second reflective device…

Support for solar energy collection

Granted: April 26, 2016
Patent Number: 9322437
A solar energy collection system can include support devices made with bearings. Such bearings can include an inner partially toroidal surface for sliding contact and support of an outer surface of a torque tube. The toroidal surface can be made with a single radius of curvature or multiple radiuses of curvature and cylindrical portions. The bearings can include connectors for connecting the bearing members to a support housing. The connectors can be tool-less connectors.

Framing system for mounting solar collecting devices

Granted: April 19, 2016
Patent Number: 9316417
A framing system for mounting solar collection devices to form a solar array can include a plurality of interconnected frame members having connectors provided on the frame members to form rows of an array solar collector devices. Mounts can be provided at the upper portion of the frame members to secure the solar collecting devices at a raised position. The framing system can simplify the installation of the wiring system before the solar collection devices are attached to the frame…

Solar power generation assembly

Granted: April 19, 2016
Patent Number: D754064

Hybrid emitter all back contact solar cell

Granted: April 12, 2016
Patent Number: 9312406
An all back contact solar cell has a hybrid emitter design. The solar cell has a thin dielectric layer formed on a backside surface of a single crystalline silicon substrate. One emitter of the solar cell is made of doped polycrystalline silicon that is formed on the thin dielectric layer. The other emitter of the solar cell is formed in the single crystalline silicon substrate and is made of doped single crystalline silicon. The solar cell includes contact holes that allow metal…

Crack resistant solar cell modules

Granted: April 12, 2016
Patent Number: 9312425
A crack resistant solar cell module includes a protective package mounted on a frame. The protective package includes a polyolefin encapsulant that protectively encapsulates solar cells. The polyolefin has less than five weight percent of oxygen and nitrogen in the backbone or side chain. In other words, the combined weight percent of oxygen and nitrogen in any location in the molecular structure of the polyolefin is less than five. The polyolefin also has a complex viscosity less than…

Metal seed layer for solar cell conductive contact

Granted: April 12, 2016
Patent Number: 9312042
Metal seed layers for solar cell conductive contacts and methods of forming metal seed layers for solar cell conductive contacts are described. For example, a solar cell includes a substrate. A semiconductor region is disposed in or above the substrate. A conductive contact is disposed on the semiconductor region and includes a seed layer in contact with the semiconductor region. The seed layer is composed of aluminum (Al) and a second, different, metal.

Radially arranged metal contact fingers for solar cells

Granted: April 5, 2016
Patent Number: 9306085
A solar cell includes negative metal contact fingers and positive metal contact fingers. The negative metal contact fingers are interdigitated with the positive metal contact fingers. The metal contact fingers, both positive and negative, have a radial design where they radially extend to surround at least 25% of a perimeter of a corresponding contact pad. The metal contact fingers have bend points, which collectively form a radial pattern with a center point within the contact pad.…

Automatic voltage regulation for photovoltaic systems

Granted: March 29, 2016
Patent Number: 9300224
A photovoltaic system includes solar cells and photovoltaic inverters configured to convert direct current generated by the solar cells to alternating current. Grid voltage at the point of interconnection (POI) of the photovoltaic system and the power grid is measured and compared to a setpoint. A control signal is generated based on the measured grid voltage. The control signal is provided to the photovoltaic inverters. The control signal is adjusted to cause the photovoltaic inverters…

Methods for electroless plating of a solar cell metallization layer

Granted: March 22, 2016
Patent Number: 9293624
A method for forming a contact region for a solar cell is disclosed. The method includes depositing a paste composed of a first metal above a substrate of the solar cell, curing the paste to form a first metal layer, electrolessly plating a second metal layer on the first metal layer and electrolytically plating a third metal layer on the second metal layer, where the second metal layer electrically couples the first metal layer to the third metal layer. The method can further include…

Solar power generation assembly

Granted: March 22, 2016
Patent Number: D751976

Thermal tracking for solar systems

Granted: March 8, 2016
Patent Number: 9281431
A power generating system is disclosed. The power generating system comprises a solar cell, a support structure coupled to the solar cell and adapted to adjust the position of the solar cell, a first thermal sensor coupled to the solar cell and adapted to detect a first temperature at a first location on the solar cell, a second thermal sensor coupled to the solar cell and adapted to detect a second temperature at a second location on the solar cell, the second location spaced apart from…

Module level solutions to solar cell polarization

Granted: March 8, 2016
Patent Number: 9281429
A solar cell module includes interconnected solar cells, a transparent cover over the front sides of the solar cells, and a backsheet on the backsides of the solar cells. The solar cell module includes an electrical insulator between the transparent cover and the front sides of the solar cells. An encapsulant protectively packages the solar cells. To prevent polarization, the insulator has resistance suitable to prevent charge from leaking from the front sides of the solar cells to other…

Localized power point optimizer for solar cell installations

Granted: March 8, 2016
Patent Number: 9281419
In one embodiment, a solar cell installation includes several groups of solar cells. Each group of solar cells has a local power point optimizer configured to control power generation of the group. The local power point optimizer may be configured to determine an optimum operating condition for a corresponding group of solar cells. The local power point optimizer may adjust the operating condition of the group to the optimum operating condition by modulating a transistor, such as by…

Nested torque tubes for photovoltaic tracking systems

Granted: March 8, 2016
Patent Number: 9279457
A sun tracking solar energy collection system can include torque tubes that can be configured to allow the cylindrical body of one torque tube to nest with projections extending from an adjacent torque tube. The torque tubes can be formed with a plurality of rotatable shafts connected to each other in an end to end fashion. The torque tubes may be connected with coupling flanges, shaped with a plurality of radially extending lobes. The coupling flanges can include a plurality of concave…

Solar panel

Granted: March 1, 2016
Patent Number: D750556