Switching power converter control
Granted: May 19, 2015
Patent Number:
9035633
A method of operating a switching power converter may include determining an average value of a measured parameter for substantially each switching cycle, and adjusting a control parameter during substantially each switching cycle in response to a corresponding one of the average values. In one embodiment, the control parameter comprises a switch duty cycle, and the measured parameter comprises an output current. Determining the average value of the measured parameter may include…
Method for connecting solar cells
Granted: May 12, 2015
Patent Number:
9029689
A method of connecting two solar cells is disclosed. In one embodiment, the method comprises gripping an interconnect with a head of positioning device, heating the interconnect with the head of the positioning device to between two predetermined temperatures, where one is higher than the other, positioning the interconnect so as to overlay two adjacent solar cells, coupling the interconnect to each of the two adjacent solar cells, and releasing the interconnect from the head.
System and method for associating a load demand with a variable power generation
Granted: April 28, 2015
Patent Number:
9020653
Systems and methods for associating a load demand with a variable power generation are described. A method of providing power from a renewable resource includes receiving a signal including an output capability value for a renewable variable power generation module. An input power demand value is calculated for a load demand module based on the output capability value of the received signal. A customer load is controlled on a power transmission and distribution grid based on the…
Solar cell with silicon oxynitride dielectric layer
Granted: April 28, 2015
Patent Number:
9018516
Solar cells with silicon oxynitride dielectric layers and methods of forming silicon oxynitride dielectric layers for solar cell fabrication are described. For example, an emitter region of a solar cell includes a portion of a substrate having a back surface opposite a light receiving surface. A silicon oxynitride (SiOxNy, 0<x, y) dielectric layer is disposed on the back surface of the portion of the substrate. A semiconductor layer is disposed on the silicon oxynitride dielectric…
Method for forming diffusion regions in a silicon substrate
Granted: April 28, 2015
Patent Number:
9018033
A method of manufacturing solar cells is disclosed. The method comprises depositing an etch-resistant dopant material on a silicon substrate, the etch-resistant dopant material comprising a dopant source, forming a cross-linked matrix in the etch-resistant dopant material using a non-thermal cure of the etch-resistant dopant material, and heating the silicon substrate and the etch-resistant dopant material to a temperature sufficient to cause the dopant source to diffuse into the silicon…
Leveler for solar module array
Granted: April 21, 2015
Patent Number:
9010041
A leveler for a solar module can include a base, a rotatable adjuster, and a follower. The rotatable adjuster can be mounted to the base with a swaging process, or other techniques. The follower can be embedded within a coupler configured to be connectable to solar modules. Turning the rotatable height adjuster changes the relative spacing between the solar module and the base.
Dopant ink composition and method of fabricating a solar cell there from
Granted: March 31, 2015
Patent Number:
8992803
Dopant ink compositions and methods of fabricating solar cells there from are described. A dopant ink composition may include a cross-linkable matrix precursor, a bound dopant species, and a solvent. A method of fabricating a solar cell may include delivering a dopant ink composition to a region above a substrate. The dopant ink composition includes a cross-linkable matrix precursor, a bound dopant species, and a solvent. The method also includes baking the dopant ink composition to…
Methods and structures for forming and improving solder joint thickness and planarity control features for solar cells
Granted: March 31, 2015
Patent Number:
8991682
A method for connecting a plurality of solar cells and an improved interconnect is disclosed. The method includes aligning an interconnect to a plurality of solar cells having solder pads, where the interconnect has a main body and tabs extending therefrom, and where each of the tabs has a downward depression, such that the tabs are positioned above the solder pads in between solar cells and pinning the interconnect against a work surface by pressing a hold down pin against the main body…
Flash testing of photovoltaic modules with integrated electronics
Granted: March 24, 2015
Patent Number:
8988096
A method for testing a photovoltaic (PV) module having an integrated power converter includes: obtaining a reference output signature of a PV module design in response to a flash pattern; applying the flash pattern to a PV module under test; acquiring an observed output signature of the PV module under test in response to the flash pattern; and comparing the observed output signature of the PV module under test to the reference output signature. Second reference output and observed…
Trench process and structure for backside contact solar cells with polysilicon doped regions
Granted: March 10, 2015
Patent Number:
8975717
A solar cell includes polysilicon P-type and N-type doped regions on a backside of a substrate, such as a silicon wafer. A trench structure separates the P-type doped region from the N-type doped region. Each of the P-type and N-type doped regions may be formed over a thin dielectric layer. The trench structure may include a textured surface for increased solar radiation collection. Among other advantages, the resulting structure increases efficiency by providing isolation between…
Solderable contact regions
Granted: March 10, 2015
Patent Number:
8975175
A contact region for a semiconductor substrate is disclosed. Embodiments can include forming a seed metal layer having an exposed solder pad region on the semiconductor substrate and forming a first metal layer on the seed metal layer. In an embodiment, a solderable material, such as silver, can be formed on the exposed solder pad region prior to forming the first metal layer. Embodiments can include forming a solderable material on the exposed solder pad region after forming the first…
Electrical insulator casing
Granted: February 24, 2015
Patent Number:
8964401
Systems, processes, and manufactures are provided that employ a casing associated with an electrical component to provide some, most, substantially all or all electrical insulative protection necessary for the electrical component. This casing may be further employed with potting or other materials to supplement and add additional or different protections for the component. These additional protections can include additional insulative resistance, thermal protection, moisture protection…
Device and method for electrically decoupling a solar module from a solar system
Granted: February 24, 2015
Patent Number:
8963375
Devices and methods for electrically decoupling a solar module from a solar system are described. In one embodiment, a solar system includes a string of a plurality of solar modules coupled with an inverter through a DC power line. An AC input is coupled with the DC power line. A device is also included and is configured to provide a closed circuit for one of the plurality of solar modules if an AC signal voltage from the AC input is present on the DC power line, and is configured to…
Continuous superstrate as transport for multiple solar cells
Granted: February 24, 2015
Patent Number:
8963185
A superstrate, such as a sheet of polymer film, is used as a transport during metallization of solar cells. The back sides of the solar cells are attached to the sheet of polymer film. Contact holes are formed through the sheet of polymer film to expose doped regions of the solar cells. Metals are formed in the contact holes to electrically connect to the exposed doped regions of the solar cells. The metals are electroplated to form metal contacts of the solar cell. Subsequently, the…
Hybrid polysilicon heterojunction back contact cell
Granted: February 24, 2015
Patent Number:
8962373
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…
Control system for non-contact edge coating apparatus for solar cell substrates
Granted: February 24, 2015
Patent Number:
8962082
A non-contact edge coating apparatus includes an applicator for applying a coating material on an edge of a solar cell substrate and a control system configured to drive the applicator. The control system may drive the applicator along an axis to maintain a distance with an edge of the substrate as the substrate is rotated to have the edge coated with a coating material. The applicator may include a recessed portion into which the edge of the substrate is received for edge coating. For…
Compact flexure bearing spring for springing multiple bodies
Granted: February 24, 2015
Patent Number:
8960655
A flexure bearing “planar” spring that can spring multiple, independently reciprocating bodies, such as springing each body to a third body or springing a first body to a second body and springing the second body to a third body. A primary arm set of primary spring arms are separated from each other by openings and extend inwardly from a peripheral frame along a non-radial primary path progressing inwardly toward a central axis and angularly about the central axis. A secondary arm…
Hole-thru-laminate mounting supports for photovoltaic modules
Granted: February 17, 2015
Patent Number:
8955267
A mounting support for a photovoltaic module is described. The mounting support includes a pedestal having a surface adaptable to receive a flat side of a photovoltaic module laminate. A hole is disposed in the pedestal, the hole adaptable to receive a bolt or a pin used to couple the pedestal to the flat side of the photovoltaic module laminate.
Brace for solar module array
Granted: February 3, 2015
Patent Number:
8943765
A brace for connecting the frames of adjacent solar modules can include one or more lower lips and one or more upper lips configured to capture an outer edge of a solar module frame. The brace can include a removable top so as to facilitate connection and disconnection of the couplers and solar modules. Additionally, the brace can be configured to allow a solar module to be engaged and disengaged by hooking the frame onto the brace then tilting the frame relative to the brace. The brace…
Formation of metal structures in solar cells
Granted: February 3, 2015
Patent Number:
8945978
A metal contact of a solar cell is formed by electroplating copper using an electroplating seed that is formed on a dielectric layer. The electroplating seed includes an aluminum layer that connects to a diffusion region of the solar cell through a contact hole in the dielectric layer. A nickel layer is formed on the aluminum layer, with the nickel layer-aluminum layer stack forming the electroplating seed. The copper is electroplated in a copper plating bath that has methanesulfonic…
