Patents Assigned to Sunpower Corporation
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Patent number: 11947880Abstract: 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 determined for a solar panel on each section of a roof of an installation location, and the energy production and energy offset are dynamically displayed in real time when any solar panel or array is selected or deselected.Type: GrantFiled: December 30, 2020Date of Patent: April 2, 2024Assignee: SUNPOWER CORPORATIONInventors: Jake Wachman, Matt Moone, Anthony Garzolini, Jeff Southard
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Patent number: 11949032Abstract: Improved photovoltaic (PV) assemblies for converting solar radiation to electrical energy and methods of installation thereof are disclosed herein. PV arrays comprising a plurality PV modules are also described herein. A PV assembly can comprise at least one PV module having a front side and a back side opposite the front side. A PV module can comprise a plurality of solar cells encapsulated within a PV laminate. In some embodiments, a PV module includes a frame at least partially surrounding the PV laminate. In such embodiments, frame can comprise an outer surface feature. The PV assembly can further comprise at least one spacing device positioned between adjacent PV modules. A spacing device can comprise a spacer body having a predetermined width for defining a predetermined distance or gap between adjacent PV modules.Type: GrantFiled: August 19, 2016Date of Patent: April 2, 2024Assignee: SunPower CorporationInventors: John Paul Kapla, Kyle Donald Feldmann
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Publication number: 20240075588Abstract: An end clamp for installation of a solar module includes a cap member that is installed in an opening of a rail. The end clamp also includes an assembly having a slider member and a base member, and also includes a fastener that attaches the assembly to the cap member. The slider member moves relative to the base member to clamp down on a flange of the solar module based on tightening of the fastener.Type: ApplicationFiled: September 1, 2022Publication date: March 7, 2024Applicant: SUNPOWER CORPORATIONInventors: Brian WARES, Ethan M. ELY
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Publication number: 20240039465Abstract: 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.Type: ApplicationFiled: August 11, 2023Publication date: February 1, 2024Applicant: SUNPOWER CORPORATIONInventors: Gary ROSSI, Ethan ELY
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Patent number: 11855482Abstract: The present disclosure provides energy control systems for whole home and partial home backup with integrated breaker spaces and metering. The energy control system includes a grid interconnection electrically coupled to a utility grid, a backup power interconnection electrically coupled to a backup power source, a backup load interconnection electrically coupled to at least one backup load, and a non-backup load interconnection electrically coupled to at least one non-backup load. The energy control system includes a microgrid interconnection device that switches between an on-grid mode to electrically connect the grid interconnection and the backup power interconnection with the backup and non-backup load interconnections and a backup mode to electrically disconnect the grid interconnection and the non-backup load interconnection from the backup power interconnection.Type: GrantFiled: November 5, 2021Date of Patent: December 26, 2023Assignee: SUNPOWER CORPORATIONInventors: Sandeep Narla, Brian Kuhn, Kevin C. Fischer, Udo Uebel, Marc A. Robinson
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Publication number: 20230369522Abstract: Photovoltaic (PV) laminates employ single polymer composites (SPCs). The SPCs may be located at various locations of the PV laminate. These locations may include being positioned as an entire back-sheet of the PV laminate as well as, as a portion of a back-sheet or other layer of the PV laminate. The SPCs may be positioned and configured in the PV laminate so as to reduce tensile and compressive forces developed on PV cells from live normal loads or other live loads or dead loads experienced by the PV laminate. The SPCs can serve to reduce the weight of a PV laminate as well as to assist in having PV cells lie along the neutral axis of the PV laminate.Type: ApplicationFiled: May 16, 2022Publication date: November 16, 2023Applicant: SunPower CorporationInventors: Ruihua Li, Yafu Lin
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Patent number: 11811261Abstract: The present disclosure provides a method for controlling an energy control system. The energy control system includes a grid interconnection, a backup load interconnection, a non-backup load interconnection, and a backup power interconnection. The method includes receiving electronic data from a plurality of backup loads. The method includes detecting a power outage at the grid interconnection electrically coupled to a utility grid. The method includes disconnecting the grid interconnection from the backup power interconnection, in which the backup power interconnection is electrically coupled to a backup power source. The method includes connecting a first set of the plurality of backup loads to the backup load interconnection, in which the backup load interconnection is electrically coupled to the backup power interconnection such that power is supplied from the backup power source to the first set of backup loads.Type: GrantFiled: March 6, 2020Date of Patent: November 7, 2023Assignee: SUNPOWER CORPORATIONInventors: Sandeep Narla, Brian Kuhn, Kevin C. Fischer, Udo Uebel, Marc A. Robinson
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Patent number: 11784276Abstract: Methods of recycling silicon swarf into electronic grade polysilicon or metallurgical-grade silicon are described herein are described. In an example, a method includes cutting a silicon ingot and recovering silicon swarf having a first purity from the cutting process. The recovered silicon is purified in an upgraded metallurgical silicon process to produce electronic grade polysilicon particles having a second purity higher than the first purity. The upgraded metallurgical silicon process can include dissolving the recovered silicon particles in a molten aluminum metal smelt.Type: GrantFiled: January 8, 2018Date of Patent: October 10, 2023Assignees: SunPower Corporation, Total Solar InternationalInventors: Moon Chun, Christoph Sachs, David Verstraeten
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Patent number: 11728764Abstract: 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.Type: GrantFiled: April 26, 2021Date of Patent: August 15, 2023Assignee: SUNPOWER CORPORATIONInventors: Gary Rossi, Ethan Ely
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Patent number: 11705736Abstract: The present disclosure provides an electrical system that includes an energy control system, a photovoltaic (PV) power generation system electrically coupled to the energy control system, an energy storage system electrically coupled to the energy control system, and a smart load panel electrically coupled to the energy control system and to a plurality of backup loads. The energy control system operates in an on-grid mode electrically connecting the PV power generation system to a utility grid and a backup mode electrically disconnecting the PV power generation system from the utility grid. The smart load panel selectively disconnects one or more of the plurality of backup loads from the energy control system when the energy control system is in the on-grid mode and when the energy control system is in the backup mode.Type: GrantFiled: April 28, 2022Date of Patent: July 18, 2023Assignee: SUNPOWER CORPORATIONInventor: Sandeep Narla
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Patent number: 11699973Abstract: A metering and control subsystem for a photovoltaic solar system is configured for metering the photovoltaic solar system using current measurement devices and individually controlling relays to selectively energize photovoltaic branch circuits. In some examples, the metering and control subsystem includes photovoltaic branch connectors, a relay matrix, current measurement devices, and a metering and relay control circuit. The metering and control circuit is configured for metering the photovoltaic solar system using current measurement data from the current measurement devices and individually controlling the relays to selectively energize each photovoltaic branch circuit.Type: GrantFiled: May 23, 2018Date of Patent: July 11, 2023Assignee: SunPower CorporationInventors: Kevin C. Fischer, Philip Rothblum, Donald H. Scrutchfield, Dylan W. Benjamin
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Patent number: 11695297Abstract: The present disclosure provides a photovoltaic (PV) disconnect device used in an electrical system. The electrical system includes an energy control system electrically coupled to a utility grid. The electrical system includes a PV power generation system electrically coupled to the energy control system. The electrical system includes an energy storage system electrically coupled to the energy control system. The PV disconnect device is electrically coupled to the PV power generation system and the energy control system. The PV disconnect device electrically disconnects the PV power generation system from the energy control system.Type: GrantFiled: May 19, 2021Date of Patent: July 4, 2023Assignee: SUNPOWER CORPORATIONInventors: Sandeep Narla, Brian Kuhn, Kevin C. Fischer, Udo Uebel
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Publication number: 20230188085Abstract: 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 member can prevent rotation of the lower clamp member relative to the rail when the clamp assembly is in the clamped and unclamped configurations. In the unclamped configuration, the stabilization member can be biased such that the upper clamp member is disposed at a sufficient clearance above the rail to permit the insertion of the solar module between the upper clamp member and the rail.Type: ApplicationFiled: February 3, 2023Publication date: June 15, 2023Applicant: SUNPOWER CORPORATIONInventors: Ryan BRAUNSTEIN, Zachary KINYON, Guillaume CARRE, David MATRAT
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Patent number: 11616159Abstract: A method of fabricating a solar cell is disclosed. The method can include forming a dielectric region on a surface of a solar cell structure and forming a metal layer on the dielectric layer. The method can also include configuring a laser beam with a particular shape and directing the laser beam with the particular shape on the metal layer, where the particular shape allows a contact to be formed between the metal layer and the solar cell structure.Type: GrantFiled: December 23, 2020Date of Patent: March 28, 2023Assignees: SunPower Corporation, Total Marketing ServicesInventors: Matthieu Moors, David D. Smith, Gabriel Harley, Taeseok Kim
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Patent number: 11615487Abstract: An energy evaluation system includes an energy system modeling framework and an Application Program Interface (API) as part of the energy system evaluation framework. The energy evaluation system can be configured to query a simulation application program interface (API) with PV system configuration parameters as arguments, generate a shade loss time series based on the system configuration parameters, simulate energy output for the PV system based on the shade loss time series, and output energy aggregations based on the simulation.Type: GrantFiled: March 9, 2020Date of Patent: March 28, 2023Assignee: SUNPOWER CORPORATIONInventors: Chetan Chaudhari, Tamir Lance, Amir Asgharzadeh Shishavan
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Publication number: 20230086161Abstract: Photovoltaic panels may be aggregated in various ways and may be aggregated with the use of a backplane where the backplane comprises electrical connectors positioned to electrically connect the PV panels. The PV panels may have various sizes and shapes and may overlap one or more other PV panels or PV panels being aggregated.Type: ApplicationFiled: November 28, 2022Publication date: March 23, 2023Applicant: SunPower CorporationInventors: David C. Okawa, Zachary S. Judkins, Tamir Lance, Tyler D. Newman, Thierry H. Nguyen, Ryan Reagan
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Patent number: 11605750Abstract: Solar cells having emitter regions composed of wide bandgap semiconductor material are described. In an example, a method includes forming, in a process tool having a controlled atmosphere, a thin dielectric layer on a surface of a semiconductor substrate of the solar cell. The semiconductor substrate has a bandgap. Without removing the semiconductor substrate from the controlled atmosphere of the process tool, a semiconductor layer is formed on the thin dielectric layer. The semiconductor layer has a bandgap at least approximately 0.2 electron Volts (eV) above the bandgap of the semiconductor substrate.Type: GrantFiled: February 23, 2021Date of Patent: March 14, 2023Assignee: SunPower CorporationInventors: Richard M. Swanson, Marius M. Bunea, Michael C. Johnson, David D. Smith, Yu-Chen Shen, Peter J. Cousins, Tim Dennis
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Patent number: 11600733Abstract: 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 plurality of second solar wafers to electrically connect horizontally adjacent solar wafers in parallel.Type: GrantFiled: July 9, 2021Date of Patent: March 7, 2023Assignee: SUNPOWER CORPORATIONInventor: Nathaniel Caswell
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Patent number: D980158Type: GrantFiled: April 9, 2021Date of Patent: March 7, 2023Assignee: SUNPOWER CORPORATIONInventors: Ratson Morad, Gilad Almogy, Itai Suez, Jean Hummel, Nathan Beckett
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Patent number: D999723Type: GrantFiled: March 11, 2021Date of Patent: September 26, 2023Assignee: SUNPOWER CORPORATIONInventors: Ratson Morad, Gilad Almogy, Itai Suez, Jean Hummel, Nathan Beckett