Patents Assigned to Nanosolar, Inc.
  • Patent number: 7605328
    Abstract: The metallic components of a IB-IIIA-VIA photovoltaic cell active layer may be directly coated onto a substrate by using relatively low melting point (e.g., less than about 500° C.) metals such as indium and gallium. Specifically, CI(G)S thin-film solar cells may be fabricated by blending molten group IIIA metals with solid nanoparticles of group IB and (optionally) group IIIA metals. The molten mixture may be coated onto a substrate in the molten state, e.g., using coating techniques such as hot-dipping, hot microgravure and/or air-knife coating. After coating, the substrate may be cooled and the film annealed, e.g., in a sulfur-containing or selenium-containing atmosphere.
    Type: Grant
    Filed: April 30, 2004
    Date of Patent: October 20, 2009
    Assignee: Nanosolar, Inc.
    Inventors: Brian M. Sager, Martin R. Roscheisen
  • Patent number: 7604843
    Abstract: A compound film may be formed by formulating a mixture of elemental nanoparticles composed of the Ib, the IIIa, and, optionally, the VIa group of elements having a controlled overall composition. The nanoparticle mixture is combined with a suspension of nanoglobules of gallium to form a dispersion. The dispersion may be deposited onto a substrate to form a layer on the substrate. The layer may then be reacted in a suitable atmosphere to form the compound film. The compound film may be used as a light-absorbing layer in a photovoltaic device.
    Type: Grant
    Filed: March 16, 2005
    Date of Patent: October 20, 2009
    Assignee: Nanosolar, Inc.
    Inventors: Matthew R. Robinson, Martin R. Roscheisen
  • Patent number: 7594982
    Abstract: Transparent conducting electrodes, methods for manufacturing such conducting electrodes, optoelectronic devices incorporating such transparent electrodes and methods for making such optoelectronic devices and solar power generation systems incorporating such electrodes are disclosed. Nanostructured transparent conducting electrodes may include a nano-architected porous film having a network of ordered interconnected pores and an electrically conductive material that substantially fills the pores. The nano-architected porous film may be disposed on a layer of transparent conducting material. The electrode may include a substrate (e.g., glass or polymer) and the layer of transparent conducting material may be disposed between the substrate and the nano-architected porous film. Nanostructured transparent conducting electrodes may be fabricated by forming a nano-architected porous film, e.g.
    Type: Grant
    Filed: January 6, 2003
    Date of Patent: September 29, 2009
    Assignee: Nanosolar, Inc.
    Inventors: Martin R. Roscheisen, Brian M. Sager
  • Patent number: 7535019
    Abstract: An optoelectronic fiber and methods for forming such a fiber are disclosed. The fiber generally includes an electrically conductive fiber core, a first semiconducting layer substantially surrounding the fiber core, and a second semiconducting layer substantially surrounding the first semiconducting layer. The first and second semiconducting layers are of complementary types, i.e., one is p-type and the other is n-type. The fiber may be made, e.g., by electrospinning a material to form a fiber core; substantially surrounding the fiber with a first semiconducting material; and substantially surrounding the first semiconducting material with a second semiconducting material. Optoelectronic fibers can be fashioned into a web to provide a solar cell material or substantially transparent conductive material.
    Type: Grant
    Filed: February 18, 2003
    Date of Patent: May 19, 2009
    Assignee: Nanosolar, Inc.
    Inventors: Brian M. Sager, Martin R. Roscheisen
  • Patent number: 7511217
    Abstract: An optoelectronic apparatus, a method for making the apparatus, and the use of the apparatus in an optoelectronic device are disclosed. The apparatus may include an active layer having a nanostructured network layer with a network of regularly spaced structures with spaces between neighboring structures. One or more network-filling materials are disposed in the spaces. At least one of the network-filling materials has complementary charge transfer properties with respect to the nanostructured network layer. An interfacial layer, configured to enhance an efficiency of the active layer, is disposed between the nanostructured network layer and the network-filling materials. The interfacial layer may be configured to provide (a) charge transfer between the two materials that exhibits different rates for forward versus backward transport; (b) differential light absorption to extend a range of wavelengths that the active layer can absorb; or (c) enhanced light absorption, which may be coupled with charge injection.
    Type: Grant
    Filed: April 19, 2003
    Date of Patent: March 31, 2009
    Assignee: Nanosolar, Inc.
    Inventors: Martin R. Roscheisen, Brian M. Sager, Klaus Petritsch, Jacqueline Fidanza
  • Patent number: 7462774
    Abstract: Photovoltaic devices, such as solar cells, and methods for their manufacture are disclosed. A device may be characterized by an architecture with an inorganic insulating nanostructured template having template elements between about 1 nm and about 500 nm in diameter with a elements density of between about 1012 elements/m2 and about 1016 elements/m2. A first charge-transfer material coats the walls of the template elements leaving behind additional space. A second charge-transfer material fills the additional space such that the first and second charge-transfer materials are volumetrically interdigitated. At least one charge transfer material has an absorbance of greater than about 103/cm. The first and second charge-transfer materials have complementary charge transfer properties with respect to each other.
    Type: Grant
    Filed: February 2, 2004
    Date of Patent: December 9, 2008
    Assignee: Nanosolar, Inc.
    Inventors: Martin R. Roscheisen, Brian M. Sager, Karl Pichler
  • Publication number: 20080149176
    Abstract: CIGS absorber layers fabricated using coated semiconducting nanoparticles and/or quantum dots are disclosed. Core nanoparticles and/or quantum dots containing one or more elements from group IB and/or IIIA and/or VIA may be coated with one or more layers containing elements group IB, IIIA or VIA. Using nanoparticles with a defined surface area, a layer thickness could be tuned to give the proper stoichiometric ratio, and/or crystal phase, and/or size, and/or shape. The coated nanoparticles could then be placed in a dispersant for use as an ink, paste, or paint. By appropriate coating of the core nanoparticles, the resulting coated nanoparticles can have the desired elements intermixed within the size scale of the nanoparticle, while the phase can be controlled by tuning the stochiometry, and the stoichiometry of the coated nanoparticle may be tuned by controlling the thickness of the coating(s).
    Type: Application
    Filed: December 11, 2007
    Publication date: June 26, 2008
    Applicant: Nanosolar Inc.
    Inventors: Brian M. Sager, Dong Yu, Matthew R. Robinson
  • Publication number: 20080041434
    Abstract: Methods and devices are provided for improved large-scale solar installations. In one embodiment, a junction-box free photovoltaic module is used comprising of a plurality of photovoltaic cells and a module support layer providing a mounting surface for the cells. The module has a first electrical lead extending outward from one of the photovoltaic cells, the lead coupled to an adjacent module without passing the lead through a junction box. The module may have a second electrical lead extending outward from one of the photovoltaic cells, the lead coupled to another adjacent module without passing the lead through a junction box. Without junction boxes, the module may use connectors along the edges of the modules which can substantially reduce the amount of wire or connector ribbon used for such connections.
    Type: Application
    Filed: August 18, 2006
    Publication date: February 21, 2008
    Applicant: Nanosolar, Inc.
    Inventors: Paul Adriani, Martin Roscheisen
  • Publication number: 20070295390
    Abstract: Methods and devices are provided for improved environmental protection for photovoltaic devices and assemblies. In one embodiment, the device comprises of an individually encapsulated solar cell, wherein the encapsulated solar cell includes at least one protective layer coupled to at least one surface of the solar cell and the protective layer may be formed from a substantially inorganic material. The protective layer has a chemical composition that prevents moisture from entering the solar cell and wherein light passes through the protective layer to reach an absorber layer in the solar cell.
    Type: Application
    Filed: August 3, 2006
    Publication date: December 27, 2007
    Applicant: Nanosolar, Inc.
    Inventors: James R. Sheats, Philip Capps, Paul Adriani
  • Publication number: 20070295387
    Abstract: Methods and devices are provided for improved environmental protection for photovoltaic devices and assemblies. In one embodiment, a photovoltaic device module is provided comprising of a multi-ply module encapsulant, a bottom module layer, and a plurality of solar cells. The multi-ply module encapsulant includes one or more discrete layers comprising of at least a first module layer and at least a second module layer. The plurality of solar cells may be sandwiched between the multi-ply module encapsulant and the bottom module layer. At least one of the cells has a protective layer that provides a level of moisture resistance equal to or higher than any of the layers above the cells. The protective layer is typically above the solar cell and light passes through the multi-ply module encapsulant and the protective layer to reach the solar cell.
    Type: Application
    Filed: July 27, 2006
    Publication date: December 27, 2007
    Applicant: Nanosolar, Inc.
    Inventors: Paul Adriani, Philip Capps, James R. Sheats
  • Publication number: 20070295388
    Abstract: Methods and devices are provided for improved environmental protection for photovoltaic devices and assemblies. In one embodiment, a photovoltaic device module is provided comprising of a multi-ply module encapsulant, a bottom module layer, and a plurality of solar cells. The multi-ply module encapsulant includes one or more discrete layers comprising of at least a first module layer and at least a second module layer. The plurality of solar cells may be sandwiched between the multi-ply module encapsulant and the bottom module layer. At least one of the cells has a protective layer that provides a level of moisture resistance equal to or higher than any of the layers above the cells. The protective layer is typically above the solar cell and light passes through the multi-ply module encapsulant and the protective layer to reach the solar cell.
    Type: Application
    Filed: August 3, 2006
    Publication date: December 27, 2007
    Applicant: Nanosolar, Inc.
    Inventors: Paul Adriani, Philip Capps, James Sheats
  • Publication number: 20070295386
    Abstract: Methods and devices are provided for improved environmental protection for photovoltaic devices and assemblies. In one embodiment, the device comprises of an individually encapsulated solar cell, wherein the encapsulated solar cell includes at least one protective layer coupled to at least one surface of the solar cell. The protective layer may be a hybrid organic/inorganic material that has a chemical composition that prevents moisture from entering the solar cell and wherein light passes through the protective layer to reach an absorber layer in the solar cell.
    Type: Application
    Filed: July 27, 2006
    Publication date: December 27, 2007
    Applicant: Nanosolar, Inc.
    Inventors: Philip Capps, Paul Adriani, James R. Sheats
  • Publication number: 20070295389
    Abstract: Methods and devices are provided for improved environmental protection for photovoltaic devices and assemblies. In one embodiment, the device comprises of an individually encapsulated solar cell, wherein the encapsulated solar cell includes at least one protective layer coupled to at least one surface of the solar cell. The protective layer may be a hybrid organic/inorganic material that has a chemical composition that prevents moisture from entering the solar cell and wherein light passes through the protective layer to reach an absorber layer in the solar cell.
    Type: Application
    Filed: August 3, 2006
    Publication date: December 27, 2007
    Applicant: Nanosolar, Inc.
    Inventors: Philip Capps, Paul Adriani, James R. Sheats
  • Publication number: 20070295385
    Abstract: Methods and devices are provided for improved environmental protection for photovoltaic devices and assemblies. In one embodiment, the device comprises of an individually encapsulated solar cell, wherein the encapsulated solar cell includes at least one protective layer coupled to at least one surface of the solar cell and the protective layer may be formed from a substantially inorganic material. The protective layer has a chemical composition that prevents moisture from entering the solar cell and wherein light passes through the protective layer to reach an absorber layer in the solar cell.
    Type: Application
    Filed: July 27, 2006
    Publication date: December 27, 2007
    Applicant: Nanosolar, Inc.
    Inventors: James R. Sheats, Philip Capps, Paul Adriani
  • Patent number: 7306823
    Abstract: CIGS absorber layers fabricated using coated semiconducting nanoparticles and/or quantum dots are disclosed. Core nanoparticles and/or quantum dots containing one or more elements from group IB and/or IIIA and/or VIA may be coated with one or more layers containing elements group IB, IIIA or VIA. Using nanoparticles with a defined surface area, a layer thickness could be tuned to give the proper stoichiometric ratio, and/or crystal phase, and/or size, and/or shape. The coated nanoparticles could then be placed in a dispersant for use as an ink, paste, or paint. By appropriate coating of the core nanoparticles, the resulting coated nanoparticles can have the desired elements intermixed within the size scale of the nanoparticle, while the phase can be controlled by tuning the stochiometry, and the stoichiometry of the coated nanoparticle may be tuned by controlling the thickness of the coating(s).
    Type: Grant
    Filed: September 18, 2004
    Date of Patent: December 11, 2007
    Assignee: Nanosolar, Inc.
    Inventors: Brian M. Sager, Dong Yu, Matthew R. Robinson
  • Patent number: 7291782
    Abstract: Charge-splitting networks, optoelectronic devices, methods for making optoelectronic devices, power generation systems utilizing such devices and method for making charge-splitting networks are disclosed. An optoelectronic device may include a porous nano-architected (e.g., surfactant-templated) film having interconnected pores that are accessible from both the underlying and overlying layers. A pore-filling material substantially fills the pores. The interconnected pores have diameters of about 1-100 nm and are distributed in a substantially uniform fashion with neighboring pores separated by a distance of about 1-100 nm. The nano-architected porous film and the pore-filling, material have complementary charge-transfer properties with respect to each other, i.e., one is an electron-acceptor and the other is a hole-acceptor. The nano-architected porous, film may be formed on a substrate by a surfactant temptation technique such as evaporation-induced self-assembly.
    Type: Grant
    Filed: November 5, 2002
    Date of Patent: November 6, 2007
    Assignee: Nanosolar, Inc.
    Inventors: Brian M. Sager, Martin R. Roscheisen, Klaus Petritsch, Greg Smestad, Jacqueline Fidanza, Gregory A. Miller, Dong Yu
  • Patent number: 7276724
    Abstract: Series interconnection of optoelectronic device modules is disclosed. Each device module includes an active layer disposed between a bottom electrode and a transparent conducting layer. An insulating layer is disposed between the bottom electrode of a first device module and a backside top electrode of the first device module. One or more vias are formed through the active layer, transparent conducting layer and insulating layer of the first device module. Sidewalls of the vias are coated with an insulating material such that a channel is formed through the insulating material to the backside top electrode of the first device module. The channel is at least partially filled with an electrically conductive material to form a plug that makes electrical contact between the transparent conducting layer and the backside top electrode of the first device module.
    Type: Grant
    Filed: January 20, 2005
    Date of Patent: October 2, 2007
    Assignee: Nanosolar, Inc.
    Inventors: James R. Sheats, Sam Kao, Gregory A. Miller, Martin R. Roscheisen
  • Patent number: 7262392
    Abstract: An elongated substrate may be heated in a roll processing system. At least a portion of the elongated substrate is loaded into the roll processing system. A sufficient electrical current is caused to flow in the portion of the elongated substrate to heat the portion to a desired temperature. The heating may be either resistive or inductive. The roll processing system may be a roll-to-roll type where the substrate moves as a portion of it is heated. Alternatively, the substrate may be wound into a coiled substrate and the turns of the coil insulated against undesired electrical contact. The entire coiled substrate may then be heated either resistively or inductively.
    Type: Grant
    Filed: September 18, 2004
    Date of Patent: August 28, 2007
    Assignee: Nanosolar, Inc.
    Inventor: Gregory A. Miller
  • Publication number: 20070186971
    Abstract: Methods and devices are provided for high-efficiency solar cells. In one embodiment, the device comprises of a solar cell having a high efficiency backside electrode configuration, wherein the solar cell comprises of: at least one transparent conductor, a photovoltaic layer, at least one bottom electrode, and at least one backside electrode. The device may include a plurality of electrical conduction fingers mounted to the transparent conductor in the solar cell. The device may include a plurality of filled vias coupled to the electrical conduction fingers, wherein the vias extend through the transparent conductor, the photovoltaic layer, and the bottom electrode, wherein the vias have a conductive core that conducts charge from the transparent conductor to the backside electrode. The via insulating layer may separate the conductive core in each via from the bottom electrode, wherein the insulating layer may be formed by a variety of techniques such as but not limited to aerosol coating of the via.
    Type: Application
    Filed: April 4, 2006
    Publication date: August 16, 2007
    Applicant: Nanosolar, Inc.
    Inventors: Darren Lochun, James Sheats, Gregory Miller
  • Publication number: 20070181177
    Abstract: Charge-splitting networks, optoelectronic devices, methods for making optoelectronic devices, power generation systems utilizing such devices and method for making charge-splitting networks are disclosed. An optoelectronic device may include a porous nano-architected (e.g., surfactant-templated) film having interconnected pores that are accessible from both the underlying and overlying layers. A pore-filling material substantially fills the pores. The interconnected pores have diameters of about 1-100 nm and are distributed in a substantially uniform fashion with neighboring pores separated by a distance of about 1-100 nm. The nano-architected porous film and the pore-filling, material have complementary charge-transfer properties with respect to each other, i.e., one is an electron-acceptor and the other is a hole-acceptor. The nano-architected porous, film may be formed on a substrate by a surfactant temptation technique such as evaporation-induced self-assembly.
    Type: Application
    Filed: November 5, 2002
    Publication date: August 9, 2007
    Applicant: Nanosolar, Inc.
    Inventors: Brian Sager, Martin Roscheisen, Klaus Petritsch, Greg Smestad, Jacqueline Fidanza, Gregory Miller, Dong Yu