Patents by Inventor Douglas H. Rose

Douglas H. Rose has filed for patents to protect the following inventions. This listing includes patent applications that are pending as well as patents that have already been granted by the United States Patent and Trademark Office (USPTO).

  • Patent number: 11264518
    Abstract: A solar cell is fabricated by etching one or more of its layers without substantially etching another layer of the solar cell. In one embodiment, a copper layer in the solar cell is etched without substantially etching a topmost metallic layer comprising tin. For example, an etchant comprising sulfuric acid and hydrogen peroxide may be employed to etch the copper layer selective to the tin layer. A particular example of the aforementioned etchant is a Co-Bra Etch® etchant modified to comprise about 1% by volume of sulfuric acid, about 4% by volume of phosphoric acid, and about 2% by volume of stabilized hydrogen peroxide. In one embodiment, an aluminum layer in the solar cell is etched without substantially etching the tin layer. For example, an etchant comprising potassium hydroxide may be employed to etch the aluminum layer without substantially etching the tin layer.
    Type: Grant
    Filed: October 8, 2018
    Date of Patent: March 1, 2022
    Assignee: SunPower Corporation
    Inventors: Douglas H. Rose, Pongsthorn Uralwong, David D. Smith
  • Patent number: 10903786
    Abstract: In one embodiment, harmful solar cell polarization is prevented or minimized by providing a conductive path that bleeds charge from a front side of a solar cell to the bulk of a wafer. The conductive path may include patterned holes in a dielectric passivation layer, a conductive anti-reflective coating, or layers of conductive material formed on the top or bottom surface of an anti-reflective coating, for example. Harmful solar cell polarization may also be prevented by biasing a region of a solar cell module on the front side of the solar cell.
    Type: Grant
    Filed: November 20, 2018
    Date of Patent: January 26, 2021
    Assignee: SunPower Corporation
    Inventors: Richard M. Swanson, Denis De Ceuster, Vikas Desai, Douglas H. Rose, David D. Smith, Neil Kaminar
  • Publication number: 20190109560
    Abstract: In one embodiment, harmful solar cell polarization is prevented or minimized by providing a conductive path that bleeds charge from a front side of a solar cell to the bulk of a wafer. The conductive path may include patterned holes in a dielectric passivation layer, a conductive anti-reflective coating, or layers of conductive material formed on the top or bottom surface of an anti-reflective coating, for example. Harmful solar cell polarization may also be prevented by biasing a region of a solar cell module on the front side of the solar cell.
    Type: Application
    Filed: November 20, 2018
    Publication date: April 11, 2019
    Applicant: SunPower Corporation
    Inventors: Richard M. SWANSON, Denis DE CEUSTER, Vikas DESAI, Douglas H. ROSE, David D. SMITH, Neil KAMINAR
  • Publication number: 20190044006
    Abstract: A solar cell is fabricated by etching one or more of its layers without substantially etching another layer of the solar cell. In one embodiment, a copper layer in the solar cell is etched without substantially etching a topmost metallic layer comprising tin. For example, an etchant comprising sulfuric acid and hydrogen peroxide may be employed to etch the copper layer selective to the tin layer. A particular example of the aforementioned etchant is a Co-Bra Etch® etchant modified to comprise about 1% by volume of sulfuric acid, about 4% by volume of phosphoric acid, and about 2% by volume of stabilized hydrogen peroxide. In one embodiment, an aluminum layer in the solar cell is etched without substantially etching the tin layer. For example, an etchant comprising potassium hydroxide may be employed to etch the aluminum layer without substantially etching the tin layer.
    Type: Application
    Filed: October 8, 2018
    Publication date: February 7, 2019
    Applicant: SunPower Corporation
    Inventors: Douglas H. ROSE, Pongsthorn URALWONG, David D. SMITH
  • Patent number: 10164567
    Abstract: In one embodiment, harmful solar cell polarization is prevented or minimized by providing a conductive path that bleeds charge from a front side of a solar cell to the bulk of a wafer. The conductive path may include patterned holes in a dielectric passivation layer, a conductive anti-reflective coating, or layers of conductive material formed on the top or bottom surface of an anti-reflective coating, for example. Harmful solar cell polarization may also be prevented by biasing a region of a solar cell module on the front side of the solar cell.
    Type: Grant
    Filed: August 5, 2016
    Date of Patent: December 25, 2018
    Assignee: SunPower Corporation
    Inventors: Richard M. Swanson, Denis De Ceuster, Vikas Desai, Douglas H. Rose, David D. Smith, Neil Kaminar
  • Patent number: 9929296
    Abstract: One embodiment relates to a bifacial photovoltaic module having an edge reflector. The module includes a plurality of solar cells in an array, each solar cell having a front side and a back side. A reflector is configured on an edge of the array of solar cells, the first reflector being configured to reflect light onto the front side of a row of solar cells adjacent to the edge. Another embodiment relates to a method of reducing non-uniformity of power generation from a bifacial photovoltaic module. Electrical current produced from solar cells along at least one edge of the array is increased by using a reflective strip facing towards the front side of the solar cells along the edge. Another embodiment relates to a bifacial photovoltaic module having an edge refractor. Other embodiments and features are also disclosed.
    Type: Grant
    Filed: December 22, 2009
    Date of Patent: March 27, 2018
    Assignee: SunPower Corporation
    Inventor: Douglas H. Rose
  • Patent number: 9774294
    Abstract: In one embodiment, harmful solar cell polarization is prevented or minimized by providing a conductive path that bleeds charge from a front side of a solar cell to the bulk of a wafer. The conductive path may include patterned holes in a dielectric passivation layer, a conductive anti-reflective coating, or layers of conductive material formed on the top or bottom surface of an anti-reflective coating, for example. Harmful solar cell polarization may also be prevented by biasing a region of a solar cell module on the front side of the solar cell.
    Type: Grant
    Filed: August 18, 2016
    Date of Patent: September 26, 2017
    Assignee: SunPower Corporation
    Inventors: Richard M. Swanson, Denis De Ceuster, Vikas Desai, Douglas H. Rose, David D. Smith, Neil Kaminar
  • Patent number: 9716465
    Abstract: One embodiment relates to a photovoltaic (PV) apparatus. The PV apparatus includes a plurality of photovoltaic modules arranged in an array and attached to a support structure which is attached to a roof. Each of the photovoltaic modules comprises a plurality of photovoltaic cells. A first array-roof integration member is attached to a first side of the array. The array-roof integration member covers a gap between the first side of the array and the roof. Another embodiment relates to a method of installing a photovoltaic apparatus upon a sloped roof. Another embodiment relates to a kit for mounting a photovoltaic apparatus on a roof. Other embodiments, aspects and features are also disclosed herein.
    Type: Grant
    Filed: October 9, 2015
    Date of Patent: July 25, 2017
    Assignee: SunPower Corporation
    Inventors: Douglas H. Rose, Carl Lenox
  • Patent number: 9691924
    Abstract: Solar cell interconnects with multiple current paths. A solar cell interconnect may include a plurality of in-plane slits arranged in several rows. The in-plane slits may be spaced to provide strain relief without unduly increasing the electrical path resistance through the solar cell interconnect. The in-plane slits may be staggered, for example.
    Type: Grant
    Filed: March 7, 2012
    Date of Patent: June 27, 2017
    Assignee: SunPower Corporation
    Inventors: Douglas H. Rose, Shandor G. Daroczi, Neil Kaminar
  • Publication number: 20170162728
    Abstract: A solar cell is fabricated by etching one or more of its layers without substantially etching another layer of the solar cell. In one embodiment, a copper layer in the solar cell is etched without substantially etching a topmost metallic layer comprising tin. For example, an etchant comprising sulfuric acid and hydrogen peroxide may be employed to etch the copper layer selective to the tin layer. A particular example of the aforementioned etchant is a Co-Bra Etch® etchant modified to comprise about 1% by volume of sulfuric acid, about 4% by volume of phosphoric acid, and about 2% by volume of stabilized hydrogen peroxide. In one embodiment, an aluminum layer in the solar cell is etched without substantially etching the tin layer. For example, an etchant comprising potassium hydroxide may be employed to etch the aluminum layer without substantially etching the tin layer.
    Type: Application
    Filed: December 12, 2016
    Publication date: June 8, 2017
    Applicant: SunPower Corporation
    Inventors: Douglas H. ROSE, Pongsthorn URALWONG, David D. SMITH
  • Publication number: 20170047888
    Abstract: In one embodiment, harmful solar cell polarization is prevented or minimized by providing a conductive path that bleeds charge from a front side of a solar cell to the bulk of a wafer. The conductive path may include patterned holes in a dielectric passivation layer, a conductive anti-reflective coating, or layers of conductive material formed on the top or bottom surface of an anti-reflective coating, for example. Harmful solar cell polarization may also be prevented by biasing a region of a solar cell module on the front side of the solar cell.
    Type: Application
    Filed: August 18, 2016
    Publication date: February 16, 2017
    Applicant: SunPower Corporation
    Inventors: Richard M. SWANSON, Denis DE CEUSTER, Vikas DESAI, Douglas H. ROSE, David D. SMITH, Neil KAMINAR
  • Publication number: 20170033248
    Abstract: In one embodiment, harmful solar cell polarization is prevented or minimized by providing a conductive path that bleeds charge from a front side of a solar cell to the bulk of a wafer. The conductive path may include patterned holes in a dielectric passivation layer, a conductive anti-reflective coating, or layers of conductive material formed on the top or bottom surface of an anti-reflective coating, for example. Harmful solar cell polarization may also be prevented by biasing a region of a solar cell module on the front side of the solar cell.
    Type: Application
    Filed: August 5, 2016
    Publication date: February 2, 2017
    Applicant: SunPower Corporation
    Inventors: Richard M. SWANSON, Denis DE CEUSTER, Vikas DESAI, Douglas H. ROSE, David D. SMITH, Neil KAMINAR
  • Patent number: 9553229
    Abstract: A solar cell is fabricated by etching one or more of its layers without substantially etching another layer of the solar cell. In one embodiment, a copper layer in the solar cell is etched without substantially etching a topmost metallic layer comprising tin. For example, an etchant comprising sulfuric acid and hydrogen peroxide may be employed to etch the copper layer selective to the tin layer. A particular example of the aforementioned etchant is a Co-Bra Etch® etchant modified to comprise about 1% by volume of sulfuric acid, about 4% by volume of phosphoric acid, and about 2% by volume of stabilized hydrogen peroxide. In one embodiment, an aluminum layer in the solar cell is etched without substantially etching the tin layer. For example, an etchant comprising potassium hydroxide may be employed to etch the aluminum layer without substantially etching the tin layer.
    Type: Grant
    Filed: August 30, 2011
    Date of Patent: January 24, 2017
    Assignee: SunPower Corporation
    Inventors: Douglas H. Rose, Pongsthorn Uralwong, David D. Smith
  • Publication number: 20160079911
    Abstract: One embodiment relates to a photovoltaic (PV) apparatus. The PV apparatus includes a plurality of photovoltaic modules arranged in an array and attached to a support structure which is attached to a roof. Each of the photovoltaic modules comprises a plurality of photovoltaic cells. A first array-roof integration member is attached to a first side of the array. The array-roof integration member covers a gap between the first side of the array and the roof. Another embodiment relates to a method of installing a photovoltaic apparatus upon a sloped roof. Another embodiment relates to a kit for mounting a photovoltaic apparatus on a roof. Other embodiments, aspects and features are also disclosed herein.
    Type: Application
    Filed: October 9, 2015
    Publication date: March 17, 2016
    Applicant: SunPower Corporation
    Inventors: Douglas H. ROSE, Carl LENOX
  • Publication number: 20150288328
    Abstract: In one embodiment, harmful solar cell polarization is prevented or minimized by providing a conductive path that bleeds charge from a front side of a solar cell to the bulk of a wafer. The conductive path may include patterned holes in a dielectric passivation layer, a conductive anti-reflective coating, or layers of conductive material formed on the top or bottom surface of an anti-reflective coating, for example. Harmful solar cell polarization may also be prevented by biasing a region of a solar cell module on the front side of the solar cell.
    Type: Application
    Filed: April 15, 2015
    Publication date: October 8, 2015
    Applicant: SunPower Corporation
    Inventors: Richard M. SWANSON, Denis DE CEUSTER, Vikas DESAI, Douglas H. ROSE, David D. SMITH, Neil KAMINAR
  • Patent number: 9035167
    Abstract: In one embodiment, harmful solar cell polarization is prevented or minimized by providing a conductive path that bleeds charge from a front side of a solar cell to the bulk of a wafer. The conductive path may include patterned holes in a dielectric passivation layer, a conductive anti-reflective coating, or layers of conductive material formed on the top or bottom surface of an anti-reflective coating, for example. Harmful solar cell polarization may also be prevented by biasing a region of a solar cell module on the front side of the solar cell.
    Type: Grant
    Filed: July 28, 2010
    Date of Patent: May 19, 2015
    Assignee: SunPower Corporation
    Inventors: Richard M. Swanson, Denis De Ceuster, Vikas Desai, Douglas H. Rose, David D. Smith, Neil Kaminar
  • Patent number: 8378706
    Abstract: A method of processing of solar cells includes determining that a back-contact solar cell is defective. The back-contact solar cell includes a first plurality of interconnect pads at a first edge thereof, and a second plurality of interconnect pads at a second, opposed thereof, the first and second pluralities of interconnect pads having opposite operational charges. The back-contact solar cell is then diced to define at least first and second back-contact solar cell sections. The first back-contact solar cell section has at least two interconnect pads, of the plurality of interconnect pads, at respective opposed edges thereof.
    Type: Grant
    Filed: August 2, 2010
    Date of Patent: February 19, 2013
    Assignee: SunPower Corporation
    Inventors: Zachary Kinyon, Douglas H. Rose, Karen Elizabeth Wilson
  • Patent number: 8148627
    Abstract: Solar cell interconnects with multiple current paths. A solar cell interconnect may include a plurality of in-plane slits arranged in several rows. The in-plane slits may be spaced to provide strain relief without unduly increasing the electrical path resistance through the solar cell interconnect. The in-plane slits may be staggered, for example.
    Type: Grant
    Filed: August 23, 2007
    Date of Patent: April 3, 2012
    Assignee: SunPower Corporation
    Inventors: Douglas H. Rose, Shandor G. Daroczi, Neil Kaminar
  • Publication number: 20120025837
    Abstract: A method of processing of solar cells includes determining that a back-contact solar cell is defective. The back-contact solar cell includes a first plurality of interconnect pads at a first edge thereof, and a second plurality of interconnect pads at a second, opposed thereof, the first and second pluralities of interconnect pads having opposite operational charges. The back-contact solar cell is then diced to define at least first and second back-contact solar cell sections. The first back-contact solar cell section has at least two interconnect pads, of the plurality of interconnect pads, at respective opposed edges thereof.
    Type: Application
    Filed: August 2, 2010
    Publication date: February 2, 2012
    Applicant: SunPower Corporation
    Inventors: Zachary Kinyon, Douglas H. Rose, Karen Elizabeth Wilson
  • Publication number: 20110312119
    Abstract: A solar cell is fabricated by etching one or more of its layers without substantially etching another layer of the solar cell. In one embodiment, a copper layer in the solar cell is etched without substantially etching a topmost metallic layer comprising tin. For example, an etchant comprising sulfuric acid and hydrogen peroxide may be employed to etch the copper layer selective to the tin layer. A particular example of the aforementioned etchant is a Co-Bra Etch® etchant modified to comprise about 1% by volume of sulfuric acid, about 4% by volume of phosphoric acid, and about 2% by volume of stabilized hydrogen peroxide. In one embodiment, an aluminum layer in the solar cell is etched without substantially etching the tin layer. For example, an etchant comprising potassium hydroxide may be employed to etch the aluminum layer without substantially etching the tin layer.
    Type: Application
    Filed: August 30, 2011
    Publication date: December 22, 2011
    Inventors: Douglas H. ROSE, Pongsthorn URALWONG, David D. SMITH