Patents Assigned to AMG Idealcast Solar Corporation
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Patent number: 8951345Abstract: This invention relates to a system and a method of use for large ceramic member support and manipulation at elevated temperatures in non-oxidizing atmospheres, such as using carbon-carbon composite materials for producing high purity silicon in the manufacture of solar modules. The high temperature apparatus of this invention includes one or more support ribs, one or more cross braces in combination with the one or more support ribs, and a shaped support liner positionable upon the one or more support ribs and the one or more cross braces.Type: GrantFiled: August 26, 2009Date of Patent: February 10, 2015Assignee: AMG Idealcast Solar CorporationInventors: Roger F. Clark, James A. Cliber, Nathan G. Stoddard, Jesse I. Gerber, Raymond J. Roberts, Mark A. Wilmerton
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Patent number: 8951344Abstract: Methods and apparatuses are provided for casting silicon for photovoltaic cells and other applications. With such methods and apparatuses, a cast body of geometrically ordered multi-crystalline silicon may be formed that is free or substantially free of radially-distributed impurities and defects and having at least two dimensions that are each at least about 10 cm is provided.Type: GrantFiled: January 18, 2007Date of Patent: February 10, 2015Assignee: AMG Idealcast Solar CorporationInventor: Nathan G. Stoddard
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Patent number: 8882077Abstract: This invention relates seed layers and a process of manufacturing seed layers for casting silicon suitable for use in solar cells or solar modules. The process includes the step of positioning tiles with aligned edges to form seams on a suitable surface, and the step of joining the tiles at the seams to form a seed layer. The step of joining includes heating the tiles to melt at least a portion of the tiles, contacting the tiles at both ends of at least one seam with electrodes, using plasma deposition of amorphous silicon, applying photons to melt a portion of the tiles, and/or layer deposition. Seed layers of this invention include a rectilinear shape of at least about 500 millimeters in width and length.Type: GrantFiled: January 28, 2010Date of Patent: November 11, 2014Assignee: AMG Idealcast Solar CorporationInventor: Nathan G. Stoddard
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Patent number: 8871169Abstract: Methods and apparatuses are provided for casting silicon for photovoltaic cells and other applications. With these methods, an ingot can be grown that is low in carbon and whose crystal growth is controlled to increase the cross-sectional area of seeded material during casting.Type: GrantFiled: October 18, 2013Date of Patent: October 28, 2014Assignee: AMG IdealCast Solar CorporationInventors: Nathan G. Stoddard, Roger F. Clark
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Patent number: 8741060Abstract: This invention relates to a system and a method for liquid silicon containment, such as during the casting of high purity silicon used in solar cells or solar modules. The containment apparatus includes a shielding ember adapted to prevent breaching molten silicon from contacting structural elements or cooling elements of a casting device, and a volume adapted to hold a quantity of breaching molten silicon with the volume formed by a bottom and one or more sides.Type: GrantFiled: April 1, 2013Date of Patent: June 3, 2014Assignee: AMG IdealCast Solar CorporationInventors: James A. Cliber, Roger F. Clark, Nathan G. Stoddard, Paul Von Dollen
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Patent number: 8709154Abstract: Methods are provided for casting one or more of a semiconductor, an oxide, and an intermetallic material. With such methods, a cast body of a monocrystalline form of the one or more of a semiconductor, an oxide, and an intermetallic material may be formed that is free of, or substantially free of, radially-distributed impurities and defects and having at least two dimensions that are each at least about 35 cm.Type: GrantFiled: July 23, 2008Date of Patent: April 29, 2014Assignee: AMG IdealCast Solar CorporationInventor: Nathan G. Stoddard
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Publication number: 20140102359Abstract: Methods and apparatuses are provided for casting silicon for photovoltaic cells and other applications. With such methods and apparatuses, a cast body of monocrystalline silicon may be formed that is free of, or substantially free of, radially-distributed impurities and defects and having at least two dimensions that are each at least about 35 cm is provided.Type: ApplicationFiled: December 5, 2013Publication date: April 17, 2014Applicant: AMG IDEALCAST SOLAR CORPORATIONInventor: Nathan G. Stoddard
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Patent number: 8628614Abstract: Methods and apparatuses are provided for casting silicon for photovoltaic cells and other applications. With such methods and apparatuses, a cast body of monocrystalline silicon may be formed that is free of, or substantially free of, radially-distributed impurities and defects and having at least two dimensions that are each at least about 35 cm is provided.Type: GrantFiled: October 19, 2011Date of Patent: January 14, 2014Assignee: AMG IdealCast Solar CorporationInventor: Nathan G. Stoddard
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Patent number: 8591851Abstract: Methods and apparatuses are provided for casting silicon for photovoltaic cells and other applications. With these methods, an ingot can be grown that is low in carbon and whose crystal growth is controlled to increase the cross-sectional area of seeded material during casting.Type: GrantFiled: March 28, 2013Date of Patent: November 26, 2013Assignee: AMG IdealCast Solar CorporationInventors: Nathan G. Stoddard, Roger F. Clark
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Patent number: 8475590Abstract: An apparatus and method for producing a crystalline ribbon continuously from a melt pool of liquid feed material, e.g. silicon. The silicon is melted and flowed into a growth tray to provide a melt pool of liquid silicon. Heat is passively extracted by allowing heat to flow from the melt pool up through a chimney. Heat is simultaneously applied to the growth tray to keep the silicon in its liquid phase while heat loss is occurring through the chimney. A template is placed in contact with the melt pool as heat is lost through the chimney so that the silicon starts to “freeze” (i.e. solidify) and adheres to the template. The template is then pulled from the melt pool thereby producing a continuous ribbon of crystalline silicon.Type: GrantFiled: May 23, 2012Date of Patent: July 2, 2013Assignee: AMG Idealcast Solar CorporationInventor: Roger F. Clark
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Patent number: 8449674Abstract: This invention relates to a system and a method for liquid silicon containment, such as during the casting of high purity silicon used in solar cells or solar modules. The containment apparatus includes a shielding member adapted to prevent breaching molten silicon from contacting structural elements or cooling elements of a casting device, and a volume adapted to hold a quantity of breaching molten silicon with the volume formed by a bottom and one or more sides.Type: GrantFiled: August 26, 2009Date of Patent: May 28, 2013Assignee: AMG Idealcast Solar CorporationInventors: James A. Cliber, Roger F. Clark, Nathan G. Stoddard, Paul Von Dollen
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Patent number: 8440157Abstract: Methods and apparatuses are provided for casting silicon for photovoltaic cells and other applications. With these methods, an ingot can be grown that is low in carbon and whose crystal growth is controlled to increase the cross-sectional area of seeded material during casting.Type: GrantFiled: July 16, 2008Date of Patent: May 14, 2013Assignee: AMG Idealcast Solar CorporationInventors: Nathan G. Stoddard, Roger F. Clark
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Publication number: 20120260849Abstract: An apparatus and method for producing a crystalline ribbon continuously from a melt pool of liquid feed material, e.g. silicon. The silicon is melted and flowed into a growth tray to provide a melt pool of liquid silicon. Heat is passively extracted by allowing heat to flow from the melt pool up through a chimney. Heat is simultaneously applied to the growth tray to keep the silicon in its liquid phase while heat loss is occurring through the chimney. A template is placed in contact with the melt pool as heat is lost through the chimney so that the silicon starts to “freeze” (i.e. solidify) and adheres to the template. The template is then pulled from the melt pool thereby producing a continuous ribbon of crystalline silicon.Type: ApplicationFiled: May 23, 2012Publication date: October 18, 2012Applicant: AMG IdealCast Solar CorporationInventor: Roger F. Clark
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Publication number: 20120228284Abstract: This invention relates to an electric cartridge heater and a method of operation, suitable for use in producing high purity silicon in solar cells or solar modules. The apparatus includes a single-piece elongated heater bar having a length, a first end, and a second end. The apparatus also includes a slot beginning at the first end and running a portion of the length, and the slot dividing the heater bar into a first arm and a second arm. An elbow at the second end joins the first arm and the second arm together. The apparatus also includes a first electrode in electrical communication with the first arm, and a second electrode in electrical communication with the second arm.Type: ApplicationFiled: May 23, 2012Publication date: September 13, 2012Applicant: AMG IdealCast Solar CorporationInventor: Roger F. Clark
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Patent number: 8262795Abstract: An apparatus and method for producing a crystalline ribbon continuously from a melt pool of liquid feed material, e.g. silicon. The silicon is melted and flowed into a growth tray to provide a melt pool of liquid silicon. Heat is passively extracted by allowing heat to flow from the melt pool up through a chimney. Heat is simultaneously applied to the growth tray to keep the silicon in its liquid phase while heat loss is occurring through the chimney. A template is placed in contact with the melt pool as heat is lost through the chimney so that the silicon starts to “freeze” (i.e. solidify) and adheres to the template. The template is then pulled from the melt pool thereby producing a continuous ribbon of crystalline silicon.Type: GrantFiled: October 9, 2009Date of Patent: September 11, 2012Assignee: AMG Idealcast Solar CorporationInventor: Roger F. Clark
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Publication number: 20110158887Abstract: This invention relates to a two or three-stage apparatus and method of use to produce high purity silicon, such as for use in solar panels and/or photovoltaics. The device of this invention includes a melting apparatus with a delivery device, a holding apparatus with a tipping or transfer mechanism, and at least one solidification apparatus for receiving a molten feedstock. The optimized designs of individual apparatuses function efficiently in combination to produce high purity silicon.Type: ApplicationFiled: August 21, 2009Publication date: June 30, 2011Applicant: AMG IdealCast Solar CorporationInventors: Nathan G. Stoddard, James A. Cliber, Roger F. Clark, Bei Wu, Soham Dey, Douglas L. Stark