Patents Assigned to First Solar, Inc.
  • Patent number: 12641890
    Abstract: A method of patterning a thin-film photovoltaic layer stack includes the steps of providing a continuous layer stack comprising a planar substrate, a first electrode layer on the substrate and a photovoltaic layer on the first electrode layer, immersing the layer stack into an electrically conductive solution, applying a bias voltage between the electrolyte solution and the first electrode layer and converting a first material or a first material composition provided in at least a first portion of the layer stack into a first reaction product by an electrochemical reaction, wherein the first reaction product has an electrical conductivity that is lower than an electrical conductivity of the first material or first material composition, or removing a first material or a first material composition provided in at least a first portion of the layer stack by an electrochemical reaction.
    Type: Grant
    Filed: May 31, 2024
    Date of Patent: May 26, 2026
    Assignee: First Solar, Inc.
    Inventors: Shuping Lin, Raffael Reineker, Hongqing Shan, Joachim Leopold Ludwig Müller, Bernd Sprecher, Kay Orgassa
  • Publication number: 20260130042
    Abstract: Photovoltaic devices having contact layers are described herein. Devices, intermediate structures, and methods for making multilayer contacts for perovskite photovoltaic devices are provided. Embodiments include materials and methods for forming back contacts.
    Type: Application
    Filed: January 5, 2026
    Publication date: May 7, 2026
    Applicants: First Solar, Inc., Alliance for Energy Innovation, LLC
    Inventors: Joseph Jonathan Berry, Le Chen, Axel Finn Palmstrom, Tze-Bin Song, Vera Steinmann, Natasha Teran, Aravamuthan Varadarajan, Xueping Yi, Zhibo Zhao, Kai Zhu
  • Patent number: 12610650
    Abstract: Provided are structures and methods for doping polycrystalline thin film semiconductor materials in photovoltaic devices. Embodiments include methods for forming and treating a photovoltaic semiconductor absorber layer.
    Type: Grant
    Filed: October 16, 2023
    Date of Patent: April 21, 2026
    Assignee: First Solar, Inc.
    Inventors: Sachit Grover, Stuart Irvine, Xiaoping Li, Roger Malik, Shahram Seyedmohammadi, Gang Xiong, Wei Zhang
  • Patent number: 12595545
    Abstract: Structures and methods for manufacturing photovoltaic devices by forming perovskite layers and perovskite precursor layers using vapor transport deposition (VTD) are described.
    Type: Grant
    Filed: October 3, 2024
    Date of Patent: April 7, 2026
    Assignee: First Solar, Inc.
    Inventors: Le Chen, David Ho, Xiaoping Li, Rick Powell, Tze-Bin Song, Vera Steinmann, Aravamuthan Varadarajan, Dirk Weiss, Gang Xiong, Zhibo Zhao
  • Patent number: 12593516
    Abstract: Photovoltaic devices, and methods of making the same, are described. A photovoltaic device comprises a plurality of electrically connected photovoltaic cells, wherein the photovoltaic cells comprise a conducting layer having a first surface and a second surface, the first surface facing an absorber layer; an insulating material disposed on the second surface over at least one of the photovoltaic cells; a conductive member on the insulating material, wherein the insulating material is configured to electrically insulate the conductive member from the second surface; a bus member electrically coupled to the one of the plurality of photovoltaic cells and to the conductive member; and an edge seal comprising a sealant material extending over at least a portion of the one of the plurality of photovoltaic cells; wherein the bus member is disposed between the edge seal and the plurality of photovoltaic cells.
    Type: Grant
    Filed: October 23, 2020
    Date of Patent: March 31, 2026
    Assignee: First Solar, Inc.
    Inventors: Christopher DiRubio, Markus Gloeckler, Weixin Li, Richard Malik, Jr., Riley Maxwell, Jason Sharrer, Jigish Trivedi
  • Patent number: 12588297
    Abstract: A photovoltaic cell can include an interfacial layer in contact with a semiconductor layer.
    Type: Grant
    Filed: June 1, 2021
    Date of Patent: March 24, 2026
    Assignee: First Solar, Inc.
    Inventors: David Eaglesham, Peter V. Meyers
  • Patent number: 12563857
    Abstract: A photovoltaic device includes a substrate structure and a p-type semiconductor absorber layer. A photovoltaic device may include a CdSeTe layer. A process for manufacturing a photovoltaic device includes forming a CdSeTe layer over a substrate. The process includes forming a p-type cadmium selenide telluride absorber layer.
    Type: Grant
    Filed: September 25, 2023
    Date of Patent: February 24, 2026
    Assignee: First Solar, Inc.
    Inventors: Dan Damjanovic, Feng Liao, Rick Powell, Rui Shao, Jigish Trivedi, Zhibo Zhao
  • Patent number: 12532548
    Abstract: In accordance with one or more embodiments herein, a method of manufacturing a photovoltaic (PV) top module, to be used together with a PV bottom module, e.g an SI-based PV bottom module, is provided. The method may include monolithically interconnecting a plurality of thin film based PV sub-cells, manufactured using a perovskite material and/or a CIGS material as solar absorbing material, in series on a substrate in order to create a PV top module including at least one first PV top sub-module, and arranging metal grid lines on top and bottom contact layers of the PV top module. The metal grid lines may be arranged either above or below the top and bottom contact layers of the PV top module.
    Type: Grant
    Filed: June 24, 2021
    Date of Patent: January 20, 2026
    Assignee: First Solar, Inc.
    Inventors: Erik Wallin, Olle Lundberg, Lars Stolt
  • Patent number: 12522911
    Abstract: Distributor assemblies for vapor transport deposition systems, and methods of conducting vapor transport deposition, are described.
    Type: Grant
    Filed: October 24, 2018
    Date of Patent: January 13, 2026
    Assignee: First Solar, Inc.
    Inventors: Zhigang Ban, John Barden, Jerry Drennan, Litian Liu, Rick Powell, Nirav Vora, Yaojun Xu
  • Patent number: 12520652
    Abstract: Photovoltaic devices having contact layers are described herein. Devices, intermediate structures, and methods for making multilayer contacts for perovskite photovoltaic devices are provided. Embodiments include back contacts for N-I-P structures.
    Type: Grant
    Filed: February 11, 2022
    Date of Patent: January 6, 2026
    Assignees: First Solar, Inc., Alliance for Sustainable Energy, LLC
    Inventors: Joseph Jonathan Berry, Le Chen, Axel Finn Palmstrom, Tze-Bin Song, Vera Steinmann, Natasha Teran, Aravamuthan Varadarajan, Xueping Yi, Zhibo Zhao, Kai Zhu
  • Patent number: 12520599
    Abstract: A photovoltaic device includes a substrate structure and at least one Se-containing layer, such as a CdSeTe layer. A process for manufacturing the photovoltaic device includes forming the CdSeTe layer over a substrate by at least one of sputtering, evaporation deposition, CVD, chemical bath deposition process, and vapor transport deposition process. The process can also include controlling a thickness range of the Se-containing layer.
    Type: Grant
    Filed: November 13, 2023
    Date of Patent: January 6, 2026
    Assignee: First Solar, Inc.
    Inventors: Dan Damjanovic, Markus Gloeckler, Feng Liao, Andrei Los, Dan Mao, Benjamin Milliron, Gopal Mor, Rick Powell, Kenneth Ring, Aaron Roggelin, Jigish Trivedi, Zhibo Zhao
  • Publication number: 20250361597
    Abstract: Distributor assemblies for vapor transport deposition systems, and methods of conducting vapor transport deposition, are described.
    Type: Application
    Filed: August 8, 2025
    Publication date: November 27, 2025
    Applicant: First Solar, Inc.
    Inventors: John Barden, Rick Powell, Aaron Roggelin, Nirav Vora
  • Publication number: 20250311473
    Abstract: According to the embodiments provided herein, a method for sputtering a TCO material onto a substrate includes process conditions that produce a textured topography at the interfaces of various layers. The textured topography can include an average roughness from about 5 to about 40 nm. The process conditions can include providing oxygen in the sputtering environment at a flow rate of from 0 to about 30 sccm; or heating the substrate to at least 200; or increasing the magnetic field strength to above 40 mT. The textured topography creates interfacial transition areas which have hybrid physical properties compared to their constituent materials.
    Type: Application
    Filed: June 16, 2025
    Publication date: October 2, 2025
    Applicant: First Solar, Inc.
    Inventors: Paulina Bourgeois, Robert Clark-Phelps, Qi Fang, Jing Guo, Gopal Mor, Rui Shao
  • Publication number: 20250267978
    Abstract: Photovoltaic devices having transparent contact layers are described herein.
    Type: Application
    Filed: March 11, 2025
    Publication date: August 21, 2025
    Applicant: First Solar, Inc.
    Inventors: James Becker, Mark Hendryx, William Huber, Jason Kephart, Andrei Los, Wei Zhang
  • Patent number: 12369426
    Abstract: A photovoltaic device is presented. The photovoltaic device includes a layer stack; and an absorber layer is disposed on the layer stack. The absorber layer comprises selenium, wherein an atomic concentration of selenium varies across a thickness of the absorber layer. The photovoltaic device is substantially free of a cadmium sulfide layer.
    Type: Grant
    Filed: January 12, 2024
    Date of Patent: July 22, 2025
    Assignee: First Solar, Inc.
    Inventors: Holly Ann Blaydes, Kristian William Andreini, William Hullinger Huber, Eugene Thomas Hinners, Joseph John Shiang, Yong Liang, Jongwoo Choi
  • Patent number: 12356755
    Abstract: According to the embodiments provided herein, a photovoltaic device can include an absorber layer. The absorber layer can be doped p-type with a Group V dopant and can have a carrier concentration of the Group V dopant greater than 4×1015 cm?3. The absorber layer can include oxygen in a central region of the absorber layer. The absorber layer can include an alkali metal in the central region of the absorber layer. Methods for carrier activation can include exposing an absorber layer to an annealing compound in a reducing environment. The annealing compound can include cadmium chloride and an alkali metal chloride.
    Type: Grant
    Filed: November 14, 2022
    Date of Patent: July 8, 2025
    Assignee: First Solar, Inc.
    Inventors: Hongbo Cao, Sachit Grover, William Hullinger Huber, Xiaoping Li, Dingyuan Lu, Roger Malik, Hongying Peng, Joseph John Shiang, Qianqian Xin, Gang Xiong
  • Patent number: 12356732
    Abstract: According to the embodiments provided herein, an island in a regular, closed shape is ablated in a first conductive layer. An interconnect is formed through the island, using the island as an alignment fiducial. The island and the interconnect are isolated from the remainder of the first conductive layer.
    Type: Grant
    Filed: March 17, 2022
    Date of Patent: July 8, 2025
    Assignee: First Solar, Inc.
    Inventors: Nikhil Bhandari, Matthew Davis, Rhett Miller, Charles Wickersham
  • Patent number: 12336321
    Abstract: According to the embodiments provided herein, a method for sputtering a TCO material onto a substrate includes process conditions that produce a textured topography at the interfaces of various layers. The textured topography can include an average roughness from about 5 to about 40 nm. The process conditions can include providing oxygen in the sputtering environment at a flow rate of from 0 to about 30 sccm; or heating the substrate to at least 200; or increasing the magnetic field strength to above 40 mT. The textured topography creates interfacial transition areas which have hybrid physical properties compared to their constituent materials.
    Type: Grant
    Filed: September 23, 2019
    Date of Patent: June 17, 2025
    Assignee: First Solar, Inc.
    Inventors: Paulina Bourgeois, Robert Clark-Phelps, Qi Fang, Jing Guo, Gopal Mor, Rui Shao
  • Patent number: D1127696
    Type: Grant
    Filed: March 19, 2024
    Date of Patent: May 26, 2026
    Assignee: First Solar, Inc.
    Inventor: Jacob Weil
  • Patent number: D1127697
    Type: Grant
    Filed: March 21, 2024
    Date of Patent: May 26, 2026
    Assignee: First Solar, Inc.
    Inventor: Jacob Weil