Patents Assigned to Sunpower Corporation
  • Publication number: 20240322753
    Abstract: Remotely surveying a photovoltaic system site includes receiving a photograph uploaded by a user device; analyzing the photograph using a trained machine learning model; receiving a confidence score from the trained machine learning model; determining if the photograph includes predetermined information, the predetermined information being used to perform a remote photovoltaic (PV) system site survey remotely; and in response to a determination that the photograph does not include the predetermined information, provide specific instructions regarding the missing information, wherein the specific instructions include guidance on how to retake the photograph to capture the predetermined information.
    Type: Application
    Filed: June 5, 2024
    Publication date: September 26, 2024
    Applicant: SunPower Corporation
    Inventors: Jacob WACHMAN, Terrence BROWN, Bradley FOLTA, Deepesh MAKKAR
  • Patent number: 12015377
    Abstract: Rooftop photovoltaic solar systems and methods for installing interconnection wiring for photovoltaic solar systems. Cabling systems can include cable support stands secured underneath shingles. Cabling systems can include molded rubber raceways mounted using raceway clips secured underneath shingles.
    Type: Grant
    Filed: January 14, 2022
    Date of Patent: June 18, 2024
    Assignee: SunPower Corporation
    Inventors: Kevin C. Fischer, Kristine Little
  • Patent number: 12003208
    Abstract: A solar-tracking photovoltaic (PV) system having several PV modules mounted on a torque tube is described. The torque tube may include several sections joined by a torque tube coupler. For example, the torque tube coupler may having a medial section and end sections to join to the torque tube sections. The medial section and the torque tube sections may have a same outer diameter.
    Type: Grant
    Filed: May 14, 2019
    Date of Patent: June 4, 2024
    Assignee: SunPower Corporation
    Inventors: Sushrut Bapat, Tyler Grushkowitz, Nicholas James McKibben, Brian Wares
  • Patent number: 11949032
    Abstract: 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: Grant
    Filed: August 19, 2016
    Date of Patent: April 2, 2024
    Assignee: SunPower Corporation
    Inventors: John Paul Kapla, Kyle Donald Feldmann
  • Publication number: 20230369522
    Abstract: 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: Application
    Filed: May 16, 2022
    Publication date: November 16, 2023
    Applicant: SunPower Corporation
    Inventors: Ruihua Li, Yafu Lin
  • Patent number: 11784276
    Abstract: 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: Grant
    Filed: January 8, 2018
    Date of Patent: October 10, 2023
    Assignees: SunPower Corporation, Total Solar International
    Inventors: Moon Chun, Christoph Sachs, David Verstraeten
  • Patent number: 11699973
    Abstract: 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: Grant
    Filed: May 23, 2018
    Date of Patent: July 11, 2023
    Assignee: SunPower Corporation
    Inventors: Kevin C. Fischer, Philip Rothblum, Donald H. Scrutchfield, Dylan W. Benjamin
  • Patent number: 11616159
    Abstract: 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: Grant
    Filed: December 23, 2020
    Date of Patent: March 28, 2023
    Assignees: SunPower Corporation, Total Marketing Services
    Inventors: Matthieu Moors, David D. Smith, Gabriel Harley, Taeseok Kim
  • Publication number: 20230086161
    Abstract: 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: Application
    Filed: November 28, 2022
    Publication date: March 23, 2023
    Applicant: SunPower Corporation
    Inventors: David C. Okawa, Zachary S. Judkins, Tamir Lance, Tyler D. Newman, Thierry H. Nguyen, Ryan Reagan
  • Patent number: 11605750
    Abstract: 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: Grant
    Filed: February 23, 2021
    Date of Patent: March 14, 2023
    Assignee: SunPower Corporation
    Inventors: Richard M. Swanson, Marius M. Bunea, Michael C. Johnson, David D. Smith, Yu-Chen Shen, Peter J. Cousins, Tim Dennis
  • Patent number: 11598018
    Abstract: A wafer plating fixture for use in simultaneously electroplating a two substrates. The wafer plating fixture including: an electrically conductive carrier bus; a plurality of contact clips electrically coupled to the carrier bus and configured to hold the two substrates in place and electrically couple the two substrates to the carrier bus; and a non-conductive substrate backer to separate the two substrates coupled to the carrier bus. A method of electroplating a plurality of substrates. The method including: mounting two substrates to be plated onto a wafer plating fixture; mounting the wafer plating fixture on a continuous belt of plating system; dipping the wafer plating fixture with the two substrates held thereon into an electroplating bath; and applying a voltage to the two substrates via the wafer plating fixture.
    Type: Grant
    Filed: March 7, 2019
    Date of Patent: March 7, 2023
    Assignee: SunPower Corporation
    Inventors: Hung-Ming Wang, Paul W. Loscutoff, Raphael M. Manalo, Arnold V. Castillo, Mohamad Ridzwan Mustafa, Mark A. Kleshock, Neil G. Bergstrom
  • Patent number: 11594648
    Abstract: Methods of fabricating solar cell emitter regions with differentiated P-type and N-type regions architectures, and resulting solar cells, are described. In an example, a solar cell can include a substrate having a light-receiving surface and a back surface. A first doped region of a first conductivity type, wherein the first doped region is disposed in a first portion of the back surface. A first thin dielectric layer disposed over the back surface of the substrate, where a portion of the first thin dielectric layer is disposed over the first doped region of the first conductivity type. A first semiconductor layer disposed over the first thin dielectric layer. A second doped region of a second conductivity type in the first semiconductor layer, where the second doped region is disposed over a second portion of the back surface. A first conductive contact disposed over the first doped region and a second conductive contact disposed over the second doped region.
    Type: Grant
    Filed: April 20, 2020
    Date of Patent: February 28, 2023
    Assignee: SunPower Corporation
    Inventors: Seung Bum Rim, Michael C. Johnson
  • Publication number: 20230059513
    Abstract: A photovoltaic panel having a distributed support frame adhered to a photovoltaic module is described. For example, the distributed support frame may include one or more support member or support mounts adhered to the photovoltaic module by an adhesive layer. The photovoltaic module may include layers bound together by an encapsulant. Accordingly, the distributed support frame may be attached to the photovoltaic module during a same lamination process used to laminate the photovoltaic module.
    Type: Application
    Filed: November 7, 2022
    Publication date: February 23, 2023
    Applicant: SunPower Corporation
    Inventor: Gabriela Elena Bunea
  • Publication number: 20230055522
    Abstract: Reconfigurable PV panels can have features that include cut lines for separating full panels into smaller subpanels, connector ribbons for assembling several reconfigurable PV panels into a one-dimensional or two-dimensional array and can be stacked upon each other and unstacked by rotating them about a shared connection.
    Type: Application
    Filed: November 4, 2022
    Publication date: February 23, 2023
    Applicant: SunPower Corporation
    Inventors: Zachary S. Judkins, David C. Okawa, Brian S. Wares, Tamir Lance, Patrick L. Chapman
  • Patent number: 11581443
    Abstract: Methods of fabricating solar cell emitter regions with differentiated P-type and N-type architectures and incorporating dotted diffusion, and resulting solar cells, are described. In an example, a solar cell includes a substrate having a light-receiving surface and a back surface. A first polycrystalline silicon emitter region of a first conductivity type is disposed on a first thin dielectric layer disposed on the back surface of the substrate. A second polycrystalline silicon emitter region of a second, different, conductivity type is disposed on a second thin dielectric layer disposed in a plurality of non-continuous trenches in the back surface of the substrate.
    Type: Grant
    Filed: October 12, 2020
    Date of Patent: February 14, 2023
    Assignee: SunPower Corporation
    Inventors: Staffan Westerberg, Gabriel Harley
  • Publication number: 20230021009
    Abstract: A bipolar solar cell includes a backside junction formed by an N-type silicon substrate and a P-type polysilicon emitter formed on the backside of the solar cell. An antireflection layer may be formed on a textured front surface of the silicon substrate. A negative polarity metal contact on the front side of the solar cell makes an electrical connection to the substrate, while a positive polarity metal contact on the backside of the solar cell makes an electrical connection to the polysilicon emitter. An external electrical circuit may be connected to the negative and positive metal contacts to be powered by the solar cell. The positive polarity metal contact may form an infrared reflecting layer with an underlying dielectric layer for increased solar radiation collection.
    Type: Application
    Filed: July 21, 2022
    Publication date: January 19, 2023
    Applicant: SunPower Corporation
    Inventor: Peter John COUSINS
  • Patent number: 11532761
    Abstract: Composite making regions are provided. These masking regions can include layers or other areas of different transparency where a first region has a first transparency and a second region has a different transparency. Masking regions can be positioned between adjacent photovoltaic cells of photovoltaic arrays.
    Type: Grant
    Filed: June 3, 2021
    Date of Patent: December 20, 2022
    Assignee: SunPower Corporation
    Inventor: Hoi Hong Ng
  • Publication number: 20220399854
    Abstract: One embodiment is a photovoltaic (PV) module including a frame to receive a perimeter of a backside of a photovoltaic (PV) laminate. The cross rail assembly may include: a conductive frame to receive a perimeter of a backside of a photovoltaic (PV) laminate; one or more conductive cross rail members provide structural rigidity to the conductive frame; and one or more pairs of couplers coupled to the conductive frame, wherein: at least one coupler comprises a grounding coupler having a first keyed section to insert into an opening in the conductive frame and a second keyed section to mate with an end of a conductive cross rail member of the one or more conductive cross rail members to ground the conductive cross rail member to the frame; or at least one coupler of at least one of the one or more pairs includes a length to define a cabling channel.
    Type: Application
    Filed: August 22, 2022
    Publication date: December 15, 2022
    Applicant: SunPower Corporation
    Inventor: Lee J. Gorny
  • Patent number: 11527990
    Abstract: 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: Grant
    Filed: February 12, 2020
    Date of Patent: December 13, 2022
    Assignee: SunPower Corporation
    Inventors: David C. Okawa, Zachary S. Judkins, Tamir Lance, Tyler D. Newman, Thierry H. Nguyen, Ryan Reagan
  • Patent number: D978081
    Type: Grant
    Filed: January 28, 2021
    Date of Patent: February 14, 2023
    Assignee: Sunpower Corporation
    Inventors: Brian Kuhn, William J. Morris, Daidipya J. Patwa, Sandeep Narla