Patents Assigned to Sunpower Corporation
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Patent number: 11038072Abstract: A high efficiency configuration for a solar cell module comprises solar cells conductively bonded to each other in a shingled manner to form super cells, which may be arranged to efficiently use the area of the solar module, reduce series resistance, and increase module efficiency.Type: GrantFiled: June 27, 2018Date of Patent: June 15, 2021Assignee: SunPower CorporationInventors: Ratson Morad, Gilad Almogy, Itai Suez, Jean Hummel, Nathan Beckett, Yafu Lin, John Gannon, Michael J. Starkey, Robert Stuart, Tamir Lance, Dan Maydan
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Publication number: 20210175375Abstract: One embodiment relates to a method of fabricating a solar cell. A silicon lamina is cleaved from the silicon substrate. The backside of the silicon lamina includes the P-type and N-type doped regions. A metal foil is attached to the backside of the silicon lamina. The metal foil may be used advantageously as a built-in carrier for handling the silicon lamina during processing of a frontside of the silicon lamina. Another embodiment relates to a solar cell that includes a silicon lamina having P-type and N-type doped regions on the backside. A metal foil is adhered to the backside of the lamina, and there are contacts formed between the metal foil and the doped regions. Other embodiments, aspects and features are also disclosed.Type: ApplicationFiled: February 16, 2021Publication date: June 10, 2021Applicant: SunPower CorporationInventors: Seung Bum RIM, Gabriel HARLEY
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Patent number: 11031515Abstract: A solar cell is disclosed. The solar cell has a front side facing the sun during normal operation, and a back side facing away from the sun. The solar cell comprises a silicon substrate, a first polysilicon layer with a region of doped polysilicon on the back side of the substrate. The solar cell also comprises a second polysilicon layer with a second region of doped polysilicon on the back side of the silicon substrate. The second polysilicon layer at least partially covers the region of doped polysilicon. The solar cell also comprises a resistive region disposed in the first polysilicon layer. The resistive region extends from an edge of the second region of doped polysilicon. The resistive region can be formed by ion implantation of oxygen into the first polysilicon layer.Type: GrantFiled: June 11, 2018Date of Patent: June 8, 2021Assignee: SunPower CorporationInventors: Seung Rim, David D. Smith
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Publication number: 20210159850Abstract: Photovoltaic (PV) frames, PV frame systems, methods of PV manufacture, articles of PV manufacture, and processes involving PVs are provided. These frames may employ a laminate receiver configured to receive a surface of a PV laminate and support that PV laminate upon installation of a PV system.Type: ApplicationFiled: November 23, 2020Publication date: May 27, 2021Applicant: SunPower CorporationInventors: Arbaz Shakir, Tamir Lance, Lydia Alicia Seymour, Jose Cornelio M. Flores, Elizabeth Schulte
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Patent number: 11018620Abstract: A solar module skirt assembly includes a skirt that is attached to a frame of a solar module, and a clip to attach the skirt to the solar module. The clip includes a first portion to attach to a frame of the solar module and to the skirt, a second portion to hold a portion of the frame of the solar module and a portion of the skirt, and a fastener to affix the clip to the frame of the solar module and the portion of the skirt.Type: GrantFiled: September 24, 2019Date of Patent: May 25, 2021Assignee: SUNPOWER CORPORATIONInventors: Gary Rossi, Ethan Ely
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Publication number: 20210152119Abstract: The present invention relates to a solar power generation assembly and method for providing same involving an array of solar generating modules on a dual-incline structure, which can achieve high energy yields over a wide range of azimuths/orientations. The assembly consists of canopy wings providing for the dual-incline structure, where, depending on specifications, the canopy wings can differ in length, width, angle of inclination, structural material and solar module or other material mounted on the surface. The canopy wings may be pivoted or hinged to enhance the energy generation and/or other functional benefits of the assembly or system, including display elements, advertising, rainwater/precipitation and snow drainage and collection and energy transmission.Type: ApplicationFiled: October 29, 2020Publication date: May 20, 2021Applicant: SunPower CorporationInventor: Laurence MACKLER
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Publication number: 20210143290Abstract: A solar module includes at least one first solar cell and at least one second solar cell, each solar cell including a top side and bottom side, a bus bar, and a plurality of wires, disposed on the top side, extending from and electrically connected to the bus bar. The first solar cell overlaps a region of the second solar cell to electrically connect to the second solar cell and to form a shingled arrangement, and in the second solar cell, the plurality of wires connect to the bus bar outside of the region in which the first solar cell overlaps the second solar cell. A method of manufacturing a solar module includes shingling solar cells using ECA to make a hybrid dense solar cell string that includes at least two hybrid dense solar cells in a shingled arrangement.Type: ApplicationFiled: November 13, 2019Publication date: May 13, 2021Applicant: SUNPOWER CORPORATIONInventor: Yafu LIN
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Publication number: 20210140187Abstract: A solar power generation assembly includes a vertical support column; a canopy including a plurality of solar modules for solar power generation; a first brace and a second brace on a first side of the support column to support the canopy; a third brace and a fourth brace on a second side of the support column to support the canopy; and a gutter system integrated into the canopy and directing precipitation along one or more of the second brace and the fourth brace to the support column. One or more of the first brace and the third brace manage electrical cables extending from the canopy to the support column.Type: ApplicationFiled: January 25, 2021Publication date: May 13, 2021Applicant: SUNPOWER CORPORATIONInventors: Nicholas J. MCKIBBEN, John KAPLA, Sushrut G. BAPAT, Elizabeth SCHULTE, Gary A. ROSSI, Jeremy MANSELL, Andrew R. WOLF
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Patent number: 11004987Abstract: Methods of fabricating a solar cell, and system for electrically coupling solar cells, are described. In an example, the methods for fabricating a solar cell can include placing conductive wires in a wire guide, where conductive wires are placed over a first semiconductor substrate having first doped regions and second doped regions. The method can include aligning the conductive wires over the first and second doped regions, where the wire guide aligns the conductive wires substantially parallel to the first and second doped regions. The method can include bonding the conductive wires to the first and second doped regions. The bonding can include applying a mechanical force to the semiconductor substrate via a roller or bonding head of the wire guide, where the wire guide inhibits lateral movement of the conductive wires during the bonding.Type: GrantFiled: March 13, 2020Date of Patent: May 11, 2021Assignees: SunPower Corporation, Total Marketing Services and Total Energies Nouvelles Activites USAInventors: Richard Hamilton Sewell, David Aaron Randolph Barkhouse, Nils-Peter Harder, Douglas Rose
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Patent number: 11005416Abstract: Modular photovoltaic (PV) panel, system, and method of mounting. The system including a mounting flashing configured to mounted to a mounting surface and a folding PV panel. The folding PV panel including: a first subpanel including first PV cells, wherein the first subpanel extends along a first lateral plane and comprises a plurality of mounting hooks extending laterally from and affixed to a backside of the first subpanel, the mounting hooks configured to couple to the mounting flashing; a second subpanel including second PV cells, wherein the second subpanel extends along a second lateral plane, wherein the second subpanel comprises a front edge support configured to hold a front edge of the second subpanel away from the mounting surface; and a hinge assembly rotationally coupling the first subpanel and the second subpanel to allow an angle between the first lateral plane and the second lateral plane to change.Type: GrantFiled: January 13, 2020Date of Patent: May 11, 2021Assignee: SunPower CorporationInventors: Brian Wares, David C. Okawa, Tamir Lance
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Patent number: 10998761Abstract: A photovoltaic system includes groups of solar cells that can be switched in and out of the photovoltaic system. In response to detecting initiation of rapid shutdown, a control circuit controls a switch device to switch out a group of solar cells to lower the output voltage of the photovoltaic system below a safety level. In response to detecting a release trigger that indicates resumption of normal operation, the control circuit controls the switch device to switch back the group of solar cells to restore the output voltage of the photovoltaic system to a normal operating level. Solar cells may be switched out by disconnecting them from the photovoltaic system and switched back by reconnecting them into the photovoltaic system. Solar cells may also be switched out by shorting them out of the photovoltaic system and switched back in by removing the short.Type: GrantFiled: July 16, 2019Date of Patent: May 4, 2021Assignee: SunPower CorporationInventors: Zachary S. Judkins, Jonathan L. Ehlmann
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Patent number: 10992237Abstract: A multi-inverter system with at least a string of inverters sharing a DC bus and outputting to a shared AC bus. Inverters are hot-swappable and configured to be turned on or off during powered cycles. Central control may comprise reducing power point tracking redundancies or promoting other operational changes at individual inverters of a group.Type: GrantFiled: November 21, 2019Date of Patent: April 27, 2021Assignee: SunPower CorporationInventors: Patrick L. Chapman, Zachary S. Judkins, Jacob Marshall
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Patent number: 10992255Abstract: A photovoltaic (PV) system can include a plurality of PV modules and circuitry configured to receive an indication of a status of the PV system and to, in response to the indication, determine whether to switch between a first state in which the PV modules output DC power and a second state in which the PV modules do not output power.Type: GrantFiled: June 23, 2015Date of Patent: April 27, 2021Assignee: SunPower CorporationInventors: Benjamin Alexander Johnson, Andrew Joseph Ponec
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Publication number: 20210117587Abstract: Determining solar panel placement enables sales representatives and homeowners to modify a solar power system by adding or removing solar panels or arrays of solar panels, or changing module type. The user sees the corresponding solar energy production update instantly in a user interface. Determining solar panel placement includes receiving data corresponding to an installation location. A maximum solar panel design is determined based on the installation location. Energy production is determined for a solar panel on each section of a roof of an installation location, and the energy production and energy offset are dynamically displayed in real time when any solar panel or array is selected or deselected.Type: ApplicationFiled: December 30, 2020Publication date: April 22, 2021Applicant: SUNPOWER CORPORATIONInventors: Jake WACHMAN, Matt MOONE, Anthony GARZOLINI, Jeff SOUTHARD
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Publication number: 20210111672Abstract: Electrical component location is provided. Employed location techniques may include providing a signal, having components to be located sense the signal and report back the sensed signal, and determining relative locations for one or more of the components using the sensed signals reported by the components.Type: ApplicationFiled: December 22, 2020Publication date: April 15, 2021Applicant: SunPower CorporationInventors: Fernando Rodriguez, Patrick L. Chapman, Jonathan Ehlmann
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Patent number: 10972046Abstract: A solar device system includes one or more solar devices shingled into an array of solar devices. Each solar device includes one or more current generation cells configured to generate electric current, a plurality of current buses, and a control circuit configured to distribute the generated electric current to the plurality of current buses, and route the generated electric current to an adjacent solar device. Additionally, the solar device system includes an array collector electrically connected to the one or more solar devices, the array collector being configured to collect the generated electrical current from the one or more solar devices and direct the generated electrical current to an inverter or a power grid.Type: GrantFiled: August 31, 2018Date of Patent: April 6, 2021Assignee: SunPower CorporationInventors: Jonathan L. Ehlmann, Lee J. Gorny, Thierry H. Nguyen, David C. Okawa
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Patent number: 10971638Abstract: Methods of fabricating a solar cell including metallization techniques and resulting solar cells, are described. In an example, a semiconductor region can be formed in or above a substrate. A first metal layer can be formed over the semiconductor region. A laser can be applied over a first region of the metal layer to form a first metal weld between the metal layer and the semiconductor region, where applying a laser over the first region comprises applying the laser at a first scanning speed. Subsequent to applying the laser over the first region, the laser can be applied over a second region of the metal layer where applying the laser over the second region includes applying a laser at a second scanning speed. Subsequent to applying the laser over the second region, the laser can be applied over a third region of the metal layer to form a second metal weld, where applying the laser over the third region comprises applying the laser at a third scanning speed.Type: GrantFiled: January 22, 2018Date of Patent: April 6, 2021Assignees: SunPower Corporation, Total Marketing SendeesInventors: Matthieu Moors, Markus Nicht, Daniel Maria Weber, Rico Bohme, Mario Gjukic, Gabriel Harley, Mark Kleshock, Mohamed A. Elbandrawy, Taeseok Kim
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Patent number: 10969414Abstract: Methods, systems, and computer readable media are disclosed for monitoring electric systems for wiring faults. In some examples, a system includes a production power meter coupled to a power generation system of a building and configured for measuring electric power generated by the power generation system, one or more consumption power meters coupled to an electric system of the building and configured for measuring electric power consumed by the electric system, and a computer system coupled to the production power meter and the consumption power meters. The computer system is programmed for determining that at least one power meter is installed with a reversed polarity that is reversed with respect to an installation specification, resulting in the computer system receiving measured values from the at least one power meter having an incorrect sign.Type: GrantFiled: April 4, 2018Date of Patent: April 6, 2021Assignee: SUNPOWER CORPORATIONInventors: Donald H. Scrutchfield, Miles F. Bintz, Dylan W. Benjamin, Kevin C. Fischer
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Patent number: D916651Type: GrantFiled: October 31, 2018Date of Patent: April 20, 2021Assignee: SUNPOWER CORPORATIONInventors: Ratson Morad, Gilad Almogy, Itai Suez, Jean Hummel, Nathan Beckett
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Patent number: D921573Type: GrantFiled: June 15, 2018Date of Patent: June 8, 2021Assignee: SunPower CorporationInventors: Brian Wares, David C. Okawa, Tamir Lance