Patents Assigned to Sunpower Corporation
  • Patent number: 11038072
    Abstract: 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: Grant
    Filed: June 27, 2018
    Date of Patent: June 15, 2021
    Assignee: SunPower Corporation
    Inventors: Ratson Morad, Gilad Almogy, Itai Suez, Jean Hummel, Nathan Beckett, Yafu Lin, John Gannon, Michael J. Starkey, Robert Stuart, Tamir Lance, Dan Maydan
  • Publication number: 20210175375
    Abstract: 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: Application
    Filed: February 16, 2021
    Publication date: June 10, 2021
    Applicant: SunPower Corporation
    Inventors: Seung Bum RIM, Gabriel HARLEY
  • Patent number: 11031515
    Abstract: 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: Grant
    Filed: June 11, 2018
    Date of Patent: June 8, 2021
    Assignee: SunPower Corporation
    Inventors: Seung Rim, David D. Smith
  • Publication number: 20210159850
    Abstract: 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: Application
    Filed: November 23, 2020
    Publication date: May 27, 2021
    Applicant: SunPower Corporation
    Inventors: Arbaz Shakir, Tamir Lance, Lydia Alicia Seymour, Jose Cornelio M. Flores, Elizabeth Schulte
  • Patent number: 11018620
    Abstract: 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: Grant
    Filed: September 24, 2019
    Date of Patent: May 25, 2021
    Assignee: SUNPOWER CORPORATION
    Inventors: Gary Rossi, Ethan Ely
  • Publication number: 20210152119
    Abstract: 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: Application
    Filed: October 29, 2020
    Publication date: May 20, 2021
    Applicant: SunPower Corporation
    Inventor: Laurence MACKLER
  • Publication number: 20210143290
    Abstract: 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: Application
    Filed: November 13, 2019
    Publication date: May 13, 2021
    Applicant: SUNPOWER CORPORATION
    Inventor: Yafu LIN
  • Publication number: 20210140187
    Abstract: 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: Application
    Filed: January 25, 2021
    Publication date: May 13, 2021
    Applicant: SUNPOWER CORPORATION
    Inventors: Nicholas J. MCKIBBEN, John KAPLA, Sushrut G. BAPAT, Elizabeth SCHULTE, Gary A. ROSSI, Jeremy MANSELL, Andrew R. WOLF
  • Patent number: 11004987
    Abstract: 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: Grant
    Filed: March 13, 2020
    Date of Patent: May 11, 2021
    Assignees: SunPower Corporation, Total Marketing Services and Total Energies Nouvelles Activites USA
    Inventors: Richard Hamilton Sewell, David Aaron Randolph Barkhouse, Nils-Peter Harder, Douglas Rose
  • Patent number: 11005416
    Abstract: 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: Grant
    Filed: January 13, 2020
    Date of Patent: May 11, 2021
    Assignee: SunPower Corporation
    Inventors: Brian Wares, David C. Okawa, Tamir Lance
  • Patent number: 10998761
    Abstract: 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: Grant
    Filed: July 16, 2019
    Date of Patent: May 4, 2021
    Assignee: SunPower Corporation
    Inventors: Zachary S. Judkins, Jonathan L. Ehlmann
  • Patent number: 10992237
    Abstract: 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: Grant
    Filed: November 21, 2019
    Date of Patent: April 27, 2021
    Assignee: SunPower Corporation
    Inventors: Patrick L. Chapman, Zachary S. Judkins, Jacob Marshall
  • Patent number: 10992255
    Abstract: 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: Grant
    Filed: June 23, 2015
    Date of Patent: April 27, 2021
    Assignee: SunPower Corporation
    Inventors: Benjamin Alexander Johnson, Andrew Joseph Ponec
  • Publication number: 20210117587
    Abstract: 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: Application
    Filed: December 30, 2020
    Publication date: April 22, 2021
    Applicant: SUNPOWER CORPORATION
    Inventors: Jake WACHMAN, Matt MOONE, Anthony GARZOLINI, Jeff SOUTHARD
  • Publication number: 20210111672
    Abstract: 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: Application
    Filed: December 22, 2020
    Publication date: April 15, 2021
    Applicant: SunPower Corporation
    Inventors: Fernando Rodriguez, Patrick L. Chapman, Jonathan Ehlmann
  • Patent number: 10972046
    Abstract: 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: Grant
    Filed: August 31, 2018
    Date of Patent: April 6, 2021
    Assignee: SunPower Corporation
    Inventors: Jonathan L. Ehlmann, Lee J. Gorny, Thierry H. Nguyen, David C. Okawa
  • Patent number: 10971638
    Abstract: 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: Grant
    Filed: January 22, 2018
    Date of Patent: April 6, 2021
    Assignees: SunPower Corporation, Total Marketing Sendees
    Inventors: Matthieu Moors, Markus Nicht, Daniel Maria Weber, Rico Bohme, Mario Gjukic, Gabriel Harley, Mark Kleshock, Mohamed A. Elbandrawy, Taeseok Kim
  • Patent number: 10969414
    Abstract: 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: Grant
    Filed: April 4, 2018
    Date of Patent: April 6, 2021
    Assignee: SUNPOWER CORPORATION
    Inventors: Donald H. Scrutchfield, Miles F. Bintz, Dylan W. Benjamin, Kevin C. Fischer
  • Patent number: D916651
    Type: Grant
    Filed: October 31, 2018
    Date of Patent: April 20, 2021
    Assignee: SUNPOWER CORPORATION
    Inventors: Ratson Morad, Gilad Almogy, Itai Suez, Jean Hummel, Nathan Beckett
  • Patent number: D921573
    Type: Grant
    Filed: June 15, 2018
    Date of Patent: June 8, 2021
    Assignee: SunPower Corporation
    Inventors: Brian Wares, David C. Okawa, Tamir Lance