Patents by Inventor Anthony Calcaterra
Anthony Calcaterra has filed for patents to protect the following inventions. This listing includes patent applications that are pending as well as patents that have already been granted by the United States Patent and Trademark Office (USPTO).
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Publication number: 20230411792Abstract: A battery includes an electrode assembly. The electrode assembly has a population of unit cells, each unit cell including an electrode current collector layer, an electrode layer, a separator layer, a counter-electrode layer, and a counter-electrode current collector layer in stacked succession. The electrode layer has an electrode active material, and the counter-electrode layer has a counter-electrode active material. One of the electrode active material and the counter-electrode material is a cathodically active material and the other of the electrode active material and the counter-electrode material is an anodically active material. A subset of the unit cell population includes a pair of spacer members located between the electrode current collector layer and the counter-electrode current collector layer. At least a portion of the counter-electrode active material is located between the spacer members in a common plane defined by the x and z axes.Type: ApplicationFiled: November 17, 2021Publication date: December 21, 2023Inventors: Jeremie J. Dalton, Robert S. Busacca, Ashok Lahiri, Murali Ramasubramanian, Bruno A. Valdes, Kim Han Lee, Anthony Calcaterra, Benjamin L. Cardozo
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Publication number: 20230395935Abstract: A method for manufacturing a structure comprising and electrode assembly having a porous electrically insulating material, and first and second endplates, is provided. The electrode assembly comprises a population of unit cells stacked in series in a stacking direction, opposing first and second longitudinal end surfaces separated along the stacking direction. First and second endplates are separated in the stacking direction and overlie the first and second longitudinal end surfaces. According to embodiments of the structure, (i) each unit cell comprises an electrode structure, a counter-electrode structure, and an electrically insulating separator between the electrode and counter-electrode structures, (ii) the electrode structures, counter-electrode structures and electrically insulating separators within each unit cell have opposing first and second vertical end surfaces separated in a vertical direction, and (iii) the vertical direction is orthogonal to the stacking direction.Type: ApplicationFiled: August 17, 2023Publication date: December 7, 2023Inventors: William H. CHANDLER, JR., Robert S. BUSACCA, Bruno A. VALDES, Kim Han LEE, Anthony CALCATERRA, Miles A. M. KOOL, Robert KINCHEN
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Patent number: 11777174Abstract: A method for manufacturing a structure comprising and electrode assembly having a porous electrically insulating material, and first and second endplates, is provided. The electrode assembly comprises a population of unit cells stacked in series in a stacking direction, opposing first and second longitudinal end surfaces separated along the stacking direction. First and second endplates are separated in the stacking direction and overlie the first and second longitudinal end surfaces. According to embodiments of the structure, (i) each unit cell comprises an electrode structure, a counter-electrode structure, and an electrically insulating separator between the electrode and counter-electrode structures, (ii) the electrode structures, counter-electrode structures and electrically insulating separators within each unit cell have opposing first and second vertical end surfaces separated in a vertical direction, and (iii) the vertical direction is orthogonal to the stacking direction.Type: GrantFiled: October 31, 2022Date of Patent: October 3, 2023Assignee: Enovix CorporationInventors: William H. Chandler, Jr., Robert S. Busacca, Bruno A. Valdes, Kim Han Lee, Anthony Calcaterra, Miles A. M. Kool, Robert Kinchen
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Publication number: 20230299425Abstract: A secondary battery for cycling between a charged and a discharged state, comprises a battery enclosure, an electrode assembly, carrier ions, and an electrolyte, wherein the electrode assembly comprises a population of unit cells, each unit cell comprising, in a stacking direction, a unit cell portion of an electrode current collector layer, an electrode layer comprising electrode active material, a separator layer, a counter-electrode layer and a unit cell portion of a counter-electrode current collector layer, and a subset of the members of the unit cell population comprises a population of spacer structures located in the stacked succession, and for each member of unit cell population subset there exists an imaginary line that extends in a direction that is orthogonal to the stacking direction and intersects the counter-electrode layer and at least one member of the spacer structure population comprised by each respective member of the unit cell population subset.Type: ApplicationFiled: May 15, 2023Publication date: September 21, 2023Inventors: JEREMIE J. DALTON, ROBERT S. BUSACCA, ASHOK LAHIRI, BENJAMIN L. CARDOZO, BRUNO A. VALDES, KIM HAN LEE, ANTHONY CALCATERRA, MURALI RAMASUBRAMANIAN
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Patent number: 11699830Abstract: A secondary battery includes an electrode assembly disposed within a constraint. The electrode assembly comprises a population of unit cells comprising an electrode current collector layer, an electrode layer, a separator layer, a counter-electrode layer, and a counter-electrode current collector layer in stacked succession. A subset of the unit cell population includes extended spacer members between the electrode current collector layer and the counter-electrode current collector layer. One of the spacer members is spaced in a transverse direction from the other extended spacer member, at least a portion of the counter-electrode active material of the counter-electrode layer being located between the spacer members such that the portion of the counter-electrode active material and the spacer members lie in a common plane defined by x and z axes, wherein each of the extended spacer members extend a distance SD in the x-axis direction beyond an x-axis edge of the constraint.Type: GrantFiled: June 13, 2022Date of Patent: July 11, 2023Assignee: Enovix Operations Inc.Inventors: Robert S. Busacca, Aditya Mandalam, Jeffrey G. Buck, Anthony Calcaterra, Kim Han Lee, Prajanya Sunil Kendrekar
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Publication number: 20230187778Abstract: A secondary battery includes a constraint and an electrode assembly disposed within the constraint. The electrode assembly includes a population of unit cells including an electrode current collector layer, an electrode layer, a separator layer, a counter-electrode layer, and a counter-electrode current collector layer in stacked succession in a longitudinal direction. The electrode layer includes an electrode active material, and the counter-electrode layer includes a counter-electrode active material. One of the electrode active material and the counter-electrode material is a cathodically active material and the other of the electrode active material and the counter-electrode material is an anodically active material.Type: ApplicationFiled: January 31, 2023Publication date: June 15, 2023Inventors: Robert S. BUSACCA, Aditya MANDALAM, Jeffrey G. BUCK, Anthony CALCATERRA, Kim Han LEE, Prajanya Sunil KENDREKAR
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Patent number: 11631921Abstract: A secondary battery includes an electrode assembly disposed within a constraint. The electrode assembly comprises a population of unit cells comprising an electrode current collector layer, an electrode layer, a separator layer, a counter-electrode layer, and a counter-electrode current collector layer in stacked succession. A subset of the unit cell population includes extended spacer members between the electrode current collector layer and the counter-electrode current collector layer. One of the spacer members is spaced in a transverse direction from the other extended spacer member, at least a portion of the counter-electrode active material of the counter-electrode layer being located between the spacer members such that the portion of the counter-electrode active material and the spacer members lie in a common plane defined by x and z axes, wherein each of the extended spacer members extend a distance SD in the x-axis direction beyond an x-axis edge of the constraint.Type: GrantFiled: June 13, 2022Date of Patent: April 18, 2023Assignee: Enovix Operations Inc.Inventors: Robert S. Busacca, Aditya Mandalam, Jeffrey G. Buck, Anthony Calcaterra, Kim Han Lee, Prajanya Sunil Kendrekar
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Publication number: 20220399612Abstract: A secondary battery includes an electrode assembly disposed within a constraint. The electrode assembly comprises a population of unit cells comprising an electrode current collector layer, an electrode layer, a separator layer, a counter-electrode layer, and a counter-electrode current collector layer in stacked succession. A subset of the unit cell population includes extended spacer members between the electrode current collector layer and the counter-electrode current collector layer. One of the spacer members is spaced in a transverse direction from the other extended spacer member, at least a portion of the counter-electrode active material of the counter-electrode layer being located between the spacer members such that the portion of the counter-electrode active material and the spacer members lie in a common plane defined by x and z axes, wherein each of the extended spacer members extend a distance SD in the x-axis direction beyond an x-axis edge of the constraint.Type: ApplicationFiled: June 13, 2022Publication date: December 15, 2022Inventors: Robert S. BUSACCA, Aditya MANDALAM, Jeffrey Glenn BUCK, Anthony CALCATERRA, Kim Han LEE, Prajanya Sunil KENDREKAR
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Publication number: 20220173485Abstract: Embodiments of secondary batteries having electrode assemblies are provided. A secondary battery can comprise an electrode assembly having a stacked series of layers, the stacked series of layers having an offset between electrode and counter-electrode layers in a unit cell member of the stacked series. A set of constraints can be provided with a primary constraint system with first and second primary growth constraints separated from each other in a longitudinal direction, and connected by at least one primary connecting member, and a secondary constraint system comprises first and second secondary growth constraints separated in a second direction and connected by members of the stacked series of layers. The primary constraint system may at least partially restrain growth of the electrode assembly in the longitudinal direction, and the secondary constraint system may at least partially restrain growth in the second direction that is orthogonal to the longitudinal direction.Type: ApplicationFiled: February 17, 2022Publication date: June 2, 2022Inventors: Robert S. BUSACCA, Ashok LAHIRI, Murali RAMASUBRAMANIAN, Bruno A. VALDES, Gardner Cameron DALES, Christopher J. SPINDT, Geoffrey Matthew HO, Harrold J. RUST, III, James D. WILCOX, John F. VARNI, Kim Han LEE, Nirav S. SHAH, Richard J. CONTRERAS, Lynn VAN ERDEN, Ken S. MATSUBAYASHI, Jeremie J. DALTON, Jason Newton HOWARD, Robert Keith ROSEN, Jonathan C. DOAN, Michael J. ARMSTRONG, Anthony CALCATERRA, Benjamin L. CARDOZO, Joshua David WINANS, Neelam SINGH, Jeffrey Glenn BUCK, Thomas John SCHUERLEIN, Kim Lester FORTUNATI, Neal SARSWAT
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Publication number: 20220123370Abstract: Embodiments of a method for the preparation of an electrode assembly, include removing a population of negative electrode subunits from a negative electrode sheet, the negative electrode sheet comprising a negative electrode sheet edge margin and at least one negative electrode sheet weakened region that is internal to the negative electrode sheet edge margin, removing a population of separator layer subunits from a separator sheet, and removing a population of positive electrode subunits from a positive electrode sheet, the positive electrode sheet comprising a positive electrode edge margin and at least one positive electrode sheet weakened region that is internal to the positive electrode sheet edge margin, and stacking members of the negative electrode subunit population, the separator layer subunit population and the positive electrode subunit population in a stacking direction to form a stacked population of unit cells.Type: ApplicationFiled: December 27, 2021Publication date: April 21, 2022Inventors: Robert S. BUSACCA, Ashok LAHIRI, Murali RAMASUBRAMANIAN, Bruno A. VALDES, Gardner Cameron DALES, Harrold J. RUST, III, John F. VARNI, Kim Han LEE, Nirav S. SHAH, Richard J. CONTRERAS, Jeremie J. DALTON, Jonathan C. DOAN, Michael J. ARMSTRONG, Anthony CALCATERRA, Benjamin J. CARDOZO, Joshua David WINANS, Neelam SINGH, Jeffrey Glenn BUCK, Thomas John SCHUERLEIN, Kim Lester FORTUNATI, Neal SARSWAT
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Publication number: 20220115753Abstract: Secondary batteries and methods of manufacture thereof are provided. A secondary battery can comprise an offset between electrode and counter-electrode layers in a unit cell. Secondary batteries can be prepared by removing a population of negative electrode subunits from a negative electrode sheet, the negative electrode sheet comprising a negative electrode sheet edge margin and at least one negative electrode sheet weakened region that is internal to the negative electrode sheet edge margin, removing a population of separator layer subunits from a separator sheet, and removing a population of positive electrode subunits from a positive electrode sheet, the positive electrode sheet comprising a positive electrode edge margin and at least one positive electrode sheet weakened region that is internal to the positive electrode sheet edge margin, and stacking members of the negative electrode subunit population, the separator layer subunit population and the positive electrode subunit population.Type: ApplicationFiled: October 19, 2021Publication date: April 14, 2022Inventors: Robert S. BUSACCA, Ashok LAHIRI, Murali RAMASUBRAMANIAN, Bruno A. VALDES, Gardner Cameron DALES, Christopher J. SPINDT, Geoffrey Matthew HO, Harrold J. RUST, III, James D. WILCOX, John F. VARNI, Kim Han LEE, Nirav S. SHAH, Richard J. CONTRERAS, Lynn VAN ERDEN, Ken S. MATSUBAYASHI, Jeremie J. DALTON, Jason Newton HOWARD, Robert Keith ROSEN, Jonathan C. DOAN, Michael J. ARMSTRONG, Anthony CALCATERRA, Benjamin L. CARDOZO, Joshua David WINANS, Neelam SINGH, Jeffrey Glenn BUCK, Thomas John SCHUERLEIN, Kim Lester FORTUNATI, Neal SARSWAT
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Publication number: 20220069421Abstract: Secondary batteries and methods of manufacture thereof are provided. A secondary battery can comprise an electrode layer comprising a population of spacer structures comprising a material other than the electrode active material, wherein (a) the spacer population occupies a total volume within the electrode layer within the range of about 0.1% to about 35% of the volume, VE, of the electrode layer, and (b) a member of the spacer population is located within each subvolume of the electrode layer comprising (i) at least 25% of the volume, VE, of the electrode layer, and (ii) bounded on all sides by (aa) the unit cell portion of the electrode current collector, (bb) the separator layer, (cc) the top surface of the electrode layer, (dd) the bottom surface of the electrode layer, (ee) the first end surface of the electrode layer, and (ff) the second end surface of the electrode layer.Type: ApplicationFiled: November 12, 2021Publication date: March 3, 2022Inventors: Jeremie J. DALTON, Robert S. BUSACCA, Ashok LAHIRI, RAMASUBRAMANIAN RAMASUBRAMANIAN, Bruno A. VALDES, Kim Han LEE, Anthony CALCATERRA, Benjamin L. CARDOZO
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Patent number: 11264680Abstract: Embodiments of secondary batteries having electrode assemblies are provided. A secondary battery can comprise an electrode assembly having a stacked series of layers, the stacked series of layers having an offset between electrode and counter-electrode layers in a unit cell member of the stacked series. A set of constraints can be provided with a primary constraint system with first and second primary growth constraints separated from each other in a longitudinal direction, and connected by at least one primary connecting member, and a secondary constraint system comprises first and second secondary growth constraints separated in a second direction and connected by members of the stacked series of layers. The primary constraint system may at least partially restrain growth of the electrode assembly in the longitudinal direction, and the secondary constraint system may at least partially restrain growth in the second direction that is orthogonal to the longitudinal direction.Type: GrantFiled: November 15, 2018Date of Patent: March 1, 2022Assignee: ENOVIX CORPORATIONInventors: Robert S. Busacca, Ashok Lahiri, Murali Ramasubramanian, Bruno A. Valdes, Gardner Cameron Dales, Christopher J. Spindt, Geoffrey Matthew Ho, Harrold J. Rust, III, James D. Wilcox, John F. Varni, Kim Han Lee, Nirav S. Shah, Richard J. Contreras, Lynn Van Erden, Ken S. Matsubayashi, Jeremie J. Dalton, Jason Newton Howard, Robert Keith Rosen, Jonathan C. Doan, Michael J. Armstrong, Anthony Calcaterra, Benjamin L. Cardozo, Joshua David Winans, Neelam Singh, Jeffrey Glenn Buck, Thomas John Schuerlein, Kim Lester Fortunati, Neal Sarswat
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Patent number: 11211639Abstract: Embodiments of a method for the preparation of an electrode assembly, include removing a population of negative electrode subunits from a negative electrode sheet, the negative electrode sheet comprising a negative electrode sheet edge margin and at least one negative electrode sheet weakened region that is internal to the negative electrode sheet edge margin, removing a population of separator layer subunits from a separator sheet, and removing a population of positive electrode subunits from a positive electrode sheet, the positive electrode sheet comprising a positive electrode edge margin and at least one positive electrode sheet weakened region that is internal to the positive electrode sheet edge margin, and stacking members of the negative electrode subunit population, the separator layer subunit population and the positive electrode subunit population in a stacking direction to form a stacked population of unit cells.Type: GrantFiled: August 6, 2019Date of Patent: December 28, 2021Assignee: ENOVIX CORPORATIONInventors: Robert S. Busacca, Ashok Lahiri, Murali Ramasubramanian, Bruno A. Valdes, Gardner Cameron Dales, Harrold J. Rust, III, John F. Varni, Kim Han Lee, Nirav S. Shah, Richard J. Contreras, Jeremie J. Dalton, Jonathan C. Doan, Michael J. Armstrong, Anthony Calcaterra, Benjamin J. Cardozo, Joshua David Winans, Neelam Singh, Jeffrey Glenn Buck, Thomas John Schuerlein, Kim Lester Fortunati, Neal Sarswat
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Patent number: 11128020Abstract: Secondary batteries and methods of manufacture thereof are provided. A secondary battery can comprise an offset between electrode and counter-electrode layers in a unit cell. Secondary batteries can be prepared by removing a population of negative electrode subunits from a negative electrode sheet, the negative electrode sheet comprising a negative electrode sheet edge margin and at least one negative electrode sheet weakened region that is internal to the negative electrode sheet edge margin, removing a population of separator layer subunits from a separator sheet, and removing a population of positive electrode subunits from a positive electrode sheet, the positive electrode sheet comprising a positive electrode edge margin and at least one positive electrode sheet weakened region that is internal to the positive electrode sheet edge margin, and stacking members of the negative electrode subunit population, the separator layer subunit population and the positive electrode subunit population.Type: GrantFiled: November 15, 2018Date of Patent: September 21, 2021Assignee: Enovix CorporationInventors: Robert S. Busacca, Ashok Lahiri, Murali Ramasubramanian, Bruno A. Valdes, Gardner Cameron Dales, Christopher J. Spindt, Geoffrey Matthew Ho, Harrold J. Rust, III, James D. Wilcox, John F. Varni, Kim Han Lee, Nirav S. Shah, Richard J. Contreras, Lynn Van Erden, Ken S. Matsubayashi, Jeremie J. Dalton, Jason Newton Howard, Robert Keith Rosen, Jonathan C. Doan, Michael J. Armstrong, Anthony Calcaterra, Benjamin L. Cardozo, Joshua David Winans, Neelam Singh, Jeffrey Glenn Buck, Thomas John Schuerlein, Kim Lester Fortunati, Neal Sarswat
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Publication number: 20200350633Abstract: Secondary batteries and methods of manufacture thereof are provided. A secondary battery can comprise an offset between electrode and counter-electrode layers in a unit cell. Secondary batteries can be prepared by removing a population of negative electrode subunits from a negative electrode sheet, the negative electrode sheet comprising a negative electrode sheet edge margin and at least one negative electrode sheet weakened region that is internal to the negative electrode sheet edge margin, removing a population of separator layer subunits from a separator sheet, and removing a population of positive electrode subunits from a positive electrode sheet, the positive electrode sheet comprising a positive electrode edge margin and at least one positive electrode sheet weakened region that is internal to the positive electrode sheet edge margin, and stacking members of the negative electrode subunit population, the separator layer subunit population and the positive electrode subunit population.Type: ApplicationFiled: November 15, 2018Publication date: November 5, 2020Inventors: Robert S. BUSACCA, Ashok LAHIRI, Murali RAMASUBRAMANIAN, Bruno A. VALDES, Gardner Cameron DALES, Christopher J. SPINDT, Geoffrey Matthew HO, Harrold J. RUST, III, James D. WILCOX, John F. VARNI, Kim Han LEE, Nirav S. SHAH, Richard J. CONTRERAS, Lynn VAN ERDEN, Ken S. MATSUBAYASHI, Jeremie J. DALTON, Jason Newton HOWARD, Robert Keith ROSEN, Jonathan C. DOAN, Michael J. ARMSTRONG, Anthony CALCATERRA, Benjamin L. CARDOZO, Joshua David WINANS, Neelam SINGH, Jeffrey Glenn BUCK, Thomas John SCHUERLEIN, Kim Lester FORTUNATI, Neal SARSWAT
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Publication number: 20200313146Abstract: Embodiments of secondary batteries having electrode assemblies are provided. A secondary battery can comprise an electrode assembly having a stacked series of layers, the stacked series of layers having an offset between electrode and counter-electrode layers in a unit cell member of the stacked series. A set of constraints can be provided with a primary constraint system with first and second primary growth constraints separated from each other in a longitudinal direction, and connected by at least one primary connecting member, and a secondary constraint system comprises first and second secondary growth constraints separated in a second direction and connected by members of the stacked series of layers. The primary constraint system may at least partially restrain growth of the electrode assembly in the longitudinal direction, and the secondary constraint system may at least partially restrain growth in the second direction that is orthogonal to the longitudinal direction.Type: ApplicationFiled: November 15, 2018Publication date: October 1, 2020Inventors: Robert S. BUSACCA, Ashok LAHIRI, Murali RAMASUBRAMANIAN, Bruno A. VALDES, Gardner Cameron DALES, Christopher J. SPINDT, Geoffrey Matthew HO, Harrold J. RUST, III, James D. WILCOX, John F. VARNI, Kim Han LEE, Nirav S. SHAH, Richard J. CONTRERAS, Lynn VAN ERDEN, Ken S. MATSUBAYASHI, Jeremie J. DALTON, Jason Newton HOWARD, Robert Keith ROSEN, Jonathan C. DOAN, Michael J. ARMSTRONG, Anthony CALCATERRA, Benjamin L. CARDOZO, Joshua David WINANS, Neelam SINGH, Jeffrey Glenn BUCK, Thomas John SCHUERLEIN, Kim Lester FORTUNATI, Neal SARSWAT
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Publication number: 20200212493Abstract: Embodiments of a method for the preparation of an electrode assembly, include removing a population of negative electrode subunits from a negative electrode sheet, the negative electrode sheet comprising a negative electrode sheet edge margin and at least one negative electrode sheet weakened region that is internal to the negative electrode sheet edge margin, removing a population of separator layer subunits from a separator sheet, and removing a population of positive electrode subunits from a positive electrode sheet, the positive electrode sheet comprising a positive electrode edge margin and at least one positive electrode sheet weakened region that is internal to the positive electrode sheet edge margin, and stacking members of the negative electrode subunit population, the separator layer subunit population and the positive electrode subunit population in a stacking direction to form a stacked population of unit cells.Type: ApplicationFiled: August 6, 2019Publication date: July 2, 2020Inventors: Robert S. BUSACCA, Ashok LAHIRI, Murali RAMASUBRAMANIAN, Bruno A. VALDES, Gardner Cameron DALES, Harrold J. RUST, III, John F. VARNI, Kim Han LEE, Nirav S. SHAH, Richard J. CONTRERAS, Jeremie J. DALTON, Jonathan C. DOAN, Michael J. ARMSTRONG, Anthony CALCATERRA, Benjamin J. CARDOZO, Joshua David WINANS, Neelam SINGH, Jeffrey Glenn BUCK, Thomas John SCHUERLEIN, Kim Lester FORTUNATI, Neal SARSWAT
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Patent number: 10181535Abstract: Fabrication methods and structures relating to backplanes for back contact solar cells that provide for solar cell substrate reinforcement and electrical interconnects are described. The method comprises depositing an interdigitated pattern of base electrodes and emitter electrodes on a backside surface of a semiconductor substrate, forming electrically conductive emitter plugs and base plugs on the interdigitated pattern, and attaching a backplane having a second interdigitated pattern of base electrodes and emitter electrodes at the conductive emitter and base plugs to form electrical interconnects.Type: GrantFiled: February 2, 2015Date of Patent: January 15, 2019Assignee: Tesla, Inc.Inventors: Mehrdad M. Moslehi, David Xuan-Qi Wang, Karl-Josef Kramer, Sean M. Seutter, Sam Tone Tor, Anthony Calcaterra
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Patent number: 9842949Abstract: Fabrication methods and structures relating to backplanes for back contact solar cells that provide for solar cell substrate reinforcement and electrical interconnects as well as Fabrication methods and structures for forming thin film back contact solar cells are described.Type: GrantFiled: August 9, 2012Date of Patent: December 12, 2017Assignee: OB REALTY, LLCInventors: Mehrdad M. Moslehi, Pawan Kapur, K.-Josef Kramer, Virendra V. Rana, Sean Seutter, Anand Deshpande, Anthony Calcaterra, Gerry Olsen, Kamran Manteghi, Thom Stalcup, George D. Kamian, David Xuan-Qi Wang, Yen-Sheng Su, Michael Wingert