Patents by Inventor David Aaron Randolph Barkhouse

David Aaron Randolph Barkhouse 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).

  • Publication number: 20190312163
    Abstract: Metallization of semiconductor substrates using a laser beam, and the resulting structures, e.g., micro-electronic devices, semiconductor substrates and/or solar cells, solar cell circuit, solar cell strings, and solar cell arrays are described. A solar cell string can include a plurality of solar cells. The plurality of solar cells can include a substrate and a plurality of semiconductor regions disposed in or above the substrate. A plurality of conductive contact structures is electrically connected to the plurality semiconductor regions. Each conductive contact structure includes a locally deposited metal portion disposed in contact with a corresponding one of the semiconductor regions.
    Type: Application
    Filed: April 5, 2019
    Publication date: October 10, 2019
    Inventors: Pei Hsuan Lu, Benjamin I. Hsia, David Aaron Randolph Barkhouse, Lewis C. Abra, George G. Correos, Marc Robinson, Paul W. Loscutoff, Ryan Reagan, David Okawa, Tamir Lance, Thierry Nguyen
  • Publication number: 20190312166
    Abstract: A method of fabricating solar cell, solar laminate and/or solar module string is provided. The method may include: locating a metal foil over a plurality of semiconductor substrates; exposing the metal foil to laser beam over selected portions of the plurality of semiconductor substrates, wherein exposing the metal foil to the laser beam forms a plurality conductive contact structures having of locally deposited metal portion electrically connecting the metal foil to the semiconductor substrates at the selected portions; and selectively removing portions of the metal foil, wherein remaining portions of the metal foil extend between at least two of the plurality of semiconductor substrates.
    Type: Application
    Filed: April 5, 2019
    Publication date: October 10, 2019
    Inventors: Pei Hsuan Lu, Benjamin I. Hsia, David Aaron Randolph Barkhouse, David C. Okawa, David F. Kavulak, Lewis C. Abra, George G. Correos, Richard Hamilton Sewell, Ryan Reagan, Tamir Lance, Thierry Nguyen
  • Publication number: 20190305167
    Abstract: Wire-based metallization and stringing techniques for solar cells, and the resulting solar cells, modules, and equipment, are described. In an example, a substrate has a surface. A plurality of N-type and P-type semiconductor regions is disposed in or above the surface of the substrate. A conductive contact structure is disposed on the plurality of N-type and P-type semiconductor regions. The conductive contact structure includes a plurality of conductive wires, each conductive wire of the plurality of conductive wires essentially continuously bonded directly to a corresponding one of the N-type and P-type semiconductor regions.
    Type: Application
    Filed: March 29, 2019
    Publication date: October 3, 2019
    Inventors: Richard Hamilton Sewell, David Aaron Randolph Barkhouse, Douglas Rose, Lewis Abra
  • Publication number: 20190074400
    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 forming a first cut portion from a conductive foil. The method can also include aligning the first cut portion to a first doped region of a first semiconductor substrate. The method can include bonding the first cut portion to the first doped region of the first semiconductor substrate. The method can also include aligning and bonding a plurality of cut portions of the conductive foil to a plurality of semiconductor substrates.
    Type: Application
    Filed: October 29, 2018
    Publication date: March 7, 2019
    Inventors: Richard Hamilton Sewell, David Aaron Randolph Barkhouse
  • Publication number: 20180358481
    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: Application
    Filed: August 21, 2018
    Publication date: December 13, 2018
    Inventors: Richard Hamilton Sewell, David Aaron Randolph Barkhouse, Nils-Peter Harder, Douglas Rose
  • Patent number: 10115855
    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 forming a first cut portion from a conductive foil. The method can also include aligning the first cut portion to a first doped region of a first semiconductor substrate. The method can include bonding the first cut portion to the first doped region of the first semiconductor substrate. The method can also include aligning and bonding a plurality of cut portions of the conductive foil to a plurality of semiconductor substrates.
    Type: Grant
    Filed: September 30, 2016
    Date of Patent: October 30, 2018
    Assignee: SunPower Corporation
    Inventors: Richard Hamilton Sewell, David Aaron Randolph Barkhouse
  • Patent number: 10109755
    Abstract: Techniques for fabrication of kesterite Cu—Zn—Sn—(Se,S) films and improved photovoltaic devices based on these films are provided. In one aspect, a method of fabricating a kesterite film having a formula Cu2?xZn1+ySn(S1?zSez)4+q, wherein 0?x?1; 0?y?1; 0?z?1; and ?1?q?1 is provided. The method includes the following steps. A substrate is provided. A bulk precursor layer is formed on the substrate, the bulk precursor layer comprising Cu, Zn, Sn and at least one of S and Se. A capping layer is formed on the bulk precursor layer, the capping layer comprising at least one of Sn, S and Se. The bulk precursor layer and the capping layer are annealed under conditions sufficient to produce the kesterite film having values of x, y, z and q for any given part of the film that deviate from average values of x, y, z and q throughout the film by less than 20 percent.
    Type: Grant
    Filed: May 26, 2016
    Date of Patent: October 23, 2018
    Assignee: International Business Machines Corporation
    Inventors: Santanu Bag, David Aaron Randolph Barkhouse, David Brian Mitzi, Teodor Krassimirov Todorov
  • Patent number: 10084098
    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: September 30, 2016
    Date of Patent: September 25, 2018
    Assignees: SunPower Corporation, Total Marketing Services and Total Energies Nouvelles Activities USA
    Inventors: Richard Hamilton Sewell, David Aaron Randolph Barkhouse, Nils-Peter Harder, Douglas Rose
  • Publication number: 20180097141
    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 forming a first cut portion from a conductive foil. The method can also include aligning the first cut portion to a first doped region of a first semiconductor substrate. The method can include bonding the first cut portion to the first doped region of the first semiconductor substrate. The method can also include aligning and bonding a plurality of cut portions of the conductive foil to a plurality of semiconductor substrates.
    Type: Application
    Filed: September 30, 2016
    Publication date: April 5, 2018
    Inventors: Richard Hamilton Sewell, David Aaron Randolph Barkhouse
  • Publication number: 20180097125
    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: Application
    Filed: September 30, 2016
    Publication date: April 5, 2018
    Inventors: Richard Hamilton Sewell, David Aaron Randolph Barkhouse, Nils-Peter Harder
  • Patent number: 9871150
    Abstract: Methods of fabricating a solar cell including metallization techniques and resulting solar cells, are described. In an example, a first and second semiconductor regions can be formed in or above a substrate, where a separation region is disposed between the first and second semiconductor regions. A protective region can be formed over the separation region. A first metal layer can be formed over the substrate, where the protective region prevents and/or inhibits damage to the separation region during the formation of the first metal layer. Conductive contacts can be formed over the first and second semiconductor regions.
    Type: Grant
    Filed: July 1, 2016
    Date of Patent: January 16, 2018
    Assignee: SunPower Corporation
    Inventors: Benjamin Ian Hsia, David Aaron Randolph Barkhouse, Todd Richards Johnson, Michael Cudzinovic
  • Publication number: 20180006170
    Abstract: Methods of fabricating a solar cell including metallization techniques and resulting solar cells, are described. In an example, a first and second semiconductor regions can be formed in or above a substrate, where a separation region is disposed between the first and second semiconductor regions. A protective region can be formed over the separation region. A first metal layer can be formed over the substrate, where the protective region prevents and/or inhibits damage to the separation region during the formation of the first metal layer. Conductive contacts can be formed over the first and second semiconductor regions.
    Type: Application
    Filed: July 1, 2016
    Publication date: January 4, 2018
    Inventors: Benjamin Ian Hsia, David Aaron Randolph Barkhouse, Todd Richards Johnson, Michael Cudzinovic
  • Patent number: 9768327
    Abstract: Fabricating a semiconductor device can include forming a metal seed region over a substrate. The method can include forming a mask over a first portion of the metal seed region. The method can also include forming a metal region over the metal seed region and removing the mask. The method can include forming metal contact fingers on the semiconductor device, where the forming includes etching the first portion of the metal seed region with an etchant comprising an acid, an oxidizer and chloride ions.
    Type: Grant
    Filed: June 25, 2015
    Date of Patent: September 19, 2017
    Assignees: SunPower Corporation, Total Marketing Services
    Inventors: Robert Woehl, David Aaron Randolph Barkhouse, Paul Loscutoff
  • Publication number: 20160380122
    Abstract: Fabricating a semiconductor device can include forming a metal seed region over a substrate. The method can include forming a mask over a first portion of the metal seed region. The method can also include forming a metal region over the metal seed region and removing the mask. The method can include forming metal contact fingers on the semiconductor device, where the forming includes etching the first portion of the metal seed region with an etchant comprising an acid, an oxidizer and chloride ions.
    Type: Application
    Filed: June 25, 2015
    Publication date: December 29, 2016
    Inventors: Robert Woehl, David Aaron Randolph Barkhouse, Paul Loscutoff
  • Publication number: 20160380126
    Abstract: A solar cell can include a substrate, a semiconductor region disposed in or above the substrate, and a conductive stack that includes a first conductive region, a multi-layer barrier region, and a second conductive region.
    Type: Application
    Filed: June 25, 2015
    Publication date: December 29, 2016
    Inventors: David Aaron Randolph Barkhouse, Todd Richards Johnson, Paul Loscutoff, Robert Woehl
  • Publication number: 20160276504
    Abstract: Approaches for the metallization of solar cells and the resulting solar cells are described. In an example, a method of fabricating a solar cell involves forming a barrier layer on a semiconductor region disposed in or above a substrate. The semiconductor region includes monocrystalline or polycrystalline silicon. The method also involves forming a conductive paste layer on the barrier layer. The method also involves forming a conductive layer from the conductive paste layer. The method also involves forming a contact structure for the semiconductor region of the solar cell, the contact structure including at least the conductive layer.
    Type: Application
    Filed: June 1, 2016
    Publication date: September 22, 2016
    Inventors: Richard Hamilton Sewell, David Aaron Randolph Barkhouse, Junbo Wu, Michael Cudzinovic, Paul Loscutoff, Joseph Behnke, Michel Arsène Olivier Ngamo Toko
  • Publication number: 20160276505
    Abstract: Techniques for fabrication of kesterite Cu—Zn—Sn—(Se,S) films and improved photovoltaic devices based on these films are provided. In one aspect, a method of fabricating a kesterite film having a formula Cu2?xZn1+ySn(S1?zSez)4+q, wherein 0?x?1; 0?y?1; 0?z?1; and ?1?q?1 is provided. The method includes the following steps. A substrate is provided. A bulk precursor layer is formed on the substrate, the bulk precursor layer comprising Cu, Zn, Sn and at least one of S and Se. A capping layer is formed on the bulk precursor layer, the capping layer comprising at least one of Sn, S and Se. The bulk precursor layer and the capping layer are annealed under conditions sufficient to produce the kesterite film having values of x, y, z and q for any given part of the film that deviate from average values of x, y, z and q throughout the film by less than 20 percent.
    Type: Application
    Filed: May 26, 2016
    Publication date: September 22, 2016
    Inventors: Santanu Bag, David Aaron Randolph Barkhouse, David Brian Mitzi, Teodor Krassimirov Todorov
  • Patent number: 9368660
    Abstract: Techniques for fabrication of kesterite Cu—Zn—Sn—(Se,S) films and improved photovoltaic devices based on these films are provided. In one aspect, a method of fabricating a kesterite film having a formula Cu2?xZn1+ySn(S1?zSez)4+q, wherein 0?x?1; 0?y?1; 0?z?1; and ?1?q?1 is provided. The method includes the following steps. A substrate is provided. A bulk precursor layer is formed on the substrate, the bulk precursor layer comprising Cu, Zn, Sn and at least one of S and Se. A capping layer is formed on the bulk precursor layer, the capping layer comprising at least one of Sn, S and Se. The bulk precursor layer and the capping layer are annealed under conditions sufficient to produce the kesterite film having values of x, y, z and q for any given part of the film that deviate from average values of x, y, z and q throughout the film by less than 20 percent.
    Type: Grant
    Filed: August 10, 2011
    Date of Patent: June 14, 2016
    Assignee: International Business Machines Corporation
    Inventors: Santanu Bag, David Aaron Randolph Barkhouse, David Brian Mitzi, Teodor Krassimirov Todorov
  • Patent number: 9362427
    Abstract: Approaches for the metallization of solar cells and the resulting solar cells are described. In an example, a method of fabricating a solar cell involves forming a barrier layer on a semiconductor region disposed in or above a substrate. The semiconductor region includes monocrystalline or polycrystalline silicon. The method also involves forming a conductive paste layer on the barrier layer. The method also involves forming a conductive layer from the conductive paste layer. The method also involves forming a contact structure for the semiconductor region of the solar cell, the contact structure including at least the conductive layer.
    Type: Grant
    Filed: December 20, 2013
    Date of Patent: June 7, 2016
    Assignees: SunPower Corporation, Total Marketing Services
    Inventors: Richard Hamilton Sewell, David Aaron Randolph Barkhouse, Junbo Wu, Michael Cudzinovic, Paul Loscutoff, Joseph Behnke, Michel Arsène Olivier Ngamo Toko
  • Publication number: 20150179836
    Abstract: Approaches for the metallization of solar cells and the resulting solar cells are described. In an example, a method of fabricating a solar cell involves forming a barrier layer on a semiconductor region disposed in or above a substrate. The semiconductor region includes monocrystalline or polycrystalline silicon. The method also involves forming a conductive paste layer on the barrier layer. The method also involves forming a conductive layer from the conductive paste layer. The method also involves forming a contact structure for the semiconductor region of the solar cell, the contact structure including at least the conductive layer.
    Type: Application
    Filed: December 20, 2013
    Publication date: June 25, 2015
    Inventors: Richard Hamilton Sewell, David Aaron Randolph Barkhouse, Junbo Wu, Michael Cudzinovic, Paul Loscutoff, Joseph Behnke, Michel Arsène Olivier Ngamo Toko