Patents by Inventor David Tanner
David Tanner 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: 20130233379Abstract: Embodiments of the invention generally relate to solar cells having reduced carrier recombination and methods of forming the same. The solar cells have eutectic local contacts and passivation layers which reduce recombination by facilitating formation of a back surface field (BSF). A patterned aluminum back contact is disposed on the passivation layer for removing current form the solar cell. The patterned back contact reduces the cost-per-watt of the solar cell by using less material than a full-surface back contact. The methods of forming the solar cells include depositing a passivation layer including aluminum oxide and silicon nitride on a back surface of a solar cell, and then forming openings through the passivation layer. A patterned aluminum back contact is disposed on the passivation layer over the holes, and thermally processed to form a silicon-aluminum eutectic within the openings.Type: ApplicationFiled: March 4, 2013Publication date: September 12, 2013Inventors: David Tanner, Prabhat Kumar
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Publication number: 20130199606Abstract: Embodiments of the present invention are directed to a process for making solar cells. In one embodiment, a method of manufacturing a solar cell device, includes providing a substrate having a first surface and a second surface, selectively disposing a first metal paste in a first pattern on the first surface of the substrate, forming a first dielectric layer over the first metal paste on the first surface of the substrate, forming a second metal paste in a second pattern over the first dielectric layer align with the first metal paste, and simultaneously heating the first and the second metal pastes disposed on the first surface of the substrate to form a first group of contacts on the first surface of the substrate, wherein at least a portion of the second metal paste forms the first group of contacts that each extend through the first dielectric layer to connect with the first metal paste to the first surface of the substrate.Type: ApplicationFiled: February 6, 2012Publication date: August 8, 2013Applicant: APPLIED MATERIALS, INC.Inventors: Shuran Sheng, Lin Zhang, David Tanner, Xuesong Lu
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Patent number: 8361835Abstract: Embodiments disclosed herein generally relate to a process of depositing a transparent conductive oxide layer over a substrate. The transparent oxide layer is sometimes deposited onto a substrate for later use in a solar cell device. The transparent conductive oxide layer may be deposited by a “cold” sputtering process. In other words, during the sputtering process, a plasma is ignited in the processing chamber which naturally heats the substrate. No additional heat is provided to the substrate during deposition such as from the susceptor. After the transparent conductive oxide layer is deposited, the substrate may be annealed and etched, in either order, to texture the transparent conductive oxide layer. In order to tailor the shape of the texturing, different wet etch chemistries may be utilized. The different etch chemistries may be used to shape the surface of the transparent conductive oxide and the etch rate.Type: GrantFiled: March 29, 2010Date of Patent: January 29, 2013Assignee: Applied Materials, Inc.Inventors: Valery V. Komin, Hien-Minh Huu Le, David Tanner, James S. Papanu, Philip A. Greene, Suresh M. Shrauti, Roman Gouk, Steven Verhaverbeke
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Patent number: 8349626Abstract: A novel method is described to create low-relief texture at a light-facing surface or a back surface of a photovoltaic cell. The peak-to-valley height and average peak-to-peak distance of the textured surface is less than about 1 microns, for example less than about 0.8 micron, for example about 0.5 microns or less. In a completed photovoltaic device, average reflectance for light having wavelength between 375 and 1010 nm at a light-facing surface with this texture is 6 percent or less, for example about 5 percent or less, in some instances about 3.5 percent. This texture is produced by forming an optional oxide layer at the surface, lightly buffing the surface, and etching with a crystallographically selective etch. Excellent texture may be produced by etching for as little as twelve minutes or less. Very little silicon, for example about 0.3 mg/cm2 or less, is lost at the textured surface during this etch.Type: GrantFiled: March 23, 2010Date of Patent: January 8, 2013Assignee: GTAT CorporationInventors: Zhiyong Li, David Tanner, Gopalakrishna Prabhu, Mohamed H. Hilali
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Patent number: 8333843Abstract: The present disclosure relates to methods and related cleaning solutions (116) for cleaning a glass substrate (10, 112), such as for removing metal ion contaminates from a glass substrate (10, 112) having a transparent conductive oxide layer (12). One method includes: providing a glass substrate (10, 112) having a transparent conductive oxide (TCO) layer (12); and exposing the glass substrate (10, 112) to a cleaning solution (116) that includes 0.5% to 5% organic acid, wherein the organic acid used includes citric acid, acetic acid, or oxalic acid.Type: GrantFiled: April 16, 2009Date of Patent: December 18, 2012Assignee: Applied Materials, Inc.Inventors: Fang Mei, David Tanner
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Patent number: 8318589Abstract: Embodiments disclosed herein generally relate to a process of depositing a transparent conductive oxide layer over a substrate. The transparent oxide layer is sometimes deposited onto a substrate for later use in a solar cell device. The transparent conductive oxide layer may be deposited by a “cold” sputtering process. In other words, during the sputtering process, a plasma is ignited in the processing chamber which naturally heats the substrate. No additional heat is provided to the substrate during deposition such as from the susceptor. After the transparent conductive oxide layer is deposited, the substrate may be annealed and etched, in either order, to texture the transparent conductive oxide layer. In order to tailor the shape of the texturing, different wet etch chemistries may be utilized. The different etch chemistries may be used to shape the surface of the transparent conductive oxide and the etch rate.Type: GrantFiled: March 29, 2010Date of Patent: November 27, 2012Assignee: Applied Materials, Inc.Inventors: Valery V. Komin, Hien-Minh Huu Le, David Tanner, James S. Papanu, Philip A. Greene, Suresh M. Shrauti, Roman Gouk, Steven Verhaverbeke
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Publication number: 20120270359Abstract: Embodiments of the present invention relate to a single step diffusion process used in selective emitter solar cell fabrication. In one embodiment, a dopant paste is selectively applied on a front surface of a substrate having opposite conductivity type from the dopant paste. The substrate is then exposed to a dopant containing vapor to deposit a doping layer having opposite conductivity type from the substrate on the front surface of the substrate. While the substrate is exposed to the dopant containing vapor, a portion of the dopant paste also contribute to deposition of the doping layer via gas phase transport of doping atoms from the dopant paste. The substrate is then heated in an atmosphere comprising oxygen and/or nitrogen to a temperature sufficient to cause the dopant atoms in the dopant paste and the doping layer to diffuse into the substrate, forming heavily and lightly doped emitter regions.Type: ApplicationFiled: February 27, 2012Publication date: October 25, 2012Applicant: APPLIED MATERIALS, INC.Inventors: PRABHAT KUMAR, Jason Dominguez, David Tanner
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Patent number: 8252624Abstract: A method and apparatus for forming solar cells is provided. In one embodiment, a photovoltaic device includes a antireflection coating layer disposed on a first surface of a substrate, a barrier layer disposed on a second surface of the substrate, a first transparent conductive oxide layer disposed on the barrier layer, a conductive contact layer disposed on the first transparent conductive oxide layer, a first p-i-n junction formed on the conductive contact layer, and a second transparent conductive oxide layer formed on the first p-i-n junction.Type: GrantFiled: December 28, 2010Date of Patent: August 28, 2012Assignee: Applied Materials, Inc.Inventors: David Tanner, Hien-Minh Huu Le, Quancheng (Tommy) Gu, Shuran Sheng, Yong Kee Chae, Tzay-Fa (Jeff) Su, Dapeng Wang
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Patent number: 8225496Abstract: The present invention generally relates to a system that can be used to form a photovoltaic device, or solar cell, using processing modules that are adapted to perform one or more steps in the solar cell formation process. The automated solar cell fab is generally an arrangement of automated processing modules and automation equipment that is used to form solar cell devices. The automated solar fab will thus generally comprise a substrate receiving module that is adapted to receive a substrate, one or more absorbing layer deposition cluster tools having at least one processing chamber that is adapted to deposit a silicon-containing layer on a surface of the substrate, one or more back contact deposition chambers, one or more material removal chambers, a solar cell encapsulation device, an autoclave module, an automated junction box attaching module, and one or more quality assurance modules that are adapted to test and qualify the completely formed solar cell device.Type: GrantFiled: August 29, 2008Date of Patent: July 24, 2012Assignee: Applied Materials, Inc.Inventors: Robert Z. Bachrach, Yong-Kee Chae, Soo Young Choi, Nicholas G. J. De Vries, Yacov Elgar, Eric A. Englhardt, Michel R. Frei, Charles Gay, Parris Hawkins, Choi (Gene) Ho, James Craig Hunter, Penchala N. Kankanala, Liwei Li, Wing Hoo (Hendrick) Lo, Danny Cam Toan Lu, Fang Mei, Stephen P. Murphy, Srujal (Steve) Patel, Matthew J. B. Saunders, Asaf Schlezinger, Shuran Sheng, Tzay-Fa (Jeff) Su, Jeffrey S. Sullivan, David Tanner, Teresa Trowbridge, Brice Walker, John M. White, Tae K. Won
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Publication number: 20120123941Abstract: A system and method for fraud prevention is provided. The computer based system and method comprises receiving a request for verification services by a merchant transmitted via an Internet browser based platform, performing a fraud assessment by a verification services tool resulting in a verification message, and transmitting a reply to the merchant via an Internet browser based platform including a verification message.Type: ApplicationFiled: November 17, 2010Publication date: May 17, 2012Applicant: American Express Travel Related Services Company, Inc.Inventors: Charlie Kimes, Clint Lowry, Romit Misra, David Tanner
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Patent number: 8138782Abstract: Embodiments of the present invention relate to a solar simulator module of a solar cell production line. In one embodiment the solar simulator receives a solar cell module in a horizontal position and reorients the module into a vertical position. A light source is oriented to emit a flash of light in a substantially horizontal orientation toward the vertically oriented solar cell module. In one embodiment, an automated labeling device affixes a label including the electrical characteristics measured onto a back surface of the solar cell module. In one embodiment, a plurality of solar cell modules are received and tested simultaneously.Type: GrantFiled: January 9, 2009Date of Patent: March 20, 2012Assignee: Applied Materials, Inc.Inventors: Yacov Elgar, Danny Cam Toan Lu, Tzay-Fa Su, Jeffrey S. Sullivan, David Tanner, Harry Whitesell
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Publication number: 20110314672Abstract: The present invention generally relates to an automated solar cell electrical connection device that is positioned within an automated solar cell fabrication system. The automated solar cell electrical connection device includes a module and process for automatically attaching a junction box to a composite solar cell structure during the fabrication of a completed solar cell device.Type: ApplicationFiled: August 30, 2011Publication date: December 29, 2011Applicant: APPLIED MATERIALS, INC.Inventors: DANNY CAM TOAN LU, Jeffrey S. Sullivan, David Tanner, Yacov Elgar
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Patent number: 8065784Abstract: Embodiments of the present invention provide a module and process for forming electrical connections on a solar cell substrate in a solar cell production line. The module generally provides a substrate handling system, a substrate positioning system, a cross-buss attachment assembly, and a side-buss attachment assembly. The module may provide adaptations for automatically adjusting the module to receive and process various sizes of solar cell substrates.Type: GrantFiled: February 27, 2009Date of Patent: November 29, 2011Assignee: Applied Materials, Inc.Inventors: Danny Cam Toan Lu, Yacov Elgar, Jeffrey S. Sullivan, David Tanner
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Publication number: 20110237013Abstract: A novel method is described to create low-relief texture at a light-facing surface or a back surface of a photovoltaic cell. The peak-to-valley height and average peak-to-peak distance of the textured surface is less than about 1 microns, for example less than about 0.8 micron, for example about 0.5 microns or less. In a completed photovoltaic device, average reflectance for light having wavelength between 375 and 1010 nm at a light-facing surface with this texture is 6 percent or less, for example about 5 percent or less, in some instances about 3.5 percent. This texture is produced by forming an optional oxide layer at the surface, lightly buffing the surface, and etching with a crystallographically selective etch. Excellent texture may be produced by etching for as little as twelve minutes or less. Very little silicon, for example about 0.3 mg/cm2 or less, is lost at the textured surface during this etch.Type: ApplicationFiled: March 23, 2010Publication date: September 29, 2011Applicant: TWIN CREEKS TECHNOLOGIES, INC.Inventors: Zhiyong Li, David Tanner, Gopalakrishna Prabhu, Mohamed H. Hilali
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Patent number: 8024854Abstract: The present invention generally relates to an automated solar cell electrical connection device that is positioned within an automated solar cell fabrication system. The automated solar cell electrical connection device includes a module and process for automatically attaching a junction box to a composite solar cell structure during the fabrication of a completed solar cell device.Type: GrantFiled: January 23, 2009Date of Patent: September 27, 2011Assignee: Applied Materials, Inc.Inventors: Danny Cam Toan Lu, Jeffrey S. Sullivan, David Tanner, Yacov Elgar
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Publication number: 20110180122Abstract: A photovoltaic device is provided. In one embodiment, a photovoltaic device includes a transparent conductive oxide (TCO) layer deposited over the substrate, and a plurality of electrical conductive paths disposed in electrical contact with the TCO layer, wherein the plurality of electrical conductive paths extend discontinuously across opposing sides of the substrate.Type: ApplicationFiled: January 26, 2010Publication date: July 28, 2011Applicant: APPLIED MATERIALS, INC.Inventors: David Tanner, Hien-minh Huu Le, Tzay-fa Su, Dapeng Wang
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Publication number: 20110174362Abstract: A method and apparatus for forming solar cells is provided. In one embodiment, a photovoltaic device includes a antireflection coating layer disposed on a first surface of a substrate, a barrier layer disposed on a second surface of the substrate, a first transparent conductive oxide layer disposed on the barrier layer, a conductive contact layer disposed on the first transparent conductive oxide layer, a first p-i-n junction formed on the conductive contact layer, and a second transparent conductive oxide layer formed on the first p-i-n junction.Type: ApplicationFiled: December 28, 2010Publication date: July 21, 2011Applicant: Applied Materials, Inc.Inventors: David Tanner, Hien-Minh Huu Le, Quancheng (Tommy) Gu, Shuran Sheng, Yong Kee Chae, Tzay-Fa (Jeff) Su, Dapeng Wang
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Publication number: 20110177648Abstract: A method and apparatus for forming solar cells is provided. In one embodiment, a photovoltaic device includes a antireflection coating layer disposed on a first surface of a substrate, a barrier layer disposed on a second surface of the substrate, a first transparent conductive oxide layer disposed on the barrier layer, a conductive contact layer disposed on the first transparent conductive oxide layer, a first p-i-n junction formed on the conductive contact layer, and a second transparent conductive oxide layer formed on the first p-i-n junction.Type: ApplicationFiled: December 28, 2010Publication date: July 21, 2011Applicant: Applied Materials, Inc.Inventors: David Tanner, Hien-Minh Huu Le, Quancheng (Tommy) Gu, Shuran Sheng, Yong Kee Chae, Tzay-Fa (Jeff) Su, Dapeng Wang
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Publication number: 20110162704Abstract: A method and apparatus for forming a protective coating on a photovoltaic device is provided. The photovoltaic device is formed by depositing photoelectric conversion units on a substrate, and by forming conductive layers and contacts on the photoelectric conversion units. The protective coating is formed by a deposition process, such as physical or chemical vapor deposition.Type: ApplicationFiled: December 10, 2010Publication date: July 7, 2011Applicant: APPLIED MATERIALS, INC.Inventors: Hien-Minh Huu Le, Mohd Fadzli Anwar Hassan, David Tanner
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Publication number: 20110126875Abstract: Methods for sputter depositing a transparent conductive layer and a conductive contact layer are provided in the present invention. In one embodiment, the method includes forming a transparent conductive layer on a substrate by materials sputtered from a first target disposed in a reactive sputter chamber, and forming a conductive contact layer on the transparent conductive layer by materials sputtered from a second target disposed in the reactive sputter chamber.Type: ApplicationFiled: December 1, 2009Publication date: June 2, 2011Inventors: Hien-Minh Huu Le, Valery V. Komin, David Tanner, Mohd Fadzli Anwar Hassan, Tzay-Fa Su, Dapeng Wang