Patents by Inventor Douglas H. Rose
Douglas H. Rose 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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Patent number: 11264518Abstract: A solar cell is fabricated by etching one or more of its layers without substantially etching another layer of the solar cell. In one embodiment, a copper layer in the solar cell is etched without substantially etching a topmost metallic layer comprising tin. For example, an etchant comprising sulfuric acid and hydrogen peroxide may be employed to etch the copper layer selective to the tin layer. A particular example of the aforementioned etchant is a Co-Bra Etch® etchant modified to comprise about 1% by volume of sulfuric acid, about 4% by volume of phosphoric acid, and about 2% by volume of stabilized hydrogen peroxide. In one embodiment, an aluminum layer in the solar cell is etched without substantially etching the tin layer. For example, an etchant comprising potassium hydroxide may be employed to etch the aluminum layer without substantially etching the tin layer.Type: GrantFiled: October 8, 2018Date of Patent: March 1, 2022Assignee: SunPower CorporationInventors: Douglas H. Rose, Pongsthorn Uralwong, David D. Smith
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Patent number: 10903786Abstract: In one embodiment, harmful solar cell polarization is prevented or minimized by providing a conductive path that bleeds charge from a front side of a solar cell to the bulk of a wafer. The conductive path may include patterned holes in a dielectric passivation layer, a conductive anti-reflective coating, or layers of conductive material formed on the top or bottom surface of an anti-reflective coating, for example. Harmful solar cell polarization may also be prevented by biasing a region of a solar cell module on the front side of the solar cell.Type: GrantFiled: November 20, 2018Date of Patent: January 26, 2021Assignee: SunPower CorporationInventors: Richard M. Swanson, Denis De Ceuster, Vikas Desai, Douglas H. Rose, David D. Smith, Neil Kaminar
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Publication number: 20190109560Abstract: In one embodiment, harmful solar cell polarization is prevented or minimized by providing a conductive path that bleeds charge from a front side of a solar cell to the bulk of a wafer. The conductive path may include patterned holes in a dielectric passivation layer, a conductive anti-reflective coating, or layers of conductive material formed on the top or bottom surface of an anti-reflective coating, for example. Harmful solar cell polarization may also be prevented by biasing a region of a solar cell module on the front side of the solar cell.Type: ApplicationFiled: November 20, 2018Publication date: April 11, 2019Applicant: SunPower CorporationInventors: Richard M. SWANSON, Denis DE CEUSTER, Vikas DESAI, Douglas H. ROSE, David D. SMITH, Neil KAMINAR
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Publication number: 20190044006Abstract: A solar cell is fabricated by etching one or more of its layers without substantially etching another layer of the solar cell. In one embodiment, a copper layer in the solar cell is etched without substantially etching a topmost metallic layer comprising tin. For example, an etchant comprising sulfuric acid and hydrogen peroxide may be employed to etch the copper layer selective to the tin layer. A particular example of the aforementioned etchant is a Co-Bra Etch® etchant modified to comprise about 1% by volume of sulfuric acid, about 4% by volume of phosphoric acid, and about 2% by volume of stabilized hydrogen peroxide. In one embodiment, an aluminum layer in the solar cell is etched without substantially etching the tin layer. For example, an etchant comprising potassium hydroxide may be employed to etch the aluminum layer without substantially etching the tin layer.Type: ApplicationFiled: October 8, 2018Publication date: February 7, 2019Applicant: SunPower CorporationInventors: Douglas H. ROSE, Pongsthorn URALWONG, David D. SMITH
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Patent number: 10164567Abstract: In one embodiment, harmful solar cell polarization is prevented or minimized by providing a conductive path that bleeds charge from a front side of a solar cell to the bulk of a wafer. The conductive path may include patterned holes in a dielectric passivation layer, a conductive anti-reflective coating, or layers of conductive material formed on the top or bottom surface of an anti-reflective coating, for example. Harmful solar cell polarization may also be prevented by biasing a region of a solar cell module on the front side of the solar cell.Type: GrantFiled: August 5, 2016Date of Patent: December 25, 2018Assignee: SunPower CorporationInventors: Richard M. Swanson, Denis De Ceuster, Vikas Desai, Douglas H. Rose, David D. Smith, Neil Kaminar
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Patent number: 9929296Abstract: One embodiment relates to a bifacial photovoltaic module having an edge reflector. The module includes a plurality of solar cells in an array, each solar cell having a front side and a back side. A reflector is configured on an edge of the array of solar cells, the first reflector being configured to reflect light onto the front side of a row of solar cells adjacent to the edge. Another embodiment relates to a method of reducing non-uniformity of power generation from a bifacial photovoltaic module. Electrical current produced from solar cells along at least one edge of the array is increased by using a reflective strip facing towards the front side of the solar cells along the edge. Another embodiment relates to a bifacial photovoltaic module having an edge refractor. Other embodiments and features are also disclosed.Type: GrantFiled: December 22, 2009Date of Patent: March 27, 2018Assignee: SunPower CorporationInventor: Douglas H. Rose
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Patent number: 9774294Abstract: In one embodiment, harmful solar cell polarization is prevented or minimized by providing a conductive path that bleeds charge from a front side of a solar cell to the bulk of a wafer. The conductive path may include patterned holes in a dielectric passivation layer, a conductive anti-reflective coating, or layers of conductive material formed on the top or bottom surface of an anti-reflective coating, for example. Harmful solar cell polarization may also be prevented by biasing a region of a solar cell module on the front side of the solar cell.Type: GrantFiled: August 18, 2016Date of Patent: September 26, 2017Assignee: SunPower CorporationInventors: Richard M. Swanson, Denis De Ceuster, Vikas Desai, Douglas H. Rose, David D. Smith, Neil Kaminar
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Patent number: 9716465Abstract: One embodiment relates to a photovoltaic (PV) apparatus. The PV apparatus includes a plurality of photovoltaic modules arranged in an array and attached to a support structure which is attached to a roof. Each of the photovoltaic modules comprises a plurality of photovoltaic cells. A first array-roof integration member is attached to a first side of the array. The array-roof integration member covers a gap between the first side of the array and the roof. Another embodiment relates to a method of installing a photovoltaic apparatus upon a sloped roof. Another embodiment relates to a kit for mounting a photovoltaic apparatus on a roof. Other embodiments, aspects and features are also disclosed herein.Type: GrantFiled: October 9, 2015Date of Patent: July 25, 2017Assignee: SunPower CorporationInventors: Douglas H. Rose, Carl Lenox
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Patent number: 9691924Abstract: Solar cell interconnects with multiple current paths. A solar cell interconnect may include a plurality of in-plane slits arranged in several rows. The in-plane slits may be spaced to provide strain relief without unduly increasing the electrical path resistance through the solar cell interconnect. The in-plane slits may be staggered, for example.Type: GrantFiled: March 7, 2012Date of Patent: June 27, 2017Assignee: SunPower CorporationInventors: Douglas H. Rose, Shandor G. Daroczi, Neil Kaminar
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Publication number: 20170162728Abstract: A solar cell is fabricated by etching one or more of its layers without substantially etching another layer of the solar cell. In one embodiment, a copper layer in the solar cell is etched without substantially etching a topmost metallic layer comprising tin. For example, an etchant comprising sulfuric acid and hydrogen peroxide may be employed to etch the copper layer selective to the tin layer. A particular example of the aforementioned etchant is a Co-Bra Etch® etchant modified to comprise about 1% by volume of sulfuric acid, about 4% by volume of phosphoric acid, and about 2% by volume of stabilized hydrogen peroxide. In one embodiment, an aluminum layer in the solar cell is etched without substantially etching the tin layer. For example, an etchant comprising potassium hydroxide may be employed to etch the aluminum layer without substantially etching the tin layer.Type: ApplicationFiled: December 12, 2016Publication date: June 8, 2017Applicant: SunPower CorporationInventors: Douglas H. ROSE, Pongsthorn URALWONG, David D. SMITH
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Publication number: 20170047888Abstract: In one embodiment, harmful solar cell polarization is prevented or minimized by providing a conductive path that bleeds charge from a front side of a solar cell to the bulk of a wafer. The conductive path may include patterned holes in a dielectric passivation layer, a conductive anti-reflective coating, or layers of conductive material formed on the top or bottom surface of an anti-reflective coating, for example. Harmful solar cell polarization may also be prevented by biasing a region of a solar cell module on the front side of the solar cell.Type: ApplicationFiled: August 18, 2016Publication date: February 16, 2017Applicant: SunPower CorporationInventors: Richard M. SWANSON, Denis DE CEUSTER, Vikas DESAI, Douglas H. ROSE, David D. SMITH, Neil KAMINAR
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Publication number: 20170033248Abstract: In one embodiment, harmful solar cell polarization is prevented or minimized by providing a conductive path that bleeds charge from a front side of a solar cell to the bulk of a wafer. The conductive path may include patterned holes in a dielectric passivation layer, a conductive anti-reflective coating, or layers of conductive material formed on the top or bottom surface of an anti-reflective coating, for example. Harmful solar cell polarization may also be prevented by biasing a region of a solar cell module on the front side of the solar cell.Type: ApplicationFiled: August 5, 2016Publication date: February 2, 2017Applicant: SunPower CorporationInventors: Richard M. SWANSON, Denis DE CEUSTER, Vikas DESAI, Douglas H. ROSE, David D. SMITH, Neil KAMINAR
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Patent number: 9553229Abstract: A solar cell is fabricated by etching one or more of its layers without substantially etching another layer of the solar cell. In one embodiment, a copper layer in the solar cell is etched without substantially etching a topmost metallic layer comprising tin. For example, an etchant comprising sulfuric acid and hydrogen peroxide may be employed to etch the copper layer selective to the tin layer. A particular example of the aforementioned etchant is a Co-Bra Etch® etchant modified to comprise about 1% by volume of sulfuric acid, about 4% by volume of phosphoric acid, and about 2% by volume of stabilized hydrogen peroxide. In one embodiment, an aluminum layer in the solar cell is etched without substantially etching the tin layer. For example, an etchant comprising potassium hydroxide may be employed to etch the aluminum layer without substantially etching the tin layer.Type: GrantFiled: August 30, 2011Date of Patent: January 24, 2017Assignee: SunPower CorporationInventors: Douglas H. Rose, Pongsthorn Uralwong, David D. Smith
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Publication number: 20160079911Abstract: One embodiment relates to a photovoltaic (PV) apparatus. The PV apparatus includes a plurality of photovoltaic modules arranged in an array and attached to a support structure which is attached to a roof. Each of the photovoltaic modules comprises a plurality of photovoltaic cells. A first array-roof integration member is attached to a first side of the array. The array-roof integration member covers a gap between the first side of the array and the roof. Another embodiment relates to a method of installing a photovoltaic apparatus upon a sloped roof. Another embodiment relates to a kit for mounting a photovoltaic apparatus on a roof. Other embodiments, aspects and features are also disclosed herein.Type: ApplicationFiled: October 9, 2015Publication date: March 17, 2016Applicant: SunPower CorporationInventors: Douglas H. ROSE, Carl LENOX
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Publication number: 20150288328Abstract: In one embodiment, harmful solar cell polarization is prevented or minimized by providing a conductive path that bleeds charge from a front side of a solar cell to the bulk of a wafer. The conductive path may include patterned holes in a dielectric passivation layer, a conductive anti-reflective coating, or layers of conductive material formed on the top or bottom surface of an anti-reflective coating, for example. Harmful solar cell polarization may also be prevented by biasing a region of a solar cell module on the front side of the solar cell.Type: ApplicationFiled: April 15, 2015Publication date: October 8, 2015Applicant: SunPower CorporationInventors: Richard M. SWANSON, Denis DE CEUSTER, Vikas DESAI, Douglas H. ROSE, David D. SMITH, Neil KAMINAR
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Patent number: 9035167Abstract: In one embodiment, harmful solar cell polarization is prevented or minimized by providing a conductive path that bleeds charge from a front side of a solar cell to the bulk of a wafer. The conductive path may include patterned holes in a dielectric passivation layer, a conductive anti-reflective coating, or layers of conductive material formed on the top or bottom surface of an anti-reflective coating, for example. Harmful solar cell polarization may also be prevented by biasing a region of a solar cell module on the front side of the solar cell.Type: GrantFiled: July 28, 2010Date of Patent: May 19, 2015Assignee: SunPower CorporationInventors: Richard M. Swanson, Denis De Ceuster, Vikas Desai, Douglas H. Rose, David D. Smith, Neil Kaminar
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Patent number: 8378706Abstract: A method of processing of solar cells includes determining that a back-contact solar cell is defective. The back-contact solar cell includes a first plurality of interconnect pads at a first edge thereof, and a second plurality of interconnect pads at a second, opposed thereof, the first and second pluralities of interconnect pads having opposite operational charges. The back-contact solar cell is then diced to define at least first and second back-contact solar cell sections. The first back-contact solar cell section has at least two interconnect pads, of the plurality of interconnect pads, at respective opposed edges thereof.Type: GrantFiled: August 2, 2010Date of Patent: February 19, 2013Assignee: SunPower CorporationInventors: Zachary Kinyon, Douglas H. Rose, Karen Elizabeth Wilson
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Patent number: 8148627Abstract: Solar cell interconnects with multiple current paths. A solar cell interconnect may include a plurality of in-plane slits arranged in several rows. The in-plane slits may be spaced to provide strain relief without unduly increasing the electrical path resistance through the solar cell interconnect. The in-plane slits may be staggered, for example.Type: GrantFiled: August 23, 2007Date of Patent: April 3, 2012Assignee: SunPower CorporationInventors: Douglas H. Rose, Shandor G. Daroczi, Neil Kaminar
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Publication number: 20120025837Abstract: A method of processing of solar cells includes determining that a back-contact solar cell is defective. The back-contact solar cell includes a first plurality of interconnect pads at a first edge thereof, and a second plurality of interconnect pads at a second, opposed thereof, the first and second pluralities of interconnect pads having opposite operational charges. The back-contact solar cell is then diced to define at least first and second back-contact solar cell sections. The first back-contact solar cell section has at least two interconnect pads, of the plurality of interconnect pads, at respective opposed edges thereof.Type: ApplicationFiled: August 2, 2010Publication date: February 2, 2012Applicant: SunPower CorporationInventors: Zachary Kinyon, Douglas H. Rose, Karen Elizabeth Wilson
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Publication number: 20110312119Abstract: A solar cell is fabricated by etching one or more of its layers without substantially etching another layer of the solar cell. In one embodiment, a copper layer in the solar cell is etched without substantially etching a topmost metallic layer comprising tin. For example, an etchant comprising sulfuric acid and hydrogen peroxide may be employed to etch the copper layer selective to the tin layer. A particular example of the aforementioned etchant is a Co-Bra Etch® etchant modified to comprise about 1% by volume of sulfuric acid, about 4% by volume of phosphoric acid, and about 2% by volume of stabilized hydrogen peroxide. In one embodiment, an aluminum layer in the solar cell is etched without substantially etching the tin layer. For example, an etchant comprising potassium hydroxide may be employed to etch the aluminum layer without substantially etching the tin layer.Type: ApplicationFiled: August 30, 2011Publication date: December 22, 2011Inventors: Douglas H. ROSE, Pongsthorn URALWONG, David D. SMITH