Patents by Inventor James R. Sheats
James R. Sheats 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: 8927315Abstract: Methods and devices are provided for high-efficiency solar cells. In one embodiment, an assembly is provided comprising of a plurality of solar cells each having at least one transparent conductor, a photovoltaic layer, at least one bottom electrode, a plurality of emitter wrap through (EWT) vias containing a conductive material, and a plurality of series interconnect vias containing a conductive material. The assembly may also include a backside support coupled to the solar cells, wherein the backside support is patterned to have electrically conductive areas and electrically nonconductive areas that create a series interconnect between solar cells electrically coupled by the support and prevents parallel connections between the solar cells. The cells may have a via insulating layer in each via separating the conductive material in each via from any side walls of the bottom electrode.Type: GrantFiled: July 31, 2012Date of Patent: January 6, 2015Assignee: aeris CAPITAL Sustainable IP Ltd.Inventors: James R. Sheats, Werner Dumanski
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Publication number: 20140106500Abstract: Methods and devices are provided for improved photovoltaic devices. Non-vacuum deposition of transparent conductive electrodes in a roll-to-roll manufacturing environment is disclosed. In one embodiment, a method is provided for forming a photovoltaic device. The method comprises processing a precursor layer in one or more steps to form a photovoltaic absorber layer; depositing a smoothing layer to fill gaps and depression in the absorber layer to reduce a roughness of the absorber layer; adding an insulating layer over the smooth layer; and forming a web-like layer of conductive material over the insulating layer. By way of nonlimiting example, the web-like layer of conductive material comprises a plurality of carbon nanotubes. In some embodiments, the absorber layer is a group IB-IIIA-VIA absorber layer.Type: ApplicationFiled: September 9, 2013Publication date: April 17, 2014Applicant: NANOSOLAR, INC.Inventors: Jeroen K.J. Van Duren, Matthew R. Robinson, James R. Sheats
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Patent number: 8530262Abstract: Methods and devices are provided for improved photovoltaic devices. Non-vacuum deposition of transparent conductive electrodes in a roll-to-roll manufacturing environment is disclosed. In one embodiment, a method is provided for forming a photovoltaic device. The method comprises processing a precursor layer in one or more steps to form a photovoltaic absorber layer; depositing a smoothing layer to fill gaps and depression in the absorber layer to reduce a roughness of the absorber layer; adding an insulating layer over the smooth layer; and forming a web-like layer of conductive material over the insulating layer. By way of nonlimiting example, the web-like layer of conductive material comprises a plurality of carbon nanotubes. In some embodiments, the absorber layer is a group IB-IIIA-VIA absorber layer.Type: GrantFiled: March 2, 2009Date of Patent: September 10, 2013Assignee: Nanosolar, Inc.Inventors: Jeroen K. J. Van Duren, Matthew R. Robinson, James R. Sheats
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Patent number: 8525152Abstract: Methods and devices are provided for absorber layers formed on foil substrate. In one embodiment, a method of manufacturing photovoltaic devices may be comprised of providing a substrate comprising of at least one electrically conductive aluminum foil substrate, at least one electrically conductive diffusion barrier layer, and at least one electrically conductive electrode layer above the diffusion barrier layer. The diffusion barrier layer may prevent chemical interaction between the aluminum foil substrate and the electrode layer. An absorber layer may be formed on the substrate. In one embodiment, the absorber layer may be a non-silicon absorber layer. In another embodiment, the absorber layer may be an amorphous silicon (doped or undoped) absorber layer. Optionally, the absorber layer may be based on organic and/or inorganic materials.Type: GrantFiled: June 7, 2010Date of Patent: September 3, 2013Assignee: Nanosolar, Inc.Inventors: Craig Leidholm, Brent Bollman, James R. Sheats, Sam Kao, Martin R. Roscheisen
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Publication number: 20120291856Abstract: Methods and devices are provided for improved roofing devices. In one embodiment of the present invention, a photovoltaic roofing assembly is provided that comprises of a roofing membrane and a plurality of photovoltaic cells supported by the roofing membrane. The photovoltaic cells may be lightweight, flexible cells formed on a lightweight foil and disposed as a layer on top of the roofing membrane. The roofing assembly may include at least one flexible encapsulant film that protects the plurality of photovoltaic cells from environmental exposure damage, wherein the encapsulant film is formed using a non-vacuum process. Optionally, the process may be a lamination process. In other embodiments, the process is a non-vacuum, non-lamination process. The resulting roofing membrane and the photovoltaic cells are constructed to be rolled up in lengths suitable for being transported to a building site for unrolling and being affixed to a roof structure.Type: ApplicationFiled: April 9, 2012Publication date: November 22, 2012Inventors: James R. Sheats, Paul Adriani, Philip Capps, Martin R. Roscheisen, Brian M. Sager
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Patent number: 8309949Abstract: Optoelectronic device modules, arrays optoelectronic device modules and methods for fabricating optoelectronic device modules are disclosed. The device modules are made using a starting substrate having an insulator layer sandwiched between a bottom electrode made of a flexible bulk conductor and a conductive back plane. An active layer is disposed between the bottom electrode and a transparent conducting layer. One or more electrical contacts between the transparent conducting layer and the back plane are formed through the transparent conducting layer, the active layer, the flexible bulk conductor and the insulating layer. The electrical contacts are electrically isolated from the active layer, the bottom electrode and the insulating layer.Type: GrantFiled: November 22, 2010Date of Patent: November 13, 2012Assignee: Nanosolar, Inc.Inventors: James R. Sheats, Sam Kao, Martin R. Roscheisen
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Patent number: 8198117Abstract: Methods and devices are provided for absorber layers formed on foil substrate. In one embodiment, a method of manufacturing photovoltaic devices may be comprised of providing a substrate comprising of at least one electrically conductive aluminum foil substrate, at least one electrically conductive diffusion barrier layer, and at least one electrically conductive electrode layer above the diffusion barrier layer. The diffusion barrier layer may prevent chemical interaction between the aluminum foil substrate and the electrode layer. An absorber layer may be formed on the substrate. In one embodiment, the absorber layer may be a non-silicon absorber layer. In another embodiment, the absorber layer may be an amorphous silicon (doped or undoped) absorber layer. Optionally, the absorber layer may be based on organic and/or inorganic materials.Type: GrantFiled: August 16, 2006Date of Patent: June 12, 2012Assignee: Nanosolar, Inc.Inventors: Craig R. Leidholm, Brent Bollman, James R. Sheats, Sam Kao, Martin R. Roscheisen
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Publication number: 20120090661Abstract: Methods and devices are provided for improved environmental protection for photovoltaic devices and assemblies. In one embodiment, the device comprises of an individually encapsulated solar cell, wherein the encapsulated solar cell includes at least one protective layer coupled to at least one surface of the solar cell. The protective layer has a chemical composition that prevents moisture from entering the solar cell and wherein light passes through the protective layer to reach an absorber layer in the solar cell.Type: ApplicationFiled: October 17, 2011Publication date: April 19, 2012Inventors: Philip Capps, Paul Adriani, James R. Sheats
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Patent number: 8158450Abstract: Methods and devices are provided for improved roofing devices. In one embodiment of the present invention, a photovoltaic roofing assembly is provided that comprises of a roofing membrane and a plurality of photovoltaic cells supported by the roofing membrane. The photovoltaic cells may be lightweight, flexible cells formed on a lightweight foil and disposed as a layer on top of the roofing membrane. The roofing assembly may include at least one flexible encapsulant film that protects the plurality of photovoltaic cells from environmental exposure damage, wherein the encapsulant film is formed using a non-vacuum process. Optionally, the process may be a lamination process. In other embodiments, the process is a non-vacuum, non-lamination process. The resulting roofing membrane and the photovoltaic cells are constructed to be rolled up in lengths suitable for being transported to a building site for unrolling and being affixed to a roof structure.Type: GrantFiled: May 10, 2007Date of Patent: April 17, 2012Assignee: Nanosolar, Inc.Inventors: James R. Sheats, Paul Adriani, Philip Capps, Martin R. Roscheisen, Brian M. Sager
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Publication number: 20120052613Abstract: Optoelectronic device modules, arrays optoelectronic device modules and methods for fabricating optoelectronic device modules are disclosed. The device modules are made using a starting substrate having an insulator layer sandwiched between a bottom electrode made of a flexible bulk conductor and a conductive back plane. An active layer is disposed between the bottom electrode and a transparent conducting layer. One or more electrical contacts between the transparent conducting layer and the back plane are formed through the transparent conducting layer, the active layer, the flexible bulk conductor and the insulating layer. The electrical contacts are electrically isolated from the active layer, the bottom electrode and the insulating layer.Type: ApplicationFiled: June 27, 2011Publication date: March 1, 2012Inventors: James R. Sheats, Sam Kao, Martin R. Roscheisen
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Patent number: 8039739Abstract: Methods and devices are provided for improved environmental protection for photovoltaic devices and assemblies. In one embodiment, the device comprises of an individually encapsulated solar cell, wherein the encapsulated solar cell includes at least one protective layer coupled to at least one surface of the solar cell. The protective layer has a chemical composition that prevents moisture from entering the solar cell and wherein light passes through the protective layer to reach an absorber layer in the solar cell.Type: GrantFiled: August 3, 2006Date of Patent: October 18, 2011Assignee: Nanosolar, Inc.Inventors: Philip Capps, Paul Adriani, James R. Sheats
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Patent number: 7968869Abstract: Optoelectronic device modules, arrays optoelectronic device modules and methods for fabricating optoelectronic device modules are disclosed. The device modules are made using a starting substrate having an insulator layer sandwiched between a bottom electrode made of a flexible bulk conductor and a conductive back plane. An active layer is disposed between the bottom electrode and a transparent conducting layer. One or more electrical contacts between the transparent conducting layer and the back plane are formed through the transparent conducting layer, the active layer, the flexible bulk conductor and the insulating layer. The electrical contacts are electrically isolated from the active layer, the bottom electrode and the insulating layer.Type: GrantFiled: October 4, 2008Date of Patent: June 28, 2011Assignee: Nanosolar, Inc.Inventors: James R. Sheats, Sam Kao, Martin R. Roscheisen
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Publication number: 20110121353Abstract: Optoelectronic device modules, arrays optoelectronic device modules and methods for fabricating optoelectronic device modules are disclosed. The device modules are made using a starting substrate having an insulator layer sandwiched between a bottom electrode made of a flexible bulk conductor and a conductive back plane. An active layer is disposed between the bottom electrode and a transparent conducting layer. One or more electrical contacts between the transparent conducting layer and the back plane are formed through the transparent conducting layer, the active layer, the flexible bulk conductor and the insulating layer. The electrical contacts are electrically isolated from the active layer, the bottom electrode and the insulating layer.Type: ApplicationFiled: November 22, 2010Publication date: May 26, 2011Inventors: James R. Sheats, Sam Kao, Martin R. Roscheisen
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Publication number: 20110094576Abstract: Methods and devices are described for thin film solar cell manufacturing. In one embodiment, the method includes displacing the residual insulator in vias with the pins of the present invention, which may greatly reduce the amount of material to be removed and hence make the laser more cost-effective. It is still desirable to use a laser or other device to completely clear the bottom of the via of residual material (to prepare for making a good electrical connection) but the film remaining under the pins would be microns in thickness, compared to the hundreds of microns of via depth.Type: ApplicationFiled: May 24, 2010Publication date: April 28, 2011Inventors: James R. Sheats, Phil Stob
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Patent number: 7919337Abstract: Optoelectronic device modules, arrays optoelectronic device modules and methods for fabricating optoelectronic device modules are disclosed. The device modules are made using a starting substrate having an insulator layer sandwiched between a bottom electrode made of a flexible bulk conductor and a conductive back plane. An active layer is disposed between the bottom electrode and a transparent conducting layer. One or more electrical contacts between the transparent conducting layer and the back plane are formed through the transparent conducting layer, the active layer, the flexible bulk conductor and the insulating layer. The electrical contacts are electrically isolated from the active layer, the bottom electrode and the insulating layer.Type: GrantFiled: October 31, 2007Date of Patent: April 5, 2011Assignee: Nanosolar, Inc.Inventors: James R. Sheats, Sam Kao, Martin R. Roscheisen
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Publication number: 20110041890Abstract: Methods and devices are provided for high-efficiency solar cells. In one embodiment, a high current photovoltaic apparatus is provided comprising of a thin-film absorber layer solar module of arbitrary size having an electrical output with a current of greater than about 2 amperes when the module is under AM1.5G illumination at 25° C. Optionally, the current is at least about 5 amperes. Optionally, the current is at least about 15 amperes. Optionally, the current is at least about 50 amperes. Optionally, the current is at least about 100 amperes.Type: ApplicationFiled: November 19, 2008Publication date: February 24, 2011Inventor: James R. Sheats
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Publication number: 20110019277Abstract: Methods and devices are provided for improved anti-reflective coatings. Non-vacuum deposition of transparent conductive electrodes in a roll-to-roll manufacturing environment is disclosed. In one embodiment of the present invention, a device is provided comprising a multi-layer anti-reflective coating formed over a substantially transparent substrate; wherein the multi-layer anti-reflective coating comprises of a plurality of nanostructured layers, wherein each of the layers has a tuned porosity and at least some of the nanostructured layers have different porosities to create a different index of refraction for those layers. In some embodiments, the absorber layer for use with this anti-reflective layer is a group IB-IIIA-VIA absorber layer.Type: ApplicationFiled: November 10, 2008Publication date: January 27, 2011Inventors: Brian M. Sager, James R. Sheats
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Publication number: 20100297798Abstract: Methods and devices are provided for improved environmental protection for photovoltaic devices and assemblies. In one embodiment, the device comprises of an individually encapsulated solar cell, wherein the encapsulated solar cell includes at least one protective layer coupled to at least one surface of the solar cell and the protective layer may be formed from a substantially inorganic material. The protective layer has a chemical composition that prevents moisture from entering the solar cell and wherein light passes through the protective layer to reach an absorber layer in the solar cell.Type: ApplicationFiled: July 27, 2007Publication date: November 25, 2010Inventors: Paul M. Adriani, James R. Sheats, Philip Capps
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Patent number: 7838868Abstract: Optoelectronic device modules, arrays optoelectronic device modules and methods for fabricating optoelectronic device modules are disclosed. The device modules are made using a starting substrate having an insulator layer sandwiched between a bottom electrode made of a flexible bulk conductor and a conductive back plane. An active layer is disposed between the bottom electrode and a transparent conducting layer. One or more electrical contacts between the transparent conducting layer and the back plane are formed through the transparent conducting layer, the active layer, the flexible bulk conductor and the insulating layer. The electrical contacts are electrically isolated from the active layer, the bottom electrode and the insulating layer.Type: GrantFiled: August 16, 2005Date of Patent: November 23, 2010Assignee: Nanosolar, Inc.Inventors: James R. Sheats, Sam Kao, Martin R. Roscheisen
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Publication number: 20100243049Abstract: Methods and devices are provided for absorber layers formed on foil substrate. In one embodiment, a method of manufacturing photovoltaic devices may be comprised of providing a substrate comprising of at least one electrically conductive aluminum foil substrate, at least one electrically conductive diffusion barrier layer, and at least one electrically conductive electrode layer above the diffusion barrier layer. The diffusion barrier layer may prevent chemical interaction between the aluminum foil substrate and the electrode layer. An absorber layer may be formed on the substrate. In one embodiment, the absorber layer may be a non-silicon absorber layer. In another embodiment, the absorber layer may be an amorphous silicon (doped or undoped) absorber layer. Optionally, the absorber layer may be based on organic and/or inorganic materials.Type: ApplicationFiled: June 7, 2010Publication date: September 30, 2010Inventors: Craig Leidholm, Brent Bollman, James R. Sheats, Sam Kao, Martin R. Roscheisen