Patents by Inventor Matthieu Moors
Matthieu Moors 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: 10535790Abstract: Approaches for fabricating one-dimensional metallization for solar cells, and the resulting solar cells, are described. In an example, a solar cell includes a substrate having a back surface and an opposing light-receiving surface. A plurality of alternating N-type and P-type semiconductor regions is disposed in or above the back surface of the substrate and parallel along a first direction to form a one-dimensional layout of emitter regions for the solar cell. A conductive contact structure is disposed on the plurality of alternating N-type and P-type semiconductor regions. The conductive contact structure includes a plurality of metal lines corresponding to the plurality of alternating N-type and P-type semiconductor regions. The plurality of metal lines is parallel along the first direction to form a one-dimensional layout of a metallization layer for the solar cell.Type: GrantFiled: June 25, 2015Date of Patent: January 14, 2020Assignees: SunPower Corporation, Total Marketing ServicesInventors: Richard Hamilton Sewell, David Fredric Joel Kavulak, Lewis Abra, Thomas P. Pass, Taeseok Kim, Matthieu Moors, Benjamin Ian Hsia, Gabriel Harley
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Publication number: 20190267505Abstract: A method of fabricating a solar cell is disclosed. The method can include forming a dielectric region on a surface of a solar cell structure and forming a metal layer on the dielectric layer. The method can also include configuring a laser beam with a particular shape and directing the laser beam with the particular shape on the metal layer, where the particular shape allows a contact to be formed between the metal layer and the solar cell structure.Type: ApplicationFiled: May 9, 2019Publication date: August 29, 2019Inventors: Matthieu Moors, David D. Smith, Gabriel Harley, Taeseok Kim
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Patent number: 10290758Abstract: A method of fabricating a solar cell is disclosed. The method can include forming a dielectric region on a surface of a solar cell structure and forming a metal layer on the dielectric layer. The method can also include configuring a laser beam with a particular shape and directing the laser beam with the particular shape on the metal layer, where the particular shape allows a contact to be formed between the metal layer and the solar cell structure.Type: GrantFiled: April 27, 2017Date of Patent: May 14, 2019Assignees: SunPower Corporation, Total Marketing ServicesInventors: Matthieu Moors, David D. Smith, Gabriel Harley, Taeseok Kim
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Publication number: 20190097077Abstract: A solar cell can include a substrate and a semiconductor region disposed in or above the substrate. The solar cell can also include a conductive contact disposed on the semiconductor region with the conductive contact including a conductive foil bonded to the semiconductor region.Type: ApplicationFiled: November 27, 2018Publication date: March 28, 2019Inventors: Richard Hamilton Sewell, Michel Arsène Olivier Ngamo Toko, Matthieu Moors, Jens Dirk Moschner
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Publication number: 20190058067Abstract: A method for fabricating a solar cell is disclosed. The method can include forming a dielectric region on a surface of a solar cell structure and forming a first metal layer on the dielectric region. The method can also include forming a second metal layer on the first metal layer and locally heating a particular region of the second metal layer, where heating includes forming a metal bond between the first and second metal layer and forming a contact between the first metal layer and the solar cell structure. The method can include forming an adhesive layer on the first metal layer and forming a second metal layer on the adhesive layer, where the adhesive layer mechanically couples the second metal layer to the first metal layer and allows for an electrical connection between the second metal layer to the first metal layer.Type: ApplicationFiled: October 22, 2018Publication date: February 21, 2019Inventors: Matthieu Moors, Taeseok Kim
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Publication number: 20190019900Abstract: Approaches for the foil-based metallization of solar cells and the resulting solar cells are described. In an example, a solar cell includes a substrate. A plurality of alternating N-type and P-type semiconductor regions is disposed in or above the substrate. A conductive contact structure is disposed above the plurality of alternating N-type and P-type semiconductor regions. The conductive contact structure includes a plurality of metal seed material regions providing a metal seed material region disposed on each of the alternating N-type and P-type semiconductor regions. A metal foil is disposed on the plurality of metal seed material regions, the metal foil having anodized portions isolating metal regions of the metal foil corresponding to the alternating N-type and P-type semiconductor regions.Type: ApplicationFiled: August 30, 2018Publication date: January 17, 2019Inventors: Gabriel Harley, Taeseok Kim, Richard Hamilton Sewell, Michael Morse, David D. Smith, Matthieu Moors, Jens-Dirk Moschner
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Patent number: 10177270Abstract: A solar cell can include a substrate and a semiconductor region disposed in or above the substrate. The solar cell can also include a conductive contact disposed on the semiconductor region with the conductive contact including a conductive foil bonded to the semiconductor region.Type: GrantFiled: September 27, 2017Date of Patent: January 8, 2019Assignees: SunPower Corporation, Total Marketing ServicesInventors: Richard Hamilton Sewell, Michel Arsène Olivier Ngamo Toko, Matthieu Moors, Jens Dirk Moschner
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Patent number: 10109751Abstract: A method for fabricating a solar cell is disclosed. The method can include forming a dielectric region on a surface of a solar cell structure and forming a first metal layer on the dielectric region. The method can also include forming a second metal layer on the first metal layer and locally heating a particular region of the second metal layer, where heating includes forming a metal bond between the first and second metal layer and forming a contact between the first metal layer and the solar cell structure. The method can include forming an adhesive layer on the first metal layer and forming a second metal layer on the adhesive layer, where the adhesive layer mechanically couples the second metal layer to the first metal layer and allows for an electrical connection between the second metal layer to the first metal layer.Type: GrantFiled: February 17, 2017Date of Patent: October 23, 2018Assignees: SUNPOWER CORPORATION, TOTAL MARKETING SERVICESInventors: Matthieu Moors, Taeseok Kim
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Patent number: 10090421Abstract: Approaches for the foil-based metallization of solar cells and the resulting solar cells are described. In an example, a solar cell includes a substrate. A plurality of alternating N-type and P-type semiconductor regions is disposed in or above the substrate. A conductive contact structure is disposed above the plurality of alternating N-type and P-type semiconductor regions. The conductive contact structure includes a plurality of metal seed material regions providing a metal seed material region disposed on each of the alternating N-type and P-type semiconductor regions. A metal foil is disposed on the plurality of metal seed material regions, the metal foil having anodized portions isolating metal regions of the metal foil corresponding to the alternating N-type and P-type semiconductor regions.Type: GrantFiled: April 12, 2017Date of Patent: October 2, 2018Assignees: SunPower Corporation, Total Marketing ServicesInventors: Gabriel Harley, Taeseok Kim, Richard Hamilton Sewell, Michael Morse, David D. Smith, Matthieu Moors, Jens-Dirk Moschner
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Patent number: 10032942Abstract: Methods of fabricating solar cells using a metal-containing thermal and diffusion barrier layer in foil-based metallization approaches, and the resulting solar cells, are described. For example, a method of fabricating a solar cell includes forming a plurality of semiconductor regions in or above a substrate. The method also includes forming a metal-containing thermal and diffusion barrier layer above the plurality of semiconductor regions. The method also includes forming a metal seed layer on the metal-containing thermal and diffusion barrier layer. The method also includes forming a metal conductor layer on the metal seed layer. The method also includes laser welding the metal conductor layer to the metal seed layer. The metal-containing thermal and diffusion barrier layer protects the plurality of semiconductor regions during the laser welding.Type: GrantFiled: April 20, 2017Date of Patent: July 24, 2018Assignees: SunPower Corporation, Total Marketing ServicesInventors: Taeseok Kim, Robert Woehl, Gabriel Harley, Nils-Peter Harder, Jens-Dirk Moschner, Matthieu Moors, Michel Arsene Olivier Ngamo Toko
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Publication number: 20180145194Abstract: Methods of fabricating a solar cell including metallization techniques and resulting solar cells, are described. In an example, a semiconductor region can be formed in or above a substrate. A first metal layer can be formed over the semiconductor region. A laser can be applied over a first region of the metal layer to form a first metal weld between the metal layer and the semiconductor region, where applying a laser over the first region comprises applying the laser at a first scanning speed. Subsequent to applying the laser over the first region, the laser can be applied over a second region of the metal layer where applying the laser over the second region includes applying a laser at a second scanning speed. Subsequent to applying the laser over the second region, the laser can be applied over a third region of the metal layer to form a second metal weld, where applying the laser over the third region comprises applying the laser at a third scanning speed.Type: ApplicationFiled: January 22, 2018Publication date: May 24, 2018Inventors: Matthieu Moors, Markus Nicht, Daniel Maria Weber, Rico Bohme, Mario Gjukic, Gabriel Harley, Mark Kleshock, Mohamed A. Elbandrawy, Taeseok Kim
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Patent number: 9882071Abstract: Methods of fabricating a solar cell including metallization techniques and resulting solar cells, are described. In an example, a semiconductor region can be formed in or above a substrate. A first metal layer can be formed over the semiconductor region. A laser can be applied over a first region of the metal layer to form a first metal weld between the metal layer and the semiconductor region, where applying a laser over the first region comprises applying the laser at a first scanning speed. Subsequent to applying the laser over the first region, the laser can be applied over a second region of the metal layer where applying the laser over the second region includes applying a laser at a second scanning speed. Subsequent to applying the laser over the second region, the laser can be applied over a third region of the metal layer to form a second metal weld, where applying the laser over the third region comprises applying the laser at a third scanning speed.Type: GrantFiled: July 1, 2016Date of Patent: January 30, 2018Assignees: SunPower Corporation, Total Marketing ServicesInventors: Matthieu Moors, Markus Nicht, Daniel Maria Weber, Rico Bohme, Mario Gjukic, Gabriel Harley, Mark Kleshock, Mohamed A. Elbandrawy, Taeseok Kim
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Publication number: 20180019364Abstract: A solar cell can include a substrate and a semiconductor region disposed in or above the substrate. The solar cell can also include a conductive contact disposed on the semiconductor region with the conductive contact including a conductive foil bonded to the semiconductor region.Type: ApplicationFiled: September 27, 2017Publication date: January 18, 2018Inventors: Richard Hamilton Sewell, Michel Arsène Olivier Ngamo Toko, Matthieu Moors, Jens Dirk Moschner
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Publication number: 20180006171Abstract: Methods of fabricating a solar cell including metallization techniques and resulting solar cells, are described. In an example, a semiconductor region can be formed in or above a substrate. A first metal layer can be formed over the semiconductor region. A laser can be applied over a first region of the metal layer to form a first metal weld between the metal layer and the semiconductor region, where applying a laser over the first region comprises applying the laser at a first scanning speed. Subsequent to applying the laser over the first region, the laser can be applied over a second region of the metal layer where applying the laser over the second region includes applying a laser at a second scanning speed. Subsequent to applying the laser over the second region, the laser can be applied over a third region of the metal layer to form a second metal weld, where applying the laser over the third region comprises applying the laser at a third scanning speed.Type: ApplicationFiled: July 1, 2016Publication date: January 4, 2018Inventors: Matthieu Moors, Markus Nicht, Daniel Maria Weber, Rico Bohme, Mario Gjukic, Gabriel Harley, Mark Kleshock, Mohamed A. Elbandrawy, Taeseok Kim
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Publication number: 20180006172Abstract: Solar cells having conductive contacts are described. In an example, a solar cell can include a protective layer disposed over a substrate, where the protective layer comprises a contact hole. A first metal layer disposed over the protective layer, where the first metal layer is electrically connected to the substrate through the contact hole. A second metal layer disposed over the first metal layer and a bond region disposed between the first metal layer and the second metal layer, where the bond region is located above a region of the protective layer without a contact hole.Type: ApplicationFiled: July 1, 2016Publication date: January 4, 2018Inventors: Matthieu Moors, Taeseok Kim, Nils-Peter Harder
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Patent number: 9818903Abstract: A solar cell can include a substrate and a semiconductor region disposed in or above the substrate. The solar cell can also include a conductive contact disposed on the semiconductor region with the conductive contact including a conductive foil bonded to the semiconductor region.Type: GrantFiled: April 30, 2014Date of Patent: November 14, 2017Assignees: SunPower Corporation, Total Marketing ServicesInventors: Richard Hamilton Sewell, Michel Arsène Olivier Nagamo Toko, Matthieu Moors, Jens Dirk Moschner
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Publication number: 20170236966Abstract: A method of fabricating a solar cell is disclosed. The method can include forming a dielectric region on a surface of a solar cell structure and forming a metal layer on the dielectric layer. The method can also include configuring a laser beam with a particular shape and directing the laser beam with the particular shape on the metal layer, where the particular shape allows a contact to be formed between the metal layer and the solar cell structure.Type: ApplicationFiled: April 27, 2017Publication date: August 17, 2017Inventors: Matthieu Moors, David D. Smith, Gabriel Harley, Taeseok Kim
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Publication number: 20170222073Abstract: Methods of fabricating solar cells using a metal-containing thermal and diffusion barrier layer in foil-based metallization approaches, and the resulting solar cells, are described. For example, a method of fabricating a solar cell includes forming a plurality of semiconductor regions in or above a substrate. The method also includes forming a metal-containing thermal and diffusion barrier layer above the plurality of semiconductor regions. The method also includes forming a metal seed layer on the metal-containing thermal and diffusion barrier layer. The method also includes forming a metal conductor layer on the metal seed layer. The method also includes laser welding the metal conductor layer to the metal seed layer. The metal-containing thermal and diffusion barrier layer protects the plurality of semiconductor regions during the laser welding.Type: ApplicationFiled: April 20, 2017Publication date: August 3, 2017Inventors: Taeseok Kim, Robert Woehl, Gabriel Harley, Nils-Peter Harder, Jens-Dirk Moschner, Matthieu Moors, Michel Arsene Olivier Ngamo Toko
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Publication number: 20170222068Abstract: Approaches for the foil-based metallization of solar cells and the resulting solar cells are described. In an example, a solar cell includes a substrate. A plurality of alternating N-type and P-type semiconductor regions is disposed in or above the substrate. A conductive contact structure is disposed above the plurality of alternating N-type and P-type semiconductor regions. The conductive contact structure includes a plurality of metal seed material regions providing a metal seed material region disposed on each of the alternating N-type and P-type semiconductor regions. A metal foil is disposed on the plurality of metal seed material regions, the metal foil having anodized portions isolating metal regions of the metal foil corresponding to the alternating N-type and P-type semiconductor regions.Type: ApplicationFiled: April 12, 2017Publication date: August 3, 2017Inventors: Gabriel Harley, Taeseok Kim, Richard Hamilton Sewell, Michael Morse, David D. Smith, Matthieu Moors, Jens-Dirk Moschner
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Patent number: 9722105Abstract: Approaches for forming solar cells with a converted seed layer as a buffer material and the resulting solar cells are described. In an example, a method of fabricating a solar cell includes converting regions of a seed layer disposed on a plurality of p-n junctions of the solar cell to form a pattern of interdigitated converted regions. The converted regions are configured to electrically insulate non-converted regions of the seed layer from each other and provide a barrier to a laser that is, in fabricating the solar cell, directed towards the seed layer such that the barrier substantially avoids degradation of at least the plurality of p-n junctions from the laser.Type: GrantFiled: March 28, 2014Date of Patent: August 1, 2017Assignees: SunPower Corporation, Total Marketing ServicesInventors: Matthieu Moors, Thomas Pass