Patents by Inventor Michael Cudzinovic
Michael Cudzinovic 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: 20210384366Abstract: 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: ApplicationFiled: August 17, 2021Publication date: December 9, 2021Inventors: Richard Hamilton Sewell, David Aaron Randolph Barkhouse, Junbo Wu, Michael Cudzinovic, Paul Loscutoff, Joseph Behnke, Michel Arsène Olivier Ngamo Toko
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Patent number: 11127866Abstract: 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: GrantFiled: June 1, 2016Date of Patent: September 21, 2021Assignees: SunPower Corporation, Total Marketing ServicesInventors: Richard Hamilton Sewell, David Aaron Randolph Barkhouse, Junbo Wu, Michael Cudzinovic, Paul Loscutoff, Joseph Behnke, Michel Arséne Olivier Ngamo Toko
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Patent number: 10164131Abstract: Multi-layer sputtered metal seed for solar cell conductive contacts and methods of forming solar cell conductive contacts are described. In an example, a solar cell includes a substrate. A semiconductor region is disposed in or above the substrate. A conductive contact is disposed on the semiconductor region and includes a seed material stack in contact with the semiconductor region. The seed material stack includes a first aluminum layer having a first crystallinity and disposed on the semiconductor layer, and a second aluminum layer having a second crystallinity and disposed on and having an interface with the first aluminum layer. The first crystallinity is different from the second crystallinity.Type: GrantFiled: December 19, 2014Date of Patent: December 25, 2018Assignees: SunPower Corporation, Total Marketing ServicesInventors: Michael Cudzinovic, Amjad Deyine, Robert Woehl
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Patent number: 9871150Abstract: 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: GrantFiled: July 1, 2016Date of Patent: January 16, 2018Assignee: SunPower CorporationInventors: Benjamin Ian Hsia, David Aaron Randolph Barkhouse, Todd Richards Johnson, Michael Cudzinovic
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Publication number: 20180006170Abstract: 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: ApplicationFiled: July 1, 2016Publication date: January 4, 2018Inventors: Benjamin Ian Hsia, David Aaron Randolph Barkhouse, Todd Richards Johnson, Michael Cudzinovic
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Patent number: 9525082Abstract: Solar cell contact structures formed from metal paste and methods of forming solar cell contact structures from metal paste are described. In a first example, a solar cell includes a substrate. A semiconductor region is disposed in or above the substrate. A contact structure is disposed on the semiconductor region and includes a conductive layer in contact with the semiconductor region. The conductive layer includes a matrix binder having aluminum/silicon (Al/Si) particles and an inert filler material dispersed therein. In a second example, a solar cell includes a substrate. A semiconductor region is disposed in or above the substrate. A contact structure is disposed on the semiconductor region and includes a conductive layer in contact with the semiconductor region. The conductive layer includes an agent for increasing a hydrophobic characteristic of the conductive layer.Type: GrantFiled: September 27, 2013Date of Patent: December 20, 2016Assignee: SunPower CorporationInventors: Richard Hamilton Sewell, Michael Cudzinovic
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Publication number: 20160276504Abstract: 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: ApplicationFiled: June 1, 2016Publication date: September 22, 2016Inventors: Richard Hamilton Sewell, David Aaron Randolph Barkhouse, Junbo Wu, Michael Cudzinovic, Paul Loscutoff, Joseph Behnke, Michel Arsène Olivier Ngamo Toko
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Publication number: 20160190354Abstract: Approaches for forming barrier-less seed stacks and contacts are described. In an example, a solar cell includes a substrate and a conductive contact disposed on the substrate. The conductive contact includes a copper layer directly contacting the substrate. In another example, a solar cell includes a substrate and a seed layer disposed directly on the substrate. The seed layer consists essentially of one or more non-diffusion-barrier metal layers. A conductive contact includes a copper layer disposed directly on the seed layer. An exemplary method of fabricating a solar cell involves providing a substrate, and forming a seed layer over the substrate. The seed layer includes one or more non-diffusion-barrier metal layers. The method further involves forming a conductive contact for the solar cell from the seed layer.Type: ApplicationFiled: March 8, 2016Publication date: June 30, 2016Inventors: Mukul Agrawal, Seung Bum Rim, Michael Cudzinovic
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Publication number: 20160190364Abstract: Seed layers for solar cell conductive contacts and methods of forming seed layers for solar cell conductive contacts are described. For example, a solar cell includes a substrate. An emitter region is disposed above the substrate. A conductive contact is disposed on the emitter region and includes a conductive layer in contact with the emitter region. The conductive layer is composed of aluminum/silicon (Al/Si) particles having a composition of greater than approximately 15% Si with the remainder Al. In another example, a solar cell includes a substrate having a diffusion region at or near a surface of the substrate. A conductive contact is disposed above the diffusion region and includes a conductive layer in contact with the substrate. The conductive layer is composed of aluminum/silicon (Al/Si) particles having a composition of greater than approximately 15% Si with the remainder Al.Type: ApplicationFiled: March 4, 2016Publication date: June 30, 2016Inventors: Michael Cudzinovic, Junbo Wu, Xi Zhu
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Publication number: 20160181450Abstract: Multi-layer sputtered metal seed for solar cell conductive contacts and methods of forming solar cell conductive contacts are described. In an example, a solar cell includes a substrate. A semiconductor region is disposed in or above the substrate. A conductive contact is disposed on the semiconductor region and includes a seed material stack in contact with the semiconductor region. The seed material stack includes a first aluminum layer having a first crystallinity and disposed on the semiconductor layer, and a second aluminum layer having a second crystallinity and disposed on and having an interface with the first aluminum layer. The first crystallinity is different from the second crystallinity.Type: ApplicationFiled: December 19, 2014Publication date: June 23, 2016Inventors: Michael Cudzinovic, Amjad Deyine, Robert Woehl
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Patent number: 9362427Abstract: 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: GrantFiled: December 20, 2013Date of Patent: June 7, 2016Assignees: SunPower Corporation, Total Marketing ServicesInventors: Richard Hamilton Sewell, David Aaron Randolph Barkhouse, Junbo Wu, Michael Cudzinovic, Paul Loscutoff, Joseph Behnke, Michel Arsène Olivier Ngamo Toko
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Patent number: 9293624Abstract: A method for forming a contact region for a solar cell is disclosed. The method includes depositing a paste composed of a first metal above a substrate of the solar cell, curing the paste to form a first metal layer, electrolessly plating a second metal layer on the first metal layer and electrolytically plating a third metal layer on the second metal layer, where the second metal layer electrically couples the first metal layer to the third metal layer. The method can further include electrolytically plating a fourth metal layer on the third metal layer.Type: GrantFiled: December 4, 2013Date of Patent: March 22, 2016Assignee: SunPower CorporationInventors: Michael Cudzinovic, Joseph Behnke
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Patent number: 9263601Abstract: Enhanced adhesion of seed layers for solar cell conductive contacts and methods of forming solar cell conductive contacts are described. For example, a method of fabricating a solar cell includes forming an adhesion layer above an emitter region of a substrate. A metal seed paste layer is formed on the adhesion layer. The metal seed paste layer and the adhesion layer are annealed to form a conductive layer in contact with the emitter region of the substrate. A conductive contact for the solar cell is formed from the conductive layer.Type: GrantFiled: December 21, 2012Date of Patent: February 16, 2016Assignee: SunPower CorporationInventors: Junbo Wu, Michael C. Johnson, Michael Cudzinovic, Joseph Behnke, Xi Zhu, David D. Smith, Richard Sewell Hamilton, Xiuwen Tu, Seung Bum Rim
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Publication number: 20150179836Abstract: 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: ApplicationFiled: December 20, 2013Publication date: June 25, 2015Inventors: Richard Hamilton Sewell, David Aaron Randolph Barkhouse, Junbo Wu, Michael Cudzinovic, Paul Loscutoff, Joseph Behnke, Michel Arsène Olivier Ngamo Toko
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Publication number: 20150179834Abstract: Approaches for forming barrier-less seed stacks and contacts are described. In an example, a solar cell includes a substrate and a conductive contact disposed on the substrate. The conductive contact includes a copper layer directly contacting the substrate. In another example, a solar cell includes a substrate and a seed layer disposed directly on the substrate. The seed layer consists essentially of one or more non-diffusion-barrier metal layers. A conductive contact includes a copper layer disposed directly on the seed layer. An exemplary method of fabricating a solar cell involves providing a substrate, and forming a seed layer over the substrate. The seed layer includes one or more non-diffusion-barrier metal layers. The method further involves forming a conductive contact for the solar cell from the seed layer.Type: ApplicationFiled: December 20, 2013Publication date: June 25, 2015Inventors: Mukul Agrawal, Seung Rim, Michael Cudzinovic
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Publication number: 20150090330Abstract: Solar cell contact structures formed from metal paste and methods of forming solar cell contact structures from metal paste are described. In a first example, a solar cell includes a substrate. A semiconductor region is disposed in or above the substrate. A contact structure is disposed on the semiconductor region and includes a conductive layer in contact with the semiconductor region. The conductive layer includes a matrix binder having aluminum/silicon (Al/Si) particles and an inert filler material dispersed therein. In a second example, a solar cell includes a substrate. A semiconductor region is disposed in or above the substrate. A contact structure is disposed on the semiconductor region and includes a conductive layer in contact with the semiconductor region. The conductive layer includes an agent for increasing a hydrophobic characteristic of the conductive layer.Type: ApplicationFiled: September 27, 2013Publication date: April 2, 2015Inventors: Richard Hamilton Sewell, Michael Cudzinovic
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Patent number: 8901010Abstract: Methods for protecting a texturized region and a lightly doped diffusion region of a solar cell to improve solar cell lifetime and efficiency are disclosed. In an embodiment, an example method includes providing a solar cell having a front side which faces the sun during normal operation and a back side opposite the front side, a silicon substrate and where the silicon substrate includes a texturized region and a lightly doped diffusion region. The method includes placing the solar cell on a receiving medium with the front side of the solar cell placed on an upper surface of the receiving medium, where the upper surface of the receiving medium prevents damage to the to the lightly doped diffusion region and damage to the texturized region on the front side of the solar cell during a contact printing process or transferring. In an embodiment, the lightly doped diffusion region has a doping concentration below 1×1019 cm?3 and the receiving medium includes a material having a moh's hardness in the range of 5-10.Type: GrantFiled: March 15, 2013Date of Patent: December 2, 2014Assignee: SunPower CorporationInventors: Staffan Westerberg, Florito Dennis Tingchuy Vicente, Michael Cudzinovic, Princess Carmi Tomada, Jemellee Guiao
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Publication number: 20140273326Abstract: Methods for protecting a texturized region and a lightly doped diffusion region of a solar cell to improve solar cell lifetime and efficiency are disclosed. In an embodiment, an example method includes providing a solar cell having a front side which faces the sun during normal operation and a back side opposite the front side, a silicon substrate and where the silicon substrate includes a texturized region and a lightly doped diffusion region. The method includes placing the solar cell on a receiving medium with the front side of the solar cell placed on an upper surface of the receiving medium, where the upper surface of the receiving medium prevents damage to the to the lightly doped diffusion region and damage to the texturized region on the front side of the solar cell during a contact printing process or transferring. In an embodiment, the lightly doped diffusion region has a doping concentration below 1×1019 cm?3 and the receiving medium includes a material having a moh's hardness in the range of 5-10.Type: ApplicationFiled: March 15, 2013Publication date: September 18, 2014Applicant: SunPower CorporationInventors: Staffan Westerberg, Florito Dennis Tingchuy Vicente, Michael Cudzinovic
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Publication number: 20140174518Abstract: Enhanced adhesion of seed layers for solar cell conductive contacts and methods of forming solar cell conductive contacts are described. For example, a method of fabricating a solar cell includes forming an adhesion layer above an emitter region of a substrate. A metal seed paste layer is formed on the adhesion layer. The metal seed paste layer and the adhesion layer are annealed to form a conductive layer in contact with the emitter region of the substrate. A conductive contact for the solar cell is formed from the conductive layer.Type: ApplicationFiled: December 21, 2012Publication date: June 26, 2014Inventors: Junbo Wu, Michael C. Johnson, Michael Cudzinovic, Joseph Behnke, Xi Zhu, David D. Smith, Richard Sewell Hamilton, Xiuwen Tu, Seung Bum Rim
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Publication number: 20140158192Abstract: Seed layers for solar cell conductive contacts and methods of forming seed layers for solar cell conductive contacts are described. For example, a solar cell includes a substrate. An emitter region is disposed above the substrate. A conductive contact is disposed on the emitter region and includes a conductive layer in contact with the emitter region. The conductive layer is composed of aluminum/silicon (Al/Si) particles having a composition of greater than approximately 15% Si with the remainder Al. In another example, a solar cell includes a substrate having a diffusion region at or near a surface of the substrate. A conductive contact is disposed above the diffusion region and includes a conductive layer in contact with the substrate. The conductive layer is composed of aluminum/silicon (Al/Si) particles having a composition of greater than approximately 15% Si with the remainder Al.Type: ApplicationFiled: December 6, 2012Publication date: June 12, 2014Inventors: Michael Cudzinovic, Junbo Wu, Xi Zhu