Patents by Inventor Peter John Cousins

Peter John Cousins 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).

  • Publication number: 20240030864
    Abstract: A photovoltaic module can include a high voltage photovoltaic laminate that include a plurality of high voltage photovoltaic cells with each of the high voltage photovoltaic cells including a plurality of sub-cells. A boost-less conversion device can be configured to convert a first voltage from the high voltage photovoltaic laminate to a second voltage.
    Type: Application
    Filed: September 29, 2023
    Publication date: January 25, 2024
    Inventors: GOPAL KRISHAN GARG, SEUNG BUM RIM, PETER JOHN COUSINS
  • Patent number: 11811360
    Abstract: A photovoltaic module can include a high voltage photovoltaic laminate that include a plurality of high voltage photovoltaic cells with each of the high voltage photovoltaic cells including a plurality of sub-cells. A boost-less conversion device can be configured to convert a first voltage from the high voltage photovoltaic laminate to a second voltage.
    Type: Grant
    Filed: March 28, 2014
    Date of Patent: November 7, 2023
    Assignee: Maxeon Solar Pte. Ltd.
    Inventors: Gopal Krishan Garg, Seung Bum Rim, Peter John Cousins
  • Publication number: 20230021009
    Abstract: A bipolar solar cell includes a backside junction formed by an N-type silicon substrate and a P-type polysilicon emitter formed on the backside of the solar cell. An antireflection layer may be formed on a textured front surface of the silicon substrate. A negative polarity metal contact on the front side of the solar cell makes an electrical connection to the substrate, while a positive polarity metal contact on the backside of the solar cell makes an electrical connection to the polysilicon emitter. An external electrical circuit may be connected to the negative and positive metal contacts to be powered by the solar cell. The positive polarity metal contact may form an infrared reflecting layer with an underlying dielectric layer for increased solar radiation collection.
    Type: Application
    Filed: July 21, 2022
    Publication date: January 19, 2023
    Applicant: SunPower Corporation
    Inventor: Peter John COUSINS
  • Patent number: 11437528
    Abstract: Contact holes of solar cells are formed by laser ablation to accommodate various solar cell designs. Use of a laser to form the contact holes is facilitated by replacing films formed on the diffusion regions with a film that has substantially uniform thickness. Contact holes may be formed to deep diffusion regions to increase the laser ablation process margins. The laser configuration may be tailored to form contact holes through dielectric films of varying thicknesses.
    Type: Grant
    Filed: February 18, 2020
    Date of Patent: September 6, 2022
    Assignee: SunPower Corporation
    Inventors: Gabriel Harley, David D. Smith, Tim Dennis, Ann Waldhauer, Taeseok Kim, Peter John Cousins
  • Patent number: 11398576
    Abstract: Solar cells having a plurality of sub-cells coupled by metallization structures, and singulation approaches to forming solar cells having a plurality of sub-cells coupled by metallization structures, are described. In an example, a solar cell, includes a plurality of sub-cells, each of the sub-cells having a singulated and physically separated semiconductor substrate portion. Adjacent ones of the singulated and physically separated semiconductor substrate portions have a groove there between. The solar cell also includes a monolithic metallization structure. A portion of the monolithic metallization structure couples ones of the plurality of sub-cells. The groove between adjacent ones of the singulated and physically separated semiconductor substrate portions exposes a portion of the monolithic metallization structure.
    Type: Grant
    Filed: March 27, 2020
    Date of Patent: July 26, 2022
    Assignee: SunPower Corporation
    Inventors: Gabriel Harley, Michael Morse, Peter John Cousins
  • Publication number: 20220029038
    Abstract: The formation of solar cell contacts using a laser is described. A method of fabricating a back-contact solar cell includes forming a poly-crystalline material layer above a single-crystalline substrate. The method also includes forming a dielectric material stack above the poly-crystalline material layer. The method also includes forming, by laser ablation, a plurality of contacts holes in the dielectric material stack, each of the contact holes exposing a portion of the poly-crystalline material layer; and forming conductive contacts in the plurality of contact holes.
    Type: Application
    Filed: October 12, 2021
    Publication date: January 27, 2022
    Applicant: SunPower Corporation
    Inventors: Gabriel HARLEY, David D. SMITH, Peter John COUSINS
  • Patent number: 11195964
    Abstract: Voltage breakdown devices for solar cells are described. For example, a solar cell includes a semiconductor substrate. A plurality of alternating N-type and P-type semiconductor regions is disposed in or above the substrate. A plurality of conductive contacts is coupled to the plurality of alternating N-type and P-type semiconductor regions. A voltage breakdown device is disposed above the substrate. The voltage breakdown device includes one of the plurality of conductive contacts in electrical contact with one of the N-type semiconductor regions and with one of the P-type semiconductor regions of the plurality of alternating N-type and P-type semiconductor regions disposed in or above the substrate.
    Type: Grant
    Filed: February 25, 2019
    Date of Patent: December 7, 2021
    Assignee: SunPower Corporation
    Inventor: Peter John Cousins
  • Patent number: 11152518
    Abstract: The formation of solar cell contacts using a laser is described. A method of fabricating a back-contact solar cell includes forming a poly-crystalline material layer above a single-crystalline substrate. The method also includes forming a dielectric material stack above the poly-crystalline material layer. The method also includes forming, by laser ablation, a plurality of contacts holes in the dielectric material stack, each of the contact holes exposing a portion of the poly-crystalline material layer; and forming conductive contacts in the plurality of contact holes.
    Type: Grant
    Filed: February 14, 2019
    Date of Patent: October 19, 2021
    Assignee: SunPower Corporation
    Inventors: Gabriel Harley, David D. Smith, Peter John Cousins
  • Patent number: 11107935
    Abstract: In one embodiment, a solar cell has base and emitter diffusion regions formed on the back side. The emitter diffusion region is configured to collect minority charge carriers in the solar cell, while the base diffusion region is configured to collect majority charge carriers. The emitter diffusion region may be a continuous region separating the base diffusion regions. Each of the base diffusion regions may have a reduced area to decrease minority charge carrier recombination losses without substantially increasing series resistance losses due to lateral flow of majority charge carriers. Each of the base diffusion regions may have a dot shape, for example.
    Type: Grant
    Filed: January 16, 2020
    Date of Patent: August 31, 2021
    Assignee: SunPower Corporation
    Inventors: Denis De Ceuster, Peter John Cousins
  • Patent number: 10840395
    Abstract: Methods of fabricating solar cells, and the resulting solar cells, are described herein. In an example, a method of fabricating a solar cell includes forming a thin dielectric layer on a surface of a substrate by radical oxidation or plasma oxidation of the surface of the substrate. The method also involves forming a silicon layer over the thin dielectric layer. The method also involves forming a plurality of emitter regions from the silicon layer.
    Type: Grant
    Filed: June 7, 2018
    Date of Patent: November 17, 2020
    Assignee: SunPower Corporation
    Inventors: Michael C. Johnson, Taiqing Qiu, David D. Smith, Peter John Cousins, Staffan Westerberg
  • Publication number: 20200279967
    Abstract: Solar cells having a plurality of sub-cells coupled by metallization structures, and singulation approaches to forming solar cells having a plurality of sub-cells coupled by metallization structures, are described. In an example, a solar cell, includes a plurality of sub-cells, each of the sub-cells having a singulated and physically separated semiconductor substrate portion. Adjacent ones of the singulated and physically separated semiconductor substrate portions have a groove there between. The solar cell also includes a monolithic metallization structure. A portion of the monolithic metallization structure couples ones of the plurality of sub-cells. The groove between adjacent ones of the singulated and physically separated semiconductor substrate portions exposes a portion of the monolithic metallization structure.
    Type: Application
    Filed: March 27, 2020
    Publication date: September 3, 2020
    Inventors: Gabriel Harley, Michael Morse, Peter John Cousins
  • Publication number: 20200212234
    Abstract: In one embodiment, a solar cell has base and emitter diffusion regions formed on the back side. The emitter diffusion region is configured to collect minority charge carriers in the solar cell, while the base diffusion region is configured to collect majority charge carriers. The emitter diffusion region may be a continuous region separating the base diffusion regions. Each of the base diffusion regions may have a reduced area to decrease minority charge carrier recombination losses without substantially increasing series resistance losses due to lateral flow of majority charge carriers. Each of the base diffusion regions may have a dot shape, for example.
    Type: Application
    Filed: January 16, 2020
    Publication date: July 2, 2020
    Applicant: SunPower Corporation
    Inventors: Denis DE CEUSTER, Peter John COUSINS
  • Publication number: 20200212230
    Abstract: Leakage pathway layers for solar cells and methods of forming leakage pathway layers for solar cells are described.
    Type: Application
    Filed: March 11, 2020
    Publication date: July 2, 2020
    Inventors: Andy Luan, David D. Smith, Peter John Cousins, Sheng Sun
  • Publication number: 20200185546
    Abstract: Contact holes of solar cells are formed by laser ablation to accommodate various solar cell designs. Use of a laser to form the contact holes is facilitated by replacing films formed on the diffusion regions with a film that has substantially uniform thickness. Contact holes may be formed to deep diffusion regions to increase the laser ablation process margins. The laser configuration may be tailored to form contact holes through dielectric films of varying thicknesses.
    Type: Application
    Filed: February 18, 2020
    Publication date: June 11, 2020
    Applicant: SunPower Corporation
    Inventors: Gabriel HARLEY, David D. SMITH, Tim DENNIS, Ann WALDHAUER, Taeseok KIM, Peter John COUSINS
  • Patent number: 10608126
    Abstract: Contact holes of solar cells are formed by laser ablation to accommodate various solar cell designs. Use of a laser to form the contact holes is facilitated by replacing films formed on the diffusion regions with a film that has substantially uniform thickness. Contact holes may be formed to deep diffusion regions to increase the laser ablation process margins. The laser configuration may be tailored to form contact holes through dielectric films of varying thicknesses.
    Type: Grant
    Filed: October 26, 2017
    Date of Patent: March 31, 2020
    Assignee: SunPower Corporation
    Inventors: Gabriel Harley, David D. Smith, Tim Dennis, Ann Waldhauer, Taeseok Kim, Peter John Cousins
  • Patent number: 10608133
    Abstract: Solar cells having a plurality of sub-cells coupled by metallization structures, and singulation approaches to forming solar cells having a plurality of sub-cells coupled by metallization structures, are described. In an example, a solar cell, includes a plurality of sub-cells, each of the sub-cells having a singulated and physically separated semiconductor substrate portion. Adjacent ones of the singulated and physically separated semiconductor substrate portions have a groove there between. The solar cell also includes a monolithic metallization structure. A portion of the monolithic metallization structure couples ones of the plurality of sub-cells. The groove between adjacent ones of the singulated and physically separated semiconductor substrate portions exposes a portion of the monolithic metallization structure.
    Type: Grant
    Filed: December 28, 2017
    Date of Patent: March 31, 2020
    Assignee: SunPower Corporation
    Inventors: Gabriel Harley, Michael Morse, Peter John Cousins
  • Patent number: 10573764
    Abstract: In one embodiment, a solar cell has base and emitter diffusion regions formed on the back side. The emitter diffusion region is configured to collect minority charge carriers in the solar cell, while the base diffusion region is configured to collect majority charge carriers. The emitter diffusion region may be a continuous region separating the base diffusion regions. Each of the base diffusion regions may have a reduced area to decrease minority charge carrier recombination losses without substantially increasing series resistance losses due to lateral flow of majority charge carriers. Each of the base diffusion regions may have a dot shape, for example.
    Type: Grant
    Filed: January 20, 2014
    Date of Patent: February 25, 2020
    Assignee: SunPower Corporation
    Inventors: Denis De Ceuster, Peter John Cousins
  • Publication number: 20200052140
    Abstract: A bipolar solar cell includes a backside junction formed by a silicon substrate and a first doped layer of a first dopant type on the backside of the solar cell. A second doped layer of a second dopant type makes an electrical connection to the substrate from the front side of the solar cell. A first metal contact of a first electrical polarity electrically connects to the first doped layer on the backside of the solar cell, and a second metal contact of a second electrical polarity electrically connects to the second doped layer on the front side of the solar cell. An external electrical circuit may be electrically connected to the first and second metal contacts to be powered by the solar cell.
    Type: Application
    Filed: October 7, 2019
    Publication date: February 13, 2020
    Applicant: SunPower Corporation
    Inventor: Peter John COUSINS
  • Publication number: 20190393368
    Abstract: A bipolar solar cell includes a backside junction formed by an N-type silicon substrate and a P-type polysilicon emitter formed on the backside of the solar cell. An antireflection layer may be formed on a textured front surface of the silicon substrate. A negative polarity metal contact on the front side of the solar cell makes an electrical connection to the substrate, while a positive polarity metal contact on the backside of the solar cell makes an electrical connection to the polysilicon emitter. An external electrical circuit may be connected to the negative and positive metal contacts to be powered by the solar cell. The positive polarity metal contact may form an infrared reflecting layer with an underlying dielectric layer for increased solar radiation collection.
    Type: Application
    Filed: July 2, 2019
    Publication date: December 26, 2019
    Applicant: SunPower Corporation
    Inventor: Peter John COUSINS
  • Patent number: 10475945
    Abstract: A bipolar solar cell includes a backside junction formed by a silicon substrate and a first doped layer of a first dopant type on the backside of the solar cell. A second doped layer of a second dopant type makes an electrical connection to the substrate from the front side of the solar cell. A first metal contact of a first electrical polarity electrically connects to the first doped layer on the backside of the solar cell, and a second metal contact of a second electrical polarity electrically connects to the second doped layer on the front side of the solar cell. An external electrical circuit may be electrically connected to the first and second metal contacts to be powered by the solar cell.
    Type: Grant
    Filed: August 5, 2016
    Date of Patent: November 12, 2019
    Assignee: SunPower Corporation
    Inventor: Peter John Cousins