Patents by Inventor Tim Dennis

Tim Dennis 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).

  • Patent number: 9831359
    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: January 7, 2016
    Date of Patent: November 28, 2017
    Assignee: SunPower Corporation
    Inventors: Gabriel Harley, David D. Smith, Tim Dennis, Ann Waldhauer, Taeseok Kim, Peter John Cousins
  • Publication number: 20170263795
    Abstract: Methods of fabricating emitter regions of solar cells are described. Methods of forming layers on substrates of solar cells, and the resulting solar cells, are also described.
    Type: Application
    Filed: May 22, 2017
    Publication date: September 14, 2017
    Inventors: David D. Smith, Helen Liu, Tim Dennis, Jane Manning, Hsin-Chiao Luan, Ann Waldhauer, Genevieve A. Solomon, Brenda Pagulayan Malgapu, Joseph Ramirez
  • Patent number: 9537030
    Abstract: Methods of fabricating solar cells with tunnel dielectric layers are described. Solar cells with tunnel dielectric layers are also described.
    Type: Grant
    Filed: May 29, 2015
    Date of Patent: January 3, 2017
    Assignee: SunPower Corporation
    Inventors: Tim Dennis, Scott Harrington, Jane Manning, David D. Smith, Ann Waldhauer
  • Patent number: 9520507
    Abstract: A method of fabricating a solar cell can include forming a dielectric region on a silicon substrate. The method can also include forming an emitter region over the dielectric region and forming a dopant region on a surface of the silicon substrate. In an embodiment, the method can include heating the silicon substrate at a temperature above 900 degrees Celsius to getter impurities to the emitter region and drive dopants from the dopant region to a portion of the silicon substrate.
    Type: Grant
    Filed: December 22, 2014
    Date of Patent: December 13, 2016
    Assignee: SunPower Corporation
    Inventors: David D. Smith, Tim Dennis, Russelle De Jesus Tabajonda
  • Publication number: 20160329441
    Abstract: A method of fabricating a solar cell can include forming a dielectric region on a silicon substrate. The method can also include forming an emitter region over the dielectric region and forming a dopant region on a surface of the silicon substrate. In an embodiment, the method can include heating the silicon substrate at a temperature above 900 degrees Celsius to getter impurities to the emitter region and drive dopants from the dopant region to a portion of the silicon substrate.
    Type: Application
    Filed: July 18, 2016
    Publication date: November 10, 2016
    Inventors: David D. Smith, Tim Dennis, Russelle De Jesus Tabajonda
  • Publication number: 20160181444
    Abstract: A method of fabricating a solar cell can include forming a dielectric region on a silicon substrate. The method can also include forming an emitter region over the dielectric region and forming a dopant region on a surface of the silicon substrate. In an embodiment, the method can include heating the silicon substrate at a temperature above 900 degrees Celsius to getter impurities to the emitter region and drive dopants from the dopant region to a portion of the silicon substrate.
    Type: Application
    Filed: December 22, 2014
    Publication date: June 23, 2016
    Inventors: David D. Smith, Tim Dennis, Russelle De Jesus Tabajonda
  • Publication number: 20160118516
    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: January 7, 2016
    Publication date: April 28, 2016
    Applicant: SunPower Corporation
    Inventors: Gabriel HARLEY, David D. SMITH, Tim DENNIS, Ann WALDHAUER, Taeseok KIM, Peter John COUSINS
  • Publication number: 20160071996
    Abstract: Solar cells having emitter regions composed of wide bandgap semiconductor material are described. In an example, a method includes forming, in a process tool having a controlled atmosphere, a thin dielectric layer on a surface of a semiconductor substrate of the solar cell. The semiconductor substrate has a bandgap. Without removing the semiconductor substrate from the controlled atmosphere of the process tool, a semiconductor layer is formed on the thin dielectric layer. The semiconductor layer has a bandgap at least approximately 0.2 electron Volts (eV) above the bandgap of the semiconductor substrate.
    Type: Application
    Filed: November 19, 2015
    Publication date: March 10, 2016
    Inventors: Richard M. Swanson, Marius M. Bunea, Michael C. Johnson, David D. Smith, Yu-Chen Shen, Peter J. Cousins, Tim Dennis
  • Patent number: 9263602
    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 23, 2013
    Date of Patent: February 16, 2016
    Assignee: SunPower Corporation
    Inventors: Gabriel Harley, David D. Smith, Tim Dennis, Ann Waldhauer, Taeseok Kim, Peter John Cousins
  • Patent number: 9219173
    Abstract: Solar cells having emitter regions composed of wide bandgap semiconductor material are described. In an example, a method includes forming, in a process tool having a controlled atmosphere, a thin dielectric layer on a surface of a semiconductor substrate of the solar cell. The semiconductor substrate has a bandgap. Without removing the semiconductor substrate from the controlled atmosphere of the process tool, a semiconductor layer is formed on the thin dielectric layer. The semiconductor layer has a bandgap at least approximately 0.2 electron Volts (eV) above the bandgap of the semiconductor substrate.
    Type: Grant
    Filed: May 7, 2015
    Date of Patent: December 22, 2015
    Assignee: SunPower Corporation
    Inventors: Richard M. Swanson, Marius M. Bunea, Michael C. Johnson, David D. Smith, Yu-Chen Shen, Peter J. Cousins, Tim Dennis
  • Publication number: 20150263200
    Abstract: Methods of fabricating solar cells with tunnel dielectric layers are described. Solar cells with tunnel dielectric layers are also described.
    Type: Application
    Filed: May 29, 2015
    Publication date: September 17, 2015
    Inventors: Tim Dennis, Scott Harrington, Jane Manning, David D. Smith, Ann Waldhauer
  • Publication number: 20150243803
    Abstract: Solar cells having emitter regions composed of wide bandgap semiconductor material are described. In an example, a method includes forming, in a process tool having a controlled atmosphere, a thin dielectric layer on a surface of a semiconductor substrate of the solar cell. The semiconductor substrate has a bandgap. Without removing the semiconductor substrate from the controlled atmosphere of the process tool, a semiconductor layer is formed on the thin dielectric layer. The semiconductor layer has a bandgap at least approximately 0.2 electron Volts (eV) above the bandgap of the semiconductor substrate.
    Type: Application
    Filed: May 7, 2015
    Publication date: August 27, 2015
    Inventors: Richard M. Swanson, Marius M. Bunea, Michael C. Johnson, David D. Smith, Yu-Chen Shen, Peter J. Cousins, Tim Dennis
  • Patent number: 9112066
    Abstract: Method of fabricating solar cells with tunnel dielectric layers are described. Solar cells with tunnel dielectric layers are also described.
    Type: Grant
    Filed: January 16, 2014
    Date of Patent: August 18, 2015
    Assignee: SunPower Corporation
    Inventors: Tim Dennis, Scott Harrington, Jane Manning, David D. Smith, Ann Waldhauer
  • Patent number: 9054255
    Abstract: Solar cells having emitter regions composed of wide bandgap semiconductor material are described. In an example, a method includes forming, in a process tool having a controlled atmosphere, a thin dielectric layer on a surface of a semiconductor substrate of the solar cell. The semiconductor substrate has a bandgap. Without removing the semiconductor substrate from the controlled atmosphere of the process tool, a semiconductor layer is formed on the thin dielectric layer. The semiconductor layer has a bandgap at least approximately 0.2 electron Volts (eV) above the bandgap of the semiconductor substrate.
    Type: Grant
    Filed: March 23, 2012
    Date of Patent: June 9, 2015
    Assignee: SunPower Corporation
    Inventors: Richard M. Swanson, Marius M. Bunea, Michael C. Johnson, David D. Smith, Yu-Chen Shen, Peter J. Cousins, Tim Dennis
  • Publication number: 20140134788
    Abstract: Method of fabricating solar cells with tunnel dielectric layers are described. Solar cells with tunnel dielectric layers are also described.
    Type: Application
    Filed: January 16, 2014
    Publication date: May 15, 2014
    Inventors: Tim Dennis, Scott Harrington, Jane Manning, David D. Smith, Ann Waldhauer
  • Patent number: 8709851
    Abstract: Methods of fabricating solar cells with tunnel dielectric layers are described. Solar cells with tunnel dielectric layers are also described.
    Type: Grant
    Filed: November 15, 2012
    Date of Patent: April 29, 2014
    Assignee: SunPower Corporation
    Inventors: Tim Dennis, Scott Harrington, Jane Manning, David D. Smith, Ann Waldhauer
  • Publication number: 20140096824
    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: October 23, 2013
    Publication date: April 10, 2014
    Applicant: SUNPOWER CORPORATION
    Inventors: Gabriel HARLEY, David D. SMITH, Tim DENNIS, Ann WALDHAUER, Taeseok KIM, Peter John COUSINS
  • Patent number: 8586403
    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 15, 2011
    Date of Patent: November 19, 2013
    Assignee: SunPower Corporation
    Inventors: Gabriel Harley, David D. Smith, Tim Dennis, Ann Waldhauer, Taeseok Kim, Peter John Cousins
  • Publication number: 20130247965
    Abstract: Solar cells having emitter regions composed of wide bandgap semiconductor material are described. In an example, a method includes forming, in a process tool having a controlled atmosphere, a thin dielectric layer on a surface of a semiconductor substrate of the solar cell. The semiconductor substrate has a bandgap. Without removing the semiconductor substrate from the controlled atmosphere of the process tool, a semiconductor layer is formed on the thin dielectric layer. The semiconductor layer has a bandgap at least approximately 0.2 electron Volts (eV) above the bandgap of the semiconductor substrate.
    Type: Application
    Filed: March 23, 2012
    Publication date: September 26, 2013
    Inventors: Richard M. Swanson, Marius M. Bunea, Michael C. Johnson, David D. Smith, Yu-Chen Shen, Peter J. Cousins, Tim Dennis
  • Publication number: 20130078758
    Abstract: Methods of fabricating solar cells with tunnel dielectric layers are described. Solar cells with tunnel dielectric layers are also described.
    Type: Application
    Filed: November 15, 2012
    Publication date: March 28, 2013
    Inventors: Tim Dennis, Scott Harrington, Jane Manning, David D. Smith, Ann Waldhauer