| Patent application number | Description | Published |
|---|
| 20090077804 | PRODUCTION LINE MODULE FOR FORMING MULTIPLE SIZED PHOTOVOLTAIC DEVICES - The present invention generally relates to a sectioning module positioned within an automated solar cell device fabrication system. The solar cell device fabrication system is adapted to receive a single large substrate and form multiple silicon thin film solar cell devices from the single large substrate. | 03-26-2009 |
| 20090077805 | PHOTOVOLTAIC PRODUCTION LINE - The present invention generally relates to a system that can be used to form a photovoltaic device, or solar cell, using processing modules that are adapted to perform one or more steps in the solar cell formation process. The automated solar cell fab is generally an arrangement of automated processing modules and automation equipment that is used to form solar cell devices. The automated solar fab will thus generally comprise a substrate receiving module that is adapted to receive a substrate, one or more absorbing layer deposition cluster tools having at least one processing chamber that is adapted to deposit a silicon-containing layer on a surface of the substrate, one or more back contact deposition chambers, one or more material removal chambers, a solar cell encapsulation device, an autoclave module, an automated junction box attaching module, and one or more quality assurance modules that are adapted to test and qualify the completely formed solar cell device. | 03-26-2009 |
| 20090188102 | AUTOMATED SOLAR CELL ELECTRICAL CONNECTION APPARATUS - The present invention generally relates to an automated solar cell electrical connection device that is positioned within an automated solar cell fabrication system. The automated solar cell electrical connection device includes a module and process for automatically attaching a junction box to a composite solar cell structure during the fabrication of a completed solar cell device. The automated solar cell electrical connection module may include a composite solar cell structure conveyor for positioning the composite solar cell structure, an adhesive dispense module for applying adhesive to the junction box, a flux dispenser for applying flux to electrical connection tabs in the junction box, a vision system for locating features on the composite solar cell structure, a robot for positioning the junction box onto the composite solar cell structure, a heating element to make electrical connections between the junction box and the solar cell device, a potting material dispensing assembly for dispensing potting material into the junction box, and a system controller for controlling the functions of the module. | 07-30-2009 |
| 20090211071 | METHOD AND APPARATUS FOR FORMING AN ELECTRICAL CONNECTION ON A SOLAR CELL - Embodiments of the present invention provide a module and process for forming electrical connections on a solar cell substrate in a solar cell production line. The module generally provides a substrate handling system, a substrate positioning system, a cross-buss attachment assembly, and a side-buss attachment assembly. The module may provide adaptations for automatically adjusting the module to receive and process various sizes of solar cell substrates. | 08-27-2009 |
| 20090277006 | METHOD FOR FORMING AN ELECTRICAL CONNECTION - Embodiments of the present invention provide a method of forming an electrical connection on a device. In one embodiment, the electrical connection is attached to the device via an adhesive having electrically conductive particles disposed therein. In one embodiment, the adhesive is cured while applying pressure such that the conductive particles align, have a reduced particle-to-particle spacing, or come into contact with each other to provide a more directly conductive (less resistive) path between the electrical connection and the device. In one embodiment of the present invention, a method for forming an electrical lead on a partially formed solar cell during formation of the solar cell device is provided. The method comprises placing a side-buss wire onto a pattern of electrically conductive adhesive disposed on a back contact layer of a solar cell device substrate, laminating the side-buss wire and electrically conductive adhesive between the solar cell device substrate and a back glass substrate to form a composite solar cell structure, and curing the electrically conductive adhesive while applying pressure and heat to the composite solar cell structure | 11-12-2009 |
| 20090287446 | PHOTOVOLTAIC CELL REFERENCE MODULE FOR SOLAR TESTING - The present invention generally includes an apparatus and method of forming a reference module device that is able to deliver a repeatable and desirable amount of power that does not degrade or change over time. The reference module can be used to help test and calibrate various testing equipment used in the production of a photovoltaic device that may be formed in a solar cell fab. The solar cell fab is generally an arrangement of processing modules and automation equipment that is used to form solar cell devices. | 11-19-2009 |
| 20100047954 | PHOTOVOLTAIC PRODUCTION LINE - The present invention generally relates to a system that can be used to form a photovoltaic device, or solar cell, using processing modules that are adapted to perform one or more steps in the solar cell formation process. The automated solar cell fab is generally an arrangement of automated processing modules and automation equipment that is used to form solar cell devices. The automated solar fab will thus generally comprise a substrate receiving module that is adapted to receive a substrate, one or more absorbing layer deposition cluster tools having at least one processing chamber that is adapted to deposit a silicon-containing layer on a surface of the substrate, one or more back contact deposition chambers, one or more material removal chambers, a solar cell encapsulation device, an autoclave module, an automated junction box attaching module, and one or more quality assurance modules that are adapted to test and qualify the completely formed solar cell device. | 02-25-2010 |
| 20100068835 | THIN FILM SCRIBE PROCESS - A method and apparatus for improving a thin film scribing procedure is presented. Embodiments of the invention include a method and apparatus for determining a scribe setting for removal of an absorber layer of a photovoltaic device that improves contact resistance between a back contact layer and a front contact layer of the device. | 03-18-2010 |
| 20100132759 | CELL ISOLATION ON PHOTOVOLTAIC MODULES FOR HOT SPOT REDUCTION - Embodiments of the present invention provide methods for fabricating a solar cell on a substrate that have proportionally reduced current to minimize or reduce the likelihood of shading of a portion of the solar cell causing damage to the formed device. In one embodiment, a method for fabricating a series of solar cell arrays on a substrate includes providing a substrate having a TCO layer formed thereon, forming a first plurality of vertical scribing lines and a first plurality of horizontal scribing lines in the TCO layer, forming a film stack and a back metal layer on the scribed TCO layer, and forming a second plurality of the horizontal scribing lines in the film stack and the back metal layer, wherein the second plurality of horizontal scribing lines comprise pairs of scribing lines formed adjacent to each respective one of the first plurality of the horizontal scribing lines formed in the TCO layer. | 06-03-2010 |
| 20100132775 | ADHESION BETWEEN AZO AND AG FOR THE BACK CONTACT IN TANDEM JUNCTION CELL BY METAL ALLOY - Methods of promoting adhesion between a reflective backing layer and a solar cell substrate are provided. The reflective backing layer is formed over a conductive metal oxide layer as an alloy using reflective and adhesive components, the adhesive components being present in levels generally below about 5 atomic percent. Techniques are disclosed for depositing varying the concentration of the reflective backing layer to localize the adhesive components in an adhesion region near the conductive metal oxide layer. Techniques are also disclosed for boosting bonding species in the conductive metal oxide layer to further enhance adhesion. | 06-03-2010 |
| 20100132783 | TRANSPARENT CONDUCTIVE FILM WITH HIGH SURFACE ROUGHNESS FORMED BY A REACTIVE SPUTTER DEPOSITION - Methods for sputter depositing a transparent conductive layer are provided in the present invention. The transparent conductive layer may be utilized as a contact layer on a substrate or a back reflector in a photovoltaic device. In one embodiment, the method includes supplying a gas mixture into a processing chamber, sputtering source material from a target disposed in the processing chamber, wherein the target has dopants doped into a base material, wherein the dopants are selected from a group consisting of boron containing materials, titanium containing materials, tantalum containing materials, tungsten containing materials, alloys thereof, or combinations thereof, and reacting the sputtered material with the gas mixture to deposit a transparent conductive layer on a substrate disposed in the processing chamber. | 06-03-2010 |
| 20100133094 | TRANSPARENT CONDUCTIVE FILM WITH HIGH TRANSMITTANCE FORMED BY A REACTIVE SPUTTER DEPOSITION - Methods for sputter depositing a transparent conductive layer are provided in the present invention. The transparent conductive layer may be utilized as a contact layer on a substrate or a back reflector in a photovoltaic device. In one embodiment, the method includes supplying a gas mixture into the processing chamber, sputtering source material from a target disposed in the processing chamber, wherein the target is fabricated from a zinc containing material having an aluminum containing dopant concentration less than 3 percent by weight, and reacting the sputtered material with the gas mixture. | 06-03-2010 |
| 20100163406 | SUBSTRATE SUPPORT IN A REACTIVE SPUTTER CHAMBER - An apparatus for sputter depositing a transparent conductive oxide (TCO) layer are provided in the present invention. The transparent conductive oxide layer may be utilized as a contact layer on a substrate or a back reflector in a photovoltaic device. In one embodiment, the apparatus includes a processing chamber having an interior processing region, a substrate carrier system disposed in the interior processing region, the substrate carrier system having a plurality of rollers for conveying a substrate through the interior processing region, and an insulating member electrically isolating the rollers from the processing chamber. | 07-01-2010 |
| 20100224243 | ADHESION BETWEEN AZO AND AG FOR THE BACK CONTACT IN TANDEM JUNCTION CELL BY METAL ALLOY - Methods of promoting adhesion between a reflective backing layer and a solar cell substrate are provided. The reflective backing layer is formed over a conductive metal oxide layer as an alloy using reflective and adhesive components, the adhesive components being present in levels generally below about 5 atomic percent. Techniques are disclosed for depositing varying the concentration of the reflective backing layer to localize the adhesive components in an adhesion region near the conductive metal oxide layer. Techniques are also disclosed for boosting bonding species in the conductive metal oxide layer to further enhance adhesion. | 09-09-2010 |
| 20100267192 | PROCESS TO REMOVE METAL CONTAMINATION ON A GLASS SUBSTRATE - The present disclosure relates to methods and related cleaning solutions ( | 10-21-2010 |
| 20100276571 | CALIBRATION METHOD FOR SOLAR SIMULATORS USIED IN SINGLE JUNCTION AND TANDEM JUNCTION SOLAR CELL TESTING APPARATUS - A method of calibrating a light source used to simulate the sun in solar cell testing apparatus. The method comprises using a control cell to measure the intensity of light from the light source at a first wavelength range as a function of output short circuit current, comparing the measured intensity to a targeted intensity value, optionally adjusting power to the light source until the measured intensity is substantially equal to the targeted intensity value, repeatedly using a calibrated monitoring module to periodically measure monitoring measured values for monitoring module output short circuit current, monitoring module output open circuit voltage and monitoring module quantum efficiency, obtaining average values for monitoring module output short circuit current, monitoring module output open circuit voltage and monitoring module quantum efficiency, comparing the measured values with the average values, and determining if differences in measured values and average values are within an acceptable limit. | 11-04-2010 |
| 20100311204 | METHOD FOR FORMING TRANSPARENT CONDUCTIVE OXIDE - Embodiments disclosed herein generally relate to a process of depositing a transparent conductive oxide layer over a substrate. The transparent oxide layer is sometimes deposited onto a substrate for later use in a solar cell device. The transparent conductive oxide layer may be deposited by a “cold” sputtering process. In other words, during the sputtering process, a plasma is ignited in the processing chamber which naturally heats the substrate. No additional heat is provided to the substrate during deposition such as from the susceptor. After the transparent conductive oxide layer is deposited, the substrate may be annealed and etched, in either order, to texture the transparent conductive oxide layer. In order to tailor the shape of the texturing, different wet etch chemistries may be utilized. The different etch chemistries may be used to shape the surface of the transparent conductive oxide and the etch rate. | 12-09-2010 |
| 20100311228 | METHOD FOR FORMING TRANSPARENT CONDUCTIVE OXIDE - Embodiments disclosed herein generally relate to a process of depositing a transparent conductive oxide layer over a substrate. The transparent oxide layer is sometimes deposited onto a substrate for later use in a solar cell device. The transparent conductive oxide layer may be deposited by a “cold” sputtering process. In other words, during the sputtering process, a plasma is ignited in the processing chamber which naturally heats the substrate. No additional heat is provided to the substrate during deposition such as from the susceptor. After the transparent conductive oxide layer is deposited, the substrate may be annealed and etched, in either order, to texture the transparent conductive oxide layer. In order to tailor the shape of the texturing, different wet etch chemistries may be utilized. The different etch chemistries may be used to shape the surface of the transparent conductive oxide and the etch rate. | 12-09-2010 |
| 20100313929 | CELL ISOLATION ON PHOTOVOLTAIC MODULES FOR HOT SPOT REDUCTION - Embodiments of the present invention provide methods for fabricating a solar cell on a substrate that have proportionally reduced current to minimize or reduce the likelihood of shading of a portion of the solar cell causing damage to the formed device. In one embodiment, a method for fabricating a series of solar cell arrays on a substrate includes providing a substrate having a TCO layer formed thereon, forming a first plurality of vertical scribing lines and a first plurality of horizontal scribing lines in the TCO layer, forming a film stack and a back metal layer on the scribed TCO layer, and forming a second plurality of the horizontal scribing lines in the film stack and the back metal layer, wherein the second plurality of horizontal scribing lines comprise pairs of scribing lines formed adjacent to each respective one of the first plurality of the horizontal scribing lines formed in the TCO layer. | 12-16-2010 |
| 20100313945 | Solar Cell Substrate and Methods of Manufacture - Photovoltaic cells and methods for making photovoltaic cells are described. The methods include disposing an intermediate layer within the back contact at a thickness that does not negatively impact reflection or transmission of light through the solar cell. The intermediate layer prevents peeling of metal from the back contact during laser scribing. | 12-16-2010 |
| 20100323471 | Selective Etch of Laser Scribed Solar Cell Substrate - Methods for making solar cells are described. The methods include selectively etching strips formed by laser scribing to remove oxides formed during laser scribing. | 12-23-2010 |
| 20110065227 | COMMON LASER MODULE FOR A PHOTOVOLTAIC PRODUCTION LINE - Embodiments of the present invention generally relate to an automated production line using a common laser scribe module for providing consistent scribe lines in multiple layers during the formation of thin film photovoltaic modules. The common laser scribe module includes a plurality of identical, programmable laser tools configured to emit radiation at a common wavelength. Substrates flowing through the production line are tracked by a system controller, which identifies available laser tools within the common laser scribe module and routes substrates to available tools for scribing features in one or more layers disposed on the substrates. The system controller also sets and controls laser parameters, such as power, pulse frequency, pulse width, and laser pattern, in order to accurately and consistently produce scribed lines in the appropriate material layer of the substrate. | 03-17-2011 |
| 20110088763 | METHOD AND APPARATUS FOR IMPROVING PHOTOVOLTAIC EFFICIENCY - A method and apparatus for improving efficiency of photovoltaic cells by improving light capture between the photoelectric unit and back reflector is provided. A transition layer is formed at the interface between the photoelectric unit and transmitting conducting layer of the back reflector by adding oxygen, nitrogen, or both to the surface of the photoelectric unit or the interface between the photoelectric unit and the transmitting conducting layer. The transition layer may comprise silicon, oxygen, or nitrogen, and may be silicon oxide, silicon nitride, metal oxide with excess oxygen, metal oxide with nitrogen, or any combination thereof, including bilayers and multi-layers. The sputtering process for forming the transmitting conducting layer may feature at least one of nitrogen and excess oxygen, and may be performed by sputtering at low power, followed by an operation to form the rest of the transmitting conductive layer. | 04-21-2011 |
| 20110162704 | RELIABILITY OF BACK END OF LINE PROCESS BY ADDING PVD OXIDE FILM - A method and apparatus for forming a protective coating on a photovoltaic device is provided. The photovoltaic device is formed by depositing photoelectric conversion units on a substrate, and by forming conductive layers and contacts on the photoelectric conversion units. The protective coating is formed by a deposition process, such as physical or chemical vapor deposition. | 07-07-2011 |
