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公开(公告)号：US20220271709A1
公开(公告)日：2022-08-25
申请号：US17249143
申请日：2021-02-22
Applicant: Merlin Solar Technologies, Inc.
Inventor： Edward Dechaumphai , Venkatesan Murali , Sarinee Prompanut , Chagkapong Chitsamart , Niphon Lapanaphan
Abstract: A method includes providing a mandrel having an electrical conduit electroformed in the mandrel. The second side of the electrical conduit is blackened while in the mandrel to create a black layer on the electrical conduit. The mandrel is aligned in a flatness fixture such that the mandrel is substantially flat. The mandrel remains flat and in a fixed relationship to the flatness fixture throughout the method. A beam of a laser is controlled toward the black layer. The beam has laser parameters including a power output, a frequency and a mark speed, and selected by setting the power output and the mark speed then determining the frequency. The beam removes a plurality of the portions of the black layer. Each removed portion of the plurality of the portions has a thickness equal to the black layer thickness, and a portion area of 9 mm2 to 18 mm2.
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公开(公告)号：US10181542B2
公开(公告)日：2019-01-15
申请号：US15382304
申请日：2016-12-16
Applicant: Merlin Solar Technologies, Inc.
Inventor： Venkateswaran Subbaraman , Gopal Prabhu , Venkatesan Murali , David Tanner
IPC: H01L31/044 , H01L31/05 , H01L31/0224 , B21D28/24 , H01L31/18
Abstract: A method comprises providing an expanded metal article having a plurality of first segments intersecting a plurality of second segments thereby forming a plurality of openings. The expanded metal article has a surface comprising a plurality of solder pads. A semiconductor material with a top surface and a bottom surface is provided, the bottom surface having a plurality of silver pads and the top surface serving as a light-incident surface of the photovoltaic cell. At a plurality of soldering locations, a majority of the plurality of solder pads on the surface of the expanded metal article is electrically coupled with the plurality of silver pads on the bottom surface of the semiconductor material. Also disclosed is a photovoltaic cell resulting from this method.
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公开(公告)号：US20170263787A1
公开(公告)日：2017-09-14
申请号：US15601479
申请日：2017-05-22
Applicant: Merlin Solar Technologies, Inc.
Inventor： Alejandro de la Fuente Vornbrock , Arthur Rudin , David Tanner
IPC: H01L31/02 , H01L31/05 , H01L31/042 , H01L31/048 , H02S40/34 , H01L31/18
CPC classification number: H01L31/0201 , H01L31/02013 , H01L31/042 , H01L31/048 , H01L31/0504 , H01L31/18 , H02S40/34 , Y02E10/50
Abstract: A photovoltaic module, and method of making, is disclosed in which a flexible circuit is electrically coupled to a plurality of photovoltaic cells, where the photovoltaic cells are electrically coupled in series to form a series of cells. Each photovoltaic cell has free-standing metallic articles coupled to the top and bottom surfaces of a semiconductor substrate. A cell interconnection element of each photovoltaic cell is electrically coupled to a free-standing metallic article of an adjacent photovoltaic cell, where the interconnection elements of the initial and final cells in the series serve as contact ends for the series of cells. Contact tabs of the flexible circuit are electrically coupled to the contact ends of the series of cells, and a junction box is electrically coupled to a junction box contact region of the flexible circuit.
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公开(公告)号：US09573214B2
公开(公告)日：2017-02-21
申请号：US14454720
申请日：2014-08-08
Applicant: Merlin Solar Technologies, Inc.
IPC: B23K1/08 , B23K3/06 , B23K1/00 , H01L31/0224
CPC classification number: B23K1/08 , B23K1/0016 , B23K3/0676 , H01L31/022425 , Y02E10/50 , Y02P70/521
Abstract: A method of applying solder includes providing a first roller and a second roller, where at least one of the first and second rollers has an outer surface comprising a solder wicking material. A metallic article is provided, the metallic article having a first side and a second side, and having an opening extending from the first side to the second side. The metallic article is dipped in solder, where the dipping forms an initial coating of solder on the metallic article. After the dipping, the metallic article is fed between the first and second rollers. The wicking material removes solder from the metallic article, such that a solder thickness of the initial coating on the metallic article is reduced after exiting the first and second rollers.
Abstract translation: 施加焊料的方法包括提供第一辊和第二辊，其中第一和第二辊中的至少一个具有包括焊料芯吸材料的外表面。 提供金属制品，金属制品具有第一侧和第二侧，并且具有从第一侧向第二侧延伸的开口。 将金属制品浸入焊料中，其中浸渍在金属制品上形成焊料的初始涂层。 在浸渍之后，金属制品被供给在第一和第二辊之间。 芯吸材料从金属制品中除去焊料，使得在离开第一和第二辊之后金属制品上的初始涂层的焊料厚度减小。
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公开(公告)号：US20190341514A1
公开(公告)日：2019-11-07
申请号：US16030766
申请日：2017-06-12
Applicant: Merlin Solar Technologies, Inc.
Inventor： Venkatesan Murali , Kent Riley Child , Arthur Rudin , Adam Brailove , Arvind Chari
IPC: H01L31/05 , H01L31/0224
Abstract: A metallic article for a photovoltaic cell is disclosed. The metallic article includes a first region having a plurality of electroformed elements that are configured to serve as an electrical conduit for a light-incident surface of the photovoltaic cell. A cell-to-cell interconnect is integral with the first region. The cell-to-cell interconnect is configured to extend beyond the light-incident surface and to directly couple the metallic article to a neighboring photovoltaic cell. The cell-to-cell interconnect includes a plurality of electroformed, curved appendages. Each appendage has a first end coupled to an edge of the first region and a second end opposite the first end and away from the edge. The appendages are spaced apart from each other. The metallic article is a unitary, free-standing piece.
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Patent Agency Ranking
公开(公告)号：US20170288081A1
公开(公告)日：2017-10-05
申请号：US15630763
申请日：2017-06-22
Applicant: Merlin Solar Technologies, Inc.
Inventor： Steve Babayan , Robert Brainard , Arvind Chari , Alejandro de la Fuente Vornbrock , Venkatesan Murali , Gopal Prabhu , Arthur Rudin , Venkateswaran Subbaraman , David Tanner , Dong Xu , Prashant Ramesh , Vishal Chandrashekar
CPC classification number: H01L31/0512 , H01L31/0201 , H01L31/02013 , H01L31/0504 , H01L31/0508 , H02S30/20 , H02S40/34 , Y02E10/50
Abstract: A photovoltaic module has a flexible backing substrate, a plurality of photovoltaic cells, and an electrical conduit. The photovoltaic cells are mounted on the backing substrate. Each photovoltaic cell has a metallic article, the metallic article including a plurality of electroformed elements comprising a cell interconnection element integral with a continuous grid having a plurality of first elements intersecting a plurality of second elements. The electroformed elements are interconnected and integral, with the continuous grid in contact with the light-incident surface of the photovoltaic cell. The cell interconnection element extends beyond the light-incident surface and couples the continuous grid to a neighboring photovoltaic cell. The electrical conduit has a flexible strip of electrically conductive material. The electrical conduit electrically couples the cell interconnection element of a first photovoltaic cell in the plurality of photovoltaic cells to a neighboring second photovoltaic cell in the plurality of photovoltaic cells.
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公开(公告)号：US20170098728A1
公开(公告)日：2017-04-06
申请号：US15382304
申请日：2016-12-16
Applicant: Merlin Solar Technologies, Inc.
Inventor： Venkateswaran Subbaraman , Gopal Prabhu , Venkatesan Murali , David Tanner
CPC classification number: H01L31/0508 , B21D28/24 , H01L31/022425 , H01L31/022433 , H01L31/18 , Y02E10/50
Abstract: A method comprises providing an expanded metal article having a plurality of first segments intersecting a plurality of second segments thereby forming a plurality of openings. The expanded metal article has a surface comprising a plurality of solder pads. A semiconductor material with a top surface and a bottom surface is provided, the bottom surface having a plurality of silver pads and the top surface serving as a light-incident surface of the photovoltaic cell. At a plurality of soldering locations, a majority of the plurality of solder pads on the surface of the expanded metal article is electrically coupled with the plurality of silver pads on the bottom surface of the semiconductor material. Also disclosed is a photovoltaic cell resulting from this method.
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公开(公告)号：US20230101622A1
公开(公告)日：2023-03-30
申请号：US18059528
申请日：2022-11-29
Applicant: Merlin Solar Technologies, Inc.
Inventor： Edward Dechaumphai , Venkatesan Murali , Sarinee Prompanut , Chagkapong Chitsamart , Niphon Lapanaphan
Abstract: A method of removing a plurality of portions of a black layer of an electrical conduit for a photovoltaic cell is disclosed. The method includes providing a mandrel having the electrical conduit electroformed in the mandrel. The electrical conduit is formed in a preformed pattern on an outer surface of the mandrel. The electrical conduit has the black layer with a black layer thickness on a side opposite of the outer surface of the mandrel. A beam of a laser is controlled toward the black layer of the electrical conduit. The beam is characterized by laser parameters. The beam of the laser removes the plurality of portions of the black layer on the electrical conduit. Each removed portion of the plurality of portions of the black layer has a thickness equal to the black layer thickness, and a portion area of 5 mm2 to 20 mm2.
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公开(公告)号：US10886424B2
公开(公告)日：2021-01-05
申请号：US16454581
申请日：2019-06-27
Applicant: Merlin Solar Technologies, Inc.
Inventor： Arvind Chari , Venkatesan Murali , Robert Brainard , Gopal Prabhu , Jesse Dam
IPC: H01L31/05 , C25D1/00 , H01L31/0224
Abstract: A method includes providing an electrically conductive mandrel having an outer surface layer comprising a preformed pattern. The metallic article is electroformed. The metallic article includes a plurality of electroformed elements formed in the preformed pattern on the outer surface layer of the mandrel. The plurality of electroformed elements have a first side adjacent to the outer surface layer of the mandrel and a second side. A solder is plated on the second side of the plurality of electroformed elements while on the mandrel. The metallic article is separated from the mandrel. The plurality of electroformed elements are interconnected such that the metallic article forms a unitary, free-standing piece. A solution is applied to create a blackening of the first side of the plurality of electroformed elements. The solder on the second side of the plurality of electroformed elements is not blackened.
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公开(公告)号：US20200295212A1
公开(公告)日：2020-09-17
申请号：US16886134
申请日：2020-05-28
Applicant: Merlin Solar Technologies, Inc.
Inventor： Venkateswaran Subbaraman , Gopal Prabhu , Venkatesan Murali , David Tanner
IPC: H01L31/05 , H01L31/0465 , H02S40/34 , H01L31/0224 , C25B11/03
Abstract: In embodiments, a photovoltaic cell has an expanded metal article configured as a mesh, a semiconductor material, and a front metallic article. The expanded metal article has a plurality of first segments intersecting a plurality of second segments thereby forming a plurality of openings, and has a plurality of cuts in the mesh. The expanded metal article is electrically coupled to a back surface of the semiconductor material. The front metallic article has a plurality of electroformed elements interconnected to form a unitary, free-standing piece comprising a continuous grid. The continuous grid of the front metallic article is electrically coupled to a front surface of the semiconductor material. The plurality of cuts of the expanded metal article is arranged on the photovoltaic cell to relieve stresses induced by the front metallic article on the front surface of the semiconductor material.
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