David J Ford
Accountancy in Wilmington, DE

6420643, Jul 16, 2002

Feb 2, 2001

09/776583

David H. Ford - Wilmington DE
Allen M. Barnett - Newark DE
Robert B. Hall - Newark DE
James A. Rand - Landenberg PA

AstroPower, Inc. - Newark DE

H01L 31042

136244, 136249, 136251, 136255, 136256, 136261, 136252, 257433, 257461, 257443, 257454, 257457, 257459

A polycrystalline film of silicon including silicon grains having an aspect ratio, d/t, of more than 1:1, wherein “d” is the grain diameter and “t” is the grain thickness. The polycrystalline film of silicon can be used to form an electronic device, such as a monolithically integrated solar cell having ohmic contacts formed on opposed surfaces or on the same surface of the film. A plurality of solar cells can be monolithically integrated to provide a solar cell module that includes an electrically insulating substrate and at least two solar cells disposed on the substrate in physical isolation from one another. Methods for manufacturing the film, solar cell and solar cell module are also disclosed. The simplified structure and method allow for substantial cost reduction on a mass-production scale, at least in part due to the high aspect ratio silicon grains in the film.

6362021, Mar 26, 2002

Feb 2, 2001

09/776514

David H. Ford - Wilmington DE
Allen M. Barnett - Newark DE
Robert B. Hall - Newark DE
James A. Rand - Landenberg PA

AstroPower, Inc. - Newark DE

H01L 31068

438 97, 136258, 136256, 136261, 257 64, 257461, 257465, 257459, 257431, 427588, 427578, 427 74, 427 58, 438488, 438166, 438487, 423348

A polycrystalline film of silicon including silicon grains having an aspect ratio, d/t, of more than 1:1, wherein “d” is the grain diameter and “t” is the grain thickness. The polycrystalline film of silicon can be used to form an electronic device, such as a monolithically integrated solar cell having ohmic contacts formed on opposed surfaces or on the same surface of the film. A plurality of solar cells can be monolithically integrated to provide a solar cell module that includes an electrically insulating substrate and at least two solar cells disposed on the substrate in physical isolation from one another. Methods for manufacturing the film, solar cell and solar cell module are also disclosed. The simplified structure and method allow for substantial cost reduction on a mass-production scale, at least in part due to the high aspect ratio silicon grains in the film.

RE36156, Mar 23, 1999

Jan 24, 1997

8/788660

Robert B. Hall - Newark DE
Allen M. Barnett - Newark DE
Sandra R. Collins - Chesapeake City MD
Joseph C. Checchi - Newark DE
David H. Ford - Wilmington DE
Christopher L. Kendall - Wilmington DE
Steven M. Lampo - Elkton MD
James A. Rand - Oxford PA

Astropower, Inc. - Newark DE

H01L 310392, H01L 310368, H01L 3118

136258

The invention relates to techniques for manufacturing columnar-grained polycrystalline sheets which have particular utility as substrates or wafers for solar cells. The sheet is made by applying granular silicon to a setter material which supports the granular material. The setter material and granular silicon are subjected to a thermal profile all of which promote columnar growth by melting the silicon from the top downwardly. The thermal profile sequentially creates a melt region at the top of the granular silicon and then a growth region where both liquid and a growing polycrystalline sheet layer coexist. An annealing region is created where the temperature of the grown polycrystalline silicon sheet layer is controllably reduced to effect stress relief.

5496416, Mar 5, 1996

Aug 5, 1994

8/286673

Robert B. Hall - Newark DE
Allen M. Barnett - Newark DE
Sandra R. Collins - Chesapeake City MD
Joseph C. Checchi - Newark DE
David H. Ford - Wilmington DE
Christopher L. Kendall - Wilmington DE
Steven M. Lampo - Elkton MD
James A. Rand - Oxford PA

Astropower, Inc. - Newark DE

H10L 310392, H10L 310368, H10L 3118

136258

The invention relates to techniques for manufacturing columnar-grained polycrystalline sheets which have particular utility as substrates or wafers for solar cells. The sheet is made by applying granular silicon to a setter material which supports the granular material. The setter material and granular silicon are subjected to a thermal profile all of which promote columnar growth by melting the silicon from the top downwardly. The thermal profile sequentially creates a melt region at the top of the granular silicon and then a growth region where both liquid and a growing polycrystalline sheet layer coexist. An annealing region is created where the temperature of the grown polycrystalline silicon sheet layer is controllably reduced to effect stress relief.

6111191, Aug 29, 2000

Mar 2, 1998

9/033155

Robert B. Hall - Newark DE
Allen M. Barnett - Newark DE
Sandra R. Collins - Chesapeake City MD
Joseph C. Checchi - Newark DE
David H. Ford - Wilmington DE
Christopher L. Kendall - Hockessin DE
James A Rand - Landenberg PA
Chad B. Moore - Corning NY

AstroPower, Inc. - Newark DE

H01L 2500

136258PC

The invention relates to improved techniques for manufacturing columnar-grained polycrystalline sheets which have particular utility as substrates or wafers for solar cells. The sheet is made from silicon on a setter material which supports the silicon material. The setter material and silicon are subjected to a thermal profile all of which promote columnar growth. The thermal profile sequentially creates a melt region where a thin-film capping layer grows at the top of the silicon, a nucleation region where preferential nucleation occurs at the capping-layer/molten-silicon interface, and then a growth region where both liquid and a growing polycrystalline sheet layer coexist. An annealing region is created where the temperature of the grown polycrystalline silicon sheet layer is controllably reduced to effect stress relief.

6211455, Apr 3, 2001

Jul 1, 1999

9/345862

David H. Ford - Wilmington DE
Allen M. Barnett - Newark DE
Robert B. Hall - Newark DE
James A. Rand - Landenberg PA

Astropower - Newark DE

H01L 31068, H01L 310368, H01L 27142, H01L 310392

136258

A polycrystalline film of silicon including silicon grains having an aspect ratio, d/t, of more than 1:1, wherein "d" is the grain diameter and "t" is the grain thickness. The polycrystalline film of silicon can be used to form an electronic device, such as a monolithically integrated solar cell having ohmic contacts formed on opposed surfaces or on the same surface of the film. A plurality of solar cells can be monolithically integrated to provide a solar cell module that includes an electrically insulating substrate and at least two solar cells disposed on the substrate in physical isolation from one another. Methods for manufacturing the film, solar cell and solar cell module are also disclosed. The simplified structure and method allow for substantial cost reduction on a mass-production scale, at least in part due to the high aspect ratio silicon grains in the film.

5336335, Aug 9, 1994

Oct 9, 1992

7/959009

Robert B. Hall - Newark DE
Allen M. Barnett - Newark DE
Jacob E. Brown - Newark DE
Joseph C. Checchi - Newark DE
David H. Ford - Wilmington DE
Christopher L. Kendall - Wilmington DE
William P. Mulligan - Hockessin DE
James A. Rand - Oxford PA
Todd R. Ruffins - Newark DE

AstroPower, Inc. - Newark DE

H01L 310392, H01L 310368, H01L 3118

136258

The invention relates to techniques for manufacturing columnar-grained polycrystalline sheets which have particular utility as substrates or wafers for solar cells. The sheet is made by applying granular silicon to a setter material which supports the granular material. The setter material and granular silicon are subjected to a thermal profile all of which promote columnar growth by melting the silicon from the top downwardly. The thermal profile sequentially creates a melt region at the top of the granular silicon and then a growth region where both liquid and a growing polycrystalline sheet layer coexist. An annealing region is created where the temperature of the grown polycrystalline silicon sheet layer is controllably reduced to effect stress relief.

6207891, Mar 27, 2001

Feb 1, 2000

9/495853

Robert B. Hall - Newark DE
Allen M. Barnett - Newark DE
Joseph C. Checchi - Newark DE
David H. Ford - Wilmington DE
Christopher L. Kendall - Hockessin DE
James A Rand - Landenberg PA

Astropower, Inc. - Newark DE

H01L31/00

136258PC

The invention relates to a silicon sheet having columnar grains extending axially through the sheet from one free surface of the sheet to the other free surface. The sheet has an electrical resistivity in the range of 0. 1 to 10 ohm-cm.

5057163, Oct 15, 1991

May 4, 1988

7/190138

Allen M. Barnett - Newark DE
Robert B. Hall - Newark DE
James A. Rand - Oxford PA
David H. Ford - Wilmington DE

AstroPower, Inc. - Newark DE

H01L 3106

136258

A thin-film photovoltaic solar cell features a thin polycrystalline silicon active semiconductor formed over a conductive ceramic substrate. Between the substrate and the adjacent active semiconductor layer is a barrier layer which provides for reflection of light, minimizes back surface recombination and prevents contamination of the active semiconductor.