Patent US4492812A successfully refreshed from Google Patents.
US4492812A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Electrical contacts for a solar cell
Assignee: BP Solar International LLC
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Filing: 1983-06-02
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Granted: 1985-01-08
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Expires: 2003-06-02
Abstract
Abstract Electrically conductive contacts containing solderable metals, including tin, silver, copper and nickel, with aluminum are formed on the front and/or back surfaces of a solar cell. They are deposited by spraying the metals onto the cell surfaces, together or as layers, with an aluminum-containing layer in direct contact with the cell surfaces.
Inventors
- 👤 Joseph Lindmayer
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-09 15:33
CPC Classifications
H; H10; H10D; H10D64/00; H10D64/01; H10D64/011; H10D64/0111; H10F; H10F77/00; H10F77/20; H10F77/206; H10F77/211; Y; Y02; Y02E; Y02E10/00; Y02E10/50
Claims Analysis
Total Claims: 35
Claim 1
Independent Claim
106 words
A method of applying an electrically conductive contact to the surface of a silicon-containing photovoltaic cell, said method comprising: forming a mixture of aluminum and solderable metal at a temperature in excess of the alloying temperature of said mixture and silicon, said solderable metal consisting essentially of a combination of tin and a minor amount of silver, said combination of tin and silver comprising at least about 10% of said mixture; and spraying said mixture toward said surface at a distance such that said mixture will contact said surface at a temperature at which it will alloy with said silicon and thereby adhere to said surface.
Claim 2
Independent Claim
106 words
A method of applying an electrically conductive contact to the surface of a silicon-containing photovoltaic cell, said method comprising: forming a mixture of aluminum and solderable metal at a temperature in excess of the alloying temperature of said mixture and silicon, said solderable metal consisting essentially of a combination of tin and a minor amount of silver, said combination of tin and silver comprising at least about 10% of said mixture; and spraying said mixture toward said surface at a distance such that said mixture will contact said surface at a temperature at which it will alloy with said silicon and thereby adhere to said surface.
Claim 3
Dependent Claim
21 words
A method as claimed in claim 1, in which said combination of tin and silver contains from 1 to 5% silver.
Claim 4
Dependent Claim
19 words
A method as claimed in claim 2, in which said combination of tin and silver contains about 96% tin.
Claim 5
Dependent Claim
21 words
A method as claimed in claim 3, in which said combination of tin and silver contains from 3.6 to 4.4% silver.
Claim 6
Independent Claim
87 words
A method of applying an electrically conductive contact to the surface of a silicon-containing photovoltaic cell, said method comprising: forming a mixture of aluminum and a solderable metal at a temperature in excess of the alloying temperature of said mixture and silicon, said solderable metal comprising copper and up to 10% aluminum, said solderable metal comprising at least about 10% of said mixture; and spraying said mixture toward said surface at a temperature at which it will alloy with said silicon and thereby adhere to said surface.
Claim 7
Independent Claim
87 words
A method of applying an electrically conductive contact to the surface of a silicon-containing photovoltaic cell, said method comprising: forming a mixture of aluminum and a solderable metal at a temperature in excess of the alloying temperature of said mixture and silicon, said solderable metal comprising copper and up to 10% aluminum, said solderable metal comprising at least about 10% of said mixture; and spraying said mixture toward said surface at a temperature at which it will alloy with said silicon and thereby adhere to said surface.
Claim 8
Independent Claim
87 words
A method of applying an electrically conductive contact to the surface of a silicon-containing photovoltaic cell, said method comprising: forming a mixture of aluminum and a solderable metal at a temperature in excess of the alloying temperature of said mixture and silicon, said solderable metal comprising copper and up to 7% tin, said solderable metal comprising at least about 10% of said mixture; and spraying said mixture toward said surface at a temperature at which it will alloy with said silicon and thereby adhere to said surface.
Claim 9
Independent Claim
87 words
A method of applying an electrically conductive contact to the surface of a silicon-containing photovoltaic cell, said method comprising: forming a mixture of aluminum and a solderable metal at a temperature in excess of the alloying temperature of said mixture and silicon, said solderable metal comprising copper and up to 7% tin, said solderable metal comprising at least about 10% of said mixture; and spraying said mixture toward said surface at a temperature at which it will alloy with said silicon and thereby adhere to said surface.
Claim 10
Independent Claim
98 words
A method of applying an electrically conductive contact to the surface of a silicon-containing photovoltaic cell, said method comprising; forming a mixture of aluminum and a solderable metal at a temperature in excess of the alloying temperature of said mixture and silicon, said solderable metal comprising tin and further including about 10% of a mixture of antimony and copper, said solderable metal comprising at least about 10% of said first mentioned mixture; and spraying said first mentioned mixture toward said surface at a temperature at which it will alloy with said silicon and thereby adhere to said surface.
Claim 11
Independent Claim
98 words
A method of applying an electrically conductive contact to the surface of a silicon-containing photovoltaic cell, said method comprising; forming a mixture of aluminum and a solderable metal at a temperature in excess of the alloying temperature of said mixture and silicon, said solderable metal comprising tin and further including about 10% of a mixture of antimony and copper, said solderable metal comprising at least about 10% of said first mentioned mixture; and spraying said first mentioned mixture toward said surface at a temperature at which it will alloy with said silicon and thereby adhere to said surface.
Claim 12
Independent Claim
103 words
A method of applying an electrically conductive contact to the surface of a silicon-containing photovoltaic cell, said method comprising: forming a mixture of aluminum and a solderable metal at a temperature in excess of the alloying temperature of said mixture and silicon, said solderable metal consisting essentially of a combination of lead and tin, said combination of lead and tin comprising at least about 10% of said mixture; and spraying said mixture toward said surface at a distance such that said mixture will contact said surface at a temperature at which it will alloy with said silicon and thereby adhere to said surface.
Claim 13
Independent Claim
103 words
A method of applying an electrically conductive contact to the surface of a silicon-containing photovoltaic cell, said method comprising: forming a mixture of aluminum and a solderable metal at a temperature in excess of the alloying temperature of said mixture and silicon, said solderable metal consisting essentially of a combination of lead and tin, said combination of lead and tin comprising at least about 10% of said mixture; and spraying said mixture toward said surface at a distance such that said mixture will contact said surface at a temperature at which it will alloy with said silicon and thereby adhere to said surface.
Claim 14
Dependent Claim
24 words
A method as claimed in claim 8 in which the ratio of tin to lead is in the range of from 60/40 to 63/37.
Claim 15
Dependent Claim
48 words
A method as claimed in claim 8 in which the ratio of tin to lead is in the range of from 60/40 to 65/35 and said combination further includes from 1 to 5% of an additional metal selected from the group consisting of silver, antimony, cadmium, and bismuth.
Claim 16
Independent Claim
112 words
A method of applying an electrically conductive contact to the surface of a silicon-containing photovoltaic cell, said method comprising: forming a mixture of aluminum and a solderable metal at a temperature in excess of the alloying temperature of said mixture and silicon, said solderable metal consisting essentially of a combination of tin and zinc, wherein said combination contains about 20 to 40% zinc, said combination of tin and zinc comprising at least about 10% of said mixture, and spraying said mixture toward said surface at a distance such that said mixture will contact said surface at a temperature at which it will alloy with said silicon and thereby adhere to said surface.
Claim 17
Independent Claim
112 words
A method of applying an electrically conductive contact to the surface of a silicon-containing photovoltaic cell, said method comprising: forming a mixture of aluminum and a solderable metal at a temperature in excess of the alloying temperature of said mixture and silicon, said solderable metal consisting essentially of a combination of tin and zinc, wherein said combination contains about 20 to 40% zinc, said combination of tin and zinc comprising at least about 10% of said mixture, and spraying said mixture toward said surface at a distance such that said mixture will contact said surface at a temperature at which it will alloy with said silicon and thereby adhere to said surface.
Claim 18
Dependent Claim
89 words
A silicon containing photovoltaic cell having a front surface adapted to receive and absorb light impinging thereon and a back surface opposed to said front surface, and an electrical contact covering at least a portion of at least one of said surfaces, said contact being comprised of a layer of a mixture of aluminum and a solderable soft metal, said solderable metal consisting essentially of a combination of tin and a minor amount of silver, said combination of tin and silver comprising at least about 10% of said mixture.
Claim 19
Dependent Claim
89 words
A silicon containing photovoltaic cell having a front surface adapted to receive and absorb light impinging thereon and a back surface opposed to said front surface, and an electrical contact covering at least a portion of at least one of said surfaces, said contact being comprised of a layer of a mixture of aluminum and a solderable soft metal, said solderable metal consisting essentially of a combination of tin and a minor amount of silver, said combination of tin and silver comprising at least about 10% of said mixture.
Claim 20
Dependent Claim
20 words
A cell as claimed in claim 12, wherein said combination of tin and silver contains from 1 to 5% silver.
Claim 21
Dependent Claim
18 words
A cell as claimed in claim 13, wherein said combination of tin and silver contains about 96% tin.
Claim 22
Dependent Claim
20 words
A cell as claimed in claim 14, wherein said combination of tin and silver contains from 3.6 to 4.4% silver.
Claim 23
Dependent Claim
82 words
A silicon-containing photovoltaic cell having a front surface adapted to receive and absorb light impinging thereon and a back surface opposed to said front surface, and an electrical contact covering at least a portion of at least one of said surfaces, said contact being comprised of a layer of a mixture of aluminum and a solderable soft metal, wherein said solderable metal is copper and further includes up to 7% tin, said solderable metal comprising at least about 10% of said mixture.
Claim 24
Dependent Claim
82 words
A silicon-containing photovoltaic cell having a front surface adapted to receive and absorb light impinging thereon and a back surface opposed to said front surface, and an electrical contact covering at least a portion of at least one of said surfaces, said contact being comprised of a layer of a mixture of aluminum and a solderable soft metal, wherein said solderable metal is copper and further includes up to 7% tin, said solderable metal comprising at least about 10% of said mixture.
Claim 25
Dependent Claim
89 words
A silicon-containing photovoltaic cell having a front surface adapted to receive and absorb light impinging thereon and a back surface opposed to said front surface, and an electrical contact covering at least a portion of at least one of said surfaces, said contact being comprised of a layer of a mixture of aluminum and a solderable soft metal, wherein said solderable metal is tin and further includes about 10% of a mixture of antimony and copper, said solderable metal comprising at least about 10% of said first mentioned mixture.
Claim 26
Dependent Claim
89 words
A silicon-containing photovoltaic cell having a front surface adapted to receive and absorb light impinging thereon and a back surface opposed to said front surface, and an electrical contact covering at least a portion of at least one of said surfaces, said contact being comprised of a layer of a mixture of aluminum and a solderable soft metal, wherein said solderable metal is tin and further includes about 10% of a mixture of antimony and copper, said solderable metal comprising at least about 10% of said first mentioned mixture.
Claim 27
Dependent Claim
84 words
A silicon-containing photovoltaic cell having a front surface adapted to receive and absorb light impinging thereon and a back surface opposed to said front surface, and an electrical contact covering at least a portion of at least one of said surfaces, said contact being comprised of a layer of a mixture of aluminum and a solderable soft metal, said solderable metal consisting essentially of a combination of lead and tin, said combination of lead and tin comprising at least about 10% of said mixture.
Claim 28
Dependent Claim
84 words
A silicon-containing photovoltaic cell having a front surface adapted to receive and absorb light impinging thereon and a back surface opposed to said front surface, and an electrical contact covering at least a portion of at least one of said surfaces, said contact being comprised of a layer of a mixture of aluminum and a solderable soft metal, said solderable metal consisting essentially of a combination of lead and tin, said combination of lead and tin comprising at least about 10% of said mixture.
Claim 29
Dependent Claim
24 words
A silicon-containing cell as claimed in claim 18, wherein the ratio of tin to lead is in the range of from 60/40 to 63/37.
Claim 30
Dependent Claim
47 words
A cell as claimed in claim 18, wherein the ratio of tin to lead is in the range of from 60/40 to 65/35 and said combination further includes from 1 to 5% of an additional metal selected from the group consisting of silver, antimony, cadmium, and bismuth.
Claim 31
Dependent Claim
93 words
A silicon-containing photovoltaic cell having a front surface adapted to receive and absorb light impinging thereon and a back surface opposed to said front surface, and an electrical contact covering at least a portion of at least one of said surfaces, said contact being comprised of a layer of a mixture of aluminum and a solderable soft metal, said solderable metal consisting essentially of a combination of tin and zinc, wherein said combination contains about 20 to 40% zinc, and combination of tin and zinc comprising at least about 10% of said mixture.
Claim 32
Dependent Claim
93 words
A silicon-containing photovoltaic cell having a front surface adapted to receive and absorb light impinging thereon and a back surface opposed to said front surface, and an electrical contact covering at least a portion of at least one of said surfaces, said contact being comprised of a layer of a mixture of aluminum and a solderable soft metal, said solderable metal consisting essentially of a combination of tin and zinc, wherein said combination contains about 20 to 40% zinc, and combination of tin and zinc comprising at least about 10% of said mixture.
Claim 33
Dependent Claim
32 words
A cell as claimed in claim 12, 16, 17, or 21, said contact being formed with an overcoat layer including a solderable soft metal overlying and adhered to said layer containing aluminum.
Claim 34
Dependent Claim
36 words
A cell as claimed in claim 12, 16, 17, 18 or 21, in which said contact is comprised of a layer of a mixture of aluminum and at least about 40% of said solderable soft metal.
Claim 35
Dependent Claim
35 words
A cell as claimed in claim 12, 16, 17, 18 or 21, in which said contact is comprised of a layer of a mixture of about 50% aluminum and 50% of said solderable soft metal.
References Cited (Backward Citations)
USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1988-01-08 | 1988-07-09 | 1989-01-08 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1992-01-08 | 1992-07-09 | 1993-01-08 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1996-01-08 | 1996-07-09 | 1997-01-08 | $7700.00 | Window Closed / Lapsed |