US4511600A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Solar cell metal spray process
Assignee: Solarex Corp
•
Filing: 1984-02-10
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Granted: 1985-04-16
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Expires: 2004-02-10
Abstract
Abstract The present invention provides a method of forming a metal pattern on a solar cell comprising the steps of forcing a molten metal through an aligned array of orifices by use of gas pressure; vibrating the aligned array of orifices to form the molten metal issuing from the orifices into metal droplets; moving a solar cell collinearly with the aligned array of orifices; and allowing each series of metal droplets from a single orifice to fall onto a specific region of the solar cell to build up a metal layer of increasing thickness, each metal droplet being permitted sufficient time to solidify prior to allowing the next metal droplet to strike the metal layer.
Inventors
- 👤 James M. Leas
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-30 20:34
CPC Classifications
H; H10; H10F; H10F77/00; H10F77/20; H10F77/206; H10F77/211; H10F71/00; H10F71/121; Y; Y02; Y02E; Y02E10/00; Y02E10/50; Y02E10/547; Y02P; Y02P70/00; Y02P70/50
Claims Analysis
Total Claims: 12
Claim 1
Independent Claim
118 words
A method of forming a metal pattern on a solar cell, comprising the steps of: (a) forcing a molten metal through an aligned array of orifices by use of gas pressure; (b) vibrating the aligned array of orifices to form the molten metal issuing from the orifices into metal droplets; (c) moving a solar cell collinearly with the aligned array of orifices; and (d) allowing each series of metal droplets from a single orifice to fall onto a specific region of the solar cell to build up a metal layer of increasing thickness, each metal droplet in the metal layer being permitted sufficient time to solidify prior to allowing the next metal droplet to strike the metal layer.
Claim 2
Independent Claim
118 words
A method of forming a metal pattern on a solar cell, comprising the steps of: (a) forcing a molten metal through an aligned array of orifices by use of gas pressure; (b) vibrating the aligned array of orifices to form the molten metal issuing from the orifices into metal droplets; (c) moving a solar cell collinearly with the aligned array of orifices; and (d) allowing each series of metal droplets from a single orifice to fall onto a specific region of the solar cell to build up a metal layer of increasing thickness, each metal droplet in the metal layer being permitted sufficient time to solidify prior to allowing the next metal droplet to strike the metal layer.
Claim 3
Dependent Claim
23 words
A method of claim 1, wherein the molten metal is forced through the aligned array of orifices by use of an inert gas.
Claim 4
Dependent Claim
24 words
A method of claim 1, wherein the inert gas is selected from the group consisting of nitrogen gas, hydrogen gas, and the noble gasses.
Claim 5
Dependent Claim
16 words
A method of claim 1, wherein a plurality of aligned arrays of orifices are parallelly arranged.
Claim 6
Dependent Claim
16 words
A method of claim 1, wherein the aligned array of orifices are contained within a nozzle.
Claim 7
Dependent Claim
14 words
A method of claim 1, wherein the method is conducted within an inert atmosphere.
Claim 8
Dependent Claim
11 words
A method of claim 1, wherein the molten metal is aluminum.
Claim 9
Dependent Claim
16 words
A method of claim 1, wherein the aluminum is doped with 3% to 15% of silicon.
Claim 10
Dependent Claim
13 words
A method of claim 1, wherein the solar cell is composed of silicon.
Claim 11
Dependent Claim
43 words
A method of claim 1, further comprising the step of controlling the size of the droplets by varying at least one parameter selected from the group consisting of the orifice diameter, the gas pressure, the molten metal viscosity, and the orifice vibration frequency.
Claim 12
Dependent Claim
54 words
A method of claim 1, further comprising the step of controlling the thickness of the metal layer by varying at least one parameter selected from the group consisting of the solar cell movement speed, the number of orifices, the rate the metal droplets issue from each orifice, and the size of each metal droplet.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1988-04-15 | 1988-10-15 | 1989-04-16 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1992-04-15 | 1992-10-15 | 1993-04-16 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1996-04-15 | 1996-10-15 | 1997-04-16 | $7700.00 | Window Closed / Lapsed |