Stacked satellite solar wing solar cell integrated array

Abstract

The invention discloses a stacked satellite solar wing solar cell integrated array which at least comprises M flexible solar cell panel combination pairs connected pairwise, and M is a natural number not smaller than 1. Wherein each combination pair comprises two flexible solar cell panels; the two flexible solar cell panel substrates are the same in boundary dimension; after the whole wings of the two flexible solar cell panels are folded, a face-to-face working relationship is formed; batteries on the two flexible solar cell panels are the same in size and number, and the distances between the flexible solar cell panels and the edge of the base plate and between the flexible solar cell panels and the cloth piece distribution forbidding area of the flexible plate hinge are the same. The battery assemblies on the two flexible solar cell panels are laid in the middle and are in mirror symmetry along the center line position of the joint of the two flexible solar cell panels. The positive electrode output ends of the battery strings on the two flexible solar cell panels are positioned on the same side, and the negative electrode output ends of the battery strings are positioned on the same side; and the anode output ends of the battery strings on the two flexible solar cell panels are connected in series with an isolating diode. And the adaptability of the stacked satellite solar wing solar cell arrangement is improved.

Description

Technical Field

[0001] This invention belongs to the field of space solar cell array technology, specifically relating to a stacked satellite solar array integrated with solar cells. Background Technology

[0002] Solar arrays, as the sole power source for satellites, use solar cells bonded to a substrate to absorb sunlight and convert it into electrical energy to power the satellite. Currently, space-based solar arrays primarily use adhesives to bond solar cells to rigid substrates such as carbon fiber or aluminum alloy. The number and size of clamping points and unfolding hinges on these rigid substrates vary, leading to different cell placement methods, complex processes, low production efficiency, and poor consistency. Stacked satellite solar panels, due to their unique structure, employ a novel combination of "rigid plates on both sides + flexible plate in the middle." The rigid plates on both sides are used for overall wing clamping and circuit busbars, while the flexible plate in the middle, with uniform dimensions, is mainly used for cell placement. When the wing is retracted, there is a "face-to-face" situation between the flexible plates. Using traditional rigid plate placement methods would result in different cell combinations for different product models, numerous production tooling devices, increased cell breakage rate, and greater production difficulty. By integrating and modularizing the flexible plate cells, the cell layout is optimized, reducing the types and complexity of the overall cell components, improving structural consistency, increasing product reliability, and enhancing production efficiency.

[0003] In existing technologies, such as CN114141907A (a method for arranging solar cell array sheets), CN102593213A (a method for arranging triple-junction solar cell array sheets), CN114141893A (a trapezoidal integrated solar cell array), and CN108493607A (a large integrated array of active antenna and solar cell), publicly disclosed invention patents in the field of space solar cell array technology all revolve around the arrangement, integration methods, production assembly processes, and manufacturing flows of solar cell sheets on rigid substrates of traditional satellite rigid solar panels. In terms of space applications, there are currently no related aerospace-related stacked satellite solar panel substrate structures that address the engineering practice and application of integrated, modular, and rapid assembly of solar cells, as well as the requirements for product consistency, batch production models, and production efficiency. Summary of the Invention

[0004] To address the technical problems existing in the prior art, the invention provides a stacked satellite solar array with integrated solar cells. This addresses the issues of numerous production assembly steps, low integration and modularization levels, and low efficiency caused by the unique structure of the stacked satellite solar array substrate and the positional differences between substrates. The invention aims to improve the adaptability of the stacked satellite solar array with integrated solar cell placement.

[0005] This invention is implemented as follows: a stacked satellite solar array includes at least M pairs of interconnected flexible solar panels, where M is a natural number not less than 1. Each pair includes two flexible solar panels; the substrates of the two flexible solar panels have the same external dimensions; the two flexible solar panels are arranged face-to-face when folded up; the cells on the two flexible solar panels are the same size and number, and are equidistant from the substrate edge and the fabric restriction zone of the flexible panel hinge; the cell components on the two flexible solar panels are centrally located and mirror-symmetrical along the centerline of the connection between the two panels; the positive and negative output terminals of the cell strings on the two flexible solar panels are located on the same side; and an isolation diode is connected in series with the positive output terminal of the cell string on the two flexible solar panels.

[0006] Furthermore, N solar cells are combined to form a module, where N is a natural number not less than 1; flexible solar panel combinations are composed of multiple modules; and stacked satellite solar arrays are composed of multiple combinations connected to each other.

[0007] Preferably, N equals 26.

[0008] Furthermore, the solar cell is configured as a rectangular cell and is equipped with a bypass diode.

[0009] Furthermore, the solar cell is configured as a trapezoidal cell and is equipped with a bypass diode.

[0010] Furthermore, a positive electrode braided cable and a negative electrode braided cable are provided on both the upper and lower positive and negative electrodes of the solar cell.

[0011] Furthermore, the isolation diode is located between the positive terminal of the battery at the output end of the battery string and the braided cable, and an isolation diode is connected in series at the positive output end of each battery string.

[0012] Furthermore, the cells on the two flexible solar panels are arranged in a "snake-shaped" or "straight-line" pattern depending on the number of cells connected in series.

[0013] Furthermore, adjacent flexible substrates are fixed together by steel wires with a diameter of no more than 1 mm passing through them alternately.

[0014] Furthermore, the positive and negative braided cables on each board are laid along the long side of the front side of the flexible substrate.

[0015] The advantages and positive effects of this invention are: This invention proposes an integrated solution for solar cells, bypass diodes, and isolation diodes, which solves the problem of numerous processes and low efficiency in the production of solar cell assemblies due to differences in cell size and structure.

[0016] This invention addresses the solar panel configuration of stacked satellite solar arrays, providing a simpler and more efficient integrated and modular solution for solar cell deployment. It lays the foundation for the construction of subsequent mass-production stacked constellation projects and creates conditions for rapid response, low cost, and large-scale networking in the commercial aerospace field.

[0017] The integrated and modular solar cell solution proposed in this invention is not only applicable to the production of flexible solar cell arrays for stacked satellite solar panels, but also provides a solution for the combination of traditional rigid solar cell arrays for large-scale networking satellites. It reduces the types of battery components, improves production efficiency, and can provide reference value for the construction of mass production lines for solar cell arrays.

[0018] The integrated and modular solar cell solution proposed in this invention makes it easier to assemble and produce solar cell arrays. Each assembly pair is more convenient for solar fin installation layout, with identical interfaces and consistent clamping states, and is interchangeable. At the same time, multi-fin assembly can be performed. Attached Figure Description

[0019] Figure 1 These are structural diagrams of solar cells of different shapes in embodiments of the present invention; Figure 2 These are diagrams illustrating the electrode structures of solar cells with different configurations in embodiments of the present invention. Figure 3 This is a structural diagram of a solar cell with a series isolation diode in an embodiment of the present invention; Figure 4 This is a modular structure diagram of the battery module in a preferred embodiment of the present invention; (a. rectangular battery module, b. trapezoidal battery module). Figure 5 The following are structural diagrams of flexible solar panel assembly pairs in preferred embodiments of the present invention (a. flexible solar panel assembly pair with rectangular cells, b. flexible solar panel assembly pair with trapezoidal cells). Figure 6 This is a diagram showing the composition region of the flexible substrate in a preferred embodiment of the present invention.

[0020] Figure 7 This is a view of the positive and negative cables after being pasted in a preferred embodiment of the present invention. Detailed Implementation

[0021] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to the accompanying drawings. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the invention.

[0022] In the description of this invention, it should be noted that the terms "upper", "middle", "lower", "inner", "outer", "both sides", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the purpose of simplifying the description of this invention and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limiting this invention.

[0023] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "installed," "equipped with," "connected," etc., should be interpreted broadly. For example, "connection" can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium; it can be a connection within two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0024] like Figure 1-5 As shown, the stacked satellite solar array of the present invention includes at least M pairs of flexible solar panels connected in pairs, where M is a natural number not less than 1; each pair includes two flexible solar panels; the substrates of the two flexible solar panels have the same external dimensions; the two flexible solar panels are arranged in a "face-to-face" working relationship after being fully folded; the cells on the two flexible solar panels are the same size and number, and the distances from the substrate edge and the fabric restriction area of ​​the flexible panel hinge are equal; the cell components on the two flexible solar panels are centrally laid out and mirror-symmetrical along the center line of the connection between the two panels; the positive output terminals of the cell strings on the two flexible solar panels are located on the same side, and the negative output terminals of the cell strings are located on the same side; an isolation diode is connected in series at the positive output terminals of the cell strings on the two flexible solar panels.

[0025] Furthermore, N solar cells are combined to form a module, where N is a natural number not less than 1; flexible solar panel combinations are composed of multiple modules; and stacked satellite solar arrays are composed of multiple combinations connected to each other.

[0026] Preferably, N equals 26.

[0027] Furthermore, the solar cell is configured as a rectangular cell and is equipped with a bypass diode.

[0028] Furthermore, the solar cell is configured as a trapezoidal cell and is equipped with a bypass diode.

[0029] Furthermore, a positive electrode braided cable and a negative electrode braided cable are provided on both the upper and lower positive and negative electrodes of the solar cell.

[0030] Furthermore, the isolation diode is located between the positive terminal of the battery at the output end of the battery string and the braided cable, and an isolation diode is connected in series at the positive output end of each battery string.

[0031] Furthermore, the cells on the two flexible solar panels are arranged in a "snake-shaped" or "straight-line" pattern depending on the number of cells connected in series.

[0032] Furthermore, adjacent flexible substrates are fixed together by steel wires with a diameter of no more than 1 mm passing through them alternately.

[0033] Furthermore, the positive and negative braided cables on each board are laid along the long side of the front side of the flexible substrate.

[0034] This invention, through modular and integrated structural design, is mainly used to solve the problems of complex production processes, low development efficiency, and long production time of solar cell assembly caused by the special structure and contact correspondence of stacked satellite solar panel substrates. Based on the interface layout of the flexible substrate of stacked satellite solar panels, the solar cells are modularly integrated, which can effectively improve the production consistency, reliability, and mass production development efficiency of flexible solar panels.

[0035] Specifically, the design of this invention mainly includes solar cell selection design, solar cell arrangement design, battery module design, and similar designs and extensions of solar panel assembly. First, based on the structural characteristics of current space-based solar cells, solar cells can be broadly classified into two categories: trapezoidal cells and rectangular cells, with an overall cell thickness not exceeding 0.5 mm. Figure 1 As shown, this invention selects these two types of batteries for separate cell layout, which can cover the cell layout of conventional space solar cells, and establishes a foundation for the integrated layout of flexible panels.

[0036] To increase the overall panel area of ​​the flexible solar panel, the positive and negative electrodes of rectangular and trapezoidal solar cells were designed and selected separately. Four types of solar cells were designed, such as... Figure 2 As shown, the electrodes of these four types of batteries are opposite in direction to each other. When the batteries are connected in series, the current flows in the same direction, and the batteries have the same shape, which reduces the gap between the batteries and improves the utilization rate and integration of the entire flexible board.

[0037] Because space-based solar cells are subject to hot spot effects, bypass diodes are required for their protection. By equipping rectangular and trapezoidal solar cells with bypass diodes has resulted in eight different cell types, such as... Figure 3 As shown.

[0038] Considering the impact of space debris and radiation environment on solar cell strings, an isolation diode is connected in series with the positive output terminal of each cell string. This achieves fault isolation between cell strings, reducing power loss. A total of eight configurations are formed by connecting the cells in series with the isolation diode, such as... Figure 4 As shown.

[0039] pass Figure 1 , Figure 2 and Figure 3 By selecting appropriate battery types and designing the layout of bypass and isolation diodes, a total of eight polygonal battery types were derived, laying a solid foundation for the integration and modularization of flexible solar cells.

[0040] Based on the design characteristics of low Earth orbit (LEO) satellite solar array products (500km~1000km), the bus voltage is typically 45.1V, and the on-orbit operating temperature of flexible solar array products is generally -80℃ to +65℃. Each cell string contains 26 cells connected in series. The solar module on the flexible substrate is integrated and modularly designed based on rectangular and trapezoidal cell layout methods. Figure 4 As shown, the integrated battery module is mainly composed of 26 cells / string, which can adapt to the size and configuration of the flexible substrate. At the same time, it achieves module layout matching, ensures the voltage difference between the output head and tail batteries and adjacent batteries, improves the working reliability of the product, and avoids static electricity accumulation caused by excessive voltage difference.

[0041] Considering the characteristics of stacked satellite solar panel substrates, flexible substrates are paired up, with the two substrates connected by inter-board hinges and steel wires. Each flexible substrate has an inter-board hinge area on its long sides and an inter-board flat cable pasting area on its short sides (the "ears"). The safety distance between the cells and the edge of the restricted area is no less than 10mm, within which braided cable circuits are pasted. Rectangular and trapezoidal cells are combined according to the solar cell arrangement method, while also adapting to the "slender strip" configuration of the flexible substrates. Typical "snake-shaped" or "straight-line" cell module configurations are as follows: Figure 4 As shown.

[0042] Considering the "face-to-face" contact between flexible solar panels after they are retracted and compressed in a stacked satellite solar array, symmetrical arrangement of the cell modules on the two panels in the flexible solar panel assembly, and ensuring that the compressed and bonded cells are of the same size, can reduce the increase in cell breakage rate caused by incomplete bonding due to differences in cell size. A typical flexible solar panel assembly is as follows: Figure 5 As shown, the battery layout of the two plates is symmetrical along the center line, and the current flow of the batteries within the two plates is also symmetrical along the center line, with opposite current loops. This plays an important role in reducing the residual magnetic moment of the batteries and improving the telemetry accuracy of the entire satellite signal.

[0043] The "snake-shaped" and "straight-line" solar cell modules have basically the same module structure and layout. The cell modules on the two panels in a flexible solar panel assembly are basically the same. A set of module molds with 26 strings in parallel can meet the production of different cell module combinations, shortening production costs and time costs. By modularly integrating the cells, the overall layout of the flexible solar panel can be met. The cell module size can be fixed through module tooling molds, improving the consistency and reliability of the combined products. One set of molds can adapt to multiple cell modules, which can improve the production efficiency of automated production lines and reduce process losses.

[0044] A module with 26 strings of solar cells in parallel can meet the structural layout of most current stacked flexible solar panels. Considering the structural characteristics of the flexible substrate, the substrate thickness is less than 0.3mm and all are "strip" shaped. The width and length of the flexible panels vary. In addition to "snake-shaped" and "straight" battery modules, "U-shaped" battery modules are also suitable for flexible panel battery layout. However, since "U-shaped" battery modules will cause an increase in the voltage difference between the front and rear batteries, increasing the risk of electrostatic discharge, the number of parallel "U-shaped" battery modules and the safe spacing between the batteries need to be controlled when selecting them.

[0045] like Figure 6 As shown, the flexible substrate mainly includes a battery sheet layout area, an inter-board connection hinge area, and an inter-board cable area. The battery sheet layout area is mainly used for attaching and fixing solar cell module, positive wire, and negative wire braided cables. The inter-board connection hinge area is mainly used for connecting substrates to each other. Adjacent substrates are fixed to each other by steel wires with a diameter not exceeding 1mm passing through alternately. The inter-board cable area is mainly used for circuit connection between module components between adjacent flexible boards, and can also realize the power output of the entire circuit.

[0046] like Figure 7 The image shows the positive and negative braided cables after they have been pasted on. They are mainly used for the output of the positive and negative bus circuits inside the flexible panel, which facilitates circuit connection. At the same time, the thickness of the braided cable is basically the same as the thickness of the solar cell, which ensures the flatness of the solar cell area of ​​the flexible panel.

[0047] The modular integration of flexible solar panels addresses the existing stacked satellite solar panel substrate configuration. Based on the arrangement methods of rectangular and trapezoidal cells, a typical modular integration scheme is proposed. This can effectively reduce the types of cell modules, improve the processing efficiency of cell modules, and enhance the reliability and consistency of solar cell products. It is also more conducive to the development of flexible panel products for mass production constellation projects.

[0048] The foregoing description presents preferred embodiments of the present invention and is not intended to limit the scope of the invention. Any improvements or modifications made within the scope of the present invention should be included within the protection scope of the present invention.

Claims

1. A stacked satellite solar array with integrated solar cells, characterized in that, It includes at least M pairs of flexible solar panel assemblies connected in pairs, where M is a natural number not less than 1; each assembly pair includes two flexible solar panels; the two flexible solar panel substrates have the same external dimensions; the two flexible solar panels are in a "face-to-face" working relationship when their wings are folded together; the cells on the two flexible solar panels are the same size and number, and the distances from the substrate edge and the fabric restriction area of ​​the flexible panel hinge are equal; the cell modules on the two flexible solar panels are centered and mirror-symmetrical along the center line of the connection between the two panels; the positive output terminals of the cell strings on the two flexible solar panels are on the same side, and the negative output terminals of the cell strings are on the same side; an isolation diode is connected in series at the positive output terminals of the cell strings on the two flexible solar panels.

2. The stacked satellite solar array with integrated solar cells according to claim 1, characterized in that, N solar cells are combined to form a module, where N is a natural number not less than 1; flexible solar panel combinations are composed of multiple modules; and stacked satellite solar arrays are composed of multiple combinations connected to each other.

3. The stacked satellite solar array with integrated solar cells according to claim 2, characterized in that, N equals 26.

4. The stacked satellite solar array with integrated solar cells according to claim 1, characterized in that, The solar cell is a rectangular cell and is equipped with a bypass diode.

5. The stacked satellite solar array with integrated solar cells according to claim 1, characterized in that, The solar cell is configured as a trapezoidal cell and is equipped with a bypass diode.

6. The stacked satellite solar array with integrated solar cells according to claim 1, characterized in that, Positive braided cables and negative braided cables are provided on both the upper and lower positive and negative electrodes of the solar cell.

7. The stacked satellite solar array with integrated solar cells according to claim 1, characterized in that, The isolation diode is located between the positive terminal of the battery and the braided cable at the output end of the battery string, and an isolation diode is connected in series at the positive output end of each battery string.

8. The stacked satellite solar array with integrated solar cells according to claim 1, characterized in that, The cells on the two flexible solar panels are arranged in a "snake-shaped" or "straight-line" pattern depending on the number of cells connected in series.

9. The stacked satellite solar array with integrated solar cells according to claim 1, characterized in that, Two adjacent flexible substrates are fixed together by steel wires with a diameter of no more than 1 mm passing through them alternately.

10. The stacked satellite solar array with integrated solar cells according to claim 6, characterized in that, The positive and negative braided cables on each board are laid along the long side of the front side of the flexible substrate.

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