Small-size thermistor for temperature monitoring of flexible solar wings

Abstract

This invention provides a small-sized thermistor for flexible solar panel temperature monitoring, belonging to the field of electronic temperature sensing element technology. It includes an aluminum alloy shell; a negative temperature coefficient (NTC) thermistor ceramic body with silver electrodes printed at both ends; the NTC thermistor ceramic body encapsulated within the aluminum alloy shell; two leads, each with one end soldered to a silver electrode and the other end extending from the aluminum alloy shell; a low-temperature resistant protective resin encapsulation layer encapsulating the solder joint between the leads and the silver electrodes; and a low-temperature resistant potting resin encapsulation layer encapsulated within the aluminum alloy shell. This small-sized thermistor for flexible solar panel temperature monitoring features extremely small size and light weight, enabling temperature measurement over a wide range from -100℃ to 120℃. It is compatible with various satellite flexible solar panel substrates and also possesses advantages such as radiation resistance, strong high and low temperature resistance, and a stable encapsulation structure.

Description

Technical Field

[0001] This utility model belongs to the field of electronic temperature measuring element technology, and more specifically, it relates to a small-sized thermistor for temperature monitoring of flexible solar panels. Background Technology

[0002] With the rapid development of the commercial space sector, particularly driven by the demand for low-Earth orbit communication satellite constellations, the need for high-power, high-efficiency, and lightweight energy solutions for satellites is increasing. Solar panels are the primary source of energy for satellites, and based on the substrate supporting the solar cells, they are categorized into rigid, semi-rigid, and flexible solar panels. Compared to traditional rigid solar panels, flexible solar panels are thinner, more efficient, and have a single-layer thickness of only about 1 millimeter. They also feature a small envelope, strong scalability, and high power generation. The application of flexible solar panels significantly improves the energy efficiency and carrying capacity of satellites, reduces launch costs, and provides strong support for future satellite communication and space development.

[0003] As the most important power generation device in the space station's energy system, the flexible solar array's temperature monitoring is not only a core technical aspect ensuring the reliability of energy supply and structural integrity, but also the foundation for ensuring the stable operation of the energy system, achieving intelligent thermal management, fault prediction, and iterative upgrades of space technology. Given the demands for long spacecraft lifespan and high reliability, the real-time performance and accuracy of temperature monitoring directly affect the success or failure of the mission; therefore, temperature monitoring has significant engineering and scientific implications.

[0004] 1. Ensuring stable operation of the energy system: Solar cell power generation efficiency has a significant impact. When the temperature rises, the open-circuit voltage of the cell will decrease, resulting in a reduction in overall power. Real-time monitoring can adjust the orientation of the solar panels and the working mode to optimize energy output.

[0005] 2. Prevention of structural thermal damage: The lightweight design of flexible solar panels is sensitive to the coefficient of thermal expansion. In the space environment, the temperature difference between the sun-facing side (above +120℃) and the shaded side (below -100℃) can cause non-uniform deformation of the material, which may accelerate material aging or lead to brittle fracture. Temperature detection can provide input for thermal deformation compensation algorithms and link the thermal control system to perform temperature compensation.

[0006] 3. Fault diagnosis and safety redundancy: Abnormal temperature rise may be a signal of electrical fault (such as short circuit of battery cell, cable insulation failure) or mechanical damage. Temperature detection can serve as the core input of a multi-parameter health management system (PHM). Flexible solar panels often adopt a modular design, and temperature data can help determine whether each module is operating as expected.

[0007] However, existing thermistors for satellite temperature detection have the following drawbacks: firstly, their size and weight are incompatible with flexible solar panels (1mm single-layer thickness); secondly, the existing NTC thermistor packaging structure has poor stability, failing to guarantee long-term reliability under the harsh operating environment of satellites. Therefore, there is an urgent need to develop a thermistor that is small in size, lightweight, has a highly reliable internal packaging structure with strong insulation, and can guarantee long-term reliability to meet the temperature monitoring requirements of satellite flexible solar panels. Utility Model Content

[0008] The purpose of this invention is to fill the gap in existing thermistors for temperature monitoring of flexible solar arrays. It aims to provide a small-sized thermistor for temperature monitoring of flexible solar arrays, thereby solving at least one of the shortcomings of existing thermistors in the application of flexible solar arrays. The thermistor of this invention is small in size and light in weight, which is compatible with flexible solar arrays. Moreover, the packaging structure has good stability and can ensure long-term reliability in the harsh environment of satellite operation.

[0009] To achieve the above objectives, this utility model provides a small-sized thermistor for temperature monitoring of flexible solar panels, comprising:

[0010] Aluminum alloy casing;

[0011] A negative temperature coefficient thermistor ceramic body with silver electrodes printed at both ends; the negative temperature coefficient thermistor ceramic body is encapsulated in the aluminum alloy shell.

[0012] Two leads, one end of each lead is welded to the silver electrode, and the other end extends from the aluminum alloy casing;

[0013] A low-temperature resistant protective resin encapsulation layer is used to encapsulate the weld between the lead and the silver electrode; and,

[0014] A low-temperature resistant potting resin encapsulation layer is encapsulated within the aluminum alloy shell.

[0015] Furthermore, the material of the low-temperature protective resin encapsulation layer is a silicone coating with a low-temperature resistance range of -100℃ to -150℃.

[0016] Furthermore, the material of the low-temperature potting resin encapsulation layer is epoxy resin with a low-temperature resistance range of -100℃ to -150℃.

[0017] Furthermore, the aluminum alloy shell includes an aluminum alloy base and an aluminum alloy cover plate. The aluminum alloy base is hollow inside, and the side wall of the aluminum alloy base is provided with two cable outlet slots. The low-temperature resistant potting resin encapsulation layer is encapsulated between the aluminum alloy base and the aluminum alloy cover plate.

[0018] Furthermore, the aluminum alloy cover plate is provided with through holes.

[0019] Furthermore, the aluminum alloy shell has a circular cross-section.

[0020] Furthermore, the negative temperature coefficient thermistor ceramic body is columnar.

[0021] Furthermore, the aluminum alloy casing has dimensions of φ5×1mm, and the thermistor weighs less than 0.5g.

[0022] Compared with the prior art, the present invention has the following technical effects:

[0023] This invention discloses a small-sized thermistor for flexible solar panel temperature monitoring. It encapsulates a negative temperature coefficient thermistor ceramic body with an aluminum alloy shell, a low-temperature resistant protective resin encapsulation layer, and a low-temperature resistant potting resin encapsulation layer. After encapsulation, the overall structural stability of the thermistor is improved, and the internal encapsulation structure exhibits strong insulation reliability, meeting the temperature monitoring requirements of satellite flexible solar panels and ensuring long-term reliability in the harsh environment of satellite operation. Furthermore, due to the use of an aluminum alloy shell, this small-sized thermistor can be made extremely lightweight, with an overall weight of less than 0.5g; its size can be extremely small, as small as φ5×1mm; and it possesses advantages such as radiation resistance, strong high and low temperature resistance, and a stable encapsulation structure. It can achieve temperature measurement over a wide range from -100℃ to 120℃ and is compatible with various satellite flexible solar panel substrates. This small-sized thermistor for flexible solar panel temperature monitoring is particularly suitable for temperature detection on flexible solar panels of low Earth orbit satellites operating at altitudes above 300 kilometers. Attached Figure Description

[0024] To more clearly illustrate the technical solutions in the embodiments of this utility model, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this utility model. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0025] Figure 1 A schematic diagram of the overall structure of a small-sized thermistor for temperature monitoring of a flexible solar array provided in this embodiment of the present invention;

[0026] Figure 2 for Figure 1 A schematic diagram of the connection between the ceramic body and the lead wires of a medium negative temperature coefficient thermistor.

[0027] Figure 3 for Figure 1 Schematic diagram of the structure of the aluminum alloy substrate;

[0028] Figure 4 for Figure 1 A schematic diagram of the structure of the aluminum alloy cover plate.

[0029] The following are the labeling elements in the figure:

[0030] 1. Ceramic body of negative temperature coefficient thermistor; 2. Lead wire; 3. Low temperature resistant protective resin encapsulation layer; 4. Aluminum alloy substrate; 5. Aluminum alloy cover plate; 6. Low temperature resistant potting resin encapsulation layer. Detailed Implementation

[0031] To make the technical problems, technical solutions, and beneficial effects of this utility model clearer, the present utility model will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the present utility model and are not intended to limit the present utility model.

[0032] It should be noted that when a component is referred to as being "fixed to" or "set on" another component, it can be directly on or indirectly on that other component. When a component is referred to as being "connected to" another component, it can be directly connected to or indirectly connected to that other component.

[0033] The terminology used in the embodiments of this utility model is for the purpose of describing particular embodiments only and is not intended to be limiting of the utility model. The singular forms “a,” “the,” and “the” used in the embodiments of this utility model and the appended claims are also intended to include the plural forms unless the context clearly indicates otherwise.

[0034] Please see Figures 1-4 The present invention will now describe a small-sized thermistor for temperature monitoring of a flexible solar array.

[0035] In one embodiment of this utility model, a small-sized thermistor for flexible solar panel temperature monitoring includes: an aluminum alloy shell, a negative temperature coefficient thermistor ceramic body 1, two leads 2, a low-temperature resistant protective resin encapsulation layer 3, and a low-temperature resistant potting resin encapsulation layer 6. Silver electrodes are printed at both ends of the negative temperature coefficient thermistor ceramic body 1; the negative temperature coefficient thermistor ceramic body 1 is encapsulated within the aluminum alloy shell; one end of each lead 2 is soldered to the silver electrode, and the other end extends from the aluminum alloy shell; the low-temperature resistant protective resin encapsulation layer 3 encapsulates the solder joint between the lead 2 and the silver electrode; the low-temperature resistant potting resin encapsulation layer 6 is encapsulated within the aluminum alloy shell.

[0036] In this embodiment, a negative temperature coefficient (NTC) thermistor ceramic body 1 is used as the temperature sensing element. It possesses high resistance and low dielectric constant (B) electrical properties and can be packaged in a small size, enabling accurate detection over a wide temperature range. The NTC thermistor ceramic body 1 is connected to two leads 2. After the NTC thermistor ceramic body 1 and the two leads 2 are connected by welding, the electrodes are encapsulated with low-temperature resistant protective resin to form a low-temperature resistant protective resin encapsulation layer 3, effectively ensuring the long-term reliability of the temperature sensing element. After the temperature sensing element with leads is encapsulated, it is further encapsulated in an aluminum alloy shell using low-temperature resistant potting resin to form a low-temperature resistant potting resin encapsulation layer 6, which can further improve the thermistor's shock resistance and radiation resistance.

[0037] This utility model provides a small-sized thermistor for flexible solar panel temperature monitoring. It uses an aluminum alloy shell, a low-temperature resistant protective resin encapsulation layer 3, and a low-temperature resistant potting resin encapsulation layer 6 to encapsulate the negative temperature coefficient thermistor ceramic body 1. After encapsulation, the overall structure of the thermistor has better stability and the internal encapsulation structure has strong insulation reliability, which meets the temperature monitoring requirements of satellite flexible solar panels and can ensure long-term reliability in the harsh environment of satellite operation.

[0038] Furthermore, the small-sized thermistor for temperature monitoring of flexible solar panels according to this embodiment of the invention uses an aluminum alloy shell, making it extremely lightweight, with an overall weight of less than 0.5g; its size can also be made extremely small, as small as φ5×1mm; and it possesses advantages such as radiation resistance, strong high and low temperature resistance, and stable packaging structure. It can achieve temperature measurement over a wide range of -100℃ to 120℃ and is compatible with various satellite flexible solar panel substrates. This small-sized thermistor for temperature monitoring of flexible solar panels according to this embodiment of the invention is particularly suitable for temperature detection on flexible solar panels of low Earth orbit satellites operating at altitudes above 300 km.

[0039] In one embodiment, the material of the low-temperature protective resin encapsulation layer 3 can be a silicone coating with a low-temperature resistance range of -100℃ to -150℃.

[0040] In one embodiment, the material of the low-temperature potting resin encapsulation layer 6 can be an epoxy resin with a low-temperature resistance range of -100°C to -150°C, such as epoxy resin AB glue.

[0041] In one embodiment, the aluminum alloy housing includes an aluminum alloy base 4 and an aluminum alloy cover plate 5. The aluminum alloy base 4 is hollow inside, and the side wall of the aluminum alloy base 4 is provided with two wire outlet slots for threading the lead wire 2. The low-temperature resistant potting resin encapsulation layer 6 is encapsulated between the aluminum alloy base 4 and the aluminum alloy cover plate 5.

[0042] In one embodiment, the aluminum alloy cover plate 5 has four circular through holes, such as... Figure 4As shown, the through hole is designed to counteract the thermal expansion and contraction during resin curing, preventing the aluminum alloy cover plate 5 from becoming loose or failing to seal properly under the stress of thermal expansion and contraction of the resin encapsulated inside, thus ensuring the stability of the thermistor encapsulation structure.

[0043] In one embodiment, the aluminum alloy casing has a circular cross-section. Specifically, the aluminum alloy substrate 4 is a hollow, cylindrical shape, and the aluminum alloy cover plate 5 is circular. That is, the encapsulated thermistor is cylindrical, which allows for effective compatibility with flexible solar films for mounting.

[0044] In one embodiment, the negative temperature coefficient thermistor ceramic body 1 is columnar.

[0045] In one embodiment, the aluminum alloy casing has dimensions of φ5×1mm, that is, the diameter of the aluminum alloy casing is 5mm and the thickness is 1mm, and the mass of the thermistor is less than 0.5g.

[0046] This utility model embodiment also provides a method for manufacturing a small-sized thermistor for temperature monitoring of a flexible solar array, including the following steps:

[0047] (1) The negative temperature coefficient thermistor ceramic body 1 is screen-printed with silver electrodes, and then cut into specific sizes using a dicing process and measured to select the resistor components that meet the requirements of appearance size and electrical performance.

[0048] (2) Weld the lead wires 2 to the electrodes at both ends of the qualified resistor, and then use a self-made needle-shaped fine glass rod to dip an appropriate amount of low-temperature resistant protective resin to encapsulate the welded part of the resistor electrode, and let it stand to cure to form a low-temperature resistant protective resin encapsulation layer 3.

[0049] (3) Apply a suitable amount of low-temperature potting resin to the inner wall and bottom surface of the aluminum alloy substrate 4 with a fine brush for insulation treatment. After it has cured, install the encapsulated temperature measuring element stably in the aluminum alloy substrate 4. Then inject a suitable amount of low-temperature potting resin to completely cover the resist. Let it stand until it is completely cured to form a low-temperature potting resin encapsulation layer 6.

[0050] (4) Use an appropriate amount of low-temperature potting resin to continue filling the remaining cavity of the aluminum alloy substrate 4, place the aluminum alloy cover plate 5 horizontally, wait for it to cure and complete the encapsulation, and perform resistance sorting and appearance inspection.

[0051] The temperature sensing element, aluminum alloy casing, and lead wire 2 of this embodiment of the flexible solar panel temperature monitoring small-size thermistor are all made of materials resistant to high and low temperatures and corrosion, ensuring temperature measurement within a wide range of -100℃ to 120℃. The temperature sensing element is a high-resistance, low-B-value thermistor, possessing characteristics such as low power consumption, strong anti-interference, high temperature measurement accuracy, and wide-temperature range stability compatibility. The resistive portion of the temperature sensing element is small in size, effectively compatible with small-size packages. After the temperature sensing element is soldered to the lead wire 2, the electrodes are encapsulated with low-temperature resistant protective resin, effectively achieving functions such as electrode corrosion protection, pre-insulation treatment before encapsulation, and mechanical protection of the solder joints, ensuring the long-term reliability of the temperature sensing element. After encapsulation, the temperature sensing element with lead wires is encapsulated in an aluminum alloy casing using low-temperature resistant potting resin, further improving the thermistor's shock resistance and radiation resistance. The encapsulated thermistor has a disc-shaped structure, effectively compatible with flexible solar films for mounting. The temperature sensing element and aluminum alloy shell in the packaging structure are reliably insulated.

[0052] The above embodiments only illustrate several implementation methods of this utility model, and their descriptions are relatively specific and detailed, but they should not be construed as limiting the scope of this utility model patent. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of this utility model, and these all fall within the protection scope of this utility model. Therefore, the protection scope of this utility model patent should be determined by the appended claims.

Claims

1. A small-sized thermistor for temperature monitoring of a flexible solar array, characterized in that, include: Aluminum alloy casing; The negative temperature coefficient thermistor ceramic body has silver electrodes printed at both ends. The negative temperature coefficient thermistor ceramic body is encapsulated within the aluminum alloy shell; Two leads, one end of each lead is welded to the silver electrode, and the other end extends from the aluminum alloy casing; A low-temperature resistant protective resin encapsulation layer is used to encapsulate the weld between the lead and the silver electrode; as well as, A low-temperature resistant potting resin encapsulation layer is encapsulated within the aluminum alloy shell.

2. The small-sized thermistor for temperature monitoring of a flexible solar array as described in claim 1, characterized in that, The material of the low-temperature protective resin encapsulation layer is a silicone coating with a low-temperature resistance range of -100℃ to -150℃.

3. The small-sized thermistor for temperature monitoring of a flexible solar array as described in claim 1, characterized in that, The material of the low-temperature resistant potting resin encapsulation layer is epoxy resin with a low-temperature resistance range of -100℃ to -150℃.

4. A small-sized thermistor for temperature monitoring of a flexible solar array as described in claim 1, characterized in that, The aluminum alloy shell includes an aluminum alloy base and an aluminum alloy cover plate. The aluminum alloy base is hollow inside, and the side wall of the aluminum alloy base is provided with two cable outlet slots. The low-temperature resistant potting resin encapsulation layer is encapsulated between the aluminum alloy base and the aluminum alloy cover plate.

5. A small-sized thermistor for temperature monitoring of a flexible solar array as described in claim 4, characterized in that, The aluminum alloy cover plate has a through hole.

6. A small-sized thermistor for temperature monitoring of a flexible solar array as described in claim 1, characterized in that, The aluminum alloy shell has a circular cross-section.

7. A small-sized thermistor for temperature monitoring of a flexible solar array as described in claim 1, characterized in that, The negative temperature coefficient thermistor ceramic body is columnar.

8. A small-sized thermistor for temperature monitoring of a flexible solar array as described in any one of claims 1-7, characterized in that, The aluminum alloy casing has dimensions of φ5×1mm, and the thermistor weighs less than 0.5g.

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