Aerospace panel assembly and method for modular solar arrays

Abstract

To provide a modular solar array adaptable to different solar cell array configurations after manufacture.SOLUTION: Plurality of panels 104, each one of plurality of panels 104 comprising first face sheet 112 including first grate region 126, second face sheet 114 spaced apart from first face sheet 112, and truss structure 116 connecting first face sheet 112 and second face sheet 114, splice connectors 106 coupled to directly adjacent two of plurality of panels 104, and solar cells 108 coupled to second face sheet 114 of each at least one of plurality of panels 104. 104.SELECTED DRAWING: Figure 5

Description

[Technical Field]

[0001] FIELD OF THE DISCLOSURE

[0001] The present disclosure relates generally to aerospace structures and solar energy collectors, and more particularly to additively manufactured aerospace panels and methods for fabricating modular solar arrays using aerospace panels. [Background technology]

[0002]

[0002] Solar power from photovoltaic cells, also known as solar cells, is used in a variety of space and terrestrial solar power applications. Typically, arrays of solar cells are attached to or supported by composite substrates. However, such composite substrates have complex layered structures, are costly to manufacture, and require long lead times. Furthermore, such composite substrates cannot be adapted to different solar cell array configurations after manufacture. Therefore, those skilled in the art continue their research and development efforts in modular solar energy collectors. Summary of the Invention

[0003]

[0003] Disclosed are embodiments of modular solar arrays, modular panel assemblies, and methods for manufacturing modular solar arrays and / or modular panel assemblies. The following is a non-exhaustive list of embodiments of the subject matter according to the present disclosure, which may or may not be claimed.

[0004]

[0004] In one embodiment, a modular solar array is disclosed that includes a plurality of panels, splice connectors, and solar cells. Each one of the panels includes a first face sheet, a second face sheet, and a truss structure. The first face sheet includes a first lattice region. The second face sheet is spaced apart from the first face sheet. The truss structure connects the first face sheet and the second face sheet. The splice connectors are coupled to directly adjacent two (or four) of the panels. A solar cell is coupled to the second face sheet of each of at least one of the panels.

[0005] In one embodiment, a modular panel assembly is disclosed that includes a plurality of panels and a splice connector. Each one of the panels includes a first face sheet, a second face sheet, and a truss structure. The first face sheet includes a first lattice region. The second face sheet is spaced apart from the first face sheet. The truss structure connects the first face sheet and the second face sheet. The splice connector is coupled to two (or four) directly adjacent ones of the panels.

[0006] In another embodiment, a modular solar array is disclosed that includes a modular panel assembly and a solar cell coupled to a second face sheet of each of a plurality of panels of the modular panel assembly.

[0007]

[0007] In one embodiment, the disclosed method includes (1) additively manufacturing a plurality of panels 104, each one of the plurality of panels including a first face sheet including a first lattice region, a second face sheet spaced apart from the first face sheet, and a truss structure connecting the first face sheet and the second face sheet; (2) using a splice connector to join each one of the plurality of panels to one (or three) directly adjacent ones of the plurality of panels; and (3) joining a solar cell to the second face sheet of at least one of the plurality of panels.

[0008]

[0008] In another embodiment, the disclosed method includes: (1) additively manufacturing a plurality of panels 104, each one of the plurality of panels including a first face sheet including a first lattice region, a second face sheet spaced apart from the first face sheet, and a truss structure connecting the first face sheet and the second face sheet; and (2) using a splice connector to join each one of the plurality of panels to one (or three) of the plurality of panels that are directly adjacent to each other.

[0009]

[0009] Other embodiments of modular solar arrays, modular panel assemblies, and methods will become apparent from the following detailed description, the accompanying drawings, and the appended claims. [Brief explanation of the drawings]

[0010] [Figure 1]

[0010] FIG. 1 is a schematic block diagram of one embodiment of a modular solar array. [Figure 2]

[0011] FIG. 1 is a flow diagram of an embodiment of a method for manufacturing a modular solar array. [Figure 3]

[0012] FIG. 1 is a schematic perspective exploded view of an example of a portion of a modular solar array. [Figure 4]

[0013] FIG. 10 is a schematic perspective exploded view of another embodiment of a portion of a modular solar array. [Figure 5]

[0014] FIG. 1 is a schematic perspective view of an example of a modular solar array. [Figure 6]

[0015] FIG. 1 is a schematic elevation view of an example of a portion of a modular solar array. [Figure 7]

[0016] FIG. 1 is a schematic perspective view of one embodiment of a plurality of panels of a modular panel assembly used to form a modular solar array. [Figure 8]

[0017] FIG. 1 is a schematic perspective view of one embodiment of a plurality of panels connected by splice connectors to form a modular panel assembly. [Figure 9]

[0018] 9 is a schematic perspective, partially exploded view of one embodiment of a portion of the modular panel assembly and splice connector shown in FIG. 8. [Figure 10]

[0019] FIG. 1 is a schematic plan view of one embodiment of a portion of a modular panel assembly showing a first splice connector. [Figure 11]

[0020] FIG. 10 is a schematic plan view of one embodiment of a portion of a modular panel assembly showing a second splice connector. [Figure 12]

[0021] 1 is a schematic plan view of one embodiment of a portion of a splice connection of a modular panel assembly showing a first splice connector and a second splice connector. FIG. [Figure 13]

[0022] FIG. 1 is a schematic elevation view of an embodiment of a portion of a modular solar array illustrating an embodiment of a splice connection of a modular panel assembly. [Figure 14]

[0023] FIG. 2 is a schematic perspective view of one embodiment of one of a plurality of panels of a modular panel assembly. [Figure 15]

[0024] FIG. 1 is a flow diagram of an embodiment of a manufacturing and maintenance method. [Figure 16]

[0025] 1 is a schematic block diagram of an embodiment of an aerospace vehicle. DETAILED DESCRIPTION OF THE INVENTION

[0011]

[0026] 1-14 , by way of example, the present disclosure is directed to a modular solar array 100, modular panel assemblies 102 used to form the modular solar array 100, and methods 1000 for manufacturing the modular solar array 100 and / or modular panel assemblies 102 for the modular solar array 100. In various embodiments, the modular solar array 100 includes an arrangement of additively manufactured panels 104 and solar cells 108 assembled to form a solar collector of any size.

[0012]

[0027] In various embodiments, an additively manufactured panel (e.g., panel 104) includes a pair of face sheets (e.g., first face sheet 112 and second face sheet 114) connected by a micro-truss core structure (e.g., truss structure 116). In various embodiments, at least a portion of one or both of the face sheets includes a lattice structure (e.g., first lattice region 126 and second lattice region 136). In various embodiments, the panels are joined via one or more splice fittings (e.g., splice connector 106).

[0013]

[0028] The modular solar array 100 and modular panel assembly 102 disclosed herein provide various benefits and advantages over traditional solar array manufacturing. In various embodiments, the modular panel assembly 102 advantageously enables modular design and assembly of the modular solar array 100. In various embodiments, the panels 104 of the modular panel assembly 102 used in the modular solar array 100 advantageously accommodate wiring, cables, connectors, and other operating components associated with supporting one of the solar cells 108. These may be located beneath the solar cells 108 and routed through the first lattice area 126 of the first face sheet 112, the second lattice area 136 of the second face sheet 114, and / or the truss structure 116. In various embodiments, the modular solar array 100 advantageously enables highly efficient heat transfer (e.g., compared to traditional composite substrates). This is because the solar cells 108 can radiate heat directly into the air through the lattice and core truss structure of the panel 104 rather than conducting it through the honeycomb core. In various embodiments, the modular solar array 100 advantageously enables enhanced cooling of the solar cells 108, thereby increasing the solar array's power generation capacity. In various embodiments, the modular panel assembly 102 advantageously enables design flexibility in multiple dimensions, including modularity, panel size, face sheet thickness, truss core thickness, panel thickness, panel shape, panel symmetry, etc. This allows for selectively variable face sheet thickness and core density without additional manufacturing costs. In various embodiments, each one of the panels 104 can be designed using a predetermined geometric increment (e.g., 1 inch) and additively manufactured to include the appropriate number of geometric increments. The manufactured panels 104 can then be arranged and assembled into a suitable configuration or array for connection of one or more solar cells 108 to form a modular solar array 100 of any possible desired size (e.g., 13 inches by 13 inches, 15 inches by 19 inches, etc.).In various embodiments, additively manufacturing the panels 104 of the modular solar array 100 advantageously eliminates the use of composite substrates, which result in the longest lead times for solar collectors. In various embodiments, additively manufacturing the panels 104 advantageously provides fittings that are integral to the panel structure. This eliminates the adhesion and load-bearing requirements of embedded fittings that tend to delaminate under extreme temperatures. In various embodiments, the modular solar array 100 advantageously eliminates the need for co-adhesive polyimide films (e.g., Kapton®) used as insulating layers, which tend to delaminate.

[0014]

[0029] 1 and 3-14, below are several examples of modular solar arrays 100 and modular panel assemblies 102 according to the present disclosure. The modular solar array 100 and modular panel assembly 102 include several elements, features, and components, including any combination of one or more panels 104, one or more solar cells 108, a first face sheet 112 including a first lattice region 126 and a first continuous region 128, a second face sheet 114 including a second lattice region 136 and a second continuous region 138, a truss structure 116, one or more splice connectors 106 including a first splice connector 142, a first edge splice connector 192, a first corner splice connector 194, a second splice connector 144, a second edge splice connector 186, and a second corner splice connector 188, an insulating layer 176, a non-conductive layer 162, a non-conductive coating 164, a strain isolation layer 174, a conductive layer 166, a conductive coating 168, and one or more fittings 172. Not all elements, features, and / or components described or illustrated in an embodiment are required in that embodiment, and some or all of the elements, features, and / or components described or illustrated in one embodiment may be combined in various ways with other embodiments without necessarily including other elements, features, and / or components described in those other embodiments, even if one or more such combinations are not explicitly described or illustrated by an embodiment herein.

[0015]

[0030] 3 shows one example of various components of a modular solar array 100. In the illustrated example, a panel 104 includes a first face sheet 112 and a second face sheet 114 connected by a truss structure 116. The first face sheet 112 includes a first lattice region 126 and a first continuous region 128. The second face sheet 114 includes a second continuous region 138. The second face sheet 114 is configured to couple solar cells 108 together. At least one first splice connector 142 is used to couple two (or four) directly adjacent first face sheets 112 of the panel 104. At least one second splice connector 144 is used to couple two (or four) directly adjacent second face sheets 114 of the panel 104.

[0016]

[0031] 4 shows another example of the various components of the modular solar array 100. In the example shown, the first face sheet 112 includes a first lattice region 126 and a first continuous region 128. The second face sheet 114 includes a second lattice region 136 and a second continuous region 138. The second face sheets 114 are configured to couple the solar cells 108. At least one first splice connector 142 is used to couple two (or four) directly adjacent first face sheets 112 of the panels 104. At least one second splice connector 144 is used to couple two (or four) directly adjacent second face sheets 114 of the panels 104.

[0017]

[0032] 5 shows an example of a modular solar array 100 fabricated using modular panel assemblies 102. In the example shown, two of the panels 104 are joined together using splice connectors 106, including at least one first splice connector 142 joining two directly adjacent first face sheets 112 of the panels 104 and at least one second splice connector 144 joining two directly adjacent second face sheets 114 of the panels 104. Solar cells 108 are coupled to the second face sheets 114. The first face sheets 112 include a first lattice region 126 and a first continuous region 128.

[0018]

[0033] 6 shows an example of a modular solar array 100 fabricated using modular panel assemblies 102. In the example shown, panel 104 includes first face sheet 112 and second face sheet 114 connected by truss structure 116. In one or more examples, insulating layer 176, including at least one of non-conductive layer 162 and / or strain isolation layer 174, is bonded to second face sheet 114. Solar cells 108 are bonded to insulating layer 176. Conductive layer 166 is bonded to first face sheet 112.

[0019]

[0034] 7-9 show several examples of a plurality of panels 104 arranged to form a modular panel assembly 102 (FIG. 7). In the illustrated example, each panel 104 includes a first face sheet 112 and a second face sheet 114 connected by a truss structure 116. The first face sheet 112 includes a first lattice region 126 and a first continuous region 128. The second face sheet 114 includes a second lattice region 136 and a second continuous region 138. The second face sheet 114 is configured to couple at least one solar cell 108 to form a modular solar array 100 (FIG. 8). The first continuous region 128 extends along a periphery 146 of the first face sheet 112 of each one of the panels 104 for connection with a first splice connector 142 (FIGS. 8 and 9). The second continuous region 138 extends along a second periphery 148 of the second face sheet 114 of each one of the panels 104 for connection of a second splice connector 144 (FIGS. 8 and 9).

[0020]

[0035] 10-13 illustrate various embodiments of splice connections used to connect two (or four) directly adjacent ones of the panels 104. In the illustrated embodiments, each panel 104 includes a first face sheet 112 and a second face sheet 114 connected by a truss structure 116. The first face sheet 112 includes a first lattice region 126 and a first continuous region 128 (FIGS. 11 and 12). The second face sheet 114 includes a second continuous region 138 (FIGS. 10 and 12). The second face sheet 114 is configured to couple at least one solar cell 108 to form a modular solar array 100 (FIG. 13). The first continuous region 128 extends along a periphery 146 of the first face sheet 112 of each one of the panels 104 for connection to a first splice connector 142 (FIGS. 11 and 12). The second continuous region 138 extends along a second periphery 148 of the second face sheet 114 of each one of the panels 104 for connection of a second splice connector 144 (FIGS. 10 and 12).

[0021]

[0036] 10, 12, and 13, a plurality of second splice connectors 144 are coupled to the second inner surface 132 of the second face sheet 114 of adjacent panels 104 in a second continuous region 138 of the second face sheet 114 extending along a mating second peripheral edge 148 of the second face sheet 114. In the illustrated embodiment, the second splice connectors 144 include one or more second edge splice connectors 186.

[0022]

[0037] 11-13, a plurality of first splice connectors 142 are coupled to the first outer surface 124 of the first face sheet 112 of an adjacent panel 104 in a first continuous region 128 of the first face sheet 104 extending along a mating first perimeter edge 146 of the first face sheet 112. In the illustrated embodiment, the first splice connectors 142 include one or more first edge splice connectors 192 and one or more first corner splice connectors 194.

[0023]

[0038] 14 shows another embodiment of one of the panels 104 of the modular panel assembly 102 used to form the modular solar array 100. In the illustrated embodiments, the panel 104 includes a first face sheet 112 and a second face sheet 114 connected by a truss structure 116. The first face sheet 112 includes a first lattice region 126. The second face sheet 114 includes a second continuous region 138. The second face sheet 114 is configured to couple at least one solar cell 108 to form the modular solar array 100. One or more fittings 172 (e.g., mechanical fittings, bushings, inserts, etc.) are provided and configured to couple the panel 104 to a support structure, such as a support arm or boom, of a spacecraft or satellite.

[0024]

[0039] 1 and 3-14, in one or more embodiments, several panels 104 are assembled and bonded together using several splice connectors 106, such as first splice connector 142 and second splice connector 144 bonded to first face sheet 112 and second face sheet 114, to transfer shear between the panels.

[0025]

[0040] In one or more embodiments, the second face sheet 114 is spliced ​​along second edge splice connectors 186 and / or second corner splice connectors 188 to transfer inter-panel shear. In one or more embodiments, the shape (e.g., square or diamond) of the second edge splice connectors 186 and / or second corner splice connectors 188 is configured to match the shape (e.g., square) of the adjacent grid of second continuous regions 138 of adjacent second face sheets 114.

[0026]

[0041] In one or more embodiments, the first face sheet 112 is spliced ​​along its outer surface using first edge splice connectors 192. In one or more embodiments, the finger doubler shapes (e.g., squares or diamonds connected by rectangular strap sections) of the first edge splice connectors 192 are configured to match the shape (e.g., squares) of the adjacent grids of first continuous regions 128 of adjacent first face sheets 112 to transfer loads and prevent four bar linkage behavior.

[0027]

[0042] In one or more embodiments, the first face sheets 112 are also spliced ​​along their outer surfaces using first corner splice connectors 194 to transfer shear between the panels. In one or more embodiments, the shape of the first corner splice connectors 194 (e.g., square or diamond) is configured to match the shape (e.g., square) of the adjacent grid of first continuous regions 128 of adjacent first face sheets 112.

[0028]

[0043] In one or more embodiments, the panels 104 are assembled using full-size component reference assemblies and precision holes formed in the panels 104 and the splice connectors 106, eliminating the need for shimming or match drilling. In one or more embodiments, the splice connectors 106 (e.g., first splice connector 142 and / or second splice connector 144) are coupled to their respective face sheets of the panels 104 using mechanical fasteners (e.g., fasteners 196, such as bolts, shown in FIG. 13).

[0029]

[0044] 1 and 3-14 , in one or more embodiments, a modular solar array 100 includes a plurality of panels 104, one or more splice connectors 106, and one or more solar cells 108. Each one of the panels 104 includes a first face sheet 112, a second face sheet 114, and a truss structure 116. The second face sheet 114 is spaced apart from the first face sheet 112. The truss structure 116 connects the first face sheet 112 and the second face sheet 114. The splice connectors 106 are coupled to two (or four) directly adjacent ones of the panels 104. A solar cell 108 is coupled to the second face sheet 114 of each at least one of the panels 104.

[0030]

[0045] In one or more embodiments, the first face sheet 112 and the second face sheet 114 are at least generally parallel to one another. In one or more embodiments, the panel 104, the first face sheet 112, and the second face sheet 114 may be understood to have planar extent. In one example, the panel 104, the first face sheet 112, and the second face sheet 114 are generally planar, at least when viewed along orthogonal axes or directions. For example, the panel 104 may take the form of a flat panel. In one or more embodiments, the panel 104, the first face sheet 112, and the second face sheet 114 are curved and / or more complex. In one example, the panel 104, the first face sheet 112, and the second face sheet 114 may be non-planar or otherwise include some degree of curvature or undulation in one or more directions.

[0031]

[0046] In one or more embodiments, at least a portion of the first face sheet 112 along the first perimeter 146 of one panel 104 conforms to and is aligned with at least a portion of the first face sheet 112 along the first perimeter 146 of an adjacent panel 104, such that the first splice connector 142 can extend across the aligned first perimeters 146 of the panels 104. In one or more embodiments, at least a portion of the second face sheet 114 along the second perimeter 148 of one panel 104 conforms to and is aligned with at least a portion of the second face sheet 114 along the second perimeter 148 of an adjacent panel 104, such that the second splice connector 144 can extend across the aligned second perimeters 148 of the panels 104.

[0032]

[0047] In one or more embodiments, a truss structure 116 is connected to the first face sheet 112 and the second face sheet 114. The first face sheet 112 and the second face sheet 114 are, in turn, connected to one another by the truss structure 116. In one or more embodiments, the truss structure 116 includes a plurality of truss members 152. In one or more embodiments, opposite ends of one or more of the truss members 152 are bonded to the first face sheet 112 and the second face sheet 114. In one or more embodiments, opposite ends of each truss member 152 are integral with the first face sheet 112 and the second face sheet 114. The first face sheet 112, the second face sheet 114, and the truss structure 116 thereby collectively form a single, monolithic, seamless structure.

[0033]

[0048] Embodiments of the modular solar array 100 and modular panel assembly 102 may include any number of panels 104. The panels 104 are coupled together in a desired arrangement or configuration using one or more of the splice connectors 106 based on the intended use or application of the modular solar array 100. Embodiments of the modular solar array 100 may include any number of splice connectors 106, depending on, for example, the number and arrangement of the panels 104. Embodiments of the modular solar array 100 may include any number of solar cells 108. In one or more embodiments, one solar cell 108 is coupled to an associated one of the panels 104. In these embodiments, the panel 104 is sized to correspond to the size of one solar cell 108, thereby allowing one panel 104 to be sized to support one solar cell 108. In other embodiments, one solar cell 108 is coupled to two or more of the panels 104. In these embodiments, the panels 104 are sized so that multiple panels 104 support one solar cell 108 .

[0034]

[0049] 1 , as well as FIGS. 3 , 4 , 6 , and 13 , in one or more embodiments, the first face sheet 112 of each of the panels 104 includes a first inner surface 122 and a first outer surface 124 opposite the first inner surface 122. The first face sheet 112 includes a first lattice region 126. In one or more embodiments, the first face sheet 112 also includes a first continuous region 128. The splice connector 106 includes a first splice connector 142. The first splice connector 142 is coupled to the first continuous region 128 on the first outer surface 124 of each of two (or four) directly adjacent ones of the panels 104.

[0035]

[0050] In various embodiments, the layout, shape, and arrangement of the first grid region 126 and the first continuous region 128 of the first face sheet 112 provides several advantages, including reducing the weight of the panel 104, placing structural support where needed, accommodating the passage of wiring and other electrical components through the first face sheet 112, promoting enhanced heat transfer, etc.

[0036]

[0051] In one or more embodiments, the first continuous region 128 extends along at least a portion of the first perimeter 146 of the first face sheet 112. In one or more embodiments, the first continuous region 128 extends along the entire first perimeter 146 of the first face sheet 112. The first continuous region 128 provides a solid, rigid, and / or continuous section of material for support and connection of the first splice connectors 142 between adjacent panels 104.

[0037]

[0052] In one or more embodiments, the first splice connector 142 is configured (e.g., sized and shaped) to extend along at least a portion of the mating first perimeter edges 146 of the first face sheets 112 of directly adjacent panels 104. In one or more embodiments, the first splice connector 142 includes at least one first edge splice connector 192. The first edge splice connector 192 is configured to connect two directly adjacent panels 104. The first edge splice connector 192 is configured (e.g., sized and shaped) to fit into the first continuous region 128 of the first face sheet 112 along at least a portion of the two mating first perimeter edges 146 of the two directly adjacent panels 104. In one or more embodiments, the first splice connector 142 includes at least one first corner splice connector 194. The first corner splice connector 194 is configured (e.g., sized and shaped) to fit into the first continuous region 128 of the first face sheet 112 along at least a portion of the four mating first perimeters 146 of the four directly adjacent panels 104.

[0038]

[0053] 1 , as well as FIGS. 3 , 4 , 6 , and 13 , in one or more embodiments, the second face sheet 114 of each one of the panels 104 includes a second inner surface 132 and a second outer surface 134 opposite the second inner surface 132. The second face sheet 114 includes a second continuous region 138. In one or more embodiments, the second face sheet 114 also includes a second lattice region 136. The splice connectors 106 include second splice connectors 144. The second splice connectors 144 are coupled to the second continuous region 138 on the second inner surfaces 132 of each of two (or four) directly adjacent ones of the panels 104.

[0039]

[0054] In various embodiments, the layout, shape, and arrangement of the second lattice region 136 and the second continuous region 138 of the second face sheet 114 provides several advantages, including reducing the weight of the panel 104, placing structural support where needed, accommodating the passage of wiring and other electrical components through the second face sheet 114, promoting enhanced heat transfer, etc.

[0040]

[0055] In various embodiments, the layout, shape, and arrangement of the first lattice region 126 and first continuous region 128 of the first face sheet 112 and the second lattice region 136 and second continuous region 138 of the second face sheet 114 provide several advantages, including reducing the weight of the panel 104, providing structural support where needed, accommodating the passage of wiring and other electrical components through the first face sheet 112, and promoting enhanced heat transfer. As one example, the dual lattice configuration of the first face sheet 112 and the second face sheet 114 can be designed to have or provide a thermal radiation view factor through the thickness of the panel 104. This arrangement can advantageously provide additional radiative cooling and improve solar cell performance. Functionally, a solar array orients the solar cells toward the sun, thereby causing the backside of the array to face the cooling space. Therefore, radiation from the backside of the panel is advantageous. Traditional solar arrays have to conduct energy through the underlying support substrate, through adhesives and polymer-reinforced carbon fiber (which is not a good thermal conductor).

[0041]

[0056] In one or more embodiments, the second continuous region 138 extends along at least a portion of the second perimeter 148 of the second face sheet 114. In one or more embodiments, the second continuous region 138 extends along the entire second perimeter 148 of the second face sheet 114. In one or more embodiments, the second continuous region 138 forms the entire second face sheet 114. The second continuous region 138 provides a solid, rigid, and / or continuous section of material for support and connection of the second splice connectors 144 between adjacent panels 104.

[0042]

[0057] In one or more embodiments, the second splice connector 144 is configured (e.g., sized and shaped) to extend along at least a portion of the mating second perimeters 148 of the second face sheets 114 of directly adjacent panels 104. In one or more embodiments, the second splice connector 144 includes at least one second edge splice connector 186. The second edge splice connector 186 is configured to connect two directly adjacent panels 104. The second edge splice connector 186 is configured (e.g., sized and shaped) to fit into the second continuous region 138 of the second face sheet 114 along at least a portion of the two mating second perimeters 148 of the two directly adjacent panels 104. In one or more embodiments, the second splice connector 144 includes at least one second corner splice connector 188. The second corner splice connector 188 is configured (e.g., sized and shaped) to fit into the second continuous region 138 of the second face sheet 114 along at least a portion of the four mating second perimeter edges 148 of the four directly adjacent panels 104.

[0043]

[0058] In one or more embodiments, the second splice connector 144 is configured (e.g., sized and / or shaped) to fit through or between the first lattice regions 126 of the first face sheet 112 and / or through the truss structure 116 to position the second splice connector 144 on the second inner surface 132 of the second face sheet 114 and connect the second splice connector 144 to the second inner surface 132. Positioning the second splice connector 144 on the second inner surface 132 of the second face sheet 114 and connecting the second splice connector 144 to the second inner surface 132 ensures that the second outer surfaces 134 of the panels 104 forming the modular panel assembly 102 are planar and generally flat and smooth for connection of the solar cells 108.

[0044]

[0059] 1 , 6 , and 13 , in one or more embodiments, the modular solar array 100 includes an insulating layer 176. In one or more embodiments, the insulating layer 176 includes a non-conductive layer 162. In these embodiments, the non-conductive layer 162 is disposed between the second face sheet 114 and the solar cells 108. In one or more embodiments, the non-conductive layer 162 is bonded to the second outer surface 134 of the second face sheet 114. In one or more embodiments, the non-conductive layer 162 includes a non-conductive coating 164. The non-conductive coating 164 is applied to at least a portion (e.g., one or more selected portions or the entirety) of the second outer surface 134 of the second face sheet 114. The non-conductive layer 162 is configured to insulate (e.g., separate) the solar cells 108 from the metallic material of the second face sheet 114. In one or more embodiments, the non-conductive layer 162 is an electrically non-conductive layer (e.g., an electrically isolated layer). In one or more embodiments, the non-conductive layer 162 is a thermally non-conductive layer (e.g., a thermally isolated layer). In one or more embodiments, the non-conductive layer 162 comprises an epoxy material or coating, such as an epoxy primer spray. In one or more embodiments, the non-conductive layer 162 comprises a dielectric material or coating, such as a dielectric primer spray.

[0045]

[0060] 1 , 6 , and 13 , in one or more embodiments, the insulating layer 176 includes a strain isolation layer 174. In these embodiments, the strain isolation layer 174 is disposed between the second face sheet 114 and the solar cells 108. In one or more embodiments, the strain isolation layer 174 is bonded to the second outer surface 134 of the second face sheet 114. In one or more embodiments, the strain isolation layer 174 is applied to at least a portion (e.g., one or more selected portions or the entirety) of the second outer surface 134 of the second face sheet 114. The strain isolation layer 174 is configured to accommodate differences in the coefficients of thermal expansion between the panel 104 (e.g., the second face sheet 114) and the solar cells 108. In one or more embodiments, the strain isolation layer 174 includes a sheet or film applied to the second outer surface 134. In one or more embodiments, strain isolation layer 174 comprises one or more strips of material applied to selected areas of second exterior surface 134, such as along second continuous region 138 of second face sheet 114. In one or more embodiments, strain isolation layer 174 comprises a plurality of pads applied to nodes of intersections of second lattice regions 136 of second face sheet 114. In these embodiments, strain isolation layer 174 can have a variety of two-dimensional shapes and thicknesses in any one of a variety of forms or configurations. In one example, the pads of strain isolation layer 174 can have a thickness between approximately 0.06 inches (1.5 mm) and approximately 0.125 inches (3.1 mm). In one or more embodiments, strain isolation layer 174 comprises an elastomeric material. In one or more embodiments, strain isolation layer 174 comprises a polymeric material. In one or more embodiments, strain isolation layer 174 comprises a foam material. In one or more embodiments, strain isolation layer 174 comprises a polyimide material (e.g., Kapton®). In one or more embodiments, strain isolation layer 174 comprises a silicone material, such as a room temperature vulcanizing (RTV) silicone. In one or more embodiments, strain isolation layer 174 comprises a natural or synthetic rubber material.

[0046]

[0061] 1 , 6 , and 13 , in one or more embodiments, insulating layer 176 includes both non-conductive layer 162 and strain isolation layer 174. In these embodiments, non-conductive layer 162 and strain isolation layer 174 are combined into a single functional layer, which is disposed between second face sheet 114 and solar cells 108. In these embodiments, insulating layer 176 (e.g., non-conductive layer 162 and strain isolation layer 174) is configured to provide electrical isolation, thermal isolation, and strain isolation (e.g., strain relaxation due to differential thermal expansion).

[0047]

[0062] 1 , 6 , and 13 , in one or more embodiments, the modular solar array 100 includes a conductive layer 166. The conductive layer 166 is disposed on the first face sheet 112. In one or more embodiments, the conductive layer 166 is bonded to the first exterior surface 124 of the first face sheet 112. In one or more embodiments, the conductive layer 166 includes a conductive coating 168. The conductive coating 168 is applied to at least a portion (e.g., one or more selected portions or the entirety) of the first exterior surface 124 of the first face sheet 112. In one or more embodiments, the conductive layer 166 is thermally conductive and / or configured for heat transfer and heat radiation. In one or more embodiments, the conductive layer 166 includes a thermally emissive coating, such as white paint.

[0048]

[0063] 1 and 14 , in one or more embodiments of the modular solar array 100, at least one panel 104 includes at least one fitting 172. Each panel 104 may include any number of fittings 172. The fittings 172 are configured to attach the panel 104 to an external support. In one or more embodiments, at least one of the fittings 172 is additively manufactured with and integrally formed with the panel 104 (e.g., at least the first face sheet 112). In one or more embodiments, the fitting 172 is integral with the first face sheet 112. In one or more embodiments, the fitting 172 is integral with the second face sheet 114. In one or more embodiments, the fitting 172 is integral with the truss structure 116. In one or more embodiments, the fitting 172 is integral with two or more of the first face sheet 112, the second face sheet 114, and the truss structure 116. In one or more embodiments, fitting 172 can extend between first face sheet 112 and second face sheet 114. Fitting 172 can include fittings, bushings, inserts, and other features suitable for fastening or coupling panel 104 to a support structure. Additively manufacturing fitting 172 into panel 104 advantageously results in a significant reduction in part count, reduces assembly time, in-process bonding, workmanship proof loading of bonding, etc.

[0049]

[0064] 1, 6, and 13, in one or more embodiments, the truss structure 116 includes a plurality of truss members 152. Each one of the truss members 152 is integral with the first face sheet 112 and the second face sheet 114.

[0050]

[0065] In one or more embodiments, each of the panels 104 is additively manufactured. Additive manufacturing allows the panels 104 to be produced in a variety of sizes and configurations depending on the electrical output requirements of the modular solar array 100. Additive manufacturing also allows the shape and relative position and arrangement of the first lattice region 126 and first continuous region 128 of the first face sheet 112 and the second lattice region 136 and second continuous region 138 of the second face sheet 114 to be selectively controlled depending on the structural, weight, and heat transfer requirements of the modular solar array 100. In one or more embodiments, the panels 104 are additively manufactured from a metal alloy, such as a high-strength aluminum alloy, using laser powder fusing to provide a yield strength greater than 50 ksi. However, in other embodiments, other metal materials and / or other additive manufacturing processes can be used to manufacture the panels 104.

[0051]

[0066] In one or more embodiments, the modular solar array 100 includes a modular panel assembly 102 and at least one solar cell 108 coupled to a second face sheet 114 of each of the panels 104 of the modular panel assembly 102, as described herein.

[0052]

[0067] Referring now to FIG. 2 , below are several examples of a method 1000 according to the present disclosure. The method 1000 includes several elements, steps, processes, or processes. Not all of the elements, steps, processes, or processes described or illustrated in an embodiment are required for that embodiment. Some or all of the elements, steps, processes, or processes described or illustrated in one embodiment can be combined in various ways with other embodiments without necessarily including other elements, steps, processes, or processes described in those other embodiments, even if one or more such combinations are not explicitly described or illustrated by an embodiment herein.

[0053]

[0068] 1 and 3-14 generally, and with particular reference to FIG. 2 , in one or more embodiments, a method 1000 for manufacturing a modular solar array 100 is performed. In one or more embodiments, a modular panel assembly 102 is used to perform the method 1000 for manufacturing a modular solar array 100. In one or more embodiments, a modular panel assembly 102 is used to perform the method 1000 for manufacturing a modular panel assembly 102.

[0054]

[0069] In one or more embodiments, the method 1000 includes additively manufacturing 1002 a plurality of panels 104. Each one of the panels 104 includes a first face sheet 112 including a first lattice region 126, a second face sheet 114 spaced apart from the first face sheet 112, and a truss structure 116 connecting the first face sheet 112 and the second face sheet 114.

[0055]

[0070] In one or more embodiments, according to method 1000, additively manufacturing 1002 each of the panels 104 includes additively manufacturing a first face sheet 112. Additively manufacturing 1002 each of the panels 104 also includes additively manufacturing a truss structure 116 integrated with the first face sheet 112. Additively manufacturing 1002 each of the panels 104 further includes additively manufacturing a second face sheet 114 integrated with the truss structure 116.

[0056]

[0071] In one or more embodiments, each of the panels (104) is additively manufactured from a metal alloy using laser powder fusion.

[0057]

[0072] In one or more embodiments, additive manufacturing step 1002 includes additively manufacturing multiple panels 104 simultaneously in a vertical direction. Thus, in these embodiments, multiple panels 104 may be additively manufactured (e.g., printed) together in a vertical direction (i.e., rather than horizontally, one at a time). This technique may advantageously allow multiple panels 104 to be printed and assembled together. This technique may also advantageously allow for the use of smaller additive manufacturing devices (e.g., printers) that may be used to build arrays. Thus, the panel structures that form the array do not require a single, very large, expensive printer. Small panels printed together and quickly assembled on a smaller printer also offer cost advantages compared to larger machines.

[0058]

[0073] In one or more embodiments, according to method 1000, additively manufacturing the first face sheet 112 includes additively manufacturing a plurality of first lattice grid squares 182. In one or more embodiments, according to method 1000, additively manufacturing the truss structure 116 includes additively manufacturing a plurality of truss members 152 integrated with the first lattice grid squares 182. In one or more embodiments, according to method 1000, additively manufacturing the second face sheet 114 includes additively manufacturing a plurality of second lattice grid squares 184 integrated with the truss members 152.

[0059]

[0074] In one or more embodiments, according to method 1000, additively manufacturing 1002 each of panels 104 includes additively manufacturing fittings 172 integral with first face sheet 112.

[0060]

[0075] In one or more embodiments, the method 1000 includes applying 1004 an insulating layer 176 to the second outer surface 134 of the second face sheet 114 of at least one or each of the panels 104. As one example, the applying 1004 includes applying a non-conductive layer 162, such as a non-conductive coating 164, to the second outer surface 134 of the second face sheet 114 of each of the panels 104. As another example, the applying 1004 includes applying a strain isolation layer 174 to the second outer surface 134 of the second face sheet 114 of each of the panels 104.

[0061]

[0076] In one or more embodiments, the method 1000 includes a step 1006 of applying a conductive layer 166 , such as a conductive coating 168 , to the first exterior surface 124 of the first face sheet 112 of each of the panels 104 .

[0062]

[0077] In one or more embodiments, the method 1000 includes step 1008 of joining each one of the panels 104 to one (or three) directly adjacent ones of the panels 104 using splice connectors 106. In one or more embodiments, the panels 104 of the modular panel assembly 102 are constructed in a full-size-to-datum assembly (FSDA) and do not have match-drilled holes, so the modular panel assembly 102 can simply be bolted together.

[0063]

[0078] In one or more embodiments, according to method 1000, the first face sheet 112 of each one of the panels 104 includes a first inner surface 122 and a first outer surface 124. The first outer surface 124 is opposite the first inner surface 122. The first face sheet 112 also includes a first continuous region 128. In these embodiments, step 1008 of joining each one of the panels 104 to an immediately adjacent one (or three) of the panels 104 includes joining a first splice connector 142 to the first continuous region 128 on the first outer surface 124 of each of the panels 104.

[0064]

[0079] In one or more embodiments, according to method 1000, the second face sheet 114 of each one of the panels 104 includes a second inner surface 132 and a second outer surface 134. The second outer surface 134 is opposite the second inner surface 132. The second face sheet 114 also includes a second continuous region 138. In these embodiments, step 1008 of joining each one of the panels 104 to an immediately adjacent one (or three) of the panels 104 includes joining a second splice connector 144 to the second continuous region 138 at the second inner surface 132 of each of the panels 104.

[0065]

[0080] In one or more embodiments, the method 1000 includes a step 1010 of coupling solar cells 108 to the second face sheet 114 of at least one of the panels 104 .

[0066]

[0081] 1-14 , in various embodiments, the modular panel assemblies 102 and / or the panels 104 of the modular solar arrays 100 are additively manufactured, which provides several unique manufacturing and structural characteristics and advantages. The following description relates to several examples and configurations of panel structures produced by additive manufacturing processes.

[0067]

[0082] In one or more embodiments, the truss structure 116 includes or is formed by an array of core structures. Each one of the core structures includes or takes the form of a framework of truss members 152 having any suitable shape. In one or more embodiments, the shape of the core structure is uniform across the panel 104. In one or more embodiments, the shape of the core structure varies with position along the panel 104. For example, the core structure may vary with expected non-uniform loading of the panel 104 and / or the core structure may vary with curvature of the panel 104, first face sheet 112, and / or second face sheet 114. In one or more embodiments, the core structures are arranged in a grid, a repeating pattern, and / or any effective manner.

[0068]

[0083] In one or more embodiments, at least a portion of the first face sheet 112 has at least one lattice region (e.g., first lattice region 126). In one or more embodiments, at least a portion of the second face sheet 114 includes at least one lattice region (e.g., second lattice region 136). In these embodiments, the lattice region defines or takes the form of a lattice (e.g., a lattice structure). Generally, in one or more embodiments, the lattice of the lattice region is configured to exclude a secondary printing support during additive manufacturing of the panel 104. The lattice of the lattice region includes a grid of lattice members and an array of openings. The lattice includes or takes the form of a pattern or structure made of strips of material (e.g., lattice members) that intersect with each other, thereby leaving holes (e.g., openings) therebetween. In one or more embodiments, the strips of material (e.g., lattice members) of the lattice intersect with each other vertically, diagonally, or a combination thereof as a grid.

[0069]

[0084] In one or more embodiments, the panel 104 is additively manufactured or 3D printed as a single, integral structure. Thus, the panel 104 may also be described as monolithic. In other words, the first face sheet 112, the second face sheet 114, and the truss structure 116 are additively manufactured or printed together, and the panel 104 is formed of the printed material without any joints or seams. Thus, the panel 104 may have a build axis. When the panel 104 is printed, layers of material are deposited in a plane perpendicular to the build axis. In one or more embodiments, the build axis is perpendicular to the planar extent of the first face sheet 112 and / or the second face sheet 114. In such embodiments, the panel 104 may also be described as being printed in a perpendicular orientation to the first face sheet 112 and the second face sheet 114. Finally, in such multiple embodiments, first face sheet 112, second face sheet 114, and truss structure 116 may all be printed simultaneously rather than sequentially.

[0070]

[0085] In one or more embodiments, the truss members 152 of the truss structure 116 or the truss members 152 of each core structure are oriented and / or shaped relative to the build axis, thereby making the truss members 152 self-supporting during printing. That is, each core structure can be printed without the need for a secondary support or removal of support material after printing. In one or more embodiments, the truss members 152 extend at an angle of 45 degrees or less relative to the build axis. In one or more embodiments, the panel 104 includes additional structures and / or features. In such embodiments, each structure and / or feature can be oriented, shaped, and / or configured to be self-supporting during printing. The panel 104 can be configured to be manufactured without post-processing, such as machining, after printing.

[0071]

[0086] In one or more embodiments, at least a portion of the first face sheet 112, and optionally at least a portion of the second face sheet 114, includes or is formed of a lattice region and a continuous (or skin) region. In one or more embodiments, the first continuous region 128 includes or forms a boundary portion of the first face sheet 112, with the remaining interior portion of the first face sheet 112 being formed by the first lattice region 126. Similarly, in one or more embodiments, the second continuous region 138 includes or forms a boundary portion of the second face sheet 114, with the remaining interior portion of the second face sheet 114 being formed by the second lattice region 136.

[0072]

[0087] In the illustrated embodiments, the continuous region is generally disposed along the periphery of the face sheet, forming the periphery and surrounding the lattice region. However, in other embodiments, any one or more of the peripheries of any of the face sheets may be formed entirely by the lattice region, or may have a portion formed by the continuous region and a portion formed by the lattice region. Furthermore, in other embodiments, a portion of the continuous region of the face sheet may be disposed in the interior region and / or may be surrounded by the lattice region between the peripheries formed by the continuous region.

[0073]

[0088] In various embodiments, the grid regions and continuous regions of first face sheet 112 and / or second face sheet 114 can have any one of a variety of patterns, layouts, or configurations. The pattern, layout, or configuration of one or more grid regions and one or more continuous regions can depend on the size of panel 104, the end use or application of panel 104, and the attachment location of panel 104 to another structure (e.g., fitting 172).

[0074]

[0089] Regardless of the layout or configuration of the lattice regions and continuous regions, the first face sheet 112 and the second face sheet 114 are connected to and to each other by the truss structure 116. In one or more embodiments, the regions of the face sheets formed from continuous regions are bonded to or integral with the ends of the truss members 152. In one or more embodiments, the regions of the face sheets formed from lattice regions are bonded to or integral with the ends of the truss members 152.

[0075]

[0090] 15 and 16, embodiments of the modular solar array 100, modular panel assembly 102, and method 1000 described herein may be related to or used in the context of an aerospace manufacturing and service method 1100, as illustrated in the flow diagram of Figure 15, and an aerospace vehicle 1200, as illustrated generally in Figure 16. As an example, the aerospace vehicle 1200 and / or the manufacturing and service method 1100 may include or utilize embodiments of the modular solar array 100 and / or modular panel assembly 102 manufactured according to embodiments of the method 1000.

[0076]

[0091] Referring to FIG. 16 , an embodiment of an aerospace vehicle 1200 is shown. Aerospace vehicle 1200 may be any aerospace vehicle or platform. In one or more embodiments, aerospace vehicle 1200 includes an airframe 1202 having an interior 1206. Aerospace vehicle 1200 includes a plurality of on-board systems 1204 (e.g., high-level systems). Examples of on-board systems 1204 of aerospace vehicle 1200 include a propulsion system 1208, a hydraulic system 1212, an electrical system 1210, and an environmental system 1214. In other embodiments, on-board systems 1204 also include one or more control systems of aerospace vehicle 1200. In still other examples, on-board systems 1204 also include one or more other systems, such as, but not limited to, a communications system, an avionics system, a software distribution system, a network communications system, a passenger information / entertainment system, a guidance system, a radar system, or a weapons system. The aerospace vehicle 1200 may have any number of modular solar arrays 100, multiple components assembled using modular panel assemblies 102, or other types of additively manufactured modular panels 1216 (e.g., panels 104).

[0077]

[0092] 15 , during pre-production of the aerospace vehicle 1200, a manufacturing and maintenance method 1100 includes specification and design 1102 of the aerospace vehicle 1200 and procurement of materials 1104. During production of the aerospace vehicle 1200, component and subassembly manufacturing 1106 and system integration 1108 of the aerospace vehicle 1200 occurs. The aerospace vehicle 1200 then undergoes certification and delivery 1110 before being placed into service 1112. Routine maintenance and service 1114 includes modifying, reconfiguring, refurbishing, etc., one or more systems of the aerospace vehicle 1200.

[0078]

[0093] 15 may be performed or carried out by a system integrator, a third party, and / or an operator (e.g., a customer). For purposes of this specification, a system integrator may include, but is not limited to, any number of aircraft manufacturers and major system subcontractors, a third party may include, but is not limited to, any number of vendors, subcontractors, and suppliers, and an operator may be an airline, a leasing company, a military entity, a service organization, etc.

[0079]

[0094] Embodiments of the modular solar array 100, modular panel assembly 102, and method 1000 shown and described herein may be employed during any one or more stages of the manufacturing and service method 1100 illustrated in the flow diagram shown by FIG. 15 . In one example, the modular solar array 100 of an aerospace vehicle 1200 may be manufactured, assembled, and / or installed during component and subassembly manufacturing 1106 and / or system integration 1108. Additionally, the modular solar array 100 may be manufactured, assembled, and / or installed while the aerospace vehicle 1200 is in service 1112. The modular solar array 100 may also be manufactured, assembled, and / or installed during system integration 1108 and certification and delivery 1110. Similarly, the modular solar array 100 may be manufactured, assembled, and / or installed while the aerospace vehicle 1200 is in service 1112 and during maintenance and service 1114.

[0080]

[0095] The foregoing detailed description refers to the accompanying drawings, which illustrate specific embodiments described by the present disclosure. Other embodiments having different structures and steps do not depart from the scope of the present disclosure. Like reference numerals may represent the same feature, element, or component in various drawings. Throughout this disclosure, any of a plurality of items may be referred to individually as that item, and a plurality of items may be referred to collectively as items (plural) and may be represented by like reference numerals. Furthermore, as used herein, a feature, element, component, or step preceded by the term "a" or "an" should be understood not to exclude a plurality of features, elements, components, or steps, unless expressly stated to exclude it.

[0081]

[0096] Illustrative, non-exhaustive examples of the inventive subject matter according to the present disclosure may be, but are not necessarily, claimed. Reference herein to an "example" means that one or more features, structures, elements, components, properties, and / or operational steps described in connection with the example are included in at least one aspect, embodiment, and / or implementation of the subject matter according to the present disclosure. Thus, the phrases "one example," "another example," "one or more examples," and similar phrases used throughout this disclosure may, but do not necessarily, refer to the same example. Furthermore, subject matter characterizing any one of the examples may, but does not necessarily, include subject matter characterizing any other example. Furthermore, subject matter characterizing any one of the examples may, but does not necessarily, be combined with subject matter characterizing any other example.

[0082]

[0097] As used herein, a system, apparatus, device, structure, article, element, component, or hardware that is "configured to" perform a particular function is, in fact, capable of performing that particular function without any modification, rather than merely having the potential to perform that particular function after further modification. In other words, a system, apparatus, device, structure, article, element, component, or hardware that is "configured" to perform a particular function is specifically selected, created, implemented, utilized, programmed, and / or designed for the purpose of performing that particular function. As used herein, "configured to" refers to an existing characteristic of a system, apparatus, device, structure, article, element, component, or hardware that enables the system, apparatus, device, structure, article, element, component, or hardware to perform a particular function without further modification. For the purposes of this disclosure, a system, apparatus, device, structure, article, element, component, or hardware that is described as "configured" to perform a particular function may additionally or alternatively be described as "adapted" and / or "operating" to perform that function.

[0083]

[0098] Unless otherwise indicated, terms such as "first," "second," "third," etc. are used herein merely as designators and are not intended to impose any sequential, positional, or hierarchical requirements on the items to which these terms refer. Furthermore, a reference to, e.g., a "second" item does not require or preclude the presence of, e.g., a "first" or lower-numbered item and / or, e.g., a "third" or higher-numbered item.

[0084]

[0099] As used herein, the phrase "at least one of" used in conjunction with listed items means that various combinations of one or more of the listed items may be used, and that only one of each listed item may be required. For example, "at least one of item A, item B, and item C" may include, but is not limited to, "item A," or "item A and item B." This example may also include item A, item B, and item C, or item B and item C. In other examples, "at least one of" may be, for example, but is not limited to, "two item A, one item B, and ten item C," "four item B, and seven item C," and other suitable combinations. As used herein, the phrase "and / or" and the indicia " / " include any and all combinations of one or more of the associated listed items.

[0085]

[0100] For purposes of this disclosure, the terms "coupled," "coupling," and similar terms refer to two or more elements that are coupled, connected, fastened, attached, connected, in communication with, or otherwise associated (e.g., mechanically, electrically, fluidly, optically, electromagnetically) with one another. In various examples, these elements may be directly associated or indirectly associated. For example, element A may be directly associated with element B. As another example, element A may be associated with element B, e.g., through another element C. It should be understood that not all relationships between the various disclosed elements are necessarily depicted. Thus, other couplings than those shown in the figures may exist.

[0086]

[0101] As used herein, the term "approximately" refers to or describes a condition that is close to, but not exactly, a specified condition that still performs a desired function or achieves a desired result. As an example, the term "approximately" refers to a condition that is within an acceptable predetermined tolerance or precision, such as within 10% of the specified condition. However, the term "approximately" does not exclude a condition that is exactly the specified condition. As used herein, the term "substantially" refers to a condition that is essentially a specified condition that performs a desired function or achieves a desired result.

[0087]

[0102] The above-referenced Figures 1-3, 14, and 16 may depict functional elements, features, or components thereof and do not necessarily suggest any particular structure. Accordingly, modifications, additions, and / or omissions may be made to the illustrated configurations. Furthermore, those skilled in the art will recognize that not all elements, features, and / or components described and shown in the above-referenced Figures 1-3, 14, and 16 need be included in every embodiment, and not all elements, features, and / or components described herein are necessarily shown in each illustrative embodiment. Accordingly, some of the elements, features, and / or components described and shown in Figures 1, 3-14, and 16 may be combined in various ways without the need to include other features described and shown in Figures 1, 3-14, and 16, other figures, and / or the accompanying disclosure, although such combinations are not explicitly set forth herein. Similarly, additional features not limited to the examples presented may be combined with some or all of the features shown and described herein. Unless expressly stated otherwise, the schematic diagrams of the embodiments set forth in FIGS. 1-3, 14, and 16 above are not intended to imply architectural limitations with respect to the example embodiments. Rather, it is to be understood that one example configuration is depicted and may be modified as appropriate. Accordingly, modifications, additions, and / or omissions may be made to the illustrated configuration. Furthermore, elements, features, and / or components that serve similar, or at least substantially similar, purposes are similarly numbered in each of FIGS. 1-3, 14, and 16, and such elements, features, and / or components may not be described in detail herein when referring to each of FIGS. 1-3, 14, and 16. Similarly, not all elements, features, and / or components are numbered in each of FIGS. 1-3, 14, and 16, but their associated reference numbers may be used consistently herein.

[0088]

[0103] In the above-referenced Figures 2 and 15, multiple blocks may represent operations, steps, and / or portions thereof, and the lines connecting various blocks do not imply any particular order or dependency of the operations or portions thereof. It should be understood that not all dependencies between the various disclosed operations are necessarily depicted. Figures 2 and 15 and the accompanying disclosure describing the steps of the disclosed methods described herein should not be construed as necessarily dictating the sequence in which the operations are performed. Rather, although one exemplary order is shown, it should be understood that the sequence of operations may be altered as needed. Accordingly, modifications, additions, and / or omissions may be made to the illustrated operations, and certain operations may be performed in a different order or simultaneously. Additionally, those skilled in the art will recognize that not all of the operations described need be performed.

[0089]

[0104] Furthermore, throughout this specification, references to features, advantages, or similar language as used herein do not imply that all of the features and advantages that may be realized in the examples disclosed herein should or are in any single example. Rather, language referring to features and advantages is understood to mean that the particular feature, advantage, or characteristic described in connection with an example is included in at least one example. Thus, descriptions of features, advantages, and similar language as used throughout this disclosure may, but do not necessarily, refer to the same single example.

[0090]

[0105] The described features, advantages, and characteristics of one embodiment may be combined in any suitable manner in one or more other embodiments. Those skilled in the art will recognize that the embodiments described herein may be practiced without one or more of the specific features or advantages of a particular example. In other cases, additional features and advantages may be recognized in certain examples that may not be present in all examples. Furthermore, while various embodiments of the system 100, end effector 102, and method 1000 have been shown and described, modifications will occur to those skilled in the art upon reading this specification. The present application includes such modifications and is limited only by the scope of the claims.

Claims

1. A modular solar array (100), comprising: A plurality of panels (104), each one of the plurality of panels (104) comprising: a first face sheet (112) including a first lattice region (126); a second face sheet (114) spaced apart from the first face sheet (112); and a plurality of panels (104) comprising a truss structure (116) connecting said first face sheet (112) and said second face sheet (114); a splice connector (106) coupled to two or four directly adjacent ones of the plurality of panels (104); and A modular solar array (100) comprising a solar cell (108) coupled to the second face sheet (114) of each of at least one of the plurality of panels (104).

2. The second face sheet (114) of each one of the plurality of panels (104) comprises: a second inner surface (132); a second outer surface (134) opposite said second inner surface (132); and further comprising a second continuous region (138); 2. The modular solar array (100) of claim 1, wherein the splice connector (106) comprises a second splice connector (144) coupled to the second continuous region (138) at the second inner surface (132) of each of the two or four directly adjacent ones of the plurality of panels (104).

3. The modular solar array (100) of claim 2, wherein the second face sheet (114) further comprises a second lattice region (136).

4. 3. The modular solar array (100) of claim 2, wherein the second continuous region (138) extends along at least a portion of a second perimeter (148) of the second face sheet (114).

5. The modular solar array (100) of claim 2, further comprising a non-conductive layer (162) disposed between the second face sheet (114) and the solar cells (108).

6. The modular solar array (100) of claim 2, further comprising a strain isolation layer (174) disposed between the second face sheet (114) and the solar cells (108).

7. The first face sheet (112) of each one of the plurality of panels (104) comprises: a first inner surface (122); a first outer surface (124) opposite said first inner surface (122); and a first continuous region (128); 2. The modular solar array (100) of claim 1, wherein the splice connectors (106) include a first splice connector (142) coupled to the first continuous region (128) on the first outer surface (124) of each of the two or four directly adjacent ones of the plurality of panels (104).

8. 8. The modular solar array (100) of claim 7, wherein the first continuous region (128) extends along at least a portion of a first perimeter (146) of the first face sheet (112).

9. The modular solar array (100) of claim 7, further comprising a conductive layer (166) disposed on the first face sheet (112).

10. 10. The modular solar array of claim 1, wherein each of the plurality of panels is additively manufactured from a metal alloy using laser powder fusion.

11. 11. The modular solar array (100) of claim 10, wherein at least one of the plurality of panels (104) comprises a fitting (172) that is additively manufactured and integrated with at least the first face sheet (112).

12. A modular panel assembly (102) comprising: A plurality of panels (104) and a splice connector (106), each one of the plurality of panels (104) comprising: a first face sheet (112) including a first lattice region (126); a second face sheet (114) spaced apart from the first face sheet (112); and a truss structure (116) connecting the first face sheet (112) and the second face sheet (114); The splice connector (106) is coupled to two or four directly adjacent ones of the plurality of panels (104), forming a modular panel assembly (102).

13. The first face sheet (112) of each one of the plurality of panels (104) comprises: a first inner surface (122); a first outer surface (124) opposite said first inner surface (122); and further comprising a first continuous region (128); The second face sheet (114) of each one of the plurality of panels (104) comprises: a second inner surface (132); a second outer surface (134) opposite said second inner surface (132); and a second continuous region (138); The splice connector (106) a first splice connector (142) coupled to the first continuous region (128) on the first outer surface (124) of each of the two or four directly adjacent ones of the plurality of panels (104); and 13. The modular panel assembly (102) of claim 12, comprising a second splice connector (144) coupled to the second continuous region (138) on the second inner surface (132) of each of the two or four directly adjacent ones of the plurality of panels (104).

14. 14. The modular panel assembly (102) of claim 13, wherein the second face sheet (114) further comprises a second lattice region (136).

15. each of the plurality of panels (104) is additively manufactured from a metal alloy using laser powder fusion; 13. The modular panel assembly (102) of claim 12, wherein at least one of the panels (104) comprises a fitting (172) additively manufactured and integrated with at least the first face sheet (112).

16. A modular panel assembly (102) according to claim 12; and A modular solar array (100) comprising a solar cell (108) coupled to the second face sheet (114) of each of the plurality of panels (104) of the modular panel assembly (102).

17. A method (1000) for manufacturing a modular solar array (100), comprising: Additive manufacturing a plurality of panels (104), each one of the plurality of panels (104) comprising: a first face sheet (112) including a first lattice region (126); a second face sheet (114) spaced apart from the first face sheet (112); and additively manufacturing a plurality of panels (104) comprising a truss structure (116) connecting the first face sheet (112) and the second face sheet (114); using splice connectors (106) to join each one of the plurality of panels (104) to one or three immediately adjacent ones of the plurality of panels (104); and A method (1000) comprising coupling (108) a solar cell (104) to the second face sheet (114) of at least one of the plurality of panels (104).

18. The first face sheet (112) of each one of the plurality of panels (104) comprises: a first inner surface (122); a first outer surface (124) opposite said first inner surface (122); and a first continuous region (128); The second face sheet (114) of each one of the plurality of panels (104) comprises: a second inner surface (132); a second outer surface (134) opposite said second inner surface (132); and further comprising a second continuous region (138); and coupling each one of the plurality of panels (104) to the one or three directly adjacent ones of the plurality of panels (104) includes coupling a first splice connector (142) to the first continuous region (128) on the first outer surface (124) of each of the plurality of panels (104); 20. The method (1000) of claim 17, wherein joining each one of the plurality of panels (104) to the one or three directly adjacent ones of the plurality of panels (104) includes joining a second splice connector (144) to the second continuous region (138) on the second inner surface (132) of each of the plurality of panels (104).

19. a non-conductive layer (162) on at least a portion of the second outer surface (134) of the second face sheet (114) of each of the plurality of panels (104); a strain isolation layer (174) on at least a portion of the second outer surface (134) of the second face sheet (114) of each of the plurality of panels (104); and 20. The method (1000) of claim 18, further comprising applying at least one of a conductive layer (166) to at least a portion of the first outer surface (124) of the first face sheet (112) of each of the plurality of panels (104).

20. Additive manufacturing each of the plurality of panels (104) comprises: additively manufacturing the first face sheet (112); additively manufacturing the truss structure (116) integrally with the first face sheet (112); and additively manufacturing the second face sheet (114) integrally with the truss structure (116); each of the plurality of panels (104) is additively manufactured from a metal alloy using laser powder fusion; 20. The method (1000) of claim 17, wherein a plurality of the panels (104) are manufactured simultaneously in a vertical direction.

Images