Solar panel and method for manufacturing a solar panel

Abstract

To provide a solar panel and a method for producing the solar panel, the solar panel being produced by populating a front portion of a substrate with cover glass interconnected cells (CICs) and / or wiring, before bonding the front portion to a back portion of the substrate.SOLUTION: A method for producing a solar panel includes producing a tile. Producing the tile includes bonding an electrical insulation layer and a front face sheet layer together to produce a front portion of a substrate. Producing the tile also includes bonding the front portion of the substrate and a cell together. Producing the tile also includes bonding the front portion of the substrate and a wire together. The method also includes bonding a honeycomb core layer and a back face sheet layer to produce a back portion of the substrate. The method also includes bonding the tile and the back portion of the substrate together to produce the solar panel.SELECTED DRAWING: None

Description

Technical Field

[0001]

[0001] This disclosure is directed to a solar panel and a method for manufacturing a solar panel. In particular, this disclosure is directed to manufacturing a solar panel by attaching and / or wiring a cover glass interconnected cell (CIC) to a front portion of a substrate before joining the front portion of the substrate to a rear portion.

Background Art

[0002]

[0002] A solar panel includes a substrate. The substrate includes an electrical insulation layer, a first (e.g., front) surface sheet layer, a honeycomb core layer, and a second (e.g., rear) surface sheet layer. In one example, the electrical insulation layer is joined to the front surface sheet layer to produce a front portion of the substrate, and the honeycomb core layer is joined to the rear surface sheet layer to produce a rear portion of the substrate. Then, the front portion and the rear portion are joined together to complete the substrate. In particular, the front surface sheet is joined to the honeycomb core to complete the substrate.

[0003]

[0003] After the substrate is completed, a CIC including interconnected and cover glass solar cells may be joined to the substrate. In particular, the CIC may be joined to the electrical insulation layer. Wiring may also be joined to the electrical insulation layer, the rear surface sheet layer, or both. The substrate, the CIC, and the wiring manufacture a solar panel.

[0004]

[0004] However, when manufactured in this manner, it may be difficult to automate the process of joining the CIC to the front surface sheet layer using any kind of modularization / standardization. It may also be difficult to repair any failed CIC.

Summary of the Invention

[0005]

[0005] A method for manufacturing a solar panel is disclosed. The method includes manufacturing a tile. Manufacturing the tile includes joining together an electrical insulation layer and a front sheet layer to produce a front portion of a substrate. Manufacturing the tile also includes joining together the front portion of the substrate and a battery. Manufacturing the tile also includes joining together the front portion of the substrate and wiring. The method also includes joining a honeycomb core layer and a rear sheet layer to produce a rear portion of the substrate. The method also includes joining together the tile and the rear portion of the substrate to produce a solar panel.

[0006]

[0006] In another embodiment, the method includes manufacturing a tile. Manufacturing the tile includes joining together an electrical insulation layer and a front sheet layer to produce a front portion of a substrate. Manufacturing the tile also includes joining together the electrical insulation layer and a battery. Manufacturing the tile also includes joining together the electrical insulation layer and wiring. Manufacturing the tile also includes connecting a first end of the wiring to the battery. Manufacturing the tile also includes connecting a second end of the wiring to an object. The object includes another battery, another tile, or a spacecraft. The method also includes joining a honeycomb core layer and a rear sheet layer to produce a rear portion of the substrate. The wiring is not joined to the rear sheet layer. The method also includes joining together the tile and the rear portion of the substrate to produce a solar panel. The method also includes connecting the solar panel to a spacecraft.

[0007]

[0007] In another embodiment, the method includes manufacturing two or more tiles. Manufacturing each of the two or more tiles includes joining an electrical insulation layer and a front sheet layer together to manufacture the front portion of the substrate. Manufacturing each of the two or more tiles also includes joining the electrical insulation layer and the battery together. Manufacturing each of the two or more tiles also includes joining the electrical insulation layer and the wiring together. The method also includes joining a honeycomb core layer and a rear sheet layer together to manufacture the rear portion of the substrate. The wiring is not joined to the rear sheet layer. The method also includes joining two or more tiles and the rear portion of the substrate together to manufacture a solar panel. The method also includes connecting the solar panel to a spacecraft.

[0008]

[0008] The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the present teachings and, together with the description, serve to explain the principles of the present teachings.

Brief Description of the Drawings

[0009]

Figure 1

[0009] A schematic diagram of a plurality of layers used to manufacture a substrate for a solar panel according to one embodiment is shown.

Figure 2

[0010] A flowchart of a method for manufacturing a solar panel according to one embodiment is shown.

Figure 3

[0011] A schematic diagram of an electrical insulation layer joined to a front sheet layer to manufacture the front portion of a substrate according to one embodiment is shown.

Figure 4

[0012] A schematic diagram of a battery and wiring joined to the front portion of a substrate to manufacture a tile according to one embodiment is shown.

Figure 5

[0013] A schematic diagram of a honeycomb core layer joined to a rear sheet layer to manufacture the rear portion of a substrate according to one embodiment is shown.

Figure 6

[0014] An example of a solar panel including tiles joined to the rear portion of a substrate according to one embodiment is shown.

Figure 7

[0015] Another example of a solar panel including two tiles joined to a single rear portion of a substrate according to one embodiment is shown.

Figure 8

[0016] A flowchart of another method for manufacturing a solar panel according to one embodiment is shown.

Figure 9

[0017] A schematic view of a channel formed in a honeycomb core layer of the rear portion of a substrate according to one embodiment is shown.

Figure 10

[0018] A first wiring disposed at least partially within a channel according to one embodiment is shown.

Figure 11

[0019] A schematic view of the front and rear portions of a substrate joined together with a first wiring disposed at least partially within a channel according to one embodiment is shown.

Figure 12

[0020] A schematic view of a battery and a second wiring joined to the substrate of FIG. 11 to form a solar panel according to one embodiment is shown.

Figure 13

[0021] A flowchart of yet another method for manufacturing a solar panel according to one embodiment is shown.

Figure 14

[0022] A schematic view of a tile having wiring joined to a front sheet layer according to one embodiment is shown.

Figure 15

[0023] A schematic view of the tile of FIG. 14 joined to the rear portion of a substrate to form a solar panel according to one embodiment is shown.

Figure 16

[0024] Another example of a solar panel of FIG. 15 including two tiles joined to a single rear portion of a substrate according to one embodiment is shown.

Figure 17

[0025] An example of a transporter to which a solar panel can be coupled according to one embodiment is shown.

DETAILED DESCRIPTION OF THE INVENTION

[0010]

[0026] Note that some details of the drawings are illustrated in a simplified manner for the purpose of promoting understanding rather than maintaining strict structural accuracy, details, and scale.

[0011]

[0027] Next, the present teachings will be described in detail. Examples of the present teachings are shown in the accompanying drawings. In the drawings, similar reference numerals are used throughout to indicate the same elements. In the following description, reference is made to the accompanying drawings, which form a part of the description. The drawings illustrate specific embodiments for carrying out the present teachings. Therefore, the following description is merely exemplary.

[0012]

[0028] Before joining the tile to the rear portion of the substrate, join the battery and wiring to the front portion of the substrate to manufacture the tile.

[0013]

[0029] The present disclosure is directed to a solar panel and a method for manufacturing a solar panel. The solar panel can include a substrate, a battery (e.g., CIC), wiring, or a combination thereof. The substrate can include a front portion and a rear portion. The front portion can include an electrically insulating layer and a first (e.g., front) surface sheet layer. The rear portion can include a honeycomb core layer and a second (e.g., rear) surface sheet layer. The front portion of the substrate can have a battery, wiring, or both joined to the front portion of the substrate to manufacture the tile. After the tile is manufactured, the tile can be joined to the rear portion of the substrate to manufacture the solar panel.

[0014]

[0030] Tiles and / or solar panels manufactured as described herein may be standardized and may be mass-produced more easily than conventional solar panel components and conventional solar panels. Thereby, modularization and capabilities for fabricating solar panels of various sizes with various different configurations may be improved more easily than using conventional components and methods. Further, the cells may be more easily repaired on the tiles when compared to cells bonded to current larger panels. Further, the front sheet layer described herein, unlike current solar panels, can be divided into a plurality of parts.

[0015]

[0031] FIG. 1 shows a schematic view of a plurality of layers (four of 110, 120, 130, 140 are shown) that may be used to manufacture a substrate 150 for a solar panel 100 according to one embodiment. The substrate 150 may include an electrical insulation layer 110. The electrical insulation layer 110 may be or may include polyimide. In particular, the electrical insulation layer 110 may be or may include poly(4,4'-oxydiphenylene-pyromellitimide). For example, the electrical insulation layer 110 may be or may include Kapton (registered trademark). The electrical insulation layer 110 may have a thickness from about 0.001 inches to about 0.005 inches.

[0016]

[0032] The substrate 150 also includes a first (e.g., front) sheet layer 120. The front sheet layer 120 may be or may include a polymer, carbon fiber, glass fiber, metal, or a combination thereof. In particular, the front sheet layer 120 may be or may include a composite carbon fiber reinforced polymer (CFRP) or a glass fiber reinforced polymer (GFRP). The front sheet layer 120 may have a thickness from about 0.01 inches to about 0.06 inches. As described below, the electrical insulation layer 110 and the front sheet layer 120 are both joined to form a first (e.g., front) portion 152 of the substrate 150.

[0017]

[0033] Substrate 150 also includes honeycomb core layer 130. Honeycomb core layer 130 may be or may include vented metal. In particular, honeycomb core layer 130 may be or may include vented aluminum. Honeycomb core layer 130 may have a thickness from about 0.125 inches to about 5 inches. In one embodiment, an isogrid structure may be used instead of or in addition to honeycomb core layer 130. The isogrid structure may be or may include a partially hollow structure formed from a single metal plate. The isogrid structure may have triangular integrally reinforced ribs (often called stringers).

[0018]

[0034] Substrate 150 also includes a second (e.g., rear) surface sheet layer 140. Rear surface sheet layer 140 may be or may include a polymer, carbon fiber, glass fiber, metal, or combinations thereof. In particular, rear surface sheet layer 140 may be or may include CFRP or GFRP. Rear surface sheet layer 140 may have a thickness from about 0.01 inches to about 0.06 inches. As described below, honeycomb core layer 130 and rear surface sheet layer 140 may be joined together to form the second (e.g., rear) portion 154 of substrate 150.

[0019]

[0035] FIG. 2 shows a flowchart of a method 200 for manufacturing a solar panel 100 according to one embodiment. An exemplary order of method 200 is provided below, but one or more steps of method 200 may be repeated, executed in a different order, or omitted entirely.

[0020]

[0036] Method 200 also includes, at 202, manufacturing tile 156. Manufacturing tile 156 may include, at 204, joining together electrical insulation layer 110 and front sheet layer 120 to manufacture the front portion 152 of substrate 150. This is shown in FIG. 3. In one example, electrical insulation layer 110 and front sheet layer 120 may be joined together using a film adhesive such as FM300-2U.

[0021]

[0037] Manufacturing the tile 156 also includes, at 206, joining together the front portion 152 of the substrate 150 and the battery 160. In particular, this may include joining the battery 160 to the electrical insulation layer 110 using an adhesive such as room temperature vulcanizing (RTV) silicone. RTV silicone is a rubber polymer that dries at room temperature. This is shown in FIG. 4. Although a single battery 160 is illustrated, in other embodiments, two or more batteries may be joined to the front portion 152 of the substrate 150 (e.g., the electrical insulation layer 110). The battery 160 may be or may include a photovoltaic (PV) cell, also referred to as a solar cell. The battery 160 may be or may include one or more cover glass interconnected cells (CICs) that include one or more PV / solar cells with interconnects and cover glass.

[0022]

[0038] Manufacturing the tile 156 also includes, at 208, joining together the front portion 152 of the substrate 150 and the wiring 170. In particular, this may include joining the wiring 170 to the electrical insulation layer 110 using an adhesive such as RFV silicone. This is also shown in FIG. 4. Although a single wiring 170 is illustrated, in other embodiments, two or more wirings may be joined to the front portion 152 of the substrate 150 (e.g., the electrical insulation layer 110). As can be seen, the wiring 170 may only contact and / or may be joined to the electrical insulation layer 110. In other embodiments, the wiring 170 may additionally or alternatively pass through the substrate 150 and contact and / or be joined to the backsheet layer 140. The tile 156 shown in FIG. 4 includes the front portion 152 of the substrate 150, the battery 160, the wiring 170, or combinations thereof.

[0023]

[0039] Method 200 also includes, at 210, connecting a first end of wiring 170 to battery 160. This may be a sub-step of step 202 (e.g., similar to steps 204 - 208), or another step in method 200. For example, wiring 170 may be connected to battery 160 before or after battery 160 is bonded to the front portion 152 (e.g., electrical insulation layer 110) of substrate 150. Wiring 170 may additionally or alternatively be connected to battery 160 before or after wiring 170 is bonded to the front portion 152 (e.g., electrical insulation layer 110) of substrate 150.

[0024]

[0040] Method 200 also includes, at 212, connecting a second end of wiring 170 to an object. This may be a sub-step of step 202 (e.g., similar to steps 204 - 208), or another step in method 200. For example, wiring 170 may be connected to the object before or after wiring 170 is bonded to the front portion 152 (e.g., electrical insulation layer 110) of substrate 150. The object may be or include another battery, a string, another tile, a solar panel, a transporter (e.g., a spacecraft), etc.

[0025]

[0041] Method 200 may also include, at 214, testing battery 160. Battery 160 may be tested before or after it is joined to the front portion 152 of substrate 150. Battery 160 may additionally or alternatively be tested before or after tile 156 is manufactured. As described below, battery 160 may additionally or alternatively be tested before tile 156 is joined to the rear portion 154 of substrate 150. Battery 160 may be tested using a solar simulator. Battery 160 may additionally or alternatively be tested by biasing battery 160 in the forward direction. Battery 160 may be tested to determine whether there is physical damage to battery 160, whether the connections to battery 160 are robust or damaged, whether battery 160 meets a predetermined performance metric (e.g., generates a predetermined voltage and / or current), or combinations thereof.

[0026]

[0042] Method 200 may also include, at 216, repairing battery 160 in response to the test indicating that battery 160 is malfunctioning. Method 200 may also include, at 218, additionally or alternatively, replacing battery 160 with a second (e.g., replacement) battery in response to the test indicating that battery 160 is malfunctioning. Replacing battery 160 with a replacement battery may include removing battery 160 from the front portion 152 of substrate 150 (e.g., electrical insulation layer 110) and then joining the replacement battery to the front portion 152 of substrate 150 (e.g., electrical insulation layer 110). Battery 160 may be repaired or replaced before or after tile 156 is manufactured. As described below, battery 160 may additionally or alternatively be replaced with a repair or replacement battery before tile 156 is joined to the rear portion 154 of substrate 150.

[0027]

[0043] Before the solar panel is completed, it is easier to repair and / or replace the battery 160 at the tile level. This is because the tile 156 is smaller and easier to handle than larger conventional components. Further, since the tile 156 is smaller, it can be discarded if it malfunctions. Discarding a larger conventional solar panel would result in significant waste.

[0028]

[0044] Method 200 also includes, at 220, joining the honeycomb core layer 130 and the rear sheet layer 140 together to produce the rear portion 154 of the substrate 150. This is shown in FIG. 5. The honeycomb core layer 130 and the rear sheet layer 140 can be joined together using a film adhesive such as FM300-2U. The honeycomb core layer 130 and the rear sheet layer 140 can be joined together either before or after the tile 156 is manufactured.

[0029]

[0045] Method 200 also includes, at 222, joining the tile 156 and the rear portion 154 of the substrate 150 together to produce the solar panel 100. This can include joining the front portion 152 of the substrate 150 and the rear portion 154 of the substrate 150 together. In particular, the front sheet layer 120 and the honeycomb core layer 130 can be joined together using a film adhesive such as FM300-2U. This is shown in FIG. 6. Step 222 is performed after one or more (e.g., all) of steps 202 - 220. For example, step 222 can be performed after the battery 160 is joined to the front portion 152 of the substrate 150 at (206), after the wiring 170 is joined to the front portion 152 of the substrate 150 at (208), or both.

[0030]

[0046] As described above, performing method 200 in this manner (e.g., manufacturing tile 156 by joining battery 160 and / or wiring 170 to front portion 152 of substrate 150 before joining tile 156 to rear portion 154 of substrate 150) enables tile 156A and solar panel 100 to be mass-produced more easily than standardized, conventional solar panel components and conventional solar panels. This allows for improved modularization and the ability to fabricate solar panels of various sizes with various different configurations more easily than using conventional components and methods. Further, the battery can be more easily repaired on the tile when compared to a battery joined to a larger, conventional panel. Additionally, the front sheet layer described herein cannot be divided into multiple parts like a conventional solar panel.

[0031]

[0047] In the above-described embodiment, solar panel 100 may include a single tile 156 joined to a single rear portion 154 of substrate 150 (e.g., a 1:1 ratio). In another embodiment, solar panel 100 may include a plurality of tiles joined to a single rear portion 154 of substrate 150 (e.g., a 2:1 ratio, a 4:1 ratio, an 8:1 ratio, etc.). In this embodiment, method 200 can loop back to step 202 to manufacture additional tiles 156 to be joined to rear portion 154 of substrate 150.

[0032]

[0048] Method 200 also includes, at 224, joining a second tile and the rear portion 154 of the substrate 150 together to manufacture the solar panel 100. FIG. 7 shows two tiles 156A, 156B joined to a single rear portion 154 of the substrate 150 for manufacturing a solar panel 100 according to one embodiment. Each tile 156A, 156B may include a front portion 152A, 152B, cells 160A, 160B, wiring 170A, 170B, or combinations thereof. The tiles 156A, 156B may be arranged adjacent to each other (side to side or end to end) on the rear portion 154 of the substrate 150. The first tile 156A may be connected to the second tile 156B. For example, the cell 160A and / or the wiring 170A may be connected to the second tile 156B (e.g., the cell 160B and / or the wiring 170B).

[0033]

[0049] Manufacturing and repairing the solar panel 100 is made easier by joining two or more tiles 156A, 156B to a single rear portion 154. This is because it allows for increased automation and standardization. For example, if one tile fails, it can be replaced with another usable tile. Additionally, handling of the components used to fabricate the solar panel 100 can be made easier. This is because the tiles 156A, 156B can be smaller than those used to manufacture conventional solar panels. Embodiments having two or more tiles 156A, 156B may also include one or more (e.g., all) of the advantages described above.

[0034]

[0050] In this embodiment, the rear portion 154 of the substrate 150 may have a surface area larger than each of the tiles 156A, 156B. In the illustrated example, the surface area of the rear portion 154 of the substrate 150 is approximately the same as the combined surface area of the two tiles 156A, 156B. However, in other examples, the rear portion 154 of the substrate 150 may be sized to accept four tiles, six tiles, eight tiles, or more.

[0035]

[0051] Method 200 may also include, at 226, connecting the solar panel 100 to a transporter. In particular, the solar panel 100 may be connected to the exterior of the transporter. The transporter may be or may include an automobile, a bus, a train, a boat, an airplane, a helicopter, an unmanned aerial vehicle (UAV), a spacecraft, etc.

[0036]

[0052] Placing wiring within channels in the honeycomb core layer before a front portion of the substrate is joined to a rear portion of the substrate.

[0037]

[0053] FIG. 8 shows a flowchart of another method 800 for manufacturing a solar panel 100 according to one embodiment. Although an exemplary order of method 800 is provided below, one or more steps of method 800 may be repeated, performed in a different order, or omitted entirely.

[0038]

[0054] Method 800 includes, at 802, joining together an electrical insulation layer 110 and a front sheet layer 120 to produce a front portion 152 of a substrate 150. This is shown in FIG. 3. The electrical insulation layer 110 and the front sheet layer 120 may be joined together using a film adhesive such as FM300-2U.

[0039]

[0055] Method 800 also includes, at 804, joining together a honeycomb core layer 130 and a rear sheet layer 140 to produce a rear portion 154 of the substrate 150. This is shown in FIG. 5. The honeycomb core layer 130 and the rear sheet layer 140 may be joined together using a film adhesive such as FM300-2U.

[0040]

[0056] Method 800 also includes, at 806, forming one or more channels (one is shown: 132) within the honeycomb core layer 130. This is shown in FIG. 9. The channel 132 can be formed within the honeycomb core layer 130 either before or after the honeycomb core layer 130 is joined to the backsheet layer 140. In one embodiment, the channel 132 can be formed by removing a portion of the honeycomb core layer 130 (e.g., by machining). In another embodiment, the channel 132 can be formed during the formation of the honeycomb core layer 130. For example, a mold for manufacturing the honeycomb core layer 130 can form the channel 132 within the honeycomb core layer 130.

[0041]

[0057] As shown, the channel 132 can be or can include a recess that is at least partially formed within the inner surface 133 of the honeycomb core layer 130. The channel 132 can be at least partially defined by one or more channel boundary portions (two are shown: 136A, 136B) of the honeycomb core layer 130 and a reduced inner surface 134. In one example, the channel boundary portions 136A, 136B can be or can include portions of the honeycomb core layer 130 that are not removed when the channel 132 is formed.

[0042]

[0058] In another embodiment, the channel 132 can be or can include a recess that is at least partially formed within the outer surface 135 of the honeycomb core layer 130. In yet another embodiment, the channel 132 can be or can include a bore that is formed at least partially through the honeycomb core layer 130 (e.g., between the inner surface 133 and the outer surface 135). As used herein, the inner surface 133 is the surface that is joined / can be joined to the front portion 152 of the substrate 150 (e.g., the front sheet layer 120), and the outer surface 135 is the surface that is joined / can be joined to the backsheet layer 140.

[0043]

[0059] Method 800 also includes, at 808, disposing a first wiring 170 within channel 132. This is shown in FIG. 10. As described above, although a single first wiring 170 is illustrated, the first wiring 170 may additionally or alternatively include two or more wirings. The thickness of the first wiring 170 may be less than or equal to the depth of the channel 132.

[0044]

[0060] In one embodiment, method 800 also includes, at 810, joining together the rear portion 154 of the substrate 150 and the first wiring 170. In particular, once the first wiring 170 is disposed within the channel 132, the first wiring 170 may be joined to the honeycomb core layer 130. For example, the first wiring 170 may be joined to the reduced inner surface 134 of the honeycomb core layer 130 and / or the channel boundary portions 136A, 136B using an adhesive such as RFV silicone. In another embodiment, step 810 may be omitted.

[0045]

[0061] Method 800 also includes, at 812, joining together the front portion 152 of the substrate 150 and the rear portion 154 of the substrate 150. This is shown in FIG. 11. As described above, the front portion 152 and the rear portion 154 together form the substrate 150. The front portion 152 and the rear portion 154 may be joined together using a film adhesive such as FM300-2U. Joining together the front portion 152 and the rear portion 154 includes joining the front sheet layer 120 to the channel boundary portions 136A, 136B of the honeycomb core layer 130. In one embodiment, a gap may exist between the front sheet layer 120 and the first wiring 170. In another embodiment, the first wiring 170 may be compressed between the front sheet layer 120 and the reduced inner surface 134 of the honeycomb core layer 130.

[0046]

[0062] Step 812 can be performed after the channel 132 is formed and / or after the first wiring 170 is disposed within the channel 132. As illustrated, the first wiring 170 can be disposed at least partially between the front sheet layer 120 and the reduced inner surface 134 of the honeycomb core layer 130. At least a portion of the first wiring 170 can also be disposed at least partially between the channel boundary portions 136A, 136B. In one embodiment, the wiring 170 can enter the channel 132 from one side of the substrate 150 and exit the channel 132 from the other side of the substrate 150. In another embodiment, at least a portion of the first wiring 170 can extend through or beyond the openings within the channel boundary portions 136A, 136B.

[0047]

[0063] Method 800 also includes, at 814, joining the front portion 152 of the substrate 150 and the first wiring 170 together. In particular, the front sheet layer 120 and the first wiring 170 can be joined together simultaneously with, or after, or before the front portion 152 and the rear portion 154 of the substrate 150 are joined together. The first wiring 170 can be joined to the front sheet layer 120 using an adhesive such as RFV silicone. In another embodiment, step 814 can be omitted, and the first wiring 170 can instead be fixed in place by being disposed within the channel 132 between the front sheet layer 120 and the honeycomb core layer 130.

[0048]

[0064] Method 800 also includes, at 816, connecting the first wiring 170 to the first object and the second object. The first object may be or may include a battery 160, another battery, a series of batteries, a tile, a solar panel 100, or a combination thereof. The second object may be or may include another battery (e.g., not the battery 160), a series of batteries (e.g., including the battery 160), a solar panel 100, a transporter, or a combination thereof. The first wiring 170 may be connected to the first and second objects before or after the first wiring 170 is disposed within the channel 132. The first wiring 170 may be connected to the first and second objects before or after the first wiring 170 is joined to the rear portion 154 of the substrate 150.

[0049]

[0065] Method 800 also includes, at 818, joining the front portion 152 of the substrate 150 and the battery 160 together. This is shown in FIG. 12. In particular, the battery 160 may be joined to the electrical insulation layer 110 using an adhesive such as room temperature vulcanizing (RTV) silicone. Although a single battery 160 is illustrated, in other embodiments, two or more batteries may be joined to the front portion 152 of the substrate 150 (e.g., the electrical insulation layer 110). As described above, the battery 160 may be or may include a photovoltaic (PV) cell, also referred to as a solar cell. The battery 160 may be or may include one or more cover glass interconnected cells (CICs) including one or more PV / solar cells with interconnections and cover glass.

[0050]

[0066] Step 818 may be performed before or after the electrical insulation layer 110 is joined to the front sheet layer 120 to manufacture the front portion 152 of the substrate. Step 818 may alternatively be performed before or after the front portion 152 of the substrate 150 is joined to the rear portion 154 of the substrate 150 to manufacture the substrate 150.

[0051]

[0067] Method 800 also includes, at 820, joining a second wiring 172 to the substrate 150. This is also shown in FIG. 12. As described above, although a single second wiring 172 is illustrated, the second wiring 172 may also additionally or alternatively include two or more wirings. The first wiring 170 and the second wiring 172 may be different wires or different portions (e.g., a first portion and a second portion) of the same wiring.

[0052]

[0068] The second wiring 172 may be joined to the substrate 150 using an adhesive such as RFV silicone. The second wiring 172 may be joined to the electrical insulation layer 110, the backsheet layer 140, or both. As illustrated, at least a portion of the first wiring 170 may extend in a first direction that is substantially parallel to the layers 110, 120, 130, 140, and at least a portion of the second wiring 172 may extend in a second direction that is substantially perpendicular to the layers 110, 120, 130, 140. For example, the second wiring 172 may be at least partially wound around the substrate 150. In another embodiment, at least a portion of the second wiring 172 may extend through a hole formed (e.g., drilled) in the substrate 150.

[0053]

[0069] Method 800 also includes, at 822, connecting a second wiring 172 to a third object and a fourth object. In one embodiment, the third object may be the same as the first object and / or the second object. In another embodiment, the third object may be different from the first object and the second object. In one embodiment, the fourth object may be the same as the first object, the second object, the third object, or a combination thereof. In another embodiment, the fourth object may be different from the first object, the second object, and the third object. The third object may be or may include a battery 160, another battery, a series of batteries, a tile, a solar panel 100, or a combination thereof. The fourth object may be or may include another battery (e.g., not the battery 160), a series of batteries (e.g., including the battery 160), a solar panel 100, a transporter, or a combination thereof. The second wiring 172 may be connected to the third and fourth objects before or after the second wiring 172 is joined to the substrate 150.

[0054]

[0070] The substrate 150, the battery 160, the first wiring 170, the second wiring 172, or a combination thereof may manufacture the solar panel 100 shown in FIG. 12. Method 800 also includes, at 824, connecting the solar panel 100 to a transporter. In particular, the solar panel 100 may be connected to the exterior of the transporter. The transporter may be or may include an automobile, a bus, a train, a boat, an airplane, a helicopter, an unmanned aerial vehicle (UAV), a spacecraft, etc.

[0055]

[0071] Placing the first wiring 170 within the channel 132 can reduce the thickness of the solar panel 100. In particular, this can reduce the profile on the back side of the substrate 150. Placing the first wiring 170 within the channel 132 can additionally or alternatively increase the flexibility in routing the first wiring 170. This is because the channel 132 and the first wiring 170 can be routed in any manner and / or direction. In contrast, in conventional solar panels, there are obstructions (e.g., solar cells, other wirings, buffer circuits, restricted access areas) on the front and back surfaces around which the wiring is routed. Placing the first wiring 170 within the channel 132 can additionally or alternatively reduce the amount of labor required to route the first wiring 170 and / or fix the first wiring 170 in place. This is because it is not necessary to bond the first wiring 170 frequently (e.g., every about 5 inches) to hold the first wiring 170 in place. Since the channel already exists, it routes the first wiring 170. Thus, the amount of bonding between the first wiring 170 and the substrate 150 can be reduced (e.g., less than conventional) or the bonding can be omitted. Another advantage is that when used in conjunction with the tile method, there is no need for any wiring on the front portion 152 of the substrate 150, enabling a higher density of cells (e.g., cell 160). This increases efficiency and makes the overall tile concept easier to use. Another advantage is that using the channel 132 reduces or eliminates the need to drill any feed-through holes through the substrate 150, requiring less labor. Further, when the first wiring 170 is inside the channel 132 in the substrate 150, the first wiring 170 is better protected and thus less likely to be damaged. This protection is relevant to the mission assurance of a spacecraft, reducing the likelihood that small micro-meteorites will damage the first wiring 170 and result in reduced performance.

[0056]

[0072] Before placing the wiring within the honeycomb core layer, join the wiring to the front portion of the substrate.

[0057]

[0073] Figure 13 shows a flowchart of another method 1300 for manufacturing the solar panel 100 according to one embodiment. Although an exemplary order of method 1300 is provided below, one or more steps of method 1300 may be repeated, performed in a different order, or omitted entirely.

[0058]

[0074] Method 1300 includes, at 1302, manufacturing the tile 156. Manufacturing the tile 156 may include, at 1304, joining the electrical insulation layer 110 and the front sheet layer 120 together to manufacture the front portion 152 of the substrate 150. This is shown in FIG. 3. The electrical insulation layer 110 and the front sheet layer 120 may be joined together using a film adhesive such as FM300-2U.

[0059]

[0075] Manufacturing the tile 156 also includes, at 1306, joining the front portion 152 of the substrate 150 and the battery 160 together. In particular, this may include joining the battery 160 to the electrical insulation layer 110 using an adhesive such as room temperature vulcanizing (RTV) silicone. This is shown in FIG. 14. Although a single battery 160 is illustrated, in other embodiments, two or more batteries may be joined to the front portion 152 of the substrate 150 (e.g., the electrical insulation layer 110). As described above, the battery 160 may be or may include a photovoltaic (PV) cell, also referred to as a solar cell. The battery 160 may be or may include one or more cover glass interconnected cells (CICs) that include one or more PV / solar cells with interconnections and cover glass.

[0060]

[0076] Manufacturing the tile 156 also includes, at 1308, joining the front portion 152 of the substrate 150 and one or more wirings (two of the first wiring 170 and the second wiring 172 are shown). This is also shown in FIG. 14. In particular, this may include joining the first wiring 170 to the electrical insulation layer 110 and / or the front sheet layer 120. This may additionally or alternatively also include joining the second wiring 172 to the electrical insulation layer 110 and / or the front sheet layer 120. The tile 156 shown in FIG. 14 includes the front portion 152 of the substrate 150, the battery 160, the first wiring 170, the second wiring 172, or a combination thereof.

[0061]

[0077] The method 1300 also includes, at 1310, connecting the first wiring 170 to a first object and a second object. This may be a sub-step of step 1302 (e.g., similar to steps 1304 - 1308), or another step in the method 1300. The first object may be or may include the battery 160, another battery, a series of batteries, the tile 156, the solar panel 100, or a combination thereof. For example, the first wiring 170 may be connected to the battery 160 (or a series of batteries including the battery 160) before or after the battery 160 is joined to the front portion 152 of the substrate 150. The first wiring 170 may additionally or alternatively be connected to the battery 160 (or a series of batteries including the battery 160) before or after the wiring 170 is joined to the front portion 152 of the substrate 150. The second object may be or may include the battery 160, another battery (e.g., not the battery 160), a series of batteries (e.g., including the battery 160), the tile 156, the solar panel 100, a transporter, or a combination thereof.

[0062]

[0078] Method 1300 also includes, at 1312, connecting a second wiring 172 to a third object and a fourth object. This may be a sub-step of step 1302 (e.g., similar to steps 1304-1308), or may be another step in method 1300. In one embodiment, the third object may be the same as the first object and / or the second object. In another embodiment, the third object may be different from the first object and the second object. In one embodiment, the fourth object may be the same as the first object, the second object, the third object, or a combination thereof. In another embodiment, the fourth object may be different from the first object, the second object, and the third object. The third object may be or may include the battery 160, another battery, a series of batteries (including the battery 160), the tile 156, the solar panel 100, or a combination thereof. The fourth object may be or may include the battery 160, another battery (e.g., not the battery 160), a series of batteries (e.g., including the battery 160), the tile 156, the solar panel 100, a transporter, or a combination thereof. For example, the second wiring 172 may be connected to the third and / or fourth object before or after the second wiring 172 is joined to the front portion 152 of the substrate 150.

[0063]

[0079] Method 1300 also includes, at 1314, testing battery 160. Battery 160 can be tested either before or after it is joined to the front portion 152 of substrate 150. Battery 160 can additionally or alternatively be tested either before or after tile 156 is manufactured. As described below, battery 160 can additionally or alternatively be tested either before or after first wiring 170 is disposed within channel 132. As described below, battery 160 can additionally or alternatively be tested before tile 156 is joined to the rear portion 154 of substrate 150. Battery 160 can be tested using a solar simulator. Battery 160 can additionally or alternatively be tested by biasing battery 160 in the forward direction. Battery 160 can be tested to determine whether there is physical damage to battery 160, whether the connection to battery 160 is robust or damaged, whether battery 160 meets a predetermined performance metric (e.g., generates a predetermined voltage and / or current), or combinations thereof.

[0064]

[0080] Method 1300 also includes, at 1316, repairing battery 160 in response to the test indicating that battery 160 is malfunctioning. Method 200 can additionally or alternatively include, at 1318, replacing battery 160 with a second (e.g., replacement) battery in response to the test indicating that battery 160 is malfunctioning. Replacing battery 160 with a replacement battery can include removing battery 160 from the front portion 152 (e.g., electrical insulation layer 110) of substrate 150 and subsequently joining the replacement battery to the front portion 152 (e.g., electrical insulation layer 110) of substrate 150. Battery 160 can be repaired or replaced either before or after tile 156 is manufactured. As described below, battery 160 can additionally or alternatively be repaired or replaced before tile 156 is joined to the rear portion 154 of substrate 150.

[0065]

[0081] Before the solar panel is completed, it is easier to repair and / or replace the battery 160 at the tile level. This is because the tile 156 is smaller and easier to handle than larger conventional components. Further, because the tile 156 is smaller, the tile 156 can be discarded if it malfunctions. Discarding a larger conventional solar panel would be a significant waste.

[0066]

[0082] Method 1300 also includes, at 1320, joining the honeycomb core layer 130 and the backsheet layer 140 together to produce the rear portion 154 of the substrate 150. This is shown in FIG. 5. The honeycomb core layer 130 and the backsheet layer 140 can be joined together using a film adhesive such as FM300-2U. The honeycomb core layer 130 and the backsheet layer 140 can be joined together either before or after the tile 156 is manufactured.

[0067]

[0083] Method 1300 also includes, at 1322, forming one or more channels (one is shown: 132) in the honeycomb core layer 130. This is shown in FIG. 9. The channel 132 can be formed in the honeycomb core layer 130 either before or after the honeycomb core layer 130 is joined to the backsheet layer 140. In one embodiment, the channel 132 can be formed by removing a portion of the honeycomb core layer 130 (e.g., by machining). In another embodiment, the channel 132 can be formed during the formation of the honeycomb core layer 130. For example, a mold for manufacturing the honeycomb core layer 130 can form the channel 132 in the honeycomb core layer 130.

[0068]

[0084] As shown, channel 132 may be or may include a recess at least partially formed within the inner surface 133 of the honeycomb core layer 130. Channel 132 may be at least partially defined by one or more channel boundary portions (two of which, 136A and 136B, are shown) of the honeycomb core layer 130 and a reduced inner surface 134. In one embodiment, channel boundary portions 136A, 136B may be or may include portions of the honeycomb core layer 130 that are not removed when channel 132 is formed.

[0069]

[0085] In another embodiment, channel 132 may be or may include a recess at least partially formed within the outer surface 135 of the honeycomb core layer 130. In yet another embodiment, channel 132 may be or may include a bore formed at least partially through the honeycomb core layer 130 (e.g., between inner surface 133 and outer surface 135). As used herein, inner surface 133 is the surface that is or can be joined to the front portion 152 (e.g., front sheet layer 120), and outer surface 135 is the surface that is or can be joined to the rear sheet layer 140.

[0070]

[0086] Method 1300 also includes, at 1324, placing tile 156 such that at least a portion of the first wiring 170 is at least partially disposed within channel 132. This is shown in FIG. 15. In particular, tile 156 may be placed such that the front sheet layer 120 faces the rear portion 154 of the substrate 150 and the electrical insulation layer 110 faces away from the rear portion 154 of the substrate 150. Then, tile 156 and the rear portion 154 of the substrate 150 may be moved together until the front sheet layer 120 contacts the honeycomb core layer 130 (e.g., one or more of channel boundary portions 136A, 136B). At this point, at least a portion of the first wiring 170 may be at least partially disposed within channel 132.

[0071]

[0087] Method 200 also includes, at 1326, joining together the tile 156 and the rear portion 154 of the substrate 150 to manufacture the solar panel 100. This is also shown in FIG. 15. This may include joining together the front portion 152 of the substrate 150 and the rear portion 154 of the substrate 150 using a film adhesive such as FM300-2U. In particular, this may include joining together the front sheet layer 120 and the channel boundary portions 136A, 136B of the honeycomb core layer 130.

[0072]

[0088] Performing method 1300 in this manner (e.g., manufacturing tile 156 and arranging tile 156 such that first wiring 170 is disposed within channel 132) can reduce the thickness of solar panel 100. In particular, this can reduce the profile on the back side of substrate 150. Performing method 1300 in this manner can additionally or alternatively increase the flexibility in routing first wiring 170. This is because channel 132 and first wiring 170 can be routed in any manner and / or direction. In contrast, in conventional solar panels, there are obstructions (e.g., solar cells, other wiring, buffer circuits, restricted access areas) on the front and back surfaces around which the wiring is routed. Performing method 1300 in this manner can additionally or alternatively reduce the amount of labor required to route first wiring 170 and / or fix first wiring 170 in place. This is because it is not necessary to frequently bond (e.g., approximately every 5 inches) to first wiring 170 to hold first wiring 170 in place. Since the channel already exists, it routes first wiring 170. Thus, the amount of bonding between first wiring 170 and substrate 150 can be reduced (e.g., less than conventional) or bonding can be omitted. Another advantage is that a reduced amount of wiring may be present on front portion 152 of substrate 150, enabling higher density cells (e.g., cell 160). This increases efficiency and makes the overall tile concept easier to use. Another advantage is that using channel 132 reduces or eliminates the need to drill any feed-through holes through substrate 150, requiring less labor. Further, when first wiring 170 is inside channel 132 within substrate 150, first wiring 170 is better protected and thus less likely to be damaged. This protection is relevant to the mission assurance of a spacecraft, reducing the likelihood that small micro-meteorites will damage first wiring 170 and result in reduced performance.

[0073]

[0089] In an embodiment of the above-described method 1300, the solar panel 100 may include a single tile 156 joined to a single rear portion 154 of the substrate 150 (e.g., at a 1:1 ratio). In another embodiment, the solar panel 100 may include a plurality of tiles joined to a single rear portion 154 of the substrate 150 (e.g., at a 2:1 ratio, 4:1 ratio, 8:1 ratio, etc.). In this embodiment, the method 1300 can loop back to step 1302 to manufacture additional tiles 156.

[0074]

[0090] The method 1300 also includes, at 1328, joining together a second tile and the rear portion 154 of the substrate 150 to manufacture the solar panel 100. FIG. 16 shows two tiles 156A, 156B joined to a single rear portion 154 of the substrate 150 to manufacture a solar panel 100, according to one embodiment. Each tile 156A, 156B may include a front portion 152A, 152B, cells 160A, 160B, a first wiring 170A, 170B, a second wiring 172A, 172B, or a combination thereof. The tiles 156A, 156B may be arranged adjacent to each other (side-to-side or end-to-end) on the rear portion 154 of the substrate 150. In one embodiment, the tiles 156A, 156B may be connected together using the (one or more) first wirings 170A, 170B, the (one or more) second wirings 172A, 172B, or a combination thereof to form a continuous string of tiles. In another embodiment, the tiles 156A, 156B may instead be connected together using metal strips instead of wiring to form a continuous string of tiles. The tiles 156A, 156B may be connected (e.g., at step 324) to form a continuous string before the (one or more) first wirings 170A, 170B are disposed within the (one or more) channels. That continuous string may be connected to a transporter.

[0075]

[0091] Manufacturing and repairing the solar panel 100 is made easier by joining two or more tiles 156A, 156B to a single rear portion 154. This is because it enables further automation and standardization. Additionally, handling of the components used to fabricate the solar panel 100 can be made easier. This is because the tiles 156A, 156B can be smaller than those used to manufacture conventional solar panels.

[0076]

[0092] In this embodiment, the rear portion 154 of the substrate 150 can have a larger surface area than each of the tiles 156A, 156B. In the illustrated example, the surface area of the rear portion 154 of the substrate 150 is approximately the same as the combined surface area of the two tiles 156A, 156B. However, in other examples, the rear portion 154 of the substrate 150 can be sized to receive four tiles, six tiles, eight tiles, or more.

[0077]

[0093] The method 1300 also includes, at 1330, connecting the solar panel 100 to a transport vehicle. In particular, the solar panel 100 can be connected to the exterior of the transport vehicle. The transport vehicle can be or can include an automobile, a bus, a train, a boat, an airplane, a helicopter, an unmanned aerial vehicle (UAV), a spacecraft, etc.

[0078]

[0094] FIG. 17 shows an example of a transporter 1700 to which the solar panel 100 can be coupled according to one embodiment. As described above, the transporter 1700 can be or can include automobiles, buses, trains, boats, airplanes, helicopters, unmanned aerial vehicles (UAVs), spacecraft, etc. In this particular example, the transporter 1700 is an aircraft (e.g., an airplane). The solar panel 100 can be coupled to the outer surface of the transporter 1700. In this example, the solar panel 100 is coupled to the main wing 1710. However, the solar panel 100 can be additionally or alternatively coupled to other parts of the transporter 1700. The solar panel 100 can convert sunlight into energy. That energy can be supplied to the transporter 1700 and / or its internal components (e.g., communication systems, lighting, etc.).

[0079]

[0095] Further, the present disclosure comprises examples according to the following clauses. Clause 1. A method for manufacturing a solar panel, comprising manufacturing a tile by joining an electrically insulating layer and a front sheet layer together to manufacture a front portion of a substrate, joining the front portion of the substrate and a battery together, and joining the front portion of the substrate and wiring together, manufacturing a honeycomb core layer and a rear sheet layer and joining them together to manufacture a rear portion of the substrate, and joining the tile and the rear portion of the substrate together to manufacture the solar panel. Clause 2. The method according to clause 1, wherein manufacturing the tile further comprises connecting a first end of the wiring to the battery. Clause 3. The method according to clause 2, wherein the first end of the wiring is connected to the battery before the battery and the wiring are joined to the front portion of the substrate. Clause 4. The method according to clause 2, wherein the first end of the wiring is connected to the battery after the battery and the wiring are joined to the front portion of the substrate. Clause 5. The method according to any one of clauses 2 to 4, further comprising connecting the second end of the wiring to an object, the object including another tile, another battery, or a transporter. Clause 6. The method according to any one of clauses 1 to 5, further comprising testing the battery after the battery is joined to the front portion of the substrate. Clause 7. The method according to clause 6, wherein the battery is tested before the tile and the rear portion of the substrate are joined together. Clause 8. The method according to clause 7, further comprising repairing the battery in response to the test indicating that the battery is malfunctioning, the battery being repaired before the tile and the rear portion of the substrate are joined together. Clause 9. The method according to clause 7, further comprising replacing the battery with a replacement battery in response to the test indicating that the battery is malfunctioning, the battery being replaced with the replacement battery before the tile and the rear portion of the substrate are joined together. Clause 10. The method according to any one of clauses 1 to 9, further comprising connecting the solar panel to a transporter. Clause 11. A method for manufacturing a solar panel, comprising manufacturing a tile by joining together an electrical insulation layer and a front sheet layer to manufacture a front portion of a substrate, joining together the electrical insulation layer and a battery, joining together the electrical insulation layer and wiring, connecting a first end of the wiring to the battery, and connecting a second end of the wiring to an object, the object including another battery, another tile, or a spacecraft, manufacturing a tile including connecting the second end of the wiring to the object, joining together a honeycomb core layer and a rear sheet layer to manufacture a rear portion of the substrate, the wiring not being joined to the rear sheet layer, manufacturing the rear portion of the substrate, joining together the tile and the rear portion of the substrate to manufacture the solar panel, and connecting the solar panel to the spacecraft. Clause 12. The method according to clause 11, further comprising testing the battery after the battery is joined to the front portion of the substrate. Clause 13. The method according to clause 12, wherein the battery is tested before the tile and the rear portion of the substrate are joined together. Clause 14. The method according to clause 13, further comprising repairing the battery in response to the test indicating that the battery is malfunctioning, the battery being repaired before the tile and the rear portion of the substrate are joined together. Clause 15. The method according to clause 13, further comprising replacing the battery with a replacement battery in response to the test indicating that the battery is malfunctioning, the battery being replaced with the replacement battery before the tile and the rear portion of the substrate are joined together. Clause 16. A method for manufacturing a solar panel, comprising manufacturing two or more tiles, wherein manufacturing each of the two or more tiles includes joining an electrical insulation layer and a front sheet layer together to manufacture a front portion of a substrate, joining the electrical insulation layer and a battery together, and joining the electrical insulation layer and wiring together; manufacturing a rear portion of the substrate by joining a honeycomb core layer and a rear sheet layer, wherein the wiring is not joined to the rear sheet layer; joining the two or more tiles and the rear portion of the substrate together to manufacture the solar panel; and connecting the solar panel to a spacecraft. Clause 17. The method according to clause 16, wherein the two or more tiles are joined side by side to the honeycomb core layer. Clause 18. The method according to clause 16 or 17, further comprising connecting the two or more tiles together. Clause 19. The method according to clause 18, wherein connecting the two or more tiles together includes connecting the wiring of a first tile among the two or more tiles to a second tile among the two or more tiles. Clause 20. The method according to clause 19, further comprising testing the battery of the first tile and, in response to the test indicating that the battery of the first tile is malfunctioning, replacing the battery of the first tile with a replacement battery, wherein the battery of the first tile is replaced with the replacement battery before the first tile and the rear portion of the substrate are joined together.

[0080]

[0096] As used herein, the terms "inner" and "outer", "upper" and "lower", "upper side" and "lower side", "upward" and "downward", "upstream" and "downstream", "above" and "below", "inward" and "outward", and other similar terms refer to relative positions with respect to each other and are not intended to specify a particular direction or spatial orientation. The terms "couple", "coupled", "connect", "connection", "connected", "connected to", and "connecting" refer to either "direct connection" or "connection via one or more intermediate elements or members". Similarly, the terms "joined" and "joining" refer to either "direct joining" or "joining via one or more intermediate elements, members, or layers".

[0081]

[0097] The numerical ranges and parameters setting forth the broad scope of the present disclosure are approximations, but the numerical values set forth in the specific examples are reported as precisely as possible. Any numerical value, however, inherently contains certain errors resulting from the standard deviation found in the respective testing measurements. Further, all ranges disclosed herein are to be understood to encompass any and all sub-ranges subsumed therein.

[0082]

[0098] While the teachings of this specification have been illustrated in connection with the above embodiments, changes and / or modifications can be made to the examples without departing from the spirit and scope of the appended claims. Also, although specific features of the present teachings may have been disclosed with respect to only one of several embodiments, such features may be combined with one or more other features of other embodiments if desired and advantageous for any given or particular function. As used herein, the terms "a," "an," and "the" can refer to one or more elements or portions of an element. As used herein, the terms "first" and "second" can refer to two different elements or portions of an element. As used herein, for example, the term "at least one of A and B" with respect to a listing of items such as A and B means only A, only B, or A and B. Those skilled in the art will understand that these and other variations are possible. Further, the words "including," "having," "with," or variations after these words are intended to be inclusive in the same sense as the word "comprising" as long as they are used in either this specification or the claims. Further, in the discussions herein and in the claims, the term "about" indicates that the listed value may be changed somewhat as long as the change does not cause an inappropriateness in the process or structure for the intended purpose described herein. Finally, "exemplary" indicates that the description is being used as an example rather than suggesting that it is ideal.

[0083]

[0099] It will be understood that the variations disclosed above, as well as other features and functions or alternatives thereof, may be incorporated into many other different systems or applications. Various alternatives, modifications, variations or improvements thereof which are presently unforeseeable or unexpected may subsequently be made by those skilled in the art, but these are also encompassed by the following claims.

Claims

A method (200) for manufacturing a solar panel (100), comprising: manufacturing a tile (156), comprising: joining an electrical insulation layer (110) and a front sheet layer (120) together to manufacture a front portion (152) of a substrate (150); joining the front portion (152) of the substrate (150) and a battery (160) together; and joining the front portion (152) of the substrate (150) and a wiring (170) together; joining a honeycomb core layer (130) and a rear sheet layer (140) together to manufacture a rear portion (154) of the substrate (150); and joining the tile (156) and the rear portion (154) of the substrate (150) together to manufacture the solar panel (100); testing the battery (160) before the tile (156) and the rear portion (154) of the substrate (150) are joined together; and further comprising repairing the battery (160) in response to the test indicating that the battery (160) is malfunctioning, wherein the battery (160) is repaired before the tile (156) and the rear portion (154) of the substrate (150) are joined together. A method (200) for manufacturing a solar panel (100), comprising: manufacturing a tile (156), comprising: joining an electrical insulation layer (110) and a front sheet layer (120) together to manufacture a front portion (152) of a substrate (150); joining the front portion (152) of the substrate (150) and a battery (160) together; and joining the front portion (152) of the substrate (150) and a wiring (170) together; joining a honeycomb core layer (130) and a rear sheet layer (140) together to manufacture a rear portion (154) of the substrate (150); and joining the tile (156) and the rear portion (154) of the substrate (150) together to manufacture the solar panel (100); testing the battery (160) before the tile (156) and the rear portion (154) of the substrate (150) are joined together; Further comprising replacing the battery (160) with a replacement battery in response to the test indicating that the battery (160) is malfunctioning, wherein the battery (160) is replaced with the replacement battery before the tile (156) and the rear portion (156) of the substrate (150) are joined together, method.

3. Manufacturing the tile (156) further includes connecting a first end of the wiring (170) to the battery (160), the method according to claim 1 or 2.

4. Before the battery (160) and the wiring (170) are joined to the front portion (152) of the substrate (150), the first end of the wiring (170) is connected to the battery (160), or, after the battery (160) and the wiring (170) are joined to the front portion (152) of the substrate (150), the first end of the wiring (170) is connected to the battery (160), the method according to claim 3.

5. Further comprising connecting a second end of the wiring (170) to an object, the object including another tile (156B), another battery (160B), or a transporter (1700), the method according to claim 3 or 4.

6. After the battery (160) is joined to the front portion (152) of the substrate (150), the battery (160) is tested, the method according to any one of claims 1 to 5.

7. Further comprising connecting the solar panel (100) to a transporter (1700), the method according to any one of claims 1 to 6.

8. A method (200) for manufacturing a solar panel (100), Manufacturing a tile (156), Joining together an electrical insulation layer (110) and a front sheet layer (120) to manufacture a front portion (152) of a substrate (150), Joining together the electrical insulation layer (110) and a battery (160), Joining together the electrical insulation layer (110) and wiring (170), Connecting a first end of the wiring (170) to the battery (160), and Connecting a second end of the wiring (170) to an object, the object including another battery (160B), another tile (156B), or a spacecraft (1700), including connecting the second end of the wiring (170) to an object, manufacturing a tile (156). To manufacture the rear portion (154) of the substrate (150), joining a honeycomb core layer (130) and a rear sheet layer (140), wherein the wiring (170) is not joined to the rear sheet layer (140), joining the honeycomb core layer (130) and the rear sheet layer (140). Joining the tile (156) and the rear portion (154) of the substrate (150) together to manufacture the solar panel (100), and Connecting the solar panel (100) to the spacecraft (1700), including Testing the battery (160) before the tile (156) and the rear portion (154) of the substrate (150) are joined together, and Further including repairing the battery (160) in response to the test indicating that the battery (160) is malfunctioning, wherein the battery (160) is repaired before the tile (156) and the rear portion (154) of the substrate (150) are joined together, a method.

9. A method (200) for manufacturing a solar panel (100), comprising Manufacturing a tile (156), including Joining an electrical insulation layer (110) and a front sheet layer (120) together to manufacture the front portion (152) of a substrate (150), Joining the electrical insulation layer (110) and a battery (160) together, Joining the electrical insulation layer (110) and wiring (170) together, Connecting a first end of the wiring (170) to the battery (160), and Connecting a second end of the wiring (170) to an object, wherein the object includes another battery (160B), another tile (156B), or a spacecraft (1700), connecting the second end of the wiring (170) to an object, manufacturing a tile (156), including To manufacture the rear portion (154) of the substrate (150), joining a honeycomb core layer (130) and a rear sheet layer (140), wherein the wiring (170) is not joined to the rear sheet layer (140), joining the honeycomb core layer (130) and the rear sheet layer (140). Joining the tile (156) and the rear portion (154) of the substrate (150) together to manufacture the solar panel (100), and Connecting the solar panel (100) to the spacecraft (1700), including testing the battery (160) before the tile (156) and the rear portion (154) of the substrate (150) are joined together; further comprising replacing the battery (160) with a replacement battery in response to the test indicating that the battery (160) is malfunctioning, wherein the battery (160) is replaced with the replacement battery before the tile (156) and the rear portion (154) of the substrate (150) are joined together, method.

10. The method according to claim 8 or 9, wherein the battery (160) is tested after the battery (160) is joined to the front portion (152) of the substrate (150).

11. A method (200) for manufacturing a solar panel (100), comprising: manufacturing two or more tiles (156A, 156B), wherein manufacturing each of the two or more tiles (156A, 156B) comprises: joining an electrical insulation layer (110) and a front sheet layer (120) together to manufacture a front portion (152) of a substrate (150); joining the electrical insulation layer (110) and a battery (160) together; and joining the electrical insulation layer (110) and a wiring (170) together to manufacture two or more tiles (156A, 156B); joining a honeycomb core layer (130) and a rear sheet layer (140) together to manufacture a rear portion (154) of the substrate (150), wherein the wiring (170) is not joined to the rear sheet layer (140); joining the two or more tiles (156A, 156B) and the rear portion (154) of the substrate (150) together to manufacture the solar panel (100); and connecting the solar panel (100) to a spacecraft (1700).

12. The method according to claim 11, wherein the two or more tiles (156A, 156B) are joined side by side to the honeycomb core layer (130).

13. The method according to claim 11 or 12, further comprising connecting the two or more tiles (156A, 156B) together.

14. Connecting the two or more tiles (156A, 156B) together includes connecting the wiring (170A) of a first tile (156A) among the two or more tiles to a second tile (156B) among the two or more tiles. The method according to claim 13.

15. Testing the battery (160A) of the first tile (156A), and Further including replacing the battery (160A) of the first tile (156A) with a replacement battery in response to the test indicating that the battery (160A) of the first tile (156A) is malfunctioning. The battery (160A) of the first tile (156A) is replaced with the replacement battery before the first tile (156A) and the rear portion (154) of the substrate (150) are joined together. The method according to claim 14.

16. Testing the battery (160A) of the first tile (156A), and Further including repairing the battery (160A) of the first tile (156A) in response to the test indicating that the battery (160A) of the first tile (156A) is malfunctioning. The battery (160A) of the first tile (156A) is repaired before the first tile (156A) and the rear portion (154) of the substrate (150) are joined together. The method according to claim 14 or 15.

Images