Stacked solar cell array

Abstract

To provide means for simplifying design and manufacture of solar cell arrays attached onto a spacecraft.SOLUTION: Each of a first solar panel 12 and a second solar panel 12 comprises a substrate 18 having one or more solar cells bonded thereto, and a frame for supporting the substrate 18 and the solar cells 17. The frame has a cutout or an opening in a center of the frame under the solar cells 17 and, when deployed, the cutout or the opening enables cooling of the solar cells 17 through the substrate 18 by exposing a back side of the substrate 18 for transferring or radiating heat directly through the cutout or the opening of the frame. The frame 16A of the first solar panel 12 is configured to be nested inside the cutout or the opening of the frame 16B of the second solar panel 12 when the first solar panel 12 and the second solar panel 12 are stored in a stacked configuration.SELECTED DRAWING: Figure 10B

Description

[Technical Field]

[0001] FIELD OF THE DISCLOSURE The present disclosure relates generally to solar panels, and more particularly to stacked solar cell arrays. [Background technology]

[0002] Spacecraft often use solar arrays to generate power. Solar arrays typically consist of solar panels connected together, each equipped with a solar cell for generating electricity. There are usually wires running across the solar panels to transfer the power to the spacecraft.

[0003] Solar cells and their assemblies need to radiate heat from the sun in order to cool down. When solar cells are constructed into a solar array, the solar cells maintain a high thermal conductivity to the radiating surface.

[0004] To reduce manufacturing costs, it is also desirable to construct solar cells on thin substrates, which may be plastic sheets such as polyimide, thin fiber composites, or thin metal sheets, which have lateral strength yet are thin, lightweight, and likely flexible.

[0005] Furthermore, it is desirable to have a solar array based on stiff solar panels, which are strengthened to provide the stiffness and frequency response required for the program. The panels are often aluminum (Al) honeycomb with a carbon composite face sheet. Therefore, it is desirable to attach thin substrates with solar cells to stiff panels.

[0006] However, this attachment requires a large area of ​​adhesive to ensure thermal contact with the radiating surface of the stiff panel, which is a large mass of material, making it undesirable for space applications.

[0007] It is also difficult to attach two flat surfaces, the substrate and the rigid panel, without trapping air, which can lead to delamination and rupture when the assembly enters the vacuum environment of space.

[0008] Therefore, there is a need for a means to simplify the design and manufacture of solar arrays. Summary of the Invention

[0009] To overcome the limitations described above, as well as others that will become apparent upon reading and understanding this specification, the present disclosure provides at least first and second solar panels. Each of the first and second solar panels comprises a substrate having one or more solar cells bonded thereto, and a frame for supporting the substrate and the solar cells. The frame has cutouts or openings below the solar cells, such that when deployed, the cutouts or openings expose the backside of the substrate for direct heat transfer or radiation through the cutouts or openings in the frame, thereby enabling cooling of the solar cells through the substrate. The frame of the first solar panel is configured to nest inside the cutout or opening in the frame of the second solar panel when the first and second solar panels are housed in a stacked configuration.

[0010] Reference is now made to the drawings, wherein like reference numerals represent corresponding parts throughout. [Brief explanation of the drawings]

[0011] [Figure 1] 1 is a schematic diagram of a spacecraft having one or more solar arrays made up of one or more solar panels. [Figure 2A] 2A, 2B, and 2C are schematic top, top, and side views, respectively, showing the components and assembly of one of the solar panels. [Figure 2B]2A, 2B, and 2C are schematic top, top, and side views, respectively, showing the components and assembly of one of the solar panels. [Figure 2C] 2A, 2B, and 2C are schematic top, top, and cross-sectional side views, respectively, showing the components and assembly of one of the solar panels. [Figure 3A] 3A and 3B are schematic cross-sectional side and top views, respectively, of a substrate attached to a frame using one or more fasteners. [Figure 3B] 3A and 3B are schematic cross-sectional side and top views, respectively, of a substrate attached to a frame using one or more fasteners. [Figure 4A] 4A and 4B are schematic cross-sectional side and top views, respectively, of a substrate attached to a frame using one or more bars positioned along one or more sides of the frame. [Figure 4B] 4A and 4B are schematic cross-sectional side and top views, respectively, of a substrate attached to a frame using one or more bars positioned along one or more sides of the frame. [Figure 5A] 5A, 5B, 5C, and 5D are top schematic views that provide more detail about the electrical connections to the solar cell, and FIG. 5E is a cross-sectional side schematic view thereof. [Figure 5B] 5A, 5B, 5C, and 5D are top schematic views that provide more detail about the electrical connections to the solar cell, and FIG. 5E is a cross-sectional side schematic view thereof. [Figure 5C] 5A, 5B, 5C, and 5D are top schematic views that provide more detail about the electrical connections to the solar cell, and FIG. 5E is a cross-sectional side schematic view thereof. [Figure 5D] 5A, 5B, 5C, and 5D are top schematic views that provide more detail about the electrical connections to the solar cell, and FIG. 5E is a cross-sectional side schematic view thereof. [Figure 5E]5A, 5B, 5C, and 5D are top schematic views that provide more detail about the electrical connections to the solar cell, and FIG. 5E is a cross-sectional side schematic view thereof. [Figure 6A] FIG. 6A is a top schematic view and FIG. 6B is a cross-sectional side schematic view showing a reinforcing material that may be used to fill the center of the frame. [Figure 6B] FIG. 6A is a top schematic view and FIG. 6B is a cross-sectional side schematic view showing a reinforcing material that may be used to fill the center of the frame. [Figure 7A] 7A and 7B are cross-sectional side schematic diagrams showing one configuration of a solar panel. [Figure 7B] 7A and 7B are cross-sectional side schematic diagrams showing one configuration of a solar panel. [Figure 8A] 8A, 8B, and 8C are schematic top, cross-sectional, and side views, respectively, of another configuration of a solar panel. [Figure 8B] 8A, 8B, and 8C are schematic top, cross-sectional, and side views, respectively, of another configuration of a solar panel. [Figure 8C] 8A, 8B, and 8C are schematic top, cross-sectional, and side views, respectively, of another configuration of a solar panel. [Figure 9A] 9A, 9B, and 9C are schematic top, cross-sectional, and side views, respectively, of yet another configuration for a solar panel. [Figure 9B] 9A, 9B, and 9C are schematic top, cross-sectional, and side views, respectively, of yet another configuration for a solar panel. [Figure 9C] 9A, 9B, and 9C are schematic top, cross-sectional, and side views, respectively, of yet another configuration for a solar panel. [Figure 10A] 10A and 10B are cross-sectional side schematic views illustrating yet another configuration including solar panels mounted on a spacecraft. [Figure 10B]10A and 10B are cross-sectional side schematic views illustrating yet another configuration including solar panels mounted on a spacecraft. [Figure 11] A method for manufacturing an apparatus with a solar array for a spacecraft is presented. [Figure 12] The resulting device is shown with a spacecraft having a solar array. [Figure 13] FIG. 1 is a diagram of a method for deploying and operating a solar array in the form of a functional block diagram. DETAILED DESCRIPTION OF THE INVENTION

[0012] In the following description, reference is made to the accompanying drawings, which form a part hereof, and in which are shown, by way of illustration, specific embodiments in which the present disclosure may be practiced. It is to be understood that other embodiments may be utilized and structural changes may be made without departing from the scope of the present disclosure.

[0013] overview This disclosure provides a "flex on frame" concept for solar arrays. Solar arrays include at least one solar panel, which consists of one or more solar cells bonded onto a substrate. The substrate may be a flexible substrate, and the substrate and solar cells are then attached to a support frame with a cutout or opening in the center of the support frame below the solar cells. The substrate is thin to facilitate heat flow and therefore has low stiffness. As such, it is undesirable to fly it as it is prone to bending and flexing. The substrate is attached to a frame that provides the rigidity for the structure to be used as a solar panel.

[0014] The "flex-on-frame" concept for solar arrays has several advantages. For example, the "flex-on-frame" concept has both cost and cycle time advantages compared to solar arrays with solid solar panels.

[0015] Another advantage of the "flex-on-frame" concept is the cutouts or openings in the frame. The cutouts or openings allow the substrate to radiate into space, thus eliminating the typical thick rigid panels from heat flowing to the radiating surface. Solid solar panels must integrate features to facilitate heat removal from the solar array, which can add complexity and weight to the assembly.

[0016] The "flex-on-frame" concept does not require a thermal connection to the frame, although this is acceptable and simplifies the attachment of the circuitry to the panel (e.g., simple mechanical fasteners or clamps). This differs from solid panels that use a solid substrate or other material (e.g., a metal plate) that is intended to transfer heat from the solar cells laterally.

[0017] Furthermore, by having such cutouts or openings, the frame can, but does not necessarily, participate in the heat transfer from the solar cells, as in a solid solar panel. Primarily, the frame provides mechanical support for the substrate with the solar cells bonded thereon. This allows for a separation of thermal and mechanical roles, if desired, compared to a solid solar panel.

[0018] The "flex-on-frame" concept for solar arrays can result in a structure that is less stiff than a solid solar panel for a structure of comparable thickness. There is a correlation between the stiffness of the solar panel and the fundamental mode or frequency. If the solar panel is solid, as opposed to just a frame with cutouts or openings, the fundamental mode or frequency will be different. A solid solar panel will have a higher stiffness with a higher fundamental mode or frequency, while the "flex-on-frame" concept will have a lower fundamental mode or frequency than a solid solar panel of the same thickness.

[0019] The vibration frequency of the solar panels is an important measurement: a stiffer structure with a higher fundamental mode or frequency results in a more stable spacecraft.

[0020] The present disclosure provides a "flex-on-frame" in a stacked configuration with at least two frames, each having a thickness. The first frame is configured to nest with the second frame. A cutout or opening in the center of the frame allows multiple frames to be stacked inside each other. This allows the frame to be thicker than a solid solar panel, thus increasing stiffness in the stacked configuration during launch and transportation, while reducing weight and allowing for efficient heat dissipation during deployment and operation.

[0021] These and other novel aspects of the "flex-on-frame" concept are described in more detail below.

[0022] Technical Description 1 is a schematic diagram of a spacecraft 10 having one or more solar arrays 11 composed of one or more solar panels 12. In this embodiment, the spacecraft 10 comprises a satellite, and there are two (2) solar arrays 11 and four (4) solar panels 12. Each of the solar arrays 11 is composed of two of the solar panels 12, and the solar arrays 11 and solar panels 12 extend on opposite sides of the spacecraft 10. The solar arrays 11 are attached to the spacecraft 10 by a three-chord truss 13 or other mechanism, and each of the solar panels 12 is attached to an adjacent solar panel 12 by a hinge 14 or other mechanism. In this case, the three-chord truss 13 and hinge 14 allow the solar arrays 11 and solar panels 12 to be folded for storage during launch and then extended and deployed during operation.

[0023] 2A, 2B, and 2C are schematic top, top, and cross-sectional side views, respectively, showing the components and assembly of one of the solar panels 12, including a solar photovoltaic module (SPM) 15 and a frame 16.

[0024] 2A shows an SPM 15 comprised of an array of solar cells 17 bonded to a substrate 18. In one embodiment, the substrate 18 is a flexible substrate, i.e., a flexible circuit comprised of a laminate of one or more Kapton™ insulating layers and one or more metal layers that provide electrical connections.

[0025] 2B shows a frame 16 for supporting solar cells 17 and substrate 18. Frame 16 is, for example, a rectangular structure formed from joined elements that define a rim around a notch or opening in the center of frame 16 below solar cells 17.

[0026] 2C shows SPM 15 mounted and attached to frame 16. Substrate 18 is attached to frame 16 at the edge of frame 16 along one or more edges of substrate 18. Once mounted and attached, SPM 15 and frame 16 comprise solar panel 12.

[0027] Conventional rigid solar panels are solid, often rectangular, but may be any shape. In the present disclosure, the solar panel 12 is largely hollow due to the shape of the frame 16.

[0028] In this embodiment, the substrate 18 is a thermal structure for radiating heat from the solar cells 17 into space, and the frame 16 is a mechanical structure for supporting the solar cells 17 and the substrate 18. Specifically, a cutout or opening in the center of the frame 16 allows cooling of the solar cells 17 through the substrate 18 by exposing the backside of the substrate 18 for direct heat radiation through the cutout or opening of the frame 16. The objective is to minimize the obstruction of the radiative heat flow from the solar cells 17 and the substrate 18 into space by the mechanical structure of the frame 16.

[0029] In another embodiment, reinforcing materials and / or support members (not shown) inside the frame 16 can provide additional rigidity. In this case, the reinforcing materials can be mesh or honeycomb materials, etc., and the support members can be various bars, channels, etc. This is described in more detail below in conjunction with Figures 6A and 6B.

[0030] 3A and 3B are schematic cross-sectional side and top views, respectively, of SPM 15, frame 16, solar cell 17, and substrate 18. Substrate 18 is attached to frame 16 using one or more fasteners 19 and reinforcement areas 20.

[0031] A wide variety of fasteners 19 may be used, including pins, posts, rivets, or other structures, and may be constructed from metals, polymers, or other types of materials. Various types of adhesives may be used in conjunction with or in place of fasteners 19, in continuous or spot applications.

[0032] The fasteners 19 may be attached to a single surface of the frame 16 or may extend through the frame 16. Desirably, the fasteners 19 are reversible so that they can be disassembled for repair, and removing the fasteners 19 may involve destroying them (such as cutting or drilling into the fasteners 19), which should not be a major concern due to their low cost.

[0033] As shown in FIG. 3B, fasteners 19 may be placed in reinforced areas 20 of substrate 18 near the edges of substrate 18 or in other areas of substrate 18 to prevent tearing of substrate 18. Reinforced areas 20 may be composed of additional Kapton™ insulating layers, carbon fiber, Kevlar™, and / or metal layers, or other combinations of layers or other materials. It would be fairly straightforward to pattern a copper (Cu) trace layer as reinforcement. Furthermore, the material of frame 16 may also be reinforced near fasteners 19.

[0034] In this embodiment, four (4) or five (5) of the fasteners 19 are positioned on each of the four (4) sides of the frame 16, around the edge of the frame 16 and near the edge of the substrate 18. In other embodiments, it may only be necessary for the SPM 15 to be attached to two (2) opposite sides of the frame 16. On the other hand, attaching the SPM 15 to all four (4) sides of the frame 16 provides assurance of the security of the attachment of the SPM 15 to the frame 16.

[0035] 4A and 4B are cross-sectional side and top schematic views, respectively, of the SPM 15, frame 16, solar cell 17, substrate 18, fasteners 19, and reinforcement area 20. The substrate 18 is attached to the frame 16 using one or more bars 21 positioned along one or more sides of the frame 16, for example, within the reinforcement area 20 near the edges of the substrate 18 and between at least some of the fasteners 19 and the substrate 18. These bars 21 help distribute the force applied by the fasteners 19 and thus minimize the risk of fracturing the substrate 18. These bars 21 may be rectangular or another shape and preferably match the geometric dimensions of the frame 16. The bars 21 may also be composed of a series of one or more shorter segments. FIG. 3B shows reinforcement at a single attachment location, while FIG. 4B shows reinforcement spanning multiple attachment locations.

[0036] Figures 5A, 5B, 5C, and 5D are top schematic views and Figure 5E is a cross-sectional side schematic view that provide more detail about the electrical connections to solar cell 17. Preferably, the wiring for the electrical connections to solar cell 17 is on the back side of substrate 18 so that as much area as possible on the front side of solar cell 17 is used to collect solar energy.

[0037] 5A is a schematic top view of SPM 15, solar cells 17, and substrate 18 prior to being mounted and attached to frame 16. Substrate 18 has one or more tabs 22 extending from one or more sides of substrate 18. Each of tabs 22 may be constructed from the same material as substrate 18 and may be a continuous portion of substrate 18. Each of tabs 22 may include one or more conductors 23 patterned from one or more metal layers disposed on a surface of tab 22 and / or embedded within the surface of tab 22 for electrical connection with at least one of solar cells 17.

[0038] 5B is a top schematic view of SPM 15, frame 16, solar cell 17, substrate 18, fasteners 19, reinforcement area 20, and bar 21. Substrate 18 is attached to frame 16 at reinforcement area 20 and bar 21 with fasteners 19, with tabs 22 and conductors 23 extending beyond frame 16.

[0039] 5C is a top schematic view of SPM 15, frame 16, solar cell 17, substrate 18, fasteners 19, reinforcement area 20, and bar 21. Tabs 22 and conductors 23 are folded around and under frame 16.

[0040] 5D is a schematic underside view of frame 16, substrate 18, fasteners 19, and bar 21. Tabs 22 and conductors 23 are folded around and under frame 16, with tabs 22 attached to the back side of substrate 18 using, for example, adhesive, fasteners, bars, etc. Tabs 22 may also be attached to one or more sides of frame 16, including the back, front, and edge sides of frame 16.

[0041] In this embodiment, tabs 22 extend around the outside of frame 16, then pass underneath and are secured by bars 21. Another option could be to thread tabs 22 through slots or channels in frame 16. In yet another option, substrate 18 could be constructed to terminate at an opening in frame 16, which could allow tabs 22 to be folded underneath the inside of frame 16 instead of outside the edge of frame 16. In yet another option, tabs 22 could also be attached to one or more sides of frame 16 and simply extend in the opposite direction, away from the sun.

[0042] Conductors 23 may be electrically connected to conductors or traces (not shown) located on the backside of and / or embedded within substrate 18 through the use of exposed conductors or traces, vias, etc.

[0043] 5E is a cross-sectional side schematic view of SPM 15, frame 16, solar cell 17, substrate 18, fastener 19, bar 21, and tab 22. Tab 22 wraps around frame 16 on the backside of substrate 18, where substrate 18 is visible on the top side of frame 16 and bends around the outside of frame 16. Preferably, tab 22 is positioned to minimize interception of radiation from the backside of substrate 18. For example, tab 22 can be positioned behind the structure of frame 16 to minimize interception.

[0044] The ends of the tabs 22 are available for connection to other conductors, such as a wiring harness (not shown), to transfer power to adjacent frames 16, panels 12, arrays 11, other structures, and the spacecraft 10 itself. For example, the wiring harness may be located on the back of the substrate 18, the back of the frame 16, or along the side of the frame 16. The wiring harness may extend partially or completely inside the frame 16 when the frame 16 is constructed from a hollow member. The conductors in the wiring harness may form part of the frame 16 when the frame 16 is constructed as a composite or via additive manufacturing.

[0045] Figure 6A is a top schematic view and Figure 6B is a cross-sectional side schematic view showing a stiffening material 24 that may be used to fill the center of frame 16. Figure 6A shows only frame 16 and stiffening material 24, while Figure 6B shows SPM 15 mounted and attached to frame 16, with substrate 18 attached to both frame 16 and stiffening material 24 and solar cells 17 bonded to substrate 18 on top of stiffening material 24.

[0046] In one embodiment, these reinforcing materials 24 may be designed to block normal incidence radiation from reaching the solar cells 17 and block non-normal incidence radiation from reaching the solar cells 17. For example, cosmic radiation (e.g., electrons, protons, gamma rays) impinges on the solar array 11 and solar panels 12 at all angles. Using a honeycomb structure as the reinforcing material 24 within the frame 16 can block non-normal incidence cosmic radiation, thus preventing damage to the solar cells 17, while allowing radiative cooling 25 to occur at normal incidence.

[0047] It is important that the solar panels 12 pass acoustic and vibration testing. Attaching the substrate 18 to a stiffening material 24 underneath the substrate 18 can limit vibration and improve survivability. An acoustic and vibration environment occurs during the launch phase while the solar panels 12 are folded and stowed against the side of the spacecraft 10. In this state, the solar cells 17 from one panel 12 may face the stiffening material 24 from the second panel 12. Their mechanical engagement should be designed to withstand the acoustic and vibration requirements. It may be advantageous to employ a shock-absorbing or soft material, such as foam, between the solar cells 17 or substrate 18 and the stiffening material 24 of the next panel 12.

[0048] Figures 7A and 7B are cross-sectional side schematic views of a solar panel 12. Figure 7A shows a pair of solar panels 12 stacked together and connected by hinges 14. Figure 7B shows a pair of solar panels 12 extended in place while connected to hinges 14. Also shown are SPM 15, solar cells 17, substrate 18, frame 16, fasteners 19, bars 21, and tabs 22.

[0049] The thickness of the stack formed by a pair of solar panels 12 includes the thickness of each solar panel 12 and the gap between them. One or more bumpers 24 may be placed between the stacked solar panels 12. The bumpers 24 are soft, shock-absorbing materials, such as foam, that maintain pressure and contact between the solar panels 12 to minimize bending and vibration of the solar panels 12.

[0050] FIGS. 8A, 8B, and 8C are schematic top, cross-sectional, and side views, respectively, illustrating another configuration for solar panels 12. While the frames 16 in FIGS. 7A and 7B are the same size, in this embodiment, various sizes for the frames 16 exist to provide different housing configurations. Specifically, as shown in FIG. 8A, one or more smaller frames 16A can be stacked inside one or more larger frames 16B. Each of the frames 16A, 16B has a slightly different width. FIG. 8B shows a cross-sectional side view of the solar panels 12 housed together in a stacked configuration, and FIG. 8C shows a side view of the solar panels 12 unfolded. In this embodiment, the SPM 15, solar cells 17, and substrate 18 are positioned on the smaller frame 16A on the same side as the SPM 15, solar cells 17, and substrate 18 on the larger frame 16B. The hinges 14 connecting the solar panels 12 are also shown, but the mechanism of the hinges 14 to achieve stacking and unfolding of the solar panels 12 will not be described in detail here.

[0051] The enclosed solar array 11 is given a certain amount of space to occupy in the design of the spacecraft 10. In the conventional fold of FIG. 7A, less than half of the height of the space is given to each solar panel 12. The new design shown in FIG. 8B shows how both panels 12 occupy more than half of the height of the space. The new design allows the panels 12 to have a greater height within the allowed space. This increased height increases its rigidity, resulting in a more stable spacecraft 10.

[0052] Figures 9A, 9B, and 9C are schematic top, cross-sectional, and side views, respectively, illustrating yet another configuration for solar panels 12. In this embodiment, SPMs 15, solar cells 17, and substrates 18 are arranged on an opposite, smaller frame 16A compared to SPMs 15, solar cells 17, and substrates 18 on a larger frame 16B. Figure 9A shows one or more smaller frames 16A stacked inside one or more larger frames 16B. Each of the frames 16A, 16B has a slightly different width. Figure 9B is a cross-sectional side view of solar panels 12 housed together in a stacked configuration, and Figure 9C is a side view of the solar panels 12 unfolded.

[0053] As mentioned above, in this configuration, the substrate 18 is on the opposite side of the smaller frame 16A, which is the side facing away from the sun. As shown in FIG. 9C, the solar cells 17 are on the inside of the frame 16A that faces the sun when deployed. As shown in FIG. 9B, when stowed, the SPM 15, solar cells 17, and substrate 18 of each solar panel 12 are positioned closely together. Gap and vibration can be controlled by one or more snubbers 26 or other mechanisms. This assembly is stiffer when stowed and more robust to the vibration and acoustic loads present during launch.

[0054] The smallest panel 12 may incorporate reinforcing material 24 and / or support members (not shown) inside the frame 16A to increase rigidity. The reinforcing material 24 may be a mesh or honeycomb material, etc., and the support members may be various bars, channels, etc.

[0055] Figures 10A and 10B are cross-sectional side schematic views showing yet another configuration including solar panels 12 mounted on a spacecraft 10. Figure 10A is a cross-sectional side view with the solar panels 12 housed together in a stacked configuration, and Figure 10B is a cross-sectional side view with the solar panels 12 deployed.

[0056] In this embodiment, as shown in FIG. 10B, a thin panel 27 is attached to the body of the spacecraft 10, and the solar panels 12 are attached to the thin panel 27. The other solar panels 12 that spread out when deployed are stacked against the solar panels 12 attached to the thin panel 27 when stowed together. Thus, all of the solar panels 12 are stacked on the thin panel 27 and the body of the spacecraft 10 when stowed together. One or more bumpers 26 may be installed to protect the spacecraft 10 and solar panels 12 during launch. This stacking configuration provides a thinner structure, which increases fundamental modes and thereby provides a more stable spacecraft 10.

[0057] Functional Block Diagram Embodiments of the present disclosure may be described in the context of a method 28 of manufacturing an apparatus with a solar array 11 for a spacecraft 10. Method 28 includes steps 29-35, as shown in FIG. 11. The resulting spacecraft 10 with solar array 11 is shown in FIG. 12.

[0058] 11 , during the pre-production phase, an exemplary method 28 may include specification and design 29 of the spacecraft 10 and / or solar array 11 and procurement 30 of their materials. During production, fabrication and system integration 32 of components and subassemblies 31 of the spacecraft 10 and / or solar array 11 occur, including fabricating the spacecraft 10 and / or solar array 11, including bonding one or more solar cells 17 to a substrate 18, and then attaching the substrate 18 and solar cells 17 to a frame 16 for support. The spacecraft 10 and / or solar array 11 may then undergo certification and delivery 33 for placement in service 34. The spacecraft 10 and / or solar array 11 may also be scheduled for maintenance and servicing 35 (including modifications, reconfigurations, refurbishment, etc.) prior to launch.

[0059] Each step of method 28 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 description, a system integrator may include, but is not limited to, any number of manufacturers and subcontractors of primary systems of solar cells 17, solar panels 12, solar arrays 11, or spacecraft 10; a third party may include, but is not limited to, any number of vendors, subcontractors, and suppliers; and an operator may be a satellite communications company, a military organization, a service organization, etc.

[0060] 12, a spacecraft 10 produced by exemplary method 28 may include multiple systems 36, a body 37, one or more solar arrays 11, and one or more antennas 38. Examples of multiple systems 36 included with spacecraft 10 include, but are not limited to, one or more of a propulsion system 39, an electrical system 40, a communication system 41, and a power system 42. Any number of other systems 36 may also be included.

[0061] FIG. 13 is a diagram, in the form of a functional block diagram, of how the solar array 11 is housed, deployed, and operated, according to one embodiment.

[0062] When stowed and deployed, the solar array 11 is comprised of at least first and second solar panels 12. Each of the first and second solar panels 12 includes one or more SPMs 15, each of which is comprised of a substrate 18, which may be a flexible substrate 18, to which one or more solar cells 17 are bonded. Each of the first and second solar panels 12 further includes a frame 16 for supporting the substrate 18 and the solar cells 17. The frame 16 has cutouts or openings below the solar cells 17, such that when deployed, the cutouts or openings expose the backside of the substrate 18 for direct heat transfer or radiation through the cutouts or openings in the frame 16, thereby enabling cooling of the solar cells 17 through the substrate 18. The frame 16 of the first solar panel 12 is configured to nest inside the cutout or opening in the frame 16 of the second solar panel 12 when the first and second solar panels 12 are stowed in a stacked configuration.

[0063] In operation, each of the solar cells 17 absorbs light 43 from the light source 44 and in response generates electrical output 45, which results in excess heat being generated by the solar cells 17.

[0064] The frame 16 of the first solar panel 12 has a different thickness than the frame 16 of the second solar panel 12 to increase the rigidity of the first solar panel 12 and the second solar panel 12 in the stacked configuration, while reducing weight and allowing for efficient heat dissipation when deployed for operation.

[0065] The first and second solar panels 12 may be connected by a hinge that stacks the first and second solar panels 12 together when stowed and extends the first and second solar panels 12 into position when deployed.

[0066] When housed in a stacked configuration, one or more snubbers 26 may be positioned between the spacecraft 10 and the first and second solar panels 12 .

[0067] The frames 16 for the first and second solar panels 12 may be different sizes so that, when housed in a stacked configuration, a smaller one of the frames 16 can be housed inside a larger one of the frames 16.

[0068] The substrates 18 and solar cells 17 for the first and second solar panels 12 may be positioned on the same side of the frame 16 for the first and second solar panels 12, or the substrates 18 and solar cells 17 for the first and second solar panels 12 may be positioned on opposite sides of the frame 16 for the first and second solar panels 12. The substrates 18 and solar cells 17 for the first and second solar panels 12 positioned on opposite sides of the frame 16 for the first and second solar panels 12 may face the same direction when deployed. The substrates 18 and solar cells 17 for the first and second solar panels 12 positioned on opposite sides of the frame 16 for the first and second solar panels 12 may be positioned adjacent to each other when stowed.

[0069] The solar array 11 may include a third solar panel 12. The third solar panel 12 comprises a substrate 18 having one or more solar cells 17 bonded thereto, and a frame 16 for supporting the substrate 18 and the solar cells 17. The third solar panel 12 is mounted to a panel 25 on the body of the spacecraft 10. The first and second solar panels 12 are stacked against the third solar panel 12 when housed together.

[0070] Additionally, the present disclosure includes embodiments according to the following clauses: Article 1. 1. An apparatus comprising at least a first solar panel and a second solar panel, each of the first solar panel and the second solar panel comprises a substrate having one or more solar cells bonded thereto, and a frame for supporting the substrate and the solar cells; the frame has a cutout or opening in the center of the frame that, when unfolded, allows cooling of the solar cells through the substrate by exposing the backside of the substrate and the solar cells for direct heat transfer or radiation through the cutout or opening in the frame, and the frame of the first solar panel is configured to nest inside the cutout or opening in the frame of the second solar panel when the first solar panel and the second solar panel are accommodated in a stacked configuration. Article 2. 10. The device of claim 1, wherein the substrate is a flexible substrate. Article 3. 3. The apparatus of clause 1 or 2, wherein the frame of the first solar panel has a different thickness than the frame of the second solar panel, increasing stiffness of the first solar panel and the second solar panel in the stacked configuration, reducing weight, and enabling efficient heat dissipation when deployed for operation. Article 4. 4. The apparatus of any one of clauses 1 to 3, wherein the first solar panel and the second solar panel are connected by a hinge that stacks the first solar panel and the second solar panel together when stowed and extends the first solar panel and the second solar panel into position when deployed. Article 5. 5. The apparatus of any one of clauses 1 to 4, further comprising one or more buffers positioned between the spacecraft, the first solar panel, and the second solar panel when housed in a stacked configuration. Article 6. 6. The apparatus of any one of clauses 1 to 5, wherein the frame for the first solar panel and the frame for the second solar panel are different sizes such that, when housed in a stacked configuration, a smaller one of the frames can be stacked inside a larger one of the frames. Article 7. 7. The apparatus of any one of clauses 1 to 6, wherein the substrate and the solar cells for the first solar panel and the substrate and the solar cells for the second solar panel are arranged on the same side of the frame for the first solar panel and the frame for the second solar panel. Article 8. 7. The apparatus of any one of clauses 1 to 6, wherein the substrate and the solar cells for the first solar panel and the substrate and the solar cells for the second solar panel are arranged on opposite sides of the frame for the first solar panel and the frame for the second solar panel. Article 9. 9. The apparatus of claim 8, wherein the substrate and solar cells for the first solar panel and the substrate and solar cells for the second solar panel, located on opposite sides of the frame for the first solar panel and the frame for the second solar panel, face in the same direction when deployed. Article 10. 10. The apparatus of clause 8 or 9, wherein the substrate and solar cells for the first solar panel and the substrate and solar cells for the second solar panel, located on opposite sides of the frame for the first solar panel and the frame for the second solar panel, are positioned adjacent to each other when stored. Article 11. further comprising a third solar panel; 11. The apparatus of any one of clauses 1 to 10, wherein the third solar panel comprises a substrate having one or more solar cells bonded thereto and a frame for supporting the substrate and the solar cells, the third solar panel being mounted to a panel on the body of the spacecraft, and the first solar panel and the second solar panel being stacked against the third solar panel when housed together. Article 12. 1. A method comprising: housing at least a first solar panel and a second solar panel, each of the first solar panel and the second solar panel comprising a substrate having one or more solar cells bonded thereto, and a frame for supporting the substrate and the solar cells, the frame having a cutout or opening in a center of the frame, the cutout or opening, when unfolded, exposing backsides of the substrate and the solar cells for direct heat transfer or radiation through the cutout or opening in the frame, thereby enabling cooling of the solar cells through the substrate, and the frame of the first solar panel configured to nest inside the cutout or opening of the frame of the second solar panel when the first solar panel and the second solar panel are housed in a stacked configuration. Article 13. 13. The method of clause 12, wherein the substrate is a flexible substrate. Article 14. 14. The method of claim 12 or 13, wherein the frame of the first solar panel has a different thickness than the frame of the second solar panel to increase stiffness of the first solar panel and the second solar panel in the stacked configuration, reduce weight, and enable efficient heat dissipation when deployed for operation. Article 15. 15. The method of any one of clauses 12 to 14, wherein the first solar panel and the second solar panel are connected by a hinge that stacks the first solar panel and the second solar panel together when stowed and extends the first solar panel and the second solar panel into position when deployed. Article 16. 16. The method of any one of clauses 12 to 15, further comprising disposing one or more snubbers between the spacecraft and the first solar panel and the second solar panel when housed in a stacked configuration. Article 17. 17. The method of any one of clauses 12 to 16, wherein the frame for the first solar panel and the frame for the second solar panel are different sizes such that, when housed in a stacked configuration, a smaller one of the frames can be stacked inside a larger one of the frames. Article 18. 18. The method of any one of clauses 12 to 17, wherein the substrate and the solar cells for the first solar panel and the substrate and the solar cells for the second solar panel are positioned on the same side of the frame for the first solar panel and the frame for the second solar panel. Article 19. 19. The method of any one of clauses 12 to 18, wherein the substrate and the solar cells for the first solar panel and the substrate and the solar cells for the second solar panel are positioned on opposite sides of the frame for the first solar panel and the frame for the second solar panel. Article 20. 20. The method of claim 19, wherein the substrate and the solar cells for the first solar panel and the substrate and the solar cells for the second solar panel, located on opposite sides of the frame for the first solar panel and the frame for the second solar panel, face in the same direction when deployed. Article 21. 21. The method of claim 19 or 20, wherein the substrate and the solar cells for the first solar panel and the substrate and the solar cells for the second solar panel, located on opposite sides of the frame for the first solar panel and the frame for the second solar panel, are positioned adjacent to each other when stored. Article 22. 22. The method of any one of clauses 12 to 21, further comprising a third solar panel, the third solar panel comprising a substrate having one or more solar cells bonded thereto and a frame for supporting the substrate and the solar cells, the third solar panel being mounted to a panel on the body of the spacecraft, and the first solar panel and the second solar panel being stacked against the third solar panel when housed together. Article 23. 1. A method comprising at least unfolding a first solar panel and a second solar panel, each of the first solar panel and the second solar panel comprising a substrate having one or more solar cells bonded thereto, and a frame for supporting the substrate and the solar cells, the frame having a cutout or opening in a center of the frame, the cutout or opening, when unfolded, exposing backsides of the substrate and the solar cells for direct heat transfer or radiation through the cutout or opening in the frame, thereby enabling cooling of the solar cells through the substrate, and the frame of the first solar panel configured to nest inside the cutout or opening in the frame of the second solar panel when the first solar panel and the second solar panel are accommodated in a stacked configuration.

[0071] conclusion The above description of the explicit examples has been presented for purposes of illustration and description and is not intended to be exhaustive or to be limited to the disclosed examples. Many alternatives, modifications, and variations may be used in place of the specific examples described above.

Claims

1. An apparatus comprising at least a first solar panel (12) and a second solar panel (12), Each of the first solar panel (12) and the second solar panel (12) comprises a substrate (18) to which one or more solar cells (17) are bonded, and a frame (16) for supporting the substrate (18) and the solar cells (17); the frame (16) has a cutout or opening in the center of the frame (16), which when deployed exposes the backside of the substrate (18) for direct heat radiation through the cutout or opening of the frame (16), thereby allowing cooling of the solar cells (17) through the substrate (18); the frame (16) of the first solar panel (12) is configured to nest inside the cutout or opening in the frame (16) of the second solar panel (12) when the first solar panel (12) and the second solar panel (12) are accommodated in a stacked configuration; The first solar panel (12) and the second solar panel (12) are connected by a hinge (14) for stacking the first solar panel (12) and the second solar panel (12) together when stowed and for extending the first solar panel (12) and the second solar panel (12) into position when deployed.

2. The device of claim 1 , wherein the substrate (18) is a flexible substrate (18).

3. 3. The apparatus of claim 1 or 2, wherein the frame (16) of the first solar panel (12) has a different thickness than the frame (16) of the second solar panel (12).

4. 4. The apparatus of claim 1, further comprising one or more snubbers (24, 26) disposed between a spacecraft (10), the first solar panel (12), and the second solar panel (12) when housed in a stacked configuration.

5. 5. The apparatus of claim 1, wherein the frames for the first solar panel (12) and the second solar panel (12) are different sizes such that, when housed in a stacked configuration, a smaller one of the frames (16A) can be stacked inside a larger one of the frames (16B).

6. 6. The device according to claim 1, wherein the substrate (18) and the solar cells (17) for the first solar panel (12) and the substrate (18) and the solar cells (17) for the second solar panel (12) are arranged on the same side of the frame (16) of the first solar panel (12) and the second solar panel (12) when unfolded, or are arranged on opposite sides of the frame (16) of the first solar panel (12) and the second solar panel (12).

7. 7. The device of claim 6, wherein when the substrate (18) and the solar cells (17) for the first solar panel (12) and the substrate (18) and the solar cells (17) for the second solar panel (12) are positioned on opposite sides of the frame (16) of the first solar panel (12) and the second solar panel (12) when unfolded, the substrate (18) and the solar cells (17) for the first solar panel (12) and the substrate (18) and the solar cells (17) for the second solar panel (12) face in the same direction when unfolded.

8. An apparatus as described in claim 6 or 7, wherein when the substrate (18) and the solar cell (17) for the first solar panel (12) and the substrate (18) and the solar cell (17) for the second solar panel (12) are arranged on opposite sides of the frame (16) of the first solar panel (12) and the second solar panel (12) when unfolded, the substrate (18) and the solar cell (17) for the first solar panel (12) and the substrate (18) and the solar cell (17) for the second solar panel (12) are arranged adjacent to each other when stored.

9. a third solar panel (12); The third solar panel (12) is composed of a substrate (18) to which one or more solar cells (17) are bonded, and a frame (16) for supporting the substrate (18) and the solar cells (17); the third solar panel (12) is mounted on the body (37) of the spacecraft (10); 9. The apparatus of claim 1, wherein the first solar panel (12) and the second solar panel (12), when housed together, are stacked against the third solar panel (12).

10. 1. A method comprising housing at least a first solar panel (12) and a second solar panel (12), Each of the first solar panel (12) and the second solar panel (12) comprises a substrate (18) to which one or more solar cells (17) are bonded, and a frame (16) for supporting the substrate (18) and the solar cells (17); the frame (16) has a cutout or opening in the center of the frame (16), which when deployed exposes the backside of the substrate (18) for direct heat radiation through the cutout or opening of the frame (16), thereby allowing cooling of the solar cells (17) through the substrate (18); the frame (16) of the first solar panel (12) is configured to nest inside the cutout or opening in the frame (16) of the second solar panel (12) when the first solar panel (12) and the second solar panel (12) are accommodated in a stacked configuration; the first solar panel (12) and the second solar panel (12) are connected by a hinge (14) for stacking the first solar panel (12) and the second solar panel (12) together when stowed and for extending the first solar panel (12) and the second solar panel (12) into position when deployed.

11. 11. The method of claim 10, wherein the frame (16) of the first solar panel (12) has a different thickness than the frame (16) of the second solar panel (12).

12. 12. The method of claim 10 or 11, further comprising disposing one or more snubbers (24, 26) between the spacecraft (10) and the first and second solar panels (12) when housed in a stacked configuration.

13. 13. The method of any one of claims 10 to 12, wherein the frames for the first solar panel (12) and the second solar panel (12) are different sizes such that, when housed in a stacked configuration, a smaller one of the frames (16A) can be stacked inside a larger one of the frames (16B).

14. 14. The method according to any one of claims 10 to 13, wherein the substrate (18) and the solar cells (17) for the first solar panel (12) and the substrate (18) and the solar cells (17) for the second solar panel (12) are arranged on the same side of the frame (16) of the first solar panel (12) and the second solar panel (12) when unfolded, or are arranged on opposite sides of the frame (16) of the first solar panel (12) and the second solar panel (12).

15. 15. The method of claim 14, wherein when the substrate (18) and the solar cells (17) for the first solar panel (12) and the substrate (18) and the solar cells (17) for the second solar panel (12) are positioned on opposite sides of the frame (16) of the first solar panel (12) and the second solar panel (12) when unfolded, the substrate (18) and the solar cells (17) for the first solar panel (12) and the substrate (18) and the solar cells (17) for the second solar panel (12) face in the same direction when unfolded.

16. A method as described in claim 14 or 15, wherein when the substrate (18) and the solar cell (17) for the first solar panel (12) and the substrate (18) and the solar cell (17) for the second solar panel (12) are arranged on opposite sides of the frame (16) of the first solar panel (12) and the second solar panel (12) when unfolded, the substrate (18) and the solar cell (17) for the first solar panel (12) and the substrate (18) and the solar cell (17) for the second solar panel (12) are arranged adjacent to each other when stored.

17. a third solar panel (12); The third solar panel (12) is composed of a substrate (18) to which one or more solar cells (17) are bonded, and a frame (16) for supporting the substrate (18) and the solar cells (17); the third solar panel (12) is mounted on the body (37) of the spacecraft (10); 17. The method of any one of claims 10 to 16, wherein the first solar panel (12) and the second solar panel (12), when housed together, are stacked against the third solar panel (12).

18. 1. A method comprising at least deploying a first solar panel (12) and a second solar panel (12), Each of the first solar panel (12) and the second solar panel (12) comprises a substrate (18) to which one or more solar cells (17) are bonded, and a frame (16) for supporting the substrate (18) and the solar cells (17); the frame (16) has a cutout or opening in the center of the frame (16), which when deployed exposes the backside of the substrate (18) for direct heat radiation through the cutout or opening of the frame (16), thereby allowing cooling of the solar cells (17) through the substrate (18); the frame (16) of the first solar panel (12) is configured to nest inside the cutout or opening in the frame (16) of the second solar panel (12) when the first solar panel (12) and the second solar panel (12) are accommodated in a stacked configuration; the first solar panel (12) and the second solar panel (12) are connected by a hinge (14) for stacking the first solar panel (12) and the second solar panel (12) together when stowed and for extending the first solar panel (12) and the second solar panel (12) into position when deployed.

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