Space-grade solar cells with customized voltage

Abstract

To provide a commercial spaceflight-capable solar cell array that can be rapidly tailored to achieve a variety of output voltages.SOLUTION: A solar cell array comprises one or more solar cells 102 attached to a substrate 104, such as a pre-fabricated flex circuit. The substrate includes one or more insulating layers, and one or more conductive layers patterned as one or more conductors for making electrical connections with the solar cells. The substrate includes one or more decision points 124 for removing or adding electrical conduction to the conductors, for customizing circuits of the solar cells to a desired dimension of the solar cells and a desired output voltage.SELECTED DRAWING: Figure 4A

Description

Technical Field

[0001] The present disclosure relates generally to solar panels, and more particularly to space solar cell arrays having a customized voltage.

Background Art

[0002] The assembly of a typical space - viable solar panel involves constructing a solar cell array composed of long strings of solar cells connected in series. These strings have a variable length, i.e., the number of solar cells, and can be very long.

[0003] Conventional solar cell arrays are constructed with a certain number of solar cells to generate the required output voltage. That number also varies depending on the operating temperature and radiation dose. For example, a string of 50 solar cells connected in series can generate an output voltage of 100V.

[0004] This output voltage needs to meet or exceed the requirements of the power system for supplying power. The temperature and radiation dose are mission - dependent. On the other hand, the number of solar cells in the circuit is variably set to meet the output voltage requirements of the power system.

[0005] Since missions change, adjustable solar panels are needed.

Summary of the Invention

[0006] To overcome the limitations described above, and other limitations that would be obvious from reading and understanding this specification, this disclosure describes a solar cell array, a method for manufacturing a solar cell array, and a method for operating a solar cell array. A solar cell array comprises one or more solar cells mounted on a substrate, such as a pre-fabricated flex circuit. The substrate includes one or more insulating layers and one or more conductive layers patterned as one or more conductors for forming electrical connections with the solar cells. To customize the circuit of the solar cells to the desired dimensions and voltage of the solar cells, the substrate includes one or more determination points for removing or adding electrical conduction to the conductors.

[0007] Here, we refer to the drawings. Throughout each drawing, similar reference numbers represent the corresponding parts. [Brief explanation of the drawing]

[0008] [Figure 1A] Figures 1A, 1B, and 1C are cross-sectional side views illustrating an example of a solar cell mounted on a substrate. [Figure 1B] Figures 1A, 1B, and 1C are cross-sectional side views illustrating an example of a solar cell mounted on a substrate. [Figure 1C] Figures 1A, 1B, and 1C are cross-sectional side views illustrating an example of a solar cell mounted on a substrate. [Figure 2] An example of an embodiment showing an array of solar cells mounted on a substrate is provided. [Figure 3A] Figures 3A, 3B, and 3C illustrate another embodiment of the substrate, which is a modified example of Figure 2. [Figure 3B] Figures 3A, 3B, and 3C illustrate another embodiment of the substrate, which is a modified example of Figure 2. [Figure 3C] Figures 3A, 3B, and 3C illustrate another embodiment of the substrate, which is a modified example of Figure 2. [Figure 4A] Figures 4A, 4B, 4C, 4D, 4E, 4F, and 4G illustrate another embodiment which is a modification of Figure 3. [Figure 4B] Figures 4A, 4B, 4C, 4D, 4E, 4F, and 4G illustrate another embodiment which is a modification of Figure 3. [Figure 4C] Figures 4A, 4B, 4C, 4D, 4E, 4F, and 4G illustrate another embodiment which is a modification of Figure 3. [Figure 4D] Figures 4A, 4B, 4C, 4D, 4E, 4F, and 4G illustrate another embodiment which is a modification of Figure 3. [Figure 4E] Figures 4A, 4B, 4C, 4D, 4E, 4F, and 4G illustrate another embodiment which is a modification of Figure 3. [Figure 4F] Figures 4A, 4B, 4C, 4D, 4E, 4F, and 4G illustrate another embodiment which is a modification of Figure 3. [Figure 4G] Figures 4A, 4B, 4C, 4D, 4E, 4F, and 4G illustrate another embodiment which is a modification of Figure 3. [Figure 5] Another embodiment of the substrate, which is a modified example of Figure 4A, is shown. [Figure 6] Figure 5 illustrates another embodiment of the substrate, which is a modified example. [Figure 7] Figures 7, 8, 9, 10, 11, and 12 provide details of each corner region. They show the conductive paths and discontinuities in the corner regions formed to realize 12 battery circuit lengths for the solar panel. [Figure 8] Figures 7, 8, 9, 10, 11, and 12 provide details of each corner region. They show the conductive paths and discontinuities in the corner regions formed to realize 12 battery circuit lengths for the solar panel. [Figure 9] Figures 7, 8, 9, 10, 11, and 12 provide details of each corner region. They show the conductive paths and discontinuities in the corner regions formed to realize 12 battery circuit lengths for the solar panel. [Figure 10]Figures 7, 8, 9, 10, 11, and 12 provide details of each corner region. They show the conductive paths and discontinuities in the corner regions formed to achieve 12 cell circuit lengths for the solar cell panel. [Figure 11] Figures 7, 8, 9, 10, 11, and 12 provide details of each corner region. They show the conductive paths and discontinuities in the corner regions formed to achieve 12 cell circuit lengths for the solar cell panel. [Figure 12] Figures 7, 8, 9, 10, 11, and 12 provide details of each corner region. They show the conductive paths and discontinuities in the corner regions formed to achieve 12 cell circuit lengths for the solar cell panel. [Figure 13] Illustrate how the size of the solar cell array can be customized. [Figure 14] Illustrate an example of a method for manufacturing a solar cell array for a satellite. [Figure 15] Illustrate an example of a satellite including a solar cell array. [Figure 16] Illustrate an example of a solar cell array in the form of a functional block diagram.

Best Mode for Carrying Out the Invention

[0009] In the following description, reference is made to the accompanying drawings which form a part of this specification. These drawings are shown for the purpose of illustrating specific examples in which the present disclosure may be practiced. It is to be understood that other examples are available and structural changes may be made without departing from the scope of the present disclosure.

[0010] overview There is a need for commercially available solar cell arrays that can be rapidly adjusted to achieve various output voltages for the rapid supply of missions with diverse settings. For example, high-priority missions often require supply within a few weeks, but current approaches can take months for extensive design, manufacture, and testing of solar cell arrays.

[0011] This disclosure describes a commercially available space-capable solar cell array that can be rapidly adjusted to achieve various output voltages. Solar cell arrays for satellites vary for each mission, and previous attempts to standardize solar cell arrays have resulted in power losses that negate the sought-after cost or schedule advantages.

[0012] This disclosure describes a new layout and improved process for a substrate with a prefab flex circuit used in a solar power generation module (SPM) that can be customized to the desired dimensions and output voltage of a solar cell for a mission and supplied quickly. Specifically, this disclosure makes an intelligent determination of what the final layout will be and removes unnecessary traces. Known switching techniques can be used as well.

[0013] One aspect of this disclosure forms an efficient layout for conductors and traces. Conductive paths can be set as needed, unused paths removed, and flexibility can be achieved by switches. Specifically, this disclosure starts with a commercially available set of paths and removes any excess (i.e., unnecessary) paths.

[0014] Current path selection U.S. Utility Patent Application No. 15 / 643,277, filed on July 6, 2017, by Eric Rehder, entitled “PREFABRICATED CONDUCTORS ON A SUBSTRATE TO FACILITATE CORNER CONNECTIONS FOR A SOLAR CELL ARRAY,” is described above in a section entitled “Cross-references to Related Applications.” This application, incorporated herein by reference, describes a method for selecting current paths for a solar cell by adding conductive elements to a corner region to bridge between conductive paths, or by removing conductive elements from a corner region to separate conductive paths.

[0015] The use of electrical connections between solar cells within corner areas not only simplifies manufacturing but also supports customization. The use of prefabricated conductors results in traces and conductors being placed throughout the entire circuit, allowing for design flexibility. Electrical connections can be customized for any circuit length to assist in panel manufacturing, guiding current or power to the next solar cell in the circuit, or terminating a string. However, this also results in unnecessary traces and conductors.

[0016] To achieve a desired design or output voltage, it is necessary to remove or add conductive elements, determine how many conductive elements to remove or add, and determine from which locations the conductive elements should be removed or added. This disclosure satisfies these requirements.

[0017] Furthermore, removal and addition techniques, including, for example, cutting, laser cutting, deposition, and welding, are known for removing and / or adding metal. However, prior use of such techniques has resulted in complexity in achieving the desired power output level. This disclosure reduces that complexity.

[0018] Prefabricated flex circuit with customized voltage This disclosure improves manufacturing time by reducing the amount of work involved in blocking or forming conductive paths. The new layout and improved process enable commercially available solar cell arrays to be constructed and rapidly tuned to achieve a variety of output voltages.

[0019] Figures 1A, 1B, and 1C are cross-sectional side views. They illustrate embodiments showing a solar panel 100 that includes not only the layers and components of the substrate 104, such as a prefabricated flexible circuit, but also the circuitry of the solar cell 102 mounted on the substrate 104.

[0020] Figure 1A illustrates one embodiment showing two solar cells 102 mounted on a substrate 104. In this embodiment, the substrate 104 is composed of one or more insulating layers 106 made of Kapton®, polyimide, or other insulating material, and a plurality of conductors 108 consisting of at least one patterned conductive metal layer, such as a copper (Cu) layer, placed on top of the insulating layers 106. The solar cells 102 are attached to the insulating layers 106 using an adhesive 112.

[0021] Figure 1B illustrates one embodiment showing two solar cells 102 mounted on a substrate 104. In this case, the substrate 104 is composed of multiple insulating layers 106A, 106B. At least one conductor 110, composed of one or more patterned conductive metal layers such as a copper layer, is deposited on insulating layer 106A. Insulating layer 106B is attached to the conductor 110 and on or above insulating layer 106A using adhesive 112B. The conductor 110 is embedded in the substrate 104 to form a series connection between the solar cells 102. The solar cells 102 are attached to insulating layer 106B using adhesive 112A.

[0022] Figure 1C illustrates one embodiment showing two solar cells 102 mounted on a substrate 104. In this case, the substrate 104 is composed of multiple insulating layers 106A, 106B, and 106C. At least one conductor 110A, composed of one or more patterned conductive metal layers such as a copper layer, is deposited at the bottom of insulating layer 106C, and at least one conductor 110B, composed of one or more patterned conductive metal layers such as a copper layer, is deposited on top of insulating layer 106C. Insulating layer 106A is attached to the bottom of conductor 110A and to insulating layer 106C or below it using adhesive 112C, and insulating layer 106B is attached to conductor 110B and to insulating layer 106C or above it using adhesive 112B. Solar cells 102 are attached to insulating layer 106B using adhesive 112A.

[0023] Figures 2, 3A, 3B, 4A, 4B, 4C, 4D, 4E, 4F, 4G, 5, 6, 7, 8, 9, 10, 11, 12, and 13 are top views showing a transparent solar cell 102 and substrate 104 for illustrative purposes of the arrangement and function of the conductor 110. As described above in Figures 1A, 1B, and 1C, the conductor 110 is actually embedded in the substrate 104, preferably enclosed by an insulating layer 106, extends below the solar cell 102, and is electrically interconnected with the group of solar cells 102.

[0024] Figure 2 illustrates one embodiment showing an array of solar cells 102 mounted on a substrate 104. In this case, the array of solar cells 102 comprises 24 solar cells 102 arranged in 4 rows and 6 columns. The array of solar cells 102 generates an output voltage of 48V (i.e., approximately 2V per solar cell 102 at operating temperature and end-of-life (EOL) radiation damage).

[0025] In this embodiment, each solar cell 102 has at least one cut-off corner 114 that defines a corner region 116. A group of four adjacent solar cells 102 are aligned and mounted on a substrate 104. Thereafter, the four cut-off corners 114 from each solar cell 102 are brought together in the corner region 116. The substrate 104 is configured such that when the corner regions 116 of adjacent solar cells 102 are aligned and the solar cells 102 are mounted on the substrate 104, an area 118 of the substrate 104 remains exposed. The exposed area 118 of the substrate 104 includes one or more conductors 110, and one or more electrical connections between the solar cell 102 and the conductors 110 are formed within the exposed area 118.

[0026] In one embodiment, the electrical connection between the solar cells 102 and the conductor 110 is formed using a metal foil interconnect 120 with each solar cell 102. The metal foil interconnect 120 has at least one interconnect 120 attached to the n-type side of the solar cell 102 and at least one interconnect 120 attached to the p-type side of the solar cell 102. As described above in Figures 1A, 1B, and 1C, the conductor 110 is shown in this top view for illustrative purposes, but the conductor 110 is embedded in the substrate 104, preferably sealed by an insulating layer 106, extends below the solar cells 102, and is electrically interconnected with the group of solar cells 102. In the embodiment of Figure 2, the conductor 110 and interconnect 120 connect all of the solar cells 102, both horizontally and vertically.

[0027] In one embodiment, the ends of the conductor 110 are aligned and exposed through the surface of the substrate 104 in an area 118 of the substrate 104, which remains exposed, in order to electrically connect to the interconnect 120. The conductor 110 is also electrically connected to the interconnect 120 using vias within the substrate 104. Furthermore, the conductor 110 may be mounted, printed, or deposited on the surface of the substrate 104 before and / or after the solar cells 102 are mounted on the substrate 104. This also facilitates connections between the solar cells 102.

[0028] Figure 3A illustrates another embodiment of the substrate 104, i.e., a modification of Figure 2. It adds one or more conductors 122, which are circuit termination lines for the solar cell 102. The one or more conductors 122 are also embedded in the substrate 104, like the conductors 110. As stated above, the drawings show the solar cell 102 and the substrate 104 as transparent for the purpose of illustrating the arrangement and function of both conductors 110 and 122 in this example. At least some of the conductors 122 are connected together at their intersections. In the corner region 116, the conductors 122 intersect with the conductors 110. In this case, the conductors 122 and conductors 110 are connected.

[0029] At least some of the conductors 110 and 122 can be patterned within a plurality of separate conductive metal layers in the substrate 104. In this case, the conductors 110 and 122 on the plurality of conductive metal layers of the substrate 104 are connected using vias or the like within the substrate 104.

[0030] Furthermore, at least some of the conductors 110 and 122 can be formed together within a single conductive metal layer in the substrate 104. The advantage of this layout is that it can be implemented with a single metal layer, which is preferable. A single metal layer is less expensive to manufacture, lighter, and more flexible.

[0031] Figure 3B provides further details of the connections formed within the corner region of the solar cell 102. The metal foil interconnect 120 connects to either the n-type or p-type side of the solar cell 102. The metal foil interconnect 120 connects to the conductor 110. The conductor 110 is embedded within the substrate 104, covered by an insulating layer 106, and extends beneath the solar cell 102. There is an opening within the insulating layer 106 that is not depicted. It allows the metal foil interconnect 120 to connect to the conductor 110.

[0032] Conductor 122 is also embedded within the substrate 104, covered by an insulating layer 106, and extends beneath the solar cell 102. Conductor 122 may, for example, form an electrical connection. In this case, conductor 122 intersects, contacts, or is adjacent to other conductors 110 or 122. In one embodiment, conductors 110 and 122 are patterned within one or more metal layers of the substrate 104, and the electrical connection between conductors 110 and 122 includes a continuous metal layer. Nevertheless, conductors 110 and 122 have different functions and purposes from one another.

[0033] Figure 3C is an enlarged view of Figure 3B, further illustrating conductors 110 and 122. In this figure, the solar cell 102 is attached to the insulating layer 106B using adhesive 112A. Conductors 110 and 122 are formed on top of the insulating layer 106A. The insulating layer 106B is attached on top of or above conductors 110 and 122 and insulating layer 106A using adhesive 112B. Thus, like conductor 110, conductor 122 is embedded between insulating layers 106A and 106B. However, in other embodiments, conductors 110 and 122 may be formed on different insulating layers or embedded between different insulating layers.

[0034] Figure 4A illustrates another embodiment of the substrate 104, i.e., a modification of Figure 3A. It provides the ability to remove or add electrical conduction to conductors 110, 122 using determination points 124 located at many key points across the substrate 104 to define a series configuration of solar cells 102, a parallel configuration of solar cells 102, or both a parallel and series configuration of solar cells 102. These determination points 124 are locations where decisions can be made to form or interrupt electrical conduction of conductors 110 and / or conductors 122 in order to minimize the number of conductors 110, 122, thereby assigning each of the solar cells 102 to conductors 110, 122 as a series connection or circuit termination. Thus, at least some of the conductors 110 are series connections for solar cells 102, and at least some of the conductors 122 are circuit terminations for solar cells 102.

[0035] In this diagram, decision point 124 is represented by a circle. It does not actually exist on the substrate 104, but is used simply to clarify and illustrate the solution. The circle for decision point 124 may be solid or hollow. In that case, a solid white circle represents a decision point 124 where electrical continuity is interrupted or does not exist for conductors 110, 122, while a hollow circle (indicated that conductors 110, 122 pass through it) represents a decision point 124 where electrical continuity is formed for conductors 110, 122 or is not interrupted. Electrical continuity may be interrupted at decision point 124 by, for example, cutting a trace, removing an interconnect, or inducing a fuse. Alternatively, electrical continuity may be maintained or formed at decision point 124 by, for example, adding a jumper, adding an interconnect, or inducing an antifuse.

[0036] In this embodiment, a determination point 124 is used to configure conductor 122 to become three sets of termination lines, each labeled as V1+ and V1-, V2+ and V2-, and V3+ and V3-, respectively. The solar cells 102 begin in series connection, thereby forming circuit V1, followed by circuits V2 and V3. In the corner region 116 of each solar cell 102, conductors 110, 122 are formed or interrupted to reassign each cell-to-cell connection as a series connection or as circuit terminations for V+ / - pairs. The layout in this embodiment has conductors 122 interrupted to form three (3) circuits V1, V2, and V3. Circuits V1 and V2 have nine (9) solar cells 102, while circuit V3 has six (6) solar cells.

[0037] For illustrative purposes, the numbering of solar cells 102 begins with the top-left solar cell 102 (cell 1) in the first column, proceeds down the rows of the first column, goes up the rows of the second column from the bottom of the second column, goes down the rows of the third column from the top solar cell 102 (cell 9) in the third column (cell 10 and the solar cell 102 in the third column below cell 10), and continues in a snake-like pattern through the fourth and fifth columns (cells 18 and 19) to the top-right solar cell 102 (cell 24) in the sixth column.

[0038] The corner region 116 for cell 1 has a hollow circle representing a determination point 124 with an uninterrupted conductor 122. This shows how cell 1 is connected to V1- and in series with cell 2. The solid circle representing the determination point 124 with an interrupted conductor 122 also shows V1- disconnected from the traces in the circuit of V2- and V3-. A bypass diode (not shown) may be positioned within the corner region 116 to protect the solar cell 102 from reverse bias.

[0039] In this embodiment, the positive contact of cell 9 is connected to V1+, cell 10 is connected to V2-, cell 18 is connected to V2+, cell 19 is connected to V3-, and cell 24 is connected to V3+. The V3 circuit may have fewer solar cells 102 and have a lower voltage than the V1 and V2 circuits. Voltage may be added to the V3 circuit using another circuit (not shown) on another panel. Alternatively, the size of the panel 100 may be increased.

[0040] Further details of the trace within the corner region 116 between row 1 and row 2 are provided in Figures 4B, 4C, and 4D.

[0041] Figure 4B shows traces for various conductors 110 and 122, and has a circle indicating the determination point 124. Thus, each conductor 110 and 122 from each solar cell 102 may be connected in series or have circuit terminations V+ and V-, and each may be independently open or closed.

[0042] Figure 4C analyzes the result of decision point 124. In this figure, the result is shown within circle 126. It does not actually exist on the substrate 104, but is used simply to clarify and illustrate the solution. Only decision point 124 within circle 126 is analyzed. In Figure 4C, the connection for the series connection between cells is explicitly shown. Within circle 126, there are two gaps or discontinuities 128 in the horizontal conductor 122. These discontinuities 128 are a result of decision point 124 being used to interrupt the current to the V+ and V- conductors 122. The other conductors 110, 122 remain intact.

[0043] Figure 4D shows the configuration of a determination point 124 within a circle 126 for terminating the circuit between these solar cells 102. Within the circle 126, there is a single gap or discontinuity 128. This indicates that the conductor 122 is disconnected at this point. In this alternative scenario, the series connection between the solar cells 102 is disconnected, with the upper left solar cell 102 terminated to the V+ output and the lower left solar cell 102 terminated to the V- output.

[0044] Figure 4E shows conductors 110 and 122 between rows 3 and 4, with a determination point 124. Conductors 122 from each solar cell 102 are circuit terminations V+ and V-.

[0045] In Figure 4F, a connection is formed to maintain a series connection for the solar cells 102. The series connection uses the conductor 110 between the lower left and lower right solar cells 102. Within the circle 126, there is a discontinuity 128 formed within the conductor 122 connected to the V+ and V- outputs.

[0046] In Figure 4G, connections are formed to maintain circuit terminations to V+ and V- for solar cells 102. Within circle 126, a series connection of conductors 122 has a discontinuity 128. The lower left solar cell 102 is connected to the V+ output, and the lower right solar cell 102 is connected to the V- output. The lower right solar cell 102 also has the opportunity to connect to the V+ output, but this path also has a discontinuity 128.

[0047] It should be noted that these embodiments have a number of conductors 110, 122 and determination points 124 from which conductors 110, 122 can be blocked. This disclosure describes a new way of modifying this configuration. Specifically, the concept described in Figure 4A provides complete control over the connections of the solar cells 102 to the array. In fact, this level of control is unnecessary and leads to overly complex solutions in which more conductors 110, 122 and determination points 124 are formed or blocked.

[0048] Figure 5 illustrates another embodiment of the substrate 104, i.e., a modification of Figure 4A. It simplifies the layout of conductors 110, 122 while servicing arrays for a wide range of applications, more completely optimizing the configuration to the desired dimensions and / or desired output voltage of the solar cells. This embodiment is for various applications where the circuit length can be adjusted to 8 to 17 solar cells 102. These solar cells 102 produce output voltages in the range of approximately 16V to 34V, but other ranges can also be used. Insights into the application of the array of solar cells 102 can inform vendors that outputs below 16V are unlikely and outputs above 34V are unlikely.

[0049] Therefore, the design can be simplified to accommodate anticipated changes in needs. The desired output voltage and adjustment range for the application will be determined. This allows for a significant simplification from the baseline in Figures 4A, 4B, 4C, 4D, 4E, 4F, and 4G, providing complete configuration control.

[0050] This is often unnecessary, and a simpler design, such as that shown in Figure 5, may be preferable. It eliminates a large number of conductors 110, 122, and determination points 124. Connections are identified by solid and hollow circles at determination points 124 to form two circuits V1 and V2, each having 12 solar cells 102. The result is that this improved version has only 27 determination points 124 between solar cells 102, rather than an array of 24 solar cells 102 with 100 determination points 124 between them. The number of conductors 122 providing circuit terminations is also substantially reduced.

[0051] In one embodiment of Figure 6, the determination point 124 is set to generate a circuit length of 12 solar cells 102. Thus, cell 1 is directly connected to V- using a series connection for each solar cell 102 in the circuit up to cell 9. Cells 1 through 8 are connected in series without the ability to change. Between cell 8 and cell 24, the determination point 124 exists. In this case, conductors 110 and 122 can be interrupted to adjust the output voltage. While the series connection between cell 9 and cell 10 is interrupted, these cells are connected to V1+ and V2-, respectively. The determination point is set for a series connection between cell 10 and cell 18 for a second circuit. Between cell 18 and cell 19, the series connection is interrupted, while these cells are connected to V2+ and V3-, respectively. The determination point has a series connection from cell 19 to cell 24. Cell 24 is directly connected to V3+. Different selections of the determination point can result in the end of the first circuit being any of the cells from cell 8 to cell 12. Similar settings can be made to adjust the length and output voltage of the second and third circuits.

[0052] Figures 7, 8, 9, 10, 11, and 12 provide further detail of each corner region 116, showing the conductors 110, 122 within the corner region 116 and the discontinuity 128 formed at the determination point 124 to realize the circuit length of the 12 solar cells 102. These drawings also highlight that bypass diodes are not included in these examples, although bypass diodes may be desired in most applications.

[0053] As clearly shown in Figure 13, in addition to customizing the circuit length, the size of the array of solar cells 102 can also be customized. The array of solar cells 102 shown in Figure 6 can be electrically reconfigured as shown in Figures 7, 8, 9, 10, 11, and 12. Figure 13 shows how its length can also be adjusted. In this embodiment, cells 13 to 24 can be removed. Then, to adjust the size of the substrate 104 and the overall amount of solar cells 102, the substrate with conductors 110, 122 can be cut along the vertical dashed lines. It would be desirable to attach a sealing insulator to the upper edges of the exposed conductors 110, 122. This can be achieved by adhesive or tape.

[0054] These embodiments illustrate the design of series conductive paths 110, 122 integrated into a substrate 104 for mounting to a solar cell 102. The resulting solar panel 100 can be constructed and tested. This requires a considerable amount of time, after which the assembly can be stored. At some point in the future, the panel 100 can be configured in detail with the configuration of determination points 124. For example, each determination point 124 could be a solid conductor 110, 122. Once the determination points are formed around a circular connection configuration, the conductors 110, 122 can be interrupted at a desired determination point 124. Conversely, the panel 100 can be formed such that each determination point 124 is an open conductor 110, 122. At that determination point 124, another conductor 110, 122 can be added to bridge the open conductors 110, 122. The panel 100 can also be physically cut to the length required for the end user.

[0055] This manufacturing sequence allows for the rapid completion of the customization, testing, and supply of solar panels 100. Long procurement delays, assembly, adhesive curing, and environmental testing for manufacturing solar panels 100 are completed previously using materials stored in stock. When supply is needed, customization can be completed in days rather than months. Stock can always be built ahead of schedule and stored for immediate supply. This is feasible for a single solar panel 100 item. However, the mission is highly customized, and therefore the stock approach requires a huge amount of hardware with many circuit lengths and dimensions. The design of this solar panel 100 allows a single solar panel 100 to be stocked, and then, when needed, that solar panel 100 can be customized to the required size and output voltage configuration for supply in days.

[0056] The embodiment used a solar cell that was roughly square with a single cut-off corner. The solar cell may be more rectangular and may have two or four cut-off corners. Solar cells without cut-off corners may also be used, but they must be spaced apart to allow connections to be formed. The routine and ability of these connections, which form the physical and electrical configuration after assembly and testing, is independent of the shape of the solar cell. However, some of these solar cells will have multiple interconnections to either n-type or p-type contacts. These multiple interconnections provide redundancy and lower resistance paths. These can be utilized in this solar panel design by extending traces to each interconnection of a common type.

[0057] The embodiment uses solar cells with cut-off corners that are aligned. This would be undesirable for some cell shapes and dimensions. This is not a requirement for solar panel layout. Flexible circuit-based wiring can be easily routed to reach single or multiple interconnections of solar cells, wherever it may be.

[0058] production Embodiments of this disclosure may be described in the context of a method 130 for fabricating a solar cell 102, a solar panel 100 comprising a solar cell array, and / or a satellite, including steps 132-144 shown in Figure 14. In this case, the resulting satellite 146 has a solar panel 100 comprising an array of solar cells 102, which is shown in Figure 15.

[0059] As shown in Figure 14, in the pre-manufacturing stage, exemplary method 130 may include specification and design 132 of the solar cell 102, solar panel 100, and / or satellite 146, and procurement 134 of these materials. In the manufacturing stage, the components and subassemblies of the solar cell 102, solar panel 100, and / or satellite 146 are manufactured 136, and system integration 138 is performed. These include the manufacture of the solar cell 102, solar panel 100, and / or satellite 146. Subsequently, the solar cell 102, solar panel 100, and / or satellite 146 may undergo authorization and delivery 140 for use in operation 142. The solar cell 102, solar panel 100, and / or satellite 146 may be further scheduled for maintenance and servicing 144 (including modifications, reconfigurations, and refitting) before launch.

[0060] Each step of Method 130 may be performed or carried out by a system integrator, a third party, and / or an operator (e.g., a customer). For the purposes of this specification, the system integrator may include, but is not limited to, any number of manufacturers and subcontractors of major systems of solar cells, solar cell panels, satellites, or spacecraft; the third party may include, but is not limited to, any number of vendors, subcontractors, and suppliers; and the operator may be a satellite communications company, a military organization, a service organization, etc.

[0061] As shown in Figure 15, a satellite 146 fabricated by exemplary method 130 may include a system 148, a body 150, a solar panel 100 consisting of an array of solar cells 102, and one or more antennas 152. Embodiments of system 148 included with satellite 146 include, but are not limited to, one or more of the propulsion system 154, electrical system 156, communication system 158, and power system 160. Any number of other systems 148 may also be included.

[0062] Figure 16 shows an example of a solar cell panel 100 in the form of a functional block diagram according to one embodiment. The solar cell panel 100 consists of one or more arrays of solar cells 102 individually mounted on a substrate 104. The substrate 104 includes one or more of an insulating layer 106, conductors 110, 122, and determination points 124. Each of the solar cells 102 absorbs light 162 from a light source 164 and generates an electrical output 166 accordingly.

[0063] Furthermore, this disclosure includes embodiments as provided for in the following clauses. Article 1. A method for fabricating a solar cell array, comprising mounting one or more solar cells onto a substrate, wherein the substrate comprises one or more insulating layers and one or more conductive layers patterned as one or more conductors for forming electrical connections with the solar cells, and the substrate comprises one or more determination points for electrical conductivity to the conductors in order to customize the circuit of the solar cells. Article 2. The substrate is a prefabricated flex circuit, according to the method described in Clause 1. Article 3. The method according to Clause 2, wherein at least one of the solar cells has at least one cut-off corner defining a corner region, and when the solar cell having the cut-off corner defining the corner region is mounted on the prefabricated flexible circuit, a certain area of ​​the prefabricated flexible circuit remains exposed, and the electrical connection between the solar cell and the conductor is formed using an interconnect on or within the corner region of the exposed area of ​​the prefabricated flexible circuit. Article 4. The method according to Clause 3, wherein the end of the conductor is aligned and exposed through the surface of the prefabricated flex circuit in the area of ​​the prefabricated flex circuit, which remains exposed, in order to electrically connect with the interconnect. Article 5. The method according to clause 3 or 4, wherein the conductors on multiple layers of the prefabricated flexible circuit are connected using vias within the prefabricated flexible circuit. Article 6. The method according to any one of the clauses 1 to 5, further comprising using the determination point to remove or add electrical conduction to the conductor in order to define a series configuration of the solar cells, a parallel configuration of the solar cells, or both a parallel and series configuration of the solar cells. Article 7. The method according to any one of the claims 1 to 6, further comprising assigning the solar cells to the conductors as series connections or circuit terminations in order to minimize the number of conductors. Article 8. The method according to clause 7, wherein at least some of the conductors are in series connection for the solar cell. Article 9. The method according to clause 7 or 8, wherein at least some of the conductors are circuit terminations for the solar cell. Article 10. The method according to any one of the clauses 1 to 9, wherein at least some of the conductors are connected together at their intersection. Article 11. The method according to any one of the claims 1 to 10, wherein at least some of the conductors are patterned within a plurality of separate conductive metal layers in the substrate. Article 12. The method according to any one of the claims 1 to 11, wherein at least some of the conductors are formed in one metal layer in the substrate. Article 13. The determination point is used to customize the circuit length for the solar cell array, as described in any one of the provisions 1 to 12. Article 14. The substrate is cut to adjust the size of the substrate and the overall amount of the solar cells, as described in Clause 1. Article 15. A solar cell array comprising one or more solar cells mounted on a substrate, wherein the substrate includes one or more insulating layers and one or more conductive layers patterned as one or more conductors for forming electrical connections with the solar cells, and the substrate includes one or more determination points for electrical conduction to the conductors in order to customize the circuits of the solar cells. Article 16. The solar cell array according to Clause 15, further comprising using the determination point to remove or add electrical conduction to the conductor in order to define a series configuration of the solar cells, a parallel configuration of the solar cells, or both a parallel and series configuration of the solar cells. Article 17. The solar cell array according to clause 15 or 16, further comprising assigning the solar cells to the conductors as series connections or circuit terminations in order to minimize the number of conductors. Article 18. The aforementioned determination point is used to customize the circuit length for the solar cell array, as described in any one of clauses 15 to 17. Article 19. The substrate is cut to adjust the length of the solar cell array according to any one of the clauses 15 to 17. Article 20. A method for operating a solar cell array, comprising generating an electric current using one or more solar cells mounted on a substrate, wherein the substrate comprises one or more insulating layers and one or more conductive layers patterned as one or more conductors for forming electrical connections with the solar cells, and the substrate comprises one or more determination points for electrical conduction to the conductors in order to customize the circuit of the solar cells.

[0064] conclusion The examples provided above are for illustrative and explanatory purposes only and are not intended to be exhaustive or to limit the scope to the examples disclosed. Numerous alternative, modified, and adapted examples may be used instead of the specific examples given above.

Claims

1. A method (130) for fabricating a solar cell (102) array, This includes attaching multiple solar cells (102) to a substrate (104), Each of the solar cells (102) has at least one cut-off corner (114), and the cut-off corner (114) defines at least one corner region (116), The substrate (104) includes one or more insulating layers (106, 106A, 106B, 106C) and one or more conductive layers patterned as conductors (110, 122) embedded in the substrate (104) for forming an electrical connection with the solar cell (102), wherein the first conductor (110) of the conductors (110, 122) connects the solar cell (102) in series, and the second conductor (122) of the conductors (110, 122) is the circuit termination line (122) of the solar cell (102). To customize the circuit of the solar cell (102), the substrate (104) includes one or more determination points (124) for electrical conductivity to the conductors (110, 122), Method (130), wherein at least some of the second conductors (122) are connected to one another at their intersections, and in at least one corner region (116), the second conductors (122) intersect with the first conductor (110), and the first conductor (110) and the second conductor (122) are connected at this intersection.

2. The method according to claim 1 (130), wherein the substrate (104) is a prefabricated flexible circuit (104).

3. The method according to claim 2 (130), wherein when the solar cell (102) having the cut-off corner (114) defining the corner region (116) is attached to the prefabricated flexible circuit (104), a certain area (118) of the prefabricated flexible circuit (104) remains exposed.

4. The method according to claim 3, wherein the electrical connection between the solar cell (102) and the first conductor (110) of the conductors (110, 122) is made using an interconnect (120) within the at least one corner region (116) or within the exposed area (118) of the prefabricated flexible circuit (104).

5. The method (130) of claim 4, wherein the end of the first conductor (110) of the conductors (110, 122) is aligned and exposed through the surface of the prefabricated flexible circuit (104), which remains exposed, in order to electrically connect with the interconnect (120).

6. The method according to any one of claims 2 to 5, wherein the conductors (110, 122) on multiple layers of the prefabricated flexible circuit (104) are connected using vias within the prefabricated flexible circuit (104).

7. The method according to any one of claims 1 to 6, further comprising using the determination point (124) to remove or add electrical conduction to the conductors (110, 122) in order to define a series configuration of the solar cells (102), a parallel configuration of the solar cells (102), or both a parallel and a series configuration of the solar cells (102).

8. The method according to any one of claims 1 to 7, wherein at least some of the conductors (110, 122) are patterned within a plurality of separate conductive metal layers in the substrate (104), and / or at least some of the conductors (110, 122) are formed within a single metal layer in the substrate (104).

9. The method according to any one of claims 1 to 8, wherein the determination point (124) is used to customize the circuit length for the solar cell (102) array.

10. The method according to any one of claims 1 to 9, wherein the substrate (104) is cut to adjust the size of the substrate (104) and the overall amount of the solar cell (102).

11. The method according to any one of claims 1 to 10, further comprising using the determination point (124) to remove or add electrical conduction to the conductors (110, 122) in order to define a series configuration of the solar cells (102), a parallel configuration of the solar cells (102), or both a parallel and a series configuration of the solar cells (102).

12. The method according to claim 11, further comprising assigning the solar cells (102) to the conductors (110, 122) as series connections or circuit terminations in order to minimize the number of conductors (110, 122).

13. A solar cell (102) array, Includes a plurality of solar cells (102) attached to a substrate (104), The substrate (104) includes one or more insulating layers (106, 106A, 106B, 106C) and one or more conductive layers patterned as conductors (110, 122) embedded in the substrate (104) for forming an electrical connection with the solar cell (102), wherein the first conductor (110) of the conductors (110, 122) connects the solar cell (102) in series, and the second conductor (122) of the conductors (110, 122) is the circuit termination line (122) of the solar cell (102). To customize the circuit of the solar cell (102), the substrate (104) includes one or more determination points (124) for electrical conductivity to the conductors (110, 122), and A solar cell (102) array in which at least some of the second conductors (122) are connected to one another at their intersections, and in at least one corner region (116), the second conductors (122) intersect with the first conductor (110), and the first conductor (110) and the second conductor (122) are connected at this intersection.

14. The solar cell array according to claim 13, wherein the determination point (124) is used to customize the circuit length for the solar cell (102) array.

15. The solar cell array according to claim 13 or 14, wherein the substrate (104) is cut to adjust the length of the solar cell (102).

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