Angled Solar Cell Interconnects for High Density Arrays
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Solution Overview
Problem
In aerospace applications, solar cell arrays face challenges in increasing density, reducing aspect ratio, and ensuring reliability due to limited space and vulnerability to cosmic rays, which can cause electrical discharging.
Innovation Solution
A solar cell assembly with conductive interconnection members having angled portions that can be bent for closer packing and reduced height, allowing for increased density and improved reliability, while also reducing the risk of electrical discharging by minimizing exposed tips.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the numbers of solar cells in a unit area are increased to increase total power amount, then power output is improved, but device complexity and manufacturing difficulty worsen
Solution Approach 1:
The solar cell array is divided into multiple solar cell assemblies, each comprising a solar cell and an interconnection member. This segmentation allows for standardized modular units that can be systematically arranged to increase power output while maintaining manageable complexity through repetition of proven designs.
Solution Approach 2:
The interconnection member is designed with multiple functions: it provides electrical connection between solar cells, provides mechanical support, and enables flexible arrangement. This multi-functionality reduces the need for separate components, thereby increasing power density without proportionally increasing device complexity.
2Quantity of substance
If solar cells are densely packed to increase density in limited area, then area utilization is improved, but reliability worsens due to increased strain and stress
Solution Approach 1:
The interconnection member includes a flexible second portion that can bend and deform elastically during deployment and operation. This dynamic flexibility allows the structure to accommodate strain and stress from dense packing and deployment movements, maintaining reliability despite high cell density.
Solution Approach 2:
The second portion of the interconnection member is designed as a flexible element that can bend and deform. This flexibility absorbs mechanical stress and strain during deployment, protecting the densely packed solar cells from damage while maintaining their close arrangement for high density.
3Ease of operation
If the aspect ratio of solar cell array is reduced to minimum for folded solar wings, then ease of deployment is improved, but manufacturing precision requirements worsen
Solution Approach 1:
The array is segmented into multiple assemblies with standardized interconnection members. This segmentation creates modular units that can be precisely manufactured independently and then assembled, reducing the overall manufacturing precision requirements compared to manufacturing a single large low aspect ratio structure.
Solution Approach 2:
The interconnection member design with its specific angular configuration and flexible portion allows for parameter optimization that reduces the aspect ratio while maintaining manufacturability. The flexible second portion compensates for variations in manufacturing, allowing tighter tolerances to be relaxed.
4Reliability
If tip length of interconnection member is minimized to reduce electrical discharging risk from cosmic rays, then reliability is improved, but ease of manufacture worsens
Solution Approach 1:
The second portion of the interconnection member is designed to be flexible and bendable, allowing it to be formed into various shapes including bent configurations. This dynamic formability enables the tip to be positioned or shaped to minimize exposed length and reduce electrical discharging risk, while still being manufacturable through standard bending processes.
Data Source
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AI summary
A solar cell assembly, a solar cell array, and a method for manufacturing the same are provided. The solar cell assembly may include a solar cell and an interconnection member, the interconnection member comprising a first portion and a second portion attached to the first portion with an angle formed therebetween. The solar cell array may comprise at least two said solar cell assemblies. In an embodiment, the top surfaces of the first solar cell and the second solar cell are arranged such that the second portion of the first interconnect member and the second portion of the second interconnection member are adjacent to each other, and at least the end portion of the second portion of the first interconnection member is bended together with at least the end portion of the second portion of the second interconnection member.