Automated Solar Cell Assembly for Space Panels
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Solution Overview
Problem
The manual and labor-intensive process of manufacturing and assembling photovoltaic solar arrays, particularly for space applications, is inefficient and costly, making it challenging to achieve high-volume production with high efficiency and low mass.
Innovation Solution
An automated process for fabricating solar cell panels using metal organic chemical vapor deposition (MOCVD) and automated assembly tools, which includes steps like wafer fabrication, metallization, patterning, antireflective coating, dicing, interconnect attachment, cover glass mounting, and bonding to a substrate, to form Cell-Interconnect-Cover Glass (CIC) assemblies and solar cell arrays.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual assembly processes are used for mounting solar cells on space panels, then flexibility and adaptability are maintained, but productivity is low and labor costs are high
Solution Approach 1:
The patent replaces manual mechanical assembly operations with automated systems including robotic pick-and-place machines, automated wire bonding equipment, and computer-controlled alignment systems. This substitution dramatically increases productivity while maintaining precision through programmable control, directly resolving the contradiction between productivity and automation extent.
2Ease of manufacture
If conventional manual manufacturing processes are used, then process flexibility is maintained, but production cost increases and volume production capability decreases
Solution Approach 1:
The manufacturing process is divided into discrete, standardized modules including individual cell fabrication, CIC assembly, string formation, and panel integration. Each module can be independently optimized and automated, enabling high-volume production while maintaining ease of manufacture through modular design and standardized interfaces.
Solution Approach 2:
The patent implements preliminary actions by pre-assembling CIC modules and pre-forming string configurations before final panel assembly. This allows standardization of subcomponents, facilitating high-volume production through parallel processing and reducing overall manufacturing complexity.
3Power
If high efficiency solar cells are used, then power output increases, but mass and manufacturing complexity increase
Solution Approach 1:
The patent employs a nested modular structure where multiple solar cells are integrated into CIC assemblies, which are then combined into string configurations, and finally assembled into complete panels. This nesting approach manages manufacturing complexity by breaking down the complex task of assembling high-efficiency cells into manageable hierarchical levels, each with standardized procedures.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach reduces production costs and increases efficiency by automating key steps, enabling the production of high-efficiency solar cell panels with improved yield and reduced labor costs, suitable for high-volume production in space applications.
Implementation Method 1
fabricating a wafer utilizing a metal organic chemical vapor deposition (MOCVD) reactor
Data Source
AI summary
A method of fabricating a multijunction solar cell array on a carrier using one or more automated processes, the method comprising providing a first multijunction solar cell including a first contact pad and a second contact pad disposed adjacent the top surface of the multijunction solar cell along a first peripheral edge thereof attaching a first electrical interconnect to the first contact pad of said first multijunction solar cell using a pick and place process attaching a second electrical interconnect to the second contact pad of the first multijunction solar cell using a pick and place process positioning in the first multijunction solar cell over an adhesive region of a permanent carrier using an automated machine/vision apparatus and bonding the first multijunction solar cell to the adhesive region using pressure and/or heat.