Dual Back Plane Solar Cell Interconnection for Space Arrays
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Solution Overview
Problem
The existing manufacturing of solar cell arrays for space applications faces challenges with high cost, material waste, and complexity due to the use of large, rigid solar cells, which are inefficient in terms of weight, area utilization, and flexibility, and have reliability issues with numerous interconnections.
Innovation Solution
A modular solar cell assembly design featuring a support with conductive layers on both sides, allowing for series and parallel connections of small solar cells with varying dimensions, optimized conductive interconnects, and the use of bypass diodes for enhanced reliability and flexibility, facilitating automated manufacturing and efficient wafer utilization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If large solar cells are used to minimize assembly costs, then manufacturing cost is reduced, but wafer utilization efficiency deteriorates and material waste increases
Solution Approach 1:
The patent divides a circular solar cell wafer into multiple smaller rectangular solar cells through a segmented cutting pattern. This allows the rectangular cells to be efficiently arranged and utilized from the circular wafer, minimizing the unused peripheral material while maintaining cost-effective assembly processes for the smaller individual cells.
2Ease of manufacture
If large solar cells are used to minimize assembly costs, then manufacturing cost is reduced, but manufacturing reliability deteriorates due to increased fragility and handling challenges
Solution Approach 1:
By segmenting the wafer into smaller solar cells, the patent reduces the size and fragility of individual cells that need to be handled during manufacturing. Smaller cells are less prone to breakage during handling, mounting, and interconnection processes, thereby improving overall manufacturing yield and reliability while maintaining cost-effectiveness.
3Ease of manufacture
If large solar cells are used to minimize assembly costs, then manufacturing cost is reduced, but adaptability deteriorates for panels of arbitrary aspect ratios and configurations
Solution Approach 1:
The patent segments the wafer into smaller rectangular solar cells that can be flexibly arranged and configured to match various panel aspect ratios and designs. These smaller modular cells can be easily adapted to different satellite wing configurations and panel layouts, providing greater design flexibility compared to using large fixed-size cells.
4Ease of manufacture
If large solar cells are used to minimize assembly costs, then manufacturing cost is reduced, but power-to-weight ratio deteriorates
Solution Approach 1:
By dividing the wafer into smaller solar cells with optimized dimensions, the patent reduces the overall amount of material and interconnection requirements per unit of power generated. The segmented design allows for more efficient packing and reduced structural support needs, thereby improving the power-to-weight ratio of the final solar array while maintaining cost-effective manufacturing.
5Power
If numerous interconnections are used to connect solar cells in series, then output voltage is increased, but system reliability deteriorates due to more potential failure points
Solution Approach 1:
The patent segments the solar cells into smaller units that can be connected in series strings. By using smaller cells with standardized dimensions and interconnection points, the number of interconnections per unit length is reduced, and each interconnection can be made more reliable through standardized mounting and wiring procedures, thereby improving overall system reliability while achieving the required output voltage.
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 material waste, enhances wafer utilization, simplifies manufacturing, and improves the power-to-weight and power-to-area ratios, while ensuring high reliability and flexibility in solar cell arrays, making them suitable for space applications.
Implementation Method 1
a first conductive layer disposed on the first side of the support and a second conductive layer disposed on the second side of the support
Implementation Method 2
a plurality of solar cells mounted on the first side of the support, each solar cell of the plurality of solar cells comprising a top surface including a contact of a first polarity type
Data Source
AI summary
A solar assembly or module comprising a plurality of solar cells and a support, the support comprising a conductive layer or back plane on each planar side. Each one of the plurality of solar cells is placed on the first conductive portion with the first contact electrically connected to the first conductive portion so that the solar cells are connected in parallel through the first conductive portion. A second contact of each solar cell can be connected to the second conductive portion so that the first and second conductive portions form terminals of opposite conductivity type. The modules can be interconnected to form a string or an electrical series connection of discrete modules by overlapping and bonding the first terminal of a first module with the second terminal of a second module.