Flexible Glass Support for Solar Cell Assembly

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Solution Overview

Problem

Existing flexible solar panel supports, such as Gore™ mesh and Kapton™ polyimide films, are prone to deformation, lack radiation protection, and are incompatible with high temperature processes, and have porous or rough surfaces, making them unsuitable for robust and efficient solar cell assembly.

Innovation Solution

A glass support with integrated metallized traces and a polyimide intermediate layer is used, where the solar cell component is bonded using soldering or conductive adhesive, providing a mechanically robust and thermally stable assembly with enhanced radiation protection.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If flexible support materials such as Gore mesh or Kapton polyimide film are used, then the solar panel can be made flexible and lightweight, but the support is easily cut or punctured during handling and lacks mechanical robustness

Engineering Contradiction:

Improvemechanical robustnessVSAvoidhandling durability

Core Design Contradiction:

StrengthVSEase of operation

Solution Approach 1:

The patent uses a composite structure combining a flexible polymer film base with a woven fibreglass reinforcement layer. This composite material provides both the flexibility needed for portable solar panels and the mechanical strength to resist cutting and puncturing during handling. The fibreglass weave embedded in the polymer matrix creates a structurally robust support that maintains flexibility.

Inventive Principle:

Principle #40Composite materials

2Adaptability or versatility

If polyimide support materials are used, then the support can be made flexible, but the material is susceptible to degradation from atomic oxygen

Engineering Contradiction:

ImproveflexibilityVSAvoidresistance to atomic oxygen degradation

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The patent introduces a barrier layer or protective coating as an intermediary between the polyimide support material and the atomic oxygen environment. This protective layer acts as a mediator that prevents direct interaction between atomic oxygen and the polyimide, thereby preventing degradation while maintaining the flexibility of the underlying polyimide structure.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Adaptability or versatility

If mesh or weave support structures are used, then the support can be made flexible, but the surface is porous and not smooth on a microscopic scale

Engineering Contradiction:

ImproveflexibilityVSAvoidsurface smoothness

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The patent applies different surface treatments to different regions or layers of the support structure. The bulk structure maintains a woven or mesh configuration for flexibility, while the bonding surface is treated to provide smoothness. This local differentiation allows the support to be flexible in its overall structure while providing a smooth bonding surface where needed.

Inventive Principle:

Principle #3Local quality

4Adaptability or versatility

If conventional flexible support materials are used, then the support can be bent and folded, but the material retains permanent deformation

Engineering Contradiction:

ImprovebendabilityVSAvoidshape retention

Core Design Contradiction:

Adaptability or versatilityVSStability of the object's composition

Solution Approach 1:

The patent employs a support structure with dynamic mechanical properties that allow reversible deformation. The composite structure of flexible polymer and woven fibreglass enables the support to bend and fold temporarily while maintaining its ability to return to its original shape. The fibreglass reinforcement provides structural memory that prevents permanent deformation while allowing necessary flexibility during installation.

Inventive Principle:

Principle #15Dynamics

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

The glass support offers improved mechanical robustness, radiation protection, and compatibility with high temperatures, while maintaining a smooth surface for efficient bonding, addressing the limitations of previous support materials.

Implementation Method 1

The glass support offers improved mechanical robustness

Methodology Applied

Scientific EffectMechanical strength and rigidity:

Implementation Method 2

enhanced radiation protection

Methodology Applied

Scientific EffectRadiation protection:

Implementation Method 3

metallized traces on the support

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Implementation Method 4

bonding adhesive located between the support and the solar cell component

Methodology Applied

Scientific EffectAdhesion: Adhesive

Implementation Method 5

compatibility with high temperatures

Methodology Applied

Scientific EffectThermal expansion resistance: Thermal Expansion

Data Source

PatentUS10439083B1Flexible glass support for a solar cell assembly

Publication Date: 2019.10.08 SOLAERO TECHNOLOGIES CORP

AI summary

A method of bonding solar cell component to a support and the solar cell assembly thus obtained. The method of bonding solar cell component to a support comprises: disposing metallized traces on the support; dispensing bonding adhesive on front of the support or on back of the solar cell component; and laying down the solar cell component on the support and soldering the solar cell component to the metallized traces on the support. The support is a glass support with integrated circuits.