Flexible Photovoltaic Array Using Polyimide Substrate
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Solution Overview
Problem
Traditional photovoltaic arrays are heavy due to graphite panels and have high manufacturing costs due to extensive manual labor, making them unsuitable for lightweight applications like spacecraft and consumer use.
Innovation Solution
A flexible photovoltaic array is manufactured by bonding photovoltaic cells to a flexible printed circuit board on a polyimide film substrate reinforced with aramid fiber, using automated assembly equipment and covered with a transparent abrasion-resistant film, with a bladder sleeve for inflatable deployment and high-emissivity coating for heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional graphite panels are used as the substrate for photovoltaic arrays, then structural strength and stability are improved, but weight increases significantly
Solution Approach 1:
The patent replaces traditional rigid graphite panels with flexible thin film substrates (polyimide film, polyester film, or glass) that maintain sufficient structural strength while dramatically reducing weight. The flexible substrate serves as the base for mounting photovoltaic cells and contains conductive traces for electrical connections, eliminating the need for heavy rigid panels while providing mechanical support.
Solution Approach 2:
The patent employs composite material structures combining flexible substrate materials (polyimide, polyester, or glass) with conductive trace materials and photovoltaic cell materials. This composite approach achieves the necessary structural strength and electrical functionality without the weight penalty of traditional graphite panels, creating a lightweight yet durable photovoltaic array.
2Manufacturing precision
If extensive manual labor is used in manufacturing photovoltaic arrays, then assembly precision is improved, but manufacturing cost increases
Solution Approach 1:
The patent replaces manual mechanical assembly operations with automated pick-and-place machines that use robotic mechanisms to precisely position and mount photovoltaic cells onto the flexible substrate. This automation maintains high assembly precision while dramatically reducing labor costs and manufacturing time, making the production process more efficient and scalable.
Solution Approach 2:
The patent changes the manufacturing process parameters from manual operations to automated processes with controlled positioning systems. The automated pick-and-place machines use programmed motion control and vision systems to achieve precise cell placement, transforming the manufacturing approach from labor-intensive to automation-intensive, thereby reducing costs while maintaining or improving precision.
3Stability of the object's composition
If rigid structures are used for photovoltaic arrays, then structural stability is improved, but flexibility and deployability are reduced
Solution Approach 1:
The patent uses flexible thin film substrates (polyimide, polyester, or glass) instead of rigid panels, enabling the photovoltaic array to be bent, folded, or conformally mounted on curved surfaces while maintaining structural integrity. The flexible substrate provides sufficient mechanical stability for operation while allowing diverse deployment configurations and adaptability to different mounting surfaces.
Solution Approach 2:
The patent transitions from static rigid structures to dynamic flexible structures that can adapt their shape and configuration. The flexible substrate allows the array to be deployed in various states (rolled, folded, or flat-mounted) and to conform to moving or curved surfaces, providing mechanical stability in each configuration while enabling adaptability across different operational states.
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 solution results in a low-cost, lightweight photovoltaic array suitable for spacecraft and airplane applications, reducing manufacturing costs and weight while maintaining efficiency and durability.
Implementation Method 1
the other side of the polyimide film substrate is coated with a high-emissivity coating (e.g., high-emissivity paint) to facilitate dissipation of waste heat
Implementation Method 2
one side of the polyimide film substrate, to which the photovoltaic cells are to be applied is coated with an adhesive
Data Source
AI summary
A flexible, lightweight photovoltaic cell array includes one or more individual photovoltaic cell strings attached to a polyimide film substrate and covered with a polyvinyl fluoride film. Each photovoltaic cell string includes one or more photovoltaic cells attached to a flexible printed circuit board. The photovoltaic cell array may be manufactured by a method that includes bonding at least one photovoltaic cell to a flexible printed circuit board, mounting the flexible printed circuit board on a polyimide film substrate, and covering the flexible printed circuit board with a substantially transparent polyvinyl fluoride film.