Flexible Solar Array with Conductive Coating for Electrostatic Dissipation
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Solution Overview
Problem
Rigid solar array substrates are heavy, difficult to scale, and not ideal for packing in launch vehicles, while flexible solar arrays without proper electrostatic charge dissipation can be damaged by charge buildup in space environments.
Innovation Solution
A flexible solar array design with solar cell modules featuring a conductive coating on the backside layer, structural ground extension harnesses, and conductive tapes and jumpers for electrostatic charge dissipation, utilizing carbon nanotubes for protection and conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If rigid solar array substrates are used, then structural strength and electrostatic charge dissipation are ensured, but weight increases and scalability decreases
Solution Approach 1:
The solar array is divided into multiple solar cell modules (SCMs) that can be independently folded and connected. Each SCM contains a subset of solar cells with its own conductive pathways, allowing the array to be segmented for easier deployment and reduced weight while maintaining electrostatic dissipation through modular conductive elements.
Solution Approach 2:
The patent replaces rigid substrates with flexible thin-film substrates that allow the solar array to be folded and compacted for launch. These thin films maintain electrostatic charge dissipation through integrated conductive coatings and pathways, eliminating the need for heavy rigid structural support while ensuring reliability in space environments.
2Weight of moving object
If flexible solar arrays are used, then weight and stowage volume are reduced, but susceptibility to electrostatic discharge damage increases
Solution Approach 1:
The conductive coating is integrated directly into the flexible substrate structure, merging the electrostatic dissipation function with the mechanical support function. This combination ensures that the flexible array maintains charge dissipation pathways without requiring separate heavy grounding structures, thereby reducing weight while protecting against electrostatic discharge.
Solution Approach 2:
Conductive adhesive strips and conductive coatings serve as intermediary elements between the flexible substrate and the electrostatic charge dissipation system. These intermediaries provide continuous conductive pathways across module boundaries and through the flexible structure, enabling charge dissipation while maintaining the flexibility and light weight of the array.
3Reliability
If conductive coating is added to flexible substrates, then electrostatic charge dissipation is enabled, but manufacturing complexity increases
Solution Approach 1:
The patent uses composite material structures where conductive coatings are applied to flexible substrates, creating a multi-functional material that provides both mechanical support and electrostatic dissipation. This composite approach integrates multiple functions into a single manufactured component, reducing the number of separate assembly steps and simplifying the overall manufacturing process despite the added functionality.
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 provides effective electrostatic charge dissipation and protection from atomic oxygen, enhancing the mechanical structure and thermal management of the solar array, allowing for efficient operation and reduced risk of damage from electrostatic discharge.
Implementation Method 1
Each SCM includes a backside layer with a surface opposite the frontside layer having a conductive coating. Structural ground extension harnesses are intermediate the frontside layer and backside layer in a selected portion the SCMs.
Implementation Method 2
Heritage rigid solar panels, as well as other large space structures in general, dissipate electrostatic charge through, a grounding path of graphite facesheets, conductive overlays, aluminum core, and copper wire. In contrast, a flexible solar array or other space structure whose substrate would otherwise be fully insulating may be subject to damage from charge build up and electrostatic discharge.
Implementation Method 3
Atomic oxygen and electrostatic-resistant, flexible structure for space applications
Data Source
AI summary
A flexible space structure such as a solar array is composed of multiple solar cell modules (SCMs) each supporting an arrangement of solar cells on a frontside layer and incorporating a backside layer with a surface opposite from the frontside layer having a conductive coating. A selected portion of the SCMs have structural ground extension harnesses intermediate the frontside layer and backside layer. Conductive tapes secure vertically adjacent SCMs by attachment to the conductive coating and electrical jumpers interconnect the structural ground extension harnesses across gapped hinge lines of laterally adjacent SCMs.