Flexible Solar Cell With Polyimide Support Layer
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Solution Overview
Problem
Flexible solar cells are prone to cracks and breaks during processing and handling due to their reduced cross-sectional thickness, compromising their performance, especially in space applications where structural integrity is crucial.
Innovation Solution
A solar cell structure incorporating a flexible support layer, such as polyimide, between the solar cell and a reflective layer to enhance mechanical support and efficiency, with the reflective layer having high reflectance to redirect incoming radiation and minimize heat accumulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If solar cell thickness is reduced to improve flexibility, then flexibility is improved, but structural integrity deteriorates
Solution Approach 1:
The patent applies composite materials by combining the thin solar cell with a flexible support layer and reflective layer to create a composite structure. The flexible support layer (e.g., polyimide) provides mechanical strength and flexibility, while the reflective layer enhances optical performance. This composite approach allows the solar cell to maintain flexibility while gaining the structural integrity needed to resist cracks and breaks during handling and space launch.
2Productivity
If reflective layer is added to increase efficiency, then radiation absorption is improved, but device complexity increases
Solution Approach 1:
The flexible support layer serves multiple functions: it provides mechanical support to prevent cracking, acts as an adhesive layer to bond the solar cell to the reflective layer, and maintains flexibility for wrapping. The reflective layer simultaneously reflects infrared radiation to reduce heat accumulation and reflects visible light back through the solar cell to increase efficiency. This multi-functionality reduces the need for additional separate components.
3Strength
If flexible support layer is added to improve structural integrity, then strength is improved, but weight increases
Solution Approach 1:
The patent uses thin film materials, specifically a flexible support layer made of polyimide or similar material with thickness in the range of micrometers to tens of micrometers. This thin film provides the necessary mechanical strength and flexibility while adding minimal weight. The flexible support layer is thin enough to allow the solar cell to be wrapped around drums with 10-inch diameters while providing sufficient support to prevent cracks during handling and launch.
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 improved structural integrity and efficiency by preventing damage during handling and increasing radiation absorption, while maintaining flexibility and optical transparency, thus enhancing the performance of thin, flexible solar cells.
Implementation Method 1
a reflective layer disposed proximate the back surface
Implementation Method 2
the polyimide having at least 90 percent optical transparency at a wavelength of greater than 900 nanometers
Data Source
AI summary
A solar cell structure including a solar cell having a front surface and a back surface, a reflective layer disposed proximate the back surface and a flexible support layer disposed between the back surface and the reflective layer.