Flexible Solar Panel Module with Conductive Adhesive Assembly
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Solution Overview
Problem
Solar array manufacturers face challenges in achieving maximum power output per unit surface area and manufacturing cost efficiencies, particularly in aeronautical and space applications where size, weight, and extreme temperature conditions are critical.
Innovation Solution
A solar panel module design featuring a flexible circuit board with a matrix of surface-mounted solar cells, conductive adhesive for electrical connections, and bypass diodes, integrated with a support panel and coverglass, allowing for robotic assembly and efficient manufacturing processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If conventional rigid solar panel designs are used, then structural stability is maintained, but weight and size restrictions are not optimized for aeronautical and space applications
Solution Approach 1:
The patent employs a flexible circuit board as the substrate for mounting solar cells, replacing traditional rigid panels. This flexible substrate significantly reduces weight while maintaining structural integrity through its bonding to a support panel, directly addressing the weight versus strength contradiction in aeronautical and space applications.
Solution Approach 2:
The solar panel assembly combines multiple materials including flexible circuit board, rigid support panel, coverglass, and adhesive layers to create a composite structure. This composite approach optimizes the weight-strength balance by distributing structural loads across different material properties.
2Productivity
If manual assembly processes are used, then flexibility in assembly is maintained, but manufacturing efficiency and cost are reduced
Solution Approach 1:
The solar panel is designed as a modular assembly with distinct components (flexible circuit board, solar cells, bypass diodes, coverglass) that can be independently manufactured and then systematically assembled. This segmentation enables automated robotic assembly while maintaining design flexibility.
Solution Approach 2:
The flexible circuit board serves as an intermediary substrate that simplifies assembly by providing pre-defined mounting locations and electrical connection points. This intermediary structure enables automated placement of solar cells and bypass diodes, increasing manufacturing efficiency without excessive complexity.
3Manufacturing precision
If non-uniform adhesive application is used, then assembly flexibility is maintained, but manufacturing precision and consistency are reduced
Solution Approach 1:
The flexible circuit board is prepared in advance with precisely positioned conductive adhesive pads before solar cell assembly. This preliminary action ensures uniform adhesive distribution and precise positioning, enabling both manufacturing precision and ease of assembly through automated processes.
Solution Approach 2:
The conductive adhesive pads are designed to self-align with solar cell contact points during assembly, eliminating the need for complex alignment mechanisms. This self-service feature maintains manufacturing precision while simplifying the assembly process for automated systems.
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 design enhances manufacturing efficiencies, reduces costs, and improves performance by enabling automated robotic assembly and uniform adhesive application, suitable for demanding aeronautical and space applications.
Implementation Method 1
conductive adhesive may adhere each of the solar cells to the flex circuit at the electrical connection pads
Implementation Method 2
conductive adhesive may adhere each of the solar cells to the flex circuit
Implementation Method 3
A solar panel module has a flexible circuit board, a matrix of solar cells surface mounted thereto
Data Source
AI summary
A solar panel module has a flexible circuit board, a matrix of solar cells surface mounted thereto, a coverglass extending over the matrix of solar cells and the flexible circuit board bonded to a rigid support panel. The circuitry including electrical connection pads in an arrangement on the first side surface for electrical connection of the circuitry to each of the matrix of solar cells, flat bypass diodes may be disposed on the first side surface under the cells and connecting to the circuitry. Conductive adhesives adhering each of the solar cells to the flex circuit at the electrical connection pads that correlate to electrical connection points on underside of each solar cells. The first side having a plurality of standoffs for receiving each of the matrix of solar cells providing raised levels for the solar cells, the landing portions projecting outwardly from a base level surface.