Single-Sheet Foldout Solar Array With Embedded Flex Wiring
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Solution Overview
Problem
Existing solar array designs for spacecraft are labor-intensive and mechanically complex, with wiring that is prone to damage during folding and unfolding, particularly in smaller satellites and larger arrays.
Innovation Solution
A single sheet foldout solar array using a flex circuit with embedded wiring, allowing solar cells to be connected in series and folded between panels, reducing manufacturing and testing labor, and ensuring the wiring can withstand deployment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional wiring methods are used to connect solar cells across panels, then electrical connections can be established, but the wiring is prone to damage during folding and unfolding operations
Solution Approach 1:
The patent merges the wiring with the panel structure by embedding conductive traces directly into the panel substrate. This integration eliminates separate wiring components that are prone to damage during folding operations, while maintaining electrical connectivity across panel boundaries through the unified structure.
Solution Approach 2:
The patent employs flexible printed circuit boards (FPCBs) with thin film conductive traces to connect solar cells across panels. These thin film structures can withstand repeated folding and unfolding operations without damage, replacing traditional rigid wiring while maintaining electrical connectivity.
2Adaptability or versatility
If mechanical hinges are used to connect multiple solar panels, then the array can be folded for storage and deployed for power generation, but extensive labor is required for design, manufacturing, and testing
Solution Approach 1:
The patent combines multiple panels into a single integrated foldout structure with embedded wiring, eliminating the need for separate mechanical hinge assemblies. This integration reduces manufacturing steps and testing requirements while preserving the foldable configuration capability for storage and deployment.
Solution Approach 2:
The patent segments the solar array into foldable panels that can be independently manufactured and then integrated. Each panel contains pre-configured wiring and solar cells, allowing modular assembly that reduces overall manufacturing labor compared to traditional custom-built hinge systems.
3Power
If traditional panel configurations are used, then solar cells can be arranged in arrays, but the wiring requires extensive manual design, manufacturing, and testing
Solution Approach 1:
The patent changes the manufacturing parameters by using automated printed circuit board fabrication techniques to create conductive traces and wiring structures. This replaces manual wiring processes with automated printing and lamination, significantly improving manufacturing efficiency while maintaining the solar cell array configuration for power generation.
Solution Approach 2:
The patent replaces manual mechanical wiring processes with automated printed circuit board fabrication. The wiring is created through automated deposition and lamination processes rather than manual wire routing and connection, dramatically reducing manufacturing labor and testing requirements while preserving electrical connectivity for power generation.
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
Simplifies the design, manufacturing, and testing of solar arrays by embedding wiring in a flexible substrate, enhancing durability and reducing complexity and weight.
Implementation Method 1
each panel is populated with multiple solar cells to produce electric power
Data Source
Figure 1
Figure 2A~2E
Figure 3
AI summary
One or more solar cells are connected to a flex circuit, wherein: the flex circuit is single sheet; the flex circuit is comprised of a flexible substrate having one or more conducting layers for making electrical connections to the solar cells; and the flex circuit includes one or more flat sections where the solar cells are attached to the flex circuit that remain flat when the flex circuit is folded and one or more folding sections between the flat sections where the flex circuit is folded.