Solar Panel Array with Hinged PCB Interconnects

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Solution Overview

Problem

Conventional methods for interconnecting solar cells and panels in solar panel arrays often require additional real estate for wiring and cabling, which can hinder the efficient use of space and reduce the coverage area for solar cells, particularly in applications like spacecraft and solar vehicles.

Innovation Solution

The use of elongate printed circuit boards (PCBs) with hinge assemblies, including hinge bodies, springs, and backing plates, allows for electrical interconnection of solar panels in a fanfold arrangement, eliminating the need for physical connections like wiring and cabling by using PCB traces and springs to pass electric current between panels.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If wiring and cabling are used to interconnect solar cells and panels, then electrical interconnection is achieved, but real estate for solar cell coverage is reduced

Engineering Contradiction:

Improveelectrical interconnectionVSAvoidreal estate for solar cell coverage

Core Design Contradiction:

ReliabilityVSArea of stationary object

Solution Approach 1:

The patent merges the electrical interconnection function with the mechanical support structure by integrating conductive traces directly into the PCB substrate. This eliminates the need for separate wiring and cabling, as the PCB itself serves as both the structural support and the electrical connection medium, thereby preserving real estate for solar cell coverage.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent extracts the electrical interconnection function from the mechanical support structure by using the PCB as the intermediary. The conductive traces are embedded within the PCB layers, separating the electrical connection path from the physical wiring that would otherwise occupy space on the panel surface.

Inventive Principle:

Principle #2Taking out (Extraction)

2Reliability

If wiring and cabling are used for interconnection, then electrical connections are established, but the arrangement of solar cells is hindered

Engineering Contradiction:

Improveelectrical connectionVSAvoidarrangement of solar cells

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The patent combines the electrical interconnection function with the mechanical support structure by integrating conductive traces directly into the PCB substrate. This eliminates the need for separate wiring and cabling, as the PCB itself serves as both the structural support and the electrical connection medium, thereby preserving real estate for solar cell coverage.

Inventive Principle:

Principle #5Merging (Combining)

3Ease of manufacture

If conventional interconnection methods are used, then solar panels can be assembled, but bulky wiring and cabling are required

Engineering Contradiction:

Improveassembly of solar panelsVSAvoidwiring and cabling

Core Design Contradiction:

Ease of manufactureVSVolume of moving object

Solution Approach 1:

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent replaces the mechanical wiring and cabling system with an integrated PCB trace system. The electrical connections are established through conductive pathways embedded within the PCB layers, eliminating the need for external wires and cables that would increase the overall volume of the assembly.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 solution optimizes available real estate for solar cell coverage while maintaining efficient power delivery, as the panels can be folded and unfolded, reducing the need for bulky wiring and cabling, and enhancing the energy collection efficiency of solar vehicles.

Implementation Method 1

each hinge assembly including two or more hinge bodies, two backing plates, one spring, and one hinge pin

Methodology Applied

Scientific EffectElasticity: Elasticity

Implementation Method 2

PCB supporting a number of individual solar cells linearly mounted thereon and electrically connected in series

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Data Source

PatentUS9882330B2Solar panel array

Publication Date: 2018.01.30 KALMAN ANDREW E

AI summary

A solar panel array includes a number of elongate printed circuit boards (PCBs), each PCB supporting a number of individual solar cells linearly mounted thereon and electrically connected in series to form a solar panel, and a number of hinge assemblies, each hinge assembly including two or more hinge bodies, two backing plates, one spring, and one hinge pin, the hinge assemblies mounted between adjacent solar panels using conventional hardware in a manner connecting them together such that they may be folded over one another in a fanfold arrangement or deployed out to one hundred and eighty degrees.