Layered Bus Bar Solar Cell Module for Stress Reduction
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Solution Overview
Problem
Traditional flexible solar panels face stress-induced cracking and solar cell failures during handling and deployment, and the harnessing system increases panel size and stress concentrations, necessitating research for improved solar cell modules with enhanced durability and reduced size.
Innovation Solution
A solar cell module with a layered substrate structure, including a base layer of carbon-filled polyimide, insulation layers, and bus bar layers for electrical interconnection, which is flexible, thin, and designed to minimize thermal expansion mismatches and provide atomic oxygen protection, allowing for modular repair and reduced overall size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If harnessing is extended along the outer edges of the solar panel to collect electrical energy, then electrical energy collection is achieved, but the overall size of the solar panel increases and stress concentrations are created during deployment and thermal cycling
Solution Approach 1:
The bus bar structure transitions from a two-dimensional planar arrangement to a three-dimensional layered configuration. Multiple bus bar layers are stacked vertically with insulating layers between them, allowing electrical connections to be made without extending the horizontal footprint of the panel. This vertical stacking enables energy collection while maintaining a compact panel size.
Solution Approach 2:
The substrate incorporates a porous or cellular foam structure that provides mechanical support and stress distribution throughout the panel. This foam core allows the panel to flex and expand during deployment without creating concentrated stress points, while still maintaining structural integrity for electrical connections.
2Use of energy by moving object
If harnessing is extended along the outer edges of the solar panel to collect electrical energy, then electrical energy collection is achieved, but stress concentrations are created on the solar panel during deployment and eclipse thermal cycling
Solution Approach 1:
The foam core structure acts as a stress-distributing framework that counteracts concentrated loads. The cellular structure of the foam provides numerous pathways for stress distribution, preventing any single point from bearing excessive mechanical or thermal stress during deployment and thermal cycling.
Solution Approach 2:
The layered bus bar structure with insulating layers provides flexibility and movement capability. The design allows the electrical connections to accommodate thermal expansion and contraction during eclipse cycles without creating rigid stress concentrations, enabling the system to dynamically adapt to changing thermal conditions.
3Ease of repair
If large solar panels are constructed from multiple solar cell modules to enable repairability, then repair or rework can be performed on affected modules, but the device complexity and manufacturing difficulty increase
Solution Approach 1:
The solar panel is divided into discrete solar cell modules that can be independently replaced. Each module is a self-contained unit with its own electrical connections to the bus bar system, allowing damaged modules to be identified and replaced without affecting the entire panel. This segmentation enables targeted repair while maintaining overall system functionality.
Solution Approach 2:
The bus bar layers serve multiple functions: they provide electrical connections for current collection, structural support for the solar cells, and a framework for modular assembly. The standardized bus bar design can accommodate different module configurations, making the system versatile and simplifying manufacturing despite the modular complexity.
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 enhances the durability and flexibility of solar cell modules, enabling easier repair and reduced maintenance costs, while minimizing size and stress concentrations, thus improving the performance and reliability of solar panels in space applications.
Implementation Method 1
a base layer comprising carbon-filled polyimide (could be any material that is highly emissive and/or electrically conductive and/or atomic oxygen protective)
Implementation Method 2
a base layer comprising carbon-filled polyimide (could be any material that is highly emissive and/or electrically conductive and/or atomic oxygen protective)
Implementation Method 3
a first insulation layer positioned over the base layer, a second insulation layer positioned over the first insulation layer
Data Source
AI summary
A solar cell module including a substrate and solar cells mounted on the substrate, the substrate including a base layer, a first insulation layer positioned over the base layer, a second insulation layer positioned over the first insulation layer and defining a surface, a first bus bar layer positioned between the first and second insulation layers, the first bus bar layer including at least one bus bar extending across the substrate, and a second bus bar layer positioned over the second insulation layer, the second bus bar layer including bus bars, wherein the solar cells are mounted on the surface and are electrically interconnected by the bus bars of the second bus bar layer.