Modular Photovoltaic Blanket Assembly for Space Solar Arrays
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Solution Overview
Problem
Current flexible blanket solar array technologies for spacecraft are not modular, leading to high production costs, labor-intensive construction, and limited reconfigurability, with issues such as mechanical loading stress on solar cells and circuits, thermal mismatches, and contamination from exposed adhesives, which affect reliability and longevity.
Innovation Solution
The Integrated Modular Blanket Assembly (IMBA) uses standard power modules (SPMs) with a discrete tension load-bearing backplane and low-profile fasteners for attachment, allowing for rapid assembly and disassembly, and includes a compliant interleave material for shock absorption and grouting for arc mitigation, reducing mechanical and thermal stress on solar cells and circuits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If flexible blanket solar arrays use continuous area laminated construction with glass reinforcement core, then structural strength and stiffness are provided, but mass is significantly increased
Solution Approach 1:
The solar array is divided into discrete modular panels that can be independently attached to the flexible blanket substrate. Each panel is a separate unit with its own structural support, allowing the blanket itself to be lighter without bearing the full structural load. This segmentation enables using lighter materials for the blanket while maintaining overall structural integrity through the distributed panel architecture.
2Ease of operation
If solar cells and electrical interconnects are in tension during deployment, then mechanical loading is accommodated, but reliability decreases due to stress on delicate components
Solution Approach 1:
The electrical interconnects and solar cells are extracted from the primary mechanical load path. The blanket and deployment structure handle all mechanical tension and deployment forces, while the electrical components are protected within panel assemblies that isolate them from mechanical stress. This separation allows the electrical system to operate reliably without being subjected to deployment tensions.
Solution Approach 2:
The panel assemblies serve as protective enclosures that cushion and protect the delicate solar cells and electrical interconnects from mechanical loads before they can cause damage. The rigid or semi-rigid panel structures absorb and distribute mechanical stresses, preventing direct transmission of forces to the sensitive electrical components during deployment and operation.
3Productivity
If standard power modules are used with discrete fasteners for modular construction, then production time and labor are reduced, but mechanical attachment complexity increases
Solution Approach 1:
The fastening mechanism is localized to specific attachment points at the panel corners or edges, rather than requiring continuous fastening across the entire panel surface. This localized approach uses simple discrete fasteners only where structurally necessary, maintaining ease of assembly while providing adequate mechanical attachment. The rest of the panel interface can be simpler, reducing overall complexity.
4Power
If solar array systems use optimized structures and photovoltaic blanket subsystems, then specific power increases beyond 100 W/kg, but manufacturing precision requirements increase
Solution Approach 1:
The modular panel design segments the solar array into standardized units with built-in alignment features and tolerance compensation mechanisms. Each panel is manufactured to standard specifications rather than custom dimensions, allowing for easier quality control and assembly. The modular nature enables precision to be achieved through repetition of standardized components rather than requiring high precision in every unique dimension.
Solution Approach 2:
The system uses adjustable and compensable parameters in the attachment mechanism, such as flexible mounting options or tolerance ranges in fastener positioning, that allow assembly within broader tolerance bands. This enables high specific power performance to be achieved without requiring extremely tight manufacturing precision, as the system can accommodate variations through design flexibility rather than demanding perfect precision.
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 significantly reduces production time, enhances reliability, and achieves affordability, modularity, and adaptability, with improved thermal stability and high voltage operability, while minimizing mechanical and thermal loading on solar cells and circuits, thus extending their lifespan.
Implementation Method 1
an open pattern of compliant, formable interleave material on the backside partially covering the blanket assembly backside for absorption of mechanical shock
Implementation Method 2
grouting for arc mitigation
Implementation Method 3
photovoltaic solar cells to collect solar radiation and convert it into the electrical power necessary to operate the spacecraft
Data Source
AI summary
A modular, lightweight, high-survivable, photovoltaic flexible blanket assembly for a space solar array is disclosed. The modular blanket is an accordion foldable or rollable flexible photovoltaic solar panel blanket assembly comprising a plurality of common photovoltaic modules spaced in an orthogonal pattern. Each module is mechanically attached with multiple low profile fasteners on their backside to an open weave mesh tensioned backplane structure. The backplane forms a tensioned dimensionally stable planar surface in the deployed configuration onto which the modules are suspended. Each module is common and comprised of a rectangular substrate that includes solar cell assemblies, circuitry, exposed electrical contacts for integration of blanket-level harnessing, and frontside and rearside shielding and coatings as required for the mission application. The blanket assembly may be dispersed with an open pattern of compliant and formable material on the backside to provide insulation against the vigorous vibration of the launch environment.