Nano-Metal Solar Cell Interconnects for Flexible Array Assembly

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Solution Overview

Problem

The manual and labor-intensive process of assembling long, variable-length solar cell strings for spaceflight-capable solar cell panels hinders automation and customization, particularly in space applications where precise power generation and panel dimensions are critical.

Innovation Solution

A new approach where solar cells are individually attached to a substrate with corner conductors forming electrical connections, allowing for a two-dimensional grid layout and automated manufacturing, enabling customization and efficient power routing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If manual assembly of long solar cell strings is used, then customization of panel dimensions and power generation is achieved, but assembly complexity and labor intensity increase significantly

Engineering Contradiction:

Improvecustomization of panel dimensionsVSAvoidassembly complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The solar cell array is divided into modular CIC units (cell-interconnect-coverglass) that can be independently manufactured and then assembled. Each CIC unit contains pre-assembled solar cells with interconnects, creating standardized modules that simplify the overall assembly process while allowing flexible configuration of different panel dimensions through varying numbers and arrangements of these modular units.

Inventive Principle:

Principle #1Segmentation

2Adaptability or versatility

If manual assembly of long solar cell strings is used, then customization of power generation is achieved, but productivity and delivery time decrease

Engineering Contradiction:

Improvecustomization of power generationVSAvoidassembly productivity

Core Design Contradiction:

Adaptability or versatilityVSProductivity

Solution Approach 1:

Solar cells are pre-assembled into CIC units with interconnects attached before final panel assembly. This preliminary preparation of modular units with integrated electrical connections enables faster final assembly while maintaining the ability to customize power generation by selecting different combinations and configurations of these pre-prepared modular units.

Inventive Principle:

Principle #10Preliminary action

3Productivity

If automated manufacturing is implemented, then productivity increases, but manufacturing precision and reliability of fragile solar cells decrease

Engineering Contradiction:

Improveassembly productivityVSAvoidalignment precision

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The CIC unit structure serves as an intermediary that protects fragile solar cells during automated handling and assembly. The coverglass and interconnect framework provide mechanical support and alignment features that enable automated equipment to manipulate the modules without directly contacting the delicate solar cells, thus maintaining manufacturing precision while enabling automation.

Inventive Principle:

Principle #24Intermediary (Mediator)

4Reliability

If CIC units with metal foil interconnects are used, then electrical connections are established, but assembly difficulty increases due to fragility of long strings

Engineering Contradiction:

Improveelectrical connection reliabilityVSAvoidassembly ease

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

Instead of assembling long continuous strings of solar cells which are fragile and difficult to handle, the system segments the array into smaller CIC units with built-in interconnects. This segmentation creates self-contained modules with pre-established electrical connections, eliminating the need to manually assemble long strings while maintaining reliable electrical connectivity through the modular interface.

Inventive Principle:

Principle #1Segmentation

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 method simplifies the manufacturing process, enables automation, reduces costs, and shortens delivery times while maintaining flexibility in panel dimensions and power generation optimization.

Implementation Method 1

heating the nano-metal material to a melting or solidification temperature forming a heated nano-metal material, to form the electrical connection

Methodology Applied

Scientific EffectMelting: Melting

Implementation Method 2

heating the nano-metal material to a melting or solidification temperature forming a heated nano-metal material

Methodology Applied

Scientific EffectSolidification: Freezing

Data Source

PatentEP3297034B1NANO-metal connections for a solar cell array

Publication Date: 2023.11.22 THE BOEING CO

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Figure 3A~3B

AI summary

An electrical connection is formed between first and second conductive elements, by inserting a nano-metal material between the first and second conductive elements; and heating the nano-metal material to a melting temperature to form the electrical connection between the first and second conductive elements. The nano-metal material may comprise a nano-metal paste or ink comprised of one or more of Gold (Au), Copper (Cu), Silver (Ag), and/or Aluminum (Al) nano-particles that melt or fuse into a solid to form the electrical connection, at a melting temperature of about 150-250 degrees C, and more preferably, about 175-225 degrees C. The electrical connection may be formed between a solar cell and a substrate by creating a via in the solar cell between a front and back side of the solar cell, wherein the via is connected to a contact on the front side of the solar cell and a trace on the substrate.