Nested Solar Panel Frames for Cooling and Low-Mass Stowage
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Solution Overview
Problem
Existing solar array designs for spacecraft face challenges in simplifying attachment to rigid panels while maintaining thermal conductivity and avoiding trapped air that can cause delamination in vacuum environments.
Innovation Solution
The 'flex on frame' concept involves solar panels with a flexible substrate and solar cells attached to a support frame with a central cutout for heat dissipation. This design allows for nesting of frames in a stacked configuration, enhancing rigidity during launch and reducing weight and thermal complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a large area adhesive bond is used to attach the thin substrate with solar cells to the rigid panel, then thermal contact to the radiating surface is ensured, but the mass of material increases which is undesirable for space applications
Solution Approach 1:
The adhesive bond is segmented into discrete thermal contact features (protrusions or recesses) rather than a continuous large-area bond. This segmentation maintains necessary thermal pathways from solar cells to the radiating surface while significantly reducing the total volume and mass of adhesive material required.
Solution Approach 2:
Thermal conductivity is concentrated at specific local regions where thermal contact features are positioned between the solar cell substrate and the rigid panel. These localized high-conductivity pathways provide efficient heat transfer without requiring broad-area adhesive coverage, thus reducing overall adhesive mass.
2Area of stationary object
If two flat surfaces of the substrate and rigid panel are attached together, then bonding area is maximized, but trapped air causes delamination or blowout in vacuum environment
Solution Approach 1:
Air is extracted or removed from the bonding interface by creating non-planar thermal contact features (protrusions or recesses) that eliminate flat surface contact. This prevents trapped air pockets that would cause delamination in vacuum, while the features are designed to maintain adequate bonding area through controlled contact regions.
Solution Approach 2:
Instead of creating flat surfaces that trap air, the design inverts the approach by creating deliberately non-flat thermal contact features. The protrusions or recesses ensure air is excluded from the bonding interface, and the features are configured so that the bonding occurs at the edges or surfaces of these features rather than across flat faces.
3Strength
If solar cells are built up into a solar array with rigid panels, then structural strength and rigidity are improved, but thermal conductivity path becomes more complex
Solution Approach 1:
The thermal contact features are nested within or integrated into the rigid panel structure itself. The protrusions or recesses are formed as part of the panel's construction, allowing thermal pathways to be embedded within the panel thickness rather than requiring external attachments or complex multi-layer assemblies.
Solution Approach 2:
The thermal contact features serve multiple functions simultaneously: they provide thermal conduction pathways, maintain structural rigidity of the panel, and enable mechanical attachment of the solar cell substrate. This multi-functionality reduces overall system complexity by consolidating thermal and structural roles into single integrated features.
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 'flex on frame' concept simplifies manufacturing and attachment, reduces weight, and enhances thermal dissipation while maintaining structural integrity and stability, making it suitable for space applications.
Implementation Method 1
exposing a back side of the substrate and the solar cells for transferring or radiating heat directly through the cutout or opening of the frame
Data Source
Figure 1
Figure 2A~2B
Figure 2C
AI summary
At least first and second solar panels are provided, wherein: each of the first and second solar panels is comprised of a substrate having one or more solar cells bonded thereto, and a frame for supporting the substrate and the solar cells; the frame has a cutout or opening in a center of the frame under the solar cells and, when deployed, the cutout or opening enables cooling of the solar cells through the substrate by exposing a back side of the substrate for transferring or radiating heat directly through the cutout or opening of the frame; and the frame of the first solar panel is configured to be nested inside the cutout or opening of the frame of the second solar panel when the first and second solar panels are stowed in a stacked configuration.