Flexible Satellite Solar Module PCB Layout Without Wire Harnesses
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Solution Overview
Problem
Existing solar generators for satellites face challenges with bulky wire harnesses, erosion of electrically conductive traces due to space conditions, and lack of modularity, which affects reliability and adjustability to meet satellite power needs.
Innovation Solution
A flexible solar generator design featuring a common protective layer for photovoltaic cells and conductive traces, integrated into a printed circuit board with serial and parallel connections, allowing for adjustable design and enhanced protection against space radiation and ions, using a foldable substrate with deployment plates for configuration changes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If wire harnesses are used to connect photovoltaic cells, then high power levels can be delivered to the satellite, but the wire harnesses become bulky and increase device complexity
Solution Approach 1:
The patent replaces the mechanical wire harness system with an electrical trace system integrated into the flexible substrate. The conductive traces are printed or etched directly onto the flexible substrate, eliminating the need for separate wire harnesses while maintaining high power delivery capability. This substitution reduces device complexity and bulkiness.
Solution Approach 2:
The patent merges the electrical connection function with the structural substrate by integrating conductive traces directly into the flexible substrate. This consolidation combines multiple functions (structural support and electrical connection) into a single component, reducing overall device complexity while maintaining power delivery capability.
2Device complexity
If electrically conductive traces are placed on the surface of the flexible substrate, then device complexity is reduced, but the traces are exposed to atomic oxygen and ions causing erosion
Solution Approach 1:
The patent uses a multi-layer composite structure where the flexible substrate consists of multiple layers including protective layers that shield the conductive traces from atomic oxygen and ion erosion. The composite structure combines materials with different properties: conductive layers for electrical connection and protective layers for erosion resistance, maintaining both simplicity and reliability.
Solution Approach 2:
The patent applies protective coatings or layers to the flexible substrate before deploying the conductive traces, or integrates protective layers that precede the traces in the structural hierarchy. This beforehand protection shields the traces from erosion by atomic oxygen and ions before damage can occur.
3Reliability
If a common protective layer covers both photovoltaic cells and conductive traces, then protection against space radiation and ions is improved, but manufacturing precision requirements increase
Solution Approach 1:
The patent segments the protective function into multiple specialized layers rather than relying on a single common protective layer. Each layer provides specific protection (e.g., one layer for radiation, another for ion erosion) and can be optimized independently, reducing the overall manufacturing precision requirements while maintaining comprehensive protection.
Solution Approach 2:
The patent modifies material parameters such as flexibility, thickness, and composition of protective layers to accommodate the flexible substrate's deformation characteristics. By adjusting these parameters, the system maintains effective protection against space radiation while accommodating manufacturing tolerances and substrate flexibility.
4Ease of manufacture
If the solar generator design is fixed with traces created in the flexible substrate, then manufacturing is simplified, but the design cannot be easily adjusted to meet varying satellite power needs
Solution Approach 1:
The patent implements a modular design where the flexible substrate with conductive traces can be dynamically reconfigured or replaced to meet different power requirements. The system allows for adjustable configurations through modular photovoltaic cell arrays that can be arranged in different series/parallel configurations, providing adaptability while maintaining manufacturing simplicity through standardized components.
Solution Approach 2:
The patent creates a universal flexible substrate platform with standardized conductive trace patterns that can support multiple photovoltaic cell configurations. This universal base design maintains manufacturing simplicity while enabling adaptability through different cell arrangements and connection configurations to meet varying satellite power needs.
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 provides improved protection, increased nominal operating voltage, reduced structure weight, and simplified manufacturing, enabling flexible and adjustable solar generators that can efficiently meet varying satellite power requirements.
Implementation Method 1
comprising a printed circuit board, comprising at least one substrate made of an electrically insulating material, and electrically conductive traces arranged on at least one face of the substrate... at least two chains of photovoltaic cells attached to the face of the printed circuit board
Data Source
AI summary
A photovoltaic module for a satellite solar generator, and a flexible satellite solar generator are disclosed including a module having a printed circuit board comprising a substrate made of an insulating material and conductive traces, at least two chains of photovoltaic cells mounted on the face of the substrate supporting the electrically conductive traces and which are connected to the traces such that the traces establish an electrical connection between the chains of cells, and a protective layer that is optically transparent within a range of wavelengths corresponding to the cells' range of photovoltaic conversion, the layer being attached to the printed circuit board so as to cover at least all of the photovoltaic cells and all of the electrically conductive traces of the printed circuit board.