Solar Cell Array Substrate Layout for Reworkable Corner Interconnects
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Solution Overview
Problem
The manual assembly of long, variable-length solar cell strings in solar cell arrays for spaceflight applications hinders automation and customization, leading to high manufacturing costs and delivery times.
Innovation Solution
A substrate-based design where solar cells are attached individually with corner conductors on the substrate, allowing for automated manufacturing and customization of solar cell arrays by making electrical connections between cells in corner regions, enabling flexible layout and rework/repair capabilities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If solar cells are assembled into long linear strings manually, then customization of array layout is achieved, but manufacturing complexity and time increase significantly
Solution Approach 1:
The solar array is segmented into modular CIC units, each comprising a solar cell with front and back interconnects. These standardized modules can be assembled in different configurations to create custom array layouts, enabling adaptability while maintaining manufacturing simplicity through repetition of the same basic unit.
Solution Approach 2:
The CIC module design serves multiple functions: it provides structural support, electrical connection (both front and back contacts), and defines the basic geometric unit for array assembly. This multi-functionality reduces the number of separate components needed and simplifies the overall manufacturing process.
2Adaptability or versatility
If solar cells are assembled into long linear strings manually, then variable length strings are created, but automation of assembly is prevented
Solution Approach 1:
The array design allows dynamic configuration by varying the number of CIC modules connected in series. Standardized interconnects enable automated assembly processes to quickly connect modules in different quantities and arrangements, achieving variable length strings through programmable assembly rather than manual customization.
3Productivity
If highly customized layout of CICs and strings is used to fill panel space, then maximum power generation is achieved, but fabrication process becomes highly manual
Solution Approach 1:
The CIC modules are pre-assembled with integrated interconnects in a standardized configuration before being deployed into the final array. This preliminary preparation of modular units allows automated assembly lines to efficiently create customized high-density layouts without requiring complex manual fabrication processes during final array assembly.
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 approach simplifies manufacturing, enables automation, reduces costs, and allows for customized solar cell array designs with improved efficiency and flexibility, including efficient rework and repair processes.
Implementation Method 1
a solar cell array (22) comprising a plurality of solar cells (14) individually attached to the substrate (12)
Data Source
Figure 1
Figure 2
Figure 3A~3B
AI summary
A substrate for solar cells is configured such that an area of the substrate remains exposed when at least one solar cell having at least one cropped corner that defines a corner region is attached to the substrate, one or more electrical connections for the solar cell are made in the corner region resulting from the cropped corner of the solar cell, and at least one of the electrical connections, connecting a first interconnect in a first location, is repaired by connecting a second interconnect in a second location in the at least one of the electrical connections different from the first location. (Fig. 16)