Flex-Circuit Solar Cell Array for Custom Output Voltage
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Solution Overview
Problem
Conventional solar cell arrays for space missions are inflexible and require extensive design, manufacturing, and testing to meet varying output voltage requirements, leading to long delivery times and loss of power, which undermines cost and schedule advantages.
Innovation Solution
A solar cell array with a pre-fabricated flex circuit substrate that includes insulating and conductive layers for customizable electrical connections, allowing for the removal or addition of conductive elements at decision points to tailor circuit lengths and output voltages quickly, reducing manufacturing complexity and time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional solar cell arrays are built with a fixed number of solar cells to meet power system requirements, then the output voltage can be maintained, but the design, manufacturing, and testing time increases significantly when missions vary
Solution Approach 1:
The solar cell array is divided into multiple strings of solar cells, where each string can be independently configured. The substrate includes multiple conductive layers patterned as conductors that can be selectively connected or disconnected to create different circuit configurations. This segmentation allows the same physical array to be customized for different output voltages by changing which strings are active and how they are connected, without requiring complete redesign and remanufacturing for each mission.
Solution Approach 2:
The patent introduces decision points in the conductive paths that allow the electrical circuit configuration to be dynamically changed after manufacturing. By removing or adding electrical continuity at these decision points, the circuit length and output voltage can be tailored to match specific mission requirements. This dynamic reconfigurability eliminates the need for fixed manufacturing configurations for each mission variant.
2Manufacturing precision
If solar cell arrays are customized for each mission, then the output voltage meets requirements, but extensive design and manufacturing complexity increases
Solution Approach 1:
The substrate is designed with a universal structure that includes multiple conductive layers, insulating layers, and decision points that can serve multiple mission configurations. The same substrate can be used to create arrays with different output voltages by simply changing the connectivity at the decision points, rather than manufacturing entirely different arrays for each voltage requirement. This multi-functionality reduces design and manufacturing complexity while maintaining precision.
Solution Approach 2:
The conductive layers and insulating layers are pre-fabricated on the substrate with all necessary conductors and decision points included before the solar cells are attached. This preliminary preparation of the electrical circuit structure allows for rapid customization by simply modifying connections at pre-established decision points, rather than performing complex design and manufacturing operations after assembly.
3Power
If the number of solar cells is increased to meet higher voltage requirements, then the output voltage increases, but the array size and weight increase
Solution Approach 1:
Instead of increasing voltage by adding more solar cells in series (one-dimensional increase), the patent uses multi-layer conductive structures (adding spatial dimensions) to reconfigure existing cells into different series/parallel combinations. The conductive layers are patterned to create multiple possible current paths, allowing the same physical cells to produce different output voltages by changing the electrical connectivity topology rather than adding more cells.
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
Enables rapid customization of solar cell arrays to achieve a variety of output voltages, significantly reducing delivery times from months to days, while maintaining performance and flexibility to meet diverse mission requirements.
Implementation Method 1
A solar cell array with pre-fabricated flex circuit custom voltage... solar cells that are attached to a substrate... generating electrical connections... customizing circuits of the solar cells to a desired dimension of the solar cells and a desired output voltage
Data Source
Figure 1A
Figure 1B
Figure 1C
AI summary
A solar cell array comprised of one or more solar cells attached to a substrate, such as a pre-fabricated flex circuit, wherein: the substrate includes one or more insulating layers and one or more conductive layers patterned as one or more conductors for making electrical connections with the solar cells; and the substrate includes one or more decision points for removing or adding electrical continuity to the conductors, for customizing circuits of the solar cells to a desired dimension of the solar cells and a desired output voltage. (Fig. 4B)