Perimeter-Mounted Solar Array Frame for Direct Cell Cooling
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Solution Overview
Problem
Existing solar array designs face challenges in attaching flexible substrates with solar cells to rigid panels for space applications, requiring large area adhesive bonds that are heavy and prone to delamination in vacuum environments, while also needing efficient heat radiation and mechanical support.
Innovation Solution
A 'flex on frame' concept where solar cells are bonded to a flexible substrate attached to a rigid frame with a cutout or opening, allowing direct heat radiation through the substrate and separating thermal and mechanical roles, using simple mechanical fasteners instead of adhesives and incorporating reinforcing materials for added stiffness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a large area adhesive bond is used to attach the flexible substrate with solar cells to the rigid panel, then thermal contact to the radiating surface is ensured, but the mass of the assembly increases significantly
Solution Approach 1:
The patent divides the attachment system into discrete segments: flexible substrate with solar cells, rigid panel with radiating surface, and localized adhesive bonds at perimeter regions. This segmentation allows thermal contact to be achieved through distributed perimeter bonds rather than a continuous large-area adhesive layer, reducing overall adhesive mass while maintaining thermal pathways from solar cells to radiating surface
Solution Approach 2:
The patent transitions from a two-dimensional large-area adhesive bond to a one-dimensional perimeter-based attachment system. By concentrating adhesive bonds along the perimeter edges rather than distributing them across the entire substrate area, the solution reduces adhesive mass while maintaining structural integrity and thermal contact through the substrate's inherent flexibility and the panel's radiating surface geometry
2Strength
If a large area adhesive bond is used to attach the flexible substrate with solar cells to the rigid panel, then structural attachment is achieved, but delamination occurs in vacuum environment
Solution Approach 1:
The patent extracts the adhesive bonding function from the entire substrate area and concentrates it only at the perimeter regions. This extraction eliminates the trapped air pockets that would form under a large-area adhesive bond, preventing delamination and blowout in vacuum environment while maintaining sufficient attachment strength through the perimeter bonds and the substrate's flexibility
Solution Approach 2:
The patent effectively creates a porous or open structure by leaving the center region unbonded, allowing the flexible substrate to conform to the rigid panel without trapped air. This open configuration eliminates the vacuum environment problems associated with sealed adhesive bonds while maintaining structural integrity through perimeter attachment points
3Ease of manufacture
If a thin flexible substrate is used for low cost manufacturing, then manufacturing cost is reduced, but the substrate lacks rigidity for structural support
Solution Approach 1:
The patent merges the functions of the flexible substrate and rigid panel into a hybrid assembly. The thin flexible substrate provides solar cell support and thermal conduction, while the rigid panel with radiating surface provides structural strength and rigidity. This merging allows the system to achieve both low-cost manufacturing through the thin substrate and structural integrity through the rigid panel attachment
Solution Approach 2:
The flexible substrate serves multiple functions: supporting solar cells, conducting heat to the radiating surface, and providing a lightweight, low-cost structure. The rigid panel simultaneously provides structural strength, rigidity, and a radiating surface for thermal management. This multi-functionality allows each component to be optimized for its specific role while contributing to overall system performance
4Strength
If a rigid panel is used for structural strength, then rigidity and frequency response are improved, but the attachment process becomes complex requiring large area adhesive bond
Solution Approach 1:
The patent segments the attachment process to focus bonding efforts only at the perimeter regions rather than requiring uniform coverage across the entire substrate area. This segmentation simplifies the attachment process for rigid panel construction while maintaining the structural integrity and rigidity needed for the application
Solution Approach 2:
The patent uses the flexible substrate as a thin film that naturally conforms to the rigid panel surface, eliminating the need for complex bonding processes. The flexibility of the substrate allows it to adapt to the rigid panel's geometry, simplifying attachment while maintaining the rigidity and frequency response characteristics of the rigid panel structure
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 configuration simplifies attachment, reduces mass, prevents delamination, and enhances thermal efficiency by allowing direct heat transfer from solar cells, while providing mechanical support and reducing the need for multifunctional adhesives, thus improving the design and manufacturing of solar arrays for space applications.
Implementation Method 1
the solar cells need to maintain high thermal conductivity to a radiating surface
Implementation Method 2
the frame has a cutout or opening under the solar cells, and the cutout or opening enables direct cooling of the solar cells through the substrate by 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
A solar array including at least one solar panel comprised of a substrate having one or more solar cells bonded thereto, and a frame for supporting the substrate and the solar cells, wherein the substrate is attached to the frame at a perimeter of the frame along one or more edges of the substrate, the frame has a cutout or opening in a center of the frame under the solar cells, and the cutout or opening enables direct 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.