Spring-Loaded Solar Array Connector for Thermal Cycling
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Solution Overview
Problem
The reliability of electrical connections in solar arrays is compromised due to cyclic stresses caused by thermal changes, leading to fatigue crack propagation and joint failure, which reduces system efficiency and requires complex bonding and welding of dissimilar materials.
Innovation Solution
An electro-mechanical connector system with conductive housings and springs allows for flexible motion and thermal expansion of solar cells without inducing stress, maintaining electrical contact through a compliant mechanical and electrical interface, enabling individual cell replacement and tailored contact forces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If rigid bonding and welding are used to connect solar cells, then electrical connection is established, but cyclic thermal stresses cause fatigue crack propagation and joint failure
Solution Approach 1:
The patent applies dynamics by replacing rigid bonding with a compliant mechanical connector system that includes springs and movable housing sections. This allows the connector to dynamically adapt to thermal expansion and contraction of solar cells, absorbing cyclic stresses without causing fatigue cracks. The movable parts enable the system to accommodate dimensional changes while maintaining reliable electrical connection.
Solution Approach 2:
The patent changes the mechanical parameters of the connection system by introducing elastic springs with specific force constants and designing housing sections with controlled mobility. These parameter changes allow the connector to maintain optimal contact force across temperature cycles, preventing both excessive stress (which causes cracking) and insufficient contact (which causes connection failure).
2Reliability
If dissimilar materials are bonded together, then electrical connection is achieved, but the bonding process creates weakened areas susceptible to fatigue
Solution Approach 1:
The patent introduces an intermediary mechanical connector system that couples the solar cell to the support structure without direct bonding or welding of dissimilar materials. The connector acts as a mediator, providing both mechanical support and electrical conductivity through conductive housing sections and contact elements, thereby eliminating the need for complex bonding processes while maintaining reliable electrical connection.
Solution Approach 2:
The patent replaces the chemical bonding and welding processes with a purely mechanical connection system. The connector uses mechanical elements such as springs, housing sections, and contact elements to achieve both mechanical support and electrical connection, eliminating the need for thermal processing and reducing manufacturing complexity associated with bonding dissimilar materials.
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 connector system enhances the longevity of solar cells by reducing stress-induced failures, allowing for efficient energy transfer and easy maintenance by enabling relative motion between cells while maintaining constant electrical connection under thermal cycling and vibrations.
Implementation Method 1
springs, both being electrically conductive, will provide a constant electrical connection as well as mechanical connection under thermal cycling, vibration, and small motions between connecting parts
Implementation Method 2
The housings and springs, both being electrically conductive, will provide a constant electrical connection
Data Source
AI summary
A connector assembly is provided for connecting two planar surfaces or structures together to permit electrical transmission between the two. As described, the connector have at least two housing sections having grooves formed therein for receiving springs, such as canted coil springs. The springs are configured to provide constant mechanical and electrical connection between multiple parts and allow for small motions between such parts. By allowing for movement of the connected parts, adequate connection during thermal changes and/or vibrations is maintained. This is possible due to the spring contact interface between the connector assembly and the connecting parts, which allows relative movement between the springs and the connecting parts.