Solar Cell Assembly on Airfoils via Concave Fixture
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Solution Overview
Problem
There is a need for improved methods of manufacturing and assembling photovoltaic solar arrays that can reduce costs and increase performance, particularly for aerospace applications where a highly smooth surface is required to achieve laminar flow, such as on an aircraft wing.
Innovation Solution
A method involving an assembly fixture with a smooth concave surface, using ethylene tetrafluoroethylene (ETFE) film and a non-crosslinked silicone pressure-sensitive adhesive to mount and bond III-V compound semiconductor multijunction solar cells, along with a composite material support, to create a compact and efficient solar cell panel.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional solar cells are mounted on support structures with multiple components and fasteners, then structural strength is improved, but surface smoothness deteriorates
Solution Approach 1:
The patent combines multiple separate components (solar cells, support structures, fasteners, adhesives) into a single integrated thin-film assembly. The solar cells are directly deposited onto the support substrate as a unified structure, eliminating the need for separate mounting hardware and fasteners, thereby achieving both structural integrity and surface smoothness
Solution Approach 2:
The patent employs thin-film technology where solar cells are deposited as flexible films onto a support substrate. This thin-film approach creates a smooth, continuous surface that conforms to the airfoil contour without the protrusions and irregularities caused by conventional rigid mounting structures and fasteners
2Reliability
If multiple separate components and fasteners are used to mount solar cells, then structural reliability is improved, but assembly complexity increases
Solution Approach 1:
The patent merges multiple assembly steps and components into a single integrated process. Solar cells are directly deposited onto the support substrate in one continuous operation, eliminating the need for separate mounting, fastening, and sealing steps required by conventional approaches
Solution Approach 2:
The support substrate is pre-coated with adhesive material before solar cell deposition. This preliminary action ensures that solar cells are immediately secured upon contact with the substrate, eliminating the need for separate fastening and sealing operations that would increase assembly complexity
3Strength
If conventional mounting methods with multiple components are used, then structural strength is improved, but manufacturing cost increases
Solution Approach 1:
The patent combines multiple manufacturing processes (solar cell fabrication, adhesive application, mounting, sealing) into a single integrated thin-film deposition process. This consolidation reduces the number of manufacturing steps, material handling operations, and quality control checkpoints, thereby lowering manufacturing costs while maintaining structural strength
Solution Approach 2:
The thin-film approach enables simplified manufacturing processes with fewer materials and less labor. The flexible nature of thin-film solar cells allows for direct deposition and conformal mounting without requiring complex structural supports or extensive assembly operations
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 method results in a cost-effective and high-performance solar cell panel with a smooth outer surface, reducing assembly complexity and enhancing energy conversion efficiency, suitable for aerospace applications.
Implementation Method 1
applying an adhesive film to a fixture of support, positioning a solar cell assembly over the adhesive film, applying pressure to adhere the assembly to the support
Data Source
AI summary
A method of fabricating an airfoil, and the airfoil or airfoil skin so fabricated, including a solar cell array arranged on the surface of the airfoil by providing and utilizing an assembly fixture having a smooth, concave surface. An uncured supporting film composed of a composite material (such as a carbon fiber composite) is mounted directly on the back side of the solar cells; and the film of composite material is co-cured on the assembly fixture so that the array of interconnected solar cells is bonded to the supporting film. The bonded and cured film of composite material and an array of interconnected solar cells is then removed from the assembly fixture.