Solar Cell Corner Interconnects for Automated Array Assembly
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Solution Overview
Problem
The manual assembly of long, variable, and fragile solar cell strings for spaceflight-capable solar cell panel assemblies has hindered automation and customization in solar cell array fabrication.
Innovation Solution
The approach involves attaching solar cells individually to a substrate, aligning corner regions of adjacent cells to expose substrate areas, and making electrical connections using corner conductors embedded in the substrate, allowing for automated manufacturing and customization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If solar cells are assembled into long linear strings with manual construction, then the solar cell array can be customized to fit panel dimensions, but the assembly process becomes difficult and prevents automation
Solution Approach 1:
The solar cell array is segmented into modular CIC units, each comprising a solar cell with integrated interconnects and coverglass. These standardized modules can be systematically arranged to form custom panel layouts while enabling automated assembly through consistent interface designs
Solution Approach 2:
Interconnect structures serve as intermediaries between adjacent CIC units, providing standardized electrical and mechanical coupling. These interconnects enable automated joining processes while maintaining the ability to configure arrays in custom patterns by varying the arrangement of modular units
2Adaptability or versatility
If solar cells are assembled into long variable-length strings, then the array can accommodate different power needs, but the fragile materials become difficult to assemble
Solution Approach 1:
The array is divided into discrete CIC modules of standardized length, which can be combined in varying numbers to achieve different total lengths and power outputs. This segmentation reduces handling complexity compared to assembling single long strings of fragile cells
Solution Approach 2:
The coverglass and interconnect structures provide protective cushioning for the fragile solar cells during assembly and operation. The interconnects act as protective elements that shield cell edges while enabling mechanical coupling, reducing damage risk during manufacturing
3Reliability
If CIC units are arranged in linear strings with parallel interconnects, then electrical connections are established, but the fabrication process becomes highly manual and customized for each panel
Solution Approach 1:
The CIC module design creates universal, standardized units with consistent electrical and mechanical interfaces. This universality allows the same fabrication processes to be applied across different panel configurations, enabling automation while maintaining reliable electrical connections through standardized interconnect geometries
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 simplifies manufacturing, enables automation, reduces costs and delivery times, and allows for customized solar cell array designs with improved power generation efficiency.
Implementation Method 1
solar cell array comprised of solar cells
Data Source
Figure 1
Figure 2
Figure 3A~3B
AI summary
A solar cell for a solar cell array with one or more grid on a surface thereof, wherein electrical connections are made to the grids in a plurality of locations positioned around the solar cell; and the electrical connections extend to one or more conductors located under the solar cell. The conductors located under the solar cell are buried within a substrate, and each of the conductors comprises a low resistance conducting path that distributes current from the solar cell. The conductors are loops, U-shaped, or have only up or down pathways. The solar cell comprises a full cell that has four cropped corners and the locations are in the cropped corners.