Solar Array Frame Cutout for Direct Cell Cooling
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Solution Overview
Problem
The challenge in designing solar arrays for spacecraft is to simplify the attachment of flexible solar cell substrates to rigid panels while ensuring effective thermal conductivity and avoiding the use of large area adhesives and trapped air, which are problematic in vacuum environments.
Innovation Solution
The 'flex on frame' concept involves attaching a flexible substrate with solar cells to a rigid support frame that has a cutout or opening under the solar cells, allowing direct heat radiation through the substrate and separating thermal and mechanical roles, thus eliminating the need for thick rigid panels and multifunctional adhesives.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a large area adhesive bond is used to attach the substrate to the rigid panel, then thermal contact is ensured, but the mass of material increases and trapped air causes delamination in vacuum
Solution Approach 1:
The patent divides the attachment area into discrete attachment points or regions along the perimeter edges rather than using a continuous large-area adhesive bond. This segmentation reduces the total amount of adhesive material needed while maintaining adequate thermal contact pathways from the solar cells to the rigid panel through the substrate edges.
Solution Approach 2:
The patent extracts or removes the problematic trapped air from the attachment system by using a perimeter attachment scheme that allows the substrate to be bonded only at its edges to the rigid panel. This eliminates the large volumes of trapped air between the substrate and panel that would cause delamination in vacuum, while still providing sufficient thermal conduction paths through the substrate material itself.
2Ease of manufacture
If a thin substrate is used to achieve low cost manufacturing, then manufacturing cost decreases, but the substrate lacks rigidity and requires attachment to a rigid panel
Solution Approach 1:
The patent merges the thin flexible substrate (which provides low-cost manufacturing and good thermal conductivity) with a rigid panel frame structure (which provides mechanical strength and rigidity). The combination allows the thin substrate to maintain its advantages while the rigid frame compensates for the lack of substrate rigidity, enabling the assembly to function as a structurally sound solar array support.
Solution Approach 2:
The patent applies rigidity locally at the perimeter edges where the substrate attaches to the rigid panel, rather than requiring the entire substrate to be rigid. The thin substrate maintains its flexibility and thermal properties in the central area where solar cells are mounted, while the edge regions provide structural attachment points to the rigid frame, creating a optimized distribution of mechanical properties.
3Weight of stationary object
If the substrate is attached at the perimeter edges only, then mass is reduced and thermal efficiency is enhanced, but the attachment process must be simplified
Solution Approach 1:
The patent segments the attachment process into perimeter-edge operations only, concentrating all bonding activities along the edges of the substrate rather than requiring full-surface adhesive application. This segmentation simplifies the manufacturing process by reducing the complexity of adhesive distribution, air bubble removal, and pressure application, while achieving the dual benefits of reduced mass and maintained thermal efficiency through edge-proximity attachment to the rigid panel.
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 the attachment process, reduces mass, and enhances thermal efficiency by allowing direct heat radiation, while providing mechanical support and preventing delamination, thus making it suitable for space applications.
Implementation Method 1
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
Implementation Method 2
transferring or radiating heat directly through the cutout or opening of the frame
Data Source
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.