Solar Cell Power Routing Module for Flexible Array Assembly
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Solution Overview
Problem
The manual and labor-intensive process of assembling long, variable-length solar cell strings for spaceflight applications hinders automation and customization in solar cell array manufacturing, necessitating a more efficient method for electrical connections and layout optimization.
Innovation Solution
A new approach where solar cells are individually attached to a substrate with corner conductors forming electrical connections, allowing for a two-dimensional grid layout and the use of a power routing module to customize and automate the assembly process, enabling flexible and efficient power routing within the array.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If long, variable-length solar cell strings are assembled manually, then customization and flexibility in array layout are achieved, but manufacturing complexity and labor intensity increase significantly
Solution Approach 1:
The solar cell array is divided into modular CIC units (cell, interconnect, and coverglass assemblies) that can be independently manufactured and then systematically assembled. This segmentation allows standardization of components while maintaining flexibility in overall array configuration, resolving the contradiction between customization and manufacturing complexity.
Solution Approach 2:
A substrate is introduced as an intermediary element that receives and organizes the CIC units in predetermined patterns. This substrate acts as a mediator between individual solar cells and the final array structure, enabling automated placement while accommodating various custom layouts through different substrate designs.
2Adaptability or versatility
If manual assembly of solar cell strings is used, then flexible customization is possible, but productivity and manufacturing efficiency decrease
Solution Approach 1:
CIC units are pre-assembled and pre-configured with interconnects and coverglass before being placed on the substrate. This preliminary preparation of modular units enables faster, more systematic assembly on the substrate, increasing productivity while maintaining layout flexibility through different pre-configured unit designs.
Solution Approach 2:
The invention changes the fundamental parameter of assembly organization from continuous manual stringing to discrete modular unit placement. This parameter change enables automated handling and placement mechanisms, significantly increasing manufacturing throughput while allowing customization through variation in unit configurations and substrate patterns.
3Power
If customized layouts are created for each satellite mission, then optimal power generation is achieved, but manufacturing time and cost increase
Solution Approach 1:
The substrate and CIC unit designs are created to serve multiple functions and configurations. A single substrate design can accommodate different array layouts by varying the placement pattern of identical CIC units, enabling power optimization for different satellite missions without requiring custom manufacturing for each application, thus reducing fabrication time and cost.
Data Source
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Figure 3A~3B
AI summary
A power routing module for electrically interconnecting solar cells in an array, wherein the power routing module includes: an electrically conductive layer for electrically interconnecting the solar cells; and an insulation layer for electrically insulating the electrically conductive layer. At least one of the solar cells has at least one cropped corner that defines a corner region. An area of a substrate in the corner region remains exposed when the solar cells are attached to the substrate, and the power routing module is attached to the substrate in the area of the substrate in the corner region that remains exposed.