Strain Isolation Layer Assembly for Buckle-Free Solar Mounting
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Solution Overview
Problem
Existing methods for mounting photovoltaic solar cells or solar panels on structures, such as aircraft or UAVs, face challenges due to strain limitations, thermal expansion issues, and buckling or wrinkling, leading to reduced efficiency and increased costs and complexity.
Innovation Solution
A strain isolation layer assembly with a discontinuous configuration, vertical rigidity, and horizontal shear flexibility is introduced, which is coupled between the rigid solar layer and the underlying substrate to isolate strains, reducing mechanical and thermal stresses and preventing buckling or wrinkling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If photovoltaic solar cells are directly connected to the vehicle structure, then the solar cells can be securely mounted, but the solar cells are forced to approximate the same strain levels as the aircraft structure, resulting in cessation of proper function
Solution Approach 1:
A strain isolation layer is introduced as an intermediary component between the solar cell array and the aircraft wing structure. This layer has high vertical rigidity to support the solar cells while exhibiting horizontal shear flexibility to isolate strains from the wing structure, preventing strain transmission to the solar cells and maintaining their functional reliability
Solution Approach 2:
The strain isolation layer is designed with specific mechanical property parameters: high vertical rigidity (high modulus in the vertical direction) to provide structural support, and low horizontal shear modulus (high shear flexibility) to allow strain isolation. This parameter differentiation enables the layer to simultaneously support the solar cells and protect them from structural strains
2Ease of manufacture
If thin solar cells are curved to follow the wing upper surface airfoil, then they can be mounted on the aircraft surface, but they may buckle when subjected to compressive strains even at very low strain levels, disrupting laminar flow or damaging the solar cells
Solution Approach 1:
The strain isolation layer functions as a flexible intermediate film that can accommodate the curved geometry of the wing surface while providing strain isolation. Its horizontal shear flexibility allows it to conform to the airfoil shape without transmitting compressive strains that would cause buckling of the thin solar cells
Solution Approach 2:
The strain isolation layer provides beforehand cushioning by absorbing and isolating compressive strains before they can reach the solar cells. This protective function prevents buckling and wrinkling of the thin solar cells under compressive loads, maintaining their structural stability
3Adaptability or versatility
If gaps are provided between photovoltaic solar cells to accommodate strains, then strain accommodation is improved, but the gaps and connections between solar cells disrupt laminar flow
Solution Approach 1:
The strain isolation layer serves as a mediator that accommodates strains horizontally through its shear flexibility while providing a continuous, smooth surface that does not disrupt laminar flow. This eliminates the need for gaps between solar cells, as the isolation layer itself absorbs the strain accommodation function
4Ease of operation
If individual photovoltaic solar cells are mounted with adhesive or double-sided adhesive tape, then the solar cells can be connected to the wing surface, but the cost and complexity of mounting numerous individual solar cells increases due to increased time, labor and complexity
Solution Approach 1:
Multiple individual solar cells are merged into a single solar cell array that is mounted as one unit on the wing surface. The strain isolation layer is positioned between the entire array and the wing, allowing the array to be installed as a single component rather than mounting each cell individually, thereby reducing mounting time, labor, and complexity
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 solution effectively reduces strains on solar panels, prevents buckling and wrinkling, and simplifies the assembly process, resulting in improved efficiency and reduced weight and cost, while maintaining aerodynamic smoothness and structural integrity.
Implementation Method 1
The strain isolation layer has a discontinuous configuration, a vertical rigidity, and a horizontal shear flexibility
Implementation Method 2
The strain isolation layer has a discontinuous configuration, a vertical rigidity, and a horizontal shear flexibility
Implementation Method 3
thermal strains may be induced on photovoltaic solar cells or solar arrays if they are bonded or attached to materials with different coefficients of thermal expansion (CTEs) when the temperature changes
Data Source
AI summary
In an embodiment of the disclosure, there is provided a strain isolation layer assembly. The assembly has a rigid solar layer; a strain isolation layer having a discontinuous configuration, a vertical rigidity, and a horizontal shear flexibility; and an underlying substrate layer. The strain isolation layer is coupled between the rigid solar layer and the underlying substrate layer to form a strain isolation layer assembly, such that the strain isolation layer isolates the rigid solar layer to reduce one or more strains induced on the rigid solar layer.