JP3840963B2 - Solar array panel and manufacturing method thereof - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a solar array panel for supplying electric power to a space structure such as an artificial satellite or a space station, and a method for manufacturing the same.
[0002]
[Prior art]
FIG. 8 is a diagram showing an artificial satellite, 8 is a solar array panel, 9 is a satellite structure, and 10 is an antenna reflector.
An artificial satellite is composed of a structure such as a solar array panel 8, a satellite structure 9, and an antenna reflector 10, and solar cells are frequently used to supply electric power to space structures such as artificial satellites and space stations. .
[0003]
The space structure requires a large number of solar cells, and in order to hold these solar cells, a flat sandwich panel is used, and the solar cells are arranged on the surface thereof. As the skin material of this sandwich panel, carbon fiber reinforced plastic (hereinafter referred to as CFRP) is frequently used in order to increase the specific elastic modulus and specific strength.
[0004]
FIG. 9 is a sectional view showing a conventional solar array, and FIG. 10 is a perspective view showing the conventional solar array. In the figure, 1 is a sandwich panel, 1a is a sandwich panel skin, 1b is a sandwich panel core, 3 is an insulator film layer, and 4 is a solar cell.
[0005]
The insulator layer is attached to the skin of the sandwich panel. In order to reduce the weight of the space structure, a polyimide film having a thickness ranging from 12 μm to 100 μm is used for the insulator film layer.
[0006]
[Problems to be solved by the invention]
The solar array panel with the above structure has a thin insulating film layer and CFRP, which is an electrical conductor directly below it. There was a problem that electric discharge occurred and the generated power decreased.
[0007]
In order to prevent holes from being formed in the insulator film layer, it is conceivable to increase the thickness of the insulator film layer, but this is not practical because it leads to an increase in the mass of the solar array panel.
[0008]
The present invention has been made to solve such a problem, and an object of the present invention is to provide a solar array panel that has significantly higher insulation than the conventional one.
[0009]
[Means for Solving the Problems]
A solar array panel according to a first invention is a solar array panel used in outer space, a sandwich panel that is an electrical conductor, and an insulating layer that is installed on one side of the sandwich panel and has a space made of an insulating core. An insulator film layer that is attached to a surface of the insulator layer having the space opposite to the sandwich panel, and a solar battery cell bonded to the insulator film layer, the insulator having the space. The insulating core of the layer is formed of an aramid paper honeycomb core, and a slit is provided on a side wall of the honeycomb core .
[0010]
According to a second aspect of the present invention, there is provided a solar array panel manufacturing method according to the first aspect, wherein the solar cell is attached to the insulator film layer on a surface plate, and the sandwich panel. A second step of bonding the insulator layer having the space to the upper surface of the solar cell, and bonding the solar battery cell pasted in the first step on the insulator layer having the space bonded in the second step. And a third step of manufacturing.
[0011]
According to a third aspect of the present invention, there is provided a solar array panel manufacturing method comprising: the solar cell panel according to claim 1, wherein the solar cell attached to the upper surface of the insulating layer having the space with the insulating film layer interposed therebetween; It manufactures by the 1st process to join, and the 2nd process of joining the insulator layer joined by the said 1st process on the said sandwich panel.
[0014]
DETAILED DESCRIPTION OF THE INVENTION
Embodiment 1 FIG.
1 and 3 are both cross-sectional views showing Embodiment 1 of the present invention, FIG. 2 is a perspective view showing Embodiment 1 of the present invention, 2 is an insulator layer having a space, and 5 is a spherical space. Insulator layers 1, 1 a, 1 b, 3, and 4 are the same as those in FIGS. 9 and 10 of the prior art.
[0015]
By providing an insulating layer including a space between the insulating film layer 3 having a thickness of 12 μm to 100 μm and the skin of the sandwich panel 1 used in the conventional solar array panel, electric conduction with the solar cell 4 is achieved. The distance of the skin material of the sandwich panel 1 which is a body increases, and higher insulation is ensured than the conventional one.
[0016]
Further, since the insulator layer includes a space, an increase in mass can be made small. Further, in the conventional solar array panel, when a small hole is generated in the insulator film layer 3 due to foreign matter or the like in the manufacturing process, a polyimide tape with an adhesive is attached to the hole portion to ensure insulation. However, in the present invention, even if a hole is formed in the insulator film layer 3, the insulation of the solar battery cell 4 is not lost because there is the insulator layer 2 having a space between the skins 1a of the sandwich panel.
[0017]
1 and 2, an insulating layer 2 having a space is provided between the sandwich panel 1 and the insulating film layer 3. As a result, the distance between the solar battery cell 4 and the sandwich panel 1 which is an electric conductor is larger than that of the conventional solar array panel 8, so that a short circuit is formed between the solar battery cell 4 and the skin 1a of the sandwich panel. Is suppressed.
[0018]
Moreover, even if a small hole is formed in the insulator film layer 3 in the manufacturing process, the insulation of the solar battery cell 4 is not lost because there is the insulator layer 2 having a space between the skins 1a of the sandwich panel.
[0019]
Further, in FIG. 3, an insulator layer 5 including a spherical space is used instead of the insulator layer 2 having a space, and a short circuit is formed between the solar battery cell 4 and the skin 1a of the sandwich panel. Is suppressed. In outer space using the solar array panel 8, the insulator layer 2 having a space and the insulator layer 5 including a spherical space have the same function.
[0020]
The material of the insulator layer 2 having a space needs to be a material made of an insulating material and having a space inside, for example, an aramid paper honeycomb core.
In the perspective view of FIG. 2, the case where a honeycomb core is used as the material of the insulating layer 2 having a space is schematically shown.
[0021]
When used in outer space, it is desirable to secure an exhaust path such as by providing a slit in the side wall of the honeycomb core so that the honeycomb core of the aramid paper can discharge the air inside because the outside is in a vacuum state.
[0022]
Other materials include honeycomb cores made of fiber reinforced composite materials. In this case, generally, the fibers constituting the composite material are in the form of a woven fabric, and since there are holes between the woven tows, the air inside can be exhausted through these holes. There is no need to intentionally produce an exhaust passage such as a slit like a paper honeycomb core.
[0023]
Examples of the insulator layer 5 including a spherical space include a foaming adhesive and a thermosetting plastic in which hollow beads are placed.
Since the function of the insulator layer 5 including a spherical space is the same as that of the material of the insulator layer 2 having a space, in the following description, the material of the insulator layer 2 having a space is the insulator layer 5 including a spherical space. Shall also be included.
[0024]
According to the above, by providing an insulating layer including a space between the insulating film layer and the skin of the sandwich panel, the distance between the solar cell and the skin material of the sandwich panel, which is an electrical conductor, is increased. Ensure higher insulation than the ones.
[0025]
Embodiment 2. FIG.
FIG. 4 is a cross-sectional view showing a second embodiment of the present invention. 1, 1a, 1b, 3, 4 are the same as those of FIGS. 9 and 10 of the prior art, and 2, 5 are those of the first embodiment. It is the same as the explanation.
[0026]
FIG. 4 shows a manufacturing method according to the first invention. An insulator layer having a space generated in the solar array panel according to the first invention by joining the solar battery cell 4 and the insulator film layer 3 in advance. When the solar cell 4 is bonded and attached with the unevenness 2, the solar cell 4 can be prevented from being damaged.
[0027]
In the solar array panel according to the first aspect of the present invention, when a material having irregularities such as a honeycomb core is used for the insulating layer 2 having a space, and the solar battery cell 4 is attached and attached, the insulating layer having a space The insulating film layer 3 also has an uneven shape due to the unevenness of 2, and there is concern about the occurrence of breakage in the attachment of the solar battery cell 4, but the insulating film layer 3 is previously placed on a smooth table, etc. By bonding the battery cell 4, the solar battery cell 4 is not damaged.
[0028]
Then, when attaching what adhered the photovoltaic cell 4 and the insulator film layer 3 to what joined the insulator panel 2 which has the sandwich panel 1 and the space, the insulator film layer 3 has flexibility, so that the sun The battery cell 4 can be attached with a pressure that is weaker than the adhesion of the battery cell 4, and in this case, the solar battery cell 4 is not damaged.
[0029]
According to the above, the solar cell and the insulator film layer are bonded in advance, so that the insulator layer 2 having a space, which is generated in the solar array panel according to the first invention, has unevenness and is attached to the solar cell. In this case, damage to the solar battery cell can be eliminated.
[0030]
Embodiment 3 FIG.
FIG. 5 is a cross-sectional view showing a third embodiment of the present invention. 1, 1a, 1b, 3, 4 are the same as those in FIGS. 9 and 10 of the prior art, and 2, 5 are those of the first embodiment. It is the same as the explanation.
[0031]
FIG. 5 shows the manufacturing method of the first invention. The solar battery cell produced in the solar array panel by previously joining the solar battery cell 4, the insulator film layer 3, and the insulator layer 2 having a space. In the attachment of 4, the insulation layer 2 having a space can be prevented from being crushed.
[0032]
In the solar array panel according to the first invention, it is considered that when the solar battery cell 4 is attached, the unevenness of the sandwich panel also causes the insulating film layer 3 to be uneven via the insulating layer 2 having a space. There is a concern about the damage of the solar battery cell 4 due to the non-uniform pressure.
[0033]
Moreover, when the bulk density of the insulator layer 2 having a space is as small as 50 kg / m ³ or less, if the insulator layer 2 having a space is uneven when the solar battery cell 4 is attached, the pressure at the time of bonding becomes uniform. There is also concern about the destruction of the insulating layer 2 having a space.
[0034]
The solar cell 4 is not damaged by placing the insulator film layer 3 and the insulating layer 2 having a space on a smooth table and bonding the solar cell 4 in advance.
[0035]
Moreover, the unevenness | corrugation of the insulator layer 2 which has space is lose | eliminated, the pressure at the time of joining becomes uniform, and the failure | damage of the insulator layer 2 which has space does not arise.
Furthermore, this manufacturing method is effective when it is desired to make the weight lighter than that of the method of Embodiment 4 and to facilitate the handling of the parts to which the solar cells 4 are joined.
[0036]
In the manufacturing method according to FIG. 4, the second moment of section of the joined parts is larger than that of the second embodiment and is difficult to bend, so that the handling becomes easy.
[0037]
According to the above, the insulation having a space in the attachment of the solar battery cell generated in the solar array panel according to the first invention by joining the solar battery cell, the insulator film layer, and the insulator layer having a space in advance. The collapse of the body layer can be eliminated.
[0038]
Embodiment 4 FIG.
FIG. 6 is a cross-sectional view showing Embodiment 4 of the present invention, 6 is a film layer, 1, 1a, 1b, 3, 4 are the same as those in FIGS. 9 and 10 of the prior art, Reference numeral 5 is the same as that described in the first embodiment.
[0039]
FIG. 6 shows the manufacturing method of the first invention. In the solar array panel, the solar battery cell, the insulating film layer, and the insulating layer having a space are joined in the shape of a sandwich panel in advance. In the solar array panel according to the first aspect of the present invention, it is possible to eliminate the collapse of the insulating layer having a space in the installation of the solar battery cells.
[0040]
In the method according to the second embodiment or the third embodiment, a part to which the solar battery cell 4 has been joined in advance is bent during handling, and the solar battery cell 4 is damaged particularly when the thickness of the solar battery cell 4 is as thin as 200 μm or less. Is predicted.
[0041]
In the manufacturing method in FIG. 5, the insulating layer 2 having a space in advance has a sandwich structure of the insulating film layer 3 and the film layer 6, so that the portion where the solar cells 4 are joined is the second embodiment or the embodiment. 3 has a cross-sectional second moment larger than that according to 3, the solar battery cell 4 becomes difficult to bend, and damage can be reduced.
[0042]
According to the above, the attachment of the solar battery cell which occurs in the solar array panel according to the first invention by joining the solar battery cell, the insulator film layer and the insulator layer having a space in the shape of the sandwich panel in advance. It is possible to eliminate the collapse of the insulating layer having a space.
[0043]
Embodiment 5 FIG.
FIG. 7 is a sectional view showing Embodiment 5 of the present invention, and 7 is an insulator layer in which space is formed after reaching outer space.
[0044]
FIG. 7 shows the manufacturing method of the first invention. Since the insulator layer expands in outer space, the occupied volume inside the rocket during launch can be reduced. The size of the space structure is limited by the internal shape of the rocket, but by reducing the launch volume, the thickness of the solar array panel can be made larger than the conventional one without being limited by the internal shape of the rocket. can do.
[0045]
Since the insulator layer 7 in which the space is formed after reaching the outer space expands in the outer space, the volume occupied by the solar array panel can be reduced at the time of launch.
[0046]
The size of the space structure is limited by the internal shape of the rocket, but by reducing the launch volume, the influence of the internal shape of the rocket can be reduced.
The insulator layer 7 in which the space is formed after reaching the outer space includes a method of injecting a gas such as air and nitrogen, a method of mechanically raising the upper part, and foaming adhesive in the outer space. The method of hardening and obtaining space is mentioned.
[0047]
According to the above, since the insulator layer is formed in outer space, the thickness of the solar array panel can be made thinner than the conventional one without being restricted by the internal shape of the rocket by reducing the volume at the time of launch. Can be bigger.
[0048]
【The invention's effect】
As described above, according to the present invention, the distance between the solar cell and the skin material of the sandwich panel, which is an electric conductor, is increased, and higher insulation can be ensured than the conventional one.
[Brief description of the drawings]
FIG. 1 is a cross-sectional view showing a first embodiment.
FIG. 2 is a perspective view showing the first embodiment.
FIG. 3 is a cross-sectional view showing the first embodiment.
4 is a cross-sectional view showing a second embodiment. FIG.
FIG. 5 is a cross-sectional view showing a third embodiment.
FIG. 6 is a cross-sectional view showing a fourth embodiment.
7 is a cross-sectional view showing a fifth embodiment. FIG.
FIG. 8 is a diagram showing the arrangement of solar array panels in an artificial satellite.
FIG. 9 is a cross-sectional view of a conventional solar array panel.
FIG. 10 is a perspective view of a conventional solar array panel.
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 1 Sandwich panel, 2 Insulator layer which has space, 3 Insulator film layer, 4 Solar cell, 5 Insulator layer containing spherical space, 6 Film layer, 7 Insulator layer, 8 Solar array panel, 9 Satellite structure , 10 Antenna reflector

Claims (3)

In solar array panels used in outer space,
A sandwich panel that is an electrical conductor;
An insulator layer installed on one side of the sandwich panel and having a space composed of an insulating core;
An insulator film layer to be affixed to the surface opposite to the sandwich panel of the insulator layer having the space;
Comprising solar cells joined to the insulator film layer,
The solar array panel , wherein the insulating core of the insulating layer having the space is formed of an aramid paper honeycomb core, and a slit is provided on a side wall of the honeycomb core . In the solar array panel according to claim 1 ,
A first step of attaching solar cells to the insulator film layer on a surface plate;
A second step of joining the insulator layer having the space to the upper surface of the sandwich panel;
A third step of joining the solar cells pasted in the first step on the insulator layer having the space joined in the second step;
The manufacturing method of the solar array panel characterized by manufacturing by these. In the solar array panel according to claim 1 ,
A first step of joining the solar cell attached to the upper surface of the insulator layer having the space with the insulator film layer interposed therebetween;
A second step of bonding the insulator layer bonded in the first step on the sandwich panel;
The manufacturing method of the solar array panel characterized by manufacturing by these.

Images