US20090301544A1 - Method of manufacturing flexible, lightweight photovoltaic array - Google Patents
Method of manufacturing flexible, lightweight photovoltaic array Download PDFInfo
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- US20090301544A1 US20090301544A1 US12/540,685 US54068509A US2009301544A1 US 20090301544 A1 US20090301544 A1 US 20090301544A1 US 54068509 A US54068509 A US 54068509A US 2009301544 A1 US2009301544 A1 US 2009301544A1
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- film substrate
- circuit board
- printed circuit
- polyimide film
- flexible printed
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- 229920001721 polyimide Polymers 0.000 claims abstract description 36
- 238000000034 method Methods 0.000 claims abstract description 16
- 229920002620 polyvinyl fluoride Polymers 0.000 claims abstract description 8
- 239000011248 coating agent Substances 0.000 claims description 11
- 238000000576 coating method Methods 0.000 claims description 11
- 239000000853 adhesive Substances 0.000 claims description 10
- 230000001070 adhesive effect Effects 0.000 claims description 10
- 229920006231 aramid fiber Polymers 0.000 claims description 5
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- 229910000679 solder Inorganic materials 0.000 description 10
- 230000000903 blocking effect Effects 0.000 description 7
- 238000010586 diagram Methods 0.000 description 4
- 229920001296 polysiloxane Polymers 0.000 description 4
- 238000005299 abrasion Methods 0.000 description 3
- 238000003491 array Methods 0.000 description 3
- 239000002918 waste heat Substances 0.000 description 3
- 230000008901 benefit Effects 0.000 description 2
- 239000002184 metal Substances 0.000 description 2
- 238000005476 soldering Methods 0.000 description 2
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Classifications
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L31/00—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
- H01L31/04—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof adapted as photovoltaic [PV] conversion devices
- H01L31/042—PV modules or arrays of single PV cells
- H01L31/05—Electrical interconnection means between PV cells inside the PV module, e.g. series connection of PV cells
- H01L31/0504—Electrical interconnection means between PV cells inside the PV module, e.g. series connection of PV cells specially adapted for series or parallel connection of solar cells in a module
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L31/00—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
- H01L31/04—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof adapted as photovoltaic [PV] conversion devices
- H01L31/042—PV modules or arrays of single PV cells
- H01L31/048—Encapsulation of modules
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L31/00—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
- H01L31/02—Details
- H01L31/02002—Arrangements for conducting electric current to or from the device in operations
- H01L31/02005—Arrangements for conducting electric current to or from the device in operations for device characterised by at least one potential jump barrier or surface barrier
- H01L31/02008—Arrangements for conducting electric current to or from the device in operations for device characterised by at least one potential jump barrier or surface barrier for solar cells or solar cell modules
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L31/00—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
- H01L31/18—Processes or apparatus specially adapted for the manufacture or treatment of these devices or of parts thereof
- H01L31/1876—Particular processes or apparatus for batch treatment of the devices
- H01L31/188—Apparatus specially adapted for automatic interconnection of solar cells in a module
-
- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K1/00—Printed circuits
- H05K1/18—Printed circuits structurally associated with non-printed electric components
- H05K1/189—Printed circuits structurally associated with non-printed electric components characterised by the use of a flexible or folded printed circuit
-
- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K3/00—Apparatus or processes for manufacturing printed circuits
- H05K3/22—Secondary treatment of printed circuits
- H05K3/28—Applying non-metallic protective coatings
- H05K3/281—Applying non-metallic protective coatings by means of a preformed insulating foil
-
- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K3/00—Apparatus or processes for manufacturing printed circuits
- H05K3/30—Assembling printed circuits with electric components, e.g. with resistor
- H05K3/303—Surface mounted components, e.g. affixing before soldering, aligning means, spacing means
- H05K3/305—Affixing by adhesive
-
- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K2201/00—Indexing scheme relating to printed circuits covered by H05K1/00
- H05K2201/01—Dielectrics
- H05K2201/0137—Materials
- H05K2201/015—Fluoropolymer, e.g. polytetrafluoroethylene [PTFE]
-
- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K2201/00—Indexing scheme relating to printed circuits covered by H05K1/00
- H05K2201/01—Dielectrics
- H05K2201/0137—Materials
- H05K2201/0154—Polyimide
-
- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K2201/00—Indexing scheme relating to printed circuits covered by H05K1/00
- H05K2201/10—Details of components or other objects attached to or integrated in a printed circuit board
- H05K2201/10007—Types of components
- H05K2201/10121—Optical component, e.g. opto-electronic component
-
- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K3/00—Apparatus or processes for manufacturing printed circuits
- H05K3/0058—Laminating printed circuit boards onto other substrates, e.g. metallic substrates
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
- Y02E10/00—Energy generation through renewable energy sources
- Y02E10/50—Photovoltaic [PV] energy
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P70/00—Climate change mitigation technologies in the production process for final industrial or consumer products
- Y02P70/50—Manufacturing or production processes characterised by the final manufactured product
Definitions
- the invention relates to photovoltaic arrays. More particularly, the invention relates to flexible, lightweight photovoltaic arrays suitable for mounting directly on a surface of, or being deployed from, a spacecraft or an airplane.
- Photovoltaic cell strings include individual photovoltaic cells connected in series so as to obtain a desired voltage, according to characteristics of the photovoltaic cells. The photovoltaic cell strings are then connected in parallel so as to obtain a desired output capacity or current, thus creating a photovoltaic cell array.
- photovoltaic arrays have been fabricated on a graphite panel.
- this panel is the thickest member of an array of photovoltaic cells and contributes most of the weight to the array. In spacecraft or certain consumer applications, it is desirable to minimize the weight of the photovoltaic array.
- the invention relates to a method of manufacturing a low-cost, flexible, lightweight photovoltaic array.
- the invention relates to a photovoltaic array that includes at least one photovoltaic cell bonded to a flexible printed circuit board.
- the flexible printed circuit board is mounted on a substrate of a polyimide film, such as that sold by E.I. du Pont de Nemours and Company under the trademark KAPTON®, reinforced with aramid fiber such as that sold by E.I. du Pont de Nemours and Company under the trademark KEVLAR®.
- the flexible printed circuit board may then be covered by a substantially transparent abrasion-resistant film (e.g., a polyvinyl fluoride film, such as that sold by E.I. du Pont de Nemours and Company under the trademark TEDLAR®).
- the photovoltaic array is suitable for mounting directly on a surface of, or being deployed from, a spacecraft or an airplane.
- a bladder sleeve is attached to the polyimide film substrate to facilitate inflatable deployment.
- the bladder sleeve preferably is applied prior to covering the polyimide film substrate with the abrasion-resistant transparent film. Additionally, the bladder sleeve may also be used for mechanical boom deployment.
- a substantial reduction in manufacturing costs is achieved by bonding the one or more photovoltaic cells to the printed circuit board using automated assembly equipment such as for example, surface-mount technology placement systems (e.g., pick-and-place machines).
- automated assembly equipment such as for example, surface-mount technology placement systems (e.g., pick-and-place machines).
- one side of the polyimide film substrate, to which the photovoltaic cells are to be applied is coated with an adhesive, while the other side of the polyimide film substrate is coated with a high-emissivity coating (e.g., high-emissivity paint) to facilitate dissipation of waste heat.
- the adhesive preferably is a silicone-based adhesive, such as CV10-2568, available from NuSil Technology, of Carpinteria, Calif.
- FIG. 1 is a diagram illustrating the process of assembling a string carrier, according to an illustrative embodiment of the invention
- FIG. 2 is a diagram illustrating the process of assembling a flexible lightweight photovoltaic array, according to an illustrative embodiment of the invention
- FIG. 3 is a schematic diagram of the flexible lightweight photovoltaic array manufactured according to the process of FIG. 2 ;
- FIG. 4 is a flow chart of a method of manufacturing the flexible lightweight photovoltaic array of FIG. 3 , according to an illustrative embodiment of the invention.
- FIG. 1 shows the assembly of individual photovoltaic cell strings 104 in accordance with an illustrative embodiment of the present invention.
- one or more photovoltaic cells 100 are bonded onto a printed circuit board (PCB) 102 to create a photovoltaic cell string 104 .
- PCB 102 is preferably a flexible PCB, but alternatively may be a rigid PCB.
- Photovoltaic cells 100 preferably are bonded to PCB 102 using automated assembly equipment such as, for example, surface-mount technology placement systems. In one embodiment, photovoltaic cells 100 may be soldered to PCB 102 using pick-and-place machines.
- Photovoltaic cells 100 may soldered to PCB 102 using, for example, wave soldering.
- a solder mask is applied to areas of the photovoltaic cells 100 and the PCB 102 on which solder is not desired.
- Photovoltaic cells 100 are then glued to PCB 102 using pick-and-place machines, and PCB 102 is then run through a wave of molten solder.
- the solder wets metal surfaces not coated with the solder mask to form electrical connections between the photovoltaic cells 100 and the PCB 102 .
- the use of automated assembly equipment reduces labor costs and improves the rate at which photovoltaic cell strings are assembled.
- the photovoltaic cells 100 , within a photovoltaic cell string 104 are wired in series to generate a fixed voltage for each photovoltaic cell string 104 .
- the number of photovoltaic cells 100 in a particular photovoltaic cell string 104 is determined by the voltage requirement of the specific application.
- the return trace is routed on the mounting surface of the PCB 102 .
- PCB 102 is a multi-layer PCB, and the return trace is routed underneath the photovoltaic cell string to reduce the magnetic moment and the associated loop area.
- a multi-layer PCB also allows for proper separation, thus reducing breakdown potential between layers which would result in string loss.
- string blocking diodes are also installed onto PCB 102 using automated assembly equipment. Blocking diodes are used to prevent current from flowing back into one or more photovoltaic cell strings 104 which are not exposed to sunlight (e.g., in shaded areas or at nighttime). Additionally, blocking diodes may be installed between photovoltaic array 200 and the battery (not shown). Once a photovoltaic cell string 104 is assembled, individual photovoltaic cell strings 104 are wired together in parallel to generate the necessary capacity, thus creating a photovoltaic array 200 .
- FIG. 2 shows the assembly of a photovoltaic array 200 in accordance with an illustrative embodiment of the present invention.
- one or more individual photovoltaic cell strings 104 are mounted onto a polyimide film substrate 106 .
- the polyimide film substrate 106 preferably is reinforced with aramid fiber.
- a bladder sleeve 110 may also be mounted onto polyimide film substrate 106 to facilitate inflatable deployment in spacecraft or other applications.
- Photovoltaic cell strings 104 and bladder sleeve 110 are mounted onto polyimide film substrate 106 using, for example, a silicone-based adhesive.
- the adhesive is applied to the front face of polyimide film substrate 106 where photovoltaic cell strings 104 and bladder sleeve 110 are mounted.
- the back side of polyimide film substrate may be coated with a high-emissivity coating (e.g., high-emissivity paint) to facilitate dissipation of waste heat.
- one or more wire harnesses are also mounted on the front face of polyimide film substrate 106 .
- Photovoltaic cell strings 104 may be mounted to polyimide film substrate 106 , the entire assembly including photovoltaic cell strings 104 , film substrate 106 and bladder sleeve 110 , may be covered with a substantially transparent film 108 .
- Film 108 may be, for example, a polyvinyl fluoride film to provide abrasion resistance for photovoltaic cells 102 ( FIG. 1 ).
- FIG. 3 is a schematic diagram of photovoltaic array 200 in accordance with an illustrative embodiment of the present invention.
- Photovoltaic array 200 includes photovoltaic cells 100 bonded onto PCB 102 .
- PCB 102 is mounted onto film substrate 106 , and photovoltaic cells 100 are then covered with film 108 .
- Photovoltaic array 200 is suitable for mounting directly on a surface of, or being deployed from, a spacecraft or an airplane.
- FIG. 4 is a flow chart of a method 300 of manufacturing the flexible lightweight photovoltaic array 200 of FIG. 3 , in accordance with an illustrative embodiment of the present invention.
- one or more photovoltaic cells are bonded to a flexible printed circuit board (PCB) using, for example, automated assembly equipment.
- the photovoltaic cells may be soldered onto the flexible PCB using a pick-and-place machine.
- blocking diodes also may be soldered onto the PCB using a pick-and-place machine.
- Photovoltaic cells (and blocking diodes) are soldered to the PCB using, for example, wave soldering.
- a solder mask is applied to areas of the photovoltaic cells 100 and the PCB 102 on which solder is not desired.
- Photovoltaic cells 100 (and blocking diodes) are then glued to PCB 102 using pick-and-place machines, and PCB 102 is then run through a wave of molten solder. The solder wets metal surfaces not coated with the solder mask to form electrical connections between the photovoltaic cells 100 and the PCB 102 .
- the flexible PCB including photovoltaic cells (and blocking diodes) may then be mounted on a polyimide film substrate (step 304 ).
- the polyimide film substrate may be, for example, a 1 mil sheet of polyimide film reinforced with aramid fibers.
- the flexible PCB preferably is attached to the polyimide film substrate preferably using a silicone-based adhesive.
- one or more wire harnesses and/or one or more inflatable bladder sleeves are also mounted on the polyimide film substrate using a silicone-based adhesive.
- the adhesive is applied to the front face of the polyimide film substrate, on which the flexible PCB, one or more wire harnesses, and/or one or more bladder sleeves are mounted.
- the back side of the polyimide film substrate may be coated with a high-emissivity coating (e.g., high-emissivity paint) to facilitate dissipation of waste heat.
- step 306 the entire assembly including photovoltaic cells bonded to the flexible PCB, which is attached to the film substrate is encapsulated by a substantially transparent film.
- the substantially transparent film may be, for example, a polyvinyl fluoride film.
- the assembled photovoltaic array is suitable for mounting directly on a surface of, or being deployed from, a spacecraft or an airplane.
Abstract
Description
- This is a continuation-in-part of U.S. application Ser. No. 12/471,094 filed May 22, 2009, which claims the benefit of U.S. Provisional Application No. 61/128,510 filed May 22, 2008, and U.S. Provisional Application No. 61/130,148 filed May 27, 2008, the entirety of each of which is incorporated herein by reference.
- The invention relates to photovoltaic arrays. More particularly, the invention relates to flexible, lightweight photovoltaic arrays suitable for mounting directly on a surface of, or being deployed from, a spacecraft or an airplane.
- Photovoltaic cell strings include individual photovoltaic cells connected in series so as to obtain a desired voltage, according to characteristics of the photovoltaic cells. The photovoltaic cell strings are then connected in parallel so as to obtain a desired output capacity or current, thus creating a photovoltaic cell array.
- Traditionally, photovoltaic arrays have been fabricated on a graphite panel. Typically, this panel is the thickest member of an array of photovoltaic cells and contributes most of the weight to the array. In spacecraft or certain consumer applications, it is desirable to minimize the weight of the photovoltaic array.
- Additionally, traditional photovoltaic array manufacturing methods involve extensive manual labor, which gives rise to relatively high manufacturing costs.
- The invention relates to a method of manufacturing a low-cost, flexible, lightweight photovoltaic array.
- According to one aspect, the invention relates to a photovoltaic array that includes at least one photovoltaic cell bonded to a flexible printed circuit board. The flexible printed circuit board is mounted on a substrate of a polyimide film, such as that sold by E.I. du Pont de Nemours and Company under the trademark KAPTON®, reinforced with aramid fiber such as that sold by E.I. du Pont de Nemours and Company under the trademark KEVLAR®. The flexible printed circuit board may then be covered by a substantially transparent abrasion-resistant film (e.g., a polyvinyl fluoride film, such as that sold by E.I. du Pont de Nemours and Company under the trademark TEDLAR®). In one embodiment, the photovoltaic array is suitable for mounting directly on a surface of, or being deployed from, a spacecraft or an airplane.
- In one embodiment, a bladder sleeve is attached to the polyimide film substrate to facilitate inflatable deployment. The bladder sleeve preferably is applied prior to covering the polyimide film substrate with the abrasion-resistant transparent film. Additionally, the bladder sleeve may also be used for mechanical boom deployment.
- In one embodiment, a substantial reduction in manufacturing costs is achieved by bonding the one or more photovoltaic cells to the printed circuit board using automated assembly equipment such as for example, surface-mount technology placement systems (e.g., pick-and-place machines).
- In one embodiment, one side of the polyimide film substrate, to which the photovoltaic cells are to be applied is coated with an adhesive, while the other side of the polyimide film substrate is coated with a high-emissivity coating (e.g., high-emissivity paint) to facilitate dissipation of waste heat. The adhesive preferably is a silicone-based adhesive, such as CV10-2568, available from NuSil Technology, of Carpinteria, Calif.
- The above and other features of the present invention, its nature and various advantages will be more apparent upon consideration of the following detailed description, taken in conjunction with the accompanying drawings, in which like reference characters represent like parts throughout and in which:
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FIG. 1 is a diagram illustrating the process of assembling a string carrier, according to an illustrative embodiment of the invention; -
FIG. 2 is a diagram illustrating the process of assembling a flexible lightweight photovoltaic array, according to an illustrative embodiment of the invention; -
FIG. 3 is a schematic diagram of the flexible lightweight photovoltaic array manufactured according to the process ofFIG. 2 ; and -
FIG. 4 is a flow chart of a method of manufacturing the flexible lightweight photovoltaic array ofFIG. 3 , according to an illustrative embodiment of the invention. - To provide an overall understanding of the invention, certain illustrative embodiments will now be described, including a flexible lightweight photovoltaic array and a method for manufacturing the photovoltaic array. However, it will be understood by one of ordinary skill in the art that the systems and methods described herein may be adapted and modified as is appropriate for the application being addressed and that the systems and methods described herein may be employed in other suitable applications, and that such other additions and modifications will not depart from the scope hereof.
- Individual photovoltaic cells are connected in series so as to obtain a desired voltage, according to characteristics of the photovoltaic cells, to create photovoltaic cell strings. The photovoltaic cell strings are then connected in parallel so as to obtain a desired output capacity, thus creating a photovoltaic cell array.
FIG. 1 shows the assembly of individualphotovoltaic cell strings 104 in accordance with an illustrative embodiment of the present invention. As shown inFIG. 1 , one or morephotovoltaic cells 100 are bonded onto a printed circuit board (PCB) 102 to create aphotovoltaic cell string 104. PCB 102 is preferably a flexible PCB, but alternatively may be a rigid PCB.Photovoltaic cells 100 preferably are bonded to PCB 102 using automated assembly equipment such as, for example, surface-mount technology placement systems. In one embodiment,photovoltaic cells 100 may be soldered to PCB 102 using pick-and-place machines. -
Photovoltaic cells 100 may soldered toPCB 102 using, for example, wave soldering. A solder mask is applied to areas of thephotovoltaic cells 100 and thePCB 102 on which solder is not desired.Photovoltaic cells 100 are then glued toPCB 102 using pick-and-place machines, and PCB 102 is then run through a wave of molten solder. The solder wets metal surfaces not coated with the solder mask to form electrical connections between thephotovoltaic cells 100 and thePCB 102. The use of automated assembly equipment reduces labor costs and improves the rate at which photovoltaic cell strings are assembled. - The
photovoltaic cells 100, within aphotovoltaic cell string 104 are wired in series to generate a fixed voltage for eachphotovoltaic cell string 104. The number ofphotovoltaic cells 100 in a particularphotovoltaic cell string 104 is determined by the voltage requirement of the specific application. Preferably, the return trace is routed on the mounting surface of thePCB 102. In at least one embodiment, PCB 102 is a multi-layer PCB, and the return trace is routed underneath the photovoltaic cell string to reduce the magnetic moment and the associated loop area. A multi-layer PCB also allows for proper separation, thus reducing breakdown potential between layers which would result in string loss. - In at least one embodiment, string blocking diodes (not shown) are also installed onto PCB 102 using automated assembly equipment. Blocking diodes are used to prevent current from flowing back into one or more
photovoltaic cell strings 104 which are not exposed to sunlight (e.g., in shaded areas or at nighttime). Additionally, blocking diodes may be installed betweenphotovoltaic array 200 and the battery (not shown). Once aphotovoltaic cell string 104 is assembled, individualphotovoltaic cell strings 104 are wired together in parallel to generate the necessary capacity, thus creating aphotovoltaic array 200. -
FIG. 2 shows the assembly of aphotovoltaic array 200 in accordance with an illustrative embodiment of the present invention. As shown inFIG. 2 , one or more individualphotovoltaic cell strings 104 are mounted onto apolyimide film substrate 106. Thepolyimide film substrate 106 preferably is reinforced with aramid fiber. In addition tophotovoltaic cell strings 104, abladder sleeve 110 may also be mounted ontopolyimide film substrate 106 to facilitate inflatable deployment in spacecraft or other applications.Photovoltaic cell strings 104 andbladder sleeve 110 are mounted ontopolyimide film substrate 106 using, for example, a silicone-based adhesive. In at least one embodiment, the adhesive is applied to the front face ofpolyimide film substrate 106 wherephotovoltaic cell strings 104 andbladder sleeve 110 are mounted. The back side of polyimide film substrate may be coated with a high-emissivity coating (e.g., high-emissivity paint) to facilitate dissipation of waste heat. In at least one embodiment, one or more wire harnesses (not shown) are also mounted on the front face ofpolyimide film substrate 106. - Once the appropriate number of photovoltaic cell strings 104 are mounted to
polyimide film substrate 106, the entire assembly including photovoltaic cell strings 104,film substrate 106 andbladder sleeve 110, may be covered with a substantiallytransparent film 108.Film 108 may be, for example, a polyvinyl fluoride film to provide abrasion resistance for photovoltaic cells 102 (FIG. 1 ). -
FIG. 3 is a schematic diagram ofphotovoltaic array 200 in accordance with an illustrative embodiment of the present invention.Photovoltaic array 200 includesphotovoltaic cells 100 bonded ontoPCB 102.PCB 102 is mounted ontofilm substrate 106, andphotovoltaic cells 100 are then covered withfilm 108.Photovoltaic array 200 is suitable for mounting directly on a surface of, or being deployed from, a spacecraft or an airplane. -
FIG. 4 is a flow chart of amethod 300 of manufacturing the flexible lightweightphotovoltaic array 200 ofFIG. 3 , in accordance with an illustrative embodiment of the present invention. Instep 302, one or more photovoltaic cells are bonded to a flexible printed circuit board (PCB) using, for example, automated assembly equipment. The photovoltaic cells may be soldered onto the flexible PCB using a pick-and-place machine. In some embodiments, in addition to photovoltaic cells, blocking diodes also may be soldered onto the PCB using a pick-and-place machine. - Photovoltaic cells (and blocking diodes) are soldered to the PCB using, for example, wave soldering. A solder mask is applied to areas of the
photovoltaic cells 100 and thePCB 102 on which solder is not desired. Photovoltaic cells 100 (and blocking diodes) are then glued toPCB 102 using pick-and-place machines, andPCB 102 is then run through a wave of molten solder. The solder wets metal surfaces not coated with the solder mask to form electrical connections between thephotovoltaic cells 100 and thePCB 102. - The flexible PCB including photovoltaic cells (and blocking diodes) may then be mounted on a polyimide film substrate (step 304). The polyimide film substrate may be, for example, a 1 mil sheet of polyimide film reinforced with aramid fibers.
- The flexible PCB preferably is attached to the polyimide film substrate preferably using a silicone-based adhesive. In at least one embodiment, one or more wire harnesses and/or one or more inflatable bladder sleeves are also mounted on the polyimide film substrate using a silicone-based adhesive. The adhesive is applied to the front face of the polyimide film substrate, on which the flexible PCB, one or more wire harnesses, and/or one or more bladder sleeves are mounted. The back side of the polyimide film substrate may be coated with a high-emissivity coating (e.g., high-emissivity paint) to facilitate dissipation of waste heat. In
step 306, the entire assembly including photovoltaic cells bonded to the flexible PCB, which is attached to the film substrate is encapsulated by a substantially transparent film. The substantially transparent film may be, for example, a polyvinyl fluoride film. The assembled photovoltaic array is suitable for mounting directly on a surface of, or being deployed from, a spacecraft or an airplane. - The invention may be embodied in other specific forms without departing from the spirit or essential characteristics thereof. The foregoing embodiments are therefore to be considered in all respects illustrative, rather than limiting of the invention. The present invention is limited only by the claims which follow.
Claims (17)
Priority Applications (2)
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US12/540,685 US20090301544A1 (en) | 2008-05-22 | 2009-08-13 | Method of manufacturing flexible, lightweight photovoltaic array |
US15/076,081 US9960301B2 (en) | 2008-05-22 | 2016-03-21 | Method of manufacturing flexible, lightweight photovoltaic array |
Applications Claiming Priority (4)
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US12851008P | 2008-05-22 | 2008-05-22 | |
US13014808P | 2008-05-27 | 2008-05-27 | |
US12/471,094 US20090292407A1 (en) | 2008-05-22 | 2009-05-22 | Solar-powered aircraft with rotating flight surfaces |
US12/540,685 US20090301544A1 (en) | 2008-05-22 | 2009-08-13 | Method of manufacturing flexible, lightweight photovoltaic array |
Related Parent Applications (1)
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US12/471,094 Continuation-In-Part US20090292407A1 (en) | 2008-05-22 | 2009-05-22 | Solar-powered aircraft with rotating flight surfaces |
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US15/076,081 Continuation US9960301B2 (en) | 2008-05-22 | 2016-03-21 | Method of manufacturing flexible, lightweight photovoltaic array |
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US20090301544A1 true US20090301544A1 (en) | 2009-12-10 |
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US15/076,081 Active US9960301B2 (en) | 2008-05-22 | 2016-03-21 | Method of manufacturing flexible, lightweight photovoltaic array |
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US15/076,081 Active US9960301B2 (en) | 2008-05-22 | 2016-03-21 | Method of manufacturing flexible, lightweight photovoltaic array |
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