Solar Cell Array For Use In Aerospace Application, And A Method Of Assembly Thereof
A space based solar array has a substrate on which are placed a plurality of spaced apart solar cells. A transparent adhesive bonding layer is on the plurality of solar cells covering the solar cells and the substrate between said solar cells. In a preferred embodiment, the adhesive bonding layer is silicone. A transparent rigid buffer layer is on the transparent adhesive bonding layer. In a preferred embodiment, the transparent rigid buffer layer is made of polyimide and has properties suitable for the application of performance- or durability-enhancing thin-film coatings. A transparent thin-film stack including inorganic radiation protection layer is on the transparent rigid buffer layer. In a preferred embodiment, the transparent radiation protection layer is made of silica, alumina or thin glass. Performance enhancing layers can also be included into the thin film stack for anti-reflection and ESD control purposes.
1 . A solar array comprising:
a substrate;
a plurality of solar cells spaced apart from one another and bonded onto said substrate;
a transparent adhesive bonding layer on said plurality of solar cells covering said solar cells and said substrate between said solar cells;
a transparent buffer layer on said transparent adhesive bonding layer; and
a transparent protective film over said transparent buffer layer.
2 . The array of claim 1 wherein said buffer layer having a Coefficient of Thermal Expansion (CTE) lower than the CTE of the adhesive bonding layer.
3 . The array of claim 1 further comprising:
a transparent anti-reflective coating on said transparent protective film.
4 . The array of claim 1 wherein said protective film is made from an inorganic material.
5 . The array of claim 4 wherein said inorganic material is a material chosen from silica, alumina or thin glass.
6 . The array of claim 5 wherein said protective film comprises a stack of inorganic material.
7 . The array of claim 1 wherein said transparent buffer layer is made from polyimide.
8 . The array of claim 1 wherein said transparent adhesive bonding layer is made from silicone.
9 . The array of claim 8 wherein said silicone is molded to provide an index for the placement of the solar cells.
10 . The array of claim 8 wherein said silicone is molded to provide cavities for wire bonds between the plurality of solar cells
11 . The array of claim 9 wherein said index comprises a plurality of cavities in said silicone for the placement of the solar cells,
12 . The array of claim 1 wherein said substrate comprises a plurality of layers.
13 . The array of claim 12 wherein said substrate further comprises:
a structural layer for providing structural support;
a flexible circuit electrical wiring layer on said structural layer;
an insulating layer on said flexible circuit electrical wiring layer, on which the plurality of solar cells are placed.
14 . The array of claim 13 wherein said structural layer has substantially the same Coefficient of Thermal Expansion as said plurality of solar cells.
15 . The array of claim 15 wherein said insulating layer is made from Kapton.
16 . A method of manufacturing a solar cell array, said method comprising:
providing a substrate;
molding a superstrate having a layer of transparent adhesive bonding material, molded to provide a plurality of spaced apart cavities on one side, and a layer of transparent rigid buffer material on said layer of transparent adhesive bonding material on a side opposite the one side, and a transparent radiation protection layer on the layer of transparent rigid buffer layer;
placing a plurality of solar cells in said superstrate with a solar cell positioned in each cavity of said transparent adhesive bonding material, to form a resultant structure; and
placing said resultant structure on said substrate, with said one side of said transparent adhesive bonding material contacting said substrate.