Assembly and mounting of solar cells on airfoils

Abstract

A method of fabricating an airfoil, and the airfoil or airfoil skin so fabricated, including a solar cell array arranged on the surface of the airfoil by providing and utilizing an assembly fixture having a smooth, concave surface. An uncured supporting film composed of a composite material (such as a carbon fiber composite) is mounted directly on the back side of the solar cells; and the film of composite material is co-cured on the assembly fixture so that the array of interconnected solar cells is bonded to the supporting film. The bonded and cured film of composite material and an array of interconnected solar cells is then removed from the assembly fixture.

Claims

1. A method of fabricating a solar cell array carrier in an assembly fixture comprising: providing a composite face sheet on the surface of the assembly fixture; providing a double sided adhesive film and positioning it on the top surface of the face sheet; bonding the bottom surface of the adhesive film to the to the top surface of the face sheet by co-curing; positioning an array of solar cell assemblies over the top surface of the adhesive film; bonding each of the array of solar cell assemblies to a predefined region on the top surface of the face sheet; and removing the carrier with the array of solar cell assemblies from the assembly fixture.

2. A method as defined in claim 1, wherein the composite face sheet includes a poly (4, 4-oxydiphenylene-pyromellitimide) material.

3. A method as defined in claim 2, further comprising bonding a foam supporting structure to the composite face sheet.

4. A method as defined in claim 1, wherein the solar cell assemblies are electrically connected III-V compound semiconductor multijunction solar cells.

5. A method as defined in claim 1, wherein the assembly fixture has a concave surface with a surface roughness of less than 0.001 inches rms.

6. A method as defined in claim 1, wherein the concave surface of the assembly fixture forms an airfoil shaped surface.

7. A method as defined in claim 1, wherein the adhesive film is a single monomer or co-monomer blend.

8. A method as defined in claim 1, wherein the surface of the assembly fixture is in the shape of an airfoil skin.

9. A method of fabricating a solar cell array carrier in an assembly fixture comprising: providing a carbon fiber composite face sheet; providing a double sided adhesive film having a top surface and a bottom surface and positioning the bottom surface thereof on the top surface of the face sheet; bonding the bottom surface of the adhesive film to the to the top surface of the face sheet by co-curing; positioning a plurality of strings of solar cell assemblies over the top surface of the adhesive film; and sequentially bonding each of the strings of solar cell assemblies to predefined regions on the top surface of the face sheet.

Description

BRIEF DESCRIPTION OF THE DRAWING

(1) To complete the description and in order to provide for a better understanding of the disclosure, a set of drawings is provided. Said drawings form an integral part of the description and illustrate embodiments of the disclosure, which should not be interpreted as restricting the scope of the disclosure, but just as examples of how the disclosure can be carried out. The drawings comprise the following figures:

(2) FIG. 1 is a perspective view of a fixture for assembling the airfoil or solar cell assembly according to the present disclosure;

(3) FIG. 2 is a cross-sectional view of the surface of the fixture of FIG. 1;

(4) FIG. 3 is a cross-sectional view of the assembly of FIG. 2 after the next process step;

(5) FIG. 4 is a cross-sectional view of the assembly of FIG. 2 after the next process step;

(6) FIG. 5 is a cross-sectional view of the assembly of FIG. 2 after the next process step;

(7) FIG. 6 is a cross-sectional view of the assembly of FIG. 2 after the next process step;

(8) FIG. 7 is a cross-sectional view of a solar cell assembly or airfoil structure as fabricated in FIG. 6 after removal from the fixture;

(9) FIG. 8 is a perspective view of an airfoil of FIG. 7;

(10) FIG. 9 is a perspective view of an exemplary embodiment of a watercraft having a solar assembly, according to the present disclosure, attached to a non-planar surface of the watercraft;

(11) FIG. 10 is a perspective view of an exemplary embodiment of an aircraft having a solar assembly, according to the present disclosure, attached to different, non-planar surfaces of the aircraft; and

(12) FIGS. 11 and 12 are perspective views of exemplary embodiments of land vehicles having solar assemblies, according to the present disclosure, attached to surfaces of the land vehicles.

DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS

(13) Details of the present invention will now be described including exemplary aspects and embodiments thereof. Referring to the drawings and the following description, like reference numbers are used to identify like or functionally similar elements, and are intended to illustrate major features of exemplary embodiments in a highly simplified diagrammatic manner. Moreover, the drawings are not intended to depict every feature of the actual embodiment nor the relative dimensions of the depicted elements, and are not drawn to scale.

(14) FIG. 1 is a perspective view of a fixture 100 for assembling the airfoil according to the present disclosure. The operative surface 110 of the fixture is generally concave and in the shape of the solar cell assembly to be formed, which in one embodiment is a portion of an airfoil.

(15) FIG. 2 is an enlarged cross-sectional view of the surface of the fixture of FIG. 1 after placement of an ethylene tetrafluoroethylene (EFTE) film 102 on the surface 110.

(16) FIG. 3 is a cross-sectional view of the assembly of FIG. 2 after the next process step of mounting a film 103 composed of a non-crosslinked silicone pressure sensitive adhesive directly over the ETFE film 102.

(17) In some embodiments, the pressure sensitive adhesive film is between 0.001 and 0.010 inches in thickness.

(18) In some embodiments, the array of solar cells is between 0.010 and 0.030 inches in thickness.

(19) FIG. 4 is a cross-sectional view of the assembly of FIG. 3 after the next process step of mounting an array of interconnected solar cells 104 directly over the adhesive film 103.

(20) FIG. 5 is a cross-sectional view of the assembly of FIG. 4 after the next process step of mounting an uncured supporting film 105 composed of a composite material directly on the pressure sensitive adhesive film 103, and co-curing the film 104 of composite material so that the array of interconnected solar cells is bonded to the supporting film.

(21) FIG. 6 is a cross-sectional view of the assembly of FIG. 2 after the next process step in which a support structure 106 is bonded to the supporting film 105. In one embodiment, the supporting structure is an airfoil.

(22) FIG. 7 is a cross-sectional view of a solar cell assembly or airfoil structure 106 as fabricated in FIG. 6 after removal from the fixture 100.

(23) FIG. 8 is a perspective view of an airfoil 200 with individual solar cells 104 mounted on the top surface thereof, with the top surface being formed by the EFTE film 102.

(24) In addition to an airfoil, the present technique may be used to fabricate solar cells on the non-planar surface of a variety of different vehicles or other structures (e.g., building materials).

(25) Exemplary aircraft having non-planar surfaces include aerostats (which are lighter than air), and aerodynes (which are heavier than air). Exemplary aerostats can include, for example, unpowered vessels (e.g., balloons such as hot air balloons, helium balloons, and hydrogen balloons) and powered vessels (e.g., airships or dirigibles). Exemplary aerodynes can include, for example, unpowered vessels (e.g., kites and gliders) and powered vessels (e.g., airplanes and helicopters). Exemplary aerodynes can be fixed wing vessels (e.g., airplanes and gliders) or rotorcraft (e.g., helicopters and autogyros).

(26) Exemplary watercraft having non-planar surfaces can be motorized or non-motorized, and can be propelled or tethered. Exemplary watercraft can include surface vessels (e.g., ships, boats, and hovercraft) and submersible vessels (e.g., submarines and underwater flotation vessels).

(27) Exemplary land vehicles having non-planar surfaces can be motorized (e.g., automobiles, trucks, buses, motorcycles, rovers, and trains) or non-motorized (e.g., bicycles).

(28) FIG. 9 is a perspective view of an exemplary embodiment of a watercraft. A submersible watercraft 904 has a non-planar surface and is attached to platform 903 via tether 902. Submersible watercraft 904 includes the underwater flotation vessel 901 that is held at a desired depth below the water surface by controlling the length of the tether 902. The solar cell assembly 900 is attached to a non-planar surface of the underwater flotation vessel 901. In certain embodiments, when light impinges on the solar cell assembly 900 of submersible watercraft 904, electrical current generated from the solar cell assembly 900 can be provided to platform 903 via the tether 902.

(29) FIG. 10 is a perspective view of an exemplary embodiment of an unmanned aircraft. Aircraft 1000 has a non-planar surface and is a fixed wing vessel. The solar cell assembly 1001 is attached to a non-planar surface of the wing of the aircraft 1000. In certain embodiments, when light impinges on the solar cell assembly 1001 of aircraft 1000, electrical current generated from the solar cell assembly 1001 can be provided for operation of systems (e.g., navigational systems, propulsion systems, and the like) of aircraft 1000.

(30) FIG. 11 is a perspective view of an exemplary embodiment of a land vehicle. Land vehicle 2000 has a non-planar surface and is an automobile. The solar cell assembly 2001 is attached to a non-planar surface of an automobile 2000. In certain embodiments, when light impinges on the solar cell assembly 2001 of automobile 2000, electrical current generated from solar cell assembly 2001 can be provided for operation systems (e.g., navigational systems, propulsion systems, and the like) of automobile 2000. In certain embodiments, automobile 2000 is a hybrid or electric powered automobile.

(31) FIG. 12 is a perspective view of another exemplary embodiment of a land vehicle. Land vehicle 3000 has a non-planar surface and is a rover that can be used for land navigation and/or exploration on earth or other planets. The solar cell assembly 3001 is attached to a non-planar surface of the rover 3000. In certain embodiments, when light impinges on the solar cell assembly 3001 of rover 3000, electrical current generated from solar cell assembly 3001 can be provided for operation of systems (e.g., navigational systems, propulsion systems, and the like) of rover 3000. In certain embodiments, rover 3000 is a hybrid or electric powered land vehicle.

(32) Although this disclosure has been described in certain specific embodiments, many additional modifications and variations would be apparent to those skilled in the art. The present disclosure is therefore considered in all respects to be illustrative and not restrictive. The scope of the disclosure is indicated by the appended claims, and all changes that come within the meaning and range of equivalents thereof are intended to be embraced therein.

(33) It will be understood that each of the elements described above, or two or more together, also may find a useful application in other types of constructions differing from the types described above.

(34) It is to be noted that the terms front, back, top, bottom, over, on, under, and the like in the description and in the claims, if any, are used for descriptive purposes and not necessarily for describing permanent relative positions. It is understood that the terms so used are interchangeable under appropriate circumstances such that the embodiments of the disclosure described herein are, for example, capable of operation in other orientations than those illustrated or otherwise described herein.

(35) The present disclosure can be embodied in various ways. The above described orders of the steps for the methods are only intended to be illustrative, and the steps of the methods of the present disclosure are not limited to the above specifically described orders unless otherwise specifically stated. Note that the embodiments of the present disclosure can be freely combined with each other without departing from the spirit and scope of the disclosure.

(36) Although some specific embodiments of the present disclosure have been demonstrated in detail with examples, it should be understood by a person skilled in the art that the above examples are only intended to be illustrative but not to limit the scope of the present disclosure. It should be understood that the above embodiments can be modified without departing from the scope and spirit of the present disclosure which are to be defined by the attached claims.