SOLAR PANEL MODULE

Abstract

A solar panel module has a flexible circuit board, a matrix of solar cells surface mounted thereto, a coverglass extending over the matrix of solar cells and the flexible circuit board bonded to a rigid support panel. The circuitry including electrical connection pads in an arrangement on the first side surface for electrical connection of the circuitry to each of the matrix of solar cells, flat bypass diodes may be disposed on the first side surface under the cells and connecting to the circuitry. Conductive adhesives adhering each of the solar cells to the flex circuit at the electrical connection pads that correlate to electrical connection points on underside of each solar cells. The first side having a plurality of standoffs for receiving each of the matrix of solar cells providing raised levels for the solar cells, the landing portions projecting outwardly from a base level surface.

Claims

1. A solar panel module comprising a flexible circuit, a matrixical arrangement of at least twelve solar cells disposed on the flexible circuit, a coverglass extending over the entire matrixical arrangement, and a support panel with a planar surface to which the flexible circuit is attached: the flexible circuit comprising a copper circuitry layer sandwiched between at least two layers of polyimide, the flexible circuit having a top side with a top surface and a bottom side with a bottom surface, the flexible circuit having a solar cell mounting portion and an elongate connector strip portion extending from the solar cell mounting portion, the top side of the solar cell mounting portion having a base level portion with a base level surface and a raised stand-off portion with a raised surface, the copper circuitry layer defining circuitry, the circuitry with electrical connection pads at the base level surface of the top side of the solar cell mounting portion for connection to the solar cells and conductors extending along the elongate connector strip portion; the matrixical arrangement of solar cells adhered to the top surface of the flexible circuit; each solar cell having a top side for receiving solar energy and a back side and back side connector that is operably connectable connected to the circuitry by way of conductive adhesive extending between the electrical connection pads of the solar cell mounting portion of the flexible circuit and the back side of each respective solar cell, each solar cell having a respective bypass diode positioned on the flexible circuitry and operably connected to the respective solar cell through the circuitry of the flexible circuit; one or more blocking diodes operably connected to the circuitry on the elongate connector strip portion; and wherein the solar cell mounting portion of the flexible circuit is bonded to the planar surface of the support panel and the coverglass is bonded to the matrixical arrangement of solar cells.

2. The solar panel module of claim 1, wherein the adherence of each of the solar panels to the flexible circuitry is exclusively by way of the conductive adhesive.

3. The solar panel module of claim 1, wherein the adherence of each of the solar panels to the flexible circuitry is by way of the conductive adhesive and a non-conductive adhesive.

4. The solar panel module of claim 1, wherein the support panel is part of an electrical bus assembly and wherein the elongate connector strip portion extends through or around the bus assembly and has a connector portion on an end of the elongate connector strip portion that is operably attached to bus assembly.

5. The solar panel module of claim 4, wherein the back side connector is a surface mount adapter attached to the front side of the solar cell and extends around to the back side at a periphery of the solar cell.

6. The solar panel module of claim 1, wherein each bypass diode is integrated onto the flexible circuit with the diode configured as flat and rectangular and is bonded to an electrical connection pad at the top side of the flexible circuit.

7. The solar panel module of claim 6, wherein each bypass diode has a height and is bonded to the base level surface and extends a height above the base level surface and said height is less than or equal to a height of the raised surface of the raised standoff portion from the base level surface.

8. The solar panel module of claim 6, wherein the support panel is part of structural exterior wall of a space vehicle.

9. The solar panel module of claim 1, wherein there are a plurality of blocking diodes that are positioned in a cluster proximate a connector end of the elongate connector strip portion.

10. A solar panel module comprising a flexible circuit, a matrixical arrangement of a plurality of solar cells disposed on the flexible circuit, a coverglass extending over the matrixical arrangement, and a rigid support panel with a planar surface to which the flexible circuit is bonded, the flexible circuit having a conductive layer sandwiched between at least two layers of polyimide, the conductive layer comprising copper and defining circuitry, the flexible circuit having a top side with a top surface and a bottom side with a bottom surface, the flexible circuit having a solar cell mounting portion and an elongate connector strip portion extending from the solar cell mounting portion, the circuitry having electrical connection pads at the top surface of the top side of the solar cell mounting portion electrically connected to the solar cells and conductors extending along the elongate connector strip portion; the matrixical arrangements of solar cells adhered to the top surface of the flexible circuit; each solar cell having a top side for receiving solar energy and a back side with a back side connector terminal that is electrically and operably connectable, each of the solar cells electrically connected to the circuitry by way of conductive adhesive extending between the exposed electrical connection pads of the solar cell mounting portion of the flexible circuit and the back side of each respective solar cell; the coverglass extending over and covering the matrixical arrangement of at least twelve solar cells, the coverglass having a planar inner surface; and one or more blocking diodes operably connected to the circuitry.

11. The solar panel module of claim 10, the top side of the solar cell mounting portion having a base level portion with a base level surface and a plurality of raised stand-off portions with a raised surface, and wherein the solar panel module comprises a respective bypass diode for each of the plurality of solar cells, and the respective bypass diodes are mounted on the top of the flexible circuit and do not extend upwardly past the raised surfaces of the stand-off portions.

12. The solar panel module of claim 11, wherein each of the solar panels seat on raised surfaces of the standoffs.

13. The solar panel module of claim 10, wherein the circuitry connects the plurality of solar cells in series.

14. The solar panel module of claim 13, each of the plurality of solar cells having a respective bypass diode operably connected to the respective solar cell.

15. A solar panel module comprising a flexible circuit, a matrixical arrangement of at least twelve solar cells disposed on the flexible circuit, a coverglass extending over the matrixical arrangement, and a rigid support panel with a planar surface; the flexible circuit bonded to the flexible circuit comprising a circuitry layer sandwiched between at least two polymeric layers, the circuitry layer comprising copper, the flexible circuit having a top side with a top surface and a bottom side with a bottom surface, the flexible circuit having a solar cell mounting portion and an elongate connector strip portion extending from the solar cell mounting portion, wherein the copper circuitry layer defining circuitry, the circuitry with exposed electrical connection pads at the base level surface of the top side of the solar cell mounting portion for connection to the solar cells and conductors extending along the elongate connector strip portion; the matrixical arrangements of solar cells adhered to the top surface of the flexible circuit; each solar cell having a top side for receiving solar energy, a back side and a connector thereon that is electrically and operably connectable, each of the solar cells electrically connected to the circuitry at the electrical connection pads, each solar cell having a bypass diode integrated on the top side of the flexible circuit and operably connected to the respective solar cell; and the coverglass extending over and covering the matrixical arrangement of at least twelve solar cells.

16. The solar panel module of claim 15 further comprising one or more blocking diodes operably connected to the circuitry.

17. A flexible circuit for mounting on a panel and for receiving a plurality of solar cells, the flexible circuit comprising a copper circuitry layer sandwiched between at least two polyimide layers, the flexible circuit having a top side with a top surface and a bottom side with a bottom surface, the flexible circuit having a solar cell mounting portion and an elongate connector strip portion extending from the solar cell mounting portion, wherein the copper circuitry layer defining circuitry, the circuitry with a plurality of exposed electrical connection pads at the base level surface of the top side of the solar cell mounting portion for connection to the solar cells, and conductors extending along the elongate connector strip portion; the solar cell mounting portion of the flexible circuit bonded to a planar surface of a support panel; and conductive adhesive disposed on each the plurality of electrical connection pads.

18-22. (canceled)

23. A method of manufacture of a solar panel module, the method comprising: a) receiving or providing a flexible circuit formed of thin layers of insulative polymeric material with a conductive layer sandwiched therebetween, the flexible circuit having a solar cell attachment portion and a connector strip portion extending therefrom, the solar cell attachment portion having a solar cell attachment side with a solar cell attachment surface having a plurality of attachment sites for a plurality of solar cells, the conductive layer defining circuitry with a multiplicity of connection pads at the solar cell attachment side, the flexible circuit having alignment portions thereon; b) receiving or providing a matrix tray with a plurality of pockets, the matrix tray loaded with a plurality of solar cells, the matrix tray having alignment portions thereon, the pockets corresponding to the plurality of attachment sites of the solar cell attachment surface; c) placing and aligning the flexible circuit on a carrier, the carrier having alignment portions corresponding to the alignment portions of the matrix tray and the alignment portions of the flexible circuit; d) dispensing a multiplicity of blobs of conductive adhesive on the multiplicity of connection pads at the solar cell attachment side; e) aligning and engaging the matrix tray with the plurality of solar cells with the flexible circuit on the carrier utilizing the respective alignment portions, whereby the plurality of solar cells engage with the multiplicity of blobs thereby operably connecting each of the plurality of solar cells with the circuitry and thereby mounting each of the solar cells on respective attachment sites of the flexible circuit; f) separating the matrix tray from the plurality of solar cells; g) separating the carrier from the flexible circuit; h) placing and bonding a backside of the flexible circuit to a planar surface of a front side of a rigid support panel; i) extending the connector strip portion rearwardly of the front side of the rigid support panel; wherein the receiving or providing the flexible circuit includes receiving the flexible circuit with a plurality of raised seating portions for seating each of the solar cells, the raised seating portions each having a height of about 0.012 inches; and further comprising selecting bypass diodes that have a height such that when mounted on the flexible circuit, do not exceed a height of the raised seating portions, the height being 0.008 inches or less.

24. The method of claim 23, further providing dispensing the blobs of conductive adhesive with a height extending above a height of the raised seating portions.

25-46. (canceled)

Description

DESCRIPTION OF THE FIGURES

[0012] FIG. 1 is a perspective you have a space vehicle configured as a Satellite having a pair of solar panel a raise.

[0013] FIG. 2 is a perspective you have a pair of solar panel modules.

[0014] FIG. 3A is a cross-sectional view of a solar panel module.

[0015] FIG. 3B is a cross-sectional view of in body meant of a solar panel module.

[0016] FIG. 4A is a perspective view of a solar cell with surface mount adapters thereon.

[0017] FIG. 4B is a perspective view of a surface mount adapter for a solar cell.

[0018] FIG. 5A is a plan view of a flexible circuit.

[0019] FIG. 5B is a plan view of a flexible circuit with raised standoff portions.

[0020] FIG. 5C is a plan view of the flexible circuit of FIG. 5A illustrating solar panel receiving positions.

[0021] FIG. 5D is a plan view of the flexible panel of FIG. 5A with solar cells attached thereto.

[0022] FIG. 6A is a perspective view of a flexible circuit with raised standoff portions.

[0023] FIG. 6B is a perspective view of a flexible circuit with raised standoff portions.

[0024] FIG. 7 is a cross-sectional view of a flexible circuit with two conductive metallic layers and depicting exemplary and relative thicknesses.

[0025] FIG. 8 is a cross-sectional view of a flexible circuit with a single conductive metallic layer.

[0026] FIG. 9 is a cross-sectional view of an embodiment with standoffs in the flexible circuit.

[0027] FIG. 10 is the flexible circuit of FIG. 9 with a blob of conductive adhesive placed on a pad.

[0028] FIG. 11 is a cross-sectional view of the flexible circuit of figured 10 with the solarSell seeded there on.

[0029] FIG. 12 is a diagrammatic view of a manufacturing process for solar panel modules.

[0030] FIG. 13 is a schematic view of a carrier for a flexible circuit.

[0031] FIG. 14 is a diagrammatic view of a manufacturing process of solar panel modules.

[0032] FIG. 15 is a plan view of a matrix tray for solar cells.

[0033] FIG. 16 is a diagrammatic view of manufacturing steps for the manufacture of solar panel modules.

[0034] FIG. 17 is a plan view of a matrix tray for solar cells.

[0035] FIG. 18 is a diagrammatic view of manufacturing steps for the manufacture of solar panel modules.

[0036] FIG. 19 is a table of steps in accord with embodiments.

[0037] While embodiments of the disclosure are amenable to various modifications and alternative forms, specifics thereof have been shown by way of example in the drawings and will be described in detail. It should be understood, however, that the intention is not to limit the disclosure to the particular embodiments described. On the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the disclosure.

DETAILED DESCRIPTION

[0038] Referring to FIG. 1, a space vehicle 20 is illustrated with a central body portion 22 and a pair of deployed solar arrays 24, 26. Each array comprising a plurality of solar panel modules 30. Additionally, the space vehicle body may also have one or more solar panel modules 32 attached thereto. Referring to FIG. 2, to a portion of a deployed solar array is illustrated showing two solar panel modules 30 connected by a bus assembly 38. Each solar panel module comprising a multiplicity of solar cells 40 closely packed together in a matrixical array 42 and mounted upon respective support panels 44.

[0039] Referring to FIG. 3A, cross-sections through the solar panel module 30 illustrate the components of embodiments. The support panel may have face sheets 45, 46, a honeycomb core 47 providing rigidity and light weight, and an end cap 48. A flexible circuit 50 (often termed a flex circuit) is bonded by way of an adhesive layer 52 to a planar front side surface 56 of a front side 58 of the support panel 44. FIG. 5A illustrates a flexible circuit 50 suitable for use in this embodiment. The flexible circuit has a solar cell mounting portion 62 and an elongate connector strip portion 66. The flexible circuit 50 has a front or top side 67 with a front side surface 67.2 and a back side 68 with the backside surface 68.2. Other than the exposed conductive pads 98 and the pads with the bypass diodes 64, the entirety of the front side 67 is an insulative layer such as polyimide. Polyimide has transparency so that copper strips 67.5 that define a conductive layer 67.6 in the flex circuit 50 are visible through the insulative layer. The bypass diodes may be attached by conductive adhesive or solder.

[0040] In embodiments, the solar cells are attached to the flexible circuit by way of conductive adhesive portions 70 (identified by the dense dots) configured as blobs that are placed on exposed copper pads 98 and that connect to surface mount adaptors, not shown in this view, that extend to the top surface of the solar cell. The solar cells are covered by a coverglass 72 and are bonded there too by way of an adhesive 73. The connector strip portion 66 of the flexible circuit 50 extends through an opening (not shown) in the support panel to a backside 74 of the support panel 44 and has a connector 76 for connection to, for example, the bus assembly. One or more blocking diodes 80 are attached to the connector strip portion 66 proximate the connector 76.

[0041] Referring to FIG. 3B another embodiment of a solar panel module 30 is illustrated in cross section with solar cells 40 having surface mount adapters 77. FIGS. 4A and 4B illustrate the solar cell 40 and the surface mount adapter 77. The solar cell 40 has a front solar energy receiving side 78 with a front side surface 78.1, an opposite back side 78.2 with a back side surface 78.3, an edgewall 78.4 with an edgewall surface 78.5, and a periphery 78.6. On the front side are front side are a plurality of exposed connection pads 79 including P-pads 79.1 and N-pads 79.2, with the surface mount adaptor 77 on each pad. The adapter is generally C-shaped and has flattened front side terminal 79.5 and a flattened back side connection terminal 79.7.

[0042] Referring to FIGS. 3B-4B and 5B, the flexible circuit 50 of solar panel module 30 has a plurality of raised seating portions or stand-offs 84. The standoffs each have a raised surface 86 on which the solar cells 40 may seat. The support panel may have face sheets 45, 46, a honeycomb core 47 providing rigidity and light weight, and an end cap 48. The flex circuit 50 is bonded by way of an adhesive layer 52 to a planar front side surface 56 of a front side 58 of the support panel 44. The flexible circuit has a solar cell mounting portion 62 and an elongate connector strip portion 66. The flexible circuit 50 has a front or top side 67 with a front side surface 67.2 and a back side 68 with the backside surface 68.2. Attached to the top side surface are the solar cells 40, and in embodiments, bypass diodes 64. The solar cells are attached to the flexible circuit both by way of conductive adhesive portions 70 and non-conductive adhesive portions 70.2, both which may be configured as blobs, with the conductive adhesive blobs placed on exposed copper pads 98 on the front side of the flex circuit, not shown in this view and that also connect to the surface mount adapters 77. The non conductive adhesive 70.2 connecting the solar cells to the flex circuit is indicated by diagonal short dashes in the figures.

[0043] In embodiments, the standoffs 84 may be configured as a grid 87 as illustrated in FIGS. 6A and 6B or as ribs as illustrated in FIG. 5B or pillars or other configurations.

[0044] FIG. 5C illustrates six solar cell receiving regions 89 on the flex circuits of FIGS. 5A and 5B. FIG. 5D illustrates twelve solar cells 40 placed in all regions providing the closely packed matrixical array 42, the solar cells having surface mount adapters 77 exposed on the solar energy receiving side of the solar cells, the adapters extend around the edges of the respective solar cells to be conductively connected to the copper pads 98 on the flex circuit.

[0045] Referring to FIGS. 7-11, several embodiments of the layering of flex circuits suitable for embodiments are illustrated. FIG. 7 illustrates a flexible circuit 50.1 layered arrangement with two copper conductor layers 92, 92.1. The polyimide standoff 84 may in embodiments have a Black Kapton static dissipative layer thereon, in embodiments the standoff will not have the layer. FIG. 8 is a flexible circuit arrangement with a single conductor layer. The raised surface extending a distance D above a base level surface 88. The height of the bypass diodes 64 being less than or equal to the distance D. In embodiments, the bypass diodes are 0.005 to 0.007 inches thick and they extend outwardly or upwardly from the base level 95 of the flexible circuit 50 that distance. The conductive layer may comprise copper and defines circuitry 96 with electrical connection pads 98 exposed on the top surface 58 of the flexible circuit. The circuitry comprising a plurality of conductor strips 97 within the solar cell mounting portion and conductors 92 in the connector strip portion 66. The conductor strips arranged to connect the solar cells that attach to the respective flexible circuit in series.

[0046] The flexible circuit 50 in cross-section of FIGS. 9-11, have a conductive layer 92 sandwiched between a pair of insulative layers 93, 94, for example polymeric layers, such as polyimide. The copper layer may be 0.0007 to 0.001 inches thick, the polyimide insulative layers may be 0.002 to 0.004 inches thick. The standoffs may be created by additional polyimide material on the upper insulative layer 93 and may be, for example, 0.008 to 0.015 inches high, projecting outwardly from a flex circuit base level 95, see FIG. 7. Techniques for manufacturing flexible circuits are known in the art.

[0047] FIG. 10 illustrates a blob 70 of conductive adhesive material 100 that has been dispensed on the pad. As a solar cell is seated on the raised seating portions or stand-offs the blob is compressed and forms a connection 102 between the back side connections 104 of the solar cell and the circuitry 96, see FIG. 11. The back side connection can be the surface mount adapter 77 as best shown in FIGS. 4A and 4B. The flexible circuit may have a polymeric, such as polyimide, static dissipative exterior layers 106, 108 for prevention of buildup of static charges. Such layers may be 0.001 inches thick. The dimensions disclosed in the Figures are exemplary, suitable ranges for such dimensions are plus or minus 25% of any of the given parameters.

[0048] The flexible circuits having circuitry 96 connecting the solar cells in series with a bypass diode positioned on the front or top side of the flexible circuit, each bypass diode being thin and flat and positioned below or at the same elevation as standoffs that are unitary with an insulative layer of the flexible circuit. Such thin bypass diodes are known. The insulative layer may comprise polyimide.

[0049] In embodiments, the solar panel modules described herein are amenable to automated robotic manufacturing, particularly pick and place of components and spot dispensing of adhesives, conductive and nonconductive, and alignment of respective components and fixtures. Referring to FIG. 12 suitable steps in manufacturing a solar panel module include providing a flexible circuit board 50 with circuitry 96 and exposed electrical connection pads 98, adhering the flexible circuit board to a planar surface of a support panel 44, robotically dispensing conductive adhesive onto the connection pads, robotically placing the solar cells onto the flexible panel. Nonconductive adhesive 116 blobs may also supplement the adhesion provided by the conductive adhesive 100. The connector strip portion 66 is wrapped around the side 119 of the support panel to be secured to the back side 74 of the panel. A coverglass 72 is secured over the solar cells such as by a layer of adhesive.

[0050] Referring to FIGS. 13 and 14, in and embodiment a rigid carrier 124 is utilized to hold the flexible circuit while adhesive is dispensed and as solar cells are picked up and placed there on. Conductive adhesive 100 may be placed on the electrical connection pads 98, instead of solder, and may be supplemented by structural non-conductive adhesive 116. The solar cells 40 are picked up and placed upon the flexible circuit secured by the carrier 124. The adhesive is allowed to cure and then a plurality of the flexible circuits with solar cells thereon our mounted onto a support panel 44 with the elongate connector strip portions 66 are routed to the backside 74 of the panel for a connection to, for example, a bus assembly.

[0051] Referring to FIGS. 15 and 16, in embodiments, a solar cell matrix tray 130 with solar cell pockets 133 and alignment portions 134, such as a pair of tabs 135 with alignment holes, cooperates with a flexible circuit carrier 136 with cooperating alignment portions 138, such as tabs with pins. The solar cell matrix tray 130 can arrive at the manufacturing facility pre-loaded with solar cells or may be loaded at the manufacturing facility. The matrix tray has a capacity of, for example, 12 cells. The flexible circuit 50 with connector strip portion 66 has a cooperating alignment portion 142, for example pin holes thereon, to key with the alignment portions of the flexible circuit carrier and alignment portions of the matrix tray. The flexible circuit 50 is installed on the carrier 136 and positioned for application of the conductive adhesive such as by robotic spot dispensing or by screening. The carrier with the flexible circuit installed thereon, the flexible circuit having uncured conductive adhesive, is aligned with and joined to the matrix tray with the solar cells seated therein thereby adhering the solar cells to the flexible circuit by way of the conductive adhesive. Such may be performed robotically. Referring to FIGS. 17 and 18, a similar process is illustrated including robotically dispensing conductive adhesive and nonconductive structural adhesive.

[0052] Referring to FIG. 19, discrete steps associated with embodiments herein are illustrated. These steps can be selected and combined in any order and with any of the steps identified in FIGS. 12-18.

[0053] The solar cell mounting portion of the flexible circuit is bonded to the planar surface of the support panel. In embodiments, a bonding layer coats the entirety of the lower surface of the solar cell mounting portion. In embodiments, the bonding layer coats most of the lower surface of the solar cell mounting portion.

[0054] In embodiments, the surface area of the solar cell attachment portion is several times as great as the area of the connector strip portion. In embodiments the solar cell attachment portion is substantially rectangular with a width and a length and the connector strip portion has a length and a maximum width, the maximum width being 0.30 or less the width of the solar cell attachment portion. In embodiments, the width being 0.20 or less the width of the solar cell attachment portion. In embodiments, the length of the strip portion is at least 5 times the maximum width of the strip portion.

[0055] When used herein connected and attached do no required direct physical contact between the components at issue, there may be intermediate components or material, for example adhesive material.

[0056] The following U.S. patents and patent publications are incorporated by reference herein for all purposes: U.S. Pat. Nos. 5,723,205; 7,709,729; 8,356,770; 2010/0114679; 2011/0126878; 9,214,573; 9,214,892; 9,748,432; 9,960,301; 9,728,663; 9,882,330; and 10,475,944. All of the features disclosed in this specification (including the references incorporated by reference, including any accompanying claims, abstract and drawings), and/or all of the steps of any method or process so disclosed, may be combined in any combination, except combinations where at least some of such features and/or steps are mutually exclusive.

[0057] Each feature disclosed in this specification (including references incorporated by reference, any accompanying claims, abstract and drawings) may be replaced by alternative features serving the same, equivalent or similar purpose, unless expressly stated otherwise. Thus, unless expressly stated otherwise, each feature disclosed is one example only of a generic series of equivalent or similar features.

[0058] The invention is not restricted to the details of the foregoing and claimed embodiments. The invention extends to any novel one, or any novel combination, of the features disclosed in this specification (including any incorporated by reference references, any accompanying claims, abstract and drawings), or to any novel one, or any novel combination, of the steps of any method or process so disclosed. The above references in all sections of this application are herein incorporated by references in their entirety for all purposes. The inventive processes may interchange steps and delete steps. That is, it is not contemplated that the inventions herein require all of the steps as described or claimed. Individual steps or combinations of a few steps are contemplated to be inventive.

[0059] Although specific examples have been illustrated and described herein, it will be appreciated by those of ordinary skill in the art that any arrangement calculated to achieve the same purpose could be substituted for the specific examples shown. This application is intended to cover adaptations or variations of the present subject matter. Therefore, it is intended that the invention be defined by the attached claims and their legal equivalents, as well as the following illustrative aspects. The above described aspects embodiments of the invention are merely descriptive of its principles and are not to be considered limiting. Further modifications of the invention herein disclosed will occur to those skilled in the respective arts and all such modifications are deemed to be within the scope of the invention.