METHOD OF MANUFACTURING FLEXIBLE, LIGHTWEIGHT PHOTOVOLTAIC ARRAY

• US 20090301544A1
• Filed: 08/13/2009
• Published: 12/10/2009
• Est. Priority Date: 05/22/2008
• Status: Abandoned Application

• Current Assignee: Orbital Sciences Corporation (Northrop Grumman Corporation)
• Original Assignee: Orbital Sciences Corporation (Northrop Grumman Corporation)
• Inventors: Minelli, Robert
• Application Number:
  US12/540,685
• Publication Number:
  US 20090301544A1
• Time in Patent Office: Days
• US Class Current: 136/244
• CPC Class Codes: H01L 31/02008 for solar cells or solar cell modules
• CPC Class Codes: H01L 31/048 Encapsulation of modules
• CPC Class Codes: H01L 31/0504 specially adapted for series or parallel connection of solar cells in a module
• CPC Class Codes: H01L 31/188 Apparatus specially adapted for automatic interconnection of solar cells in a module
• CPC Class Codes: H05K 1/189 characterised by the use of a flexible or folded printed circuit H05K3/326 takes precedence
• CPC Class Codes: H05K 2201/015 Fluoropolymer, e.g. polytetrafluoroethylene [PTFE]
• CPC Class Codes: H05K 2201/0154 Polyimide
• CPC Class Codes: H05K 2201/10121 Optical component, e.g. opto-electronic component
• CPC Class Codes: H05K 3/0058 Laminating printed circuit boards onto other substrates, e.g. metallic substrates H05K1/0281 takes precedence
• CPC Class Codes: H05K 3/281 by means of a preformed insulating foil H05K3/284 takes precedence
• CPC Class Codes: H05K 3/305 Affixing by adhesive
• CPC Class Codes: Y02E 10/50 Photovoltaic [PV] energy
• CPC Class Codes: Y02P 70/50 Manufacturing or production processes characterised by the final manufactured product

Abstract

A flexible, lightweight photovoltaic cell array includes one or more individual photovoltaic cell strings attached to a polyimide film substrate and covered with a polyvinyl fluoride film. Each photovoltaic cell string includes one or more photovoltaic cells attached to a flexible printed circuit board. The photovoltaic cell array may be manufactured by a method that includes bonding at least one photovoltaic cell to a flexible printed circuit board, mounting the flexible printed circuit board on a polyimide film substrate, and covering the flexible printed circuit board with a substantially transparent polyvinyl fluoride film.

Claims

1. A method of manufacturing a flexible photovoltaic array, the method comprising:

bonding at least one photovoltaic cell to a flexible printed circuit board;

mounting said flexible printed circuit board on a first side of a polyimide film substrate; and

covering said flexible printed circuit board with a substantially transparent film.

2. The method of claim 1, further comprising:

coating said first side of said polyimide film substrate with an adhesive; and

coating a second side of said polyimide film substrate with a high-emissivity coating.

3. The method of claim 2, wherein coating the second side of said polyimide film substrate with the high-emissivity coating comprises coating the second side of said polyimide film substrate with high-emissivity paint.

4. The method of claim 1, further comprising:

attaching a bladder sleeve to said polyimide film substrate prior to covering said flexible printed circuit board with said film.

5. The method of claim 4 wherein said attaching is performed prior to covering said flexible printed circuit board with said film.

6. The method of claim 1, wherein mounting said flexible printed circuit board comprises mounting said flexible printed circuit board on said polyimide film substrate reinforced with aramid fibers.

7. The method of claim 1, wherein covering said flexible printed circuit board comprises covering said flexible printed circuit board with a substantially transparent polyvinyl fluoride film.

8. The method of claim 1, further comprising:

mounting said film substrate directly to a surface of a spacecraft or an airplane.

9. A flexible photovoltaic array comprising:

at least one photovoltaic cell bonded to a flexible printed circuit board;

a polyimide film substrate on which said flexible printed circuit board is mounted; and

a substantially transparent film covering said flexible printed circuit board.

10. The flexible photovoltaic array of claim 9, wherein:

a first side of said polyimide film substrate is coated with an adhesive; and

a second side of said polyimide film substrate is coated with a high-emissivity coating.

11. The flexible photovoltaic array of claim 10, wherein said flexible printed circuit board is mounted on said first side of said polyimide film substrate.

12. The flexible photovoltaic array of claim 10, wherein said high-emissivity coating is high-emissivity paint.

13. The flexible photovoltaic array of claim 9, further comprising:

a bladder sleeve attached thereto.

14. The flexible photovoltaic array of claim 13 wherein said bladder sleeve is attached to said polyimide film substrate and is covered by said substantially transparent film.

15. The flexible photovoltaic array of claim 9, wherein said polyimide film substrate is reinforced with aramid fibers.

16. The flexible photovoltaic array of claim 9, wherein said substantially transparent film is a polyvinyl fluoride film.

17. The flexible photovoltaic array of claim 9, wherein said polyimide film substrate is mounted directly to a surface of a spacecraft or an airplane.