Method of manufacturing flexible, lightweight photovoltaic array

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.

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.