Assembly and mounting of solar cells on a suppor

Abstract

A method of a solar cell array arranged on the surface of a support 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.

1 . A method of fabricating a solar cell array on the surface of a support comprising:
 providing an assembly fixture having a smooth, concave surface;   mounting a supporting film layer directly on the surface of the fixture;   mounting a pressure sensitive adhesive directly over the supporting film layer;   mounting an array of interconnected solar cells having a front (light receiving) side and a back side, with the front side being mounted directly over the adhesive;   bonding a supporting member composed of a composite material directly on the back side of the solar cells; and   removing the supporting film layer with the array of interconnected solar cells and the bonded supporting member from the assembly fixture.   
     
     
         2 . A method as defined in  claim 1 , wherein the pressure sensitive adhesive is between 0.001 and 0.010 inches in thickness and the array of solar cells is between 0.010 and 0.030 inches in thickness. 
     
     
         3 . A method as defined in  claim 1 , wherein the supporting film layer includes a film composed of ethylene tetrafluoroethylene (ETFE). 
     
     
         4 . A method as defined in  claim 1 , wherein the supporting member composed of a composite material is between 0.001 and 0.020 inches in thickness. 
     
     
         5 . A method as defined in  claim 1 , wherein the supporting member is composed of a para-aramid fabric. 
     
     
         6 . A method as defined in  claim 1 , wherein the supporting member is composed of a poly (4, 4′-oxydiphenylene-pyromellitimide) material. 
     
     
         7 . A method as defined in  claim 1 , further comprising bonding a foam supporting structure to the supporting member. 
     
     
         8 . A method as defined in  claim 1 , wherein the concave surface of the assembly fixture has a surface roughness of less than 0.001 inches rms. 
     
     
         9 . A method as defined in  claim 1 , wherein the concave surface of the assembly fixture forms an airfoil shaped surface. 
     
     
         10 . A method as defined in  claim 1 , wherein the pressure sensitive adhesive is a single monomer or co-monomer silicone blend.