A solar array and method of its fabrication wherein the solar cells are attached to a supporting substrate and electrically joined by interconnects having end terminals attached to the cell contacts with predetermined center distances between adjacent cell-substrate attachment points and the terminal attachment points of each interconnect, such that during thermal cycling of the solar array, each interconnect and the portion of the substrate between the adjacent cell-substrate attachment points undergo substantially equal thermal expansion and contraction so as to virtually eliminate stressing and flexing of the interconnects and thereby eliminate the need for flexibility in and avoid fatigue failure of the interconnects.
A solar battery module having the component members thereof joined uniformly and sustaining no distortion in the surface thereof and a method for the production thereof are disclosed, The solar battery module comprises a solar battery unit and a honeycomb structure. The honeycomb structure comprises a honeycomb core possessed of a plurality of cells and a first surface panel and a second surface panel respectively joined to opposite opening sides of the honeycomb core. The second surface panel has a plurality of perforations communicating with cavities in the cells of the honeycomb core. The honeycomb core has at least a pair of perforations in the walls of each of the cells or is made of a porous material. The solar battery unit provided with a plurality of solar battery elements is mounted on the second surface panel of the honeycomb structure through the medium of a joining member and they are joined by application of heat and pressure while the air remaining in the gap therebetween is caused to flow into cavities of the honeycomb structure.
A method for welding together the broad faces of two conductive sheets increases the reliability and consistency from weld to weld. The sheets are accessible from only one side for parallel electrical resistance welding. The electrical resistance between one sheet and the other is measured and taken as an indication of the amount of dirt or corrosion in the interface between the sheets. The measured resistance is compared with a predetermined standard. If the resistance exceeds the standard, the faces are cleaned. If the resistance is below the standard, electrical power is applied to fuse the sheets together.
A first set of pre-tabbed solar cells are assembled in a predetermined array with at least part of each tab facing upward, each tab being fixed to a bonding pad on one cell and abutting a bonding pad on an adjacent cell. The cells are held in place with a first vacuum support. The array is then inverted onto a second vacuum support which holds the tabs firmly against the cell pads they abut. The cells are exposed to radiation to melt and reflow the solder pads for bonding the tab portions not already fixed to bonding pads to these pads.
A thin conductive sheet having elongated openings extending inward from the edges to define a connecting arm extending from one end of one connecting surface to the diagonally opposite end of a second connecting surface. In one embodiment, the connecting arm extends directly from one corner to the diagonally opposite corner. In a second embodiment, the connecting arm changes direction to define a generally Z-shaped, reverse diagonal connecting path. Ties are provided across the elongated openings to hold the interconnector together during assembly, but which later break to permit the elongated openings to open up to define the connecting arm. One or more slits may be provided in the connecting arm to reduce buckling out of plane. The interconnector may be chrome plated in the central area to keep solder from flowing into the elongated openings and slits. To minimize the stress transition from the plated to the unplated portion, the plating terminates in a sine-wave-like wavy line which is 180.degree. out of phase with the corresponding wavy line on the reverse side.
A silicon solar cell assembly comprising a large, thin silicon solar cell bonded to a metal mount for use when there exists a mismatch in the thermal expansivities of the device and the mount.
