Solar arrays and related assemblies and methods

Patent metadata

Field	Value
Publication number	US-11444571-B2
Application number	US-202017121274-A
Country	US
Kind code	B2
Filing date	Dec 14, 2020
Priority date	Dec 14, 2020
Publication date	Sep 13, 2022
Grant date	Sep 13, 2022

Abstract

A solar array may include a first rigid composite solar panel including solar cells secured to a first substrate. The solar array may further include a second rigid composite solar panel including solar cells secured to a second substrate. The solar array may also include solar panel modules including solar cells secured to a flexible sheet of material. The solar panel modules may be coupled between the first composite solar panel and the second composite solar panel. The solar array may be configured to be retained in a stowed arrangement with the solar panel modules between the first rigid composite solar panel and the second rigid composite solar panel. The solar array further configured to be extended with an extendable arm until each of the first rigid composite solar panel, the second rigid composite solar panel and the solar panel modules are arranged in a substantially straight line.

First claim

What is claimed is:

1. A solar array comprising:
a first composite solar panel comprising solar cells secured to a first substrate, the first composite solar panel having a first thickness;
a second composite solar panel comprising solar cells secured to a second substrate, the second composite solar panel having a second thickness; and
at least one solar panel module comprising solar cells secured to a flexible sheet of material, the at least one solar panel module coupled between the first composite solar panel and the second composite solar panel, the at least one solar panel module having a third thickness less than the first thickness of the first composite solar panel and the second thickness of the second composite solar panel.

2. The solar array of claim 1 , further comprising a cable configured to couple the at least one solar panel module to the first composite solar panel and the second composite solar panel.

3. The solar array of claim 2 , further comprising a preload assembly coupled to the cable.

4. The solar array of claim 3 , the preload assembly comprising one or more tensioner elements configured to apply a biasing load to the cable.

5. The solar array of claim 1 , wherein the at least one solar panel module comprises one or more frame elements.

6. The solar array of claim 5 , wherein the one or more frame elements comprise thin strips of material having a width that is greater than a thickness.

7. The solar array of claim 5 , further comprising corner supports configured to couple the one or more frame elements together.

8. The solar array of claim 7 , wherein the corner supports are coupled to adjacent corner supports of an adjacent solar panel module.

9. The solar array of claim 8 , wherein the corner supports and the adjacent corner supports form a hinge between the at least one solar panel module and the adjacent solar panel module.

10. The solar array of claim 1 , wherein the flexible sheet of material comprises an open weave scrim material.

11. A method of extending a solar array comprising:
releasing a stowed solar array assembly comprising:
a first composite solar panel comprising solar cells secured to a first substrate, the first composite solar panel having a first thickness;
a second composite solar panel comprising solar cells secured to a second substrate, the second composite solar panel having a second thickness;
at least one solar panel module comprising solar cells secured to a flexible sheet of material, the at least one solar panel module coupled between the first composite solar panel and the second composite solar panel, the at least one solar panel module having a third thickness less than the first thickness of the first composite solar panel and the second thickness of the second composite solar panel; and
an arm;

rotating the solar array assembly about a first hinge coupled between the arm and a vehicle body, wherein the arm is coupled to the first composite solar panel;
rotating the second composite solar panel and the multiple solar panel modules in an opposite direction about a second hinge coupled between the second composite solar panel and the arm; and
extending the arm until the at least one solar panel module is arranged in a substantially straight line, wherein the at least one solar panel module is coupled to adjacent solar panel modules by a hinged connection and wherein the at least one solar panel module is coupled between the first composite solar panel and the second composite solar panel by one or more cables.

12. The method of claim 11 , wherein the first composite solar panel and the second composite solar panel each comprise solar cells coupled to a substrate.

13. The method of claim 11 , further comprising rotating the second composite solar panel about the second hinge until the second composite solar panel is substantially aligned with the first composite solar panel after the at least one solar panel module is arranged in the substantially straight line.

14. The method of claim 11 , further comprising preloading the one or more cables.

15. A solar panel assembly comprising:
a first rigid solar panel comprising a first arrangement of solar cells coupled to a first rigid substrate;
a second rigid solar panel comprising a second arrangement of solar cells coupled to a second rigid substrate;
multiple solar panel modules comprising a third arrangement of solar cells coupled to a flexible sheet, the multiple solar panel modules coupled to adjacent solar panel modules through hinged connections, a first solar panel module of the multiple solar panel modules coupled to the first rigid solar panel through a cable, and a second solar panel module of the multiple solar panel modules coupled to the second rigid solar panel through the cable; and
the solar panel assembly configured to be retained in a stowed position wherein each of the multiple solar panel modules is arranged in a front-to-front or back-to-back arrangement with the adjacent solar panel modules through the hinged connection.

16. The solar panel assembly of claim 15 , further comprising an extendable mast coupled to the first rigid solar panel and the second rigid solar panel.

17. The solar panel assembly of claim 16 , the extendable mast coupled to the second rigid solar panel through a biased hinge.

18. The solar panel assembly of claim 16 , further comprising a drive system configured to extend the extendable mast.

19. The solar panel assembly of claim 16 , wherein the extendable mast is configured to unfold the multiple solar panel modules about the hinged connections until each of the multiple solar panel modules are substantially aligned at the hinged connections as the extendable mast extends.

Assignees

• Northrop Grumman Systems Corp
• Nortnrop Grumman Systems Corp

Inventors

• Eskenazi Michael I
• Mceachen Michael E
• Peterson Christopher

Classifications

• B64G1/443

  Photovoltaic cell arrays · CPC title

• H02S30/20 Primary

  Collapsible or foldable PV modules · CPC title

• H02S30/10

  Frame structures · CPC title

• B64G1/2228

  characterised by the hold-down or release mechanisms · CPC title

• B64G1/2229

  characterised by the deployment actuating mechanism (inflating B64G1/2227) · CPC title