# US 12,119,424 B2 · Automated assembly and mounting of solar cells on a honeycomb support > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 12,119,424 B2 - Document ID: US12119424B2 - Status: Granted - Kind: B2 - Application number: 17/198,916 - Filed: 2021-03-11 - Published: 2021-07-01 - Granted: 2024-10-15 - Earliest claimed: 2015-07-09 - Assignees: SolAero Technologies Corp. - Applicants: SolAero Technologies Corp. - Inventors: Marvin B. Clevenger; Benjamin C. Richards; Cory Tourino - Web page: https://patentgrep.com/patent/US12119424B2 ## CPC - H10F 71/137: {Batch treatment of the devices} - B29C 65/78: Means for handling the parts to be joined, e.g. for making containers or hollow articles {, e.g. means for handling sheets, plates, web-like materials, tubular articles, hollow articles or elements to be joined therewith; Means for discharging the joined articles from the joining apparatus} - H10F 19/00: Integrated devices, or assemblies of multiple devices, comprising at least one photovoltaic cell covered by group H10F10/00, e.g. photovoltaic modules - H10F 19/80: Encapsulations or containers for integrated devices, or assemblies of multiple devices, having photovoltaic cells - H10F 19/85: Protective back sheets - Y02E 10/50: Photovoltaic [PV] energy - Y02P 70/50: Manufacturing or production processes characterised by the final manufactured product - H10F: INORGANIC SEMICONDUCTOR DEVICES SENSITIVE TO INFRARED RADIATION, LIGHT, ELECTROMAGNETIC RADIATION OF SHORTER WAVELENGTH OR CORPUSCULAR RADIATION - B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00) - Y02E: REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION - Y02P: CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS ## Abstract A method of fabricating a solar cell array module comprising providing a support, providing a face sheet having a top side and an opposite bottom side, mounting the bottom side of the face sheet on the support, providing a pattern of discrete predefined adhesive regions in an automated manner on the top side of the face sheet using machine vision and mounting an array of solar cell assemblies on the adhesive regions in an automated manner on the top side of the face sheet. ## Claims ### Claim 1 A method of fabricating a solar cell array module comprising: a. providing a support; b. providing a face sheet having a top side and an opposite bottom side; c. mounting the bottom side of the face sheet on the support; d. providing a pattern of discrete predefined adhesive regions in an automated manner on the top side of the face sheet using machine vision; and e. mounting an array of solar cell assemblies on the adhesive regions in an automated manner on the top side of the face sheet. ### Claim 2 (depends on 1) A method of fabricating a solar array module as defined in claim 1, wherein the step of providing a pattern of discrete predefined adhesive regions is performed subsequent to the mounting of the bottom side of the face sheet on the support. ### Claim 3 (depends on 2) A method as defined in claim 2, wherein the support is an aluminum honeycomb support and the face sheet is composed of a polyimide sheet, a carbon composite, or an aluminum panel. ### Claim 4 (depends on 1) A method as defined in claim 1, wherein the pattern of discrete predefined adhesive regions is a patch that is sized and shaped to match and be congruent to that of a peripheral outline of the solar cell assembly. ### Claim 5 (depends on 4) A method of claim 4, wherein the patch is double-sided and bonded to the face sheet by a co-curing process. ### Claim 6 (depends on 1) A method as defined in claim 1, further comprising providing a pattern of discrete predefined adhesive regions on the bottom side of the support which are shaped and sized to match selected surface portions of the support. ### Claim 7 (depends on 1) A method of claim 1, wherein the face sheet is a flexible film composed of a polyimide. ### Claim 8 (depends on 7) A method of claim 7, wherein the flexible film is composed of a poly (4, 4′-oxydiphenylene-pyromellitimide) material. ### Claim 9 (depends on 7) A method of claim 7, wherein a bottom surface of each of the solar cell assemblies is composed of a metal layer, and each of the solar cell assemblies is sequentially bonded to the support by automatic application of pressure or heat. ### Claim 10 (depends on 7) A method of claim 7, wherein the bottom side of the face sheet is mounted to a plurality of layers of carbon composite sheets embedded in a matrix of cyanate ester adhesive and co-cured with the face sheet. ### Claim 11 (depends on 1) A method of claim 1, wherein the solar cell assembly has a dimension in the range of 100 microns to 3 cm. ### Claim 12 (depends on 1) A method of claim 1, wherein the support has a thickness of between 25 and 100 microns. ### Claim 13 (depends on 1) A method of claim 1, wherein the solar cell assemblies are provided on a release carrier and are automatically transferred from the release carrier to the face sheet. ### Claim 14 (depends on 1) A method of claim 1, wherein the adhesive region is composed of an acrylic or a silicone adhesive. ### Claim 15 (depends on 1) A method of claim 1, wherein the discrete predefined regions on the second side of the support is composed of a double-faced pressure-sensitive adhesive (PSA) and is mounted to the surface of a supporting panel of a satellite or space vehicle. ### Claim 16 (depends on 15) A method of claim 15, wherein the discrete predefined PSA regions on the second side of the support are mounted adjacent to a surface of a supporting panel of a CubeSat. ### Claim 17 (depends on 1) A method as defined in claim 1, wherein the pattern of discrete predefined adhesive regions is a double-sided patch that is positioned on the backside of the solar cell assembly before making the bonding connection. ### Claim 18 (depends on 1) A method of claim 1, wherein the array of solar cell assemblies are automatically interconnected using a pick and place process for positioning the interconnectors between adjacent solar cell assemblies followed by automatic parallel gap welding. ### Claim 19 (depends on 1) A method of claim 1, wherein the solar cell assembly is a cover glass-interconnect-solar cell assembly with a multijunction solar cell based on III-V compound semiconductor material.