High altitude aircraft with integrated solar cells, and associated systems and methods

A method of making a solar cell assembly, comprising:

• electrically connecting contact terminals on the backsides of multiple solar cells to each other with electrical connectors to form an electrically connected assembly of solar cells;
• placing the backsides of the multiple solar cells including the contact terminals in contact with a substrate;
• and
• applying heat and pressure to the electrically connected assembly of solar cells and the substrate after the solar cells have been electrically connected via the electrical connectors to simultaneously impress the electrically connected assembly of solar cells including the contact terminals and the electrical connectors into the substrate and bond the solar cells to the substrate,
• wherein the backsides of the multiple solar cells are opposite light incident sides of the multiple solar cells,
• wherein the substrate comprises a composite structure including:
• first and second fabric layers coated in adhesive;
• and
• a center core layer disposed between the first and second fabric layers,
• wherein the adhesive is cured when applying the heat and the pressure,
• wherein the solar cells are impressed into both the first fabric layer and the center core layer of the substrate while applying the heat and the pressure.

A method for making solar powered aircraft, comprising:

• placing multiple bare solar cells on a transparent film bearing a first adhesive with active surfaces of the solar cells against the first adhesive and backside surfaces of the bare solar cells facing away from the transparent film;
• electrically connecting contact terminals on the backside surfaces of the bare solar cells with electrical connectors to form an electrically connected assembly of solar cells;
• disposing a second adhesive against the backside surfaces of the bare solar cells;
• placing a substrate including two layers of fabric disposed on either side of a center core against the first and second adhesives;
• drawing a vacuum on a region including the bare solar cells, the contact terminals, the electrical connectors, the transparent film, and the substrate, wherein drawing the vacuum causes the backside surfaces of the bare solar cells and the contact terminals of the electrically connected assembly of solar cells to recess into a first one of the layers of fabric and the center core of the substrate while the bare solar cells are connected with the electrical connectors;
• and
• forming a wing surface or a stabilizer surface by heating the region to simultaneously cure the first and second adhesives and form a cohesive bond between the substrate, the bare solar cells and the transparent film.