The Integration of Solar Panels onto a Carbon Fiber Structure for a Solar-Powered UAS

For a solar-powered unmanned aerial system (UAS), the performance and integration of the solar panel are of paramount importance. This paper examines the safety aspects of solar panels in electrical power systems, with a particular focus on the installation of solar cells onto an aircraft’s carbon fiber wing. Three distinct installation techniques are evaluated, and their respective advantages and disadvantages are discussed. A preliminary test is conducted to assess the viability of adhering commercial solar panels intended for boats using a bio-adhesive layer placed underneath the series of encapsulated solar panels. To ensure adhesion, the piece is placed under a vacuum. The subsequent test evaluates the lamination of the solar cells onto the carbon fiber skin with a resin as a component of the laminate. Finally, as a definitive solution, the adhesion of the solar panels onto the entire polymer layer used to seal the solar cells themselves was evaluated. This solution offers objective advantages in terms of adhesion, lightness and whiteness. Adhesion is guaranteed by the bond of the thermoplastic polymer used to seal the photovoltaic cells and the epoxy resin of the laminate. The bond is created through the autoclave process, which involves placing the laminate and solar cells in an oven at a specific temperature and pressure for a defined period of time. This solution results in a weight reduction of approximately three times compared to a solution not specifically designed for these materials and a reduction in thickness of approximately two times.