Process for fabricating lightweight, rigid solar array substrate

Claim 2

A process for making a rigid ultralightweight substrate from a thermoset plastic film comprising the steps of: (a) forming rigidizing members on a first sheet of the film by placing the sheet over a female mold having the desired configuration including indentations therein corresponding to the rigidizing members to be formed in the sheets, (b) bonding the first sheet and a second sheet together with an adhesive applied to the side of the first sheet opposite the rigidizing members, (c) curing the adhesive to bond the sheets together so that the rigidizing members will not collapse, and (d) removing the first sheet with the second sheet bonded thereto from the female mold.

Claim 3

The process of claim 1 wherein step (a) further includes: urging the first sheet into the indentations by means of male mating bars, and applying heat and pressure to the assemblage of the female mold, first sheet having rigidized members.

Claim 4

The process of claim 1 wherein a vacuum is applied to the first sheet to hold the sheet in the desired configuration prior to the curing of the adhesive.

Claim 5

The process of claim 3 wherein the assemblage of the female mold, first sheet, adhesive, and second sheet are subjected to pressure and heat to cure the adhesive.

Claim 6

The process of claim 4 wherein the vacuum is removed while the pressure is applied to the assemblage.

Claim 7

The process of claim 2 where prior to step (b), step (a) is repeated on the second sheet of film to thereby form rigidizing members in the second sheet, such that the adhesive of step (b) is applied to the side of the second sheet opposite the rigidizing members.

Claim 8

The process of claim 1 where the thermoset plastic is a polyimide that is resistant to ultraviolet light.

Claim 9

The process of claim 1 or 2 where the rigidizing members have a height greater than their width.

Claim 10

The process of claim 1, where during step (b) the adhesive flows in the ribs but does not completely fill them.

Claim 11

A process for making a rigid, ultralightweight substrate from a thermoset plastic film comprising the steps of: (a) forming ribs in a first sheet of the film by: (i) placing the sheet over a female mold of a desired configuration including elongated parallel grooves therein corresponding to the ribs to be formed in the sheet, (ii) urging the sheet into the grooves by means of male mating bars; and (iii) applying heat and pressure to the assemblage of the female mold, first sheet, and mating bars to thereby form a first ribbed sheet; (b) repeating step (a) on a second sheet of film to thereby form a second ribbed sheet; (c) removing the mating bars from the assemblages used in steps (a) and (b); (d) bonding the first and second ribbed sheets together with the ribs in the first sheet generally at right angles to the ribs in the second sheet and with the ribs of each sheet facing away from each other, said bonding including the application of an adhesive to the mating surfaces of the ribbed sheets, with the ribbed sheets held in the desired configuration in the female molds by a vacuum; (e) curing the adhesive to bond the ribbed sheets together so that the ribs will not collapse, and (f) removing the bonded ribbed sheets from the female molds.

Claim 12

A process for making a rigid, ultralightweight substrate from a thermoset plastic film comprising the steps of: (a) forming ribs in a first sheet of the film by: (i) placing the sheet over a female mold of a desired configuration including elongated parallel grooves therein corresponding to the ribs to be formed in the sheet, (ii) urging the sheet into the grooves by means of male mating bars; and (iii) applying heat and pressure to the assemblage of the female mold, first sheet, and mating bars to thereby form a first ribbed sheet; (b) repeating step (a) on a second sheet of film to thereby form a second ribbed sheet; (c) removing the mating bars from the assemblages used in steps (a) and (b); (d) bonding the first and second ribbed sheets together with the ribs in the first sheet generally at right angles to the ribs in the second sheet and with the ribs of each sheet facing away from each other, said bonding including the application of an adhesive to the mating surfaces of the ribbed sheets, with the ribbed sheets held in the desired configuration in the female molds by a vacuum; (e) curing the adhesive to bond the ribbed sheets together so that the ribs will not collapse, and (f) removing the bonded ribbed sheets from the female molds.

Claim 13

The process of claim 10 wherein the ribbed sheets are subjected to heat and pressure to cure the adhesive.

Claim 14

The process of claim 11 wherein the vacuum is removed while pressure is being applied.

Claim 15

The process of claim 10 where the thermoset plastic is a polyamide that is resistant to ultraviolet light.

Claim 16

The process of claim 10 where the male mating bars are placed in the female molds in a manner which does not stress the film excessively, causing it to tear.

Claim 17

The process of claims 10 or 13 where the ribs have a height greater than their width.

Claim 18

The process of claim 10 where, during steps (d) and (e), the adhesive flows in the ribs but does not completely fill them.

Claim 19

A process for making a rigid ultralightweight substrate from an ultraviolet resistant polyimide thermoset film having a thickness ranging between 0.005 to 0.010 inches comprising the steps of: (a) forming ribs in a first sheet of the film by: (i) placing the sheet over a female mold of a desired configuration including elongated parallel grooves therein corresponding to the ribs to be formed in the sheet, (ii) urging the sheet into the grooves by means of male mating bars; and (iii) applying heat and pressure to the assemblage of the female mold, first sheet, and mating bars to thereby form a first ribbed sheet; (b) repeating step (a) on a second sheet of film to thereby form a second ribbed sheet; (c) removing the mating bars from the assemblage used in steps (a) and (b); (d) bonding the first and second ribbed sheets together with the ribs in the first sheet generally at right angles to the ribs in the second sheet and with the ribs of each sheet facing away from each other, said bonding including the application of an adhesive to the mating surfaces of the ribbed sheets, with the ribbed sheets held in the desired configuration in the female molds by a vacuum; (e) curing the adhesive to bond the ribbed sheets together so that the ribs will not collapse, and (f) removing the bonded ribbed sheets from the female molds.

Claim 20

A process for making a rigid ultralightweight substrate from an ultraviolet resistant polyimide thermoset film having a thickness ranging between 0.005 to 0.010 inches comprising the steps of: (a) forming ribs in a first sheet of the film by: (i) placing the sheet over a female mold of a desired configuration including elongated parallel grooves therein corresponding to the ribs to be formed in the sheet, (ii) urging the sheet into the grooves by means of male mating bars; and (iii) applying heat and pressure to the assemblage of the female mold, first sheet, and mating bars to thereby form a first ribbed sheet; (b) repeating step (a) on a second sheet of film to thereby form a second ribbed sheet; (c) removing the mating bars from the assemblage used in steps (a) and (b); (d) bonding the first and second ribbed sheets together with the ribs in the first sheet generally at right angles to the ribs in the second sheet and with the ribs of each sheet facing away from each other, said bonding including the application of an adhesive to the mating surfaces of the ribbed sheets, with the ribbed sheets held in the desired configuration in the female molds by a vacuum; (e) curing the adhesive to bond the ribbed sheets together so that the ribs will not collapse, and (f) removing the bonded ribbed sheets from the female molds.

Claim 21

The process of claim 13 where, during the heating of the film, the temperature does not exceed 900° F.

Claim 22

The process of claim 14 where the width of the ribs is at least 0.010 inch.

Claim 23

A process for making rigidized ribs in a thermoset plastic film comprising steps of: (a) placing a sheet of the film over a female vacuum die of a desired configuration including a plurality of parallel spaced apart grooves, (b) urging the sheet into the grooves utilizing male form bars which are placed into the grooves in a manner which does not stress the sheet excessively, causing a tear, (c) placing the female vacuum mold, film and male form bars into a platen press, (d) closing the platen press and applying heat to the assembly to form a first ribbed sheet, (e) removing the female vacuum die and male form bars from the platen press and cooling them to ambient temperature, (f) applying a vacuum to the ribbed film to maintain the desired configuration of the film when the male form bars are removed, and (g) removing the male form bars from the female vacuum die.

Claim 24

A process for making rigidized ribs in a thermoset plastic film comprising steps of: (a) placing a sheet of the film over a female vacuum die of a desired configuration including a plurality of parallel spaced apart grooves, (b) urging the sheet into the grooves utilizing male form bars which are placed into the grooves in a manner which does not stress the sheet excessively, causing a tear, (c) placing the female vacuum mold, film and male form bars into a platen press, (d) closing the platen press and applying heat to the assembly to form a first ribbed sheet, (e) removing the female vacuum die and male form bars from the platen press and cooling them to ambient temperature, (f) applying a vacuum to the ribbed film to maintain the desired configuration of the film when the male form bars are removed, and (g) removing the male form bars from the female vacuum die.

Claim 25

The process of claim 20 wherein the heat applied in step (d) is at a temperature of 300° to 350° F. for one (1) hour at about 50 psig to shrink the film and eliminate wrinkling.

Claim 26

A process for making rigidized ribs in a thermoset plastic film comprising the steps of: (a) placing a first sheet of the film over a female die having a desired configuration including a plurality of grooves therein corresponding to the ribs to be formed in the sheet, (b) urging the sheet into the grooves utilizing male form bars which are placed into the grooves in a manner which does not stress the film excessively causing it to tear, (c) placing the male form bars, film, and female die into a platen press, (d) closing the platen press and raising the temperature of the film to approximately 700° to 750° F. for approximately five (5) minutes, (e) cooling the female die to a minimum of 200° F., (f) opening the platen press and removing the female die, film, and male form bars from the press, and (g) removing the male form bars from the grooves.

Claim 27

A process for making rigidized ribs in a thermoset plastic film comprising the steps of: (a) placing a first sheet of the film over a female die having a desired configuration including a plurality of grooves therein corresponding to the ribs to be formed in the sheet, (b) urging the sheet into the grooves utilizing male form bars which are placed into the grooves in a manner which does not stress the film excessively causing it to tear, (c) placing the male form bars, film, and female die into a platen press, (d) closing the platen press and raising the temperature of the film to approximately 700° to 750° F. for approximately five (5) minutes, (e) cooling the female die to a minimum of 200° F., (f) opening the platen press and removing the female die, film, and male form bars from the press, and (g) removing the male form bars from the grooves.