Engineering Papers⌕ Search

Engineering topics

Costogue, E. N.

Publications and source records attributed to Costogue, E. N..

At least 19 records
All sourcesNASA NTRSDOE OSTI
NASA NTRS1985

Potential of thin-film solar cell module technology

During the past five years, thin-film cell technology has made remarkable progress as a potential alternative to crystalline silicon cell technology. The efficiency of a single-junction thin-film cell, which is the most promising for use in flat-plate modules, is now in the range of 11 percent with 1-sq cm cells consisting of amorphous silicon, CuInSe2 or CdTe materials. Cell efficiencies higher than 18 percent, suitable for 15 percent-efficient flat plate modules, would require a multijunction configuration such as the CdTe/CuInSe2 and tandem amorphous-silicon (a-Si) alloy cells. Assessments are presented of the technology status of thin-film-cell module research and the potential of achieving the higher efficiencies required for large-scale penetration into the photovoltaic (PV) energy market.

Shimada, K.↗
NASA NTRS1984

Silicon-sheet and thin-film cell and module technology potential: Issue study

The development of high-efficiency low-cost crystalline silicon ribbon and thih-film solar cells for the energy national photovoltaics program was examined. The findings of an issue study conducted are presented. The collected data identified the status of the technology, future research needs, and problems experienced. The potentials of present research activities to meet the Federal/industry long-term technical goal of achieving 15 cents per kilowatt-hour levelized PV energy cost are assessed. Recommendations for future research needs related to crystalline silicon ribbon and thin-film technologies for flat-plate collectors are also included.

Shimada, K.↗
NASA NTRS1984

Multijunction cells for concentrators: Technology prospects

Development of high-efficiency multijunction solar cells for concentrator applications is a key step in achieving the goals of the U.S. Department of Energy National Photovoltaics Program. This report summarizes findings of an issue study conducted by the Jet Propulsion Laboratory Photovoltaic Analysis and Integration Center, with the assistance of the Solar Energy Research Institute and Sandia National laboratoies, which surveyed multijunction cell research for concentrators undertaken by federal agencies and by private industry. The team evaluated the potentials of research activities sponsored by DOE and by corporate funding to achieve projected high-efficiency goals and developed summary statements regarding industry expectations. Recommendations are made for the direction of future work to address specific unresolved aspects of multijunction cell technology.

Ferber, R. R.↗
NASA NTRS1984

Polycrystalline silicon study: Low-cost silicon refining technology prospects and semiconductor-grade polycrystalline silicon availability through 1988

Photovoltaic arrays that convert solar energy into electrical energy can become a cost effective bulk energy generation alternative, provided that an adequate supply of low cost materials is available. One of the key requirements for economic photovoltaic cells is reasonably priced silicon. At present, the photovoltaic industry is dependent upon polycrystalline silicon refined by the Siemens process primarily for integrated circuits, power devices, and discrete semiconductor devices. This dependency is expected to continue until the DOE sponsored low cost silicon refining technology developments have matured to the point where they are in commercial use. The photovoltaic industry can then develop its own source of supply. Silicon material availability and market pricing projections through 1988 are updated based on data collected early in 1984. The silicon refining industry plans to meet the increasing demands of the semiconductor device and photovoltaic product industries are overviewed. In addition, the DOE sponsored technology research for producing low cost polycrystalline silicon, probabilistic cost analysis for the two most promising production processes for achieving the DOE cost goals, and the impacts of the DOE photovoltaics program silicon refining research upon the commercial polycrystalline silicon refining industry are addressed.

Costogue, E. N.↗
NASA NTRS1984

Polycrystalline silicon material availability and market pricing outlook for 1980 through 1988

The results of the second JPL update to an original report to assess the availability and prices of polycrystalline Si for solar cells in the 1983-88 interval are reported. It is noted that the demand for poly-Si for solar cells competes with the demand for the same material for semiconductors, although the solar cell industry can use material rejected from the semiconductor industry. A sufficient supply is projected for the 6 yr period, rising from 3224 metric tons to 10,220 metric tons in 1988, with prices dropping from the 1980 level of $140/kg to $25/kg. The price reduction and improved production are noted to be due in large part to DOE efforts at defining lower-cost production processes.

Costogue, E. N.↗
NASA NTRS1982

Polycrystalline silicon availability for photovoltaic and semiconductor industries

Markets, applications, and production techniques for Siemens process-produced polycrystalline silicon are surveyed. It is noted that as of 1982 a total of six Si materials suppliers were servicing a worldwide total of over 1000 manufacturers of Si-based devices. Besides solar cells, the Si wafers are employed for thyristors, rectifiers, bipolar power transistors, and discrete components for control systems. An estimated 3890 metric tons of semiconductor-grade polycrystalline Si will be used in 1982, and 6200 metric tons by 1985. Although the amount is expected to nearly triple between 1982-89, research is being carried out on the formation of thin films and ribbons for solar cells, thereby eliminating the waste produced in slicing Czolchralski-grown crystals. The free-world Si production in 1982 is estimated to be 3050 metric tons. Various new technologies for the formation of polycrystalline Si at lower costs and with less waste are considered. New entries into the industrial Si formation field are projected to produce a 2000 metric ton excess by 1988.

Ferber, R. R.↗
NASA NTRS1981

A photovoltaic industry overview - The results of a survey on photovoltaic technology industrialization

The National Photovoltaics Program of the United States Department of Energy has the objective of bringing photovoltaic power systems to a point where they can supply a significant portion of the United States energy requirements by the year 2000. This is planned to be accomplished through substantial research and technology development activities aimed at achieving major cost reductions and market penetration. This paper presents information derived from a limited survey performed to obtain photovoltaic industry attitudes concerning industrialization, and to determine current industry plans to meet the DOE program goals. Silicon material production, a key photovoltaic manufacturing industry, is highlighted with regards to implementation of technology improvement and silicon material supply outlook.

Ferber, R. R.↗
NASA NTRS1979

Solar array technology developments and design for electric propulsion application

The design, fabrication, and test of foldout and rollout multikilowatt solar array models are discussed. Consideration is given to the development of (1) thin 50-micron solar cells; (2) laminated Kapton plus substrates; (3) thin 50 to 100-micron coverglass; (4) low-mass structure designs; (5) low-mass blanket designs; and (6) solar insolation concentrators to enhance solar array performance. It is noted that the recent achievements in solar cell technology have shown that blanket specific power of 120 W/kg and higher is realizable for solar arrays, thus meeting propulsion stage requirements.

Costogue, E. N.↗
NASA NTRS1979

Bonding machine for forming a solar array strip

A machine is described for attaching solar cells to a flexable substrate on which printed circuitry has been deposited. The strip is fed through: (1) a station in which solar cells are elevated into engagement with solder pads for the printed circuitry and thereafter heated by an infrared lamp; (2) a station at which flux and solder residue is removed; (3) a station at which electrical performance of the soldered cells is determined; (4) a station at which an encapsulating resin is deposited on the cells; (5) a station at which the encapsulated solar cells are examined for electrical performance; and (6) a final station at which the resulting array is wound on a takeup drum.

Costogue, E. N.↗
NASA NTRS1978

Parametric study of two planar high power flexible solar array concepts

The design parameters examined were: frequency, aspect ratio, packaging constraints, and array blanket flatness. Specific power-to-mass ratios for both solar arrays as a function of array frequency and array width were developed and plotted. Summaries of the baseline design data, developed equations, the computer program operation, plots of the parameters, and the process for using the information as a design manual are presented.

Garba, J. A.↗
NASA NTRS1978

Automated solar-cell-array assembly machine

Continuous-feeding machine automatically bonds solar cells to printed-circuit substrate. In completed machine, cells move to test station where electrical characteristics could be checked. If performance of cell is below specifications, that cell is marked and removed. All machine functions are synchronized by electronics located within unit. It may help to lower costs in future solar-cell production.

Costogue, E. N.↗
NASA NTRS1978

Ultralow-mass solar-array designs for Halley's comet rendezvous mission

This paper describes the conceptual design study results of photovoltaic arrays capable of powering a Halley's comet rendezvous mission. This mission would be Shuttle-launched, employ a unique form of propulsion (ion drive) which requires high power levels for operation, and operate at distances between 0.6 and 4.5 AU. These requirements make it necessary to develop arrays with extremely high power-to-mass ratio (200 W/kg). In addition, the dual requirements of providing ion thruster power as well as housekeeping power leads to the development of unique methods for mode switching. Both planar and variable-concentrator-enhanced array concepts using ultrathin (50 micron) high-efficiency (up to 12.5%) silicon solar cells coupled with thin (75 micron) plastic encapsulants are considered. In order to satisfy the Shuttle launch environment it was necessary to provide novel methods of both storing and deploying these arrays.

Costogue, E. N.↗
NASA NTRS1978

Ultra-low-mass flexible planar solar arrays using 50-micron-thick solar cells

A conceptual design study has been completed which has shown the feasibility of ultra-low-mass planar solar arrays with specific power of 200 watts/kilogram. The beginning of life (BOL) power output of the array designs would be 10 kW at 1 astronomical unit (AU) and a 55C deg operating temperature. Two designs were studied: a retractable rollout design and a non-retractable fold-out. The designs employed a flexible low-mass blanket and low-mass structures. The blanket utilized 2 x 2 cm high-efficiency (13.5% at 28C deg AM0), ultra-thin (50 micron), silicon solar cells protected by thin (75 micron) plastic encapsulants. The structural design utilized the 'V'-stiffened approach which allows a lower mass boom to be used. In conjunction with the conceptual design, modules using the thin cells and plastic encapsulant were designed and fabricated.

Costogue, E. N.↗
NASA NTRS1977

Performance data for a terrestrial solar photovoltaic/water electrolysis experiment

A description is presented of the equipment used in the experiment, taking into account the surplus solar panel from the Mariner 4 spacecraft which was used as a solar array source and an electrolytic hydrogen generator. Attention is also given to operational considerations and performance data, system considerations and aspects of optimization, and large-scale hydrogen production considerations.

Costogue, E. N.↗
NASA NTRS1976

Comparison of candidate solar array maximum power utilization approaches

A study was made of five potential approaches that can be utilized to detect the maximum power point of a solar array while sustaining operations at or near maximum power and without endangering stability or causing array voltage collapse. The approaches studied included: (1) dynamic impedance comparator, (2) reference array measurement, (3) onset of solar array voltage collapse detection, (4) parallel tracker, and (5) direct measurement. The study analyzed the feasibility and adaptability of these approaches to a future solar electric propulsion (SEP) mission, and, specifically, to a comet rendezvous mission. Such missions presented the most challenging requirements to a spacecraft power subsystem in terms of power management over large solar intensity ranges of 1.0 to 3.5 AU. The dynamic impedance approach was found to have the highest figure of merit, and the reference array approach followed closely behind. The results are applicable to terrestrial solar power systems as well as to other than SEP space missions.

Costogue, E. N.↗
NASA NTRS1975

A reliability tradeoff study of interconnecting power processors to mercury ion thrusters

A Monte Carlo mission simulation program has been developed to optimize the solar electric propulsion (SEP) thrust subsystem configuration for an Encke comet rendezvous mission. This program examines several possible options for interconnecting power processors to the mercury ion thrusters in order to enhance mission reliability and to reduce SEP subsystem weight. The quantity of power processors and ion thrusters required to perform the mission successfully depends not only on the total required thrust, but also on the individual thruster and power processor performance and reliability. Based on these considerations, it was necessary to determine the quantity of the active power processors and ion thrusters required at any time and the means of providing redundancy. The results provide the basis for selecting an optimum SEP thrust subsystem for this mission and other missions.

Costogue, E. N.↗
NASA NTRS1974

Power processor design considerations for a solar electric propulsion spacecraft

Propulsion power processor design options are described. The propulsion power processor generated the regulated dc voltages and currents from a solar array source of a solar electric propelled spacecraft. The power processor consisted of 12 power supplies that provide the regulated voltages and currents necessary to power a 30-cm mercury ion thruster. The design options for processing unregulated solar array power and for generating the regulated power required by each supply are studied. The technical approaches utilized in the developed design and the technological limitation of the identified design options are discussed. Alternate approaches for delivering power to a number of mercury ion thrusters and methods of optimizing are described. It was concluded that this power processor design should be considered for application in solar electric propulsion missions of the future.

Costogue, E. N.↗