Development of lightweight solar panels Summary report, Jan. 1966 - Mar. 1969
Fabrication and test evaluation of lightweight solar panels
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Fabrication and test evaluation of lightweight solar panels
Problems were identified, using N/P solar cells at low temperature and low intensity; these problems were solved and the solutions incorporated in a manufacturing procedure. Theoretical analysis of the effects of low temperature and low intensity on the various solar cell characteristics indicated that the following behavior might be expected: (1) lower short circuit current,(2) higher open circuit voltage,(3) series resistance becoming less significant, and (4) shunt resistance becoming more critical.
This is the second quarterly technical report on a program, the goal of which is to achieve high efficiency GaAs solar cells. Analysis was concerned with providing design information for use in experimentally determining optimum solar cell process parameters. The first quarterly report contained the results of those design calculations. Using those results as a guide, experimental work was initiated to determine optimum cell process parameters. The initial results on this phase of the program are reported.
Solar cells and mesa diodes were fabricated by the implantation of zinc or beryllium ions into n-type gallium arsenide. Annealing temperatures above 750 C (zinc) or 650 C (beryllium) were found to produce 50% to 100% activation of the implanted ions. Junction depths of about 0.4 micron were produced by 600 keV zinc implants or 70 keV beryllium implants. P-layer sheet resistance was about 150 ohms for 2 x 10 to the 15th power cm/2 zinc or 1 x 10 to the 15th power cm/2 beryllium implants. This is sufficiently low for efficient solar cell fabrication. Contacting procedures were improved to yield reproducibly adherent, low resistance front and back contacts.
The UCSD solar X-ray instrument on the OSO-7 satellite observes X-ray bursts in the 2- to 300-keV range with 10.24-sec time resolution. Spectra obtained from the proportional counter and scintillation counter are analyzed for the event of Nov. 16, 1971, at 0519 UT in terms of thermal (exponential spectrum) and nonthermal (power law) components. The energy content of the approximately 20,000,000 K thermal plasma increased with the 60-sec duration hard X-ray burst, which entirely preceded the 5-keV soft X-ray maximum. If the hard X-rays arise by thick target bremsstrahlung, the nonthermal electrons above 10 keV have sufficient energy to heat the thermally emitting plasma. In the thin target case the collisional energy transfer from nonthermal electrons suffices if the power law electron spectrum is extrapolated below 10 keV, or if the ambient plasma density exceeds 4 x 10 to the 10th power per cu cm.
A solar energy collector design is disclosed that would be efficient for both energy transfer and fluid flow, based upon extensive parametric analyses. Thermal design requirements are generated for the energy storage systems which utilizes sensible heat storage in water. Properly size system components (including the collector and storage) and a practical, efficient total system configuration are determined by means of computer simulation of system performance.
High temporal and spatial resolution solar X-ray pictures of a flare at 1827 UT on 5 September 1973 were taken with the S-056 telescope on the Apollo telescope mount. Photographs taken at 9 sec intervals allow detailed information to be obtained about the site of the energy release, as well as about the evolution of the flare itself. Observations suggest that the flare occurred in an entire arcade of loops rather than in any single loop. Sequential brightening of different X-ray features indicates that some excitation moved perpendicular to the magnetic field of the arcade at velocities of 180 to 280 km/sec. The most intense X-ray features were located in places where the magnetic field composing the arcade had a small radius of curvature with horizontal field gradients higher than the surroundings region and where the axis of the arcade changed direction. It was felt that the arcade geometry strongly influenced the propagation of the triggering disturbance, as well as the storage and site of the subsequent deposition of energy. A magnetosonic wave is suggested as the propagating mechanism triggering instabilities that may have existed in the preflare structure.
A commercially available 3-ton residential Lithium Bromide (LiBr) absorption air conditioner was modified for use with lower temperature solar heated water. The modification included removal of components such as the generator, concentration control chamber, liquid trap, and separator; and the addition of a Chrysler designed generator, an off-the-shelf LiBr-solution pump. The design goal of the modified unit was to operate with water as the heat-transfer fluid at a target temperature of 85 C (185 F), 29.4 C (85 F) cooling water inlet, producing 10.5 kW (3 tons) of cooling. Tests were performed on the system before and after modification to provide comparative data. At elevated temperatures (96 C, 205 F), the test results show that Lithium Bromide was carried into the condenser due to the extremely violent boiling and degraded the evaporator performance.
Morphological and quantitative analyses are presented of a 1B solar flare that was observed with high spatial and temporal resolution by the S-054 grazing-incidence X-ray telescope aboard Skylab. It is found that the flare had the configuration of a compact region with a characteristic size of the order of 30 arcsec at the intensity peak, the interior of the region appeared to be highly structured and to consist of temporally changing complex loop systems, brightening over an extended part of the active region preceded the flare onset, and the impulsive phase was marked by rapid brightening in the loop structures. The X-ray photographs also indicate that the X-ray emission was centered over the neutral line of the longitudinal magnetic field, loop systems formed at successively increasing heights during the decay phase, and different regions of the flare had distinctly different light curves. The flux profiles for the different regions are shown to suggest continued heating during the decay phase. It is concluded that flare models should be based on a multiplicity of volumes ordered in loops of successively larger scale lengths and heights rather than on a single point of energy release and deposition.
A solar flare which occurred on Sept. 5, 1973, is discussed on the basis of high temporal and spatial resolution pictures taken with the Skylab S-056 X-ray telescope. The temporal evolution of the flare is outlined, and magnetic-field data for the active region are compared with the soft X-ray observations. A close similarity between calculated magnetic-field lines and the overall structure of the X-ray core is shown to suggest that the flare occurred in an entire arcade of loops rather than in a single loop. Sequential brightening of different X-ray features is taken as an indication that some triggering disturbance moved from one side to the other in the flare core at velocities of 180 to 280 km/s. The two most intense X-ray features were found in places where the magnetic field composing the arcade had a small radius of curvature with horizontal field gradients higher than the surrounding area and where the axis of the arcade changed direction. It is suggested that a magetosonic wave triggered the energy releases as it propagated down the arcade and steepened the field gradients
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Design and building of two unique components for solar heating (1. flatplate solar collector using no metal components, and 2. solar powered pump for heating and cooling systems are outlined in report. Report also discusses hardware, deliverable end items, problems encountered during fabrication and testing, and performance certification.
A baseline sequence for the manufacture of solar cell modules was specified. Starting with silicon wafers, the process goes through damage etching, texture etching, junction formation, plasma edge etch, aluminum back surface field formation, and screen printed metallization to produce finished solar cells. The cells were then series connected on a ribbon and bonded into a finished glass tedlar module. A number of steps required additional developmental effort to verify technical and economic feasibility. These steps include texture etching, plasma edge etch, aluminum back surface field formation, array layup and interconnect, and module edge sealing and framing.
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Two types of lightweight solar cell modules were prepared. The goal is to achieve a module with a power to weight ratio of 350 watts per kilogram. Both structures use thin cells approximately 50 micrometers thick and glass covers approximately 75 micrometers thick. In one structure the glass is bonded to the module using 93-500 silicone adhesive; while the other relies on heat and pressure bonding using FEP as the adhesive. Specific powers of about 335 watts per kilogram were achieved.
The Automated Lamination Station is mechanically complete and is currently undergoing final wiring. The high current driver and isolator boards have been completed and installed, and the main interface board is under construction. The automated vacuum chamber has had a minor redesign to increase stiffness and improve the cover open/close mechanism. Design of the Final Assembly Station has been completed and construction is underway.
Early studies of flat-plate arrays have projected costs on the order of $50/square meter for installed array support structures. This report describes an optimized low-cost frame-truss structure that is estimated to cost below $25/square meter, including all markups, shipping an installation. The structure utilizes a planar frame made of members formed from light-gauge galvanized steel sheet and is supposed in the field by treated-wood trusses that are partially buried in trenches. The buried trusses use the overburden soil to carry uplift wind loads and thus to obviate reinforced-concrete foundations. Details of the concept, including design rationale, fabrication and assembly experience, structural testing and fabrication drawings are included.