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At least 469 records · Page 26

Semiconductor Laser Low Frequency Noise Characterization

This work summarizes the efforts in identifying the fundamental noise limit in semiconductor optical sources (lasers) to determine the source of 1/F noise and it's associated behavior. In addition, the study also addresses the effects of this 1/F noise on RF phased arrays. The study showed that the 1/F noise in semiconductor lasers has an ultimate physical limit based upon similar factors to fundamental noise generated in other semiconductor and solid state devices. The study also showed that both additive and multiplicative noise can be a significant detriment to the performance of RF phased arrays especially in regard to very low sidelobe performance and ultimate beam steering accuracy. The final result is that a noise power related term must be included in a complete analysis of the noise spectrum of any semiconductor device including semiconductor lasers.

SEMICONDUCTOR LASERS↗

Tunable Dielectric Materials and Devices for Broadband Wireless Communications

Wireless and satellite communications are a rapidly growing industries which are slated for explosive growth into emerging countries as well as countries with advanced economies. The dominant trend in wireless communication systems is towards broadband applications such as multimedia file transfer, video transmission and Internet access. These applications require much higher data transmission rates than those currently used for voice transmission applications. To achieve these higher data rates, substantially larger bandwidths and higher carrier frequencies are required. A key roadblock to implementing these systems at K-band (18-26.5 GHz) and Ka-band (26.5-40 GHz) is the need to develop hardware which meets the requirements for high data rate transmission in a cost effective manner. In this chapter, we report on the status of tunable dielectric thin films for devices, such as resonators, filters, phased array antennas, and tunable oscillators, which utilize nonlinear tuning in the control elements. Paraelectric materials such as Barium Strontium Titanate ((Ba, Sr)TiO3) have dielectric constants which can be tuned by varying the magnitude of the electric field across the material. Therefore, these materials can be used to control the frequency and/or phase response of various devices such as electronically steerable phased array antennas, oscillators, and filters. Currently, tunable dielectric devices are being developed for applications which require high tunability, low loss, and good RF power-handling capabilities at microwave and millimeter-wave frequencies. These properties are strongly impacted by film microstructure and device design, and considerable developmental work is still required. However, in the last several years enormous progress has occurred in this field, validating the potential of tunable dielectric technology for broadband wireless communication applications. In this chapter we summarize how film processing techniques, microwave test configurations, and prototype devices have combined to drive the field to its current stage of development.

Mueller, Carl H.↗

Potential Applications of Active Antenna Technologies for Emerging NASA Space Communications Scenarios

Abstract—The National Aeronautics and Space Administration (NASA) is presently embarking on the implementation of far-reaching changes within the framework of both space and aeronautics communications architectures. For example, near earth relays are looking to transition from the traditional few large geostationary satellites to satellite constellations consisting of thousands of small low earth orbiting satellites while lunar space communications will require the need to relay data from many assets distributed on the lunar surface back to earth. Furthermore, within the aeronautics realm, satellite communications for beyond line of sight (BLOS) links are being investigated in tandem with the proliferation of unmanned aerial systems (UAS) within the urban air mobility (UAM) environment. In all of these scenarios, future communications architectures will demand the need to connect and quickly transition between many nodes for large data volume transport. As such, NASA Glenn Research Center (GRC) has been heavily investigating the development of low cost phased array technologies that can readily address these various scenario conditions. In particular, GRC is presently exploring 5G-based beamformer technologies to leverage commercial timescale and volume production cycles which have heretofore not existed within the frequency allocations utilized for NASA applications. In this paper, an overview of the potential future applications of phased arrays being envisioned by NASA are discussed, along with technology feasibility demonstrations being conducted by GRC implementing low cost, 5G based beamformer technologies.

Nessel, James A.↗

Airframe Noise Results from the QTD II Flight Test Program

With continued growth in air travel, sensitivity to community noise intensifies and materializes in the form of increased monitoring, regulations, and restrictions. Accordingly, realization of quieter aircraft is imperative, albeit only achievable with reduction of both engine and airframe components of total aircraft noise. Model-scale airframe noise testing has aided in this pursuit; however, the results are somewhat limited due to lack of fidelity of model hardware, particularly in simulating full-scale landing gear. Moreover, simulation of true in-flight conditions is non-trivial if not infeasible. This paper reports on an investigation of full-scale landing gear noise measured as part of the 2005 Quiet Technology Demonstrator 2 (QTD2) flight test program. Conventional Boeing 777-300ER main landing gear were tested, along with two noise reduction concepts, namely a toboggan fairing and gear alignment with the local flow, both of which were down-selected from various other noise reduction devices evaluated in model-scale testing at Virginia Tech. The full-scale toboggan fairings were designed by Goodrich Aerostructures as add-on devices allowing for complete retraction of the main gear. The baseline-conventional gear, faired gear, and aligned gear were all evaluated with the high-lift system in the retracted position and deployed at various flap settings, all at engine idle power setting. Measurements were taken with flyover community noise microphones and a large aperture acoustic phased array, yielding far-field spectra, and localized sources (beamform maps). The results were utilized to evaluate qualitatively and quantitatively the merit of each noise reduction concept. Complete similarity between model-scale and full-scale noise reduction levels was not found and requires further investigation. Far-field spectra exhibited no noise reduction for both concepts across all angles and frequencies. Phased array beamform maps show inconclusive evidence of noise reduction at selective frequencies (1500 to 3000 Hz) but are otherwise in general agreement with the far-field spectra results (within measurement uncertainty).

Elkoby, Ronen↗

A combined electron beam/optical lithography process step for the fabrication of sub-half-micron-gate-length MMIC chips

Advanced radar and communication systems rely heavily on state-of-the-art microelectronics. Systems such as the phased-array radar require many transmit/receive (T/R) modules which are made up of many millimeter wave - microwave integrated circuits (MMIC's). The heart of a MMIC chip is the Gallium Arsenide (GaAs) field-effect transistor (FET). The transistor gate length is the critical feature that determines the operating frequency of the radar system. A smaller gate length will typically result in a higher frequency. In order to make a phased array radar system economically feasible, manufacturers must be capable of producing very large quantities of small-gate-length MMIC chips at a relatively low cost per chip. This requires the processing of a large number of wafers with a large number of chips per wafer, minimum processing time, and a very high chip yield. One of the bottlenecks in the fabrication of MIMIC chips is the transistor gate definition. The definition of sub-half-micron gates for GaAs-based field-effect transistors is generally performed by direct-write electron beam lithography (EBL). Because of the throughput limitations of EBL, the gate-layer fabrication is conventionally divided into two lithographic processes where EBL is used to generate the gate fingers and optical lithography is used to generate the large-area gate pads and interconnects. As a result, two complete sequences of resist application, exposure, development, metallization and lift-off are required for the entire gate structure. We have baselined a hybrid process, referred to as EBOL (electron beam/optical lithography), in which a single application of a multi-level resist is used for both exposures. The entire gate structure, (gate fingers, interconnects and pads), is then formed with a single metallization and lift-off process. The EBOL process thus retains the advantages of the high-resolution E-beam lithography and the high throughput of optical lithography while essentially eliminating an entire lithography/metallization/lift-off process sequence. This technique has been proven to be reliable for both trapezoidal and mushroom gates and has been successfully applied to metal-semiconductor and high-electron-mobility field-effect transistor (MESFET and HEMT) wafers containing devices with gate lengths down to 0.10 micron and 75 x 75 micron gate pads. The yields and throughput of these wafers have been very high with no loss in device performance. We will discuss the entire EBOL process technology including the multilayer resist structure, exposure conditions, process sensitivities, metal edge definition, device results, comparison to the standard gate-layer process, and its suitability for manufacturing.

Sewell, James S.↗

Automated Array Assembly, Phase 2

The solar cell module process development activities in the areas of surface preparation are presented. The process step development was carried out on texture etching including the evolution of a conceptual process model for the texturing process; plasma etching; and diffusion studies that focused on doped polymer diffusion sources. Cell processing was carried out to test process steps and a simplified diode solar cell process was developed. Cell processing was also run to fabricate square cells to populate sample minimodules. Module fabrication featured the demonstration of a porcelainized steel glass structure that should exceed the 20 year life goal of the low cost silicon array program. High efficiency cell development was carried out in the development of the tandem junction cell and a modification of the TJC called the front surface field cell. Cell efficiencies in excess of 16 percent at AM1 have been attained with only modest fill factors. The transistor-like model was proposed that fits the cell performance and provides a guideline for future improvements in cell performance.

Carbajal, B. G.↗

PIV Measurements of a Low-noise Top-mounted Propulsion Installation for a Supersonic Airliner

A model-scale exhaust system was tested to validate low-noise propulsion concepts and noise prediction methods. The tests involved far-field acoustics, phased array, and particle image velocimetry (PIV). This paper covers the particle image velocimetry portion. Data was acquired at NASA Glenn's Aero-Acoustic Propulsion Lab for a series of nozzles with different chevron designs, both uninstalled and installed on a representative aircraft planform. The impact of the various chevron treatments on the turbulent velocity field was documented, along with the impact of the pylon and planform. When correlated with far-field acoustic measurements and phased array measurements, reported in companion papers, the explanation of acoustic benefits from top-mounted propulsion is clear as is the path toward optimization of the concept.

Propulsion Airframe Integration↗

Airframe Noise from a Hybrid Wing Body Aircraft Configuration

A high fidelity aeroacoustic test was conducted in the NASA Langley 14- by 22-Foot Subsonic Tunnel to establish a detailed database of component noise for a 5.8% scale HWB aircraft configuration. The model has a modular design, which includes a drooped and a stowed wing leading edge, deflectable elevons, twin verticals, and a landing gear system with geometrically scaled wheel-wells. The model is mounted inverted in the test section and noise measurements are acquired at different streamwise stations from an overhead microphone phased array and from overhead and sideline microphones. Noise source distribution maps and component noise spectra are presented for airframe configurations representing two different approach flight conditions. Array measurements performed along the aircraft flyover line show the main landing gear to be the dominant contributor to the total airframe noise, followed by the nose gear, the inboard side-edges of the LE droop, the wing tip/LE droop outboard side-edges, and the side-edges of deployed elevons. Velocity dependence and flyover directivity are presented for the main noise components. Decorrelation effects from turbulence scattering on spectral levels measured with the microphone phased array are discussed. Finally, noise directivity maps obtained from the overhead and sideline microphone measurements for the landing gear system are provided for a broad range of observer locations.

Hutcheson, Florence V.↗

Optical technologies for space communication systems; Proceedings of the Meeting, Los Angeles, CA, Jan. 15, 16, 1987

The conference presents papers on optical communications in space, diode laser transmitters, lasercom link transmission characteristics, lasercom systems and technologies, high frequency optical components, and optically controlled phased array antennas. Particular attention is given to a deep space optical communications development program, 0.87-micron CSP diode lasers for spaceborne communications, performance measurements of a diode laser optical communications link with Q = 4 PPM signaling, the optical communications link design for the tracking and data acquisition system, and a cost-performance model for ground-based optical communications receiving telescopes. Other topics include optoelectronic componentry for the direct transmission of microwave signals over optical fiber, applications of monolithic detectors, and optical control considerations for phased array antennas.

Bhasin, Kul↗

Status of the Direct Data Distribution (D(exp 3)) Experiment

NASA Glenn Research Center's Direct Data Distribution (D3) project will demonstrate an advanced, high-performance communications system that transmits information from an advanced technology payload carried by a NASA spacecraft in low Earth orbit (LEO) to a small receiving terminal on Earth. The space-based communications package will utilize a solid-state, K-band phased-array antenna that electronically steers the radiated energy beam toward a low-cost, tracking ground terminal, thereby providing agile, vibration-free, electronic steering at reduced size and weight with increased reliability. The array-based link will also demonstrate new digital processing technology that will allow the transmission of substantially increased amounts of latency-tolerant data collected from the LEO spacecraft directly to NASA field centers, principal investigators, or into the commercial terrestrial communications network. The technologies demonstrated by D3 will facilitate NASA's transition from using Government-owned communication assets to using commercial communication services. The hardware for D3 will incorporate advanced technology components developed under the High Rate Data Delivery (HRDD) Thrust Area of NASA's Office of Aerospace Technology Space Base Program at Glenn's Communications Technology Division. The flight segment components will include the electrically steerable phased-array antenna, which is being built by the Raytheon System Corporation and utilizes monolithic microwave integrated circuit (MMIC) technology operating at 19.05 GHz; and the digital encoder/modulator chipset, which uses four-channel orthogonal frequency division multiplexing (OFDM). The encoder/modulator will use a chipset developed by SICOM, Inc., which is both bandwidth and power efficient. The ground segment components will include a low-cost, open-loop tracking ground terminal incorporating a cryoreceiver to minimize terminal size without compromising receiver capability. The project is planning to hold a critical design review in the second quarter of fiscal year 2002.

Wald, Lawrence↗

Noise Measurements of a Low-Noise Top-Mounted Propulsion Installation for a Supersonic Airliner

A model-scale exhaust system was tested to validate low-noise concepts and noise prediction methods. The tests involved far-field acoustics, translating phased array, and particle image velocimetry; this report covers the far-field acoustic measurements. Data were acquired for a series of nozzles with different chevron designs, both uninstalled and installed on a representative aircraft planform. The impact of the various chevron treatments on the far-field noise was documented, along with the impact of the pylon and planform. For the baseline nozzle, installation produced a 2EPNdB reduction, as assumed in system studies. Chevrons were used to shift noise sources upstream to maximize the installation benefits and to reduce unshielded sources downstream. These resulted in reductions of 4-5EPNdB relative to the uninstalled baseline nozzle. Detailed analysis of spectral directivities behind the integrated EPNL metric gave insight into how well these concepts actually work. When correlated with particle image velocimetry measurements and phased array measurements, reported in companion papers, the explanation of acoustic benefits from top-mounted propulsion is clear as is the path toward optimization of the concept.

Supersonics↗

Electrically-Tunable Group Delays Using Quantum Wells in a Distributed Bragg Reflector

There is a growing interest in the fabrication of semiconductor optical group delay lines for the development of phased arrays of Vertical-Cavity Surface-Emitting Lasers (VCSELs). We present a novel structure incorporating In(x)GA(1-x)As quantum wells in the GaAs quarter-wave layers of a GaAs/AlAs distributed Bragg reflector (DBR). Application of an electric field across the quantum wells leads to red shifting and peak broadening of the el-hhl exciton peak via the quantum-confined Stark effect. Resultant changes in the index of refraction thereby provide a means for altering the group delay of an incident laser pulse. We discuss the tradeoffs between the maximum amount of change in group delay versus absorption losses for such a device. We also compare a simple theoretical model to experimental results, and discuss both angle and position tuning of the BDR band edge resonance relative to the exciton absorption peak. The advantages of such monolithically grown devices for phased-array VCSEL applications will be detailed.

Nelson, Thomas R., Jr.↗

Flexible User Radio for Lunar Missions

NASA’s Artemis program and other lunar exploration and development programs are planning over 40 lunar missions before 2030. Lunar missions, both crewed and uncrewed, include orbiters, landers, rovers, and surface stations. All these missions require communications with Earth, either via Direct to Earth (DTE) links or through relays in lunar orbit. Multiple DTE options are available among existing and planned ground stations: Deep Space Network (DSN), European Space Agency, and others. Relay options include the planned Lunar Gateway, LunaNet compliant relays, and some lunar landers propose to launch dedicated orbiters. The dilemma for lunar system designers is to identify a communication link which meets mission requirements but does not have issues of limited access (e.g. DSN is in high demand supporting deep space missions with high priority and some with inflexible schedules), system impacts (high power Radio Frequency (RF) for DTE links), cost (dedicated relay), or operational date. To avoid this difficult decision, a Flexible Radio for Lunar Missions is proposed, which will enable system designs to proceed prior to any final decision on the communication network to be used, by enabling compatibility with any of multiple DTE or orbital relay communication systems. The Flexible Radio will support the necessary frequency, bandwidth, modulation, and power requirements to interoperate with the majority of known or planned DTE or relay systems, and can be designed into a lunar mission without prior knowledge of which link will ultimately be used. Furthermore, the link being used can be changed as needed during the mission, in near real time. The Flexible Radio design will leverage work already completed at NASA in the areas of Wideband RF, Software Defined Radio, Adaptive Coding and Modulation, and Phased Array antennas. The Flexible Radio requires sufficient bandwidth to cover the allocated frequencies for both the operation of links in cislunar space and for space-to-Earth links; the flexibility to support multiple modulations, data rates, and coding schemes; the ability to identify available relays, detect and recognize the signals of those relays, and adapt its own frequency, modulation, symbol rate, and code rate to operate with the detected relay (or DTE station); and finally, it requires appropriate software to support network configuration and interoperability with the detected network. The Flexible Radio can be designed in a sufficiently small, lightweight, and low-power package to be used in a wide variety of lunar systems. The initial implementation, as proposed, will focus on the Ka-band, supporting up to 2 GHz bandwidth around the 27 GHz frequency for return links, and 23 GHz for forward links. Other frequency bands are under consideration for future configurations. The software defined modem will support OQPSK, BPSK, and NASA-defined modulations which also support two-way ranging with data. For near-real time adaptation, the Flexible Radio will scan the sky for available relays, using a phased array antenna with Adaptive/Cognitive Communications. It will then configure for network interoperability supporting DTN and other protocol options. The Flexible Radio will support scheduled connections and on-demand use when available.

Lunar Space Communications↗

Flexible User Radio for Lunar Missions

NASA’s Artemis program and other lunar exploration and development programs are planning over 40 lunar missions before 2030. Lunar missions, both crewed and uncrewed, include orbiters, landers, rovers, and surface stations. All these missions require communications with Earth, either via Direct to Earth (DTE) links or through relays in lunar orbit. Multiple DTE options are available among existing and planned ground stations: Deep Space Network (DSN), European Space Agency, and others. Relay options include the planned Lunar Gateway, LunaNet compliant relays, and some lunar landers propose to launch dedicated orbiters. The dilemma for lunar system designers is to identify a communication link which meets mission requirements but does not have issues of limited access (e.g. DSN is in high demand supporting deep space missions with high priority and some with inflexible schedules), system impacts (high power Radio Frequency (RF) for DTE links), cost (dedicated relay), or operational date. To avoid this difficult decision, a Flexible Radio for Lunar Missions is proposed, which will enable system designs to proceed prior to any final decision on the communication network to be used, by enabling compatibility with any of multiple DTE or orbital relay communication systems. The Flexible Radio will support the necessary frequency, bandwidth, modulation, and power requirements to interoperate with the majority of known or planned DTE or relay systems, and can be designed into a lunar mission without prior knowledge of which link will ultimately be used. Furthermore, the link being used can be changed as needed during the mission, in near real time. The Flexible Radio design will leverage work already completed at NASA in the areas of Wideband RF, Software Defined Radio, Adaptive Coding and Modulation, and Phased Array antennas. The Flexible Radio requires sufficient bandwidth to cover the allocated frequencies for both the operation of links in cislunar space and for space-to-Earth links; the flexibility to support multiple modulations, data rates, and coding schemes; the ability to identify available relays, detect and recognize the signals of those relays, and adapt its own frequency, modulation, symbol rate, and code rate to operate with the detected relay (or DTE station); and finally, it requires appropriate software to support network configuration and interoperability with the detected network. The Flexible Radio can be designed in a sufficiently small, lightweight, and low-power package to be used in a wide variety of lunar systems. The initial implementation, as proposed, will focus on the Ka-band, supporting up to 2 GHz bandwidth around the 27 GHz frequency for return links, and 23 GHz for forward links. Other frequency bands are under consideration for future configurations. The software defined modem will support OQPSK, BPSK, and NASA-defined modulations which also support two-way ranging with data. For near-real time adaptation, the Flexible Radio will scan the sky for available relays, using a phased array antenna with Adaptive/Cognitive Communications. It will then configure for network interoperability supporting DTN and other protocol options. The Flexible Radio will support scheduled connections and on-demand use when available.

Lunar Space Communications↗

Automated Antenna Design with Evolutionary Algorithms

Current methods of designing and optimizing antennas by hand are time and labor intensive, and limit complexity. Evolutionary design techniques can overcome these limitations by searching the design space and automatically finding effective solutions. In recent years, evolutionary algorithms have shown great promise in finding practical solutions in large, poorly understood design spaces. In particular, spacecraft antenna design has proven tractable to evolutionary design techniques. Researchers have been investigating evolutionary antenna design and optimization since the early 1990s, and the field has grown in recent years as computer speed has increased and electromagnetic simulators have improved. Two requirements-compliant antennas, one for ST5 and another for TDRS-C, have been automatically designed by evolutionary algorithms. The ST5 antenna is slated to fly this year, and a TDRS-C phased array element has been fabricated and tested. Such automated evolutionary design is enabled by medium-to-high quality simulators and fast modern computers to evaluate computer-generated designs. Evolutionary algorithms automate cut-and-try engineering, substituting automated search though millions of potential designs for intelligent search by engineers through a much smaller number of designs. For evolutionary design, the engineer chooses the evolutionary technique, parameters and the basic form of the antenna, e.g., single wire for ST5 and crossed-element Yagi for TDRS-C. Evolutionary algorithms then search for optimal configurations in the space defined by the engineer. NASA's Space Technology 5 (ST5) mission will launch three small spacecraft to test innovative concepts and technologies. Advanced evolutionary algorithms were used to automatically design antennas for ST5. The combination of wide beamwidth for a circularly-polarized wave and wide impedance bandwidth made for a challenging antenna design problem. From past experience in designing wire antennas, we chose to constrain the evolutionary design to a monopole wire antenna. The results of the runs produced requirements-compliant antennas that were subsequently fabricated and tested. The evolved antenna has a number of advantages with regard to power consumption, fabrication time and complexity, and performance. Lower power requirements result from achieving high gain across a wider range of elevation angles, thus allowing a broader range of angles over which maximum data throughput can be achieved. Since the evolved antenna does not require a phasing circuit, less design and fabrication work is required. In terms of overall work, the evolved antenna required approximately three person-months to design and fabricate whereas the conventional antenna required about five. Furthermore, when the mission was modified and new orbital parameters selected, a redesign of the antenna to new requirements was required. The evolutionary system was rapidly modified and a new antenna evolved in a few weeks. The evolved antenna was shown to be compliant to the ST5 mission requirements. It has an unusual organic looking structure, one that expert antenna designers would not likely produce. This antenna has been tested, baselined and is scheduled to fly this year. In addition to the ST5 antenna, our laboratory has evolved an S-band phased array antenna element design that meets the requirements for NASA's TDRS-C communications satellite scheduled for launch early next decade. A combination of fairly broad bandwidth, high efficiency and circular polarization at high gain made for another challenging design problem. We chose to constrain the evolutionary design to a crossed-element Yagi antenna. The specification called for two types of elements, one for receive only and one for transmit/receive. We were able to evolve a single element design that meets both specifications thereby simplifying the antenna and reducing testing and integration costs. The highest performance antenna found using a getic algorithm and stochastic hill-climbing has been fabricated and tested. Laboratory results correspond well with simulation. Aerospace component design is an expensive and important step in space development. Evolutionary design can make a significant contribution wherever sufficiently fast, accurate and capable software simulators are available. We have demonstrated successful real-world design in the spacecraft antenna domain; and there is good reason to believe that these results could be replicated in other design spaces.

Hornby, Gregory S.↗

Silicon materials task of the low cost solar array project, phase 2

The object of phase 2 of this program is to investigate and define the effects of various processes, contaminants and process-contaminant interactions in the performance of terrestrial solar cells. The major effort this quarter was in the areas of crystal growth and thermal processing, comparison of impurity effects in low and high resistivity silicon, modeling the behavior of p-type ingots containing Mo, and C and, quantitative analysis of bulk lifetime and junction degradation effects in contaminated solar cells. The performance of solar cells fabricated on silicon web crystals grown from melts containing about 10 to the 18th power/cu cm of Cr, Mn, Fe, Ni, Ti, and V, respectively were measured. Deep level spectroscopy of metal-contaminated ingots was employed to determine the level and density of recombination centers due to Ti, V, Ni, and Cr.

Hopkins, R. H.↗

Silicon materials task of the low cost solar array project. Phase 3: Effect of impurities and processing on silicon solar cells

The 13th quarterly report of a study entitled an Investigation of the Effects of Impurities and Processing on Silicon Solar Cells is given. The objective of the program is to define the effects of impurities, various thermochemical processes and any impurity-process interactions on the performance of terrestrial silicon solar cells. The Phase 3 program effort falls in five areas: (1) cell processing studies; (2) completion of the data base and impurity-performance modeling for n-base cells; (3) extension of p-base studies to include contaminants likely to be introduced during silicon production, refining or crystal growth; (4) anisotropy effects; and (5) a preliminary study of the permanence of impurity effects in silicon solar cells. The quarterly activities for this report focus on tasks (1), (3) and (4).

Hopkins, R. H.↗

The Array Automated Assembly Task for the Low Cost Solar Array Project, Phase 2

During the program a process sequence was proposed and tested for the fabrication of dendritic welb silicon into solar modules. This sequence was analyzed as to yield and cost and these data suggest that the price goals of 1986 are attainable. Specifically, it was shown that a low cost POCL3 is a suitable replacement for the semiconductor grade, and that a suitable CVD oxide can be deposited from a silane/air mixture using a Silox reactor. A dip coating method was developed for depositing an antireflection coating from a metalorganic precursor. Application of photoresist to define contact grids was made cost effective through use of a dip coating technique. Electroplating of both Ag and Cu was shown feasible and cost effective for producing the conductive metal grids on the solar cells. Laser scribing was used to separate the cells from the dendrites without degradation. Ultrasonic welding methods were shown to be feasible for interconnecting the cells. A study of suitable low cost materials for encapsulation suggest that soda lime glass and phenolic filled board are preferred.

Campbell, R. B.↗