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At least 487 records · Page 27

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

Using silk screened evaporated and sputtered Al as the metal source, the formation of Al back surface fields was studied. The most satisfactory results were those obtained with the sputtered A1 and in which open circuit voltages (V sub oc) of 0.585 v (12 ohm cm FZ silicon) were achieved. The ultrasonic interconnect process is discussed. The process is shown to be satisfactory, but increased pull-strength may be obtained if some form of sintering is carried out on the metallized contacts. Plasma etching is shown to be feasible as a replacement for wet chemical cleaning prior to diffusion. Initial results on cells prepared by using electroless Pd/Ni plus either electroplated Ag or Cu show slightly poor performance than cells with the baseline evaporated Ti/Pd/Ag system. A mask designed for the 1.6 x 7.0 cm and 2.0 x 7.0 cm cells is described. This mask has a lower area coverage and total lower resistive loss than the previous mask design. It is also shown that the cell width should not exceed 2.0 - 3.0 cm for optimum efficiency.

Campbell, R. B.↗

Silicon Materials Task of the Low Cost Solar Array Project, Phase 3. Effect of Impurities and Processing on Silicon Solar Cells

The effects of impurities, various thermochemical processes, and any impurity process interactions on the performance of terrestrial silicon solar cells are defined. Determinations of the segregation coefficients of tungsten, tantalum, and cobalt for the Czochralski pulling of silicon single crystals are reported. Sensitive neutron activation analysis was used to determine the metal impurity content of the silicon while atomic absorption was used to measure the metal content of the residual liquid from which the doped crystals were grown. Gettering of Ti doped silicon wafers improved cell performance by one to two percent for the highest temperatures and longest times. The HCl is more effective than POCl3 treatments for deactivating Ti but POCl3 and HCl produced essentially identical results for Mo or Fe.

Hopkins, R. H.↗

The Automated Array Assembly Task of the Low-cost Silicon Solar Array Project, Phase 2

An advanced process sequence for manufacturing high efficiency solar cells and modules in a cost-effective manner is discussed. Emphasis is on process simplicity and minimizing consumed materials. The process sequence incorporates texture etching, plasma processes for damage removal and patterning, ion implantation, low pressure silicon nitride deposition, and plated metal. A reliable module design is presented. Specific process step developments are given. A detailed cost analysis was performed to indicate future areas of fruitful cost reduction effort. Recommendations for advanced investigations are included.

Coleman, M. G.↗

Phase 2: Array automated assembly task low cost silicon solar array project

Several microwave systems for use in solar cell fabrication were developed and experimentally tested. The first system used a standing wave rectangular waveguide horn applicator. Satisfactory results were achieved with this system for impedance matching and wafer surface heating uniformity. The second system utilized a resonant TM sub 011 mode cylindrical cavity but could not be employed due to its poor energy coupling efficiency. The third and fourth microwave systems utilized a circular waveguide operating in the TM sub 01 and TM sub 11 but had problems with impedance matching, efficiency, and field uniformity.

Jones, G. T.↗

Automated array assembly, phase 2

Tasks of scaling up the tandem junction cell (TJC) from 2 cm x 2 cm to 6.2 cm and the assembly of several modules using these large area TJC's are described. The scale-up of the TJC was based on using the existing process and doing the necessary design activities to increase the cell area to an acceptably large area. The design was carried out using available device models. The design was verified and sample large area TJCs were fabricated. Mechanical and process problems occurred causing a schedule slippage that resulted in contract expiration before enough large-area TJCs were fabricated to populate the sample tandem junction modules (TJM). A TJM design was carried out in which the module interconnects served to augment the current collecting buses on the cell. No sample TJMs were assembled due to a shortage of large-area TJCs.

Carbajal, B. G.↗

The automated array assembly task of the low-cost silicon solar array project, phase 2

Several specific processing steps as part of a total process sequence for manufacturing silicon solar cells were studied. Ion implantation was identified as the preferred process step for impurity doping. Unanalyzed beam ion implantation was shown to have major cost advantages over analyzed beam implantation. Further, high quality cells were fabricated using a high current unanalyzed beam. Mechanically masked plasma patterning of silicon nitride was shown to be capable of forming fine lines on silicon surfaces with spacings between mask and substrate as great as 250 micrometers. Extensive work was performed on advances in plated metallization. The need for the thick electroless palladium layer was eliminated. Further, copper was successfully utilized as a conductor layer utilizing nickel as a barrier to copper diffusion into the silicon. Plasma etching of silicon for texturing and saw damage removal was shown technically feasible but not cost effective compared to wet chemical etching techniques.

Coleman, M. G.↗

Automated array assembly, phase 2

A manufacturing sequence which is capable of mass producing silicon solar cells is described. The sequence was arrived at after the evaluation of many processes and three related manufacturing sequences which are discussed.

Daiello, R. V.↗

Array automated assembly task low cost silicon solar array project, phase 2

Analyses of solar cell and module process steps for throughput rate, cost effectiveness, and reproductibility are reported. In addition to the concentration on cell and module processing sequences, an investigation was made into the capability of using microwave energy in the diffusion, sintering, and thick film firing steps of cell processing. Although the entire process sequence was integrated, the steps are treated individually with test and experimental data, conclusions, and recommendations.

Olson, C.↗

Silicon materials task of the low-cost solar array project. Phase 4: Effects of impurities and processing on silicon solar cells

The results of the study form a basis for silicon producers, wafer manufacturers, and cell fabricators to develop appropriate cost-benefit relationships for the use of less pure, less costly solar grade silicon. Cr is highly mobile in silicon even at temperatures as low as 600 C. Contrasting with earlier data for Mo, Ti, and V, Cr concentrations vary from place to place in polycrystalline silicon wafers and the electrically-active Cr concentration in the polysilicon is more than an order of magnitude smaller than would be projected from single crystal impurity data. We hypothesize that Cr diffuses during ingot cooldown after growth, preferentially segregates to grain and becomes electrically deactivated. Accelerated aging data from Ni-contaminated silicon imply that no significant impurity-induced cell performance reduction should be expected over a twenty year device lifetime.

Hopkins, R. H.↗

Silicon materials task of the low-cost solar array project. Phase 4: Effects of impurities and processing on silicon solar cells

The effects of impurities, various thermochemical processes, and any impurity-process interactions upon the performance of terrestrial solar cells are defined. The results form a basis for silicon producers, wafer manufacturers, and cell fabricators to develop appropriate cost benefit relationships for the use of less pure, less costly solar grade silicon.

Hopkins, R. H.↗

Spiral slotted phased antenna array

A flush mounting, cavity-backed, dual orthogonal slot antenna for aircraft and space vehicles is described. Improved radiation pattern characteristics are obtained by making the spiral slot pattern elliptical in the aperture plane. A cavity and a flanged aperture plate are configured such that one slot pair is orthogonal with respect to another slot pair within the aperture plate. Coaxial split-tube baluns are used to drive the junctions between corresponding slot pairs. An optional cavity dielectric is provided and a drive coupling arrangement includes a four port comparator hybrid having sum and difference ports respectively, for alternate excitation to produce a single lobe or a double lobe pattern with null. Switching apparatus is provided to connect a common terminal to either of the ports.

Ellis, H., Jr.↗

Far-field distributions of semiconductor phase-locked arrays with multiple contacts

Experimental results on far-field patterns of semiconductor laser arrays with multiple contacts are reported. It is found that, by tailoring the distribution of the currents through the array elements, narrow single-lobe patterns, which are more useful in most applications, can be obtained from arrays that usually operate in a double-lobe mode. A diffraction-limited 1.8 deg-wide far field pattern was obtained from a three-element array.

Katz, J.↗

A Deconvolution Approach for the Mapping of Acoustic Sources (DAMAS) Determined from Phased Microphone Arrays

Current processing of acoustic array data is burdened with considerable uncertainty. This study reports an original methodology that serves to demystify array results, reduce misinterpretation, and accurately quantify position and strength of acoustic sources. Traditional array results represent noise sources that are convolved with array beamform response functions, which depend on array geometry, size (with respect to source position and distributions), and frequency. The Deconvolution Approach for the Mapping of Acoustic Sources (DAMAS) method removes beamforming characteristics from output presentations. A unique linear system of equations accounts for reciprocal influence at different locations over the array survey region. It makes no assumption beyond the traditional processing assumption of statistically independent noise sources. The full rank equations are solved with a new robust iterative method. DAMAS is quantitatively validated using archival data from a variety of prior high-lift airframe component noise studies, including flap edge/cove, trailing edge, leading edge, slat, and calibration sources. Presentations are explicit and straightforward, as the noise radiated from a region of interest is determined by simply summing the mean-squared values over that region. DAMAS can fully replace existing array processing and presentations methodology in most applications. It appears to dramatically increase the value of arrays to the field of experimental acoustics.

Brooks, Thomas F.↗

A Deconvolution Approach for the Mapping of Acoustic Sources (DAMAS) Determined from Phased Microphone Arrays

Current processing of acoustic array data is burdened with considerable uncertainty. This study reports an original methodology that serves to demystify array results, reduce misinterpretation, and accurately quantify position and strength of acoustic sources. Traditional array results represent noise sources that are convolved with array beamform response functions, which depend on array geometry, size (with respect to source position and distributions), and frequency. The Deconvolution Approach for the Mapping of Acoustic Sources (DAMAS) method removes beamforming characteristics from output presentations. A unique linear system of equations accounts for reciprocal influence at different locations over the array survey region. It makes no assumption beyond the traditional processing assumption of statistically independent noise sources. The full rank equations are solved with a new robust iterative method. DAMAS is quantitatively validated using archival data from a variety of prior high-lift airframe component noise studies, including flap edge/cove, trailing edge, leading edge, slat, and calibration sources. Presentations are explicit and straightforward, as the noise radiated from a region of interest is determined by simply summing the mean-squared values over that region. DAMAS can fully replace existing array processing and presentations methodology in most applications. It appears to dramatically increase the value of arrays to the field of experimental acoustics.

Brooks, Thomas F.↗

Electromagnetic Modeling for the Conformal Lightweight Antenna System for Aeronautical Communications Technologies (CLAS-ACT) Program: Final Report

A series of electromagnetic simulations was conducted for the Conformal Lightweight Antenna System for Aeronautical Communications Technologies (CLAS-ACT) Program. The program designed, built, and flight tested a 14.25 GHz conformal patch array antenna for satellite communications on a T-34C airplane. Various studies were performed to evaluate the effects of antenna element spacing, array shape, signal taper, phased array pointing angle, null steering coefficients, antenna platform, and location on the airplane. This report documents the methods and some of the results of tests done over a 2 ½ year period.

Mackenzie, Anne I.↗

Coupled Oscillator Based Agile Beam Transmitters and Receivers: A Review of Work at JPL

This is a review of the work done at Caltech's Jet Propulsion Laboratory during the past decade on development of the coupled oscillator technology in phased array applications to spacecraft telecommunications. First, some historical background is provided to set the work in context. However, this is by no means intended to be a comprehensive review of all work in this area. Rather, the focus is on the JPL contribution with some mention of other work which provided either insight or motivation. In the mid 1990's, R. A. York, and collaborators proposed that an array of mutually injection locked electronic oscillators could provide appropriately phased signals to the radiating elements of an array antenna such that the radiated beam could be steered merely by tuning the end or perimeter oscillators of the array. York, et al. also proposed a receiving system based on such oscillator arrays in which the oscillators provide properly phased local oscillator signals to be mixed with the signals received by the array elements to remove the phase due to angle of arrival of the incident wave. These concepts were viewed as a promising simplification of the beam steering control system that could result in significant cost, mass, and prime power reduction and were therefore attractive for possible space application.

mutual injection locking↗

Injection Phase-Locked Laser-Diode Array

Phase-coherent emission with negligible far-field supermodes produced by proposed surface-emitting laser-diode array stimulated by holographically directed emission from single master diode. To achieve same coherence and output power, single laser diode requires high power density, which substantially reduces working lifetime. Proposed integrated optical array useful in communications

Lesh, James R.↗