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Elastic hinge folds to small thickness, allows easy replacement of panels attached, and provides part of torque for refolding without additional springs. Holds modules of solar-cell array. Modules kept in open position by external restraint. When restraint removed, elasticity of molybdenum hinge elements helps to fold facing modules together. Hinge developed for foldable modules for solar-cell panels.
The Boeing Company has evaluated the use of Tape Automated Bonding (TAB) and Surface Mount Technology (SMT) for a highly reliable, low cost interconnect for concentrator solar cell arrays. TAB and SMT are currently used in the electronics industry for chip interconnects and printed circuit board assembly. TAB tape consists of sixty-four 3-mil/1-oz tin-plated copper leads on 8-mil centers. The leads are thermocompression gang bonded to GaAs concentrator solar cell with silver contacts. This bond, known as an Inner Lead Bond (ILB), allows for pretesting and sorting capability via nondestruct wire bond pull and flash testing. Destructive wire pull tests resulted in preferred mid-span failures. Improvements in fill factor were attributed to decreased contact resistance on TAB bonded cells. Preliminary thermal cycling and aging tests were shown excellent bond strength and metallurgical results. Auger scans of bond sites reveals an Ag-Cu-Tin composition. Improper bonds are identified through flash testing as a performance degradation. On going testing of cells are underway at Lewis Research Center. SMT techniques are utilized to excise and form TAB leads post ILB. The formed leads' shape isolates thermal mismatches between the cells and the flex circuit they are mounted on. TABed cells are picked and placed with a gantry x-y-z positioning system with pattern recognition. Adhesives are selected to avoid thermal expansion mismatch and promote thermal transfer to the flex circuit. TAB outer lead bonds are parallel gap welded (PGW) to the flex circuit to finish the concentrator solar cell subassembly.
Preliminary investigations on large solar cell arrays for lunar-based water electrolysis
A heat sealable transparent plastic film, such as a flourinated ethylene propylene copolymer, is used both as a cover material and as an adhesive for mounting a solar cell array to a flexible substrate.
Thin cells processed and stored safely. Major parts of handling fixture hold components of solar cell array modules safely, yet allow assembly process to proceed without interference. Fixture used with or without internal vacuum. Concept allows handling of thin, relatively-fragile cells, and offers potential for savings in silicon material and cost.
Limitations in both space and terrestial markets for solar cells are described. Based on knowledge of the state-of-the-art, six cell options are discussed; as a result of this discussion, the three most promising options (involving high, medium and low efficiency cells respectively) were selected and analyzed for their probable costs. The results showed that all three cell options gave promise of costs below $10 per watt in the near future. Before further cost reductions can be achieved, more R and D work is required; suggestions for suitable programs are given.
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.
Modified 70 mm movie film editor automatically attaches solar cells to flexible film substrate. Machine can rapidly and inexpensively assemble cells for solar panels at rate of 250 cells per minute. Further development is expected to boost production rate to 1000 cells per minute.
Structural problems in high power solar photovoltaic arrays technology, discussing configuration, materials selection, thermal control coatings and tests results
Hot spots and voltage breakdowns due to open or shadowed solar cells, studying effect in orbital workshop array
Strong supporting structures for flat solar photovoltaic arrays built with such commonly available materials as wood and galvanized steel sheet. Structures resist expected static loads from snow and ice as well as dynamic loads from winds and even Earthquake vibrations. Supporting structure uses inexpensive materials. Parts prefabricated to minimize assembly work in field.
The method of constructing a high voltage, low power, multicell solar array is described. A solar cell base region is formed in a substrate such as but not limited to silicon or sapphire. A protective coating is applied on the base and a patterned etching of the coating and base forms discrete base regions. A semiconductive junction and upper active region are formed in each base region, and defined by photolithography. Thus, discrete cells which are interconnected by metallic electrodes are formed.
An ion plating process by which solar cells can be metallized and AR coated, yielding efficiencies equal to or better than state-of-the-art cells, was developed. It was demonstrated that ion plated AR films may be used as an effective encapsulant, offering primary protection for the metallization. It was also shown that ion plated metallization and AR coatings can be consistent with the project cost goals.
As part of the energy conversion/self sufficiency efforts of DSN engineering, it was necessary to have a simplified computer model of a solar photovoltaic (PV) system. This article describes the analysis and simplifications employed in the development of a PV cell array computer model. The analysis of the incident solar radiation, steady state cell temperature and the current-voltage characteristics of a cell array are discussed. A sample cell array was modelled and the results are presented.
Solar array systems have been studied and compared for earth orbital and orbit transfer missions with the principal objective of quantifying the cost tradeoffs between gallium arsenide and silicon array for specific classes of missions and system characteristics. For the missions considered, it is found that the purchase cost advantage of Si arrays is not overcome by the greater radiation resistance of GaAs arrays. The use of reflectors for concentration may significantly reduce the power system cost. However, GaAs arrays benefit considerably more from solar concentration than Si arrays in terms of mission cost because of their higher allowable temperature. In the case of orbit transfer missions, a cover glass thickness of at least 0.05 cm is recommended to reduce total mission cost.
Progress is reported on the design and development of lightweight, flexible, FEP encapsulated solar cell modules. Such modules are intended to form standardized building blocks for larger roll-up or fold-up solar cell blankets having specific performance in the order of 100 W/sq m and 80 W/kg in space near earth. Modules are constructed by heat-laminating interconnected 200-micron thick single crystal silicon solar cells with solderless front and back contacts between two layers of clear FEP. The outer FEP layer is 125 microns thick and serves as the solar cell cover material. The inner layer is 50 microns thick and serves as the adhesive between the solar cells and a 25-micron thick loadbearing Kapton substrate sheet.
The liquid transparent film-forming, fluorocarbon, Spraylon, a protective coating for terrestrial solar cell modules was evaluated. Two modules were completed and field tested. Problems developed early in the field testing which led to the shortened test period, specifically, lifting of the antireflection coating, followed in some areas by complete film delamination. It is believed that although these problems were certainly induced by the presence of the SPRAYLON film, they were not failures of the material per se. Instead, assembly procedures, module design, and cell coating quality should be evaluated to determine cause of failure.
Paper presents design concept for mass-producible arrays of solar electric batteries and concentrators tailored to individual requirements. Arrays intended primarily for space stations needing about 100 kW of power. However, modular, lightweight, compact, and relatively low-cost design also fulfill requirements of some terrestrial applications. Arrays built with currently available materials. Pultrusions, injectionmolded parts, and composite materials used extensively to keep weight low. For added flexibility in design and construction, silicon and gallium arsenide solar-cell panels interchangeable.