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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 73 records · Page 4
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Novel PV Array System Design to Accelerate Solar Deployment, Reduce LCOE, Reduce Land Use Competition, and Increase Siting Flexibility

The increasing demand for solar energy faces significant barriers, including inefficient construction processes, high project costs limiting LCOE reductions, and diminishing availability of "good" sites with favorable interconnection. Conventional solar installations are often constrained by long construction timelines and the need for flat, large plots. Furthermore, the industry struggles with a shortage of skilled labor. Planted Solar aims to address these challenges by fundamentally transforming solar deployment from a construction project into a streamlined manufacturing process. Our novel approach combines high-density racking, integrated terrain-following design software, and installation automation. Unlike competing solutions that either assist with standard array assembly or offer dense packing without terrain adaptability or automation, Planted's technology uniquely brings together a new array product with in-place automated manufacturing to achieve the lowest possible cost, greater site flexibility, and accelerated deployment.

14 SOLAR ENERGY↗
NASA NTRS1986

Circuit transients due to negative bias arcs-II

Two new models of negative-bias arcing on a solar cell power system in Low Earth Orbit are presented. One is an extended, analytical model and the other is a non-linear, numerical model. The models are based on an earlier analytical model in which the interactions between solar cell interconnects and the space plasma as well as the parameters of the power circuit are approximated linearly. Transient voltages due to arcs struck at the negative thermal of the solar panel are calculated in the time domain. The new models treat, respectively, further linear effects within the solar panel load circuit and non-linear effects associated with the plasma interactions. Results of computer calculations with the models show common-mode voltage transients of the electrically floating solar panel struck by an arc comparable to the early model but load transients that differ substantially from the early model. In particular, load transients of the non-linear model can be more than twice as great as those of the early model and more than twenty times as great as the extended, linear model.

Metz, R. N.↗
NASA NTRS1985

Orbital atomic oxygen effects on thermal control and optical materials - STS-8 results

The effects of exposing 23 specimens of optical and thermal control materials to space at 120 km altitude for over 40 hrs during the STS-8 mission are discussed. Ten samples of paint targeted for the Space Telescope (ST) and the Tethered Satellite were exposed, and included polyurethane, oxide, silicone, and glossy black and white samples which were scanned for alterations in the optical properties after being retrieved. Nine mirror-type materials were also investigated, along with silver specimens typical of solar cell interconnects. The oxygen flow at the orbital altitude was 3.5 x 10 to the 20th atoms/cu cm. The exposures caused no degradation of the magnesium fluoride mirror coatings, while the Kapton coating for the ST solar cell panels showed evidence of losing thickness. The Ag solar cell contacts will require coatings to extend their lifetimes. Overcoatings were also proven necessary for inhibiting degradation of painted surfaces.

Whitaker, A. F.↗
NASA NTRS1991

Thermal cycle testing of Space Station Freedom solar array blanket coupons

Lewis Research Center is presently conducting thermal cycle testing of solar array blanket coupons that represent the baseline design for Space Station Freedom. Four coupons were fabricated as part of the Photovoltaic Array Environment Protection (PAEP) Program, NAS 3-25079, at Lockheed Missile and Space Company. The objective of the testing is to demonstrate the durability or operational lifetime of the solar array welded interconnect design within the durability or operational lifetime of the solar array welded interconnect design within a low earth orbit (LEO) thermal cycling environment. Secondary objectives include the observation and identification of potential failure modes and effects that may occur within the solar array blanket coupons as a result of thermal cycling. The objectives, test articles, test chamber, performance evaluation, test requirements, and test results are presented for the successful completion of 60,000 thermal cycles.

Scheiman, David A.↗
NASA NTRS1971

Shunt regulation electric power system

A regulated electric power system having load and return bus lines is described. A plurality of solar cells interconnected in a power supplying relationship and having a power shunt tap point electrically spaced from the bus lines is provided. A power dissipator is connected to the shunt tap point and provides for a controllable dissipation of excess energy supplied by the solar cells. A dissipation driver is coupled to the power dissipator and controls its conductance and dissipation and is also connected to the solar cells in a power taping relationship to derive operating power therefrom. An error signal generator is coupled to the load bus and to a reference signal generator to provide an error output signal which is representative of the difference between the electric parameters existing at the load bus and the reference signal generator. An error amplifier is coupled to the error signal generator and the dissipation driver to provide the driver with controlling signals.

Wright, W. H.↗
NASA NTRS1981

Review of biased solar arraay. Plasma interaction studies

The Solar Electric Propulsion System (SEPS) is proposed for a variety of space missions. Power for operating SEPS is obtained from large solar array wings capable of generating tens of kilowatts of power. To minimize resistive losses in the solar array bus lines, the array is designed to operate at voltages up to 400 volts. This use of high voltage can increase interactions between the biased solar cell interconnects and plasma environments. With thrusters operating, the system ground is maintained at space plasma potential which exposes large areas of the arrays at the operating voltages. This can increase interactions with both the natural and enhanced charged particle environments. Available data on interactions between biased solar array surfaces and plasma environments are summarized. The apparent relationship between collection phenomena and solar cell size and effects of array size on interactions are discussed. The impact of these interactions on SEPS performance is presented.

Stevens, N. J.↗
NASA NTRS1982

Annular Electrode Improves Solar-Cell Welds

Improved method of electrical-resistance welding of solar-cell inter-connections developed by using an annular welding-electrode shape. Improved weld electrode consists of two coaxial cylinders, outer one with annular cross section and inner one with circular cross section. Possible annular weld-electrode configurations result in better quality welds for interconnecting solar-array elements.

Baraona, C. R.↗
NASA NTRS1982

Solar array construction

An interconnect tab on each cell of a first set of circular solar cells connects that cell in series with an adjacent cell in the set. This set of cells is arranged in alternate columns and rows of an array and a second set of similar cells is arranged in the remaining alternate columns and rows of the array. Three interconnect tabs on each solar cell of the said second set are employed to connect the cells of the second set to one another, in series and to connect the cells of the second set to those of the first set in parallel. Some tabs (making parallel connections) connect the same surface regions of adjacent cells to one another and others (making series connections) connect a surface region of one cell to the opposite surface region of an adjacent cell; however, the tabs are so positioned that the array may be easily assembled by depositing the cells in a certain sequence and in proper orientation.

Crouthamel, Marvin S.↗
NASA NTRS1982

Development of technologies for welding interconnects to fifty-micron thick silicon solar cells

A program was conducted to develop technologies for welding interconnects to 50 microns thick, 2 by 2 cm solar cells. The cells were characterized with respect to electrical performance, cell thickness, silver contact thickness, contact waviness, bowing, and fracture strength. Weld schedules were independently developed for each of the three cell types and were coincidentally identical. Thermal shock tests (100 cycles from 100 C to -180 C) were performed on 16 cell coupons for each cell type without any weld joint failures or electrical degradation. Three 48 cell modules (one for each cell type) were assembled with 50 microns thick cells, frosted fused silica covers, silver clad Invar interconnectors, and Kapton substrates.

Patterson, R. E.↗
NASA NTRS1976

Flexible, FEP-Teflon covered solar cell module development

Techniques and equipment were developed for the large scale, low-cost fabrication of lightweight, roll-up and fold-up, FEP-Teflon encapsulated solar cell modules. Modules were fabricated by interconnecting solderless single-crystal silicon solar cells and heat laminating them at approximately 300 C between layers of optically clear FEP and to a loadbearing Kapton substrate sheet. Modules were fabricated from both conventional and wraparound contact solar cells. A heat seal technique was developed for mechanically interconnecting modules into an array. The electrical interconnections for both roll-up and fold-up arrays were also developed. The use of parallel-gap resistance welding, ultrasonic bonding, and thermocompression bonding processes for attaching interconnects to solar cells were investigated. Parallel-gap welding was found to be best suited for interconnecting the solderless solar cells into modules. Details of the fabrication equipment, fabrication processes, module and interconnect designs, environmental test equipment, and test results are presented.

Rauschenbach, H. S.↗
NASA NTRS1971

Silicon solar cell interconnectors for low temperature applications.

Discussion of the design and techniques of solar cell interconnections meeting the requirements of mission life expectancies of 5 to 10 years in the face of the vibration stresses of launch and the stresses induced (especially between dissimilar materials with different thermal coefficients of expansion) by thermal cycling throughout the mission. Generalized stress equations are developed that give the minimum stress relief loop dimensions for a 'no fatigue' interconnector. Also, the thermal expansion stresses induced at the metal-to-silicon interface were investigated and generalized equations developed for determining the stresses in each of the members. These relationships, as verified by experimental tests, can be used to determine the maximum allowable interconnector thickness for failure prevention in thermal cycling environments.

Ralph, E. L.↗
NASA NTRS1979

High temperature, low mass solar blanket development

This paper presents methods of incorporating ultrathin silicon solar cells into photovoltaic blankets for space applications. This type of cell has the highest power-to-mass ratio and best performance under space radiation of any silicon solar cell. Interconnect materials and designs, and the results of the investigation of the applicability of parallel-gap resistance welding for interconnecting ultrathin cells are discussed. Data relating contact pull strength and cell electrical degradation to welding parameters such as time, voltage, and pressure are presented. Methods for bonding ultrathin cells to flexible substrates and for bonding thin covers to these cells are described, and the results of vacuum thermal cycling and thermal soak tests on prototype ultrathin cell test coupons are included.

Mesch, H. G.↗
NASA NTRS1981

Solar cell modules for plasma interaction evaluation

A plasma interaction analysis in support of the solar electric propulsion subsystem examined the effects of a large high voltage solar array interacting with an ion thruster produced plasma. Two solar array test modules consisting of 36 large area wraparound contact solar cells welded to a flexible Kapton integrated circuit substrate were abricated. The modules contained certain features of the effects of insulation, din-holes, and bonding of the cell to the substrate and a ground plane. The possibility of a significant power loss occurring due to the collection of charged particles on the solar array interconnects was the focus of the research.

Source record↗
NASA NTRS1982

Evaluation of solar cell welds by scanning acoustic microscopy

Scanning laser acoustic microscopy was used to nondestructively evaluate solar cell interconnect bonds made by resistance welding. Both copper-silver and silver-silver welds were analyzed. The bonds were produced either by a conventional parallel-gap welding technique using rectangular electrodes or new annular gap design with a circular electrode cross section. With the scanning laser acoustic microscope, it was possible to produce a real time television image which reveales the weld configuration as it relates to electrode geometry. The effect of electrode misalinement with the surface of the cell was also determined. A preliminary metallographic analysis was performed on selected welds to establish the relationship between actual size and shape of the weld area and the information available from acoustic micrographs.

Klima, S. J.↗
NASA NTRS1984

LEO atomic oxygen effects on spacecraft materials: STS-5 results

Effects of low Earth orbit (LEO) atomic oxygen were measured on a variety of spacecraft materials which obtained exposure on STS-5. Material degradation dependency on temperature was found in one material. Of the five paints flown, only S13GLO was unaffected. Generally, the glossy paints became Lambertian and the diffuse coatings improved. Scanning electron microscope examinations indicated removal of urethane and epoxy paint binder materials. Reaction products were evident on the surfaces of Z302 paint and Mylar. Thin films showed thickness losses ranging from negligible loss in Teflon to considerable loss in Mylar and Kapton. Glossy films such as black Kapton and white Tedlar became diffused. Kevlar 29 rope lost tensile strength and silver solar cell interconnect material oxidized. Oxidation on the backside of an elevated specimen indicated that reflections of oxygen atoms were occurring and that reflecting surfaces, probably Kapton, were not fully accommodating the incident atoms.

Whitaker, A. F.↗
NASA NTRS1984

NASA welding assessment program

A long duration test was conducted for comparing various methods of attaching electrical interconnects to solar cells for near Earth orbit spacecraft. Representative solar array modules were thermally cycled for 36,000 cycles between -80 and +80 C. The environmental stress of more than 6 years on a near Earth spacecraft as it cycles in and out of the earth's shadow was simulated. Evaluations of the integrity of these modules were made by visual and by electrical examinations before starting the cycling and then at periodic intervals during the cycling tests. Modules included examples of parallel gap and of ultrasonic welding, as well as soldering. The materials and fabrication processes are state of the art, suitable for forming large solar arrays of spacecraft quality. The modules survived this extensive cycling without detectable degradation in their ability to generate power under sunlight illumination.

Stofel, E. J.↗
NASA NTRS1985

Interactions between large space power systems and low-Earth-orbit plasmas

There is a growing tendency to plan space missions that will incorporate very large space power systems. These space power systems must function in the space plasma environment, which can impose operational limitations. As the power output increases, the operating voltage also must increase and this voltage, exposed at solar array interconnects, interacts with the local plasma. The implications of such interactions are considered. The available laboratory data for biased array segment tests are reviewed to demonstrate the basic interactions considered. A data set for a floating high voltage array test was used to generate approximate relationships for positive and negative current collection from plasmas. These relationships were applied to a hypothetical 100 kW power system operating in a 400 km, near equatorial orbit. It was found that discharges from the negative regions of the array are the most probable limiting factor in array operation.

Stevens, N. J.↗