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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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NASA NTRS1983

Applications of ethylene vinyl acetate as an encapsulation material for terrestrial photovoltaic modules

Terrestrial photovoltaic modules must undergo substantial reductions in cost in order to become economically attractive as practical devices for large scale production of electricity. Part of the cost reductions must be realized by the encapsulation materials that are used to package, protect, and support the solar cells, electrical interconnects, and other ancillary components. As many of the encapsulation materials are polymeric, cost reductions necessitate the use of low cost polymers. The performance and status of ethylene vinyl acetate, a low cost polymer that is being investigated as an encapsulation material for terrestrial photovoltaic modules, are described.

Cuddihy, E. F.↗

NASA NTRS1983

Chemical bonding technology for terrestrial photovoltaic modules

Encapsulated photovoltaic modules must hold together for 20 years, reliably resisting delamination and separation of any of the component materials. Delamination of encapsulation materials from each other, or from solar cells and interconnects, can create voids for accumulation of water, promoting corrosive failure. Delamination of silicone elastomers from unprimed surfaces was a common occurrence with early modules, but the incidences of silicone delamination with later modules decreased when adhesion promoters recommended by silicone manufacturers were used. An investigation of silicone delamination from unprimed surfaces successfully identified the mechanism, which was related to atmospheric oxygen and moisture. This early finding indicated that reliance on physical bonding of encapsulation interfaces for long life in an outdoor environment would be risky. For long outdoor life, the material components of a module must therefore be held together by weather-stable adhesion promoters that desirably form strong, interfacial chemical bonds.

Coulter, D. R.↗

NASA NTRS2001

MIR Solar Array Return Experiment: Power Performance Measurements and Molecular Contamination Analysis Results

A solar array segment was recently removed from the Mir core module and returned for ground-based analysis. The segment, which is similar to the ones the Russians have provided for the FGB and Service Modules, was microscopically examined and disassembled by US and Russian science teams. Laboratory analyses have shown the segment to he heavily contaminated by an organic silicone coating, which was converted to an organic silicate film by reactions with atomic oxygen within the. orbital flight environment. The source of the contaminant was a silicone polymer used by the Russians as an adhesive and bonding agent during segment construction. During its life cycle, the array experienced a reduction in power performance from approx. 12%, when it was new and first deployed, to approx. 5%, when it was taken out of service. However, current-voltage measurements of three contaminated cells and three pristine, Russian standard cells have shown that very little degradation in solar array performance was due to the silicate contaminants on the solar cell surfaces. The primary sources of performance degradation is attributed to "thermal hot-spotting" or electrical arcing; orbital debris and micrometeoroid impacts; and possibly to the degradation of the solar cells and interconnects caused by radiation damage from high energy protons and electrons.

Visentine, James↗

NASA NTRS2001

The Lunar L1 Gateway: Portal to the Stars and Beyond

Our Solar System is interconnected by a vast system of winding tunnels generated by the Lagrange Points of all the planets and their moons. These passageways are identified by portals around L1 and L2, the halo orbits. By passing through a halo orbit portal, one enters the ancient and colossal labyrinth of the Sun. This natural Interplanetary Supher highway System (IPS) provides ultra-low energy transport throughout the Earth's Neighborhood, the region between Earth's L1 and L2. This is enabled by an accident: the current energy levels of the Earth L1 and L2 Lagrange points differ from that of the Earth-Moon by only about 50 rn/s (as measured by AV). The significance of this happy coincidence to the development of space cannot be overstated. For example, this implies that Lunar L1 halo orbits are connected to halo orbits around Earth's L1 or L2 via low energy pathways...

lunar gateways↗

NASA NTRS1976

Solar cell electrical connections

Study was conducted to find best methods of attaching pure silver and silver plated Kovar (trademark) interconnect ribbons to silicon solar cells with titanium-silver solderless contacts. Investigations include thermocompression bonding, parallel-gap welding, and ultrasonic welding.

Rauschenbach, H. S.↗

NASA NTRS1976

Interconnnect and bonding technologies for large flexible solar arrays

Thermocompression bonding and conductive adhesive bonding are developed and evaluated as alternate methods of joining solar cells to their interconnect assemblies. Bonding materials and process controls applicable to fabrication of large, flexible substrate solar cell arrays are studied. The primary potential use of the techniques developed is on the solar array developed by NASA/MSFC and LMSC for solar electric propulsion (SEP) and shuttle payload applications. This array is made up of flexible panels approximately 0.7 by 3.4 meters. It is required to operate in space between 0.3 and 6 AU for 5 years with limited degradation. Materials selected must be capable of enduring this space environment, including outgassing and radiation.

Source record↗

NASA NTRS1971

Integrated thin film cadmium sulfide solar cell module

The design, development, fabrication and tests of flexible integrated thin-film cadmium sulfide solar cells and modules are discussed. The development of low cost and high production rate methods for interconnecting cells into large solar arrays is described. Chromium thin films were applied extensively in the deposited cell structures as a means to: (1) achieve high adherence between the cadmium sulfide films and the vacuum-metallized copper substrates, (2) obtain an ohmic contact to the cadmium sulfide films, and (3) improve the adherence of gold films as grids or contact areas.

Mickelsen, R. A.↗

NASA NTRS2007

Ultra-Lightweight Hybrid Thin-Film Solar Cells: A Survey of Enabling Technologies for Space Power Applications

The development of hybrid inorganic/organic thin-film solar cells on flexible, lightweight, space-qualified, durable substrates provides an attractive solution for fabricating solar arrays with high mass specific power (W/kg). Next generation thin-film technologies may well involve a revolutionary change in materials to organic-based devices. The high-volume, low-cost fabrication potential of organic cells will allow for square miles of solar cell production at one-tenth the cost of conventional inorganic materials. Plastic solar cells take a minimum of storage space and can be inflated or unrolled for deployment. We will explore a cross-section of in-house and sponsored research efforts that aim to provide new hybrid technologies that include both inorganic and polymer materials as active and substrate materials. Research at University of Texas at Arlington focuses on the fabrication and use of poly(isothianaphthene-3,6-diyl) in solar cells. We describe efforts at Norfolk State University to design, synthesize and characterize block copolymers. A collaborative team between EIC Laboratories, Inc. and the University of Florida is investigating multijunction polymer solar cells to more effectively utilize solar radiation. The National Aeronautics and Space Administration (NASA)/Ohio Aerospace Institute (OAI) group has undertaken a thermal analysis of potential metallized substrates as well as production of nanoparticles of CuInS2 and CuInSe2 in good yield at moderate temperatures via decomposition of single-source precursors. Finally, preliminary work at the Rochester Institute of Technology (R.I.T.) to assess the impact on performance of solar cells of temperature and carbon nanotubes is reported. Technologies that must be developed to enable ultra-lightweight solar arrays include: monolithic interconnects, lightweight array structures, and new ultra-light support and deployment mechanisms. For NASA applications, any solar cell or array technology must not only meet weight and AMO efficiency goals, but also must be durable enough to survive launch conditions and space environments.

Hepp, Aloysius F.↗

NASA NTRS1981

Low cost, high concentration ratio solar cell array for space applications

A miniaturized Cassegrainian-type concentrator solar array concept for space applications is described. In-orbit cell operating temperatures near 80 C are achieved with purely passive cell cooling and a net concentration ratio of 100. A multiplicity of miniaturized, rigid solar cell concentrator subassemblies are electrically interconnected in conventional fashion and mounted into rigid frames to form concentrator solar panel assemblies approximately 14-mm thick. A plurality of such interconnected panels forms a stowable and deployable solar cell blanket. It is projected that for 20% efficient silicon cells an array of 500 kW beginning-of-life output capability, including orbiter cradle structures, can be transported by a single shuttle orbiter flight into low earth orbit. In-orbit array specific performance is calculated to be approximately 100 W/sq m and 20 W/kg, including all stowage, deployment and array figure control equipment designed for a 30-year orbital life. Higher efficiency gallium arsenide and multiple band gap solar cells will improve these performance factors correspondingly.

Patterson, R. E.↗

NASA NTRS2011

A Snapshot of the Sun Near Solar Minimum: The Whole Heliosphere Interval

We present an overview of the data and models collected for the Whole Heliosphere Interval, an international campaign to study the three-dimensional solar heliospheric planetary connected system near solar minimum. The data and models correspond to solar Carrington Rotation 2068 (20 March 16 April 2008) extending from below the solar photosphere, through interplanetary space, and down to Earth's mesosphere. Nearly 200 people participated in aspects of WHI studies, analyzing and interpreting data from nearly 100 instruments and models in order to elucidate the physics of fundamental heliophysical processes. The solar and inner heliospheric data showed structure consistent with the declining phase of the solar cycle. A closely spaced cluster of low-latitude active regions was responsible for an increased level of magnetic activity, while a highly warped current sheet dominated heliospheric structure. The geospace data revealed an unusually high level of activity, driven primarily by the periodic impingement of high-speed streams. The WHI studies traced the solar activity and structure into the heliosphere and geospace, and provided new insight into the nature of the interconnected heliophysical system near solar minimum.

Thompson, Barbara J.↗

NASA NTRS1976

Skylab observations of X-ray loops connecting separate active regions

One hundred loops interconnecting 94 separate active solar regions detectable in soft X-rays were identified during the Skylab mission. While close active regions are commonly interconnected with loops, the number of such interconnections decreases steeply for longer distances; the longest interconnecting loop observed in the Skylab data connected regions separated by 37 deg. Several arguments are presented which support the point of view that this is the actual limit of the size of magnetic interconnections between active regions. No sympathetic flares could be found in the interconnected regions. These results cast doubt on the hypothesis that accelerated particles can be guided in interconnecting loops from one active region to another over distances of 100 deg or more and eventually produce sympathetic flares in them.

Chase, R. C.↗

NASA NTRS1984

Space station design - Innovation and compromise

The NASA manned space station will consist of three main elements: habitable modules, solar collectors, and their interconnecting hardware. The most arduous of the requirements to be met by this configuration is the simultaneous integration of terrestrial, solar, and celestial viewing instruments, since omnidirectional simultaneous viewing is made difficult by the station's large solar energy collection devices. The space station also imposes unique design conditions on individual subsystems, such as the power distribution and energy storage hardware. In particular, the thermal control subsystem must be designed to meet a variety of mission, payload, and housekeeping tasks that demand a large heat rejection capacity. Novel environmental control and life support subsystem technology will be indispensable.

Powell, L. E.↗

NASA NTRS1996

Effects of the solar wind conditions on the global magnetospheric configuration as deduced from data-based field models

The results of data based modeling of the magnetospheric configuration and its response to changes in the solar wind dynamical pressure and the interplanetary magnetic field (IMF) are described. Previous models did not have a pre-defined magnetopause and were calibrated by the Kp index, and therefore did not correctly model the solar wind effects. Models are presented which include the effects of the solar wind-controlled magnetopause, the region 1 and 2 Birkeland currents, and the interconnection of the magnetospheric and solar wind fields at the boundary. They predict the most significant effects of solar wind variation on the global magnetospheric structure. On the dayside, the region 1 Birkeland currents cause major changes of the magnetic configuration as the IMF turns southward. The tail current intensity is controlled mainly by the pressure of the solar wind, although the influence of the southward IMF is clearly seen. The effects of the IMF-induced interconnection field were found to be significant.

Tsyganenko, N. A.↗

NASA NTRS1985

Interconnect resistance of photovoltaic submodules

Small area amorphous silicon solar cells generally have higher efficiencies than large interconnected submodules. Among the reasons for the differences in performance are the lack of large area uniformity, the effect of nonzero tin oxide sheet resistance, and possibly pinholes in the various layers. Another and usually small effect that can contribute to reduced performance of interconnected cells is the resistance of the interconnection i.e., the series resistance introduced by the metal to tin oxide contact through silicon. Proper processing problems to avoid poor contacts are discussed.

Volltrauer, H.↗

NASA NTRS1982

Microstructural analysis of solar cell welds

Parallel-gap resistance welding of silicon solar cells with copper interconnects results in complex microstructural variations that depend on the welding variables. At relatively low heat input solid-state welds are produced. At medium heat the Ag-Cu eutectic forms resulting in a braze joint. High heat produces a fusion weld with complete melting of the silver layer on the silicon solar cell. If the silicon is also melted, cracking occurs in the silicon cell below the weld nugget. These determinations were made using light microscopy, microprobe, and scanning electron microscopy analyses.

Moore, T. J.↗

NASA NTRS1976

On the thermoelastic analysis of solar cell arrays and related material properties

Accurate prediction of failure of solar cell arrays requires accuracy in the computation of thermally induced stresses. This was accomplished by using the finite element technique. Improved procedures for stress calculation were introduced together with failure criteria capable of describing a wide range of ductile and brittle material behavior. The stress distribution and associated failure mechanisms in the N-interconnect junction of two solar cell designs were then studied. In such stress and failure analysis, it is essential to know the thermomechanical properties of the materials involved. Measurements were made of properties of materials suitable for the design of lightweight arrays: microsheet-0211 glass material for the solar cell filter, and Kapton-H, Kapton F, Teflon, Tedlar, and Mica Ply PG-402 for lightweight substrates. The temperature-dependence of the thermal coefficient of expansion for these materials was determined together with other properties such as the elastic moduli, Poisson's ratio, and the stress-strain behavior up to failure.

Salama, M. A.↗

NASA NTRS1985

Multi-kW solar arrays for Earth orbit applications

The multi-kW solar array program is concerned with developing the technology required to enable the design of solar arrays required to power the missions of the 1990's. The present effort required the design of a modular solar array panel consisting of superstrate modules interconnected to provide the structural support for the solar cells. The effort was divided into two tasks: (1) superstrate solar array panel design, and (2) superstrate solar array panel-to-panel design. The primary objective was to systematically investigate critical areas of the transparent superstrate solar array and evaluate the flight capabilities of this low cost approach.

Source record↗

NASA NTRS1985

Series Connection of Solar Cells

Roll soldering from continuous string of cells. Automatic, continuous process attaches interconnecting strips to series string of silicon solar cells. Manufacturing process attaches each conductor from positive side of one cell to negative side of next. For reliability, 22 contacts are soldered on each side of each cell.

Keenan, R.↗