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At least 1,099 records · Page 61

Silicon-on Ceramic Process: Silicon Sheet Growth and Device Development for the Large-area Silicon Sheet and Cell Development Tasks of the Low-cost Solar Array Project

The technical and economic feasibility of producing solar cell-quality silicon was investigated. This was done by coating one surface of carbonized ceramic substrates with a thin layer of large-grain polycrystalline silicon from the melt. Significant progress in the following areas was demonstrated: (1) fabricating a 10 sq cm cell having 9.9 percent conversion efficiency; (2) producing a 225 sq cm layer of sheet silicon; and (3) obtaining 100 microns thick coatings at pull speed of 0.15 cm/sec, although approximately 50 percent of the layer exhibited dendritic growth.

Chapman, P. W.↗

Development of Surfaces Optically Suitable for Flat Solar Panels

A reflectometer which can separately evaluate the spectral and diffuse reflectivities of surfaces is described. A phase locked detection system for the reflectometer is also described. A selective coating on aluminum potentially useful for flat plate solar collector applications is presented. The coating is composed of strongly bound copper oxide (divalent) and is formed by an etching process performed on an aluminum alloy with high copper content. Fabrication costs are expected to be small due to the one stop fabrication process. A number of conclusions gathered from the literature as to the required optical properties of flat plate solar collectors are discussed.

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Development of processes for the production of solar grade silicon from halides and alkali metals

High temperature reactions of silicon halides with alkali metals for the production of solar grade silicon in volume at low cost were studied. Experiments were performed to evaluate product separation and collection processes, measure heat release parameters for scaling purposes, determine the effects of reactants and/or products on materials of reactor construction, and make preliminary engineering and economic analyses of a scaled-up process.

Dickson, C. R.↗

Development of a high efficiency thin silicon solar cell

Significant improvements in open-circuit voltage and conversion efficiency, even on relatively high bulk resistivity silicon, were achieved by using a screen-printed aluminum paste back surface field. A 4 sq cm 50 micron m thick cell was fabricated from textured 10 omega-cm silicon which had an open-circuit voltage of 595 mV and AMO conversion efficiency at 25 C of 14.3%. The best 4 sq cm 50 micron thick cell (2 omega-cm silicon) produced had an open-circuit voltage of 607 mV and an AMO conversion efficiency of 15%. Processing modifications are described which resulted in better front contact integrity and reduced breakage. These modifications were utilized in the thin cell pilot line to fabricate 4 sq cm cells with an average AMO conversion efficiency at 25 C of better than 12.5% and with lot yields as great as 51% of starts; a production rate of 10,000 cells per month was demonstrated. A pilot line was operated which produced large area (25 cm) ultra-thin cells with an average AMO conversion efficiency at 25 deg of better than 11.5% and a lot yield as high as 17%.

Storti, G.↗

Investigation of test methods, material properties, and processes for solar cell encapsulants

The development of pottant compounds is emphasized. Formulation of the butyl acrylate syrup/casting pottant was completed. The formulation contains an ultraviolet stabilizer system and may be cured with an initiator that, unlike former selections, presents no shipping of handling hazards to the user. The catalyzed syrup is stable at room temperature and has a pot life of at least eight hours. The formulation of the ethylene/methyl acrylate lamination pottant was also completed. This compound is the alternative pottant to EVA and is similarly produced as an extruded sheet that is wound into rolls. This resin is inherently nonblocking.

Willis, P. B.↗

Development of processes for the production of solar grade silicon from halides and alkali metals, phase 1 and phase 2

High temperature reactions of silicon halides with alkali metals for the production of solar grade silicon are described. Product separation and collection processes were evaluated, measure heat release parameters for scaling purposes and effects of reactants and/or products on materials of reactor construction were determined, and preliminary engineering and economic analysis of a scaled up process were made. The feasibility of the basic process to make and collect silicon was demonstrated. The jet impaction/separation process was demonstrated to be a purification process. The rate at which gas phase species from silicon particle precursors, the time required for silane decomposition to produce particles, and the competing rate of growth of silicon seed particles injected into a decomposing silane environment were determined. The extent of silane decomposition as a function of residence time, temperature, and pressure was measured by infrared absorption spectroscopy. A simplistic model is presented to explain the growth of silicon in a decomposing silane enviroment.

Dickson, C. R.↗

Low cost Czochralski crystal growing technology. Near implementation of the flat plate photovoltaic cost reduction of the low cost solar array project

Equipment developed for the manufacture of over 100 kg of silicon ingot from one crucible by rechanging from another crucible is described. Attempts were made to eliminate the cost of raising the furnace temperature to 250 C above the melting point of silicon by using an RF coil to melt polycrystalline silicon rod as a means of rechanging the crucible. Microprocessor control of the straight growth process was developed and domonstrated for both 4 inch and 6 inch diameter. Both meltdown and melt stabilization processes were achieved using operator prompting through the microprocessor. The use of the RF work coil in poly rod melting as a heat sink in the accelerated growth process was unsuccessful. The total design concept for fabrication and interfacing of the total cold crucible system was completed.

Roberts, E. G.↗

Development of metallization process

Solar cells were produced using a Mo/Sn/TiH screen printed paste with a lead/borosilicate frit that are electrically comparable to control silver cells. The process is currently unsuccessful because the soldering of interconnects to these cells has proved difficult. Future work will investigate using CO instead of H2 as the reducing gas and putting an ITO coating on the cell prior to metallization.

Garcia, A., III↗

Development of a computational model for predicting solar wind flows past nonmagnetic terrestrial planets

A computational model for the determination of the detailed plasma and magnetic field properties of the global interaction of the solar wind with nonmagnetic terrestrial planetary obstacles is described. The theoretical method is based on an established single fluid, steady, dissipationless, magnetohydrodynamic continuum model, and is appropriate for the calculation of supersonic, super-Alfvenic solar wind flow past terrestrial ionospheres.

Stahara, S. S.↗

The flow of plasma in the solar terrestrial environment

The development of electric fields in an expanding plasma was studied. With regard to the polar wind, it was found that hot magnetospheric electrons have a pronounced effect on the polar wind. In addition, there is no O(+) charge exchange barrier and substantial fluxes of O(+) ions can escape with the polar wind. In the auroral plasma physics area, the excitation of electrostatic waves by field aligned auroral electron beams was examined. It was demonstrated that the auroral field aligned current density can be large enough to excite Buneman double layers. For situations that lead to strong double layers, it was shown that the temporal evolution of the potential profile is controlled by current fluctuations. Two dimensional particle in cell simulations were conducted, and the high frequency wave turbulence excited by an auroral electron beam of finite width perpendicular to an ambient magnetic field was investigated. The formation of V shaped auroral potential structures was studied, and numerical simulations of double layers and auroral electric fields were reviewed.

Schunk, R. W.↗

Advanced module development overview

Crystalline silicon solar power modules are examined for reliability and cost effectiveness. A goal of 12% solar energy conversion efficiency is considered feasible at a cost of 12/kWh, and a decision is made to limit consideration to float zone silicon wafer and dendritic web silicone modules. A preliminary module packaging configuration of glass/ethylene vinyl acetate/plastic film is selected. Anticipated module efficiency levels are 12.6% at 25 C and 11.5% at NOCT (Nominal Operating Cell Temperature).

Smokler, M. I.↗

The new space transportation system and the Solar Maximum Repair Mission

A development history, program management and performance capability assessment account is presented for the NASA Solar Maximum Repair Mission conducted by the Space Shuttle Orbiter, which incorporated extravehicular activity as an integral part of servicing efforts. It was determined soon after assessment of the Solar Maximum Mission satellite's hardware malfunction that such a repair mission could be undertaken by the Orbiter at substantially lower cost than the construction and launch of a comparable new spacecraft. A photographic account is given of the various stages of the Shuttle Orbiter-based repair procedure.

Turner, D. N.↗

Development of optical modulators for measurements of solar magnetic fields

The measurement of polarized light allows solar astronomers to infer the magnetic field on the Sun. The accuracy of these measurements is dependent on the stable retardation characteristics of the polarization modulators used to minimize the atmospheric effects seen in ground-based observations. This report describes the work by the Space Science Laboratory at Marshall Space Flight Center to improve two types of polarization modulators. As a result, the timing characteristics for both electrooptic crystals (KD*Ps) and liquid crystal devices (LCDs) have been studied and will be used to enhance the capabilities of the MSFC Vector Magnetograph.

West, E. A.↗

High power CW iodine laser pumped by solar simulator

An iodine photodissociation laser was pumped by a long Ar arc as the solar simulator to produce a 10-W CW output. Continuous lasing for 1 h was achieved with a flow of the laser material n-C3F7I. The 10-W CW output is the highest produced to date and establishes the feasibility of developing a solar-pumped laser for space power transmission.

Lee, Ja H.↗

Momentum accumulation due to solar radiation torque, and reaction wheel sizing, with configuration optimization

This paper has a two-fold objective: determination of yearly momentum accumulation due to solar radiation pressure, and optimum reaction wheel sizing. The first objective is confronted while determining propellant consumption by the attitude control system over a spacecraft's lifetime. This, however, cannot be obtained from the daily momentum accumulation and treating that constant throughout the year, because the orientation of the solar arrays relative to the spacecraft changes over a wide range in a year, particularly if the spacecraft has two arrays, one normal and the other off-normal to different extent at different times to the sun rays. The paper first develops commands for the arrays for tracking the sun, the arrays articulated to earth-pointing spacecraft with two rotational degrees of freedom, and spacecraft in an arbitrary circular orbit. After developing expressions for solar radiation torque due to one or both arrays, arranged symmetrically or asymmetrically relative to the spacecraft bus, momentum accumulation over an orbit and then over a year are determined. The remainder of the paper is concerned with designing reaction wheel configurations. Four-, six-, and three-wheel configurations are considered, and for given torque and momentum requirements, their cant angles with the roll/yaw plane are optimized for minimum power consumption. Finally, their momentum and torque capacities are determined for one-wheel failure scenario, and six configurations are compared and contrasted.

Hablani, Hari B.↗

Advanced design for orbital debris removal in support of solar system exploration

The development of an Autonomous Space Processor for Orbital Debris (ASPOD) is the ultimate goal. The craft will process, in situ, orbital debris using resources available in low Earth orbit (LEO). The serious problem of orbital debris is briefly described and the nature of the large debris population is outlined. This year, focus was on development of a versatile robotic manipulator to augment an existing robotic arm; incorporation of remote operation of robotic arms; and formulation of optimal (time and energy) trajectory planning algorithms for coordinating robotic arms. The mechanical design of the new arm is described in detail. The versatile work envelope is explained showing the flexibility of the new design. Several telemetry communication systems are described which will enable the remote operation of the robotic arms. The trajectory planning algorithms are fully developed for both the time-optimal and energy-optimal problem. The optimal problem is solved using phase plane techniques while the energy optimal problem is solved using dynamics programming.

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Develop Silicone Encapsulation Systems for Terrestrial Silicon Solar Arrays

This work resulted in two basic accomplishments.The first was the identification of DOW CORNING Q1-2577 as a suitable encapsulation material for use in a cost effective encapsulation system. The second was the preparation of a silicon-acrylic cover material containing a durable ultraviolet screening agent for the protection of photo-oxidatively sensitive polymers.

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