Methods for fabricating CdS thin-film solar cell modules.
CdS thin film solar cells series and parallel interconnection into modules, using soldered or conductive epoxy bonding methods
Ratajczak, A. F.↗
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Thin-Film Solar Cells on Metal Foil Substrates for Space Power
Photovoltaic arrays have played a key role in power generation in space. The current technology will continue to evolve but is limited in the important mass specific power metric (MSP or power/weight ratio) because it is based on bulk crystal technology. The objective of this research is to continue development of an innovative photovoltaic technology for satellite power sources that could provide up to an order of magnitude saving in both weight and cost, and is inherently radiation-tolerant through use of thin film technology and thin foil substrates such as 5-mil thick stainless steel foil or 1-mil thick Ti. Current single crystal technology for space power can cost more than $300 per watt at the array level and weigh more than 1 kg/sq m equivalent to specific power of approx. 65 W/kg. Thin film material such as CuIn(1-x),Ga(x)S2, (CIGS2), CuIn(1-x), G(x)Se(2-y),S(y), (CIGSS) or amorphous hydrogenated silicon (a-Si:H) may be able to reduce both the cost and mass per unit area by an order of magnitude. Manufacturing costs for solar arrays are an important consideration for total spacecraft budget. For a medium sized 5kW satellite, for example, the array manufacturing cost alone may exceed $2 million. Moving to thin film technology could reduce this expense to less than $500 K. Previous work at FSEC demonstrated the potential of achieving higher efficiencies from CIGSS thin film solar cells on 5-mil thick stainless steel foil as well as initial stages of facility augmentation for depositing thin film solar cells on larger (6"x 4") substrates. This paper presents further progress in processing on metal foil substrates. Also, previous work at DayStar demonstrated the feasibility of flexible-thin-film copper-indium-gallium-diselenide (CIGS) solar cells with a power-to-weight ratio in excess of 1000 W/kg. We will comment on progress on the critical issue of scale-up of the solar cell absorber deposition process. Several important technical issues need to be resolved to realize the benefits of lightweight technologies for solar arrays, such as: monolithic interconnects, lightweight array structures, and new ultra-light support and deployment mechanisms. Once the technology has gained spaceflight certification it should find rapid acceptance in specific satellite markets.
Raffaelle, Ryne P.↗
Thin-Film Solar Cells on Polymer Substrates for Space Power
Photovoltaic arrays have played a key role in power generation in space. The current technology will continue to evolve but is limited in the important mass specific power metric (MSP or power/weight ratio) because it is based on bulk crystal technology. Solar cells based on thin-film materials offer the promise of much higher MSP and much lower cost. However, for many space applications, a 20% or greater AM0 efficiency (eta) may be required. The leading thin-film materials, amorphous Si, CuInSe, and CdTe have seen significant advances in efficiency over the last decade but will not achieve the required efficiency in the near future. Several new technologies are herein described to maximize both device eta and MSP. We will discuss these technologies in the context of space exploration and commercialization. One novel approach involves the use of very lightweight polyimide substrates. We describe efforts to enable this advance including materials processing and device fabrication and characterization. Another approach involves stacking two cells on top of each other. These tandem devices more effectively utilize solar radiation by passing through non-absorbed longer wavelength light to a narrow-bandgap bottom cell material. Modeling of current devices in tandem format indicates that AM0 efficiencies near 20% can be achieved with potential for 25% in the near future. Several important technical issues need to be resolved to realize the benefits of lightweight technologies for solar arrays, such as: monolithic interconnects, lightweight array structures, and new ultra-light support and deployment mechanisms. Recent advances will be stressed.
Hepps, A. F.↗
Space platforms
The expanded scientific capabilities available by interfacing an orbital, free-flying experiments platform with Shuttle tending are outlined. The platform would be lifted to orbit by the Shuttle, and modularly increased in size on subsequent flights. Science packages could be left on the 26,000 lb space platform for up to six months. Component sections would include electrical and thermal control systems, berthing ports for payloads and an Orbiter, and an attitude control, communications, and data handling subsection. A 12 kW solar array would furnish power, and interconnect with Spacelab would further enhance the operations range. All berthed science packages would have individual pointing ability and grapples for the Orbiter RMS. Eventual evolution to include facilities for a human crew and a 25 kW solar array is projected.
Source record↗
Breakdown of organic insulators
Solar cells and their associated electrical interconnects and leads were encapsulated in transparent elastomeric materials. Their purpose in a photovoltaic module, one of the most important for these elastomeric encapsulation materials, is to function as electrical insulation. This includes internal insulation between adjacent solar cells, between other encapsulated electrical parts, and between the total internal electrical circuitry and external metal frames, grounded areas, and module surfaces. Catastrophic electrical breakdown of the encapsulant insulation materials or electrical current through these materials or module edges to external locations can lead to module failure and can create hazards to humans. Electrical insulation stability, advanced elastomeric encapsulation materials are developed which are intended to be intrinsically free of in-situ ionic impurities, have ultralow water absorption, be weather-stable (UV, oxygen), and have high mechanical flexibility. Efforts to develop a method of assessing the life potential of organic insulation materials in photovoltaic modules are described.
Cuddihy, E. F.↗
Linear force-free magnetic fields for solar extrapolation and interpretation
This paper discusses the interconnection of the various linear force-free magnetic field formulations, the specific phenomenological and topological parameters of these formulations, and their usefulness. Particularly, the limitations and usefulness of linear force-free fields are discussed. Specific field configurations are related to magnetographic interpretation. The relationship of the integral and Fourier procedures is shown explicitly. The physical interpretation of linear force-free fields is shown by analytic models and from the Marshall Space Flight Center solar vector magnetograms.
Gary, G. Allen↗
FEP-Teflon covered solar cell array advancements
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.
Rauschenbach, H. S.↗
Assessment of atomic oxygen erosion of silver interconnects on Intelsat 6, F3
Intelsat 6 F-3 was launched from Cape Canaveral on a Titan 3 launch vehicle. Failure of the launch vehicle resulted in the satellite being marooned in Low Earth Orbit (LEO). During its sojourn in LEO, Intelsat 6 is exposed to an unanticipated environment consisting primarily of atomic oxygen, which will subject the unprotected silver interconnects (nominally 12.5 microns thick) on the solar panel to oxidation and erosion. Rescue by Space Shuttle is being examined. Consequently, Intelsat and Comsat have joined in an effort to determine the condition of the silver interconnects at the anticipated time of reboost and to assess the long term risks to the intended geostationary mission. Ground based tests, theoretical analysis, and a flight experiment aboard STS-41 were executed, and new software was written to calculate the expected total atomic oxygen fluence on the interconnects.
A. Dunnet↗
A Solar Thermophotovoltaic Electric Generator for Remote Power Applications
We have successfully demonstrated that a solar thermophotovoltaic (TPV) system with a SiC graybody emitter and the monolithic interconnected module device technology can be realized. A custom-designed solar cavity was made to house the SiC emitter and the Monolithic Integrated Module (MIM) strings for testing in a Stirling dish solar concentrator. Five 1x1-cm MIMs, with a bandgap of 0.74 eV, were mounted on a specially designed water-cooled heatsink and were electrically connected in series to form a string. Two such strings were fabricated and tested, as well as high-performance 2x2-cm MIMs with a bandgap of 0.74 eV. Very high output power density values between 0.82 and 0.90 W/ square cm were observed for an average emitter temperature of 1501 K.
Fatemi, Navid S.↗
A Solar Thermophotovoltaic Electric Generator for Remote Power Applications
We have successfully demonstrated that a solar thermophotovoltaic (TPV) system with a SiC graybody emitter and the monolithic interconnected module device technology can be realized. A custom-designed solar cavity was made to house the SiC emitter and the MIM strings for testing in a Stirling dish solar concentrator. Five 1x1-cm MIMs, with a bandgap of 0.74 eV,were mounted on a specially designed water-cooled heatsink and were electrically connected in series to form a string. Two such strings were fabricated and tested, as well as high-performance 2x2-cm MIMs with a bandgap of 0.74 eV. Very high output power density values between 0.82 and 0.90 W/sq cm were observed for an average emitter temperature of 1501 K.
Fatemi, Navid S.↗
Did Geomagnetic Activity Challenge Electric Power Reliability During Solar Cycle 23? Evidence from the PJM Regional Transmission Organization in North America
During solar cycle 22, a very intense geomagnetic storm on 13 March 1989 contributed to the collapse of the Hydro-Quebec power system in Canada. This event clearly demonstrated that geomagnetic storms have the potential to lead to blackouts. This paper addresses whether geomagnetic activity challenged power system reliability during solar cycle 23. Operations by PJM Interconnection, LLC (hereafter PJM), a regional transmission organization in North America, are examined over the period 1 April 2002 through 30 April 2004. During this time PJM coordinated the movement of wholesale electricity in all or parts of Delaware, Maryland, New Jersey, Ohio, Pennsylvania, Virginia, West Virginia, and the District of Columbia in the United States. We examine the relationship between a proxy of geomagnetically induced currents (GICs) and a metric of challenged reliability. In this study, GICs are proxied using magnetometer data from a geomagnetic observatory located just outside the PJM control area. The metric of challenged reliability is the incidence of out-of-economic-merit order dispatching due to adverse reactive power conditions. The statistical methods employed make it possible to disentangle the effects of GICs on power system operations from purely terrestrial factors. The results of the analysis indicate that geomagnetic activity can significantly increase the likelihood that the system operator will dispatch generating units based on system stability considerations rather than economic merit.
storms↗
Evaluation of glass resin coatings for solar cell applications
Using a variety of non-vacuum deposition techniques coatings were implemented on silicon solar cells and arrays of cells interconnected on Kapton substrates. The coatings provide both antireflection optical matching and environmental protection. Reflectance minima near 2% was achieved at a single wavelength in the visible. Reflectance averaging below 5% across the useful collection range was demonstrated. The coatings and methods of deposition were: (1) Ta2O5 spun, dipped or sprayed; (2) Ta2O5.SiO2 spun, dipped or sprayed; (3) GR908 (SiO2) spun, dipped, or sprayed. Total coating thickness were in the range of 18 microns to 25 microns. The coatings and processes are compatible with single cells or cells mounted on Kapton substrates.
Field, M. B.↗
A transient plasticity study and low cycle fatigue analysis of the Space Station Freedom photovoltaic solar array blanket
The Space Station Freedom photovoltaic solar array blanket assembly is comprised of several layers of materials having dissimilar elastic, thermal, and mechanical properties. The operating temperature of the solar array, which ranges from -75 to +60 C, along with the material incompatibility of the blanket assembly components combine to cause an elastic-plastic stress in the weld points of the assembly. The weld points are secondary structures in nature, merely serving as electrical junctions for gathering the current. The thermal mechanical loading of the blanket assembly operating in low earth orbit continually changes throughout each 90 min orbit, which raises the possibility of fatigue induced failure. A series of structural analyses were performed in an attempt to predict the fatigue life of the solar cell in the Space Station Freedom photovoltaic array blanket. A nonlinear elastic-plastic MSC/NASTRAN analysis followed by a fatigue calculation indicated a fatigue life of 92,000 to 160,000 cycles for the solar cell weld tabs. Additional analyses predict a permanent buckling phenomenon in the copper interconnect after the first loading cycle. This should reduce or eliminate the pulling of the copper interconnect on the joint where it is welded to the silicon solar cell. It is concluded that the actual fatigue life of the solar array blanket assembly should be significantly higher than the calculated 92,000 cycles, and thus the program requirement of 87,500 cycles (orbits) will be met. Another important conclusion that can be drawn from the overall analysis is that, the strain results obtained from the MSC/NASTRAN nonlinear module are accurate to use for low-cycle fatigue analysis, since both thermal cycle testing of solar cells and analysis have shown higher fatigue life than the minimum program requirement of 87,500 cycles.
Armand, Sasan C.↗
Solar array arcing in plasmas
Solar cells in space plasma conditions are known to arc into the plasma when the interconnects are at a negative potential of a few hundred volts, relative to plasma potential. For cells with silver-coated interconnects, a threshold voltage for arcing exists at about -230 V, as found in both ground and LEO experiments. The arc rate beyond the threshold voltage depends nearly linearly on plasma density, but has a strong power-law dependence on voltage, such that for small increments in operating voltage there is a large increment in arc rate. The arcs generate broadband radio interference and visible light. In ground tests, interconnects have been damaged by arcs in cells having insufficient isolation from a source of high current. Models for the arcs are highly dependent on the choice of interconnect conductor material exposed to the plasma and possibly on the geometry and choice of adjacent insulator material. Finally, new technology solar cells use copper for the cell interconnects, a material which may have a lower arcing threshold voltage than silver. It is expected, from ground tests of simulated solar cells, that any junction of conductor and insulator exposed to space plasma conditions will arc into the plasma at a few hundred volts negative potential, relative to the local plasma.
Ferguson, Dale C.↗
Thermophotovoltaic Cell Technology Transferred to the Department of Energy Laboratory and a Commercial Manufacturer
Researchers in the NASA Lewis Research Center's Photovoltaic Branch have developed novel photovoltaic device, called a Monolithically Interconnected Module (MIM), for use in thermophotovoltaic (TPV) power systems. TPV power systems function by heating an emitter to produce light. This light is then converted into electricity by a photovoltaic device or a solar cell. Possible heat sources for the system include concentrated solar energy, the combustion of various fuels, and nuclear decay. NASA has an interest in TPV systems for deep space (nuclear-powered) and near-Sun (solar-powered) missions. There also are many commercial and military applications for TPV, given its potential for high efficiency, low noise, and reliable power. The Monolithically Interconnected Module consists of many small solar cells that are series-interconnected on a common substrate. The cells are fabricated from indium gallium arsenide (InGaAs), which can convert the near-infrared portion of the emitter output spectrum into electricity. The InGaAs devices are deposited on an indium phosphide (InP) substrate that provides electrical isolation. On the bottom the InP substrate is an infrared reflector that returns all the photons that are not converted by the InGaAs device back to the emitter where they are absorbed. This process helps maintain the emitter temperature and dramatically improves the system efficiency. Monolithically Interconnected Module InGaAs thermophotovoltaic cell developed by Lewis. Compared with conventional TPV cells, this TPV device has higher output voltages and lower resistive losses, higher output power density, simplified thermal management, improved reliability, and higher efficiency. The Monolithically Interconnected Module was initially developed under an internally funded effort (Director's Discretionary Fund). Development is now being funded by another government agency, and prototype devices are being produced by a commercial solar cell manufacturer.
Wilt, David M.↗
Evolution of integrated panel structural design and interfaces for PV power plants
The evolution of integrated photovoltaic (PV) panel design at ARCO Solar is discussed. Historically, framed PV modules of about 1 x 4-ft size were individually mounted in the field on fixed support structures and interconnected electrically with cables to build higher-power arrays. When ARCO Solar saw the opportunity in 1982 to marry its PV modules with state-of-the-art heliostat trackers developed by ARCO Power Systems, it became obvious that mounting individual modules was impractical. For this project, the framed modules were factory-assembled into panels and interconnected with cables before being mounted on the trackers. Since then, ARCO Solar made considerable progress and gained substantial experience in the design and fabrication of large PV panels. Constraints and criteria considered in these design activities included static and dynamic loads; assembly and transportation equipment and logistics, structural and electrical interfaces, and safety and grounding concerns.
Arnett, J. C.↗
34% Efficient InGaP/GaAs/GaSb Cell-Interconnected-Circuits for Line-Focus Concentrator Arrays
While monolithic multi-junction cells are preferred for flat plate arrays, mechanically stacked multi-junction cells are superior for solar concentrator applications. Reasons for this are that the mechanical stacked configuration with high efficiency Gallium Antimonide cells allows utilization of a much wider range of the solar energy spectrum, and the ability to use voltage matched interconnects results in full use of low bandgap cell currents. Herein, data are presented for simple two terminal voltage-matched circuits using InGaP/GaAs/GaSb stacked cells showing 34% average circuit efficiency for a lot of 12 circuits given prismatic covers. These circuits have been designed to fit into the ultralight Stretched Lens Array being developed by NASA. With these new cell-interconnected-circuits, we project that the power density at GEO operating temperature can be increased from 296 W/m2 to 350 W/m2 while maintaining the specific power at 190 W/kg at the full wing level.
Fraas, L. M.↗
The driving force for magnetospheric convection
Viscously driven magnetospheric models, as well as a model involving interconnection between the geomagnetic field and the magnetic field in the solar wind, have been proposed to describe the driving force for magnetospheric convection. Lack of a satisfactory theory for the interconnection in the latter model and, in the case of the viscous interaction models, inadequacies in predicting the quantity of the driving force, make these two classes of models less than successful. Accordingly, a mechanically driven magnetospheric model is proposed: solar wind plasma enters the magnetosphere around the neutral points, covers the inner surface of the magnetopause and subsequently expands, driving convection as it escapes from the open tail.
Johnson, F. S.↗