Engineering topics
Publications and source records attributed to Scott-Monck, J..
Gold has been used as a conductor material in many microelectronic applications because of its low resistivity, bondability, and oxidation/corrosion resistance.
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High efficiency liquid phase epitaxy (LPE) gallium arsenide cells were irradiated with 1 Mev electrons up to fluences of 1 times 10 to the 16th power cm-2. Measurements of spectral response and dark and illuminated I-V data were made at each fluence and then, using computer codes, the experimental data was fitted to gallium arsenide cell models. In this way it was possible to determine the extent of the damage, and hence damage coefficients in both the emitter and base of the cell.
Two solar array designs developed for the Advanced Photovoltaic Solar Array program are described. The goal of the program is to develop solar arrays with higher mass specific power and power density and good robustness. The specific design requirements are: a beginning-of-life value of 130 W/kg, and end-of-life goals of 105 W/kg and 110 W/sq m. The two array-wing designs consisted of a single blanket. The differences in the blanket material (25 micron-thick Kapton versus 50 micron-thick carbon-loaded Kapton), solar cells (100 micron-thick wrap around versus 50 micron-thick 2 x 4 cm planar contact cells), and performance objectives (proposed industry requirements versus mission objectives) of the two designs are examined.
The development of ultrathin silicon solar cell array modules from initial design to flight testing is discussed. Three 80-cell modules were subjected to the thermal soak test, the LEO thermal cycle test, and the solar array flight experiment, and six 48-cell welded modules were evaluated in the geosynchronous orbit thermal cycle test. It is observed that the electrical performance of the modules was not affected by the different environmental conditions. The automatic assembly of the cell modules, in particular the welding and solar cell glassing operation, is described. The specific power capabilities of Kapton, Kapton-Kevlar-Kapton, Kapton-graphite-Kapton, and Kapton-graphite-aluminum honeycomb-graphite solar array designs are assessed.
In the near future, Air Force mission payloads will require significant increases in power. Sophisticated sensing systems such as infrared focal plane detector arrays and radar will be employed by the Air Force to fulfill its strategic objectives. These payloads will demand that the power subsystem provide up to 50 kW at the end of mission life, more than an order of magnitude greater than is currently required. Some of these payloads must be flown in low-Earth polar orbits to satisfy mission objectives, and it is likely that large (500 to 600 sq m) solar photovoltaic arrays will operate in the low-Earth polar environment. The standard 28 volt power subsystem is not weight efficient for the array power levels being considered. The impact of the solar array operating voltage on the total weight of the array and the subsystem power conditioning and distribution components is illustrated. In the interest of reducing power subsystem weight, higher array operating voltages are considered. The problems which the higher array voltage present to the array designer are discussed. In order to provide a maximum return on the tremendous investment of resources required to develop and place these assets in orbit, they must be designed to operate effectively for extended periods of time. To achieve this, the system must be able to function in the threat-induced and natural space environment.
This paper describes the current status of the JPL high performance solar array development program. Recent progress in solar cell, blanket and structure technologies is described. Future plans for integrating this work are discussed. The impact of the Mariner Mark II mission set on the future direction taken by this development program is assessed.
Single-crystal gallium arsenide (GaAs) solar cell produced at greatly reduced cost by replacing GaAs wafer substrate with silicon substrate.
The potential cost and performance advantages of welding was understood but ignored by solar panel manufacturers in the U.S. Although NASA, DOD and COMSAT have supported welding development efforts, soldering remains the only U.S. space qualified method for interconnecting solar cells. The reason is that no U.S. satellite prime contractor found it necessary, due to mission requirements, to abandon the space proven soldering process. It appears that the proposed NASA space station program will provide an array requirement, a 10 year operation in a low Earth orbital environment, that mandates welding. The status of welding technology in the U.S. is assessed.
A program was conducted to develop technologies for welding interconnects to three types of 50-micron-thick, 2 by 2-cm solar cells. Parallel-gap resistance welding was used for interconnect attachment. Weld schedules were independently developed for each of the three cell types and were coincidentally identical. Six 48-cell modules were assembled with 50-micron (nominal) thick cells, frosted fused-silica covers, silver-plated Invar interconnectors, and four different substrate designs. Three modules (one for each cell type) have single-layer Kapton (50-micron-thick) substrates. The other three modules each have a different substrate (Kapton-Kevlar-Kapton, Kapton-graphite-Kapton, and Kapton-graphite-aluminum honeycomb-graphite). All six modules were subjected to 4112 thermal cycles from -175 to 65 C (corresponding to over 40 years of simulated geosynchronous orbit thermal cycling) and experienced only negligible electrical degradation (1.1 percent average of six 48-cell modules).
The NASA-OAST high performance solar array program is described. The rationale for this effort, its objectives and strategy, as well as progress made during the past 5 years, are discussed. It is shown that welded, ultrathin silicon solar cell array blankets are on the verge of technical readiness. It is argued that the most reasonable approach to achieving more significant performance improvements (to about 300 W/kg) involves the development of a higher efficiency (16-18 percent AM0) solar cell and a lightweight, efficient structure.
A unique polyimide polymer has been developed which shows promise as an encapsulant for interconnected solar cell modules. Such an integral cover offers important weight and cost advantages. The polymer has been characterized on silicon solar cells with respect to electrical output and spectral response. The response of the material-coated cells to electron, low-energy proton, and vacuum-ultraviolet radiation, thermal shock and humidity tests was determined.
The development of high efficiency, ultrathin silicon solar cells offers both opportunity and challenge. It is possible to consider 400 W/kg blanket designs by using this cell in conjuction with flexible substrates, ultrathin covers and welded interconnects. By designing array structure which is mechanically and dynamically compatible with very low mass blankets, solar arrays with a specific power approaching 200 W/kg are achievable. Further improvements in blanket performance (higher power and lower mass per unit area), which could come from the implementation of higher efficiency cells operating at lower temperatures (silicon or GaAs), and the use of encapsulants, would result in the development of 300 W/kg solar arrays.
A new polymer polyimide possessing optical and mechanical properties potentially suitable for space applications now exists. A preliminary evaluation of the material indicates that in its present state of development, the polyimide is not ready for space qualification. Further efforts to increase molecular weight and purify the consituents used to synthesize it are warranted. Activities addressing these needs are now being pursued. If these approaches prove successful, additional testing will take place with an emphasis on synergistic effects.
It was concluded that systems requirements would force a reassessment of the conventional approach to interconnecting cells into blanket or array modules. Defense applications (hardening) were identified as the key requirement that would force a movement away from the standard method (solder) of forming array circuits. The panel also agreed that requirements associated with the impending NASA Space Station and in-bound missions would lead to alternative interconnecting approaches. It was concluded that the diverse requirements of future space missions (high temperature and extended thermal cycling) might not be met by one approach, such as parallel-gap resistance welding. The panel suggested that other options such as high temperature solders and brazing be considered for the various mission requirements that were anticipated. The panel agreed that blanket technology was potentially suitable for in-orbit annealing to temperatures of 200 C provided that conventional soldered connecting techniques were replaced by "welding".
The developmental history of photovoltaics is examined as a basis for predicting further advances to the year 2000. Transistor technology was the precursor of solar cell development. Terrestrial cells were modified for space through changes in geometry and size, as well as the use of Ag-Ti contacts and manufacture of a p-type base. The violet cell was produced for Comsat, and involved shallow junctions, new contacts, and an enhanced antireflection coating for better radiation tolerance. The driving force was the desire by private companies to reduce cost and weight for commercial satellite power supplies. Liquid phase epitaxial (LPE) GaAs cells are the latest advancement, having a 4 sq cm area and increased efficiency. GaAs cells are expected to be flight ready in the 1980s. Testing is still necessary to verify production techniques and the resistance to electron and photon damage. Research will continue in CVD cell technology, new panel technology, and ultrathin Si cells.
A broad overview is presented of current and near-term solar array technology that could be suitable for space use. Particular consideration is given to such advanced concepts as high power arrays, concentrator arrays, and ultrathin solar cell arrays. It is concluded that if such ambitious concepts as geosynchronous space platforms, orbital space stations, and alternate forms of propulsion are realized, the type of new technology described in this paper may find acceptance for space.