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NASA NTRS2004

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.↗

NASA NTRS1979

Recent developments in the economic modeling of photovoltaic module manufacturing

Recent developments in the solar array manufacturing industry costing standards (SAMICS) are described. Consideration is given to the added capability to handle arbitrary operating schedules and the revised procedure for calculation of one-time costs. The results of an extensive validation study are summarized.

Chamberlain, R. G.↗

NASA NTRS1995

Low earth orbit durability of protected silicone for refractive photovoltaic concentrator arrays

Photovoltaic power systems with novel refractive silicone solar concentrators are being developed for use in low Earth orbit (LEO). Because of the vulnerability of silicones to atomic oxygen and ultraviolet radiation, these lenses are coated with a multilayer metal oxide protective coating. The objective of this work was to evaluate the effects of atomic oxygen and thermal exposures on multilayer coated silicone. Samples were exposed to high-fluence ground-laboratory and low-fluence in-space atomic oxygen. Ground testing resulted in decreases in both total and specular transmittance, while in-space exposure resulted in only small decreases in specular transmittance. A contamination film, attributed to exposed silicone at coating crack sites, was found to cause transmittance decreases during ground testing. Propagation of coating cracks was found to be the result of sample heating during exposure. The potential for silicone exposure, with the resulting degradation of optical properties from silicone contamination, indicates that this multilayer coated silicone is not durable for LEO space applications where thermal exposures will cause coating crack development and propagation.

McCollum, Timothy A.↗

NASA NTRS2002

The Stretched Lens Array (SLA): A Low-Risk, Cost-Effective Array Offering Wing-Level Performance of 180 W/KG and 300 W/M2 at 300 VDC

At IECEC 2001, our team presented a paper on the new stretched lens array (SLA), including its evolution from the successful SCARLET array on the NASA/JPL Deep Space 1 spacecraft. Since that conference, the SLA team has made significant advances in the SLA technology, including component-level improvements, array-level optimization, space environment exposure testing, and prototype hardware fabrication and evaluation. This paper describes the evolved version of the SLA, highlighting recent improvements in the lens, solar cell, photovoltaic receiver, rigid panel structure, and complete solar array wing.

ONeill, Mark↗

NASA NTRS2002

Plasma Interaction with International Space Station High Voltage Solar Arrays

The International Space Station (ISS) is presently being assembled in low-earth orbit (LEO) operating high voltage solar arrays (-160 V max, -140 V typical with respect to the ambient atmosphere). At the station's present altitude, there exists substantial ambient plasma that can interact with the solar arrays. The biasing of an object to an electric potential immersed in plasma creates a plasma "sheath" or non-equilibrium plasma around the object to mask out the electric fields. A positively biased object can collect electrons from the plasma sheath and the sheath will draw a current from the surrounding plasma. This parasitic current can enter the solar cells and effectively "short out" the potential across the cells, reducing the power that can be generated by the panels. Predictions of collected current based on previous high voltage experiments (SAMPIE (Solar Array Module Plasma Interactions Experiment), PASP+ (Photovoltaic Array Space Power) were on the order of amperes of current. However, present measurements of parasitic current are on the order of several milliamperes, and the current collection mainly occurs during an "eclipse exit" event, i.e., when the space station comes out of darkness. This collection also has a time scale, t approx. 1000 s, that is much slower than any known plasma interaction time scales. The reason for the discrepancy between predictions and present electron collection is not understood and is under investigation by the PCU (Plasma Contactor Unit) "Tiger" team. This paper will examine the potential structure within and around the solar arrays, and the possible causes and reasons for the electron collection of the array.

John W. Heard↗

NASA NTRS2004

International Space Station Solar Array Wing On-Orbit Electrical Performance Degradation Measured

The port-side photovoltaic power module (P6) was activated on the International Space Station in December 2000. P6 provides electrical power to channels 2B and 4B to operate ISS power loads. A P6 is shown in the preceding photograph. This article highlights the work done at the NASA Glenn Research Center to calculate the on-orbit degradation of the P6 solar array wings (SAWs) using on-orbit data from December 2000 to February 2003. During early ISS operations, the 82 strings of photovoltaic cells that make up a SAW can provide much more power than is necessary to meet the demand. To deal with excess power, a sequential shunt unit successively shunts the current from the strings. This shunt current was the parameter chosen for the SAW performance degradation study for the following reasons: (1) it is based on a direct shunt current measurement in the sequential shunt unit, (2) the shunt current has a low temperature dependence that reduces the data correction error from using a computationally derived array temperature, and (3) the SSU shunt current is essentially the same as the SAW short-circuit current on a per-string basis.

Gustafson, Eric D.↗

NASA NTRS2012

Solar Cell and Array Technology Development for NASA Solar Electric Propulsion Missions

NASA is currently developing advanced solar cell and solar array technologies to support future exploration activities. These advanced photovoltaic technology development efforts are needed to enable very large (multi-hundred kilowatt) power systems that must be compatible with solar electric propulsion (SEP) missions. The technology being developed must address a wide variety of requirements and cover the necessary advances in solar cell, blanket integration, and large solar array structures that are needed for this class of missions. Th is paper will summarize NASA's plans for high power SEP missions, initi al mission studies and power system requirements, plans for advanced photovoltaic technology development, and the status of specific cell and array technology development and testing that have already been conducted.

Piszczor, Michael↗

NASA NTRS1983

Sheet silicon cell/module technology

The cost involved in the performance of the standard operations for the manufacture of silicon wafers is insignificant in the case of space photovoltaics applications. It is, however, a decisive factor with respect to terrestrial applications of silicon photovoltaic devices. In 1975, a program was, therefore, begun to develop low cost silicon solar arrays for terrestrial applications. The goal was silicon-based photovoltaic (PV) modules ready for installation at a selling price of $0.50/watt (1975 dollars). Sheet and ribbon silicon growth held out the promise of reduced cost through continuous operation, high material throughput, high material utilization efficiency, and a product whose shape lent itself to the assembly of high packing density modules. Attention is given to ribbon growth technologies, sheet technology generic problems, and ribbon cell and module technology status. It is concluded that the potential for crystalline ribbon silicon appears to be better today than ever before.

Morrison, A. D.↗

NASA NTRS1983

Qualification and testing of modules

The experience gained in procuring solar modules soon to be installed on the Photovoltaic Higher Education National Exemplar Facility (PHENEF) at Georgetown University is discussed. The 300 KE Photovoltaic Array consists of 4464, 2' X 4', polycrystalline solar cell modules. The performance requirements for the modules are described in a detailed procurement specification which defines physical and electrical characteristics and extensive quality assurance provisions including requirements for an interface control drawing and qualification and acceptance testing.

Cohen, D. B.↗

NASA NTRS1980

Large solar arrays

A spectrophotovoltaic converter, a thermophotovoltaic converter, a cassegrainian concentrator, a large silicon cell blanket, and a high flux approach are among the concepts being investigated as part of the multihundred kW solar array program for reducing the cost of photovoltaic energy in space. These concepts involve a range of technology risks, the highest risk being represented by the thermophotovoltaics and spectrophotovoltaics approaches which involve manipulation to of the incoming spectrum to enhance system efficiency. The planar array (solar blanket) has no technology risk and a moderate payback. The primary characteristics, components, and technology concerns of each of these concepts are summarized. An orbital power platform mission in the late 1980's is being used to allow a coherent technology advancement program in order to achieve a ten year life with maintenance at a capital recurring cost of $30/watt based on 1978 dollars.

Crabtree, W. L.↗

NASA NTRS1979

Evaluation of concentrated space solar arrays using computer modeling

A general approach is developed for predicting the power output of a concentrator enhanced photovoltaic space array. A ray trace routine determines the concentrator intensity arriving at each solar cell. An iterative calculation determines the cell's operating temperature since cell temperature and cell efficiency are functions of one another. The end result of the iterative calculation is that the individual cell's power output is determined as a function of temperature and intensity. Circuit output is predicted by combining the individual cell outputs using the single diode model of a solar cell. Concentrated array characteristics such as uniformity of intensity and operating temperature at various points across the array are examined using computer modeling techniques. An illustrative example is given showing how the output of an array can be enhanced using solar concentration techniques.

Rockey, D. E.↗

NASA NTRS1976

Experiments to evaluate high-temperature rolling as a low-cost process for silicon solar cells

Mechanical rolling (a process used in industry for producing large quantities of metallic sheet and strip) has been suggested for the rapid low-cost manufacture of silicon sheet to be used for photovoltaic power generation equipment, such as solar arrays. The advantages of rolling include: high rates of production, wide sheets as products, good control of dimension, and (in the case of solar grade silicon) minimal development of impurities. Experiments have been performed using high-temperature, high-speed compression of polycrystalline silicon cylinders. Metallography and X-ray diffraction techniques have been used to examine the samples both before and after compression, and a model process has been designed to evaluate the technical practicality and economic feasibility of the method.

Noel, G. T.↗

NASA NTRS1981

The development and utilization of solar photovoltaic cells: An assessment of the potential for a new energy technology

The Government set the goal of accelerating the adaptation of photovoltaics by reducing system costs to a competitive level and overcoming the technical, institutional, legal, environmental, and social barriers impeding the diffusion of photovoltaic technology. The technology of silicon solar arrays was examined and the status of development efforts are reviewed. The political, legal, economic, social, and environmental issues are discussed, and several methods for selecting development projects are described. A number of market forecasting techniques, including time trend, judgemental, and econometric methods, were reviewed, and the results of these models are presented.

Cyr, K. J.↗

NASA NTRS1980

Concentrator designs for space photovoltaic arrays

The unique set of operating constraints determining key concentrating solar array design characteristics for low earth orbital, geosynchronous and interplanetary missions are considered. Minimum cost is crucial at low earth orbits, performance and design life are needed in geosynchronous orbit, and structural pointing accuracy and radiation resistance are essential in interplanetary designs. The impact of such emerging technologies as ultrathin cells, gallium arsenide cells and cold mirrors is discussed. Power-to-mass ratios as high as 200 W per kilogram at a distance of 1 astronomical unit from the sun are possible, using concentrators in conjunction with gallium arsenide arrays.

Rockey, D. E.↗

NASA NTRS1985

Elastomer Encapsulant for Solar-Cell Arrays

Butyl acrylate syrups useful potting compounds for encapsulating photovoltaic cells in modular arrays. Material pourable liquid pumped into module, then cured to rubbery consistency. Cured material is thermoset elastomer highly transparent, low cost, flexible and with good low-temperature properties.

Baum, B.↗

NASA NTRS1986

Photovoltaic array loss mechanisms

Loss mechanisms which come into play when solar cell modules are mounted in arrays are identified. Losses can occur either from a reduction in the array electrical performance or with nonoptimal extraction of power from the array. Electrical performance degradation is caused by electrical mismatch, transmission losses from cell surface soiling and steep angle of reflectance, and electrical losses from field wiring resistance and the voltage drop across blocking diodes. The second type of loss, concerned with the operating points of the array, can involve nonoptimal load impedance and limiting the operating envelope of the array to specific ranges of voltage and current. Each of the loss mechanisms are discussed and average energy losses expected from soiling, steep reflectance angles and circuit losses are calculated.

Gonzalez, Charles↗

NASA NTRS1992

Space power by ground-based laser transmission

A new method for providing power to space vehicles consists of using high-power CW lasers on the ground to beam power to photovoltaic receivers in space. Such large lasers could be located at cloud-free sites at one or more ground locations, and use large mirrors with adaptive optical correction to reduce the beam spread due to diffraction or atmospheric turbulence. This can result in lower requirements for battery storage, due to continuous illumination of arrays even during periods of shadow by the earth, and higher power output, due to the higher efficiency of photovoltaic arrays under laser illumination compared to solar and the ability to achieve higher intensities of illumination. Applications include providing power for satellites during eclipse, providing power to resurrect satellites which are failing due to solar array degradation, powering orbital transfer vehicles or lunar transfer shuttles, and providing night power to a solar array on the moon.

Landis, Geoffrey A.↗

NASA NTRS2012

Reverse bias protected solar array with integrated bypass battery

A method for protecting the photovoltaic cells in a photovoltaic (PV) array from reverse bias damage by utilizing a rechargeable battery for bypassing current from a shaded photovoltaic cell or group of cells, avoiding the need for a bypass diode. Further, the method mitigates the voltage degradation of a PV array caused by shaded cells.

Landis, Geoffrey A↗