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Materials which have demonstrated their suitability for space application are summarized. Common, recurring problems in encapsulants and conformal coatings, optical materials, lubrication, and bonding and joining are noted. The subjects discussed include: low density and syntactic foams, electrical encapsulants; optical glasses, interference filter, mirrors; oils, greases, lamillar lubricants; and, soldering and brazing processes.
Samples of FEP-encapsulated silicon solar cells and various potential encapsulation or cover materials were subjected to both accelerated and real-time testing. The durability of the samples was determined by measuring changes in solar cell output or optical transmission as a function of exposure. The tests revealed some problem areas in the structural integrity of the materials, e.g., delamination and cracking in FEP. These problems were probably related to defects in fabrication. FEP and Aclar had the least transmission loss after accelerated exposure equivalents of 5 and 3 years, respectively.
Production expenses are decreased by embossing encapsulating plastic film to position and secure cells. Electric circuit is printed on plastic film simultaneously with cell encapsulation process. Procedure can be used with standard-contact and wraparound contact cells.
The development of very low cost long lived Cu2S/CdS thin film solar cells for large scale energy conversion is reported. Excellent evaporated metal grid patterns were obtained using a specially designed aperture mask. Vacuum evaporated gold and copper grids of 50 lines per inch and 1 micron thickness were adequate electrically for the fine mesh contacting grid. Real time roof top sunlight exposure tests of encapsulated CdS cells showed no loss in output after 5 months. Accelerated life testing of encapsulated cells showed no loss of output power after 6 months of 12 hour dark-12 hour AMI illumination cycles at 40 C, 60 C, 80 C and 100 C temperatures. However, the cells changed their basic parameters, such as series and shunt resistance and junction capacitance.
A solar cell shingle was made of an array of solar cells on a lower portion of a substantially rectangular shingle substrate made of fiberglass cloth or the like. The solar cells may be encapsulated in flourinated ethylene propylene or some other weatherproof translucent or transparent encapsulant to form a combined electrical module and a roof shingle. The interconnected solar cells were connected to connectors at the edge of the substrate through a connection to a common electrical bus or busses. An overlap area was arranged to receive the overlap of a cooperating similar shingle so that the cell portion of the cooperating shingle may overlie the overlap area of the roof shingle. Accordingly, the same shingle serves the double function of an ordinary roof shingle which may be applied in the usual way and an array of cooperating solar cells from which electrical energy may be collected.
Coverings for solar cells are evaluated conveniently with alumina ceramic circuit board holding three pairs of cells and three field-effect translator (FET) chips overlaid with candidate encapsulant. With fixture, solar cells and encapsulants are exposed to Sunlight and weather, either natural or artificial, to provide pertinent measurement and performance data.
Environmental tests were performed of on 76 solar cell modules produced by four different manufacturers. The following tests were performed: (1) 28 day temperature and humidity; (2) rain and icing; (3) salt fog; (4) sand and dust; (5) vacuum/steam/pressure; (6) fungus; (7) temperature/altitude; and (8) thermal shock. Environmental testing of the solar cell modules produced cracked cells, cracked encapsulant and encapsulant delaminations on various modules. In addition, there was some minor cell and frame corrosion.
A machine is described for attaching solar cells to a flexable substrate on which printed circuitry has been deposited. The strip is fed through: (1) a station in which solar cells are elevated into engagement with solder pads for the printed circuitry and thereafter heated by an infrared lamp; (2) a station at which flux and solder residue is removed; (3) a station at which electrical performance of the soldered cells is determined; (4) a station at which an encapsulating resin is deposited on the cells; (5) a station at which the encapsulated solar cells are examined for electrical performance; and (6) a final station at which the resulting array is wound on a takeup drum.
A conceptual design study has been completed which has shown the feasibility of ultra-low-mass planar solar arrays with specific power of 200 watts/kilogram. The beginning of life (BOL) power output of the array designs would be 10 kW at 1 astronomical unit (AU) and a 55C deg operating temperature. Two designs were studied: a retractable rollout design and a non-retractable fold-out. The designs employed a flexible low-mass blanket and low-mass structures. The blanket utilized 2 x 2 cm high-efficiency (13.5% at 28C deg AM0), ultra-thin (50 micron), silicon solar cells protected by thin (75 micron) plastic encapsulants. The structural design utilized the 'V'-stiffened approach which allows a lower mass boom to be used. In conjunction with the conceptual design, modules using the thin cells and plastic encapsulant were designed and fabricated.
An excellent encapsulation system for a terrestrial solar array can be formed using two sheets of glass. Superior technical character, very low cost and simple assembly can result if the active components and the glass sheets are integrally bonded together such that the array is hermetically sealed without employing organic encapsulation materials. Such an approach is being developed using electrostatic bonding. Status of this development is described. Functioning integral glass test modules have been fabricated and subjected to environmental testing. Results have been excellent.
The minimum cost per unit of power output from flat plate solar modules can most likely be achieved through efficient packaging of higher efficiency solar cells. This paper outlines a module optimization method which is broadly applicable, and illustrates the potential results achievable from a specific high efficiency tandem junction (TJ) cell. A mathematical model is used to assess the impact of various factors influencing the encapsulated cell and packing efficiency. The optimization of the packing efficiency is demonstrated. The effect of encapsulated cell and packing efficiency on the module add-on cost is shown in a nomograph form.
The design of a 1.2 by 2.4 m curved glass superstrate and support clip assembly is presented, along with the results of finite element computer analysis and a glass industry survey conducted to assess the technical and economic feasibility of the concept. Installed costs for four curved glass module array configurations are estimated and compared with cost previously reported for comparable flat glass module configurations. Electrical properties of candidate module encapsulation systems are evaluated along with present industry practice for the design and testing of electrical insulation systems. Electric design requirements for module encapsulation systems are also discussed.
Encapsulated in robot end effector is RF induction-heating coil for heating solar cell while in transit. Holes in encapsulant permit end of unit to act as vacuum pickup to grip solar cell. Use of RF induction heating allows cell to be heated without requiring direct mechanical and thermal contact of bonding tool such as soldering iron.
The considered project is part of the DOE Photovoltaic Technology and Market Development Program. This program is concerned with the development and the utilization of cost-competitive photovoltaic systems. The project has the objective to develop, by 1986, the national capability to manufacture low-cost, long-life photovoltaic arrays at production rates that will realize economies of scale, and at a price of less than $0.70/watt. The array performance objectives include an efficiency greater than 10% and an operating lifetime longer than 20 years. The objective of the silicon material task is to establish the practicality of processes for producing silicon suitable for terrestrial photovoltaic applications at a price of $14/kg. The large-area sheet task is concerned with the development of process technology for sheet formation. Low-cost encapsulation material systems are being developed in connection with the encapsulation task. Another project goal is related to the development of economical process sequences.
Immersed heating and cooling elements establish desired temperature gradients. Method envisions use of high-pressure, Czochralski crystalgrowth apparatus as presently employed to grow gallium arsenide and gallium phosphide but modified to accept deep crucibles so deep layers of encapsulant used, plus X-ray or optical or sonic-imaging system to observe growth of crystal submerged in encapsulant. Method especially applicable to horizontal growth of ribbons of compound semiconductors.
The accelerated stress test results obtained on all terrestrial solar cells since the inception of the program are summarized. Tested cells were grouped according to the method used to form the conductive metallization layer: solder dipped, vacuum deposited, screen printed, and copper plated. Although metallization systems within each group were quite similar, they differed in numerous details according to the procedures employed by each manufacturer. Test results were summarized for all cells according to both electrical degradation and catastrophic mechanical changes. These results indicated a variability within each metallization category which was dependent on the manufacturer. Only one manufacturer was represented in the copper plated category and, although these showed no signs of detrimental copper diffusion during high temperature testing, their metallization was removed easily during high humidity pressure cooker testing. Preliminary testing of encapsulated cells showed no major differences between encapsulated and unencapsulated cells when subjected to accelerated testing.
NASA tests results from an 18 mo program of cleaning silicone-encapsulated and glass fronted solar cell panels in urban and desert environments to examine the effects of cleaning on module performance are reported. The panels were cleaned on weekly, monthly, quarterly, or semi-annual basis, while other panels of the same construction were not cleaned and served as controls. Commercially-available detergents and city water were employed for the tests, and the measurements were maintained of the modules' continuing short-circuit current output. The decay of the output was determined by least square regression analyses. Performance degradation was noticeably less in glass covered, rather than silicone-encapsulated modules which decayed faster in urban than in desert environments. Lower frequency cleanings are recommended where labor costs are high.
Results of an ongoing research program into the reliability of terrestrial solar cells are presented. Laboratory accelerated testing procedures are used to identify failure/degradation modes which are then related to basic physical, chemical, and metallurgical phenomena. In the most recent tests, ten different types of production cells, both with and without encapsulation, from eight different manufacturers were subjected to a variety of accelerated tests. Results indicated the presence of a number of hitherto undetected failure mechanisms, including Schottky barrier formation at back contacts and loss of adhesion of grid metallization. The mechanism of Schottky barrier formation is explained by hydrogen, formed by the dissociation of water molecules at the contact surface, diffusing to the metal semiconductor interface. This same mechanism accounts for the surprising increase in sensitivity to accelerated stress conditions that was observed in some cells when encapsulated.