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A photovoltaic Metallization Research forum, under the sponsorship of the Flat-Plate Solar Array Project consisted of five sessions, covering: (1) the current status of metallization systems, (2) system design, (3) thick-film metallization, (4) advanced techniques, and (5) future metallization challenges.
Solar Concentrator Array with Refractive Linear Element Technology (SCARLET) is one of the first practical photovoltaic concentrator array technologies that offers a number of benefits for space applications (i.e. high array efficiency, protection from space radiation effects, a relatively light weight system, minimized plasma interactions, etc.) The line-focus concentrator concept, however, also offers two very important advantages: (1) low-cost mass production potential of the lens material; and (2) relaxation of precise array tracking requirements to only a single axis. These benefits offer unique capabilities to both commercial and government spacecraft users, specifically those interested in high radiation missions, such as MEO orbits, and electric-powered propulsion LEO-to-GEO orbit raising applications. SCARLET is an aggressive hardware development and flight validation program sponsored by the Ballistic Missile Defense Organization (BMDO) and NASA Lewis Research Center. Its intent is to bring technology to the level of performance and validation necessary for use by various government and commercial programs. The first phase of the SCARLET program culminated with the design, development and fabrication of a small concentrator array for flight on the METEOR satellite. This hardware will be the first in-space demonstration of concentrator technology at the 'array level' and will provide valuable in-orbit performance measurements. The METEOR satellite is currently planned for a September/October 1995 launch. The next phase of the program is the development of large array for use by one of the NASA New Millenium Program missions. This hardware will incorporate a number of the significant improvements over the basic METEOR design. This presentation will address the basic SCARLET technology, examine its benefits to users, and describe the expected improvements for future missions.
The recent past, present state-of-the-art, and future needs in the area of large photovoltaic solar arrays are discussed. In the past most attention was focused upon performance whereas in the future most of the effort should go into cost reduction. Suggestions are made regarding possible approaches to reducing cost such as on-orbit maintenance, extended lifetime, solar concentrators, and high-voltage modular concepts.
New power control technologies, such as smart power (SP) and power integrated circuits (PICs), are being developed to decrease cost and increase performance of photovoltaic power arrays.
As a part of the Space Exploratory Initiative (SEI), NASA-Lewis is studying Solar Electric Propulsion (SEP) spacecraft to be used as a cargo transport vehicle to Mars. Two preliminary structural design concepts are offered for SEP spacecraft: a split blanket array configuration, and a ring structure. The split blanket configuration is an expansion of the photovoltaic solar array design proposed for Space Station Freedom and consists of eight independent solar blankets stretched and supported from a central mast. The ring structural concept is a circular design with the solar blanket stretched inside a ring. This concept uses a central mast with guy wires to provide additional support to the ring. The two design concepts are presented, then compared by performing stability, normal modes, and forced response analyses for varying levels of blanket and guy wire preloads. The ring structure configuration is shown to be advantageous because it is much stiffer, more stable, and deflects less under loading than the split blanket concept.
As a part of the Space Exploratory Initiative (SEI), NASA-Lewis is studying Solar Electric Propulsion (SEP) spacecraft to be used as a cargo transport vehicle to Mars. Two preliminary structural design concepts are offered for SEP spacecraft: a split blanket array configuration, and a ring structure. The split blanket configuration is an expansion of the photovoltaic solar array design proposed for Space Station Freedom and consists of eight independent solar blankets stretched and supported from a central mast. The ring structural concept is a circular design with the solar blanket stretched inside a ring. This concept uses a central mast with guy wires to provide additional support to the ring. The two design concepts are presented, then compared by performing stability, normal modes, and forced response analyses for varying levels of blanket and guy wire preloads. The ring structure configuration is shown to be advantageous because it is much stiffer, more stable, and deflects less under loading than the split blanket concept.
NASA Lewis Research Center is conducting thermal cycle testing of a new solar array blanket technologies. These technologies include test coupons for Space Station Freedom (SSF) and the advanced photovoltaic solar array (APSA). The objective of this testing is to demonstrate the durability or operational lifetime of the solar array interconnect design and blanket technology within a low earth orbit (LEO) or geosynchronous earth orbit (GEO) thermal cycling environment. Both the SSF and the APSA array survived all rapid thermal cycling with little or no degradation in peak performance. This testing includes an equivalent of 15 years in LEO for SSF test coupons and 30 years of GEO plus ten years of LEO for the APSA test coupon. It is concluded that both the parallel gap welding of the SSF interconnects and the soldering of the APSA interconnects are adequately designed to handle the thermal stresses of space environment temperature extremes.
Flexible, deployable arrays are an attractive alternative to conventional solar arrays for near-term and future space power applications, particularly due to their potential for high specific power and low storage volume. Combined with low-cost flexible thin-film photovoltaics, these arrays have the potential to become an enabling or an enhancing technology for many missions. In order to expedite the acceptance of thin-film photovoltaics for space applications, however, parallel development of flexible photovoltaics and the corresponding deployable structure is essential. Many innovative technologies must be incorporated in these arrays to ensure a significant performance increase over conventional technologies. For example, innovative mechanisms which employ shape memory alloys for storage latches, deployment mechanisms, and array positioning gimbals can be incorporated into flexible array design with significant improvement in the areas of cost, weight, and reliability. This paper discusses recent activities at Martin Marietta regarding the development of flexible, deployable solar array technology. Particular emphasis is placed on the novel use of shape memory alloys for lightweight deployment elements to improve the overall specific power of the array. Array performance projections with flexible thin-film copper-indium-diselenide (CIS) are presented, and government-sponsored solar array programs recently initiated at Martin Marietta through NASA and Air Force Phillips Laboratory are discussed.
Potentials of solar power electric propulsion including photovoltaic devices, array structures and weight reduction
In an effort to further advance a realizable form of wireless power transmission (WPT), high intensity laser power beaming (HILPB) has been developed for both space and terrestrial applications. Unique optical-to-electrical receivers are employed with near infrared (IR-A) continuous-wave (CW) semiconductor lasers to experimentally investigate the HILPB system. In this paper, parasitic feedback, uneven illumination and the implications of receiver array geometries are considered and experimental hardware results for HILPB are presented. The TEM00 Gaussian energy profile of the laser beam presents a challenge to the effectiveness of the receiver to perform efficient photoelectric conversion, due to the resulting non-uniform illumination of the photovoltaic cell arrays. In this investigation, the geometry of the receiver is considered as a technique to tailor the receiver design to accommodate the Gaussian beam profile, and in doing so it is demonstrated that such a methodology is successful in generating bulk receiver output power levels reaching 25 W from 7.2 sq cm of photovoltaic cells. These results are scalable, and may be realized by implementing receiver arraying and utilizing higher power source lasers to achieve a 1.0 sq m receiver capable of generating over 30 kW of electrical power. This type of system would enable long range optical "refueling" of electric platforms, such as MUAV s, airships, robotic exploration missions and provide power to spacecraft platforms which may utilize it to drive electric means of propulsion. In addition, a smaller HILPB receiver aperture size could be utilized to establish a robust optical communications link within environments containing high levels of background radiance, to achieve high signal to noise ratios.
For the past 2% years, our team has been developing a unique photovoltaic concentrator array for collection and conversion of infrared laser light. This laser-receiving array has evolved from the solar-receiving Stretched Lens Array (SLA). The laser-receiving version of SLA is being developed for space power applications when or where sunlight is not available (e.g., the eternally dark lunar polar craters). The laser-receiving SLA can efficiently collect and convert beamed laser power from orbiting spacecraft or other sources (e.g., solar-powered lasers on the permanently illuminated ridges of lunar polar craters). A dual-use version of SLA can produce power from sunlight during sunlit portions of the mission, and from beamed laser light during dark portions of the mission. SLA minimizes the cost and mass of photovoltaic cells by using gossamer-like Fresnel lenses to capture and focus incoming light (solar or laser) by a factor of 8.5X, thereby providing a cost-effective, ultra-light space power system.
The 9th Space Photovoltaic Research and Technology conference was held at the NASA Lewis Research Center from April 19 to 21, 1988. The papers and workshop summaries report remarkable progress on a wide variety of approaches in space photovoltaics, for both near and far term applications. Among the former is the recently developed high efficiency GaAs/Ge cell, which formed the focus of a workshop discussion on heteroepitaxial cells. Still aimed at the long term, but with a significant payoff in a new mission capability, are InP cells, with their potentially dramatic improvement in radiation resistance. Approaches to near term, array specific powers exceeding 130 W/kg are also reported, and advanced concentrator panel technology with the potential to achieve over 250 W/sq m is beginning to take shape.
The development of flat plate solar arrays is reported. Photovoltaic cells require back side metallization and a collector grid system on the front surface. Metallo-organic decomposition (MOD) silver films can eliminate most of the present problems with silver conductors. The objectives are to: (1) identify and characterize suitable MO compounds; (2) develop generic synthesis procedures for the MO compounds; (3) develop generic fabrication procedures to screen printable MOD silver inks; (4) optimize processing conditions to produce grid patterns and photovoltaic cells; and (5) develop a model which describes the adhesion between the fired silver film and the silicon surface.
A technical assessment of a program to develop photovoltaic power system technology for large-scale national energy applications was made by analyzing and judging the alternative candidate photovoltaic systems and development tasks. A program plan was constructed based on achieving the 10 year objective of a program to establish the practicability of large-scale terrestrial power installations using photovoltaic conversion arrays costing less than $0.50/peak W. Guidelines for the tasks of a 5 year program were derived from a set of 5 year objectives deduced from the 10 year objective. This report indicates the need for an early emphasis on the development of the single-crystal Si photovoltaic system for commercial utilization; a production goal of 5 x 10 to the 8th power peak W/year of $0.50 cells was projected for the year 1985. The developments of other photovoltaic conversion systems were assigned to longer range development roles. The status of the technology developments and the applicability of solar arrays in particular power installations, ranging from houses to central power plants, was scheduled to be verified in a series of demonstration projects. The budget recommended for the first 5 year phase of the program is $268.5M.
In infrared astronomy observations, one of the key detector performance parameters is the dark current which, together with the optics, establishes the fundamental limit of a space-based instrument. This technical note summarizes an effort to measure dark current performance of the MLA/Short Wave Infrared photovoltaic HgCdTe array (2.5 micron cutoff) at temperatures from 65 to 120 K. The preliminary results indicate that dark current decreased systematically to 100 K, then the value became measurement-limited at about 3.0 E-18 A/pixel, or 19 electrons/sec/pixel.
The Naval Construction Battalion Center (NCBC) in Gulfport, Mississippi, and Mississippi Power Company (MPC) have integrated a 15-acre solar photovoltaic (PV) array, battery storage, and backup generation with an innovative microgrid. The Navy and utility teams are helping ensure mission readiness at NCBC while increasing renewable energy generation on the grid in MPC's service area. The NCBC/MPC resilience effort will allow the base to more effectively deploy disaster recovery activities in the event of a grid outage.
In the new climate of smaller, faster, and cheaper space science satellites, a new power system topology has been developed at the NASA Lewis Research Center. This new topology is based on a series connected boost converter (SCBC) and can greatly affect the size, weight, fault tolerance, and cost of any small spacecraft using photovoltaic solar arrays. The paper presents electric power system design factors and requirements as background information. The series connected boost converter topology is discussed and several advantages over existing technologies are illustrated. Besides being small, lightweight, and efficient, this topology has the added benefit of inherent fault tolerance. A positive ground power system test bed has been developed for the TROPIX spacecraft program. Performance of the SCBC in the test bed is described in detail. SCBC efficiencies of 95 percent to 98 percent have been measured. Finally, a modular, photovoltaic regulator 'kit' concept is presented. Two SCBC's are used to regulate solar array charging of batteries and to provide 'utilitytype' power to the user loads. The kit's modularity will allow a spacecraft electric power system to be built from off-the-shelf hardware; resulting in smaller, faster, and cheaper spacecraft.
In this paper a photovoltaic system is proposed that achieves high energy yield by integrating bifacial silicon cells into a spectrum-splitting module. Spectrum splitting is accomplished using volume holographic optical elements to spectrally divide sunlight onto an array of photovoltaic cells with different bandgap energies. Light that is reflected from the ground surface onto the rear side of the module is converted by the bifacial silicon cells. The energy yield of the system is optimized by tuning the volume holographic element parameters, such as film thickness, index modulation, and construction point source positions. An example is presented for utility-scale illumination parameters in Tucson, Arizona, that attains an energy yield of 1010 k w ⋅ <#comment/> h r y r ⋅ <#comment/> m 2 , which is 32.8% of the incident solar insolation.