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NASA NTRS1985

Solar activity and modulation of the cosmic ray intensity

Since its discovery by Forbush (1954), the 11-year cycle modulation of the cosmic ray intensity has been studied extensively. Bowe and Hatton (1982) obtained a well-behaved transfer function F between the solar activity S and the cosmic ray intensity modulation Io-I. They suggested that the 11-year variation for sunspot cycle 20 can be attributed to the modulating effect of solar flare-induced shocks propagating through the heliosphere. The cosmic ray intensity in the absence of solar activity is denoted by Io, while I denotes the observed intensity. Bowe and Hatton infer that the boundary of the heliosphere is located at a distance of 70-90 AU. Since their conclusion is of great importance in understanding the mechanism of the 11-year modulation, the present investigation is concerned with a repetition of their study for two cycles, taking into account the use of a slightly modified method. The obtained results confirm the conclusions reached by Bowe and Hatton that there is a well-behaved transfer function for solar flares.

Akasofu, S.-I.↗

NASA NTRS1984

Four-dimensional modulation and coding - An alternate to frequency-reuse

Four dimensional modulation as a means of improving communication efficiency on the band-limited Gaussian channel, with the four dimensions of signal space constituted by phase orthogonal carriers (cos omega sub c t and sin omega sub c t) simultaneously on space orthogonal electromagnetic waves are discussed. 'Frequency reuse' techniques use such polarization orthogonality to reuse the same frequency slot, but the modulation is not treated as four dimensional, rather a product of two-D modulations, e.g., QPSK. It is well known that, higher dimensionality signalling affords possible improvements in the power bandwidth sense. Four-D modulations based upon subsets of lattice-packings in four-D, which afford simplification of encoding and decoding are described. Sets of up to 1024 signals are constructed in four-D, providing a (Nyquist) spectral efficiency of up to 10 bps/Hz. Energy gains over the reuse technique are in the one to three dB range t equal bandwidth.

Wilson, S. G.↗

NASA NTRS1985

Crystalline-silicon reliability lessons for thin-film modules

The reliability of crystalline silicon modules has been brought to a high level with lifetimes approaching 20 years, and excellent industry credibility and user satisfaction. The transition from crystalline modules to thin film modules is comparable to the transition from discrete transistors to integrated circuits. New cell materials and monolithic structures will require new device processing techniques, but the package function and design will evolve to a lesser extent. Although there will be new encapsulants optimized to take advantage of the mechanical flexibility and low temperature processing features of thin films, the reliability and life degradation stresses and mechanisms will remain mostly unchanged. Key reliability technologies in common between crystalline and thin film modules include hot spot heating, galvanic and electrochemical corrosion, hail impact stresses, glass breakage, mechanical fatigue, photothermal degradation of encapsulants, operating temperature, moisture sorption, circuit design strategies, product safety issues, and the process required to achieve a reliable product from a laboratory prototype.

Ross, R. G., Jr.↗

NASA NTRS1985

Thin-film module circuit design: Practical and reliability aspects

This paper will address several aspects of the design and construction of submodules based on thin film amorphous silicon (a-Si) p i n solar cells. Starting from presently attainable single cell characteristics, and a realistic set of specifications, practical module designs are discussed from the viewpoints of efficient designs, the fabrication requirements, and reliability concerns. The examples center mostly on series interconnected modules of the superstrate type with detailed discussions of each portion of the structure in relation to its influence on module efficiency. Emphasis is placed on engineering topics such as: area coverage, optimal geometries, and cost and reliability. Practical constraints on achieving optimal designs, along with some examples of potential pitfalls in the manufacture and subsequent performance of a-Si modules are discussed.

Daiello, R. V.↗

NASA NTRS1985

Electrical safety requirements: Implications for the module designer

Commercial photovoltaic array installations, which include residential and intermediate applications, are subject to building and electrical codes and to product safety standards. The National Electrical Code (NEC) Article 690, titled Solar Photovoltaic Systems, contains provisions defining acceptable levels of system safety and emphasizes the system design and its installation. The Underwriters Laboratories, Inc. (UL), document titled: Proposed First Edition of the Standard for Flat Plate Photovoltaic Modules and Panels, UL-1703, identifies module and panel construction requirements that ensure product safety. Together these documents describe requirements intended to minimize hazards such as shock and fire. Although initial focus of these requirements is on single crystal silicon modules, they are generic in nature, and are equally applicable to high voltage ( 30 Vdc), multikilowatt, thin film systems. A major safety concern is insulation breakdown within the module or array wiring system, or discontinuities within the electrical conductors. These failures can result in ground faults, in circuit arcs, or exposure to hazardous electrical parts. Safeguards are discussed.

Sugimura, R. S.↗

NASA NTRS1985

Amorphous silicon photovoltaic modules and test devices design, fabrication and testing

In July of 1984, Hughes and JPL initiated a contract for Hughes to design, fabricate and test 10 thin film Amorphous Silicon (a-Si) photovoltaic power modules. These modules were to be 1 ft x 4 ft in size. They were to be preceded by the delivery of 10 a-Si 4 in. square test devices. This effort is very timely since thin film PV development has progressed to the point where intermediate load power applications are on the horizon. It is important to know if current a-Si submodule design and manufacturing processes yield a product that is compatible with the packaging needed to meet a 20 to 30 year life span expectancy. The term submodule is assigned to an interconnected assembly of 28 a-Si cells deposited on a 1 foot square glass superstrate. These assemblies are equipped with electrical terminations, i.e., copper tabs at the four corners of the inverted submodules. It is these submodules that are to be interconnected and packaged into power modules, as opposed to the interconnected individual crystalline cells packaged into todays PV modules. A discussion of the fabrication methods and results follows.

Vanleeuwen, M.↗

NASA NTRS1985

Thin film module electrical configuration versus electrical performance

The as made and degraded states of thin film silicon (TFS) based modules have been modelled in terms of series resistance losses. The origins of these losses lie in interface and bulk regions of the devices. When modules degrade under light exposure, increases occur in both the interface and bulk components of the loss based on series resistance. Actual module performance can thus be simulated by use of only one unknown parameter, shunt losses. Use of the simulation to optimize module design indicates that the current design of 25 cells per linear foot is near optimum. Degradation performance suggests a shift to approx. 35 cells to effect maximum output for applications not constrained to 12 volts. Earlier studies of energy based performance and tandem structures should be updated to include stability factors, not only the initial loss factor tested here, but also appropriate annealing factors.

Morel, D. L.↗

NASA NTRS1985

Linearity optimization in a class of analog phase modulators

This paper examines the ultimate modulating linearity attainable with a phase modulation technique based on the linear addition of quadrature phase carrier signals which have been multiplied by precisely defined nonlinear transformations of the modulating signal. Optimum gain coefficients are derived and plotted to permit implementation of analog phase modulators capable of exceptionally good linearity of phase deviations as large as 5 radians.

Hearn, C. P.↗

NASA NTRS1985

High-performance deployable structures for the support of high-concentration ratio solar array modules

A study conducted on high-performance deployable structures for the support of high-concentration ratio solar array modules is discussed. Serious consideration is being given to the use of high-concentration ratio solar array modules or applications such as space stations. These concentrator solar array designs offer the potential of reduced cost, reduced electrical complexity, higher power per unit area, and improved survivability. Arrays of concentrators, such as the miniaturized Cassegrainian concentrator modules, present a serious challenge to the structural design because their mass per unit area (5.7 kg/square meters) is higher than that of flexible solar array blankets, and the requirement for accurate orientation towards the Sun (plus or minus 0.5 degree) requires structures with improved accuracy potentials. In addition, use on a space station requires relatively high structural natural frequencies to avoid deleterious interactions with control systems and other large structural components. The objective here is to identify and evaluate conceptual designs of structures suitable for deploying and accurately supporting high-concentration ratio solar array modules.

Mobrem, M.↗

NASA NTRS1985

Module flammability research

New materials were developed which show promise of fabricating modules that can pass the Underwriter Laboratories Class A burning brand test for fire ratable solar cell modules. It is concluded that fire resistant module design require special high temperature materials and constructions to achieve Class B and Class A ratings. Also, synergisms exist between back surface materials and module configuration.

Sugimura, R. S.↗

NASA NTRS1985

Dendritic web-type solar cell mini-modules

Twenty-five minimodules composed of dendritic web solar cells with nominal glass size of 12 by 40 cm were provided for study. The modules were identical with respect to design, materials, and manufacturing and assembly processes to full scale modules. The modules were also electrically functional. These minimodules were fabricated to provide test vehicle for environmental testing and to assess reliability of process and design procedures. The module design and performance are outlined.

Campbell, R. B.↗

NASA NTRS1985

Development and testing of advanced fire-resistant photovoltaic modules

The evaluation of back-surface materials flammability in order to identify fire resistant module designs is examined. The fire test apparatus, burning-brand test sequence, and spread-of-flame test sequence are described. Video recordings and time-temperature profiles of module back surfaces are utilized to study the flammability failure mechanism and identify high-temperature materials. A table of flammability test results for various module designs is provided. The data reveals that 2-mil kapton, fiberglass cloth coated or impregnated with a material to plug pores, and metal foil back-surface materials achieve class A and B fire-resistance levels, and are applicable for photovoltaic module designs.

Sugimura, R. S.↗

NASA NTRS1985

Solar powered hybrid sensor module program

Geo-orbital systems of the near future will require more sophisticated electronic and electromechanical monitoring and control systems than current satellite systems with an emphasis in the design on the electronic density and autonomy of the subsystem components. Results of a project to develop, design, and implement a proof-of-concept sensor system for space applications, with hybrids forming the active subsystem components are described. The design of the solar power hybrid sensor modules is discussed. Module construction and function are described. These modules combined low power CMOS electronics, GaAs solar cells, a crystal oscillatory standard UART data formatting, and a bidirectional optical data link into a single 1.25 x 1.25 x 0.25 inch hybrid package which has no need for electrical input or output. Several modules were built and tested. Applications of such a system for future space missions are also discussed.

Johnson, J. M.↗

NASA NTRS1986

Development of low-temperature transistor modules to improve the MSFC mid-infrared array

This report describes the low-temperature transistor modules designed for use with the MSFC mid-infrared array. The modules were developed in the Space Science Laboratory at Marshall Space Flight Center with Center Director's Discretionary Funds. The transistors (JFETs), which operate at a temperature of 77 K, are epoxied to a copper surface attached to a Teflon substrate. The module substrate insulates the JFETs from the 1.5K detector work surfaces and provides a convenient mounting structure for additional components such as solder pins. These modules have maintained their structural integrity during repeated temperature cycling, and they have to be convenient during maintenance and servicing of the infrared array.

Telesco, C. M.↗

NASA NTRS1985

Bubble memory module for spacecraft application

Bubble domain technology offers an all-solid-state alternative for data storage in onboard data systems. A versatile modular bubble memory concept was developed. The key module is the bubble memory module which contains all of the storage devices and circuitry for accessing these devices. This report documents the bubble memory module design and preliminary hardware designs aimed at memory module functional demonstration with available commercial bubble devices. The system architecture provides simultaneous operation of bubble devices to attain high data rates. Banks of bubble devices are accessed by a given bubble controller to minimize controller parts. A power strobing technique is discussed which could minimize the average system power dissipation. A fast initialization method using EEPROM (electrically erasable, programmable read-only memory) devices promotes fast access. Noise and crosstalk problems and implementations to minimize these are discussed. Flight memory systems which incorporate the concepts and techniques of this work could now be developed for applications.

Hayes, P. J.↗

NASA NTRS1985

Electrochemical degradation of amorphous-silicon photovoltaic modules

Techniques of module electrochemical corrosion research, developed during reliability studies of crystalline-silicon modules (C-Si), have been applied to this new investigation into amorphous-silicon (a-Si) module reliability. Amorphous-Si cells, encapsulated in the polymers polyvinyl butyral (PVB) and ethylene vinyl acetate (EVA), were exposed for more than 1200 hours in a controlled 85 C/85 percent RH environment, with a constant 500 volts applied between the cells and an aluminum frame. Plotting power output reduction versus charge transferred reveals that about 50 percent a-Si cell failures can be expected with the passage of 0.1 to 1.0 Coulomb/cm of cell-frame edge length; this threshold is somewhat less than that determined for C-Si modules.

Mon, G. R.↗

NASA NTRS1985

Candidate materials for advanced fire-resistant photovoltaic modules

A cooperative, cost-sharing research effort to develop a technology base required to construct fire-ratable photovoltaic modules has resulted in the identification of several high-temperature, back-surface candidate materials capable of raising the fire-resistance of modules using hydrocarbon encapsulants to Class A and B levels. Advanced experimental module configurations have been developed using back surfaces consisting of Kapton, Tedlar laminates, metal-foils, and fiberglass materials with high-temperature coatings. Test results (October 1984; March 1985; May 1985; and October 1985) indicate that several of these advanced module configurations are capable of achieving Class B fire-resistance levels, while a few configurations can achieve Class A levels. The paper summarizes activities to date, discussing flammability failure mechanisms, time-temperature profiles, and results of Block V environmental exposure tests of a candidate material suitable for both Class B and Class A fire-resistance levels.

Sugimura, R. S.↗

NASA NTRS1985

Large-area high-efficiency ion-implanted cells and flat-plate modules

This paper reports the development of a flat-plate module based on highly efficient ion-implanted silicon solar cells. The cells are 53 sq cm in area and have exhibited AM 1.5 efficiencies of over 18 percent. The use of back surface reflectors to reduce module operating temperature is discussed. A comparison of various approaches to cell design is made, and module test data for these designs are presented. Module efficiency of 14 percent (25 C) is reported.

Spitzer, M. B.↗