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Resin casting of the aluminum master pattern forms a plastic mold for encapsulating a cable connector. An elastomer is injected into the mold and cured. The mold is disassembled leaving an elastomeric encapsulation around the connector.
Encapsulation technique minimizes embedment and thermal stresses in welded electronic modules. A coating of thinned room-temperature- vulcanizing silicone rubber having a high coefficient of expansion and flexibility at low temperature, is applied first and then an encapsulating epoxy resin having a relatively low coefficient of expansion is added.
FEP-encapsulated solar cell modules and arrays have been designed and built expressly for terrestrial applications. System design including solar cell array mechanical design and the approach to system sizing is outlined. Such solar cell systems have been installed at six sites. Individual modules have undergone marine environment tests. Results from seven months of operation indicate that system is meeting its electrical design requirements. No mechanical degradation has been reported. The array on Mammoth Mountain, California has been damaged by rime ice but shows no loss in electrical output. Marine environment tests on single modules have shown that elements of the module must be completely sealed by the FEP. Based on the limited test data available, the FEP-encapsulated solar cell module appears well suited to terrestrial applications.
FEP-encapsulated solar cell modules and arrays have been designed and built expressly for terrestrial applications. System design including solar cell array mechanical design and the approach to system sizing is outlined. Such solar cell systems have been installed at six sites. Individual modules have undergone marine environment tests. Results from seven months of operation indicate that the system is meeting its electrical design requirements. No mechanical degradation has been reported. An array on Mammoth Mountain, California has been damaged by rime ice but shows no loss in electrical output. Marine environment tests on single modules have shown that elements of the module must be completely sealed by the FEP. Based on the limited test data available, the FEP-encapsulated solar cell module appears well suited to terrestrial applications.
Electric breakdown prevention in vacuum and encapsulation of high voltage electronic circuits was studied. The lap shear method was used to measure adhesive strengths. The permeation constants of air at ambient room temperature through four different space-grade encapsulants was measured. Order of magnitude was calculated for the time that air bubble pressures drop to the corona region. High voltage connectors with L-type cable attached were tested in a vacuum system at various pressures. The cable system was shown to suppress catastrophic breakdown when filled with and surrounded by gas in the corona region of pressures, but did not prove to be completely noise free.
FEP (fluorinated ethylene propylene) encapsulated solar cell modules and arrays have been designed and built expressly for terrestrial applications. Solar cell power systems have been installed at three different land sites, while individual modules are undergoing marine-environment tests. Four additional power systems are being completed for installation during the summer of 1974. These tests have revealed some minor problems which have been corrected. The results confirm the inherent utility of FEP encapsulated terrestrial solar cell systems.
A progress report, starting with November 1973, is given in the design, development, and performance of lightweight flexible FET (Fluorinated Ethylene Propylene) encapsulated solar cell modules intended to form standardized building blocks for large roll-up or fold-up solar cell blankets with performances on the order of 100 W/sq m and 80 W/kg in near space. It is shown that interconnected FEP encapsulated modules of advanced design can withstand all typical ground handling, assembly, storage, and launch conditions, and are well suited for high-power space applications.
The potentially useful encapsulating materials for Task 3 of the Low-Cost Silicon Solar Array project were studied to identify, evaluate, and recommend encapsulant materials and processes for the production of cost-effective, long-life solar cell modules. Materials for study were chosen on the basis of existing knowledge of generic chemical types having high resistance to environmental weathering. The materials varied from rubbers to thermoplastics and presented a broad range of mechanical properties and processing requirements. Basic physical and optical properties were measured on the polymers and were redetermined after exposure to indoor artificial accelerated aging conditions covering four time periods. Strengths and weaknesses of the various materials were revealed and data was accumulated for the development of predictive methodologies. To date, silicone rubbers, fluorocarbons, and acrylic polymers appear to have the most promising combination of characteristics. The fluorocarbons may be used only as films, however, because of their high cost.
Inherent weatherability is controlled by the three weather factors common to all exposure sites: insolation, temperature, and humidity. Emphasis was focused on the transparent encapsulant portion of miniature solar cell arrays by eliminating weathering effects on the substrate and circuitry (which are also parts of the encapsulant system). The most extensive data were for yellowing, which were measured conveniently and precisely. Considerable data also were obtained on tensile strength. Changes in these two properties after outdoor exposure were predicted very well from accelerated exposure data.
Electrical connections to solar cells in a module are made at the same time the cells are encapsulated for protection. The encapsulating material is embossed to facilitate the positioning of the cells during assembly.
Concepts for integral glass sheet encapsulation of terrestrial solar cell modules using techniques based upon electrostatic bonding are being developed. It is possible for the glass to provide hermetic encapsulation, the structural support, and a vehicle for integral interconnection of the solar cells. Anticipated capabilities, present status, and cost projections for large scale terrestrial utilization are discussed.
The paper is concerned with glass and polymeric candidate materials and processes for potential encapsulation systems that could be used in low-cost long-life terrestrial photovoltaic arrays. The characteristics of encapsulation systems in use are reviewed, and the properties of proposed materials are examined. These materials include acrylics, epoxies, fluorocarbons, polycarbonates, polyesters, polyimides, polyxylylenes, and silicones. Properties of glass types are also considered. The prospects for glass and polymeric systems are analyzed, and the knowledge gained from a study of existing systems is discussed with attention to weather/aging effects, failures, environments, hazards, costs, development efforts, and materials choices.
The technical activities were directed toward the assessment of encapsulation processes for use with ethylene/vinyl acetate copolymer as the pottant. Potentially successful formulations were prepared by compounding the raw polymer with ultraviolet absorbers and crosslinking agents to give stabilized and curable compositions. The compounded resin was then converted to a more useful form with an extruder to give pottant in sheets that could be more easily used in lamination. After experimenting with various techniques, the vacuum-bag process was found to be an excellent encapsulation method. Miniature single-celled and multi-celled solar modules of both substrate and superstrate designs were prepared by this technique. The resulting modules were of good appearance, were bubble-free, and successfully passed the thermal cycle test.
As a part of the Low Cost Solar Array Project an encapsulation task has been established to identify, develop, and evaluate new low-cost, long-life encapsulation systems capable of meeting the project cost and performance goals. Low-cost material system candidates have been identified and are being characterized in laboratory and field tests with detailed evaluation of their environmental stability when subjected to temperature cycling, humidity, ultraviolet radiation, dirt, and various other environmental hazards.
The use of silicone materials as thin conformal coatings for the protection of photovoltaic cells is investigated. Five silicone materials ranging from soft elastomers to high modulus resins were evaluated after exposure to UV radiation, outdoor weathering, thermal cycling at high humidity and temperature cycling from -40 C to 90 C. The effects of these tests were monitored by periodically measuring the output of two-cell circuit strings encapsulated with the various materials, and one exceptional silicone coating for which no significant changes in cell output were noted after 300 days was chosen as the best of the candidates. Because only a thin coating of the substance is needed, material costs 60% lower than those of previous encapsulants are now possible.
Test data were collected on 1035 plastic encapsulated devices and 75 hermetically scaled control group devices that were purchased from each of five different manufacturers in the categories of (1) low power Schottsky TTL (bipolar) digital circuits; (2) CMOS digital circuits; (3) operational amplifier linear circuits; and (4) NPN transistors. These parts were subjected to three different initial screening conditions, then to extended life testing, to determine any possible advantages or trends for any particular screen. Several tests were carried out in the areas of flammability testing, humidity testing, high pressure steam (auroclave) testing, and high temperature storage testing. Test results are presented. Procurement and application considerations for use of plastic encapsulated semiconductors are presented and a statistical analysis program written to study the log normal distributions resulting from life testing is concluded.
Encapsulant materials and processes for the production of cost-effective, long-life solar cell modules were investigated. The following areas were explored: (1) soil resistant surface treatment; (2) corrosion protecting coatings from mild steel substrates; (3) primers for bonding module interfaces; and (4) RS/4 accelerated aging of candidate encapsulation compounds
A photothermal test matrix and a low cost testing apparatus for encapsulant materials of photovoltaic modules were defined. Photothermal studies were conducted to screen and rank existing as well as future encapsulant candidate materials and/or material formulations in terms of their long term physiochemical stability under accelerated photothermal aging conditions. Photothermal characterization of six candidate pottant materials and six candidate outer cover materials were carried out. Principal products of photothermal degradation are identified. Certain critical properties are also monitored as a function of photothermal aging.