Development and testing of shingle-type solar cell molecules

The details of a shingle module design which produces in excess of 97 watts/sq m of module area at 1 kW/sq m insolation and at 60 C are reported. This selected design employs a tempered glass coverplate to provide the primary solar cell structural support. The fabrication and testing of a preproduction module of this design has demonstrated that this selected approach will meet the environmental testing requirements imposed by the contract

Solar cell module

An improved solar cell module for use in terrestrial environments is disclosed. It is characterized by: (1) an internally reflective plate having a planar surface of incidence and an opposed textured surface (2) a plurality of uniformly spaced silicon solar cells having the active surfaces thereof bonded to portions of the textured surface, and (3) a layer of diffusely reflective matter applied to the textured surface in surrounding relation with the solar cells for reflecting solar energy. The solar energy then strikes the surface of incidence at such angles as to be internally re-reflected and caused to progress toward the active surfaces of the solar cells, whereby concentration of incident flux on the solar cell is achieved without increased module depth

The 110 watt per kilogram lightweight solar array system

This ultralightweight solar array system is applied to three generic mission types: (1) interplanetary, (2) geosynchronous, and (3) manned space station. The requirements of each of these missions, as they pertain to the solar array, are presented. Existing lightweight solar array system concepts are reviewed, along with conclusions regarding the applicability of this technology to the feasibility of the ultralightweight solar array system. Several system concepts are included for further evaluation. The existing technology base, as it pertains to solar cells, solar cell covers, interconnects and substrates, and deployable booms, is reviewed. The attitude control of spacecraft with large flexible solar arrays is also discussed

Definition study for photovoltaic residential prototype system

A site evaluation was performed to assess the relative merits of different regions of the country in terms of the suitability for experimental photovoltaic powered residences. Eight sites were selected based on evaluation criteria which included population, photovoltaic systems performance and the cost of electrical energy. A parametric sensitivity analysis was performed for four selected site locations. Analytical models were developed for four different power system implementation approaches. Using the model which represents a direct (or float) charge system implementation the performance sensitivity to the following parameter variations is reported: (1) solar roof slope angle; (2) ratio of the number of series cells in the solar array to the number of series cells in the lead-acid battery; and (3) battery size. For a Cleveland site location, a system with no on site energy storage and with a maximum power tracking inverter which feeds back excess power to the utility was shown to have 19 percent greater net system output than the second place system. The experiment test plan is described. The load control and data acquisition system and the data display panel for the residence are discussed

Design, fabrication, test, and qualification and price analysis of third generation design solar cell modules

The Block 4 shingle type module makes it possible to apply a photovoltaic array to the sloping roof of a residential building by simply nailing the overlapping hexagon shaped shingles to the plywood roof sheathing. This third-generation shingle module design consists of nineteen series connected 100 mm diameter solar cells which are arranged in a closely packed hexagon configuration to provide in excess of 75 watts/sq m of exposed module area under standard operating conditions. The solar cells are individually bonded to the embossed underside of a 4.4 mm thick thermally tempered piece of glass. An experimental silicone pottant was used as the transparent bonding adhesive between the cells and glass. The semi-flexible portion of each shingle module is a composite laminate construction consisting of an outer layer of FLEXSEAL bonded to an inner core of closed cell polyethylene foam. Silaprene is used as the substrate laminating adhesive. The module design has satisfactorily survived qualification testing program which includes 50 thermal cycles between -40 and +90 C, a seven day temperature-humidity exposure test, and a wind resistance test

Integrated residential photovoltaic array development

An advanced, universally-mountable, integrated residential photovoltaic array concept was defined based upon an in-depth formulation and evaluation of three candidate approaches which were synthesized from existing or proposed residential array concepts. The impact of module circuitry and process sequence is considered and technology gaps and performance drivers associated with residential photovoltaic array concepts are identified. The actual learning experience gained from the comparison of the problem areas of the hexagonal shingle design with the rectangular module design led to what is considered an advanced array concept. Building the laboratory mockup provided actual experience and the opportunity to uncover additional technology gaps

Development and Testing of Shingle-type Solar Cell Modules

The design, development, fabrication and testing of a shingle-type terrestrial solar cell module which produces 98 watts/sq m of exposed module area at 1 kW/sq m insolation and 61 C are reported. These modules make it possible to easily incorporate photovoltaic power generation into the sloping roofs of residential or commercial buildings by simply nailing the modules to the plywood roof sheathing. This design consists of nineteen series-connected 53 mm diameter solar cells arranged in a closely packed hexagon configuration. These cells are individually bonded to the embossed surface of a 3 mm thick thermally tempered hexagon-shaped piece of glass. Polyvinyl butyral is used as the laminating adhesive

Bypass diode integration

Protective bypass diodes and mounting configurations which are applicable for use with photovoltaic modules having power dissipation requirements in the 5 to 50 watt range were investigated. Using PN silicon and Schottky diode characterization data on packaged diodes and diode chips, typical diodes were selected as representative for each range of current carrying capacity, an appropriate heat dissipating mounting concept along with its environmental enclosure was defined, and a thermal analysis relating junction temperature as a function of power dissipation was performed. In addition, the heat dissipating mounting device dimensions were varied to determine the effect on junction temperature. The results of the analysis are presented as a set of curves indicating junction temperature as a function of power dissipation for each diode package

Feasibility study of a 110 watt per kilogram lightweight solar array system

An investigation of the feasibility of a solar array panel subsystem which will produce 10,000 watts of electrical output at 1 A.U. with an overall beginning-of-life power-to-weight ratio of at least 110 watt/kg is reported. A description of the current baseline configuration which meets these requirements is presented. A parametric analysis of the single boom, two blanket planar solar array system was performed to arrive at the optimum system aspect ratio. A novel concept for the stiffening of a lightweight solar array by canting the solar cell blankets at a small angle to take advantage of the inherent in-plane stiffness to increase the symmetric out-of-plane frequency is introduced along with a preliminary analysis of the stiffening effect. A comparison of welded and soldered solar cell interconnections leads to the conclusion that welding is required on this ultralightweight solar array. The use of a boron/aluminum composite material in a BI-STEM type deployable boom is investigated as a possible advancement in the state-of-the-art

Feasibility study of a 30 watts per pound roll up solar array Quarterly technical report, 1 Jan. - 31 Mar. 1968

Feasibility of 30 watts per pound roll-up solar array - design of engineering demonstration model with deployability of selected flight configuration and thermal cycling tests of arra