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Report describes evolution of photovoltaic power systems designed and built for terrestrial use. Discussion focuses on technological problems impeding further systems development. Experiments and test data on seven types of solar panels and six material test specimens are described in detail.

Various candidate solar panel designs were evaluated, both theoretically and experimentally, with respect to their thermal cycling survival capability, and in particular with respect to an accelerated simulation of thermal cycles representative of Viking '75 mission requirements. The experimental results were obtained on 'mini-panels' thermally cycled in a newly installed automated test facility herein described. The resulting damage was analyzed physically and theoretically, and on the basis of these analyses the panel design was suitably modified to significantly improve its ability to withstand the thermal environment. These successful modifications demonstrate the value of the complementary theoretical-experimental approach adopted, and discussed in detail in this paper.

High altitude balloon flights carried 37 standard solar cells for calibration above 99.5 percent of the earth's atmosphere. The cells were assembled into standard modules with appropriate resistors to load each cell at short circuit current. Each standardized module was mounted at the apex of the balloon on a sun tracker which automatically maintained normal incidence to the sun within 1.0 deg. The balloons were launched to reach a float altitude of approximately 36.6 km two hours before solar noon and remain at float altitude for two hours beyond solar noon. Telemetered calibration data on each standard solar cell was collected and recorded on magnetic tape. At the end of each float period the solar cell payload was separated from the balloon by radio command and descended via parachute to a ground recovery crew. Standard solar cells calibrated and recovered in this manner are used as primary intensity reference standards in solar simulators and in terrestrial sunlight for evaluating the performance of other solar cells and solar arrays with similar spectral response characteristics.

Announced report discusses experimental test program in which five different solar cell array designs were evaluated by subjecting them to 60 thermal cycles from minus 190 deg to 0.0 deg. Results indicate that solder-coated cells combined with Kovar n-interconnectors and p-interconnectors are more durable under thermal loading than other configurations.

An investigation was conducted to determine the technology readiness of lithium-doped silicon solar cells with respect to use in space programs. A pilot line fabrication program was established, in which the pilot line cells were evaluated after being exposed to environments ordinarily imposed on nonlithium-doped silicon solar cells. Results indicate that further process improvements are required, particularly with respect to the P/N junction diffusion and the electrical contacting technique (including solder coating). It is concluded that lithium-doped cells can be fabricated to exhibit (1) high efficiencies, (2) uniform cell-to-cell recovery characteristics after exposure to 1-MeV electrons; and (3) good stability in most environments investigated (the only exception being the thermal shock environment).

Primary components of facility are test chamber and external solar simulator. Voltage--current performance characteristics of solar cells at various combinations of temperature and light intensity are plotted on X-Y recorder. Data are fed into computer for calculation of maximum power, curve shape factor, cell efficiency, and averages of each parameter.

A description is given of the evolution of photovoltaic power systems designed and built for terrestrial applications, giving attention to problem areas which are currently impeding the further development of such systems. The rooftop testing of surplus solar panels is considered along with solar powered seismic observatories, solar powered portable radio sets, and design considerations identified from past experience. Present activities discussed are related to a solar powered on-shore beacon flasher system, a solar powered buoy, and a solar powered beacon flasher buoy.

Description of a thermoelastic stress analysis procedure for predicting the thermally induced stresses and failures in silicon solar cell arrays. A prerequisite for the analysis is the characterization of the temperature-dependent thermal and mechanical properties of the solar cell materials. Extensive material property testing was carried out in the temperature range from -200 to +200 C for the filter glass, P- and N-type silicon, interconnector metals, solder, and several candidate silicone rubber adhesives. The analysis procedure is applied to several solar cell array design configurations, which were tested in the Space Molecular Sink. Results of the analysis indicate the optimum design configuration with respect to materials and geometry, effect of the solder coating, and effect of the interconnector geometry.

Results of an ongoing program set up to evaluate solar terrestrial photovoltaic power sources. The results of this program, which now includes a solar array encapsulant and materials test and a solar-powered buoy study, are updated, and the results of efforts to study the dynamic interaction of a solar photovoltaic array and a water electrolysis system coupled to produce hydrogen are reported for the first time.

A flexible solar array strip is formed by a method which lends itself to automatic production techniques. Solder pads are deposited on printed circuitry deposited on a flexible structure. The resultant substrate is stored on a drum from which it is withdrawn and incrementally advanced along a linear path. Solderless solar cells are serially transported into engagement with the pads which are then heated in order to attach the cells to the circuitry. Excess flux is cleaned from the cells which are encapsulated in a protective coating. The resultant array is then spirally wound on a drum.

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 flexible solar array strip is formed by providing printed circuitry between flexible layers of a nonconductive material, depositing solder pads on the printed circuitry, and storing the resulting substrate on a drum from which it is then withdrawn and advanced along a linear path. Solderless solar cells are serially transported into engagement with the pads and are infrared radiation to melt the solder and attach the cells to the circuitry. Excess flux is cleaned from the solar cells which are then encapsulated in a protective coating. The resulting array is then wound on a drum.

Continuous-feeding machine automatically bonds solar cells to printed-circuit substrate. In completed machine, cells move to test station where electrical characteristics could be checked. If performance of cell is below specifications, that cell is marked and removed. All machine functions are synchronized by electronics located within unit. It may help to lower costs in future solar-cell production.

A description is presented of the equipment used in the experiment, taking into account the surplus solar panel from the Mariner 4 spacecraft which was used as a solar array source and an electrolytic hydrogen generator. Attention is also given to operational considerations and performance data, system considerations and aspects of optimization, and large-scale hydrogen production considerations.

A grid pattern is described for a solar cell of the type which includes a semiconductive layer doped to a first polarity and a top counter-doped layer. The grid pattern comprises a plurality of concentric conductive grids of selected geometric shapes which are centered about the center of the exposed active surface of the counter-doped layer. Connected to the grids is one or more conductors which extend to the cell's periphery. For the pattern area, the grids and conductors are arranged in the pattern to minimize the maximum distance which any injected majority carriers have to travel to reach any of the grids or conductors. The pattern has a multiaxes symmetry with respect to the cell center to minimize the maximum temperature differentials between points on the cell surface and to provide a more uniform temperature distribution across the cell face.

A series of summary curves is presented for cells having various contact systems, depicting the effects of temperature exposure as a function of time on the electrical and mechanical characteristics. Each curve represents the results obtained from a minimum of 32 and a maximum of 1104 individual data inputs and includes the 95% confidence limits associated with each time-temperature combination for which measurements were obtained. The curves are useful for detailed analysis and comparison of the behavior of the contact system as a function of the environmental conditions studied.

Effect of high humidity and temperature on electrical and mechanical properties of stored silicon solar cell contacts

Engineering mechanics in structural design of silicon solar arrays

Thermal and electrical performances of silicon solar cell designs at high solar intensities

Electrical and mechanical characteristics of solar cell contacts after exposure to high-temperature high-humidity environments

Electrically coupled individually encapsulated solar cell matrix

Design, assembly, tests, and postflight analysis of Mariner Venus 67 solar panel

Fabrication methods for matrices of solar cell submodules

Silicon solar cell lightweight integrated array for large arrays, discussing deployment and orientation mechanisms, ribbon coverglass technique and cost estimates

Electroformed Al contact solar cells without soldering, investigating process parameters effects on performance

Ti-Ag contact N-P and P-N single crystal Si solar cells electrical and mechanical performance characteristics

Conductor for connecting parallel cells into submodules in series to form solar cell matrix

Surveyor 5 solar array panel performance during transit and on moon

Conducting strips mechanically and electrically connect individual solar cells into a linear array of cells, called a solar submodule, and then connect in series two or more submodules to form a solar cell matrix. Tiny perforations in the strip make it easy to solder them directly to the individual solar cells.

Solar cell submodule fabrication and design for Mariner and Surveyor spacecraft, describing automatic conveyor soldering oven

Solar cell submodules with bus bars that leave tabs along one end of the submodule and wires with raised portions along the other end are assembled by interlocking the tabs and wires of adjacent submodules. This structural design is lightweight and reliable and requires no metallic substructure.

A thermoelastic stress analysis procedure is reported for predicting the thermally induced stresses and failures in silicon solar cell arrays. A prerequisite for the analysis is the characterization of the temperature-dependent thermal and mechanical properties of the solar cell materials. Extensive material property testing was carried out in the temperature range -200 to +200 C for the filter glass, P- and N-type silicon, interconnector metals, solder, and several candidate silicone rubber adhesives. The analysis procedure is applied to several solar cell array design configurations. Results of the analysis indicate the optimum design configuration, with respect to compatible materials, effect of the solder coating, and effect of the interconnector geometry. Good agreement was found between results of the analysis and the test program.

The electrical performance characteristics of 2 and 10 ohms-cm N/P-type silicon solar cells were measured at simulated solar intensities of 5, 50, 100, 140, 250, 400, 550, 700, and 850 mW/sq cm. At each intensity, the temperature was varied in increments of 20 deg between extremes of +160 and -160 C. Short-circuit current, open-circuit voltage, and maximum power are presented in graphical format. Also described are three methods for predicting solar cell electrical performance as a function of temperature and intensity. Two of the methods are suitable for use at extreme temperature-intensity conditions. These methods were used sucessfully to predict the performance of the transducer on board the Mariner Mars 1971 spacecraft.

Solar cell assembly current-voltage characteristics, thermal-optical properties, and power performance were determined. Solar cell cover glass thermal radiation, optical properties, confidence limits, and temperature intensity effects on maximum power were discussed.

Four types of solar cell contacts were given pull-strength tests at temperatures between -173 and +165 C. Contacts tested were: (1) solder-coated titanium-silver contacts on n-p cells, (2) palladium-containing titanium-silver contacts on n-p cells, (3) titanium-silver contacts on 0.2-mm-thick n-p cells, and (4) solder-coated electroless-nickel-plated contacts on p-n cells. Maximum pull strength was demonstrated at temperatures significantly below the air mass zero cell equilibrium temperature of +60 C. At the lowest temperatures, the chief failure mechanism was silicon fracture along crystallographic planes; at the highest temperatures, it was loss of solder strength. In the intermediate temperatures, many failure mechanisms operated. Pull-strength tests give a good indication of the suitability of solar cell contact systems for space use. Procedures used to maximize the validity of the results are described.