SBIR-STTR Award

We propose to develop a novel, low-cost, amorphous silicon (a-Si:H) based modular to be integrated with a spacecraft thermal blanket for an auxiliary spacecraft power system. This new design is unique from ECD's present multi-junction module design in that an ultralight kapton substrate material and a monolithic cell interconnect design will be used which will allow for potential energy densities as high as 1000 W/kg. Small area (0.25 cm2) cells with this ultralight design have been fabricated with beginning-of-life AM0 efficiencies greater than 12%. Extensive tests have also demonstrated that the cell quality is resilient to electron and proton bombardment. In Phase I, we plan to scale-up the deposition process for 0.5 ft. x 0.5 ft. area cell fabrication. Deposition conditions will be optimized to achieve high cell performance and uniformity over large areas. Achievement of a highly reproducible process that produces 0.5 ft. x 0.5 ft. modules on kapton substrates with efficiencies greater than 8% will be achieved during the Phase I program. The process and module efficiencies will further be refined in Phase II of the program with the eventual goal of the implementation of the new module design and fabrication process into ECD's role-to role manufacturing line

Laser Integrated PWe propose to develop a novel, low-cost, amorphous silicon (a-Si:H) based solar module to be integrated with a spacecraft thermal blanket for an auxiliary spacecraft power system. This new design is unique from ECD's present multi-junction module structure in that an ultra-light kapton substrate material and a monolithic cell interconnect design will be used which will allow for potential energy desities as high as 2500 W/kg. In Phase I of the program, many of the laser scribing steps were developed culminating in the fabrication of a 0.33 ft(squared) module with an AMI.5 efficiency of 7.8% In Phase II, we plan on further development of this new module fabrication process in order to increase the module performance. In particular, the passivation, laser scribing thin film fabrication processes will be further optimized to achieve module AM0 efficiencies at or above10% with good yield. Also to prove long-term reliability, extensive thermal cycling tests will be completed to judge the module resiliency to large temperature variations. With achievement of the 10% efficiency and minimal degradation due to thermal variations. With achievement of the 10% efficiency and minimal degradation due to thermal cycling, ECD's solar panel manufacturing process will be modified in order to incorporate this new module fabrication process into a full-scale production plant.

Keywords:
AMORPHOUS SILICONKAPTON ULTRALIGHT SOLAR CELLS SOLAR CELLS MONOLITHIC SOLAR CELLS