Glass encapsulation of solar cell arrays to minimize voltage/plasma interaction effects in a space environment

• US 4,832,755 A
• Filed: 08/11/1987
• Issued: 05/23/1989
• Est. Priority Date: 08/11/1987
• Status: Expired due to Term

• Current Assignee: The Boeing Co.
• Original Assignee: The Boeing Co.
• Inventors: Silverman, Sidney W., Reiss, Amy C., Barton, John R.
• Primary Examiner(s): Weisstuch, Aaron
• Application Number:
  US07/084,048
• Time in Patent Office: 651 Days
• Field of Search: 136/251, 136/259, 136/245, 136/292
• US Class Current: 136/251
• CPC Class Codes: B64G 1/443 Photovoltaic cell arrays
• CPC Class Codes: B64G 1/54 Protection against radiation
• CPC Class Codes: H01L 31/02008 for solar cells or solar cell modules
• CPC Class Codes: H01L 31/048 Encapsulation of modules
• CPC Class Codes: H01L 31/0508 the interconnection means having a particular shape
• CPC Class Codes: Y02E 10/50 Photovoltaic [PV] energy
• CPC Class Codes: Y10S 136/292 Space - satellite

Abstract

The solar cells of a photovoltaic solar cell array are protected from the effects of voltage/plasma interaction in a space environment. The solar array includes a glass enclosure having a substrate and superstrate with integral cell support ridges. The solar cells are held in place, without bonding, by the integral cell support ridges. The solar array is capable of withstanding severe temperature cycling, as the solar cells can freely expand and contract independent of the substrate or superstrate. In addition, a conductive grid is provided on the outer surface of the solar array to provide a zero-potential ground plane to reduce the electric field. The conductive grid provides additional protection against voltage/plasma interaction should the glass enclosure develop holes or cracks, for example, by the penetration of a micrometeor.

Claims

1. A solar cell device comprising:

(a) solar cell means for converting solar energy to electrical energy;

(b) a substrate having cell supports extending from the inner surface thereof to contact and position said solar cell means without bonding; and

(c) a superstrate having cell support ridges extending from the inner surface to contact and position said solar cell means without bonding said solar cell means to said cell supports of said substrate or said support ridges of said superstrate.

2. A solar cell device as claimed in claim 1 wherein said substrate and said superstrate comprise glass.

3. A solar cell device as claimed in claim 2 wherein said glass is a borosilicate glass.

4. A solar cell device as claimed in claim 1 wherein said substrate and said superstrate are adhesively bonded.

5. A solar cell device as claimed in claim 2 wherein said substrate and said superstrate are electrostatically bonded.

6. A solar cell device as claimed in claim 1 further comprising a conductive grid network formed on the outer surfaces of said solar cell device.

7. A solar cell device as claimed in claim 2 wherein said substrate and said superstrate are fusion bonded.

8. A solar cell device as claimed in claim 1 wherein said substrate and said superstrate are non-adhesively bonded.

9. A solar cell device as claimed in claim 1 wherein said cell supports of said substrate are staggered with respect to said support ridges of said superstrate.

10. A solar cell device as claimed in claim 1 further comprising:

(a) a peripheral substrate bonding ridge; and

(b) a peripheral superstrate bonding ridge in bonding contact with the substrate bonding ridge to join the substrate and superstrate.

11. A solar cell device as claimed in claim 10 wherein said substrate bonding ridge and said superstrate bonding ridge are in bonding contact with one another along substantially the entire periphery of said solar cell device.

12. A solar cell device as claimed in claim 10 further comprising an intermediate bonding ridge disposed within said periphery of said substrate, and an intermediate superstrate support ridge disposed within said periphery of said superstrate for bonding the substrate and superstrate together.

13. A solar device as claimed in claim 1 further comprising a conductive grid network disposed on an outer surface of the device substrate and superstrate.

14. A solar cell array comprising:

(a) a plurality of solar cells;

(b) a substrate having integral cell supports formed on an inner surface of said substrate for supporting said solar cells above the surface;

(c) a superstrate having integral support ridges for holding said solar cells in non-bonded contact with said integral cell supports of said substrate when said superstrate is bonded to said substrate to form an enclosed cell area that encloses said solar cells;

(d) means for providing electrical connection of said solar cells from said enclosed cell area to an external element; and

(e) a conductive grid network formed on the outer surfaces of said substrate and said superstrate for providing a zero-potential ground plane.

15. A solar cell array as claimed in claim 14 wherein said substrate and said superstrate are adhesively bonded.

16. A solar cell array as claimed in claim 14 wherein said substrate and said superstrate are non-adhesively bonded.

17. A solar cell array as claimed in claim 14 wherein said enclosed cell area is hermetically sealed.

18. A solar cell array as claimed in claim 14 wherein said integral cell supports of said substrate are staggered with respect to said integral support ridges of said superstrate.

19. A solar cell array as claimed in claim 14 wherein said substrate and said superstrate include corresponding bonding surfaces for interconnecting the substrate and superstrate and for enclosing the solar cells.

20. A solar cell array comprising:

(a) a substrate having cell supports formed on the inner surface of said substrate;

(b) a first protective layer placed in non-bonding contact with said cell supports of said substrate;

(c) a plurality of solar cells placed in contact with said first protective layer;

(d) a second protective layer placed over said solar cells;

(e) a superstrate having cell contacts formed on a first surface of said glass superstrate and in non-bonding contact with said second protective layer to hold said solar cells in place;

(f) means for providing external electrical contact to said solar cells; and

(g) conductive grid means formed on an outer surface of at least one of said substrate and superstrate for providing a zero potential ground plane.

21. A solar cell array as claimed in claim 20 wherein said first and second protective layers are comprised of quartz.

22. A solar array comprising:

(a) a plurality of solar cells;

(b) a substrate having cell supports formed on an inner surface of said substrate for supporting said solar cells above the surface;

(c) a superstrate having cell support ridges for holding said solar cells in non-bonded contact with said cell supports of said substrate when said superstrate is bonded to said substrate to form an enclosed cell area that encloses said solar cells;

(d) means for providing electrical connection of said solar cells from said enclosed cell area to an external element; and

(e) conductive grid network formed on at least one of an outer surface of said substrate and an outer surface of said superstrate for providing a zero-potential ground plane.