Affordable Modular Ultra-Lightweight Photovoltaic Flexible Blanket Electrical Subsystem

Status: Completed

Start Date: 2016-01-07

End Date: 2018-04-06

Description: The proposed effort is focused on validating to TRL 6 a modular multi-junction photovoltaic flexible blanket technology that enables/enhances the ability to provide low-cost, low mass, and high voltage operability for high power arrays to support solar electric propulsion (SEP) Human Exploration and Space Science missions. The proposed multi-junction flexible blanket assembly when coupled to an optimized structural platform (such as DSS�s ROSA, and/or other optimized flexible blanket solar array structures) and MicroLink�s Epitaxial Liftoff (ELO) multi-junction solar cell technology will produce revolutionary array-system-level performance in terms of high specific power, lightweight, rapid assembly and re-configurability, compact stowage volume, reliability, modularity, adaptability, extreme affordability, adaptability to all flexible solar arrays, and rapid commercial infusion. Once successfully validated through the proposed program, the proposed lightweight multi-junction flexible blanket technology will provide incredible performance improvements over current state-of-the-art, and will be mission-enabling for future NASA and non-NASA applications. The significance / benefits of the proposed technology innovation as proposed herein will provide a revolutionary and positive performance impact to the end-user in terms of: 1) Enables lightweight and affordability for future NASA and non-NASA missions; 2) Enables rapid assembly and reconfigurability for high volume production; 3) Enables rapid repair and replacement of damaged components; 4) Provides substantial affordability (Innovative modular construction with MicorLink�s ELO PV and rapid assembly provides up to 50% cost reduction); 5) Ultra-lightweight (Innovative construction/design provides up 700 W/kg BOL with IMM PV at the encapsulated modular blanket assembly level while still providing reliable high voltage operation in a SEP plasma environment, 10X lighter than rigid panels); 6) High modularity (blanket assembly constructed from mass-produced common panel subassembly building-blocks that can be rapidly assembled into the final flexible blanket subsystem); 7) Highly adaptable for implementation into all other commercially available flight-qualified flexible blanket solar arrays; 8) Compact stowage volume (>60-80 kW/m3 BOL, 10X more compact stowage than rigid panel arrays); 9) High flexibility/durability and robust construction; 10) Implementation into rolled or Z-folded blanket configurations; 11) Applicability and scalability scalable from 500W low power to 100s kW+ high power array sizes; 12) Adaptable to many photovoltaic solar cell types (not only emerging IMM multi-junction PV, but also current ZTJ and XTJ multi-junction PV); 13) Reliable high 1000V voltage operation in a SEP plasma environment; and 14) High space environmental survivability (uses space proven materials). As NASA�s technology roadmap includes utilizing SEP for Space Human Exploration and Outer-Planets missions the significance of the proposed flexible blanket technology enables these emerging missions by providing ultra-affordability, very high power capability, ultra-lightweight, ultra-compact stowage, and high-voltage operation in a SEP plasma environment. The proposed program will focus on demonstrating the following objectives to enable future NASA Human Exploration & Space Science SEP missions and non-NASA missions: The primary objectives to be achieved during the proposed program are listed below: 1) Demonstrate TRL 6 and develop an innovative low cost, low mass, low risk, and highly reliable multi-junction photovoltaic flexible blanket system that enables (through low mass and low cost) future NASA Human Exploration & Space Science SEP missions, & other future missions; 2) Advance and mature the innovative flexible blanket technology embodiment and establish compliancy with the following requirements/goals (Low mass / high specific power goal: 750 W/kg BOL for IMM & 450 W/kg BOL for ZTJ; Affordability goal: 50% cost savings compared to state-of-the-practice; Compact stowage volume goal: stowable in a rollable or z-foldable format; Rapid assembly � reconfigurability - repair-ability goal: 70% reduction in manufacturing time to produce assembly; Compatible and survivability in typical space and high voltage (1000V) SEP plasma environments); 3) Demonstrate and validate affordability metrics for ELO wafer re-usability through manufacture and test of at least four re-claim cycles of standard area high efficiency ELO IMM devices; 4) Demonstrate and validate feasibility of a sub-scale MicroLink ELO IMM PV IMBA panel assembly comprised of super-sized 60cm2 solar cells; 5) Develop scalable analytical models and correlate with test results to validate MicroLink ELO IMM PV IMBA prototype hardware TRL 6 criteria metrics; 6) Develop readied technology and manufacture infrastructure, and accelerate commercial infusion to end-users; 7) Significantly elevate the MicroLink ELO IMM PV IMBA TRL classification through ever-increasing hardware fidelity and test environment relevance; 8) Build and test prototype / Engineering Model (EM) hardware of the proposed flexible blanket design and validate performance and technical feasibility; 9) Accelerate commercial infusion and NASA�s return on investment by involving the numerous end-users; and 10) Accomplish the above objectives through a team approach working concurrently with the lead NASA centers and prospective commercial end-users to establish the most feasible solution. The proposed program focus is to develop and validate to TRL 6 a viable rollable/foldable MicroLink ELO IMM PV IMBA panel assembly with rapid assembly and reconfigurability features for advance NASA solar array applications. Technology validation and TRL 6 demonstration will progressively occur through risk mitigation component/breadboard hardware build/test validations, and prototype / Engineering Development Unit (EDU) MicroLink ELO IMM PV IMBA panel assembly hardware build & test validations in a relevant environment. The planned relevant test environments include thermal life cycle, vibration survivability, thermal balance in vacuum and high voltage operation with pre/post LAPSS (power production) measurements. The key technical questions that will be addressed during the proposed program to validate technical feasibility and TRL 6 classification are the listed above. Additional technical questions may also arise as the program is executed. The likelihood of success of the proposed program in meeting these objectives is deemed very high based on DSS past experience and the current readiness less of the flexible blanket subsystem and proposed materials. At the completion of the proposed effort, DSS will have developed/validated a feasible photovoltaic flexible blanket system to a TRL 6 classification that exhibits low cost, very low mass, extremely compact stowage volume, and high reliability. This successful proposed effort will lay the foundation for insertion / infusion of the technology into a flight hardware qualification and/or protoflight program, and will accelerate / enable commercialization of this enabling technology.

Lead Organization: Deployable Space Systems, Inc