Development of low cost solar panel with cover glass for small satellites applications

Solar panels for power generation in space are quite expensive and even small improvements in the development, production and qualification process may result in significant savings for low cost small satellites. This paper presents the research activities carried out in collaboration between the University of Pisa and Alta SpA about the design, manufacturing and assembly of a photovoltaic panel for small satellite applications in preparation of a test flight scheduled for early 2013 on the UNISAT5 small spacecraft. The method developed is based on low cost and “low tech” (but reliable) techniques to assemble and qualify the panel. The approach adopted uses a printed circuit board where bare cells are installed by means of a double-sided insulating adhesive tape and each cell is covered with cerium doped borosilicate glass, using a controlled volatility silicone. Bonding was performed with a dedicated vacuum bag technique, developed in-house. We outline the panel design, the manufacturing processes and the results of electrical and thermal vacuum tests carried out on the protoflight model.