A solar module fabrication process for HALE solar electric UAVs

We describe a fabrication process used to manufacture high power-to-weight-ratio flexible solar array modules for use on high-altitude-long-endurance (HALE) solar-electric unmanned air vehicles (UAVs). These modules have achieved power-to-weight ratios of 315 and 396 W/kg for 150 μm-thick monofacial and 110 μm-thick bifacial silicon solar cells, respectively. These calculations reflect average module efficiencies of 15.3% (150 μm) and 14.7% (110 μm) obtained from electrical tests performed by Spectrolab, Inc. Under AM0 global conditions at 25°C, and include weight contributions from all module components (solar cells, lamination material, bypass diodes, interconnect wires, and adhesive tape used to attach the modules to the wing). The fabrication, testing, and performance of 32 m² of these modules are described