The objectives of this first project are twofold:

• Realize a first “pioneer” flexible demonstrator, using current heritage processes of rigid PVA.
• Compare different welding technologies, to choose a baseline technology for Solar Cell Assembly interconnection.

Thales Alenia Space is currently developing a flexible solar array, for future generation of telecom or observation satellites. As part of this roadmap, the PVA-Flexible-Pioneer project is the first de-risking project for Thales Alenia Space in Belgium, to develop a modular flexible PVA (PhotoVoltaic Assembly).

Different technologies (resistance welding, ultrasonic welding, laser welding) were compared, by performing welding tests on representative kovar/Ag interconnectors. From the trade-off, parallel resistance welding was chosen as preferred technology. In a second step, this process was further optimized and characterized by tensile testing, visual inspection and cross-section metallurgy. Finally, different coupons were realized, using todays rigid heritage processes, onto a kapton substrate in order to make a first evaluation of the current baseline process.

The flexible PVA is one key components to realize a flexible solar array, for next generation satellites, with multiple advantages, such as total power growth, mass saving, stowed volume saving , and a better global competiveness.