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NASA NTRS2022

What would it take to manufacture perovskite solar cells in space?

Imagine, astronauts land on the moon. They verify their arrival with mission control, and perform system checks and validations. After the dust settles, they open the airlock of the landing vehicle and venture outside. A side hatch opens, and a flexible substrate slowly unfurls on a boom. A series of printer heads raster, hovering over the substrate and sequentially vapor-depositing the constituent layers of a perovskite solar module (Figure 1). In time, a 1-megawatt array has been manufactured on the moon and can now be connected to supply power to the Artemis Base Camp. This ambitious vision could someday become a reality. On August 29, 2021, a SpaceX Falcon 9 rocket launched a commercial resupply payload from Kennedy Space Center en route to the International Space Station (ISS). On board were perovskite solar cells that will fly for 6 months outside the ISS in low earth orbit (LEO) on the 15th Materials International Space Station Experiment (MISSE-15). This will be the first long duration flight of perovskite solar cell devices in LEO and a major step toward realizing the in-space operation and, potentially, manufacture of perovskite solar cells.

Lyndsey McMillon-Brown↗

NASA NTRS2000

Ultralightweight Fresnel Lens Solar Concentrators for Space Power

The first phase of this project was completed in March 2000, and included the successful technology demonstration of a new ultralightweight photovoltaic concentrator array at the fully functional panel level. The new array is called the Stretched Lens Aurora (SLA) array, and uses deployable, flexible, thin-film silicone rubber Fresnel lenses to focus sunlight onto high efficiency multijunction solar cells, which are mounted to a composite radiator surface for waste heat dissipation. A prototype panel was delivered to NASA Marshall in March 2000, and comprised four side-by-side lenses focussing sunlight onto four side-by-side photovoltaic receivers. This prototype panel was tested by NASA Glenn prior to delivery to NASA Marshall. The best of the four lens/receiver modules achieved 27.4% efficiency at room temperature in the NASA Glenn solar simulator tests. This performance equates to 375 W/sq.m. areal power and 378 W/kg specific power at the fully functional panel level. We believe this to be the first space solar array of any kind to simulataneously meet the two long-standing NASA goals of 300 W/sq.m. and 300 W/kg at the functional panel level. Key results for the first phase of the program have been documented by ENTECH in a Draft Final Technical Report, which is presently being reviewed by NASA, and which should be published in the near future.

ONeill, M. J.↗

NASA NTRS2002

Thin-Film Solar Array Earth Orbit Mission Applicability Assessment

This is a preliminary assessment of the applicability and spacecraft-level impact of using very lightweight thin-film solar arrays with relatively large deployed areas for representative Earth orbiting missions. The most and least attractive features of thin-film solar arrays are briefly discussed. A simple calculation is then presented illustrating that from a solar array alone mass perspective, larger arrays with less efficient but lighter thin-film solar cells can weigh less than smaller arrays with more efficient but heavier crystalline cells. However, a proper spacecraft-level systems assessment must take into account the additional mass associated with solar array deployed area: the propellant needed to desaturate the momentum accumulated from area-related disturbance torques and to perform aerodynamic drag makeup reboost. The results for such an assessment are presented for a representative low Earth orbit (LEO) mission, as a function of altitude and mission life, and a geostationary Earth orbit (GEO) mission. Discussion of the results includes a list of specific mission types most likely to benefit from using thin-film arrays. NASA Glenn's low-temperature approach to depositing thin-film cells on lightweight, flexible plastic substrates is also briefly discussed to provide a perspective on one approach to achieving this enabling technology. The paper concludes with a list of issues to be addressed prior to use of thin-film solar arrays in space and the observation that with their unique characteristics, very lightweight arrays using efficient, thin-film cells on flexible substrates may become the best array option for a subset of Earth orbiting missions.

Hoffman, David J.↗

DOE OSTI2022

What Would It Take to Manufacture Perovskite Solar Cells in Space?

Imagine: Astronauts land on the moon. They verify their arrival with mission control and perform system checks and validations. After the dust settles, they open the airlock of the landing vehicle and venture outside. A side hatch opens, and a flexible substrate slowly unfurls on a boom. A series of printer heads raster, hovering over the substrate and sequentially vapor-depositing the constituent layers of a perovskite solar module. In time, a 1-megawatt array has been manufactured on the moon and can now be connected to supply power to the Artemis Base Camp. This ambitious vision could someday become a reality.

14 SOLAR ENERGY↗

NASA NTRS1977

Development of a high efficiency thin silicon solar cell

A key to the success of this program was the breakthrough development of a technology for producing ultra-thin silicon slices which are very flexible, resilient, and tolerant of moderate handling abuse. Experimental topics investigated were thinning technology, gaseous junction diffusion, aluminum back alloying, internal reflectance, tantalum oxide anti-reflective coating optimization, slice flexibility, handling techniques, production rate limiting steps, low temperature behavior, and radiation tolerance.

Lindmayer, J.↗

NASA NTRS1984

Labeling Solar-Cell Modules

Photocopying machine produces durable identification label. Process used for double glass photovoltaic-cell modules. Matrix of cells sandwiched between thin, flexible glass mats and covered above and below by protective sheets of glass. Label contains such information as manufacturer, model number, voltage and power ratings, and serial number. May also contain electrical-shock hazard warning and identification of positive and negative terminals. Method saves expense of procuring and applying conventional labels.

Watson, E. G.↗

DOE OSTI2021

Mechanism of Additive-Assisted Room-Temperature Processing of Metal Halide Perovskite Thin Films

Perovskite solar cells have received substantial attention due to their potential for low-cost photovoltaic devices on flexible or rigid substrates. Thiocyanate (SCN)-containing additives, such as MASCN (MA = methylammonium), have been shown to control perovskite film crystallization and the film microstructure to achieve effective room-temperature perovskite absorber processing. Nevertheless, the crystallization pathways and mechanisms of perovskite formation involved in MASCN additive processing are far from clear. Using in situ X-ray diffraction and photoluminescence, we investigate the crystallization pathways of MAPbI 3 and reveal the mechanisms of additive-assisted perovskite formation during spin coating and subsequent N 2 drying. In this work, we confirm that MASCN induces large precursor aggregates in solution and, during spin coating, promotes the formation of the perovskite phase with lower nucleation density and overall larger initial nuclei size, which forms upon reaching supersaturation in solution, in addition to intermediate solvent-complex phases. Finally, during the subsequent N 2 drying, MASCN facilitates the dissociation of these precursor aggregates and the solvate phases, leading to further growth of the perovskite crystals. Our results show that the nature of the intermediate phases and their formation/dissociation kinetics determine the nucleation and growth of the perovskite phase, which subsequently impact the film microstructure. These findings provide mechanistic insights underlying room-temperature, additive-assisted perovskite processing and help guide further development of such facile room-temperature synthesis routes.

36 MATERIALS SCIENCE↗

DOE OSTI2023

Influence of oxygen on the optical and electrical properties of magnetron-sputtered indium tin oxide thin films at ambient temperature

Indium Tin Oxide (ITO) thin films are commonly used as transparent conductive layers in the production of solar cells. ITO films are typically heat-treated at temperatures exceeding 200 °C after magnetron sputtering to optimize the physical, optical, and electrical characteristics for photovoltaic devices. Here, this high temperature heating procedure greatly limits the use of potential substrates, particularly those comprised of low-temperature-rated polymers. Herein, we examine the physical, optical, and electrical transport effects of oxygen:argon plasmas during radio frequency magnetron sputtering of ITO on glass and flexible polymer surfaces without subsequent heat treatment. ITO thin films were characterized via sheet resistance testing, UV-Vis spectroscopy, X-ray diffraction, and scanning electron microscopy imaging. Sheet resistance measurements revealed an increase in surface resistance with increasing oxygen concentration during sputtering. UV-Vis optical transmittance measurements demonstrated an improvement in optical transmittance with an increase in oxygen concentration reaching a maximum transmittance at an oxygen concentration of 1-2 %. Most importantly, it was discovered that producing bilayers of ITO with pure argon sputtered plasmas followed by oxygen:argon plasmas produced ITO thin films with suitable resistance and transmittance without the need for high temperature post annealing. These results highlight a methodology for the deposition of ITO thin films on temperature sensitive substrates for flexible photovoltaics and low-cost module production.

36 MATERIALS SCIENCE↗

NASA NTRS1992

Hubble Space Telescope solar cell module thermal cycle test

The Hubble Space Telescope (HST) solar array consists of two identical double roll-out wings designed after the Hughes flexible roll-up solar array (FRUSA) and was developed by the European Space Agency (ESA) to meet specified HST power output requirements at the end of 2 years, with a functional lifetime of 5 years. The requirement that the HST solar array remain functional both mechanically and electrically during its 5-year lifetime meant that the array must withstand 30,000 low Earth orbit (LEO) thermal cycles between approximately +100 and -100 C. In order to evaluate the ability of the array to meet this requirement, an accelerated thermal cycle test in vacuum was conducted at NASA's Marshall Space Flight Center (MSFC), using two 128-cell solar array modules which duplicated the flight HST solar array. Several other tests were performed on the modules. The thermal cycle test was interrupted after 2,577 cycles, and a 'cold-roll' test was performed on one of the modules in order to evaluate the ability of the flight array to survive an emergency deployment during the dark (cold) portion of an orbit. A posttest static shadow test was performed on one of the modules in order to analyze temperature gradients across the module. Finally, current in-flight electrical performance data from the actual HST flight solar array will be tested.

Douglas, Alexander↗

DOE OSTI2021

High-Performance All-Polymer Solar Cells and Photodetectors Enabled by a High-Mobility n-Type Polymer and Optimized Bulk-Heterojunction Morphology

All-polymer solar cells (all-PSCs) and all-polymer photodetectors (all-PPDs) are promising for application in flexible electronics, but their performance is greatly limited by the lack of polymer acceptors and the difficulties in morphology control. Herein, we report the use of a high-mobility n-type polymer semiconductor, PNDI-DTBT, for fabricating high-performance all-PSCs and all-PPDs. By pairing PNDI-DTBT with a matched polymer donor, a prominent power conversion efficiency of 8.5% was obtained in all-PSCs, demonstrating the great potential of high-mobility n-type polymers with a conventional donor–acceptor skeleton for photovoltaic application. Moreover, all-PPDs with a low dark current density of 1.32 × 10 –8 A cm –2 at –0.1 V bias and a high specific detectivity of 4.77 × 10 12 Jones were achieved, which belong to the best results of organic photodetectors. Morphology investigations revealed that the formation of a bicontinuous interpenetrating network with optimal phase separation scale, high domain purity, and preferential vertical composition distribution in the bulk-heterojunction active layer contribute to the remarkable device performance. Furthermore, these results suggest that combining high-mobility n-type polymers and morphology optimization is fruitful to achieving high-performance all-PSCs and all-PPDs.

36 MATERIALS SCIENCE↗

NASA NTRS1976

The ATS-5 solar cell experiment after 6-1/2 years in synchronous orbit

Several types of solar cell/coverslide combinations were launched into synchronous orbit. The cells were 2 and 10 ohm-cm crucible-grown silicon with thicknesses of 0.2 and 0.3 mm. Coverslides were fused silica, ranging in thickness from 0.15 to 1.52 mm. The cells were mounted on two panels, one a rigid aluminum honeycomb structure, giving essentially infinite backshielding; the other was a thin Kapton-fiberglass substrate, offering minimal protection to the rear surface of the cells. The current-voltage curves of the cells were measured. Correction of cell electrical output to standard temperature and solar intensity was performed, using empirical radiation-dependent corrections. It is found that the cells on the flexible panel degrade much more rapidly than predicted, while the rigid panel cells follow the predictions fairly well. The anomalous behavior of the flexible panel cells is attributed to the deposition of a contaminant on the cell coverslides.

Anspaugh, B.↗

NASA NTRS1980

Large area flexible solar array design for Space Shuttle application

A large area flexible solar array has been designed for Shuttle power augmentation. The solar array utilizes large area, low cost, weldable solar cells. The paper addresses how the unique requirements of this system are implemented into the design. Economic and reliability issues relating to the optimization of a large area, foldable solar array concomitant to the Shuttle/Orbiter system are reviewed.

Souza, C. J.↗

NASA NTRS1980

Space Shuttle power extension package

A modification kit for the Space Transportation System (STS) Orbiter is proposed to provide more power and mission duration for payloads. The power extension package (PEP), a flexible-substrate solar array deployed on the Space Shuttle Orbiter remote manipulator system, can provide as much as 29 kW total power for durations of 10 to 48 days. The kit is installed only for those flights which require enhanced power or duration. The PEP is made possible by development of the flexible-substrate array technology and, in itself, contributes to the technology base for the use of large area solar cells. Modifications to the Orbiter thermal control and life support systems to improve heat balance and to reduce consumables are proposed. The changes consist of repositioning the Orbiter forward radiators and replacing the lithium hydroxide scrubber with a regenerable solid amine.

Loftus, J. P., Jr.↗

NASA NTRS1998

A Review of Recent Thermophotovoltaic Energy Conversion Technology Development at NASA Lewis Research Center

NASA Lewis Research Center (LeRC) has had an ongoing research program in TPV since the late 1980's. This effort has included both in-house research programs on critical components such as photovoltaic cells (PV) and emitter materials, as well as an active contracting effort directed toward system, and component development. Of particular note is the in-house development of thin film selective emitters fabricated from rare-earth yttrium aluminum garnets (YAG). Also developed at LeRC is a Monolithic Interconnect Module (MIM) consisting of many small InGaAs cells series interconnected on a single InP substrate. An infrared reflector placed on the rear surface of the substrate returns unabsorbed photons to the emitter for recycling. The current contracted efforts include two TPV system developments by Tecogen, Inc., a solar powered TPV system development, a GaInAsSb cell development and several emitter development efforts (plasma-sprayed selective emitters, flexible SiC and a selective emitting light pipe).

Wilt, David M.↗

DOE OSTI2020

Learning from existing photovoltaic technologies to identify alternative perovskite module designs

Perovskite solar cells have now become the most efficient of all multicrystalline thin film photovoltaic technologies, reaching 25.2% in 2019. This outstanding figure of merit has only been achieved on small lab-scale devices, with significantly lower performance when processed on larger more industrially relevant substrate sizes. Perovskite modules, connecting several smaller area cells together, are commonly demonstrated with a superstrate monolithic interconnection method. However, several other module designs exist and remain largely unexplored by the perovskite community. In this work, we review and highlight those alternatives and discuss their advantages and limitations. We propose that a singulated substrate-oriented module design, using metallic substrates, could provide a quicker path to seeing highly efficient, lightweight, and flexible perovskite modules on the market, while mitigating near-term technical risks. Finally, as an experimental starting-point towards this design, we demonstrate a substrate-oriented all-perovskite 2-terminal tandem with 18% efficiency.

14 SOLAR ENERGY↗

DOE OSTI2024

Multifunctional Nanofiber Reinforcement for Improved Thermomechanical and Chemical Stability of Perovskite Solar Cells

This project focused on the development of metal halide perovskite-polymeric nanofiber nanocomposites for robust and efficient solar cells. Metal halide perovskite solar cells are a potentially disruptive technology with high efficiencies and low-cost solution processability amenable with roll-to-roll fabrication of flexible devices. However, perovskites exhibit extreme brittleness, high internal film stresses, and chemical instabilities that significantly limit service lifetimes under normal operating conditions. To date, most work addressing these shortcomings has been focused on encapsulating devices between thick layers of rigid materials such as glass, which increases the total weight and cost of devices. Furthermore, these rigid and heavy encapsulants do not translate well to emerging solar markets vital for national security, including integrated mobile power, emergency deployments for disaster relief and military engagement, and lightweight power for space. It is therefore critical to improve the thermomechanical and chemical stability of perovskite devices in a way that is compatible with flexible and lightweight substrates. In this project, we integrated nylon-6,6 nanofibers into MAPbI3 to mechanically reinforce the perovskite, demonstrating films that exhibited fracture energies 5-fold greater than pristine MAPbI3 while also maintaining similar power conversion efficiencies due to beneficial light scattering effects from the polymeric nanofibers. These results required successful development of approaches to control the deposition thickness of nanofiber mats down to 100s of nanometers, and to ensure the polymer nanofibers did not inhibit charge transport to the at the perovskite-transport layer interface.

14 SOLAR ENERGY↗

NASA NTRS1994

Aromatic Polyimides With Low Dielectric Constants

Linear aromatic polyimides developed containing dimethylsilane linkages in dianhydride portions of molecules and at least one trifluoromethyl group in each of diamine portions. Polyimides offer advantages of thermal stability, low density, resistance to ionizing radiation, toughness, flexibility, and exhibit lower dielectric constants. Also polyimides nearly transparent and colorless; an advantage in protective coating of solar photovoltaic cells, optical components, and antennas.

St. Clair, Anne K.↗

DOE OSTI2026

Shining Light on Halide Perovskites: Teaching Analytical Chemistry Using Flexible, Inquiry-Based Experiments

Two-dimensional (2D) metal halide perovskites are promising next generation semiconducting materials at the forefront of research in solar cells, LEDs, and other devices. Here, we report on an undergraduate intermediate analytical chemistry laboratory experience where students were taught fundamental chemistry concepts, including solubility, complexation, spectroscopy, and microscopy, through the introduction and study of 2D halide perovskite materials. Students explore multiple facets of perovskite synthesis, structure, and properties through a modular set of experiments that students used to form a holistic picture of this material. Importantly, this inquiry-based lab supports students through a guided research process, and students report high interest and learning gains from an end of the semester survey. We further discuss ways to adapt this lab to course, student, equipment, and budget needs. Overall, this laboratory experience teaches and applies the fundamental concepts and tools of analytical chemistry to the contemporary materials research field.

Analytical Chemistry↗