Investigation of test methods, material properties, and processes for solar cell encapsulants
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Integral glass encapsulation for solar arrays
The status of development of the techniques for employing electrostatic bonding in conjunction with terrestrial solar cells is presented.
Source record↗
Investigation of Test Methods, Material Properties, and Processes for Solar Cell Encapsulants
During this quarter the technical activities were directed toward the reformulation of ethylene/vinyl acetate copolymer for use as a compound in solar cell module fabrication. Successful formulations were devised that lowered the temperature required for cure and raised the gel content. A major volatile component was also eliminated (acrylate crosslinking agent) which should aid in the production of bubble free laminates. Adhesive strengths and primers for the bonding of ethylene/vinyl acetate to supersyrate and substrate materials was assessed with encouraging results. The incorporation of silane compounds gave high bond strengths. A survey of scrim materials was also conducted.
Source record↗
Investigation of Test Methods, Material Properties, and Processes for Solar Cell Encapsulants
The reformulation of a commercial grade of ethylene/vinyl acetate copolymer for use as a pottant in solar cell module manufacture was investigated. Potentially successful formulations were prepared by compounding the raw polymer with antioxidants, ultraviolet absorbers and crosslinking agents to yield stabilized and curable compositions. The resulting elastomer was found to offer low cost (approximately $0.80/lb.), low temperature processability, high transparency (91% transmission), and low modulus. Cured specimens of the final formulation endured 4000 hours of fluorescent sunlamp radiation without change which indicates excellent stability.
Willis, P. B.↗
Evaluation of solar cell covers and encapsulant materials for space application
The effects of space radiation (electrons and protons), vacuum, and thermal cycling on a variety of solar cell covers are investigated. Cover materials evaluated include glass resins, 2 mil glass applied with adhesives or electrostatically bonded, and thin plastic films of FEP or PFA applied with adhesive. Solar cells were exposed to environmental conditions simulating those encountered in outer space. These test conditions include 1 MeV electrons, 0.5 MeV protons, and thermal cycling in vacuum. During testing the solar cells were monitored for variations in electrical characteristics and structural changes.
Russell, D. A.↗
Study program for encapsulation materials interface for low-cost solar array
The service integrity of the bonded interface in solar cell modules used in solar arrays is addressed. The development of AC impedance as a nondestructive evaluation (NDE) methodology for solar arrays is reported along with development of corrosion models and materials selection criteria for corrosion resistant interfaces.
Kaelble, D. H.↗
Design, analysis, and test verification of advanced encapsulation system
Procurement of 4 in x 4 in polycrystalline solar cells were proceeded with some delays. A total of 1200 cells were procured for use in both the verification testing and qualification testing. Additional thermal structural analyses were run and the data are presented. An outline of the verification testing is included with information on test specimen construction.
Garcia, A.↗
Investigation of test methods, material properties, and processes for solar cell encapsulants
The development of pottant compounds is emphasized. Formulation of the butyl acrylate syrup/casting pottant was completed. The formulation contains an ultraviolet stabilizer system and may be cured with an initiator that, unlike former selections, presents no shipping of handling hazards to the user. The catalyzed syrup is stable at room temperature and has a pot life of at least eight hours. The formulation of the ethylene/methyl acrylate lamination pottant was also completed. This compound is the alternative pottant to EVA and is similarly produced as an extruded sheet that is wound into rolls. This resin is inherently nonblocking.
Willis, P. B.↗
Testing of solar cell covers and encapsulants conducted in a simulated space environment
The materials included in the evaluation were 0211 micro-sheet, FEP-A used as a cover and as an adhesive, DC 93-500 adhesive, PFA "hard coat" used as a cover, GE 615/UV-24 used as a cover, GR 650 used as a cover, and electrostatically bonded 7070 glass. The test environments were 1 MeV electron irradiation interspersed with thermal cycling, 0.5 MeV proton irradiation interspersed with thermal cycling and UV exposure interspersed with thermal cycling. Summary data is given describing the response of the test materials both visually and electrically to the three different environments.
Russell, D. A.↗
Design, analysis, and test verification of advanced encapsulation systems
The construction of optical and electrical verification test coupons is detailed. Testing of these coupons was completed and the results are presented. Additionally, a thermal simulation of roof mounted array conditions was done and the results documented.
Garcia, A.↗
Investigation of test methods, material properties, and processes for solar cell encapsulants
Technical investigations concerned the development of advanced cure chemistries for lamination type pottants; the continued evaluation of soil resistant surface treatments, and the results of an accelerated aging test program for the comparison of material stabilities. New compounds were evaluated for efficiency in curing both ethylene/vinyl acetate and ethylene/methyl acrylate pottants intended for vacuum bag lamination of solar cells. One compound in particular, designated Lupersol - TBEC (Lucidol Division of Pennwalt Corp.) was found to be unusually effective in promoting the rapid cure of both these materials. Formulation of these resins with TBEC resulted in compositions of very high gel content, lower temperatures of activation, and much lower cure times, even in the ethylene/methyl acrylate polymer that is more difficult to cure. It is expected that TBEC modified pottant formulations may permit the lamination/encapsulation step to be operated at lower temperatures, higher speed, higher throughput and a much wider tolerance for intentional or accidental variations in the cure schedule. An experimental program continued to determine the effectiveness of soil resistant coatings.
Willis, P. B.↗
Design, analysis and test verification of advanced encapsulation systems, phase 2 program results
Optical, electrical isolation, thermal structural, structural deflection, and thermal tests are reported. The utility of the optical, series capacitance, and structural deflection models was verified.
Garcia, A.↗
A preliminary evaluation of a potential space worth encapsulant
A new polymer polyimide possessing optical and mechanical properties potentially suitable for space applications now exists. A preliminary evaluation of the material indicates that in its present state of development, the polyimide is not ready for space qualification. Further efforts to increase molecular weight and purify the consituents used to synthesize it are warranted. Activities addressing these needs are now being pursued. If these approaches prove successful, additional testing will take place with an emphasis on synergistic effects.
Scott-Monck, J.↗
Module degradation catalyzed by metal-encapsulation reactions
Four major properties are considered to be relevant in determining service life of a photovoltaic module: (1) Mechanical: creep resistance, modulus, tensile strength; (2) Optical: integrated transmission at 0.4 to 1.1 m wavelength; (3) Chemical: inertness with respect to metals and other components, retention of stabilizers, etc. and (4) Electrical; maintaining effective isolation of conductive components. These properties were measured after exposing polymer specimens to three types of accelerated stress: thermal, ultraviolet radiation and metal catalysts. These conditions give rise to a large number of complex interrelated free-radical reactions that result in the deterioration of polymeric materials.
Gallagher, B. D.↗
Design, analysis and test verification of advanced encapsulation systems
Investigations into transparent conductive polymers were begun. Polypyrrole was electrochemically deposited, but the film characteristics were poor. A proprietary polymer material supplied by Polaroid was evaluated and showed promise as a readily processable material. A method was developed for calculating the magnitude and location of the maximum electric field for the family of solar-cell-like shapes. A method for calculating the lines of force for three dimensional electric fields was developed and applied to a geometry of interest to the photovoltaic program.
Garcia, A., III↗
Photothermal degradation studies of encapsulants
The reliability physics program at JPL is outlined. The overall objectives and approaches are given in the program. The objectives, approaches and conclusions are given for two specific parts of the programs. These two parts are mechanistic studies of photothermal degradation and performance characteristics of materials with respect to photothermal stresses.
Liang, R. H.↗
Investigation of test methods, material properties and processes for solar cell encapsulants
The historical development of ethylene vinyl acetate (EVA) is presented, including the functional requirements, polymer selection, curing, stabilization, production and module processing. The construction and use of a new method for the accelerated aging of polymers is detailed. The method more closely resembles the conditions that may be encountered in actual module field exposure and additionally may permit service life to be predicted accurately. The use of hardboard as a low cost candidate substrate material is studied. The performance of surface antisoiling treatments useful for imparting a self cleaning property to modules is updated.
Willis, P. B.↗
Thermal-capillary analysis of Czochralski and liquid encapsulated Czochralski crystal growth. II - Processing strategies
The pseudosteady-state heat transfer model developed in a previous paper is augmented with constraints for constant crystal radius and melt/solid interface deflection. Combinations of growth rate, and crucible and bottom-heater temperatures are tested as processing parameters for satisfying the constrained thermal-capillary problem over a range of melt volumes corresponding to the sequence occuring during the batchwise Czochralski growth of a small-diameter silicon crystal. The applicability of each processing strategy is judged by the range of existence of the solution, in terms of melt volume and the values of the axial and radial temperature gradients in the crystal.
Derby, J. J.↗