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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 217 records · Page 12
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Photovoltaic module antireflection coating degradation survey using color microscopy and spectral reflectance

Abstract Commercial antireflective coatings (ARCs) on photovoltaic (PV) module glass can improve module power by 2.5%–3.0%, but their long‐term field performance requires additional study. In this paper, we investigate ARC performance on fielded modules using two nondestructive techniques: reflectance spectroscopy and RGB microscopy, finding a large variation in coating durability and performance. For new coatings, the fleet average nominal power enhancement is 2.8%. This power enhancement is observed to degrade at approximately −0.05%/year absolute over the first 8 years of fielding in arrays that are not regularly cleaned. Interferometry and imaging results imply that coating loss for these modules is due to slow chemical thinning of the initial 125 nm thick coating by 1.4 to 5.0 nm/year. Due to the physics of interference coatings, the performance loss is projected to accelerate as the coating is further thinned, resulting in a coating lifetime (time to 80% of initial performance) of 7.5 to 25 years. At the higher 5.0 nm/year coating loss rates, we estimate that −0.14%/year power degradation of the module can be attributed solely to ARC degradation over the first 20 years. Extreme coating loss is observed on some modules where after 8 years fielding, the coating can be completely removed with a single wet wipe with a lens tissue. A case study is also presented comparing ARC and noncoated modules installed at a single site in 2013. We find that the ARC modules have a 2.6% higher soiling power loss than the noncoated modules; this exceeds the ARC power enhancement of 2.4% and leads to the surprising conclusion that the ARC lowers production for modules in this location due to increased soiling. These results demonstrate that RGB microscopy is a powerful, field‐capable, and quantitative characterization technique for assessing degradation of PV module ARCs.

Karin, Todd↗
DOE OSTI2021

Thermomechanical fatigue resistance of low temperature solder for multiwire interconnects in photovoltaic modules

Novel interconnect technologies leveraging low melting temperature solders, such as multiwire interconnects, are being deployed in photovoltaic (PV) modules for improved reliability through interconnect redundancy and lower thermal loads during interconnection and lamination. However, the equivalency of standardized accelerated testing to field conditions has not yet been established for these emerging technologies. In this study, the thermomechanical fatigue resistance of low temperature solder alloys is investigated and compared to that of conventional SnPb to assess the acceleration behavior of these alloys. While InSn is shown to have sufficient thermomechanical fatigue resistance on the order of that of SnPb, these results indicate Sn–Bi alloys may have poor thermomechanical fatigue resistance at field conditions. The results also show that Sn–Bi alloys have thermal cycling acceleration factors of less than one. This indicates that the standardized accelerated thermal cycling test, such as that in IEC 61215, will produce misleading results for Sn–Bi alloys and that unique testing is required for this PV module architecture. Though accelerated thermal cycling may be a meaningful qualification test for SnPb solder joints, these results suggest that mechanical loading may be a more appropriate test for Sn–Bi multiwire interconnects. This is due to the distinct processing and geometry of multiwire interconnects which may allow for mechanical, rather than strictly metallurgical interconnections.

14 SOLAR ENERGY↗
NASA NTRS1988

Tests Of Amorphous-Silicon Photovoltaic Modules

Progress in identification of strengths and weaknesses of amorphous-silicon technology detailed. Report describes achievements in testing reliability of solar-power modules made of amorphous-silicon photovoltaic cells. Based on investigation of modules made by U.S. manufacturers. Modules subjected to field tests, to accelerated-aging tests in laboratory, and to standard sequence of qualification tests developed for modules of crystalline-silicon cells.

Ross, Ronald G., Jr.↗
DOE OSTI2024

Quantifying spectral albedo effects on bifacial photovoltaic module measurements and system model predictions

We provide a comprehensive analysis of the effect of spectral albedo on photovoltaic (PV) module measurements and system model predictions. We demonstrate how to account for albedo in indoor bifacial device measurements by adjusting the applied irradiance using the scaled rear irradiance method, exemplified on fabricated silicon heterojunction (SHJ) modules. System model performance is studied using a detailed 3D finite-element model, DUET, for fixed-tilt and horizontal single-axis tracked (SAT) arrays between 15 and 75°N. Spectral effects cause variations in measured SHJ module short-circuit current up to 2% and efficiency variation up to 0.3% abs. We further demonstrate that rear-side spectral mismatch factors (SMMs) resulting from including or omitting spectral albedo in PV system modeling vary between ±13%, while total (front+rear) SMMs vary up to 3%, depending on the deployment configuration and latitude. SAT array SMMs are weakly correlated with latitude, while fixed-tilt array SMMs increase with latitude, driven by an increasing proportion of ground-reflected light on the front-side of modules. Ground-reflections can constitute between 2% and 32% of total incident module irradiance, with notably high (>10%) contributions for fixed-tilt arrays at high latitude. Effects of spectral albedo are most significant for: (1) fixed-tilt deployments at high latitudes, (2) wide bandgap technologies such as perovskite and cadmium telluride cells, (3) albedos which vary steeply over the technology's absorption range, and (4) high albedo ground covers. Overall, we demonstrate that omitting spectral albedo effects can result in PV measurement and system-level modeling uncertainties on the order of several percent in these cases.

14 SOLAR ENERGY↗
DOE OSTI2017

Optical Design and Validation of an Infrared Transmissive Spectrum Splitting Concentrator Photovoltaic Module

A new modular, hybrid solar power system is designed to generate both electrical and thermal energy by utilizing the full solar spectrum. The key element, an infrared-transparent concentrator photovoltaic (CPV) module, acts as a spectrum splitter, dividing solar radiation into two parts. The ultraviolet and visible light (“in-band”) are converted to electricity with high efficiency in CPV cells, while the infrared light (“out-of-band”) is transmitted directly to a thermal receiver, where thermal power may be converted to electricity by a suitable heat engine or used directly for industrial process heat applications whenever needed. Here, we describe the optical design, modeling, fabrication, and performance validation of this novel spectrum splitting CPV module. A transfer matrix style approach, cumulative transmission model, is built to study the reflection, absorption, and transmission in each layer of the CPV module. To optimize the optical performance, different materials for module superstrate/substrate, encapsulant, cell substrate, and cooling fluids are compared in order to enhance the transmission of out-of-band light through the CPV module by minimizing absorption. Six antireflection coatings along with front and backside electrical contact grids are designed to maximize transmittance of in-band light to the cell and out-of-band light to the thermal receiver. Here, the final design, currently being prototyped, predicts out-of-band light transmission to the thermal receiver of 74.1% (for the passively cooled version) and 65.3% (for the actively cooled version). When epitaxial liftoff technology is applied, the transmission will change to 80.8% (passively cooled) and 71.9% (actively cooled). Experimental prototypes show good agreement with modeled optical performance.

14 SOLAR ENERGY↗
NASA NTRS1984

Technology developments toward 30-year-life of photovoltaic modules

As part of the United States National Photovoltaics Program, the Jet Propulsion Laboratory's Flat-Plate Solar Array Project (FSA) has maintained a comprehensive reliability and engineering sciences activity addressed toward understanding the reliability attributes of terrestrial flat-plate photovoltaic arrays and to deriving analysis and design tools necessary to achieve module designs with a 30-year useful life. The considerable progress to date stemming from the ongoing reliability research is discussed, and the major areas requiring continued research are highlighted. The result is an overview of the total array reliability problem and of available means of achieving high reliability at minimum cost.

Ross, R. G., Jr.↗
DOE OSTI2014

Trial Run of a Junction-Box Attachment Test for Use in Photovoltaic Module Qualification (Presentation)

Engineering robust adhesion of the junction-box (j-box) is a hurdle typically encountered by photovoltaic (PV) module manufacturers during product development and manufacturing process control. There are historical incidences of adverse effects (e.g., fires), caused when the j-box/adhesive/module system has failed in the field. The addition of a weight to the j-box during the 'damp-heat', 'thermal-cycle', or 'creep' tests within the IEC qualification protocol is proposed to verify the basic robustness of the adhesion system. The details of the proposed test are described, in addition to a trial run of the test procedure. The described experiments examine 4 moisture-cured silicones, 4 foam tapes, and a hot-melt adhesive used in conjunction with glass, KPE, THV, and TPE substrates. For the purpose of validating the experiment, j-boxes were adhered to a substrate, loaded with a prescribed weight, and then subjected to aging. The replicate mock-modules were aged in an environmental chamber (at 85 deg C/85% relative humidity for 1000 hours; then 100 degrees C/<10% relative humidity for 200 hours) or fielded in Golden, Miami, and Phoenix for 1 year. Attachment strength tests, including pluck and shear test geometries, were also performed on smaller component specimens.

14 SOLAR ENERGY↗
DOE OSTI2022

Dynamic Material Flow Analysis of Silicon Photovoltaic Modules to Support a Circular Economy Transition

Solar photovoltaics (PV) are the fastest growing renewable energy technologies for clean, cheap, and sustainable electricity generation. To prepare for rapid scale-up, the PV industry needs to project material requirements to build out all aspects of the supply chain appropriately and plan to handle large volumes of module waste. Impacts of deploying different material circularity strategies to reduce waste and conserve primary resources need to be quantified to inform sustainable material management. Here, we introduce the photovoltaic dynamic material flow analysis (PV DMFA) model based on PV electricity generation. The model quantifies material flows and stocks in the cradle-to-cradle life cycles of utility-scale c-Si PV systems in the United States through 2100. We present case studies for solar flat glass and aluminum frame materials under various scenarios to project the impacts of PV performance, reliability, and processing parameters, material circularity strategies, and module design shifts. In the absence of circularity measures, ~100 million MT of flat glass and ~12 million MT of aluminum would be needed for PV installations by 2100 to meet projected growth in domestic utility PV demand to nearly 1000 TWh in 2100. With optimistic but feasible improvements in efficiency, reliability, and circularity, material intensity and waste could be reduced by nearly 50%. Efficient module collection, minimally intrusive recycling, and careful scrap handling and cleaning could improve material circularity in the PV value chain. This model serves as a sustainability data support tool that may aid in the circular economy transition for PV systems.

circular economy↗
NASA NTRS1988

Electrochemical and galvanic corrosion effects in thin-film photovoltaic modules

The electrochemical and galvanic corrosion properties of thin-film photovoltaic (TF-PV) modules and module subcomponents are determined and interpreted in the light of established corrosion science. Results of a detailed study of thin-film aluminum metallization corrosion are presented. Bar-graph corrosion, observed in fielded modules, has been induced experimentally and found to be electrochemical in nature. Corrosion rates and passivation techniques for TF-PV modules are discussed.

Mon, G.↗
DOE OSTI2016

Potential-induced degradation in photovoltaic modules: a critical review

Potential-induced degradation (PID) has received considerable attention in recent years due to its detrimental impact on photovoltaic (PV) module performance under field conditions. Both crystalline silicon (c-Si) and thin-film PV modules are susceptible to PID. While extensive studies have already been conducted in this area, the understanding of the PID phenomena is still incomplete and it remains a major problem in the PV industry. Herein, a critical review of the available literature is given to serve as a one-stop source for understanding the current status of PID research. This article also aims to provide an overview of future research paths to address PID-related issues. This paper consists of three parts. In the first part, the modelling of leakage current paths in the module package is discussed. The PID mechanisms in both c-Si and thin-film PV modules are also comprehensively reviewed. The second part summarizes various test methods to evaluate PV modules for PID. The last part focuses on studies related to PID in the omnipresent p-type c-Si PV modules. The dependence of temperature, humidity and voltage on the progression of PID is examined. Preventive measures against PID at the cell, module and system levels are illustrated. Moreover, PID recovery in standard p-type c-Si PV modules is also studied. Most of the findings from p-type c-Si PV modules are also applicable to other PV module technologies.

14 SOLAR ENERGY↗
NASA NTRS1989

Photovoltaic module on-orbit assembly for Space Station Freedom

One of the elements of the Space Station Freedom power system is the Photovoltaic (PV) module. These modules will be assembled on-orbit during the assembly phase of the program. These modules will be assembled either from the shuttle orbiter or from the Mobile Servicing Center (MSC). The different types of assembly operations that will be used to assemble PV Modules are described.

Sours, Thomas↗
NASA NTRS1989

Photovoltaic module on-orbit assembly for Space Station Freedom

One of the elements of the Space Station Freedom power system is the photovoltaic (PV) module. These modules will be assembled on-orbit during the assembly phase of the program. These modules will be assembled either from the Shuttle Orbiter or from the Mobile Servicing Center (MSC). The different types of assembly operations that will be used to assemble PV modules are described.

Sours, T.↗
NASA NTRS1990

Long-term photothermal/humidity testing of photovoltaic module polymer insulations and cover films

The life expectancies of Tedlar and other polymer films considered for use as cover materials in terrestrial photovoltaic (PV) modules were investigated by exposing them for more than 13,000 h on an outdoor test stand and for up to 10,000 h in several accelerated multistress environments. Visual observations and diagnostic analyses of weight and mechanical strength losses were periodically conducted to assess the nature and rate of degradation of mechanical properties and to assess the effects of film thickness and UV stabilizer content. Spectroscopic analyses of pristine and degraded materials linked weight and mechanical property losses to the underlying photothermal/photooxidation chemistry. It is shown that heavy doses of UV stabilizers prolong, while elevated temperatures shorten, the useful life of these materials; humidity plays only a minor role. The most heavily UV-stabilized films are expected to operate usefully in a PV module front-cover application for only five to ten years. The performance of none of the tested films appears consistent with the 20-30 year life goals of the PV industry.

Mon, G.↗
DOE OSTI2017

Numerical method for angle-of-incidence correction factors for diffuse radiation incident photovoltaic modules

Here, a numerical method is provided for solving the integral equation for the angle-of-incidence (AOI) correction factor for diffuse radiation incident photovoltaic (PV) modules. The types of diffuse radiation considered include sky, circumsolar, horizon, and ground-reflected. The method permits PV module AOI characteristics to be addressed when calculating AOI losses associated with diffuse radiation. Pseudo code is provided to aid users in the implementation, and results are shown for PV modules with tilt angles from 0° to 90°. Diffuse AOI losses are greatest for small PV module tilt angles. Including AOI losses associated with the diffuse irradiance will improve predictions of PV system performance.

14 SOLAR ENERGY↗
DOE OSTI2015

Ultraviolet Radiation Round-Robin Testing of Various Backsheets for Photovoltaic Modules

Durability testing of materials exposed to natural weathering requires testing of the ultraviolet (UV) stability, especially for polymeric materials. The type approval testing of photovoltaic (PV) modules according to standards IEC 61215 and IEC 61646, which includes a so-called UV preconditioning test with a total UV dose of 15 kWh/m2, does not correspond to the real loads during lifetime. Between 3%-10% of the UV radiation has to be in the spectral range between 280 and 320 nm (UV-B) in the recent editions of the standards. However, the spectral distribution of the radiation source is very important because different samples show very individual spectral sensitivity for the radiation offered. Less than 6% of the intensity of solar radiation exists in the UV range. In the case of an increase of the intensity of the light source for accelerating the UV test, overheating of the samples would have to be prevented more rigorously and the temperature of the samples have to be measured to avoid misinterpretation of the test results.

14 SOLAR ENERGY↗
DOE OSTI2019

Strong Attraction and Adhesion Forces of Dust Particles by System Voltages of Photovoltaic Modules

We report for the first time on direct measurements using atomic force microscopy (AFM) of electric field induced attraction and adhesion forces associated with soiling on photovoltaic (PV) modules. Real dust particles and silica spheres as surrogate to simulating dust particles were glued to AFM probe cantilevers. The electric field induced force (Fes) was measured via AFM force-distance (f-z) curves, where the electric field was generated by applying a voltage (Vs) to a simulated PV module. Fes and van der Waals (Fvw) force contributions could be separated with the f-z curves. The results show that Fes ~2.5 u N on dust particles is ~5 times larger than Fvw ~0.5 u N at even Vs = -100 V (i.e., similar to large-module operating voltages). Fes increases by an order of magnitude as the applied potential increases from Vs = -100 V to Vs = -500 V. These adhesion forces are by far the strongest that we have measured using the AFM technique for 'initial' contact of particles. Furthermore, unlike the more typical short-range forces of Fvw and liquid bridge, Fes extends sub-millimeters to a millimeter beyond the PV module surface, creating large attraction forces to even uncharged dust particles (i.e., via induced dipoles) in the air. These results indicate that the high voltages typically used with PV arrays today will attract more dust particles from the air, hold the dust particles to the surface very strongly, and potentially induce other PV module surface effects, all of which could increase the power production losses because of soiling.

14 SOLAR ENERGY↗
DOE OSTI2023

Accelerated Stress Testing of Perovskite Photovoltaic Modules: Differentiating Degradation Modes with Electroluminescence Imaging

Herein, electroluminescence (EL) and thermal imaging are used to examine p–i–n metal halide perovskite (MHP) photovoltaic (PV) mini-modules (MA0.6FA0.4PbI3, 20 cells, 78 cm2) before and after indoor-accelerated stress testing or outdoor deployment. Distinct spatial patterns in the EL images emerge, which depend on the external stress conditions experienced by the mini-module. Imaging results highlight a distribution of dark speckle features that dominate after UV stress, attributed to widespread interfacial contact degradation. Lateral intensity gradients across cells dominate after thermal cycling (TC) stress, attributed to current crowding near scribe defects. While current–voltage analysis alone does not give full insight on the degradation process, this study shows that distinct degradation modes can be further defined by multimodal electro-optical imaging (i.e., EL combined with photoluminescence and dark lock-in thermography). Neither UV exposure nor TC-accelerated stress testing alone replicates the same degradation signatures observed after outdoor deployment, suggesting that multiple degradation modes occur under concurrent stressors outdoors. Finally, spatial characterization of degradation modes in MHP PV mini-modules before and after accelerated stress testing lays the groundwork for developing targeted accelerated stress testing procedures through comparison with outdoor aging.

14 SOLAR ENERGY↗