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Technique development and test methods for improvement of polytetrafluoroethylene films for bladder expulsion
Adhesives, coatings, coated fabrics, elastomers, encapsulants, films, hardware and structural materials, and tapes are tested in a series of physical, mechanical, and electrical tests. Material properties are measured before and after exposure to the three environments.
Ultrahigh vacuum system with accurate tensile test capability for material and lubricant tests
Apparatus for determining volatile condensable material present in polymeric products
A literature survey, materials reformulation and tailoring, fabrication problems, and materials selection and evaluation for fabricating models to be used with the phase-change technique for obtaining quantitative aerodynamic heat transfer data are presented. The study resulted in the selection of two best materials, stycast 2762 FT, and an alumina ceramic. Characteristics of these materials and detailed fabrication methods are presented.
Sound-absorption coefficients are measured with or without anechoic chamber.
The potentially useful encapsulating materials for Task 3 of the Low-Cost Silicon Solar Array project were studied to identify, evaluate, and recommend encapsulant materials and processes for the production of cost-effective, long-life solar cell modules. Materials for study were chosen on the basis of existing knowledge of generic chemical types having high resistance to environmental weathering. The materials varied from rubbers to thermoplastics and presented a broad range of mechanical properties and processing requirements. Basic physical and optical properties were measured on the polymers and were redetermined after exposure to indoor artificial accelerated aging conditions covering four time periods. Strengths and weaknesses of the various materials were revealed and data was accumulated for the development of predictive methodologies. To date, silicone rubbers, fluorocarbons, and acrylic polymers appear to have the most promising combination of characteristics. The fluorocarbons may be used only as films, however, because of their high cost.
During this quarter, flat-plate solar collector systems were considered and six basic construction elements were identified: outer coatings, superstrates, pottants, substrates, undercoats, and adhesives. Materials surveys were then initiated to discover either generic classes or/and specific products to function as each construction element. Cost data included in the surveys permit ready evaluation of each material. Silicones, fluorocarbons, glass, and acrylic polymers have the highest inherent weatherability of materials studied to date. Only acrylics, however, combine low costs, environmental resistance, and potential processability. This class will receive particular emphasis.
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Article presents procedure where correction curve accounts for coincidental displacement and simplifies data analysis in three point bend test in field of materials testing. Method is applicable to any test in above field regardless of load displacement.
The results of an investigation of solar module encapsulation systems applicable to the Low-Cost Solar Array Project 1986 cost and performance goals are presented. Six basic construction elements were identified and their specific uses in module construction defined. A uniform coating basis was established for each element. The survey results were also useful in revealing price ranges for classes of materials and estimating the cost allocation for each element within the encapsulating cost goal. The six construction elements were considered to be substrates, superstrates, pottants, adhesives, outer covers and back covers.
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.
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.
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.
Encapsulant materials and processes for the production of cost effective, long life solar cell modules are identified, and evaluated. Ethylene vinyl acetate lamination pottant studies are conducted with respect to the time/temperature cure requirements for successful use of this compound. The time needed to produce successful gel contents are redetermined at a variety of temperatures and are related to the peroxide half life temperature curve. Formulation of the butyl acrylate syrup casting pottant is complete. The formulation contains an ultraviolet stabilizer system and is cured with an initiator that presents no shipping or handling hazards. The catalyzed syrup is stable at room temperature and has a pot life of at least an eight hour period of time. The syrup cures to a transparent rubber in 18 minutes at a temperature of 60 C.
Encapsulant materials and processes for the production of cost-effective, long-life solar cell modules were investigated. The following areas were explored: (1) soil resistant surface treatment; (2) corrosion protecting coatings from mild steel substrates; (3) primers for bonding module interfaces; and (4) RS/4 accelerated aging of candidate encapsulation compounds
Photovoltaic (PV) modules consist of a string of electrically interconnected silicon solar cells capable of producing practical quantities of electrical power when exposed to sunlight. To insure high reliability and long term performance, the functional components of the solar cell module must be adequately protected from the environment by some encapsulation technique. The encapsulation system must provide mechanical support for the cells and corrosion protection for the electrical components. The goal of the program is to identify and develop encapsulation systems consistent with the PV module operating requirements of 30 year life and a target cost of $0.70 per peak watt ($70 per square meter) (1980 dollars). Assuming a module efficiency of ten percent, which is equivalent to a power output of 100 watts per square meter in midday sunlight, the capital cost of the modules may be calculated to be $70.00 per square meter. Out of this cost goal, only 20 percent is available for encapsulation due to the high cost of the cells, interconnects, and other related components. The encapsulation cost allocation may then be stated as $14.00 per square meter, included all coatings, pottant and mechanical supports for the cells.
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.