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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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321 records · Page 18
All sourcesNASA NTRSDOE OSTI
NASA NTRS1999

Flexible Low-Mass Devices and Mechanisms Actuated by Electroactive Polymers

Miniature, lightweight, miser actuators that operate similar to biological muscles can be used to develop robotic devices with unmatched capabilities to impact many technology areas. Electroactive polymers (EAP) offer the potential to producing such actuators and their main attractive feature is their ability to induce relatively large bending or longitudinal strain. Generally, these materials produce a relatively low force and the applications that can be considered at the current state of the art are relatively limited. This reported study is concentrating on the development of effective EAPs and the resultant enabling mechanisms employing their unique characteristics. Several EAP driven mechanisms, which emulate human hand, were developed including a gripper, manipulator arm and surface wiper. The manipulator arm was made of a composite rod with an EAP actuator consisting of a scrolled rope that is activated longitudinally by an electrostatic field. A gripper was made to serve as an end effector and it consisted of multiple bending EAP fingers for grabbing and holding such objects as rocks. An EAP surface wiper was developed to operate like a human finger and to demonstrate the potential to remove dust from optical and IR windows as well as solar cells. These EAP driven devices are taking advantage of the large actuation displacement of these materials but there is need for a significantly greater actuation force capability.

Bar-Cohen, Y↗
DOE OSTI2023

Diffractive Multiplexing for High-Throughput Roll-to-Roll Laser Patterning of Flexible Organic Photovoltaic Modules (Final Report)

The purpose of this project is to demonstrate a cost-effective, high-throughput roll-to-roll (R2R) process for patterning of flexible, semitransparent organic photovoltaic (OPV) modules by developing diffractive optics-based laser multiplexing (DOL Multiplexing). DOL Multiplexing allows a single, high-powered laser source to perform parallel scribing across the R2R web width in a manner compatible with high process speeds. Such a process could have enormous benefits in terms of increased process speeds and reduced costs, both up-front capital costs, and long-term operational costs, over galvanometer-based step and scan methods or many-laser systems.

14 SOLAR ENERGY↗
DOE OSTI2022

High‐Performance Green Thick‐Film Ternary Organic Solar Cells Enabled by Crystallinity Regulation

Abstract The power conversion efficiency (PCE) of organic solar cells (OSCs) has reached high values of over 19%. However, most of the high‐efficiency OSCs are fabricated by spin‐coating with toxic solvents and the optimal photoactive layer thickness is limited to 100 nm, limiting practical development of OSCs. It is a great challenge to obtain ideal morphology for high‐efficiency thick‐film OSCs when using non‐halogenated solvents due to the unfavorable film formation kinetics. Herein, high‐efficiency ternary thick‐film (300 nm) OSCs with PCE of 15.4% based on PM6:BTR‐Cl:CH1007 are fabricated by hot slot‐die coating using non‐halogenated solvent (o‐xylene) in the air. Compared to PM6:BTR‐Cl:Y6 blends, the stronger pre‐aggregation of CH1007 in solution induces the earlier aggregation of CH1007 molecules and longer aggregation time, and thus results in high and balanced crystallinity of donors and acceptor in CH1007‐based ternary film, which led to high‐carrier mobility and suppressed charge recombination. The ternary strategy is further used to fabricate high‐efficiency, thick‐film, large‐area, and flexible devices processed from non‐halogenated solvents, paving the way for industrial development of OSCs.

Chemistry↗
DOE OSTI2023

Investigation of Reactive Silver Ink Formula for Reduced Silver Consumption in Silicon Heterojunction Metallization

Silver is the most expensive non-silicon component in photovoltaic cells. This is particularly salient for silicon heterojunction (SHJ) cells, which rely on large quantities of low-temperature silver pastes (LT-SP). SHJ cells would benefit greatly from an industrially scalable metallization process that simultaneously offers low silver consumption, low finger resistivities (<20 μΩ·cm), and low processing temperatures. Printed reactive silver inks (RSI) are an innovative candidate to this end. Furthermore, this work furthers the research on RSI metallization by investigating the impact of ink formula on properties pertinent to SHJ cells, including electrical properties, line width, ink splatter, silver consumption, cell performance, and adhesion. We introduce a scalable, high-throughput flexible needle contact printing approach for metallization that solves many of the issues associated with drop-on-demand printing. The printed silver fingers are characterized using electrical measurements and top-down and cross-sectional microscopy. The best performing ink, consisting of silver acetate, ethylamine, and formic acid, achieved silver fingers with total resistivities of 3.1 μΩ·cm and contact resistivities of 3.2 mΩ·cm 2 when printed at 61 °C. This ink metallized a full-sized 156 mm × 156 mm SHJ cell. This is the first reported data for RSI metallization of a full-sized SHJ cell and shows how an optimized RSI can achieve similar performances to LT-SP while consuming 80–90% less silver.

14 SOLAR ENERGY↗
DOE OSTI2023

Biomethanation to Upgrade Biogas to Pipeline Grade Methane

NREL is working closely with DOE, Electrochaea GmbH, and Southern California Gas Company (SoCalGas) to reduce costs of a biomethanation process capable of megawatt-scale deployment that upgrades organic biogas waste streams to produce pipeline quality renewable natural gas (RNG). Biomethanation is a two-step process using a single-celled methanogenic archaea that converts low-carbon low-cost hydrogen (H2) and waste carbon dioxide (CO2) to produce renewable methane (CH4). The process upgrades the biogenic CO2 - while allowing the CH4 to pass through - from biogas sources like dairies, wastewater treatment plants, and landfills. The CH4 produced is a drop-in direct replacement fuel and producers can participate in the growing number of carbon markets; like California's Low Carbon Fuel Standard and the Federal Renewable Fuel Standard. NREL and Argonne National Laboratory have completed a life cycle analysis using the GREET model to show that the biomethanation process produces RNG that is carbon negative even when H2 production via low-temperature water electrolysis is driven by the existing carbon intensity of California's electricity grid. And of course, even further carbon negative (-233 kg CO2e/kWh) when the electricity is produced from low-carbon sources like wind and solar. Leveraging lessons learned from operating SoCalGas' 700L 18-bar bioreactor system, NREL is designing and building a flexible RD&D platform that will enable field trials at biogas and other CO2 sources. A custom 16' long trailer will house a 20L 18-bar bioreactor, 3 - 25 kW proton exchange membrane electrolyzer, and dosing, thermal, and controls systems to support operations with only power, biogas, and water feedstocks required by the field locations. The end-of-project goal is to demonstrate pipeline quality RNG production (> 95% CH4, < 4% H2, <1% CO2, < 0.2% O2 and < 4 parts per million H2 sulfide) using real biogas feedstocks - thereby recycling both greenhouse gases for injection into the natural gas network or to be used onsite.

biogas upgrading↗
DOE OSTI2021

Copper Electrode on Flexible Substrate by Intense Pulsed Light Sintering of Microsized Copper Particles

Metal electrodes deposited in a grid pattern onto flexible polymer substrates have been shown to be a viable alternative to replace indium tin oxide (ITO) as the transparent anode for organic photovoltaics. copper may be a better alternative in terms of cost and stability for large area low-cost solar modules, specifically on roll-to-roll platforms. These customized electrode patterns can be fabricated from copper nanoparticles through various printing techniques applicable to solution phase processing. The Intense Pulsed Light (IPL) technique has been used to sinter copper nanoparticles (~100nm) to fabricate conductive copper electrodes on flexible polymer substrates. However, compared to nanosized (~100 nm) copper particles, microsized (~2 um) copper is much cheaper. In this work, microsized (~2 um) copper is used to produce high conductive copper inks. The conductivity of the print can be adjusted through the use of surfactant. IPL sintering was optimized to obtain high conductivity copper films. In conclusion, several microscopic and electrical spectroscopic characterization techniques such as scanning electron microscopy (SEM), x-ray diffraction (XRD), 4-point probe resistivity measurements were employed to characterize the copper electrodes.

14 SOLAR ENERGY↗
NASA NTRS2000

Thin-Film Photovoltaic Solar Array Parametric Assessment

This paper summarizes a study that had the objective to develop a model and parametrically determine the circumstances for which lightweight thin-film photovoltaic solar arrays would be more beneficial, in terms of mass and cost, than arrays using high-efficiency crystalline solar cells. Previous studies considering arrays with near-term thin-film technology for Earth orbiting applications are briefly reviewed. The present study uses a parametric approach that evaluated the performance of lightweight thin-film arrays with cell efficiencies ranging from 5 to 20 percent. The model developed for this study is described in some detail. Similar mass and cost trends for each array option were found across eight missions of various power levels in locations ranging from Venus to Jupiter. The results for one specific mission, a main belt asteroid tour, indicate that only moderate thin-film cell efficiency (approx. 12 percent) is necessary to match the mass of arrays using crystalline cells with much greater efficiency (35 percent multi-junction GaAs based and 20 percent thin-silicon). Regarding cost, a 12 percent efficient thin-film array is projected to cost about half is much as a 4-junction GaAs array. While efficiency improvements beyond 12 percent did not significantly further improve the mass and cost benefits for thin-film arrays, higher efficiency will be needed to mitigate the spacecraft-level impacts associated with large deployed array areas. A low-temperature approach to depositing thin-film cells on lightweight, flexible plastic substrates is briefly described. The paper concludes with the observation that with the characteristics assumed for this study, ultra-lightweight arrays using efficient, thin-film cells on flexible substrates may become a leading alternative for a wide variety of space missions.

Hoffman, David J.↗
DOE OSTI2020

The Technical and Economic Potential of the H2@Scale Hydrogen Concept within the United States

The U.S. energy system is evolving as society and technologies change. Renewable electricity generation - especially from wind and solar - is growing rapidly, and alternative energy sources are being developed and implemented across the residential, commercial, transportation, and industrial sectors to take advantage of their cost, security, and health benefits. Systemic changes present numerous challenges to grid resiliency and energy affordability, creating a need for synergistic solutions that satisfy multiple applications while yielding system-wide cost and emissions benefits. One such solution is an integrated hydrogen energy system. This is the focus of H2@Scale - a U.S. Department of Energy (DOE) initiative led by the Office of Energy Efficiency and Renewable Energy’s Hydrogen and Fuel Technologies Office. H2@Scale brings together stakeholders to advance affordable hydrogen production, transport, storage, and utilization in multiple energy sectors. The H2@Scale concept involves hydrogen as an energy intermediate. Hydrogen can be produced from various conventional and renewable energy sources including as a responsive load on the electric grid. Hydrogen has many current applications and many more potential applications, such as energy for transportation - used directly in fuel cell electric vehicles (FCEVs), as a feedstock for synthetic fuels, and to upgrade oil and biomass - feedstock for industry (e.g., for ammonia production, metals refining, and other end uses), heat for industry and buildings, and electricity storage. Owing to its flexibility and fungibility, a hydrogen intermediate could link energy sources that have surplus availability to markets that require energy or chemical feedstocks, benefiting both. This document builds upon a growing body of analyses of hydrogen as an energy intermediate by reporting the results from our initial analysis of the potential impacts of the H2@Scale vision by the mid-21 st century for the 48 contiguous U.S. states. Previous estimates have been based on expert elicitation and focused on hydrogen demands. We build upon them, first, by estimating hydrogen’s serviceable consumption potential for possible hydrogen applications and the technical potential for producing hydrogen from various resources. We define the serviceable consumption potential as the quantity of hydrogen that would be consumed to serve the portion of the market that could be captured without considering economics (i.e., if the price of hydrogen were $0/kg over an extended period); thus, it can be considered an upper bound for the size of the market. We define the technical potential as the resource potential constrained by real-world geography and system performance, but not by economics. We then compare the cumulative serviceable consumption potential with the technical potential of a number of possible sources. Second, we estimate economic potential: the quantity of hydrogen at an equilibrium price at which suppliers are willing to sell and consumers are willing to buy the same quantity of hydrogen. We believe this method provides a deeper understanding than was available in the previous analyses. We develop economic potentials for multiple scenarios across various market and technology-advancement assumptions.

08 HYDROGEN↗
NASA NTRS2011

Power and Propulsion System Design for Near-Earth Object Robotic Exploration

Near-Earth Objects (NEOs) are exciting targets for exploration; they are relatively easy to reach but relatively little is known about them. With solar electric propulsion, a vast number of interesting NEOs can be reached within a few years and with extensive flexibility in launch date. An additional advantage of electric propulsion for these missions is that a spacecraft can be small, enabling a fleet of explorers launched on a single vehicle or as secondary payloads. Commercial, flight-proven Hall thruster systems have great appeal based on their performance and low cost risk, but one issue with these systems is that the power processing units (PPUs) are designed for regulated spacecraft power architectures which are not attractive for small NEO missions. In this study we consider the integrated design of power and propulsion systems that utilize the capabilities of existing PPUs in an unregulated power architecture. Models for solar array and engine performance are combined with low-thrust trajectory analyses to bound spacecraft design parameters for a large class of NEO missions, then detailed array performance models are used to examine the array output voltage and current over a bounded mission set. Operational relationships between the power and electric propulsion systems are discussed, and it is shown that both the SPT-100 and BPT-4000 PPUs can perform missions over a solar range of 0.7 AU to 1.5 AU - encompassing NEOs, Venus, and Mars - within their operable input voltage ranges. A number of design trades to control the array voltage are available, including cell string layout, array offpointing during mission operations, and power draw by the Hall thruster system.

Near Earth Object (NEO)↗
NASA NTRS1993

A photovoltaic catenary-tent array for the Martian surface

To provide electrical power during an exploration mission to Mars, a deployable tent-shaped structure with a flexible photovoltaic (PV) blanket is proposed. The array is designed with a self-deploying mechanism utilizing pressurized gas expansion. The structural design for the array uses a combination of cables, beams, and columns to support and deploy the PV blanket. Under the force of gravity a cable carrying a uniform load will take the shape of a catenary curve. A catenary-tent collector is self shadowing which must be taken into account in the solar radiation calculation. The shape and the area of the shadow on the array was calculated and used in the determination of the global radiation on the array. The PV blanket shape and structure dimension were optimized to achieve a configuration which maximizes the specific power (W/kg). The optimization was performed for four types of PV blankets (Si, GaAs/Ge, GaAs CLEFT, and amorphous Si) and four types of structure materials (Carbon composite, Aramid Fiber composite, Aluminum, and Magnesium). The results show that the catenary shape of the PV blanket, which produces the highest specific power, corresponds to zero end angle at the base with respect to the horizontal. The tent angle is determined by the combined effect of the array structure specific mass and the PV blanket output power. The combination of carbon composite structural material and GaAs CLEFT solar cells produce the highest specific power. The study was carried out for two sites on Mars corresponding to the Viking Lander locations. The designs were also compared for summer, winter, and yearly operation.

Crutchik, M.↗
DOE OSTI2020

Colloidal Quantum Dot Photovoltaics: Current Progress and Path to Gigawatt Scale Enabled by Smart Manufacturing

Colloidal quantum dots (QDs) have lately been pursued with intense vigor for optoelectronic applications such as photovoltaics (PV), flexible electronics, displays, mid-infrared photodetectors, lasers, and single-photon emitters. These nanometer-sized semiconducting crystals can be suitably mass-produced and size-tuned via cost-effective solution-based synthetic routes to operate in the quantum size confinement regime, endowing them with a wide array of exotic optical and electronic properties. While the first potential market entry could be in displays and in niche applications such as “internet-of-things”, ultimately, the technology has the potential to influence large-scale terrestrial power generation, because it is amenable to high-throughput synthesis from Earth-abundant materials and large-area solution-based coating techniques and can be air-stable. In this Review, we chronicle the recent advances that have propelled QD PV toward commercialization and highlight potential areas for further progress. We present an account of the material compositions being explored as QDs and their various benefits, major chemical passivation and doping strategies that have been developed to allay QD surface traps, and advanced device designs deployed to maximize charge extraction. We also discuss pathways to >20% efficient QD PV and describe recent advances in high-precision and autonomous synthesis of such materials. With recent demonstrations of scalable synthesis of high-quality QDs, smart manufacturing of QDs and QD solids, and fabrication of stable solar cells under ambient conditions, we suggest that the technology is on the road to achieving maturity and technological relevance and that gigawatt per year distributed panel production sites may be within reach.

14 SOLAR ENERGY↗
NASA NTRS2021

Relocatable 10 kW Solar Array for Lunar South Pole Missions

Deployable, relocatable, free-standing solar arrays are being developed to provide modular power for future lunar South Pole missions. Major design requirements for these arrays will be low mass, compact launch stowage, and highly reliable deployment and retraction. This paper presents a novel conceptual design for a10 kW solar array to address these requirements referred to as the Relocatable Solar Array (RSA).Simply stated, the concept is a pair of solar cell blankets freely hanging from a horizontal cross arm supported by a vertical, slender, telescoping mast resting on a deployable tripod base. A major factor in simplifying the design is that the force exerted by lunar gravity is used to deploy and maintain extension of the hanging array blankets. A second major factor in achieving the desired low mass and high volumetric efficiency is that the array operates in the vacuum, low-gravity, lunar environment with no deployed vibration frequency requirement. Such a low-load environment enables use of extraordinarily slender and low mass structural members to support the hanging array blankets. This concept was developed, in part, to serve as a NASA reference solar array concept against which other proposed arrays can be compared.

Lunar Surface Power↗
DOE OSTI2026

Innovative Interfacial Engineering for Simultaneous Enhancement in Efficiency, Stability, and Reliability in Perovskite Devices

The overarching objective of this project was to increase significantly the mechanical adhesion toughness of the key interfaces in PSCs, thereby improving the durability and reliability of PSCs and minimodules, while simultaneously enhancing their PCE. This is achieved by incorporating rationally-chosen self-assembled monolayers (SAMs) at key PSC interfaces. Inherently scalable methods for the deposition of MHP light-absorber thin films and SAMs are employed to ensure a viable path towards manufacturability. Furthermore, detailed understanding of mechanisms of PSCs and minimodules degradation, and SAMs-induced mitigation, is provided. As part of the project accomplishments, >60% increase in the adhesion toughness of the key PSC interfaces over their SAMs-free control counterparts was achieved. Also, PCEs >20% and >19% in rigid and flexible, respectively, single-junction PSCs (~1 cm 2 area) were achieved. It was shown that <20% PCE loss in flexible PSCs with SAMs can be achieved after bend testing. It was demonstrated that T80 (80% retention of initial PCE) of >5,000 hours in rigid PSCs (~1 cm2 area) can be achieved. Comprehensive understanding of the degradation mechanisms in PSCs was obtained. These strategies were adopted towards developing minimodules. PCE of >21% was obtained in an 6-cm 2 area minimodule, with T91 of 1,000 hours.

14 SOLAR ENERGY↗
NASA NTRS2016

Europa Spacecraft Configuration Optimization for the Solar Powered Vehicle

A mission to Europa has been on the minds of NASA and JPL for many years. After the Galileo mission to Jupiter in the 1990s there have been various proposals for missions to the Jovian moon. The most recent proposal, previously named the Europa Clipper, has gone through numerous iterations of spacecraft configurations on its road to becoming an official NASA project in June of 2015. Most of these configurations included options for either multi mission radioisotope thermoelectric generators (MMRTGs) or solar power. In 2014, the decision was made to focus on solar arrays as the source for spacecraft power. The decision to move forward with a baseline design that utilized only solar arrays as its power system meant that some configuration choices had to be re- evaluated. Initially, a configuration was adapted to keep as much of the previous spacecraft design the same while replacing MMRTGs with solar panels. This proved to be difficult as the arrays presented a slew of new challenges that the nuclear vehicle was not optimized for. The solar arrays needed to be large due to Jupiter's substantial distance from the Sun. This meant that many of the instrument and radiator FOVs would now be obstructed, or would receive reflected light and heat from the large panel s. Also, the mass of the panels meant that mounting near the bottom of the spacecraft would be sub-optimal as the wings would cause major disturbance to the vehicle as they oscillated in their deployed state. Another major, and possibly the largest, concern was the fact that as the high gain antenna pointed to Earth for communication, the Ice Penetrating Radar (IPR) would cast a large shadow on the cell -side of the array. This resulted in an estimated 10% power loss to the vehicle. On top of all this, NASA announced the selection of the instruments that would fly on the Europa mission and replace the notional instrument suite that had been used to develop and submit the project proposal. The selected instruments, while not varying widely from the notional suite, did come with a new set of challenges including a size increase over the notional package, thus requiring more room for accommodation. They also introduced new features not previously addressed by the notional package, such as a two-axis gimbal on one of the imagers. Additionally, two new instruments, an ultraviolet plume -hunting spectrograph, and an atmospheric dust analyzer we added to the payload and presented new challenges not previously covered in the proposal. Finally, additional payloads were under consideration, such as a 250kg ejectable payload that would be released at Jupiter and would accomplish flybys of some of the other Jovian moons. All of this resulted in a drastically different "family" of configurations that were capable of addressing these issues, and staying flexible to the numerous potential changes that could come. This paper discusses the details of the various configurations considered to address these items, and the configuration concepts that were selected as the baseline for moving forward with the proposal.

Horner, Matthew D.↗
NASA NTRS2007

Ultra-Thin, Triple-Bandgap GaInP/GaAs/GaInAs Monolithic Tandem Solar Cells

The performance of state-of-the-art, series-connected, lattice-matched (LM), triple-junction (TJ), III-V tandem solar cells could be improved substantially (10-12%) by replacing the Ge bottom subcell with a subcell having a bandgap of approx.1 eV. For the last several years, research has been conducted by a number of organizations to develop approx.1-eV, LM GaInAsN to provide such a subcell, but, so far, the approach has proven unsuccessful. Thus, the need for a high-performance, monolithically integrable, 1-eV subcell for TJ tandems has remained. In this paper, we present a new TJ tandem cell design that addresses the above-mentioned problem. Our approach involves inverted epitaxial growth to allow the monolithic integration of a lattice-mismatched (LMM) approx.1- eV GaInAs/GaInP double-heterostructure (DH) bottom subcell with LM GaAs (middle) and GaInP (top) upper subcells. A transparent GaInP compositionally graded layer facilitates the integration of the LM and LMM components. Handle-mounted, ultra-thin device fabrication is a natural consequence of the inverted-structure approach, which results in a number of advantages, including robustness, potential low cost, improved thermal management, incorporation of back-surface reflectors, and possible reclamation/reuse of the parent crystalline substrate for further cost reduction. Our initial work has concerned GaInP/GaAs/GaInAs tandem cells grown on GaAs substrates. In this case, the 1- eV GaInAs experiences 2.2% compressive LMM with respect to the substrate. Specially designed GaInP graded layers are used to produce 1-eV subcells with performance parameters nearly equaling those of LM devices with the same bandgap (e.g., LM, 1-eV GaInAsP grown on InP). Previously, we reported preliminary ultra-thin tandem devices (0.237 cm2) with NREL-confirmed efficiencies of 31.3% (global spectrum, one sun) (1), 29.7% (AM0 spectrum, one sun) (2), and 37.9% (low-AOD direct spectrum, 10.1 suns) (3), all at 25 C. Here, we include recent results of testing similar devices under the concentrated AMO spectrum, and also present the first demonstration of a high-efficiency, ultra-thin GaInP/GaAs/GaInAs tandem cell processed on a flexible kapton handle.

Wanlass, M. W.↗