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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 37 records · Page 2
All sourcesNASA NTRSDOE OSTI
NASA NTRS1978

Block 2 solar cell module environmental test program

Environmental tests were performed of on 76 solar cell modules produced by four different manufacturers. The following tests were performed: (1) 28 day temperature and humidity; (2) rain and icing; (3) salt fog; (4) sand and dust; (5) vacuum/steam/pressure; (6) fungus; (7) temperature/altitude; and (8) thermal shock. Environmental testing of the solar cell modules produced cracked cells, cracked encapsulant and encapsulant delaminations on various modules. In addition, there was some minor cell and frame corrosion.

Holloway, K. L.↗
DOE OSTI2022

Overall Performance Losses and Activated Mechanisms in Double Glass and Glass-backsheet Photovoltaic Modules with Monofacial and Bifacial PERC Cells, under Accelerated Exposures

Commercial PV modules have various packaging choices nowadays, which influence their long-term reliability. This study compared the degradation behaviors of sixteen module variants from two brands with varying encapsulant materials (EVA or POE), encapsulant types, module architectures (GB or DG), and cell types (monofacial or bifacial) using null hypothesis testing to determine statistical significant findings. The modules were exposed for 2,520 hours under two accelerated exposures: modified damp heat (mDH) and modified damp heat with full-spectrum light (mDH+FSL). For both brands, two DG module variants with UV-Cutoff rear encapsulant are found to have significantly lower average power loss than the module variants of EVA+GB with opaque rear encapsulant after each accelerated exposure. Metallization interconnect corrosion is identified as the primary degradation mechanism. Furthermore, unsupervised hierarchical clustering finds that the degradation behaviors of modules from one brand with a more strict manufacturing quality control depends on module architectures only.

14 SOLAR ENERGY↗
DOE OSTI2020

Accurate Efficiency Measurements for Emerging PV: A Comparison of NREL's Steady-State Performance Calibration Protocol Between Conventional and Emerging PV Technologies

Emerging PV technologies (e.g. Perovskite, and Quantum Dot) are commonly known to possess challenges for accurate performance measurement under the existing IEC 60904 series of standards, which were developed for conventional Si solar cells. Potential performance artifacts depending on scan rates and directions and light bias exposure history are often seen in those emerging solar cells. To avoid these artifacts and provide an unbiased and reliable efficiency measurement, NREL's Cell and Module Performance (CMP) Group has developed a steady-state performance calibration protocol - the asymptotic P MAX method. In this paper, we applied this procedure to four PV cell technologies, Si, CIGS, perovskite, and Quantum Dot (QD), and compared their performance variations between the transient and the steady-state conditions. By comparison, we found that the performance parameters ( i.e. V OC , I SC , FF, ..eta..) measured between fast I-V scans (and the asymptotic method (steady-state) change significantly for perovskite and QD cells. These changes do not happen for Si and CIGS cells. Furthermore, the statistical performance analysis on nearly 100 emerging cells received globally (including OPV, Perovskite, and QD) shows that over 70 % of the fast I-V scans have a relative performance deviation larger than 1% compared to those determined using the asymptotic P MAX scan. Given the complex dynamic behavior observed in emerging PV devices, the CMP group at NREL thus only certifies their steady steady-state performance using the Asymptotic P MAX method. We highly recommend similar steady-state performance calibration protocol for all researchers in emerging PV because accuracy in reported efficiencies is critical to the long-term success of those promising new PV technologies.

41 EE - Solar Energy Technologies Office (EE-4S)↗
DOE OSTI2013

Materials and Modules for Low Cost, High Performance Fuel Cell Humidifiers

The objective of this program was to demonstrate a durable, high performance water transport membrane; and a compact, low-cost, membrane-based module utilizing that membrane for use in an automotive, stationary and/or portable fuel cell water transport exchangers. Over the past 20 years, great technical progress has been made in improving power density and durability of fuel cell stacks. Yet, operating durably at high performance levels under very dry conditions, e.g., < 20% RH at 80°C or above, remains beyond even the best fuel cell membrane electrode assemblies. Thus, today it is essential to humidify the gases supplied to the fuel cell inlets. In this work, we have produced a new, inexpensive, composite membrane capable of very high water vapor transport and low air cross-over. The composite structure consists of a very thin ionomer layer (e.g., < 5 μm) sandwiched between two microporous polymer layers. The thin ionomer layer facilitates the rapid water transport and provides an impermeable layer to prevent gas cross-over. Such an approach reduces cost, but maintains performance. The microporous layer protects the thin ionomer layer from mechanical damage during handling; confers strength to the thin layer allowing it to be more durable during use; and allows it to withstand higher automotive pressures and temperatures. The composite structure will therefore allow lower total cost while still meeting automotive humidifier water transport and durability targets. Because the transport rates of these new materials are so high, existing planar membrane humidifier module designs available at the start of the program were incapable of efficiently utilizing the high rates. Therefore, the assembled team designed, tested and demonstrated an innovative, low-cost humidifier module with customized channel geometries that can take advantage of the high the water transport rates. The objectives of the program have been fully met. The optimized membrane produced in the program has very high transport rates, nearly twice that of the closest competitive option, a homogeneous perfluorosulfonic acid (PFSA) membrane. Furthermore, the composite structure imparts significant durability advantages, allowing the membrane to remain gas impermeable during 20,000 relative humidity (RH) cycles, unlike the closest competitive options that fail very rapidly. It does suffer from a loss of performance with time at temperature because of inherent properties of the PFSA polymer, but this degradation is manageable through relatively simple system design changes. The final membrane of this program has been produced on manufacturing level equipment in a roll to roll form in the scale of hundreds of square meters. The process is readily scalable to automotive level volumes to allow production of a low-cost membrane required for this application. A full scale automotive air-to-air humidifier module has been designed, tested and built. The final module meets the design specifications required for automotive fuel cell use, and exceeds all the DOE 2017 targets for a cathode humidification module as determined in independent testing at Ford Motor Company. It has a small volume, less than 5 liters; a high water transfer rate, significantly greater than 5 g/s at the DOE specified conditions; acceptably low pressure drop; and is projected to maintain these properties over 5000 hours. Additionally, high volume cost projections suggest that the module can be produced for less than $\$$100 per unit in a scale of 500,000 units per year.

08 HYDROGEN↗
DOE OSTI2016

Photovoltaic Calibrations at the National Renewable Energy Laboratory and Uncertainty Analysis Following the ISO 17025 Guidelines

The measurement of photovoltaic (PV) performance with respect to reference conditions requires measuring current versus voltage for a given tabular reference spectrum, junction temperature, and total irradiance. This report presents the procedures implemented by the PV Cell and Module Performance Characterization Group at the National Renewable Energy Laboratory (NREL) to achieve the lowest practical uncertainty. A rigorous uncertainty analysis of these procedures is presented, which follows the International Organization for Standardization (ISO) Guide to the Expression of Uncertainty in Measurement. This uncertainty analysis is required for the team’s laboratory accreditation under ISO standard 17025, “General Requirements for the Competence of Testing and Calibration Laboratories.” The report also discusses additional areas where the uncertainty can be reduced.

14 SOLAR ENERGY↗
NASA NTRS1995

One year of flight data from the PASP-Plus experiment

The PASP-Plus (Photovoltaic Array Space Power Plus Diagnostics) program is a photovoltaic experiment which is flying on the Air Force satellite APEX (Advanced Photovoltaic and Electronics Experiments). The satellite was launched on August 3, 1994 with a Pegasus low-cost launch vehicle. There are two other small experiments on APEX, however PASP-Plus is the largest, uses the most power, and accounts for the largest portion of the data requirements. The satellite is in an elliptical orbit with an apogee of 2552 km and a perigee of 363 km. The inclination is 70 degrees. The PASP-Plus experiment consists of twelve photovoltaic panels containing a total of sixteen separate cell modules. Two of the modules are concentrator modules, while the rest are planar. There are several different solar cell types flying on PASP-Plus including silicon, GaAs on germanium substrates, InP, amorphous silicon, and three multi-bandgap cells. The purpose of this paper is to present some of the data from the first year of the PASP-Plus flight. Cell performance and module thermal performance will be discussed as well as other relevant data.

Curtis, Henry↗
DOE OSTI2023

Engineering Perovskite Precursor Inks for Scalable Production of High‐Efficiency Perovskite Photovoltaic Modules

Abstract Blade coating of perovskite solar cells (PSCs) and modules has progressed considerably toward the industrial production of perovskite photovoltaics. Developing stable perovskite precursors is critical for achieving uniform coating over large areas. Here, the engineering of a perovskite precursor solution consisting of 2‐methoxyethanol (2‐Me) and 1,3‐dimethyl‐imidazolidinone (DMI) with superior intermediate phase stability that enables scalable production of efficient perovskite solar modules is reported. With this perovskite precursor solution, uniform and pinhole‐less perovskite film is deposited over a large area of > 100 cm 2 and higher‐efficiency PSCs and modules are obtained. The best‐performing unit cell and module with n‐i‐p configuration reach power conversion efficiencies of 23.4% and 20.1%, respectively. Additionally, a series of non‐destructive metrology methods, such as spectroscopic ellipsometry, hyperspectral photoluminescence, electroluminescence, and laser beam‐induced current mapping, are employed to assess and guide the development the blade‐coated perovskite modules. This results show that rational engineering of precursor inks for blade coating is promising for the scalable production of efficient perovskite solar modules.

36 MATERIALS SCIENCE↗
DOE OSTI2015

Contactless Electroluminescence Imaging for Cell and Module Characterization

Module performance can be characterized by imaging using baseline and periodic images to track defects and degradation. Both thermal images, which can be acquired during sunny operating conditions, and photoluminescence images, which could be acquired at night, can be collected without electrical connection. Electroluminescence (EL) images, which are useful to detect many types of defects such as cracks, interconnect and solder faults, and resistances, have typically required electrical connection to drive current in the cells and modules. Here, a contactless EL imaging technique is proposed, which provides an EL image without the need for electrical connection to drive current through the module. Such EL imaging has the capability to be collected at night without disruption to daytime power generation.

14 SOLAR ENERGY↗
NASA NTRS1983

Qualification and testing of modules

The experience gained in procuring solar modules soon to be installed on the Photovoltaic Higher Education National Exemplar Facility (PHENEF) at Georgetown University is discussed. The 300 KE Photovoltaic Array consists of 4464, 2' X 4', polycrystalline solar cell modules. The performance requirements for the modules are described in a detailed procurement specification which defines physical and electrical characteristics and extensive quality assurance provisions including requirements for an interface control drawing and qualification and acceptance testing.

Cohen, D. B.↗
NASA NTRS1978

Block 4 solar cell module design and test specification for intermediate load center applications

Requirements for performance of terrestrial solar cell modules intended for use in various test applications are established. During the 1979-80 time period, such applications are expected to be in the 20 to 500 kilowatt size range. A series of characterization and qualification tests necessary to certify the module design for production, and the necessary performance test for acceptance of modules are specified.

Source record↗
NASA NTRS1974

Reliability analysis of Skylab ATM solar cell modules

A detailed reliability analysis was performed on both types of Skylab Apollo telescope mount solar cell modules. Failure rates used were based on testing of several modules of each type for over 4000 thermal cycles. The analysis delineated several important differences between the failure modes of the two differently designed solar cell modules, and, more importantly, showed that the modules can be expected to meet all mission requirements.

Jones, G. M.↗
DOE OSTI2013

Materials and Modules for Low Cost, High Performance Fuel Cell Humidifiers (Final Report)

Over the past 20 years, great technical progress has been made in improving power density and durability of fuel cell stacks. Yet, operating durably at high performance levels under very dry conditions, e.g., < 20% RH at 80 °C or above, remains beyond even the best fuel cell membrane electrode assemblies. Thus, today it is essential to humidify the gases supplied to the fuel cell inlets. In this work, we have produced a new, inexpensive, composite membrane capable of very high water vapor transport and low air cross-over. The composite structure consists of a very thin ionomer layer (e.g., < 5 μm) sandwiched between two microporous polymer layers. The thin ionomer layer facilitates the rapid water transport and provides an impermeable layer to prevent gas cross-over. Such an approach reduces cost, but maintains performance. The microporous layer protects the thin ionomer layer from mechanical damage during handling; confers strength to the thin layer allowing it to be more durable during use; and allows it to withstand higher automotive pressures and temperatures. The composite structure will therefore allow lower total cost while still meeting automotive humidifier water transport and durability targets. Because the transport rates of these new materials are so high, existing planar membrane humidifier module designs available at the start of the program were incapable of efficiently utilizing the high rates. Therefore, the assembled team designed, tested and demonstrated an innovative, low-cost humidifier module with customized channel geometries that can take advantage of the high the water transport rates. Program Results: The objectives of the program have been fully met. The optimized membrane produced in the program has very high transport rates, nearly twice that of the closest competitive option, a homogeneous perfluorosulfonic acid (PFSA) membrane. Furthermore, the composite structure imparts significant durability advantages, allowing the membrane to remain gas impermeable during 20,000 relative humidity (RH) cycles, unlike the closest competitive options that fail very rapidly. It does suffer from a loss of performance with time at temperature because of inherent properties of the PFSA polymer, but this degradation is manageable through relatively simple system design changes. The final membrane of this program has been produced on manufacturing level equipment in a roll to roll form in the scale of hundreds of square meters. The process is readily scalable to automotive level volumes to allow production of a low-cost membrane required for this application. A full scale automotive air-to-air humidifier module has been designed, tested and built. The final module meets the design specifications required for automotive fuel cell use, and exceeds all the DOE 2017 targets for a cathode humidification module as determined in independent testing at Ford Motor Company. It has a small volume, less than 5 liters; a high water transfer rate, significantly greater than 5 g/s at the DOE specified conditions; acceptably low pressure drop; and is projected to maintain these properties over 5000 hours. Additionally, high volume cost projections suggest that the module can be produced for less than $100 per unit in a scale of 500,000 units per year.

08 HYDROGEN↗
DOE OSTI2019

Battery Thermal Characterization

A well-designed thermal management system is critical to the life and performance of electric-drive vehicles (EDVs) hybrids (HEVs), plug-in hybrids (PHEVs), and all-electric vehicles (EVs). Temperature and temperature uniformity both significantly affect the performance, lifespan, and safety of vehicle energy storage devices. NREL conducts thermal management research and development (R&D) to optimize battery performance and extend useful life. A recognized leader in battery thermal analysis and characterization, NREL evaluates electrical and thermal performance of battery cells, modules, and packs, full energy storage systems, and the interaction of these systems with other vehicle components. The lab's performance assessments factor in the design of the thermal management system, the thermal behavior of the cell, battery lifespan, and safety of the energy storage system, as well as full integration into a vehicle. The lithium-ion (Li-ion) batteries found in most of today's electric-drive vehicles are smaller and more lightweight than previous nickel-metal hydride (NiMH) technology, but they are also more sensitive to overheating, overcharging, and extreme spikes in temperature known as thermal runaway. High temperatures diminish battery life and increase battery replacement costs, while low temperatures decrease battery power and capacity, all of which impact vehicle range, performance, and affordability. NREL's breakthrough research is focused on reducing thermal barriers to achieve more uniform temperatures. NREL uses its R&D 100 Award-winning Isothermal Battery Calorimeters, the only instruments in the world capable of such precise thermal measurements, for much of this research. Calorimeter readings are paired with thermal imaging of batteries using infrared cameras to evaluate battery temperature distribution. In addition, NREL is working with industry to develop computer-aided engineering software tools to optimize thermal management of batteries. NREL's analysis for the U.S. Advanced Battery Consortium (USABC) show that optimized thermal management can increase battery power by more than 10%. Without proper thermal management, an EDV battery can last more than 10 years in a temperate climate, like in Minnesota, but only 7 years in a hot climate, such as in Arizona. In extreme instances, battery overheating can pose safety hazards, including fires. Performance: Maintaining desired temperature ranges is critical in optimizing EDV battery storage capacity, lifespan, and performance, and eventually impacts cost and consumer acceptance. NREL's breakthrough research focuses on achieving more uniform temperatures while a vehicle is in motion and actively generating heat, as well as when it is parked and exposed to ambient temperatures over prolonged periods of time. Safety: Most energy storage systems deliver maximum performance at higher temperatures. However, this extreme heat can overload systems and create dangerous conditions. NREL evaluation helps to more effectively regulate thermal characteristics, providing greater safeguards and stronger performance. NREL has invented a device that emulates internal short circuits in batteries to better understand how to prevent future failures and related hazards.

25 ENERGY STORAGE↗
NASA NTRS2007

An Update on the Lithium-Ion Cell Low-Earth-Orbit Verification Test Program

A Lithium-Ion Cell Low-Earth-Orbit Verification Test Program is being conducted by NASA Glenn Research Center to assess the performance of lithium-ion (Li-ion) cells over a wide range of low-Earth-orbit (LEO) conditions. The data generated will be used to build an empirical model for Li-ion batteries. The goal of the modeling will be to develop a tool to predict the performance and cycle life of Li-ion batteries operating at a specified set of mission conditions. Using this tool, mission planners will be able to design operation points of the battery system while factoring in mission requirements and the expected life and performance of the batteries. Test conditions for the program were selected via a statistical design of experiments to span a range of feasible operational conditions for LEO aerospace applications. The variables under evaluation are temperature, depth-of-discharge (DOD), and end-of-charge voltage (EOCV). The baseline matrix was formed by generating combinations from a set of three values for each variable. Temperature values are 10 C, 20 C and 30 C. Depth-of-discharge values are 20%, 30% and 40%. EOCV values are 3.85 V, 3.95 V, and 4.05 V. Test conditions for individual cells may vary slightly from the baseline test matrix depending upon the cell manufacturer s recommended operating conditions. Cells from each vendor are being evaluated at each of ten sets of test conditions. Cells from four cell manufacturers are undergoing life cycle tests. Life cycling on the first sets of cells began in September 2004. These cells consist of Saft 40 ampere-hour (Ah) cells and Lith ion 30 Ah cells. These cells have achieved over 10,000 cycles each, equivalent to about 20 months in LEO. In the past year, the test program has expanded to include the evaluation of Mine Safety Appliances (MSA) 50 Ah cells and ABSL battery modules. The MSA cells will begin life cycling in October 2006. The ABSL battery modules consist of commercial Sony hard carbon 18650 lithium-ion cells configured in series and parallel combinations to create nominal 14.4 volt, 3 Ah packs (4s-2p). These modules have accumulated approximately 3000 cycles. Results on the performance of the cells and modules will be presented in this paper. The life prediction and performance model for Li-ion cells in LEO will be built by analyzing the data statistically and performing regression analysis. Cells are being cycled to failure so that differences in performance trends that occur at different stages in the life of the cell can be observed and accurately modeled. Cell testing is being performed at the Naval Surface Warfare Center in Crane, IN.

Reid, Concha M.↗
DOE OSTI2022

PV Lifetime Project (2021 NREL Annual Report)

DOE's PV Lifetime project was initiated in 2016 with the goal of accurately characterizing the early-life evolution of photovoltaic (PV) field performance. Different PV cell and module technologies result in different initial performance loss rates due to effects like light-induced degradation (LID) and light & elevated temperature-induced degradation (LeTID). To accurately characterize the initial field performance loss requires the use of high-accuracy indoor IV curve measurements at standard test conditions. Therefore, PV modules involved in this study are removed from the field once or twice per year and brought indoors for measurement. Current samples deployed and monitored in this way include Jinko Solar (2016), Trina Solar (2016), Hanwha Q-Cells (2017), Panasonic (2018), LG (2018), Canadian Solar (2018), Mission Solar (2019). More recently, modules from Sunpreme (2019), and LONGi (2020) have been deployed but not yet analyzed. Overall annual performance loss rates are as follows: our first modules to be deployed (Jinko and Trina) have annual median performance loss rate between -0.4%/yr and -0.9%/yr, mainly concentrated in the first year. The QCells mono-PERC and multi-PERC modules have an annual degradation rate of -0.76%/yr and -0.69%/yr respectively, also concentrated in the first year of operation. Panasonic and LG modules displayed negligible performance loss in the past two years, at 0.1%/yr and -0.0%/yr respectively. They also were the only modules with initial IV curve measurements consistently above the nameplate rating. Possibly relatedly, these are also the only two N-type silicon module types analyzed so far. Canadian Solar multi-PERC modules demonstrated a -1.3%/yr degradation rate which actually accelerated in the past year, so this will be a module type to monitor in future years. Mission Solar modules exhibited strong recoverable performance loss, consistent with LeTID susceptibility. (The same is true for the Jinko JKM260 module type). Annual performance loss actually showed improvement in time at +0.3%/yr after 2 years in the field, although the module initially was measured at 3% below nameplate rating. These modules could therefore be experiencing a form of post-LeTID recovery. Initial measurements have been conducted on the next two module types - Sunpreme n-HIT and LONGi bifacial mono-PERC. We will report on initial year-1 performance change for these modules in the next PV Lifetime annual report. For the remaining modules, an additional year of field exposure will provide greater certainty in annual degradation rates, particularly for those with degradation concentrated in the initial year of field deployment.

14 SOLAR ENERGY↗
DOE OSTI2019

Methodology to predict annual yield losses and gains caused by solar module design and materials under field exposure

Solar cells and modules are usually optimized separately under standard test conditions (STC). However, the actual performance under field exposure depends on module design, installation and environmental conditions. This work therefore presents a methodology to predict the annual yield of crystalline silicon solar modules for varying module configurations and environments using a time step simulation approach. We define and quantify 12 effects that affect the annual module performance, starting with solar cells in air under STC to a complete module under realistic conditions. We consider the interaction of optical, thermal and electrical effects in the module and combine it with an angular, spectral and time resolved light source. The model enables understanding the impact of the module environment, such as regions with high wind speeds or high diffuse light, on the annual output of a particular module type. We validate our model with measured power and temperature data for crystalline silicon heterojunction solar cell modules and find an agreement of the annual yield within 0.7%. We quantify the annual gains and losses for this module and identify that major losses are caused by elevated operating temperatures (2.3%) and reflection losses at the front glass (2.6%). Critically, the coupling gains at the cell surface increase significantly by 1.5% when considering angular light irradiance compared to normal incidence. To conclude, we apply our Cell-to-Module-Yield method to a 72-cell mono-crystalline PERC module, where the main annual yield losses are caused by reflection at the front glass and ohmic losses in the connector ribbons.

14 SOLAR ENERGY↗
NASA NTRS1988

The effect of different module configurations on the radiation tolerance of multijunction solar cells

The effect of different module configurations on the performance of multijunction (MJ) solar cells in a radiation environment was investigated. Module configuration refers to the electrical circuit in which the subcells of the multijunction cell are wired. Experimental data for AlCaAs, GaAs, InGaAs, and silicon single-junction concentrator cells subjected to 1 MeV electron irradiation was used to calculate the expected performance of AlGaAs/InGaAs, AlGa/silicon, GaAs/InGaAs, and GaAs/silicon Mj concentrator cells. These calculations included independent, series, and voltage-matched configurations. The module configuration was found to have a significant impact on the radiation tolerance characteristic of the MJ cells.

Gee, James M.↗