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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
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DOE OSTI2025

Screening Metal Halide Perovskite Solar Modules for Premature Field Failures

Developing metal halide perovskite (MHP) photovoltaic (PV) devices into reliable large-area solar modules could accelerate global solar energy deployment. Many MHP devices are susceptible to degradation under light and elevated temperature (LT). Published research on LT testing is limited at the module level, and LT testing has not yet been developed for qualification testing of commercial PV products. This report assesses whether results of LT testing at moderately elevated temperatures correlate with those of field-tested modules from the same batch. Six batches of samples from four manufacturers are assessed. It is shown that modules with a robust package that can maintain over 80% of their peak efficiency during LT testing at 55 °C for 100 h are more likely to retain over 80% of their peak efficiency during outdoor operation for 10 weeks. This finding is a step towards developing a validated test protocol that could be incorporated into a qualification standard for the commercialization of MHP PV technologies.

14 SOLAR ENERGY↗
DOE OSTI2024

Metal Halide Perovskite Solar Module Encapsulation Using Polyolefin Elastomers: The Role of Morphology in Preventing Delamination

The development of perovskite solar cells (PSCs) has ushered in a new era of solar technology, characterized by its exceptional efficiency and cost-effective production. However, the soft and fragile nature of perovskites makes module encapsulation challenging. Polyolefin elastomers (POEs) have been reported to be promising encapsulants for perovskite modules. However, little research exists on identifying criteria among different types of POEs as encapsulants. Here, two POEs with different morphologies were compared as encapsulants. The first POE crystallizes during encapsulation (crystal content ∼40%), and the resulting shrinkage or warpage leads to delamination, causing minimodule failure. In contrast, perovskite minimodules encapsulated with a mostly amorphous POE exhibited better reliability and reproducibility. The best perovskite minimodules passed the thermal cycling test for 240 cycles between −40 and 85 °C and the damp heat test for 1419 h, according to the IEC 61215 standard. This study highlights the importance of the morphology of encapsulants in achieving high-quality encapsulation. Published by the American Physical Society 2024

14 SOLAR ENERGY↗
DOE OSTI2025

C60-Based Ionic Salt Electron Shuttle for High-Performance Inverted Perovskite Solar Modules

Although C60 is usually the electron transport layer (ETL) in inverted perovskite solar cells, its molecular nature of C60 leads to weak interfaces that lead to non-ideal interfacial electronic and mechanical degradation. Here, we synthesized an ionic salt from C60, 4-(1',5'-dihydro-1'-methyl-2'H-[5,6] fullereno-C60-Ih-[1,9-c]pyrrol-2'-yl) phenylmethanaminium chloride (CPMAC), and used it as the electron shuttle in inverted PSCs. The CH2-NH3+ head group in the CPMA cation improved the ETL interface and the ionic nature enhanced the packing, leading to ~3-fold increase in the interfacial toughness compared to C60. Using CPMAC, we obtained ~26% power conversion efficiencies (PCEs) with ~2% degradation after 2,100 hours of 1-sun operation at 65degrees C. For minimodules (four subcells, 6 centimeters square), we achieved the PCE of ~23% with <9% degradation after 2,200 hours of operation at 55degrees C.

14 SOLAR ENERGY↗
DOE OSTI2024

Remanufacturable "Net-Zero Pb" Perovskite Solar Modules

Our introduced a low-cost recycling method for perovskite PV cells which utilize KI salt-based solvents, a more sustainable chemical compared to commonly used chemicals such as DMF, chlorobenzene etc. All steps of the recycling method were demonstrated in detail in publications and presentations of the team. In addition, the techno-economic team demonstrated that the KI-based method is a more promising option compared to other methods investigated in the literature.

14 SOLAR ENERGY↗
DOE OSTI2021

Rapid Open-Air Processing of Low-Cost Perovskite Solar Modules

We report an industrially relevant approach to both scalable and fast open-air perovskite photovoltaic (PV) module production. This work resolves some of the most formidable barriers to module-level scaling that the perovskite community has been facing. Key advances include scalable large-area spray deposition, new monolithic integration scribing techniques, advanced photoluminescence characterization, and reproducible high-throughput manufacturability. Our rapid spray processing techniques enabled the highest perovskite PV efficiency produced in open-air. Innovations in scribing techniques enabled the first single-source laser process to achieve perovskite module monolithic integration and technoeconomic analysis led to a comprehensive cost model for perovskite module manufacturing. We report significant progress in reducing perovskite manufacturing costs necessary to potentially compete with incumbent Si-based PV for utility-scale power generation.

cost modeling↗
DOE OSTI2020

Scalable fabrication and coating methods for perovskite solar cells and solar modules

Since the report in 2012 of a solid-state perovskite solar cell (PSC) with a power-conversion efficiency (PCE) of 9.7% and a stability of 500 h, intensive efforts have been made to increase the certified PCE, reaching 25.2% in 2019. The PCE of PSCs now exceeds that of conventional thin-film solar-cell technologies, and the rate at which this increase has been achieved is unprecedented in the history of photovoltaics. Moreover, the development of moisture-stable and heat-stable materials has increased the stability of PSCs. Small-area devices (<1 cm2) are typically fabricated using a spin-coating method; however, this approach may not be suitable for the preparation of the large-area (>100 cm2) substrates required for commercialization. Thus, materials and methods need to be developed for coating large-area PSCs. In this Review, we discuss solution-based and vapour-phase coating methods for the fabrication of large-area perovskite films, examine the progress in performance and the parameters affecting the properties of large-area coatings, and provide an overview of the methodologies for achieving high-efficiency perovskite solar modules.

14 SOLAR ENERGY↗
DOE OSTI2022

Efficient monolithic all-perovskite tandem solar modules with small cell-to-module derate

All-perovskite tandem solar modules are promising to reduce the cost of photovoltaic systems with their high efficiency and solution fabrication, but their sensitivity to air still imposes a great challenge. Here a hot gas-assisted blading method is developed to accelerate the perovskite solidification, forming compact and thick narrow bandgap (NBG) perovskite films. Adding a reduction agent into NBG films followed by a short period of air exposure and a post-fabrication storage surprisingly increases carrier recombination lifetime and enables laser scribing in ambient conditions without obvious loss of device performance. This combination suppresses tin and iodide oxidation and forms a thin SnO 2 layer on the NBG film surface. Monolithic all-perovskite tandem solar modules showed a champion efficiency of 21.6% with a 14.3 cm 2 aperture area, corresponding to an active area efficiency of 23.0%. Lastly, the very small cell-to-module derate of 6.5% demonstrates the advantage of a tandem monolithic structure for solar modules.

14 SOLAR ENERGY↗
DOE OSTI2026

Challenging conventional assumptions in PV: a high-throughput open-air approach to low-cost perovskite module production

Perovskite solar modules (PSMs) offer a promising pathway to low-cost photovoltaics, yet their commercialization is challenged by manufacturing scalability, device uniformity, additive costs, interlayer complexity, and module stability. This study introduces a comprehensive technoeconomic analysis of single junction PSM's and projections for tandem perovskite-Si modules that integrate all materials and manufacturing steps, module performances, projected lifetimes, and manufacturing costs across scales. Here, we highlight an open-air manufacturing approach to fabricate all active layers of serially interconnected PSMs, including electrodes and charge transport layers, enabling high-throughput production without inert or vacuum environments. The analysis reveals two orders of magnitude throughput enhancement and cost reductions of 24% in all-open-air production, escalating to over 60% at 1 GW factory capacity compared to conventional methods. Levelized cost of energy (LCOE) projections for utility-scale installations over 30 years, accounting for module replacement and recycling, demonstrate the potential to achieve the 2030 US target of $0.03 per kWh with realistic 7–11-year PSM lifetimes, outperforming incumbent silicon-based modules. Neither four terminal (4T) nor two terminal (2T) tandem-Si PSMs improve over single junction perovskite or silicon LCOE regardless of higher efficiencies at any modeled lifetime. Addressing PSM technical challenges with a cost-modeling framework guides commercialization efforts and provides a convincing pathway for challenging incumbent Si-based PV.

14 SOLAR ENERGY↗
DOE OSTI2025

Advances in Carbon Electrode Integration for Stable and Efficient Perovskite Solar Cells and Modules

Carbon-electrode-based perovskite solar cells (C-PSCs) have emerged as a cost-effective and scalable alternative to noble-metal-based PSCs, addressing critical challenges related to device stability, fabrication complexity, and commercialization potential. This review explores the recent progress in C-PSC development, focusing on the benefits of carbon electrodes (CEs), including their hydrophobicity, chemical inertness to halide corrosion, and compatibility with low-temperature cost-effective solution-based deposition methods. Despite relatively lower power conversion efficiencies (PCEs) than their metal (e.g., Au/Ag) counterparts, recent advances in carbon paste formulation, interfacial contact engineering, and work function modification have elevated C-PSC efficiencies above 22%. This review further examines strategies to enhance electrode conductivity, interfacial properties, and charge selectivity to further increase C-PSC performance. Progress in carbon-electrode-based perovskite solar modules (C-PSMs), particularly within mesoporous and planar architectures, is also analyzed, revealing significant developments in active area scaling and long-term stability. Notably, the limited research in inverted (PIN) C-PSCs is also highlighted as a compelling opportunity for innovation, given the architecture's inherent advantages in flexibility, tandem integration, and low-temperature processing. Collectively, these insights affirm the potential of C-PSCs and C-PSMs to deliver affordable, stable, and high-performance photovoltaics suitable for scalable deployment.

Carbon Electrodes↗
DOE OSTI2021

Designing Modules to Prevent Reverse Bias Degradation in Perovskite Solar Cells when Partial Shading Occurs

When a solar cell in a panel is shaded, the illuminated cells can place a large reverse bias on the shaded cell to attempt to force current through it. Although the panel can continue to produce power, the reverse bias can cause significant problems for the shaded cell. In the case of perovskite solar modules, Joule heating and irreversible electrochemical reactions will degrade the cell. Some photovoltaic technologies use bypass diodes to solve this problem. To prevent both a perovskite cell and an all-perovskite tandem cell from falling into reverse bias breakdown while shaded, no more than two cells per bypass diode are allowed, which is likely to be prohibitively expensive for many applications. Herein, how many solar cells can be protected by one bypass diode in single-junction and multijunction perovskite modules is explored. It is easier to incorporate bypass diodes into modules with singulated cells than with monolithic panels. It is shown that perovskite–silicon tandems can be protected with fewer bypass diodes than with single-junction perovskite modules. Furthermore, it is suggested that if bypass diodes cannot be feasibly incorporated, then the panels should be deployed in utility-scale power plants.

14 SOLAR ENERGY↗
DOE OSTI2026

Molecular Additive Engineering for Process-Humidity Robustness and Reproducible Fabrication of Perovskite Solar Cells and Modules

The commercialization of perovskite solar cells (PSCs) faces significant challenges due to their sensitivity to environmental humidity, which compromises film crystallization and device stability. Here, we introduce diphenylvinylphosphine (DPVP) as a Lewis base additive that enhances the performance and reproducibility of PSCs fabricated under ambient-air conditions. DPVP suppresses moisture-induced defect formation and stabilizes crystallization within realistic process-humidity ranges (20–40% relative humidity) commonly encountered in laboratory and pilot-scale manufacturing environments. It improves film uniformity, reduces trap densities, and yields highly reproducible device performance, enabling champion PCEs of 24.2% in small-area devices and 20.5% in blade-coated 12 cm 2 mini-modules. Furthermore, DPVP-assisted modules exhibit enhanced stability, retaining over 85% of their initial efficiency after 900 h of maximum power point tracking (MPPT) at 65 °C. This study demonstrates a humidity-resilient and scalable additive strategy for ambient-air perovskite photovoltaic manufacturing.

defect passivation↗
DOE OSTI2024

Advancements in Manufacturing of High-Performance Perovskite Solar Cells and Modules Using Printing Technologies

Perovskite photovoltaic technology carries immense opportunity for the solar industries because of its remarkable efficiency and prospect for cost-effective production. However, the successful deployment of perovskite solar modules (PSMs) in the solar market necessitates tackling stability-based obstacles, scalability, and environmental considerations. This paper unveils a comprehensive examination of the cutting-edge advancements in the manufacturing of perovskite solar cells (PSCs) and modules, with an emphasis on high-speed, large-area printing. The paper underscores the substantial progress achieved in printed PSCs and PSMs, demonstrating promising electrical performance and long-term device durability. This review paper categorizes printing techniques compatible with large-area high-speed manufacturing into three distinct families: blade coating, slot die coating, and screen printing, as these common printing practices offer precise control, scalability, cost-effectiveness, high resolution, and efficient material usage. Additionally, this paper presents an in-depth investigation and comparison of superior PSCs and PSMs fabricated by printing on power conversion efficiency (PCE), stability, and scalability.

14 SOLAR ENERGY↗
DOE OSTI2024

Supramolecular design principles in pseudohalides for high-performance perovskite solar mini modules

In this work, we reveal the role of non-covalent interactions, which are known to play important roles in supramolecular phenomena, in achieving efficient perovskite surface and grain boundary passivation. By using a series of pseudohalides, we find that trifluoroacetate (TFA - ) provides the strongest binding to iodide vacancies by means of non-covalent hydrogen bonding and dispersion interactions. By exploiting additional non-covalent dispersion and hydrophobic interactions in aromatic 3,3-diphenylpropylammonium (DPA + ), we present a dual-ion passivation strategy that not only minimizes the non-radiative recombination center and local chemical inhomogeneities but also induces preferentially oriented growth of α-FAPbI 3 lattice. Further, this leads to an outstanding power conversion efficiency (PCE) of 25.63% with an exceptional open-circuit voltage of 1.191 V in a perovskite solar cell with a small area, while perovskite solar mini modules with aperture areas of 25 and 64cm 2 achieved PCE of 22.47% (quasi-steady-state [QSS]-certified 20.50%) and 20.88%, respectively, with outstanding stability under high-humidity conditions.

14 SOLAR ENERGY↗