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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
DOE OSTI2022

Near-Busbar Degradation of Screen-Printed Metallization in Silicon Photovoltaic Modules

We study photovoltaic (PV) module degradation after extended accelerated stress testing including 2000 hours of damp heat followed by a current-injection procedure meant to stabilize defects linked to light-induced degradation. In addition to de-stabilization/recovery of light-induced defects, we observe severe series resistance due to loss of contact between the Si cell and near-busbar screen-printed metallization (i.e. grid finger delamination). Using scanning electron microscopy and energy dispersive x-ray spectroscopy on cell fragments cored from the module, we show poor contact is caused by a gap between the screen-printed Ag metallization and Si due to missing glass frit.

degradation↗
DOE OSTI2022

Multilevel peel-off patterning of a prototype semitransparent organic photovoltaic module

Semitransparent organic photovoltaics (ST-OPVs) with applications to power generating windows have shown substantial increases in power conversion efficiency (PCE) and average photopic transmission (APT) at the laboratory scale. Here, the demonstration of similarly efficient, large-scale ST-OPV modules with geometric fill factors (GFF) approaching 100%, however, remains a challenge. Here, we employ a multilevel peel-off patterning method that can achieve micron-scale resolution without exposing chemically sensitive organic materials to solvents. Eight, 4 cm × 0.4 cm cells are connected in series to realize a prototype ST-OPV module with GFF = 95.8%, with PCE = 7.3 ± 0.2% under simulated AM 1.5G illumination at 1 sun intensity, APT = 41.8 ± 1.4%, and a light utilization efficiency of LUE = 3.1 ± 0.1%. A neutral color STOPV module is also demonstrated with 1.7 ± 0.1% and International Commission on Illumination (CIE) LAB coordinates of (L*, a*, b*) = (53.7, -1.9, -3.9).

14 SOLAR ENERGY↗
DOE OSTI2025

Intraday Outdoor Efficiency Changes in Metal-Halide Perovskite Photovoltaic Modules

Here, we present outdoor observations of metal-halide perovskite modules deployed in the Photovoltaic Accelerator for Commercializing Technologies center, which houses one of the world's broadest efforts to test metal-halide perovskite photovoltaic modules outdoors. As of January 2025, outdoor testing has encompassed over 150 modules from 14 different partners. Our findings illustrate how daily changes in efficiency, driven by exposure to light, affect field performance in real-world conditions. These effects cannot be explained by existing outdoor performance models and frustrate the notion of a traditional temperature coefficient.

14 SOLAR ENERGY↗
DOE OSTI2021

Solar Photovoltaic Module Recycling: A Survey of U.S. Policies and Initiatives

Industry stakeholders, regulators, and policymakers in the United States are starting to develop policies for PV module recycling. Well-designed policies could reduce negative environmental impacts and resource constraints while opening new market and employment opportunities. This paper summarizes drivers, barriers, and enablers related to PV module recycling, which might be addressed via policy. It then analyzes existing and proposed U.S. policies that may affect PV module recycling. Among the global and national voluntary industry stewardship standards related to EoL PV management, this paper discusses a Solar Energy Industries Association program encouraging PV recycling among its U.S. membership. The paper concludes with a synthesis of policy-related factors that may encourage effective EoL PV module management.

14 SOLAR ENERGY↗
DOE OSTI2025

Ultraviolet Fluorescence Imaging for Photovoltaic Module Metrology: Best Practices and Survey of Features Observed in Fielded Modules

As the photovoltaics (PV) industry grows in sophistication, so must the extent to which systems are characterized. UV Fluorescence (UVF) imaging is a valuable, easy-to-perform, high-throughput, nonintrusive technique for characterizing modules in the field and in the lab. However, UVF is still a relatively new technique, and many in the PV industry are still unaware of its potential. We provide a guideline for obtaining, processing, and interpreting UVF images. We have provided a list of considerations for imaging hardware and settings, a suggested pipeline for image processing, and details on a survey of features shown in UVF images. As a result, a new database with UVF images of 7190 modules and another database curated by BrightSpot Automation are publicly available.

14 SOLAR ENERGY↗
DOE OSTI2023

Thermal behaviors of ethylene vinyl acetate encapsulants in fielded silicon photovoltaic modules

Aging of silicon photovoltaic (PV) module packaging is one of the greatest limiters of PV module service lifetimes. Module characterization typically focuses on power degradation metrics, which do not convey the complexities of often simultaneous degradation mechanisms. In this work, PV modules with pristine references and known fielding histories were investigated by non-destructive and destructive methods. Modules from Canadian Solar, Mission Solar, and Hanwha Q-Cells were fielded for up to three years; select modules were removed from fielding each year for coring to allow for characterization of the encapsulant. Modules are commonly encapsulated with two protective layers of partially-crystalline ethylene vinyl acetate (EVA) polymer that must undergo a crosslinking reaction to achieve desired properties. The extent of crystallinity of the encapsulants as studied by differential scanning calorimetry showed differences between manufacturers and over time. Some encapsulants showed different magnitudes of crystal sizes which changed after fielding; encapsulants with the monodisperse crystal sizes did not change with fielding. This is due to differences in thermal history. In conclusion, these results have implications for stress development during module aging, since EVA crystal melting and crosslinking reactions can result in encapsulant density changes.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Electrochemical mechanisms of leakage‐current in photovoltaic modules

Abstract This paper analyzes the mechanisms and pathways for leakage current flow observed in Si photovoltaic modules subjected to high temperature and humidity and a large voltage bias with respect to ground. The current inside of the frame is in the form of electron motion, but in the glass and polymer, it is in at least a large part attributable to the movement of ions. When the mode of current flow changes from electronic to ionic conduction, electrochemical reactions will take place at the interface. This can include reactions that produce volatile chemical species like H 2 , CO x , and O 2 , along with ionic species such as OH − and H 3 O + . Here, we see evidence of the importance of different charge carriers with different diffusion rates and the influence of electrochemical processes involved. The application of negative voltage to the cell circuit affects the resistivity of glass producing surfaces with poor conductivity but with some increases in the electrochemical potential producing complicated interactions that are important when the voltage is changed. In the polymer, there is the development of a space charge region and a chemical gradient providing two oppositional forces to current flow, which when released create a complicated discharge process. Here, we give a basic understanding of the charge/discharge of PV cells highlighting how the specific mechanisms are important in understanding some of the degradation processes in PV modules. We find that there is evidence of multiple significant charge carrier species with different diffusion time scales. The glass/polymer interface forms a depleted region of higher resistance after prolonged exposure to current. Charge also builds up at the polymer to cell antireflective coating interface and mostly flows to the gridlines to experience electrochemical reactions. These complexities result in non‐linear behavior where the apparent resistivities of the different layers change during charge/discharging processes, making the modeling of the current flow extremely difficult.

14 SOLAR ENERGY↗
DOE OSTI2024

Measurement of Photovoltaic Module Deformation Dynamics During Hail Impact Using Digital Image Correlation

Stereo high-speed video of photovoltaic modules undergoing laboratory hail tests was processed using digital image correlation to determine module surface deformation during and immediately following impact. The purpose of this work was to demonstrate a methodology for characterizing module impact response differences as a function of construction and incident hail parameters. Video capture and digital image analysis were able to capture out-of-plane module deformation to a resolution of ±0.1 mm at 11 kHz on an in-plane grid of 10 × 10 mm over the area of a 1 × 2 m commercial photovoltaic module. With lighting and optical adjustments, the technique was adaptable to arbitrary module designs, including size, backsheet color, and cell interconnection. Furthermore, impacts were observed to produce an initially localized dimple in the glass surface, with peak deflection proportional to the square root of incident energy. Subsequent deformation propagation and dissipation were also captured, along with behavior for instances when the module glass fractured. Natural frequencies of the module were identifiable by analyzing module oscillations postimpact. Limitations of the measurement technique were that the impacting ice ball obscured the data field immediately surrounding the point of contact, and both ice and glass fracture events occurred within 100 μs, which was not resolvable at the chosen frame rate. Increasing the frame rate and visualizing the back surface of the impact could be applied to avoid these issues. Applications for these data include validating computational models for hail impacts, identifying the natural frequencies of a module, and identifying damage initiation mechanisms.

14 SOLAR ENERGY↗
DOE OSTI2026

Surface Stress Characterization and Trends in Thermally Strengthened Photovoltaic Module Glass

Simultaneous changes in photovoltaic (PV) module architecture-such as increased area, replacing the polymeric backsheet with a glass backsheet, and reducing glass thickness from 3.2 to 2.0 mm-have resulted in a novel failure called spontaneous glass breakage. Spontaneous glass breakage results in front and/or rear glass failure without any obvious cause. The resulting low-energy fracture patterns have raised concerns about the thermal strengthening in 2.0-mm glass. We present validation of a nondestructive method for measuring the glass surface stress in PV modules. We use a scattered light polariscope to examine the glass properties of 11 modules from 6 solar fields, with and without spontaneous glass breakage. Based on a Mann-Whitney test p-value of 1.4 x 10-6, we conclude that there is a correlation between lower surface stress and susceptibility to spontaneous breakage. A Kendall's Tau test p-value of 2.0 x 10-4 indicates a correlation between increased module area and lower surface stress. We find that 2.0-mm glass can be, and often is, fully tempered (surface stress ≥69 MPa), but inspecting the fracture pattern is not a reliable way to assess the amount of thermal strengthening. A combination of factors, not just surface stress, influences glass breakage.

14 SOLAR ENERGY↗
DOE OSTI2025

Field Aging of Photovoltaic Module Packaging Materials: DuraMAT Field Module Library

To understand and develop models for silicon photovoltaic module degradation, accelerated testing is often used, however, outdoor field testing is necessary for validation. Outdoor field testing publications are often limited by the lack of a pristine, control module to compare the fielded module to. In this work, commercially available modules were purchased from seven different manufacturers for outdoor fielding then destructive characterization to investigate packaging material degradation on

14 SOLAR ENERGY↗
DOE OSTI2021

A transmissive concentrator photovoltaic module with cells directly cooled by silicone oil for solar cogeneration systems

Hybrid concentrator photovoltaic-thermal systems can cogenerate electricity and heat by beam-splitting incoming concentrated light onto photovoltaic cells and a thermal receiver to increase total conversion efficiency and potentially reduce system cost. To demonstrate this, we have designed and prototyped a transmissive spectrum-splitting concentrator photovoltaic module that maximizes solar energy conversion by utilizing the entire solar spectrum. Visible light is collected using infrared-transmissive triple-junction photovoltaic cells to achieve an in-band module efficiency of 43.3% for light of wavelength λ < 873 nm, while 44.2% of out-of-band light with λ > 873 nm is transmitted through for collection by a thermal receiver. During testing on a dual-axis tracked parabolic concentrator dish at up to 166 suns, cell temperatures were maintained at 119 °C or below via a novel active cooling method. This cooling system strictly flows silicone oil directly across both sides of the cells, without inhibiting optical transmission, as verified through experimentation and simulation. The module was validated outdoors for 572 sun·hrs, and achieved a maximum thermal receiver temperature of 180 °C. 86.1% of incident solar power is collected at 166 suns average concentration collectively among the electrical, cooling, and thermal receiver subsystems. The remaining 13.9% is lost to mirror reflectivity, dish shadowing, receiver reflection, and thermal losses. The ability to directly cool the cells with an inert silicone oil offers the potential for reduced system cost relative to previous transmissive hybrid concentrator photovoltaic-thermal systems, including microfluidic-cooled designs. This solar cogeneration capability is valuable in a wide range of commercial and industrial applications.

14 SOLAR ENERGY↗
DOE OSTI2020

High Altitude Electromagnetic Pulse Testing of Photovoltaic Modules

This report details the test setup, process, and results for radiated susceptibility testing of multicrystalline silicon photovoltaic (PV) modules as part of the EMP-Resilient Electric Grid Grand Challenge Laboratory Directed Research and Development (LDRD) project at Sandia National Laboratories. Testing was conducted over October 10-17, 2019, where 8 photovoltaic modules were exposed to E1 transient pulses with peak field levels up to 100 kV/m. Modules were terminated in a resistive load representing connected components. State of health testing conducted via I-V curve tracing of the photovoltaic modules showed no observable loss of device function due to large electric field transients. Differential mode currents were measured on the order of 10's of amps for up to a microsecond following the radiated field pulse. Common mode currents took the form of a damped sinusoid with a maximum peak of 10's to 100's of amps with a resonance near 60 MHz.

14 SOLAR ENERGY↗
DOE OSTI2022

Onymous early‐life performance degradation analysis of recent photovoltaic module technologies

Abstract The cost of photovoltaic (PV) modules has declined by 85% since 2010. To achieve this reduction, manufacturers altered module designs and bill of materials; changes that could affect module durability and reliability. To determine if these changes have affected module durability, we measured the performance degradation of 834 fielded PV modules representing 13 module types from 7 manufacturers in 3 climates over 5 years. Degradation rates ( Rd ) are highly nonlinear over time, and seasonal variations are present in some module types. Mean and median degradation rate values of −0.62%/year and −0.58%/year, respectively, are consistent with rates measured for older modules. Of the 23 systems studied, 6 have degradation rates that will exceed the warranty limits in the future, whereas 13 systems demonstrate the potential of achieving lifetimes beyond 30 years, assuming Rd trends have stabilized.

14 SOLAR ENERGY↗
DOE OSTI2023

Analyzing photovoltaic module mechanics using composite plate theories and finite element solutions

Deflection and stress calculated from an experimentally validated, high-fidelity finite element model (FEM) of a photovoltaic module experiencing mechanical load was compared to results from a simplified FEM treating the module laminate as a homogenized composite using a rule of mixtures approach, and further compared to analytical calculations treating the module as a Kirchoff-Love flat plate. The goal of this study was to determine the error incurred by analyzing module mechanics with varying levels of simplification, since resolving the aspect ratios of a module is computationally expensive. Homogenized FEMs were found to underpredict peak deflection under a 1.0 kPa load by between 13 and 19% for lower and upper bound application of the rule of mixtures. However, module shape was captured, implying that a useful replication of a resolved model could be achieved with a reduced, calibrated material stiffness. Homogenized stress results captured glass layer tensile stress components to within 46 to 52% at a sample location of interest, though agreement was poor through the remainder of the laminate due to the lack of material resolution. For plate theory, deflection was overpredicted by 45 to 67% for upper and lower bound homogenizations, and frame-adjacent module shapes were not adequately replicated. Stress results mirrored FEM trends but magnitudes were not well correlated to resolved model values. These results support the use of homogenized laminate models for module shape derivation, though resolved models remain necessary for stress analyses. The accuracy of plate theory was found to be inadequate for most applications.

14 SOLAR ENERGY↗