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DOE OSTI2022

Testing Asoleyo Decorative Solar Cell and Modules: Cooperative Research and Development, CRADA Number CRD-20-16732 (Final Report)

Team Asoleyo is transforming the utilitarian rectangular grid that dominates the visual style of standard solar panels by re-designing solar cells’ silver contact grid using principles of symmetry, rhythm, and line. Our designs use well-established manufacturing equipment, techniques, and materials, achieving similar manufacturing costs but far superior aesthetic effect- without the need for additional layers or occlusion. This project will test new decorative PV Cell front contact designs, individually and interconnected within modules, for their performance characteristics.

14 SOLAR ENERGY↗
DOE OSTI2022

Analysis of electrically conductive adhesives in shingled solar modules by X-ray imaging techniques

The failure mechanisms of electrically conductive adhesives (ECAs) in solar modules are difficult to study since the ECA layer is not easily accessible within the module package. In this work, we present two complementary imaging modalities—X-ray radiography and X-ray microcomputed tomography (XCT)—that reveal important morphological features of the ECA within a shingled module. X-ray radiography uses single X-ray projections to provide fast and non-destructive imaging of the shingled interconnection, illuminating the alignment of the ECA relative to the busbars, the size and shape of the ECA, and the presence of voids within it. Through X-ray radiography, we observed, for example, that the average void coverage area of ECA segments reduced from 36.7% to 4.4% when an ECA was cured for 60 s prior to module lamination. XCT is a three-dimensional imaging technique that can identify regions in which the ECA makes electrical contact to busbars on cells and regions in which the ECA has cracked, among other features. XCT can also be used to image the individual metal particles within ECA, from which the metal volume fraction of an ECA was found here to be 70.4%. This is a quantity that is not often reported by ECA manufacturers but is important to ensure isotropic conduction. As X-ray projections can be performed non-destructively on full modules, the technique may be used to pinpoint ECA failures in accelerated degradation testing. XCT is complementary and is suited to forensic analysis of failing modules.

14 SOLAR ENERGY↗
DOE OSTI2013

Electric Vehicle Communications Standards Testing and Validation - Phase II: SAE J2931/1

Vehicle to grid communication standards enable interoperability among vehicles, charging stations and utility providers and provide the capability to implement charge management. Several standards initiatives by the Society of Automobile Engineers (SAE), International Standards Organization and International Electrotechnical Commission (ISO/IEC), and ZigBee/HomePlug Alliance are developing requirements for communication messages and protocols. Recent work by the Electric Power Research Institute (EPRI) in collaboration with SAE and automobile manufacturers has identified vehicle to grid communication performance requirements and developed a test plan as part of SAE J2931/1 committee work. This laboratory test plan was approved by the SAE J2931/1 committee and included test configurations, test methods, and performance requirements to verify reliability, robustness, repeatability, maximum communication distance, and authentication features of power line carrier (PLC) communication modules at the internet protocol layer level. The goal of the testing effort was to select a communication technology that would enable automobile manufacturers to begin the development and implementation process. The EPRI/Argonne National Laboratory (ANL)/Pacific Northwest National Laboratory (PNNL) testing teams divided the testing so that results for each test could be presented by two teams, performing the tests independently. The PNNL team performed narrowband PLC testing including the Texas Instruments (TI) Concerto, Ariane Controls AC-CPM1, and the MAXIM Tahoe 2 evaluation boards. The scope of testing was limited to measuring the vendor systems communication performance between Electric Vehicle Support Equipment (EVSE) and plug-in electric vehicles (PEV). The testing scope did not address PEV’s CAN bus to PLC or PLC to EVSE (Wi-Fi, cellular, PLC Mains, etc.) communication integration. In particular, no evaluation was performed to delineate the effort needed to translate the IPv6/SEP2.0 messages to PEV’s CAN bus. The J2931/1 laboratory test results were presented to the SAE membership on March 20-22, 2012. The SAE committee decided to select HomePlug GreenPHY (HPGP) as the communication technology to use between the PEV and EVSE. No technology completely met all performance requirements. Both the MAXIM Tahoe 2 and TI Concerto met the 100Kbps throughput requirement, are estimated to meet the latency measurement performance, and met the control pilot impairment requirements. But HPGP demonstrated the potential to provide a data throughput rate of 10x of the requirement and either met or showed the potential to meet the other requirements with further development.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2024

Measuring Sustainability of Solar Modules for Energy Transition: Mass, Energy, and Circularity

Transition to a carbon-free energy system is crucial for global decarbonization and underpins Circular Economy (CE) goals. Photovoltaic (PV) technology is required for Energy Transition, but manufacturing and circular pathways can be material, energy, and carbon-intensive. Therefore, we need a prioritization of sustainability strategies for PV evolution and lifecycle management in the context of Energy Transition. This study employs a suite of quantitative metrics to compare different proposed sustainability strategies for PV modules on their ability to achieve Energy Transition. Proposals for sustainable PV range from high-yield, high-efficiency paradigms, to short-lived and fully recyclable, to long-lasting, indestructible modules. We leverage a global decarbonization deployment schedule through 2100 with the open-source PV in Circular Economy (PV ICE) tool to quantify the impacts of different evolving module design scenarios covering the range of proposed sustainability strategies. First, modules are compared on effective capacity and required replacements to meet and maintain decarbonization capacity targets through 2100. We demonstrate the effects of lifetime, degradation, and reliability on effective capacity. Next, we quantify and compare virgin material demands and lifecycle wastes, examining the impacts of lifetime and recycling rates. Finally, and critically for renewable energy technologies, we quantify the energy demands required to achieve the decarbonization capacity targets and calculate energy balance metrics (net energy, energy return on investment). These results are then summarized into a metric matrix, demonstrating tradeoffs and the importance of longevity. Our suite of mass and energy metrics provides stakeholders and decision-makers with quantitative data on circular economy choices for PV in the energy transition, enabling informed evaluation of tradeoffs of different PV module designs and CE pathways.

circular economy↗
DOE OSTI2024

Creating a Universal PV Plug and Socket Standard

Photovoltaic connectors are designed to be quick and easy to install. Current connector qualification standards, such as UL 6703 and IEC 62852, are only intended to evaluate connectors from the same manufacturer and were recently changed to explicitly proscribe the mating of connectors from different manufacturers. Unfortunately, the industry has chosen to design connectors that will commonly connect together with those from other manufacturers. This is done to simplify installation avoiding the situations such as when the connectors on a microinverter, or other module level power electronics, do not match the connectors on the modules in the system. This rampant violation of electrical codes worldwide indicates that there is a strong desire and need to develop a universal connector standard. Here we present the initial approach and philosophy behind the formation of an IEC subgroup under TC82 WG2 looking at this problem. We intend to develop a standard where the materials and geometry of construction are specified to ensure compatibility and the design is intended to be of the highest quality. We expect that this connector will be more costly but especially in rooftop installations where power electronics requires matching components from several manufacturers, that this may still result in a net cost savings. These connectors must be of the highest quality because we wouldn’t want to develop a connector that precluded the manufacturing of a higher quality product, and because these will most commonly be used on rooftop installations where safety is more of a concern. Additionally, because we do not know which brands of connectors will be used together, we cannot simply rely on test results to ensure safety but must create a design that is as inherently safe as possible.

connectors↗
DOE OSTI2020

Development of Perovskite (PVSK) Technology Related to Solar Cell Manufacturing Equipment (CRADA CRD-18-733 Final Report)

This CRADA between Energy Everywhere and NREL is to develop a process to fabricate flexible photovoltaic modules using a solution coated PVSK absorber with interlayers comprising materials deposited by economically feasible methods. Energy Everywhere™ will replicate and scale this process in Berkeley, California where it will ultimately commercialize the process, fabrication equipment, and PV modules.

14 SOLAR ENERGY↗
DOE OSTI2016

CsPbBr{sub 3} nanocrystal saturable absorber for mode-locking ytterbium fiber laser

Cesium lead halide perovskite nanocrystals (CsPbX{sub 3}, X = Cl, Br, I) have been reported as efficient light-harvesting and light-emitting semiconductor materials, but their nonlinear optical properties have been seldom touched upon. In this paper, we prepare layered CsPbBr{sub 3} nanocrystal films and characterize their physical properties. Broadband linear absorption from ∼0.8 to over 2.2 μm and nonlinear optical absorption at the 1-μm wavelength region are measured. The CsPbBr{sub 3} saturable absorber (SA), manufactured by drop-casting of colloidal CsPbBr{sub 3} liquid solution on a gold mirror, shows modulation depth and saturation intensity of 13.1% and 10.7 MW/cm{sup 2}, respectively. With this SA, mode-locking operation of a polarization-maintained ytterbium fiber laser produces single pulses with duration of ∼216 ps, maximum average output power of 10.5 mW, and the laser spectrum is centered at ∼1076 nm. This work shows that CsPbBr{sub 3} films can be efficient SA candidates for fiber lasers and also have great potential to become broadband linear and nonlinear optical materials for photonics and optoelectronics.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2023

Final Design of the LB650 Cryomodule for the PIP-II Linear Accelerator

The Proton Improvement Plan II (PIP-II) that will be installed at Fermilab is the first U.S. accelerator project that will have significant contributions from international partners. CEA joined the international collaboration in 2018, and its scope covers the supply of the 650 MHz low-beta cryomodule section, with the design of the cryostat (i.e the cryomodule without the cavities, the power couplers and the frequency tuning systems) and the manufacturing of its components, the assembly and tests of the pre-production cryomodule and 9 production modules. An important milestone was reached in April 2023 with the Final Design Review. This paper presents the detailed design of the 650 MHz low-beta cryomodules.

43 PARTICLE ACCELERATORS↗
DOE OSTI2018

Organization of Electric-Vehicle Production by Means of an Automated Control System

Prospects for the development of electric vehicles are considered. Recommendations are made regarding the organization of production by means of up-to-date control and information technologies. To ensure that a manufacturing enterprise remains flexible and competitive in an era of rapidly changing customer requirements, an appropriate information module must be developed and integrated with the enterprise’s information system.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2024

DuraMAT FY 2023 Annual Report: Toward Reliability Forecasting

The Durable Module Materials Consortium (DuraMAT) launched in November 2016 with five years of funding from the U.S. Department of Energy s (DOE's) Solar Energy Technologies Office (SETO). The program renewed in 2022 for an additional 6 years. DuraMAT is a multi-lab consortium led by the National Renewable Energy Laboratory, with Sandia National Laboratories (Sandia) and Lawrence Berkeley National Laboratory (LBNL) as core research labs. DuraMAT's overarching goal is to accelerate a sustainable, just, and equitable transition to zero-carbon electricity generation by 2035. 2023 has been a wild ride in the solar industry. Photovoltaic (PV) manufacturing is coming back to the United States, and deployment is booming again. DuraMAT has a unique opportunity to support flourishing manufacturing and deployment over the next couple of years.

durable module↗
DOE OSTI2018

Low-Cost III-V Photovoltaic Materials by Chloride Vapor Transport Deposition Using Safe Solid Precursors

Si-based photovoltaic devices dominate the market. As photovoltaic (PV) manufacturing costs have plummeted, technologies which increase efficiency have become critical. Si cell efficiencies are nearing theoretical limits and Si-based PV modules are unlikely to reach the 25-30% efficiency range. The use of III-V semiconductors is an obvious technical solution to improve efficiency, especially if they can be integrated directly with existing Si technology as tandems. High coefficients of light absorption along with tunable bandgaps and lattice constants have resulted in record conversion efficiencies for both one-sun and concentrator PV applications. GaAs, for example, has been used to manufacture single-junction photovoltaics with world-record efficiencies of 28.8% at one sun.2 However, costs for III-Vs must be dramatically reduced to produce cost-effective, high-efficiency PV solutions. III-V costs are controlled by two factors: semiconductor growth and the substrate. III-V growth is dominated today by metal-organic vapor phase epitaxy (MOVPE) with a lesser role played by molecular beam epitaxy (MBE). MOVPE costs are high due to the expense and low utilization (~30%) of precursors, modest growth rates (~100 nm min -1 ), equipment complexity, and safety infrastructure needed to handle toxic, pyrophoric gases.3 MBE costs are high due to slow growth rates and limitations of scalability. Details comparing plausible low-cost III-V growth methods are available in a review article published as a result of this project. The primary goal of this project was to demonstrate that close-spaced vapor transport (CSVT) using chloride (from HCl) as a transport agent can be used for the rapid growth of device-ready III-V layers from safe, solid-source precursors. In pursuit of this goal, we designed, built, and installed a new Cl-CSVT reactor based on insights from our previous H 2 O-CSVT growth system and in collaboration with equipment professionals at Malachite Technologies. This system was successfully used to grow epitaxial GaAs with controlled n-type doping, having mobilities similar to MOVPE. Detailed technical information and results can also be found in the primary publication resulting from this project. This work sets the stage for tackling the development of high-performance III-V single junctions and tandem devices directly on Si substrates, which was beyond the capabilities of our H2O-CSVT system. The design of the reactor’s source and substrate transfer system should allow for direct deposition of device structures. The collective innovations of our Cl-CSVT system might ultimately serve as an enabling process for commercialization of the technology through a collaboration with appropriate industrial partners.

14 SOLAR ENERGY↗
DOE OSTI2021

2020 ETI Annual Summer School: Data Science and Engineering

The Consortium for Enabling Technologies & Innovation (ETI) was established in 2019 to address emerging technologies within the context of nuclear nonproliferation. ETI creates a research and education environment to support cross-cutting technologies across three core disciplines: 1) computer and engineering science research specifically in a form of machine learning and high performance computing (HPC), 2) advanced manufacturing, and 3) nuclear detection technologies. For outreach and development, ETI hosted the first of three summer schools from August 24-28, 2020 with the theme of “Data Science and Engineering”. The school was hosted in an on-line format and had over 200 participants. The recorded content is available on-line as a resource for students. The summer school had four modules: 1) Fundamentals of data Applications, 2) Computational Machine Learning, 3) Bayesian Modeling and Inference, and 4) Data Science for Safeguards. Modules contained both lectures as well as student exercises. Poll Everywhere was utilized in some modules as an on-line method to engage large groups of students. Upcoming ETI Summer Schools include Novel Instrumentation in 2021 and Advanced Manufacturing in 2022.

Biegalski, Steven R.↗
DOE OSTI2021

Silicon strip defects and their impact on electrical performance of readout electronics

Abstract In preparation for the High Luminosity LHC (HL-LHC) runs, the ATLAS inner detector will be completely replaced with an all silicon Inner Tracker (ITk). Hybrid silicon pixel modules will be used for the innermost tracking layers, and silicon micro-strip detectors will be used the outer layers of the tracker. During the production of the detector, the sensors, readout electronics, and other components will undergo a series of quality control (QC) and quality assurance tests. Defects in the fabrication of the sensors will be flagged early in the manufacturer's and ATLAS QC tests. A study of the influence of sensor defects was performed to assess the characteristics of these defects in completed modules, and whether any defect posed a risk to the operation of the front-end readout electronics. All defects were found to have no impact on the performance of the front-end readout electronics for healthy amplifier channels, and defects that short the coupling between the strip implant and the metal readout electrode were only noticeable for strip leakage currents in excess of 250 nA, beyond the end-of-life currents expected for most sensors at the HL-LHC.

Instruments & Instrumentation↗
DOE OSTI2025

Uniform Mechanical Loading Can Test for Nonuniform Loading Durability

In this work, we present a method to evaluate the equivalency between any module mechanical loading conditions. The method is developed to address the specific failure mode of glass fracture and is based on Weibull analysis and weakest link theory. It considers the varying stress profile across the module to calculate the probability of glass fracture, which is used as the metric of equivalency. An idealized nonuniform loading scheme is employed to demonstrate the method and introduce the concept of the equivalent uniform load factor: a factor applied to the maximum pressure of the nonuniform load to obtain the equivalent uniform load value. It is demonstrated that this factor is less than unity for all nonuniform load cases considered, including snow and various characters of wind loading. These significant results suggest that uniform loading may be reliably, and practically, employed to evaluate photovoltaic module glass for nonuniform loading durability.

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 OSTI2012

Ultrafast Power Processor for Smart Grid: Power Module Development

This project’s goal was to increase the switching speed and decrease the losses of the power semiconductor devices and power switch modules necessary to enable Smart Grid energy flow and control equipment such as the Ultra-Fast Power Processor. The primary focus of this project involves exploiting the new silicon-based Super-GTO (SGTO) technology and build on prototype modules already being developed. The prototype super gate-turn-off thyristor (SGTO) has been tested fully under continuously conducting and double-pulse hard-switching conditions for conduction and switching characteristics evaluation. The conduction voltage drop measurement results indicate that SGTO has excellent conduction characteristics despite inconsistency among some prototype devices. Tests were conducted with two conditions: (1) fixed gate voltage and varying anode current condition, and (2) fixed anode current and varying gate voltage condition. The conduction voltage drop is relatively a constant under different gate voltage condition. In terms of voltage drop as a function of the load current, there is a fixed voltage drop about 0.5V under zero current condition, and then the voltage drop is linearly increased with the current. For a 5-kV voltage blocking device that may operate under 2.5-kV condition, the projected voltage drop is less than 2.5 V under 50-A condition, or 0.1%. If the device is adopted in a converter operating under soft-switching condition, then the converter can achieve an ultrahigh efficiency, typically above 99%. The two-pulse switching test results indicate that SGTO switching speed is very fast. The switching loss is relatively low as compared to that of the insulated-gate-bipolar-transistors (IGBTs). A special phenomenon needs to be noted is such a fast switching speed for the high-voltage switching tends to create an unexpected Cdv/dt current, which reduces the turn-on loss because the dv/dt is negative and increases the turn-off loss because the dv/dt is positive. As a result, the turn-on loss at low current is quite low, and the turn-off loss at low current is relatively high. The phenomenon was verified with junction capacitance measurement along with the dv/dt calculation. Under 2-kV test condition, the turn-on and turn-off losses at 25-A is about 3 and 9 mJ, respectively. As compared to a 4.5-kV, 60-A rated IGBT, which has turn-on and turn-off losses about 25 and 20 mJ under similar test condition, the SGTO shows significant switching loss reduction. The switching loss depends on the switching frequency, but under hard-switching condition, the SGTO is favored to the IGBT device. The only concern is during low current turn-on condition, there is a voltage bump that can translate to significant power loss and associated heat. The reason for such a current bump is not known from this study. It is necessary that the device manufacturer perform though test and provide the answer so the user can properly apply SGTO in pulse-width-modulated (PWM) converter and inverter applications.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
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↗