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All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Residual Stresses Affect Cell Fragment Movement

Predictive modeling tools such as the finite element method can be of tremendous help in assessing the reliability and long-term performance of photovoltaic modules. In order to obtain accurate results, the proper modeling of materials and manufacturing processes are of utmost importance. Module fabrication introduces thermo-mechanical stresses inside the module laminate, which need to be accounted for as residual stresses in finite element simulations. We found that cell fragment movement and crack opening displacements of fractured silicon cells within modules are affected by those residual stresses. Cell cracking remains a challenging topic in assessing the reliability and durability of damaged modules. Hence, accurately quantifying the separation and movement between cell fragments creates the foundation for establishing reliable lifetime and performance assessments of fractured silicon modules. Here, we present a modeling approach that uses upper and lower bounds to accurately account for the residual stresses introduced by the module lamination process. We designed a four-point flexure coupon test of a laminated, fractured silicon strip to validate our numerical results and found good agreement between our modeling methodology and the experimental data. Finally, we discuss the implications of the residual stresses on the normal crack opening and metallization wear-out of fractured silicon cells.

14 SOLAR ENERGY↗
DOE OSTI2021

Environmental Influence on Fracture and Delamination of Electrically Conductive Adhesives

This paper presents our continued work on developing a degradation model for electrically conductive adhesive (ECA) interconnects in photovoltaic modules. Here, we characterize the fracture mechanics properties of an epoxy based ECA, for both critical and subcritical loading conditions. Emphasis is put on the influence of different environmental conditions such as temperature and humidity. We found that high levels of humidity not only weaken the adhesive joint but also promote subcritical debonding at significantly lower driving forces than in dry environments.

41 EE - Solar Energy Technologies Office (EE-4S)↗
DOE OSTI2017

Measures of International Manufacturing and Trade of Clean Energy Technologies

The technologies that produce clean energy, such as solar photovoltaic panels and lithium ion batteries for electric vehicles, are globally manufactured and traded. As demand and deployment of these technologies grows exponentially, the innovation to reach significant economies of scale and drive down energy production costs becomes less in the technology and more in the manufacturing of the technology. Manufacturing innovations and other manufacturing decisions can reduce costs of labor, materials, equipment, operating costs, and transportation, across all the links in the supply chain. To better understand the manufacturing aspect of the clean energy economy, we have developed key metrics for systematically measuring and benchmarking international manufacturing of clean energy technologies. The metrics are: trade, market size, manufacturing value-added, and manufacturing capacity and production. These metrics were applied to twelve global economies and four representative technologies: wind turbine components, crystalline silicon solar photovoltaic modules, vehicle lithium ion battery cells, and light emitting diode packages for efficient lighting and other consumer products. The results indicated that clean energy technologies are being developed via complex, dynamic, and global supply chains, with individual economies benefiting from different technologies and links in the supply chain, through both domestic manufacturing and global trade.

2017↗
DOE OSTI2016

Clean Energy Manufacturing Analysis Center (CEMAC) 2015 Research Highlights

CEMAC has conducted four major studies on the manufacturing of clean energy technologies. Three of these focused on the end product: solar photovoltaic modules, wind turbines, and automotive lithium-ion batteries. The fourth area focused on a key material for manufacturing clean energy technologies, carbon fiber. This booklet summarizes key findings of CEMAC work to date, describes CEMAC's research methodology, and describes work to come.

14 SOLAR ENERGY↗
DOE OSTI2015

Economics of Future Growth in Photovoltaics Manufacturing

The past decade's record of growth in the photovoltaics manufacturing industry indicates that global investment in manufacturing capacity for photovoltaic modules tends to increase in proportion to the size of the industry. The slope of this proportionality determines how fast the industry will grow in the future. Two key parameters determine this slope. One is the annual global investment in manufacturing capacity normalized to the manufacturing capacity for the previous year (capacity-normalized capital investment rate, CapIR, units $/W). The other is how much capital investment is required for each watt of annual manufacturing capacity, normalized to the service life of the assets (capacity-normalized capital demand rate, CapDR, units $/W). If these two parameters remain unchanged from the values they have held for the past few years, global manufacturing capacity will peak in the next few years and then decline. However, it only takes a small improvement in CapIR to ensure future growth in photovoltaics. Any accompanying improvement in CapDR will accelerate that growth.

14 SOLAR ENERGY↗
DOE OSTI2015

Economics of Future Growth in Photovoltaics Manufacturing; NREL (National Renewable Energy Laboratory)

The past decade’s record of growth in the photovoltaic manufacturing industry indicates that global investment in manufacturing capacity for photovoltaic modules tends to increase in proportion to the size of the industry. The slope of this proportionality determines how fast the industry will grow in the future. Two key parameters determine this slope. One is the annual global investment in manufacturing capacity normalized to the manufacturing capacity for the previous year (capacity-normalized capital investment rate, CapIR, units $/W). The other is how much capital investment is required for each watt of annual manufacturing capacity, normalized to the service life of the assets (capacity-normalized capital demand rate, CapDR, units $/W). If these two parameters remain unchanged from the values they have held for the past few years, global manufacturing capacity will peak in the next few years and then decline. However, it only takes a small improvement in CapIR to ensure future growth in photovoltaics. Any accompanying improvement in CapDR will accelerate that growth.

14 SOLAR ENERGY↗
DOE OSTI2023

Close Roof Mounted System Temperature Estimation for Compliance to IEC TS 63126

When photovoltaic modules are installed on rooftops the temperature is dependent on both the geographic location and the mounting configuration. If the mounting structure does not provide sufficient air flow in a hot environment, the 98th percential temperature will exceed 70 degrees C which according to IEC TS 63126 requires higher levels of thermal stability testing. However, a simple there is not a clear way to determe which temperature level is needed for a particular location and system design. In this work we identify a relationship between the gap between the rooftop and a module and propose methods to describe minimum gaps for a given location. Because system designs vary in more ways than just the gap, we show how to determine an effective gap which can be simply applied to generic calculations. Lastly, we show measurements and calculations from several systems to demonstrate how this method could work.

IEC 63126↗
DOE OSTI2015

Orange County Government Solar Demonstration and Research Facility

Orange County Florida completed the construction of a 20 kilowatt Solar Demonstration and Research Facility in March 2015. The system was constructed at the Orange County/University of Florida Cooperative Extension Center whose electric service address is 6021 South Conway Road, Orlando, Florida 32802. The Solar Demonstration and Research Facility is comprised of 72 polycrystalline photovoltaic modules and 3 inverters which convert direct current from the solar panels to alternating current electricity. Each module produces 270 watts of direct current power, for a total canopy production of just under 20,000 watts. The solar modules were installed with a fixed tilt of 5 degrees and face south, toward the equator to maximize the amount of sunlight captures. Each year, the electricity generated by the solar array will help eliminate 20 metric tons of carbon dioxide emissions as well as provide covered parking for staff and visitors vehicles. The solar array is expected to generate 27,000 kilowatt hours of electricity annually equating to an estimated $\$$266 savings in the monthly electric bill, or $\$$3,180 annually for the Orange County/University of Florida Cooperative Extension Center. In addition to reducing the electric bill for the Extension Center, Orange County’s solar array also takes advantage of a rebate incentive offered by the local utility, Orlando Utility Commission, which provided a meter that measures the amount of power produced by the solar array. The local utility company’s Solar Photovoltaic Production Incentive will pay Orange County $\$$0.05 per kilowatt hour for the power that is produced by the solar array. This incentive is provided in addition to Net Metering benefits, which is an effort to promote the use of clean, renewable energy on the electric grid. The Photovoltaic Solar Demonstration and Research Facility also serves an educational tool to the public; the solar array is tied directly into a data logger that provides real time power generation accessible for public viewing on an interactive kiosk located in the Orange County/University of Florida Cooperative Extension Center’s lobby where visitors can review “real time” power generation, cost savings and environmental benefits of the system. Site commissioning with the software program was delayed due to Internal Security Software issues within Orange County that needed to be resolved, therefore the “real time” capture of the production data for the solar array using the software program commenced on May 1, 2015. In addition an educational flyer was developed and is available in the Orange County Education Center’s main lobby. The project completed under this grant award assisted Orange County in demonstrating leadership by installing the application of a renewable energy technology combined with energy efficiency measures; resulting in reduced energy costs for the Orange County University of Florida Cooperative Extension Center, and helping Orange County citizens and visitors move towards the goals of greater energy independence and climate protection. The addition of the new Solar Demonstration and Research Facility has advanced the Orange County/University of Florida Cooperative Extension Center’s mission of extending, educating and providing research-based information to residents and visitors of Orange County by demonstrating the application of renewable energy technology combined with energy efficiency measures; resulting in reduced energy costs, and helping Orange County move towards the goal of greater energy independence and climate protection. In 2014, the Orange County Cooperative Extension Center hosted nearly 10,800 visitors to their on-site Exploration Gardens plus 12,686 walk-in visitors to their office plant clinic and other services. The Education Center held 2,217 educational events that were attended by 46,434 adults and youth, but about half of those events occurred off-site. Based on the visitation numbers in 2014 the Orange County Cooperative Extension Center Education is a vital partner to Orange County’s continued outreach and education efforts concerning renewable energy technologies and greenhouse gas emission reduction well in the current 2015 year and future years of operation of the solar array to the future visitors of the Center which help stimulate market demand that will continue to advance the commercialization and the widespread application and use of renewable energy technologies in Orange County and the state of Florida. The project period performance date for this grant was November 1, 2009 through March 1, 2015. The Final Project costs to complete the project as reported in the FINAL SF 425 were $\$$195,512.50 (50% recipient cost share was satisfied as required by grant terms and conditions).

14 SOLAR ENERGY↗
DOE OSTI2015

Two-dimensional boron–nitrogen–carbon monolayers with tunable direct band gaps

The search for new candidate semiconductors with direct band gaps of ~1.4 eV has attracted significant attention, especially among the two-dimensional (2D) materials, which have become potential candidates for next-generation optoelectronics. In this work, we systematically studied 2D B x /2 N x /2 C 1– x (0 < x < 1) compounds in particular focus on the four stoichiometric B x /2 N x /2 C 1– x ( x = 2/3, 1/2, 2/5 and 1/3) using a recently developed global optimization method (CALYPSO) in conjunction with density functional theory. Furthermore, we examine more stoichiometries by the cluster expansion technique based on a hexagonal lattice. The results reveal that all monolayer B x /2 N x /2 C 1– x stoichiometries adopt a planar honeycomb character and are dynamically stable. Remarkably, electronic structural calculations show that most of B x /2 N x /2 C 1– x phases possess direct band gaps within the optical range, thereby they can potentially be used in high-efficiency conversion of solar energy to electric power, as well as in p–n junction photovoltaic modules. The present results also show that the band gaps of B x /2 N x /2 C 1– x can be widely tuned within the optical range by changing the concentration of carbon, thus allowing the fast development of band gap engineered materials in optoelectronics. These new findings may enable new approaches to the design of microelectronic devices.

36 MATERIALS SCIENCE↗
DOE OSTI2016

A stochastic model of solid state thin film deposition: Application to chalcopyrite growth

Developing high fidelity quantitative models of solid state reaction systems can be challenging, especially in deposition systems where, in addition to the multiple competing processes occurring simultaneously, the solid interacts with its atmosphere. In this work, we develop a model for the growth of a thin solid film where species from the atmosphere adsorb, diffuse, and react with the film. The model is mesoscale and describes an entire film with thickness on the order of microns. Because it is stochastic, the model allows us to examine inhomogeneities and agglomerations that would be impossible to characterize with deterministic methods. We demonstrate the modeling approach with the example of chalcopyrite Cu(InGa)(SeS){sub 2} thin film growth via precursor reaction, which is a common industrial method for fabricating thin film photovoltaic modules. The model is used to understand how and why through-film variation in the composition of Cu(InGa)(SeS){sub 2} thin films arises and persists. We believe that the model will be valuable as an effective quantitative description of many other materials systems used in semiconductors, energy storage, and other fast-growing industries.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2018

Experimental demonstration of voltage-matched two-terminal tandem minimodules

Mechanically stacked tandem solar cells are a potential near-term solution for increasing the efficiency of photovoltaic modules. Practical implementation requires an interconnection approach that maximizes efficiency and minimizes complexity and cost. Connecting the top and bottom cells in a voltage-matched configuration allows two-terminal modules to be fabricated without altering the cell design or processing methods. Here, we experimentally demonstrate two-terminal voltage-matched GaInP 2 / Si minimodules. The two-terminal minimodules performed just as well as four terminal configurations when voltage-matching requirements were met. The magnitude of the efficiency loss experienced by the voltage-matched minimodule when voltage-matched conditions were not met depends on whether the voltage was constrained by the GaInP 2 or Si cells. Monte Carlo simulations also indicate that the two-terminal voltage-matched tandems respond to small cell-to-cell parameter variations in a similar manner as four terminal tandems.

14 SOLAR ENERGY↗
DOE OSTI2024

Cracked Gridline Wear Out Follows a Power Law

Cracks can form in Silicon solar cells in photovoltaic modules due to mechanical stresses arising from various extrinsic factors like handling and weather. While the immediate performance degradation may be minor, continuous loading overtime will degrade module performance. One probable reason is gridline surface wear across the cracked silicon with increased cyclic loading. In this work we propose a method to correlate gridline wear to module electrical degradation. We begin by conducting cyclic four-point bending tests on laminated silicon solar cells with a single crack and 22 intact gridlines for 10,000 cycles. We measure the progressive change in resistance during each loading cycle. We correlate it to a length scale called critical crack opening displacement (CCOD) that signifies failure of individual gridlines. By employing Weibull analysis, we determine the characteristic CCOD for all cycles and fit this data to a modified version of a wear power law. We observe that this i ts the data well. We also propose to study the effect of individual parameters in the power law equation and extend the equation to include material properties.

bending↗
DOE OSTI2025

Durability Research Is Pivotal for Perovskite Photovoltaics

Metal halide perovskite solar cells have shown promising power conversion efficiencies, but commercialization requires that decent durability is also demonstrated. Under normal operation, solar cells are subject to a complex combination of stressors, such as visible light, ultraviolet light, heat, humidity, mechanical stress and electric potential, which complicates the understanding of failure mechanisms. Existing stress tests do not act as a time machine. In new materials systems such as perovskite photovoltaics, the tests have no known relationship to field service. In this Perspective we recommend following a durability learning cycle that interleaves photovoltaic module engineering with field testing; accelerated testing; and preconditioning and performance engineering. We advocate for field testing to demonstrate real-world performance and identify field-relevant failure modes, and urge the community to develop accelerated and qualification tests that account for device metastability, variations in material composition and different/various processing methods. In conclusion, these practices are more difficult, but more important, than the simple pursuit of higher initial efficiencies.

14 SOLAR ENERGY↗
DOE OSTI2020

Photovoltaic Cleaning Frequency Optimization Under Different Degradation Rate Patterns

Dust accumulation significantly affects the performance of photovoltaic modules and its impact can be mitigated by various cleaning methods. Optimizing the cleaning frequency is essential to minimize the soiling losses and, at the same time, the costs. However, the effectiveness of cleaning lowers with time because of the reduced energy yield due to degradation. Additionally, economic factors such as the escalation in electricity price and inflation can compound or counterbalance the effect of degradation on the soiling mitigation profits. The present study analyzes the impact of degradation, escalation in electricity price and inflation on the revenues and costs of cleanings and proposes a methodology to maximize the profits of soiling mitigation of any system. Here, the energy performance and soiling losses of a 1 MW system installed in southern Spain were analyzed and integrated with theoretical linear and nonlinear degradation rate patterns. The Levelized Cost of Energy and Net Present Value were used as criteria to identify the optimum cleaning strategies. The results showed that the two metrics convey distinct cleaning recommendations, as they are influenced by different factors. For the given site, despite the degradation effects, the optimum cleaning frequency is found to increase with time of operation.

14 SOLAR ENERGY↗
DOE OSTI2024

Evaluation of Surface Crack Formation in Photovoltaic Backsheets Using Fragmentation and Finite Element Simulations

Backsheet cracking is among the most commonly observed degradation modes of photovoltaic modules in the field. Cracks can reduce the ability of backsheets to fulfill their functions, such as protection of the modules from the environment or electrical insulation. Here, this work presents an evaluation of the degradation and cracking propensity of two backsheets during accelerated IEC TS 62788-7-2 (International Electrotechnical Commission) aging under the A3 condition with a fragmentation test using a coextruded polyamide backsheet (AAA), and a laminated multilayer backsheet with a polyethylene terephthalate core and outer layer and ethylene vinyl acetate inner layer (PPE). Results show the surface embrittlement of the AAA outer layer during exposure. A longer time of exposure causes cracks to form at lower strains during stretching and creates deeper cracks. Accordingly, Young's modulus of the outer layer increases, as measured by cross-sectional nanoindentation. PPE exhibits cracking after exposure as well. While no similar increase of modulus or crack depth can be observed, the outer layer of PPE exhibits more obvious signs of erosion during exposure, including progressive morphological changes and thickness losses. A finite element model is developed to simulate surface crack formation, based on initially zero-thickness decohesion elements. Decohesion criteria define a critical stress, at which these elements grow, and cracks can begin to form. These criteria are obtained via parameter optimization by comparison between simulation and experiment. The model is used to interpret crack formation in both backsheets.

14 SOLAR ENERGY↗
DOE OSTI2022

Light- and Elevated-Temperature-Induced Degradation-Affected Silicon Cells From a Utility-Scale Photovoltaic System Characterized by Deep-Level Transient Spectroscopy

Photovoltaic modules from a utility-scale field experienced power loss by light- and elevated-temperature-induced degradation (LeTID). Samples from the affected monocrystalline silicon cells are cored and extracted from the module packaging and then laser-scribed to form 2-mm diameter isolated areas. Using deep-level transient spectroscopy, a majority-carrier, hole-trap defect with an activation energy of 0.42 eV is detected on degraded and regenerated samples. The LeTID-degraded sample, however, has a larger signal corresponding to a trap density of 1.1 x 10 13 cm -3 , which is about five times larger than the 2.1 x 10 12 cm -3 trap density of the regenerated sample. An increase in filling pulse time from 50 u s to 20 ms shows a slight decrease in activation energy from 0.42 to 0.36 eV suggesting that the defect level may consist of a band of energy states where shallower states continue to fill with long filling times. The capture rate of the defect is directly measured using an increasing series of filling pulsewidths in 15 to 125 ns range. This leads to a measured capture cross section of 5.1 x 10 -17 cm 2 , and using an approximate defect density of 10 13 cm -3 , the majority-carrier-hole lifetime related to this defect is approximately 100 u s when in the LeTID-degraded state.

charge carrier lifetime↗
DOE OSTI1991

Physical and Operational Status of the Photovoltaic Systems in the Municipality of Pinotepa de Don Luis, Oaxaca, One Year after Their Installation [Estado fisico y operativo de los sistemas fotovoltaicos en el municipio de Pinotepa de Don Luis, Oaxaca un ano despues de su instalacion]

In November 1990, an inspection visit was made to the residential lighting photovoltaic systems that had been installed approximately one year before in the rural communities of the Municipality of Pinotepa de Don Luis, in the State of Oaxaca. The main purpose of the visit was to evaluate the physical and operational status of these systems. The systems typically consist of a photovoltaic module with a capacity of 30 or 35 Watts, an automotive type battery, an indicator of the status of charge of the battery, 3 fluorescent lamps and the corresponding installation, including cables, connection or outlet box and switches. It can be seen that the systems are in good physical condition and do not show any signs of intentionally caused damage. However, the incidence of failures is higher than what had been expected; therefore the operational status of these systems is considered to be below a level that could be accepted, with a tendency to getting worse. The main problem that has been detected is the lack of automatic charge controllers. This problem has caused other important failures. Serious deficiencies were appreciated in the installations, which show evidence of the poor workmanship of the installers. The lack of system standardization is evident, both regarding the components and the installation. As a consequence, there are technical factors which indicate that the installed systems will keep deteriorating at a rate faster than normal, and will stop operating in a short time unless urgent preventive and corrective measures are taken. The attitude of the users with respect to the systems is generally positive. However, there are elements that make the correct operation and maintenance of these systems a very difficult task. The users did not receive any training regarding the best way to operate and take care of their systems, nor any other information in relation to their technical limitations.

14 SOLAR ENERGY↗
DOE OSTI2018

A non-destructive method for crack quantification in photovoltaic backsheets under accelerated and real-world exposures

The long-term durability of photovoltaic modules is paramount for the continued growth of the industry. Polymer backsheets are of particular concern since they provide electrical insulation and an environmental barrier. In this paper, 23 freestanding, multilayer backsheets with nine unique material combinations underwent four different weathering exposures under accelerated and real-world conditions. Besides changes in color and gloss, the induced degradation included parallel or mudflat cracks on 11 backsheets, sometimes in combination with delamination or blistering. Similar degradation has been observed in previous studies and is concerning since cracks compromise the mechanical integrity and electrical safety of backsheets. Quantitative parameters are desirable to reliably classify categories of cracks and supply unbiased features for statistical analysis in predictive lifetime models. We developed an analysis technique that utilizes surface profilometry data to quantify the depth, width, area, spacing, and number of cracks. Parameters are automatically extracted from the raw data by an algorithm running on a high performance distributed computing cluster. Our algorithm excelled at characterizing parallel cracks with minimal de-adhesion, and only an estimated 4% of crack detections were false positives. The addition of humidity and temperature variation formed up to three times as many cracks on a photodose basis compared to dry, constant temperature exposures. Cracks in real-world and accelerated exposures propagated to similar depths with equivalent photodoses; however, the number of cracks formed in accelerated exposures was far greater on a photodose basis. Of samples that cracked, the best performing backsheet configuration was polyvinyl fluoride/poly (ethylene-terephthalate)/polyethylene (PVF/PET/PE) while the least durable was PET/PET/ethylene-vinyl acetate. Finally, none of the six PVF/PET/PVF backsheets cracked in any of the exposures.

14 SOLAR ENERGY↗