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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 883 records · Page 49
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Impact of acetic acid exposure on metal contact degradation of different crystalline silicon solar cell technologies

Degradation due to acetic acid in photovoltaic (PV) modules has been a commonly observed phenomenon for both damp-heat exposure and outdoor operations. Acetic acid is a degradation byproduct of ethylene-vinyl acetate (EVA), a common module encapsulant. To address this issue, robust metallization pastes and cell technologies are being developed. However, it is important to assess how these technologies perform in an acetic acid environment and withstand degradation before they are implemented in the solar market. In this work, we investigate the impact of acetic acid exposure on four different cell groups: monofacial passivated emitter and rear contact (PERC) cells with advanced telluride-based front contact pastes, bifacial PERC cells with novel aluminum rear contact pastes, bifacial tunnel oxide passivated contacts (TOPCon) cells, and silicon heterojunction (SHJ) cells. These cells were exposed to acetic acid for different time increments. The recombination losses were characterized by Suns-VOC, and multi-variate regression analysis of intensity-dependent photoluminescence (PL) images with Griddler AI. Resistive losses were tracked with the transmission line method (TLM). Samples showing severe performance degradation were selected for further materials characterization to understand the root cause. Top-down and cross-sectional scanning electron microscopy (SEM), energy dispersive spectroscopy (EDS), and X-ray photoelectron spectroscopy (XPS) were performed to investigate the change in materials properties. Our study shows that the front contacts of the bifacial TOPCon cells and monofacial PERC cells were significantly affected by acetic acid exposure. Here, the SHJ cells were found to be the most stable.

14 SOLAR ENERGY↗
DOE OSTI2023

PV encapsulant formulations and stress test conditions influence dominant degradation mechanisms

Polyethylene-based poly(ethylene-co-vinyl acetate) (EVA), polyolefin elastomer (POE), and thermoplastic polyolefin (TPO) are common polymer candidates for photovoltaic (PV) module encapsulants. The choice of encapsulant must be carefully considered in novel module designs, such as bifacial glass/glass laminates, to limit performance degradation through loss of optical transmittance, mechanical integrity, and corrosion - as well as potential-induced degradation. Encapsulant quality and resilience against environmental stressors are readily influenced by the additives in the encapsulant formulation. Here, we show that, the changes in optical transmittance after UV aging result from the discoloration caused by interactions between additives, and optical scattering from changes in the polymer crystal structure. We observed competing cross-linking and chain scission mechanisms, with their kinetics influenced by the presence of oxygen and elevated temperatures. Increasing chamber temperatures from 55 °C to 85 °C during the UV stress test amplified encapsulant discoloration and promoted polymer cross-linking, causing severe, irreversible damage that remains to be proven field relevant. Damp heat aging was found to be insufficient to produce significant encapsulant degradation; however, combining stress tests sequentially allowed detection of further degradation beyond the limitations of the damp heat test alone. Appropriate degradation screening methods are necessary to uncover potential encapsulant weaknesses.

14 SOLAR ENERGY↗
DOE OSTI2024

Material characterization of seven photovoltaic backsheets using seven accelerated test conditions

A variety of polymeric backsheet materials can be found in fielded photovoltaic (PV) modules, mostly based on fluoropolymer and polyethylene terephthalate (PET) materials. Cost reduction and sustainability considerations drive the recent development of alternative backsheet materials and designs [1]. In some fielded PV installations, polymeric materials are susceptible to environmental degradation in the form of backsheet cracking. To prevent backsheet degradation that can result in a module failure, thorough laboratory reliability testing is needed. In this report we studied the durability of seven commercial and experimental PV backsheets through accelerated stress testing using seven photolytic, hygrometric, and custom tests with the goal to understand if novel fluoropolymer-free backsheets are sufficiently environmentally durable to be commercialized. We divided the mechanisms observed during aging into two categories: core degradation and surface degradation. Although core degradation due to hydrolysis was observed in all commercial PET-, and polyamide (PA)-based backsheets aged with 85 degrees C/85% relative humidity, this test is unlikely to be field relevant. Photo-oxidative reactions on the exposed surface during UV weathering affected all seven backsheets regardless of the outer layer polymer material and additives. This degradation was limited to the outermost micrometers of the surface, except for backsheets containing PA-12, which resulted in surface cracking. A custom test combining UV with water spray caused the most severe backsheet degradation, including surface erosion and loss of insulating properties in polyolefin (PO)- and PA-based backsheets. This highlights the importance of combined accelerated stress testing to screen for complex backsheet degradation mechanisms. We also showed that, with material and design optimization, coextruded experimental PO-based backsheets have the potential to be a durable alternative to commercial PET- and fluoropolymer-based PV backsheets.

14 SOLAR ENERGY↗
DOE OSTI2014

Enhanced Water Vapor Blocking in Transparent Hybrid Polymer–Nanocrystal Films

Highly transparent and effective encapsulating materials have become increasingly important for photovoltaic (PV) modules to prevent water vapor molecules from permeating PV cells. The composite consists of block copolymer (PS- b -P2VP), comprised of hydrophobic and hydrophilic parts, and hygroscopic nanocrystals (Magnesium Oxide, MgO) incorporated to enhance water vapor blocking by both presenting obstacles for mass transport and also scavenging water molecules. Here, the water vapor transmission rate (WVTR) values were reduced ~3000 times, compared to homopolymer (PS), for both polymer and composite samples. Achieving both high transparency and low WVTR, it is expected that the composite materials can function as an excellent water vapor blocking layer for PV modules.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Degradation Mechanism Detection in Photovoltaic Backsheets by Fully Convolutional Neural Network

Materials and devices age with time. Material aging and degradation has important implications for lifetime performance of materials and systems. While consensus exists that materials should be studied and designed for degradation, materials inspection during operation is typically performed manually by technicians. The manual inspection makes studies prone to errors and uncertainties due to human subjectivity. In this work, we focus on automating the process of degradation mechanism detection through the use of a fully convolutional deep neural network architecture (F-CNN). We demonstrate that F-CNN architecture allows for automated inspection of cracks in polymer backsheets from photovoltaic (PV) modules. The developed F-CNN architecture enabled an end-to-end semantic inspection of the PV module backsheets by applying a contracting path of convolutional blocks (encoders) followed by an expansive path of decoding blocks (decoders). First, the hierarchy of contextual features is learned from the input images by encoders. Next, these features are reconstructed to the pixel-level prediction of the input by decoders. The structure of the encoder and the decoder networks are thoroughly investigated for the multi-class pixel-level degradation type prediction for PV module backsheets. The developed F-CNN framework is validated by reporting degradation type prediction accuracy for the pixel level prediction at the level of 92.8%.

14 SOLAR ENERGY↗
DOE OSTI2025

Scientific frontiers of agrivoltaic cropping systems

Agrivoltaic (AV) systems integrate agriculture with electricity conversion through photovoltaic (PV) modules. Compared with conventional ground-mounted PV systems, AV systems can reduce land-use competition and offer agronomic and economic advantages, such as more stable crop production and additional farm income. However, AV systems can decrease agricultural performance and are typically 20-90% costlier to install than conventional PV systems. Here, in this Review, we analyse the implementation of AV cropping systems to preserve agricultural activities and highlight challenges and barriers. The global electricity potential of AV systems is ~66-385 PWh annually, depending on PV technology and installation density, if deployed in the most suitable areas, without accounting for grid availability. Scaling up has been hindered by crop selection for shading conditions, decreased energy conversion per unit of land area and issues with social acceptance, landscape impact and environmental sustainability. These issues can be addressed by developments such as wavelength-selective PV; system configurations, such as optimizing module spacing to reduce shading; and operational methods, such as optimizing tracking strategies and integrating agricultural infrastructure. Cross-sector policies can support AV systems by addressing the needs of diverse stakeholders over shared land resources. Further development will require collaboration among the design, performance, deployment and systems research communities.

14 SOLAR ENERGY↗
DOE OSTI2015

Temperature-dependent spectral mismatch corrections

This study develops the mathematical foundation for a translation of solar cell short-circuit current from one thermal and spectral irradiance operating condition to another without the use of ill-defined and error-prone temperature coefficients typically employed in solar cell metrology. Using the partial derivative of quantum efficiency with respect to temperature, the conventional isothermal expression for spectral mismatch corrections is modified to account for changes of current due to temperature; this modification completely eliminates the need for short-circuit-current temperature coefficients. An example calculation is provided to demonstrate use of the new translation.

14 SOLAR ENERGY↗
DOE OSTI2018

Indoor Soil Deposition Chamber: Evaluating Effectiveness of Antisoiling Coatings

An indoor soil deposition method has been developed to simulate natural soil deposition on glass coupons or one-cell and multicell photovoltaic (PV) modules. This method uses variable ambient humidity, coupon/module temperature, and dust composition within a single custom-made chamber to create a natural and uniform soil deposition layer. Antisoiling (AS) coatings from two different manufacturers were applied on two one-cell monocrystalline silicon modules. Three layers of Arizona road dust have been deposited on the one-cell modules with AS coatings and an uncoated one-cell reference module at varied humidity levels. The soiled modules were exposed to an open-circuit subsonic wind tunnel at varying speeds and the effectiveness of AS coatings have been quantified using the transmittance gain. Transmittance loss resulting from the AS coating has been measured and compared with the transmittance of the uncoated reference module using a reflectance spectrophotometer. Reflectance measurements have also been taken to compare the transmittance loss of Arizona road dust and soil collected from PV modules' superstrates. The soiled one-cell modules were then exposed to rain from a rain simulator. The transmittance gain due to rain exposure is quantified using a rain gain and rain coefficient. These tests cumulatively may be used to help develop a test standard for evaluating the effectiveness of AS coatings.

14 SOLAR ENERGY↗
DOE OSTI2019

FTIR Investigation of EVA Chemical Bonding Environment and Its Impact on Debond Energy

The chemical makeup of ethylene vinyl acetate (EVA) interfaces in photovoltaic (PV) modules is probed via Fourier-transform infrared spectroscopy (FTIR) to determine the impact of the EVA formulation on the adhesion degradation. EVA samples laminated with glass particles are used to demonstrate the effect of damp heat exposure on the glass-EVA interface, showing that increasing silane content increases chemical stability. Delamination interfaces created in one cell modules demonstrate a high correlation between the siloxane bonding at the silicon cell-EVA interface and the debond energy. A significant decrease in debond energy after UV exposure is also shown to be due in part to decreasing siloxane bond density at the interface. However, FTIR results indicated contributions to the adhesion beyond the chemical interface, and a basic tensile test indicates increasing bulk mechanical properties with increasing silane. These results demonstrate the importance of the EVA formulation on its adhesion performance and long-term reliability. Furthermore, it is shown that FTIR is a capable technique for assessing and quantifying chemical mechanisms within PV modules. These results can then be used to more effectively model module lifetimes and to better design polymer systems for PV modules.

14 SOLAR ENERGY↗
DOE OSTI2021

Solder Bond Fatigue is Insensitive to Module Size

In this article, we explore the influence of module size on the rate of interconnecting solder bond thermomechanical fatigue (TMF) damage. Structural mechanics models of crystalline silicon PV models are created to solve with the finite-element method. Results conclusively demonstrate that the rate of solder bond TMF damage is independent of module size, interconnect location across the cell and cell location across the module.

14 SOLAR ENERGY↗
DOE OSTI2021

Failure Analysis of a New Polyamide-Based Fluoropolymer-Free Backsheet After Combined-Accelerated Stress Testing

The viability of novel coextruded, fluoropolymer-free backsheets for photovoltaic (PV) modules has been questioned as a result of a large number of early-life backsheet failures in PV installations containing one of the earliest co-extruded polyamide (PA)-based backsheet to reach the market, “AAA.” New PV reliability testing protocols have been recently developed and applied to backsheets to reproduce failures observed in the field and evaluate the durability of novel backsheet materials and designs prior to commercialization. A new co-extruded PA-based backsheet was tested using combined-accelerated stress testing (C-AST) and demonstrated a greater lifetime than AAA, and some other fluoropolymer-based backsheets such as polyvinylidene fluoride. The improved PA-based backsheet also eventually failed by through-thickness cracking. Using surface and bulk material characterization techniques, we performed a comprehensive study of material properties before and after the stress testing. Aging of the backsheet resulted in an increase of surface roughness by erosion of the outer PA layer. However the failure is more likely related to an increase in crystallinity of the polyolefin core layer reducing the backsheet tearing energy. The analysis can ultimately inform on the specific weaknesses of the materials so that the manufacturer can improve the backsheet design to extend its lifetime.

14 SOLAR ENERGY↗
DOE OSTI2018

The Holy Grail of Resource Assessment: Low Cost Ground-Based Measurements with Good Accuracy

Using performance data from some of the millions of installed photovoltaic (PV) modules with micro-inverters may afford the opportunity to provide ground-based solar resource data critical for developing PV projects. The method used back-solves for the direct normal irradiance (DNI) and the diffuse horizontal irradiance (DHI) from the micro-inverter ac production data. When the derived values of DNI and DHI were then used to model the performance of other PV systems, the annual mean bias deviations were within +/-4%, and only 1% greater than when the PV performance was modeled using high quality irradiance measurements. An uncertainty analysis shows the method better suited for modeling PV performance than using satellite-based global horizontal irradiance.

14 SOLAR ENERGY↗
DOE OSTI2018

Encapsulant Adhesion to Surface Metallization on Photovoltaic Cells

Delamination of encapsulant materials from PV cell surfaces often appears to originate at regions with metallization. Using a fracture mechanics based metrology, the adhesion of EVA encapsulant to screen printed silver metallization was evaluated. At room temperature, the fracture energy, G c [J/m 2 ], of the EVA/silver interface (952 J/m 2 ) was ~70% lower than that of the EVA/AR coating (>2900 J/m 2 ) and ~60% lower than that of the EVA to the surface of cell (2265 J/m 2 ). After only 300 hours of damp heat aging, the adhesion energy of the silver interface dropped to and plateaued at ~50-60 J/m 2 , while that of the EVA/AR coating and EVA/cell remained mostly unchanged. Elemental surface analysis showed that the EVA separates from the silver in a purely adhesive manner, indicating that bonds at the interface were likely displaced in the presence of humidity and chemical byproducts at elevated temperature, which in part accounts for the propensity of metallized surfaces to delaminate in the field.

14 SOLAR ENERGY↗
DOE OSTI2020

Understanding PV Polymer Backsheet Degradation through X-Ray Scattering

Understanding how photovoltaic (PV) module backsheet polymers age and degrade in response to environmental stresses is important for designing polymers that can maintain their structural integrity after decades of outdoor use. X-ray scattering is a powerful technique for exploring backsheet polymer structure at the angstrom- (wide-angle, WAXS) and nanometer- (small-angle, SAXS) length-scales. We present the use of SAXS and WAXS to study pristine and aged polymer backsheets. The structural insight from these techniques can be used to compare the degradation induced by accelerated testing with the degradation seen in field-aged PV materials.

14 SOLAR ENERGY↗
DOE OSTI2021

Representative Modules for Accelerated Thermal Cycling and Static Load Testing

In this work, we explore the influence of module size on the rate of interconnect solder bond thermomechanical fatigue (TMF) damage and the probability of cell fracture. For the solder bond TMF damage evaluation, structural mechanics models of crystalline silicon PV models are created to solve with the Finite Element Method. For the probability of cell fracture evaluation, Weibull analysis and weakest link theory are employed to resolve the probability of crystalline silicon PV cell fracture when measured as bare cells and when stressed in reduced- and full-sized modules. Results conclusively demonstrate that the rate of solder bond TMF damage is independent of module size, interconnect location across the cell and cell location across the module and that smaller, representative, modules must be loaded to a much higher level than their parent full-sized modules to achieve an equivalent driving force for cell fracture.

accelerated testing↗
DOE OSTI2021

Ultraviolet Fluorescence Bleaching Rates for New Cell Cracks

Ultraviolet Fluorescence (UVF) is an inspection tool that can be used to identify cell cracks in some photovoltaic (PV) modules. Cell cracks can also be identified with electroluminescence (EL) and similar techniques, but it is generally not possible to differentiate new cracks from old ones with EL. UVF has a unique property of taking time for the cracks to show up, which could be used to differentiate new cracks (e.g., from a recent storm) from old ones (e.g., from installation damage). We perform tests on several different modules, some the same make and model but with different bill of materials (BOMs), to characterize the amount of time that it takes for crack signatures to progress in UVF.

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