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Roll-to-roll Manufacturing of Continuous Perovskite Modules

This project researched the development of inks that were roll-to-roll compatible and that could reduce processing time to achieve high speed operation. This necessitated the development of two nanoparticle inks, tin oxide (SnO 2 ) and nickel oxide (NiO) as electron transport layer (ETL) and hole transport layer (HTL) respectively. Several PVSK inks were also developed including a methyl ammonium lead iodide (MAPI), a mixed cation chemistry (MC) and a triple cation (TC) chemistry. All of these layers were demonstrated in roll-to-roll compatible processes utilizing Intense Pulsed Light (IPL) processing.

14 SOLAR ENERGY↗

Stationary semi-solid battery module and method of manufacture

A method of manufacturing an electrochemical cell includes transferring an anode semi-solid suspension to an anode compartment defined at least in part by an anode current collector and an separator spaced apart from the anode collector. The method also includes transferring a cathode semi-solid suspension to a cathode compartment defined at least in part by a cathode current collector and the separator spaced apart from the cathode collector. The transferring of the anode semi-solid suspension to the anode compartment and the cathode semi-solid to the cathode compartment is such that a difference between a minimum distance and a maximum distance between the anode current collector and the separator is maintained within a predetermined tolerance. The method includes sealing the anode compartment and the cathode compartment.

25 ENERGY STORAGE↗

Stationary semi-solid battery module and method of manufacture

A method of manufacturing an electrochemical cell includes transferring an anode semi-solid suspension to an anode compartment defined at least in part by an anode current collector and an separator spaced apart from the anode collector. The method also includes transferring a cathode semi-solid suspension to a cathode compartment defined at least in part by a cathode current collector and the separator spaced apart from the cathode collector. The transferring of the anode semi-solid suspension to the anode compartment and the cathode semi-solid to the cathode compartment is such that a difference between a minimum distance and a maximum distance between the anode current collector and the separator is maintained within a predetermined tolerance. The method includes sealing the anode compartment and the cathode compartment.

Slocum, Alexander H.↗

Cost estimates of production scale semitransparent organic photovoltaic modules for building integrated photovoltaics

Building integrated photovoltaics (BIPVs) are attached to commercial and residential structures to enable solar energy harvesting. While conventional Si photovoltaics (PVs) are dominant in the current market, second and third generation thin film solar cells based on amorphous Si, CdTe, CIGS, perovskites or organic photovoltaics (OPVs) are often considered as an alternative for BIPV applications since they may offer reduced costs compared to Si PVs. Indeed, recent advances in performance suggest that lightweight, flexible and visibly transparent OPVs can potentially be integrated into windows or other applications to which Si PVs are less well suited. Here, we estimate the cost of high efficiency, semitransparent OPVs (ST-OPVs) based on solution processing in a roll-to-roll (R2R) manufacturing line. Assuming modules with 10% power conversion efficiency (PCE), a 70% geometric fill factor (GFF), and 95% inverter efficiency, we anticipate a %1.6 per Wp module manufacturing cost that includes the cost of the microinverter to condition the OPV dc output to be compatible with the ac line voltage of the building. The materials and inverter cost comprise ~90% of the total module cost. Hence, with simplified material synthesis and a lower inverter cost, including marginally improved PCE and GFF, we expect the cost can be as low as $0.47 per Wp. Here, while the module costs ~60% of the average (uninstalled) double-pane window, we expect the payback period can be as short as 2 to 6 years, suggesting that OPVs can be an economic and attractive candidate for BIPV applications.

14 SOLAR ENERGY↗

Final Technical Report

Tessolar Inc. developed processes for, and evaluated the performance benefits associated with the implementation of improved materials for the construction of photovoltaic solar modules and mounting hardware. In particular, Tessolar evaluated the processing and manufacturability of modules produced using advanced encapsulant materials, electrically conductive adhesives, light capturing bussing ribbon, thin front glass and a fiber-reinforced composite module frame and mounting hardware. The results demonstrate an alternative approach to solar module fabrication with improved initial power and lower lifetime degradation rate compared to the state of the art. Most significantly, the use of composite materials enables mounting hardware that allows significantly faster solar module installation compared to the state of the art. The module assembly method is projected to be slightly more expensive on a $/W basis than currently available modules but will result in increased total energy output and lower LCOE. The composite mounting hardware can be produced more cheaply and offers significant savings in installed cost compared to the state of the art. Overall, the approach can offer lower levelized cost of energy compared to state of the art systems, leading to increased technology adoption rates and significant reductions in green house gas emissions.

14 SOLAR ENERGY↗

Highly Automated Module Production Incorporating Advanced Light Management

The objective was to enable a high volume, cost effective solution for increasing the amount of light captured by PV modules through utilization of an advanced Light Re-directing Film and to follow a phased approach to develop and implement this new technology in order to achieve an expected power gain of up to 12 watts per module. Full size PV modules were manufactured using a new Light Redirecting Film (LRF) material applied to two different areas of PV modules in order to increase the amount of light captured by the modules. One configuration involved applying thin strips of LRF film over the tabbing ribbon on the cells in order to redirect the light that is normally absorbed by the tabbing ribbon to the active areas of the cells. A second configuration involved applying thin strips of LRF film over the white spaces between cells within a module in order to capture some of the light that is normally reflected from the white areas back through the front glass of the modules. Significant power increases of 1.4% (3.9 watts) and 1.0% (3.2 watts), respectively, compared to standard PV modules were measured under standard test conditions. The performance of PV modules with LRF applied to the tabbing ribbon was modeled. The results showed that the power increase provided by LRF depended greatly on the angle of incident light with the optimum performance only occurring when the light was within a narrow range of being perpendicular to the solar module. The modeling showed that most of the performance gain would be lost when the angle of incident light was greater than 28 degrees off axis. This effect made the orientation of modules with LRF applied to tabbing ribbons very important as modules mounted in “portrait” mode were predicted to provide little to no power gain from LRF under real world conditions. Based on these results, modules with LRF on tabbing ribbons would have to be mounted in “landscape” mode to realize a performance advantage. In addition, modeling showed that under diffuse lighting conditions such as when the sky is overcast, there would be no significant performance advantage for modules with LRF. Modules were sent to an outside contractor to measure the power performance under different angles of incident light in order to validate the modeling results. The measured data agreed very well with the modeling predictions and showed that the power gain for modules with LRF applied to tabbing ribbons was completely lost at an angle of 25 degrees off of perpendicular. At even larger angles, the power was lower than standard modules. From 35 degrees to 55 degrees off axis, the power loss was about 1.4% or equal to the power gain at the optimum condition of perfectly on-axis light.

14 SOLAR ENERGY↗

Annual Supply Chain for Photovoltaics (ASC-PV) in the United States: 2024 in Review

This report analyzes U.S. PV and BESS supply chains and costs in 2024, for PV module and battery technologies, structural and electrical balance of system (BOS) components, as well as PV recycling. The report concludes with an analysis of technology installation trends, government support for domestic manufacturing, manufacturing jobs, and the domestic content of PV systems installed in the United States in 2024.

14 SOLAR ENERGY↗

PACT Module Design Acceptance Criteria (Industry)

For the PACT center to both develop testing protocols and provide service to the metal halide perovskite (MHP) PV community, PACT will seek modules (mini and full-sized) for testing purposes. To ensure both safety and high-quality samples PACT publishes acceptance criteria to define the minimum characteristics of modules the center will accept for testing. These criteria help to ensure we are accepting technologies that are compatible with our technical facilities and testing equipment and can transition to large scale commercial manufacturing. This module design acceptance criteria document is for industry partners and is different from the acceptance criteria for research partners (academia, national laboratories) partners.

14 SOLAR ENERGY↗

PACT Module Design Acceptance Criteria (Research)

For the PACT center to both develop testing protocols and provide service to the metal halide perovskite (MHP) PV community, PACT will seek modules (mini and full-sized) for testing purposes. To ensure both safety and high-quality samples PACT publishes acceptance criteria to define the minimum characteristics of modules the center will accept for testing. These criteria help to ensure we are accepting technologies that are compatible with our technical facilities and testing equipment and can transition to large scale commercial manufacturing. This module design acceptance criteria document is for research partners (academia, national laboratories) and is different from the acceptance criteria for industry partners.

36 MATERIALS SCIENCE↗

Q1/Q2 2018 Solar Industry Update

Each quarter, the National Renewable Energy Laboratory (NREL) conducts a presentation of technical trends within the solar industry, which became publicly available in October 2016. Each presentation focuses on global and U.S. supply and demand, module and system price, investment trends and business models, and updates on U.S. government programs supporting the solar industry.

14 SOLAR ENERGY↗

Q2/Q3 2018 Solar Industry Update

Each quarter, the National Renewable Energy Laboratory (NREL) conducts a presentation of technical trends within the solar industry, which became publicly available in October 2016. Each presentation focuses on global and U.S. supply and demand, module and system price, investment trends and business models, and updates on U.S. government programs supporting the solar industry.

14 SOLAR ENERGY↗

Q3/Q4 2017 Solar Industry Update

This technical presentation provides an update on the major trends that occurred in the solar industry in the Q3 and Q4 of 2017. Major topics of focus include global and U.S. supply and demand, module and system price, investment trends and business models, and updates on U.S. government programs supporting the solar industry.

14 SOLAR ENERGY↗

Q4 2017/Q1 2018 Solar Industry Update

This technical presentation provides an update on the major trends that occurred in the solar industry in Q4 2017 and Q1 2018. Major topics of focus include global and U.S. supply and demand, module and system price, investment trends and business models, and updates on U.S. government programs supporting the solar industry.

14 SOLAR ENERGY↗

Fall 2021 Solar Industry Update

Each quarter, the National Renewable Energy Laboratory (NREL) conducts the Quarterly Solar Industry Update, a presentation of technical trends within the solar industry, to the solar office staff. Each presentation focuses on global and U.S. supply and demand, module and system price, investment trends and business models, and updates on U.S. government programs supporting the solar industry.

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