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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 91 records · Page 5
All sourcesNASA NTRSDOE OSTI
DOE OSTI2019

Spontaneous Formation of 1D Pattern in Monolayer VSe 2 with Dispersive Adsorption of Pt Atoms for HER Catalysis

Creation of functional patterns in two-dimensional (2D) materials provides opportunities to extend their potential for applications. Transition-metal dichalcogenides (TMDCs) are suitable 2D materials for pattern generation because of properties including alterable polymorphic phases, easy chalcogen-vacancy formation, metal-atom insertion, and alloying. Such patterning can be used for selective functionalization. Here we report the spontaneous formation of long-range, well-ordered 1D patterns in monolayer vanadium diselenide (VSe 2 ) by a single annealing stage during growth. Atomic-resolution images in real space combined with density-functional-theory (DFT) calculations reveal the 1D features of patterned VSe 2 . Further experimental characterization of the intermediate states in the growth process confirm the spontaneous formation of the 1D pattern by annealing-induced Se-deficient linear defects. The 1D pattern can be reversibly transformed to homogenous VSe 2 monolayer by reintroducing Se atoms. Moreover, additional experiments demonstrate that a dispersive deposition of Pt atoms along the 1D structures of patterned VSe 2 is achieved, while DFT calculations find that their catalytic activity for hydrogen evolution reaction (HER) is as good as that of Pt surfaces. Further, the formation of long-range, well-ordered 1D patterns not only demonstrates an effective way of dimension modulation in 2D materials but also enriches the potential of intrinsically patterned 2D materials for promising catalytic activities.

Chemical structure↗
DOE OSTI2018

Effect of processing conditions on additive DISC patterning of P3HT films

There is a critical need to develop a method to pattern semiconducting polymers for device applications on the sub-micrometer scale. Dopant induced solubility control (DISC) patterning is a recently published method for patterning semiconductor polymers that has demonstrated sub-micron resolution. DISC relies on the sequential addition of molecular dopants (here 2,3,5,6-tetrafluoro-7,7,8,8-tetracyanoquinodimethane (F4TCNQ)) to the conjugated polymer. In doped areas, the conjugated polymer is protected from dissolution while in undoped areas, the polymer dissolves into solution. Here we examine factors that affect the resolution of the developed pattern. Two factors are determined to be critical to pattern resolution, the initial crystallinity of the polymer, here poly(3-hexylthiophene) (P3HT), and the quality of the development solvent. We find that dopants diffuse more readily in highly crystalline films than in amorphous films of P3HT and that dopant diffusion reduces the fidelity of the resulting pattern. We also find that the choice of development solvent affects both the fidelity of the pattern and dopant distribution within the patterned polymer domains. Finally, we show that a dopant that diffuses more slowly than F4TCNQ in the P3HT film can be used to pattern the film with higher fidelity. These results together provide a road map for optimizing additive DISC patterning for any polymer/dopant pair.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Microbial macroecology: In search of mechanisms governing microbial biogeographic patterns

Abstract Introduction Rapidly advancing technologies and accumulating information about microbial communities across the globe allow the quantification of microbial properties and functions at a macro‐scale. These emerging microbial biogeographic patterns call for a practical macroecological approach to investigate their underlying mechanisms. Aims The primary aims of this paper are to review the advancements of microbial macroecology in seeking mechanisms governing microbial biogeographic patterns, and to further lay out a roadmap for microbial macroecology in 10 years. Methods We reviewed the progress of microbial macroecology and demonstrated the application of the microbial macroecological approach to microbial biogeographic patterns with three case studies. Results Microbial macroecology provides a platform for understanding microbial abundance, community structure, and functioning across space, time, and taxonomic hierarchy. It emphasizes the integral effects of environmental filtering, microbial responses, diversification, dispersal, and local extinction that drive the microbial biogeographic patterns. The microbial macroecological approach emphasizes the last two stages of the four‐stage scientific method applied to microbial ecology: (a) describing microbial traits across scales to reveal patterns, (b) mathematically representing these patterns, (c) developing and testing conceptual models to build a mechanistic understanding of these patterns from a macroecological perspective, (d) plugging the new knowledge into the theoretical advancements. Three case studies were used to demonstrate the microbial macroecological approach for understanding the global patterns of microbial biomass carbon, microbial composition (fungi : bacteria ratio), and microbial carbon use efficiency. Conclusions Microbial macroecology offers a platform for understanding the mechanisms that drive biogeographic patterns of microbial abundance, diversity and functions. It is likely that these patterns and mechanisms will be increasingly incorporated into predictive models that link climate, carbon dynamics, and biogeochemical processes. A roadmap is outlined for the growing microbial macroecology field; we expect significant progress will be made in five research directions over the next 10 years.

Xu, Xiaofeng↗
DOE OSTI2023

Seasonal and Geographical Variations in Fundamental Weather Patterns during Extreme Precipitation as Identified from Omega Equation Forcing

Abstract We investigate the large-scale weather patterns during extreme precipitation (PEx) events over the conterminous United States (CONUS) by applying a version of the quasigeostrophic (QG) omega equation. This work aims to develop a climatology of the weather patterns most related to PEx events during current climate. Extreme events are examined for each of seven regions defined by consistent annual cycles of precipitation and spanning the CONUS. For the CONUS we train several self-organizing maps (SOM) on a pressure–time series of vertical velocity from each of the advective forcing terms in the QG omega equation for each extreme event. The unsupervised learning of the SOM allows us to identify the most descriptive set of nine patterns in vertical velocity associated with precipitation extremes. This method finds multiple frontal- and cyclone-driven patterns while grouping primarily convective events into one pattern. Frontal events include a synoptic pattern consistent with West Coast atmospheric river events as well as pattern groups linked to developing and to mature (“occluded”) frontal cyclones. The primary patterns found during PEx events vary seasonally and geographically. Frontal cyclone patterns are most common during PEx events during summer in the part of the Great Plains and during winter for the Northeast, Southeast, Pacific Northwest, and Southwest. Convection is the most common pattern during summer in all regions. Except in the Southeast, the annual cycles of monthly number of PEx events and average precipitation match well, partially validating our choice of regions to aggregate PEx events.

Meteorology & Atmospheric Sciences↗
DOE OSTI2023

Pangeo-Enabled ESM Pattern Scaling (PEEPS): A customizable dataset of emulated Earth System Model output

Emulation through pattern scaling is a well-established method of rapidly producing climate fields (like temperature or precipitation) from existing Earth System Model (ESM) output that, while inaccurate, is often useful for a variety of downstream purposes. Conducting pattern scaling has historically been a laborious process, in large part due to the increasing volume of ESM output data that has often required downloading and storing locally to train on. Here we describe the Pangeo-Enabled ESM Pattern Scaling (PEEPS) dataset, a repository of trained annual and monthly patterns from CMIP6 outputs. This manuscript describes and validates these updated patterns so that users can save effort calculating and reporting error statistics in manuscripts focused on the use of patterns. The trained patterns are available as NetCDF files on Zenodo for ease of use in the impact community, and are reproducible with the code provided via GitHub in both Jupyter notebook and Python script formats. Because all training data for the PEEPS data set is cloud-based, users do not need to download and house the ESM output data to reproduce the patterns in the zenodo archive, should that be more efficient. Validating the PEEPS data set on the CMIP6 archive for annual and monthly temperature, precipitation, and near-surface relative humidity, pattern scaling performs well over a variety of future scenarios except for regions in which there are strong, potentially nonlinear climate feedbacks. Although pattern scaling is normally conducted on annual mean ESM output data, it works equally well on monthly mean ESM output data. We identify several downstream applications of the PEEPS data set, including impacts assessment and evaluating certain types of Earth system uncertainties.

54 ENVIRONMENTAL SCIENCES↗
NASA NTRS2008

Scene Context Dependency of Pattern Constancy of Time Series Imagery

A fundamental element of future generic pattern recognition technology is the ability to extract similar patterns for the same scene despite wide ranging extraneous variables, including lighting, turbidity, sensor exposure variations, and signal noise. In the process of demonstrating pattern constancy of this kind for retinex/visual servo (RVS) image enhancement processing, we found that the pattern constancy performance depended somewhat on scene content. Most notably, the scene topography and, in particular, the scale and extent of the topography in an image, affects the pattern constancy the most. This paper will explore these effects in more depth and present experimental data from several time series tests. These results further quantify the impact of topography on pattern constancy. Despite this residual inconstancy, the results of overall pattern constancy testing support the idea that RVS image processing can be a universal front-end for generic visual pattern recognition. While the effects on pattern constancy were significant, the RVS processing still does achieve a high degree of pattern constancy over a wide spectrum of scene content diversity, and wide ranging extraneousness variations in lighting, turbidity, and sensor exposure.

Woodell, Glenn A.↗
DOE OSTI2025

3D pattern formation of a protein–membrane suspension

Many essential cellular processes, including cell division and the establishment of cell polarity during embryogenesis, are regulated by pattern-forming proteins. These proteins often need to bind to a substrate, such as the cell membrane, onto which they interact and form two-dimensional (2D) patterns. It is unclear how the membrane’s continuity and dimensionality impact pattern formation. Here, we address this gap using the MinDE system, a prototypical example of pattern-forming membrane proteins. We show that when the lipid substrate is fragmented into submicrometer-sized diffusive liposomes, adenosine triphosphate-driven protein–protein interactions generate three-dimensional (3D) spatially extended patterns, despite the complete loss of membrane continuity. Remarkably, these 3D patterns emerge at scales four orders of magnitude larger than the individual liposomes. By systematically varying protein concentration, liposome size, and density, we observed and characterized a variety of 3D dynamical patterns not seen on continuous 2D membranes, including traveling waves, dynamical spirals, and a coexistence phase. Simulations and linear stability analysis of a coarse-grained model revealed that the physical properties of the dispersed membrane effectively rescale both the protein–membrane binding rates and diffusion, two key parameters governing pattern formation and wavelength selection. These findings highlight the robustness of Min’s pattern-forming ability, suggesting that protein–membrane suspensions could serve as an adaptable template for studying out-of-equilibrium self-organization in 3D, beyond in vivo contexts.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Electrostatically driven pattern formation in mixed charged–neutral multicomponent elastic membranes

Multicomponent crystalline and amorphous elastic shells exhibit heterogeneous surface patterns that provide distinctive functionalities in cellular environments. Such patterning typically arises from the competition between short-range attractive and long-range repulsive interactions in membranes. Here, we demonstrate that the intrinsic competition between electrostatic repulsion and elastic deformation is sufficient to drive spontaneous surface patterning in elastic shells, requiring no additional attractive interactions. Using numerical simulations, we demonstrate pattern formation in mechanically homogeneous membranes with heterogeneous surface charge composition across different topologies, including spheres, discs, and flat periodic membranes. We also examine patterns in crystalline and amorphous shells of coassembled charged and neutral components with different bending rigidities. At low charge fraction, discrete charged surface domains form. At intermediate charge fraction, the competition between electrostatics and elasticity leads to elongated domains (rods) of the charged component, which results in lamellar patterns at nearly equal fraction of the charged and neutral components. At high charge fraction, nanodomains of the neutral component form. Amorphous shells exhibit similar progressions but with disordered structures rather than ordered lamellar patterns. These pattern morphologies are observed in both the closed shells and flat membranes. As salt concentration increases, all patterns coarsen due to the screening of electrostatic interactions.

charge heterogeneity↗
DOE OSTI2022

Self-organized patterns at the plasma–liquid anode interface in a helium glow discharge: temporal development and mechanisms

Self-organization at the plasma–liquid anode interface is a commonly observed phenomenon for atmospheric pressure glow plasmas, resulting in patterns with distinctive shapes such as circular ring, star-shaped, and gear-like structures, depending primarily on the discharge current and solution conductivity. Recent studies have shown that the electrode gap distance, solute used for liquid anode solution, and gas composition can also significantly impact pattern formation. Nonetheless, an overarching model or explanation of the key underlying mechanisms consistent with all experimentally observed trends is not yet reported. We propose a key underlying mechanism enabling pattern formation motivated by a detailed parametric study of pattern formation complemented by the temporal development of patterns and consistent with all observed trends. Pattern formation was observed to be on a time scale of 100 μs, similar to the time scales of gas heating and evaporation. It was found that a minimum water evaporation rate of (3.5 ± 0.5) × 10 –6 kg s –1 and reduced electric field in the positive column of 16.6 ± 0.4 Td is required for pattern formation in the investigated cases irrespective of solution conductivity and gas composition for NaCl solutions. Nonetheless, the presence of cations for which the corresponding metal atom has a low ionization energy was identified as a necessary condition for pattern formation. Furthermore, the reported results suggest that the presence of a small amount of metal atoms in the gas phase with low ionization energy enhances the overall ionization rate in the near anode region which triggers pattern formation.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2022

A Pattern Dictionary Method for Anomaly Detection

In this paper, we propose a compression-based anomaly detection method for time series and sequence data using a pattern dictionary. The proposed method is capable of learning complex patterns in a training data sequence, using these learned patterns to detect potentially anomalous patterns in a test data sequence. The proposed pattern dictionary method uses a measure of complexity of the test sequence as an anomaly score that can be used to perform stand-alone anomaly detection. We also show that when combined with a universal source coder, the proposed pattern dictionary yields a powerful atypicality detector that is equally applicable to anomaly detection. The pattern dictionary-based atypicality detector uses an anomaly score defined as the difference between the complexity of the test sequence data encoded by the trained pattern dictionary (typical) encoder and the universal (atypical) encoder, respectively. We consider two complexity measures: the number of parsed phrases in the sequence, and the length of the encoded sequence (codelength). Specializing to a particular type of universal encoder, the Tree-Structured Lempel–Ziv (LZ78), we obtain a novel non-asymptotic upper bound, in terms of the Lambert W function, on the number of distinct phrases resulting from the LZ78 parser. This non-asymptotic bound determines the range of anomaly score. As a concrete application, we illustrate the pattern dictionary framework for constructing a baseline of health against which anomalous deviations can be detected.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2022

Algebraic Theory of Patterns as Generalized Symmetries

We generalize the exact predictive regularity of symmetry groups to give an algebraic theory of patterns, building from a core principle of future equivalence. For topological patterns in fully-discrete one-dimensional systems, future equivalence uniquely specifies a minimal semiautomaton. We demonstrate how the latter and its semigroup algebra generalizes translation symmetry to partial and hidden symmetries. This generalization is not as straightforward as previously considered. Here, though, we clarify the underlying challenges. A stochastic form of future equivalence, known as predictive equivalence, captures distinct statistical patterns supported on topological patterns. Finally, we show how local versions of future equivalence can be used to capture patterns in spacetime. As common when moving to higher dimensions, there is not a unique local approach, and we detail two local representations that capture different aspects of spacetime patterns. A previously developed local spacetime variant of future equivalence captures patterns as generalized symmetries in higher dimensions, but we show that this representation is not a faithful generator of its spacetime patterns. This motivates us to introduce a local representation that is a faithful generator, but we demonstrate that it no longer captures generalized spacetime symmetries. Taken altogether, building on future equivalence, the theory defines and quantifies patterns present in a wide range of classical field theories.

97 MATHEMATICS AND COMPUTING↗
NASA NTRS2022

Layer by layer thin film fabrication with in-process laser patterning

A modification of the traditional layer by layer process where the substrate is irradiated with laser light during the polycation and/or polyanion dipping cycles is described. By adjusting the laser irradiation time during dipping, irradiation power, number of bilayers, and the location and speed of laser irradiation, a variety of structures with controlled thicknesses can be fabricated. Laser patterned multilayer PAH/PTEBS polymer thin films were fabricated and characterized with absorbance mapping to demonstrate several patterning approaches. Results for 1) two laser patterned tracks, 2) single laser patterned track with varied average laser power across the sample from a continuously variable neutral density filter, and 3) laser patterning using a beam sent through multiple circular apertures are described. Based on the variable neutral density filter laser pattern, for 20 bilayer PAH/PTEBS films, an absorbance difference between off and on pattern of 0.1 requires an average laser power of less than 15 mW at 405 nm. The patterns produced are on the scale of several millimeters, though they could be made much smaller by focusing the laser used for patterning.

Nanoengineering↗
DOE OSTI2023

Historical Pattern Analysis of Global Geothermal Power Capacity Development: Preprint

Between 1913 and 1958, Italy was the only country with an operational geothermal power plant until New Zealand installed its first plant in 1958. At present, 24 countries are involved in the geothermal power market, and they have a combined installed capacity of 16,127 GW. This study analyzes the historical patterns of geothermal power capacity in the world and in individual countries to investigate the ideal global geothermal development pattern by examining the annual cumulative capacity (ACC) and the annual capacity addition (ACA) graphs of the historical development of geothermal power capacity in 24 countries. First, the global patterns are analyzed using these graphs in five periods (1945-1957, 1958-1976, 1977-1991, 1992-2002, and 2003-2020) that are marked by a series of characteristics of ACA peaks separated by two major troughs. Then, five characteristic patterns are developed in five periods globally. These patterns correspond to the early-stage linear, the first acceleration, the first steady-state linear, the second acceleration, and the second steady-state linear developments. A positive relationship exists between global patterns and the 5-year shifted oil-price curve: two major factors influenced global development: 1) increasing oil prices and increasing awareness of global climate change, and 2) global development of geothermal power. Last, we investigate these patterns in each country. The top ten countries, which comprise 93.3% of the world's total installed capacity are separated into five groups based on the availability and characteristics of patterns globally developed in five periods. Group-1 (the United States) has an installed capacity of 3,794 MW, Group-2 (Mexico and Philippines) 963-1935 MW, Group-3 (New Zealand, Italy, Iceland, and Japan) 601-1,037 MW, and Group-4 (Indonesia, Kenya, and Turkiye) 944-2,356 MW. The remaining 14 countries (6.7%), which are called Group 5, are still in an immature stage and have installed capacities of 7-262 MW and are not involved in pattern analysis. Overall, geothermal power in the world is in its third stage of development, which had its peak development after 1977. A fourth development peak may be expected to occur after this through business-as-usual cases. The biggest barrier to the development of the global geothermal power market is the risk associated with exploration and drilling. If risk mitigation systems and funds are employed, the growth of geothermal power production projects could accelerate.

GEOTHERMAL ENERGY↗
DOE OSTI2023

Historical Pattern Analysis of Global Geothermal Power Capacity Development

Between 1913 and 1958, Italy was the only country with an operational geothermal power plant until New Zealand installed its first plant in 1958. At present, 24 countries are involved in the geothermal power market, and they have a combined installed capacity of 16,127 GW. This study analyzes the historical patterns of geothermal power capacity in the world and in individual countries to investigate the ideal global geothermal development pattern by examining the annual cumulative capacity (ACC) and the annual capacity addition (ACA) graphs of the historical development of geothermal power capacity in 24 countries. First, the global patterns are analyzed using these graphs in five periods (1945-1957, 1958-1976, 1977-1991, 1992-2002, and 2003-2020) that are marked by a series of characteristics of ACA peaks separated by two major troughs. Then, five characteristic patterns are developed in five periods globally. These patterns correspond to the early-stage linear, the first acceleration, the first steady-state linear, the second acceleration, and the second steady-state linear developments. A positive relationship exists between global patterns and the 5-year shifted oil-price curve: two major factors influenced global development: 1) increasing oil prices and increasing awareness of global climate change, and 2) global development of geothermal power. Last, we investigate these patterns in each country. The top ten countries, which comprise 93.3% of the world's total installed capacity are separated into five groups based on the availability and characteristics of patterns globally developed in five periods. Group-1 (the United States) has an installed capacity of 3,794 MW, Group-2 (Mexico and Philippines) 963-1935 MW, Group-3 (New Zealand, Italy, Iceland, and Japan) 601-1,037 MW, and Group-4 (Indonesia, Kenya, and Turkiye) 944-2,356 MW. The remaining 14 countries (6.7%), which are called Group 5, are still in an immature stage and have installed capacities of 7-262 MW and are not involved in pattern analysis. Overall, geothermal power in the world is in its third stage of development, which had its peak development after 1977. A fourth development peak may be expected to occur after this through business-as-usual cases. The biggest barrier to the development of the global geothermal power market is the risk associated with exploration and drilling. If risk mitigation systems and funds are employed, the growth of geothermal power production projects could accelerate.

GEOTHERMAL ENERGY↗
DOE OSTI2019

Capability of CAM5.1 in simulating maximum air temperature patterns over West Africa during boreal spring

This study classifies maximum air temperature patterns over West Africa into six groups and evaluates the capability of a global climate model (Community Atmospheric Model version 5.1; CAM) to simulate them. We analyzed 45-year (1961–2005) multi-ensemble (50 members) simulations from CAM and compared the results with those of the Climate Research Unit (CRU) and the twentieth Century Reanalysis data sets. Using Self Organizing Map algorithm to classify the spatial patterns of maximum air temperature during boreal spring, the study reveals the temperature patterns that CAM can simulate well and those the model struggles to reproduce. The results show that the best agreements between the composites of observation and CAM occur in the first temperature pattern group (which features positive temperatures anomalies over the Sahel) and Node 2 (which features near-normal temperature) pattern of the third group. CAM succeeded in reproducing some of the associated regional atmospheric dynamics and thermodynamic features in winds (horizontal and vertical), temperature fields, the cloud fractions, and the mean sea-level pressure. Although CAM struggles to capture the relationship between air temperature patterns and tele-connection indices during the boreal spring season over West Africa, it agrees with observations that temperature patterns over the sub-region cannot be associated with a single climate index. An ensemble member (SIM48) captures the inter-annual variation of the observed temperaure patterns with high sycronization (η > 44%), much better than that of ensembles mean (η < 30%). SIM48 also captures adequately four of the spatial patterns in comparison to three captured by the ensembles mean. This indicates that, for better seasonal forecasts and more reliable future climate projections, the practice whereby an ensemble mean is based on uniformly averaging the members rather than the performance of individual ensemble members needs to be reviewed. Finally, the results of the study may be used to improve the perfomance of CAM over West Africa, thereby strengthening the on-going efforts to include CAM as part of multi-model forecasting system over West Africa.

Lawal, Kamoru A. (ORCID:0000000281988844)↗
DOE OSTI2018

Resolving pseudosymmetry in γ-TiAl using cross-correlation electron backscatter diffraction with dynamically simulated reference patterns

Pseudosymmetry is a phenomenon that occurs when grains with different lattice parameters produce nearly identical diffraction patterns such that conventional electron backscatter diffraction (EBSD) techniques are unable to unambiguously differentiate the lattice orientations. This commonly occurs in materials with near-unity tetragonality, such as γ-TiAl. The current study uses cross-correlation EBSD to resolve pseudosymmetry in γ-TiAl. Three dynamically simulated reference patterns are generated for each point in the scan, one for each of the three potential pseudosymmetric orientations, which are subsequently correlated with the original pattern using six different methods in order to identify the correct orientation. The methods are first applied to a scan of dynamically simulated patterns, which is used to evaluate the sensitivity of the method to pattern resolution, pattern noise and pattern center error. It was determined that all six methods were 100% successful up to about 13 µm of pattern center error and pattern resolutions of about 80 × 80 pixels, and hence the methods were applied to an experimental sample of lamellar γ-TiAl. A hybrid combination of two of the methods was shown to successfully select the correct pseudosymmetry for about 96% of the points in the scan, improving upon the 70% accuracy of the Hough-based methods for the current study and 90% accuracy for previous studies resolving pseudosymmetry in lamellar γ-TiAl.

36 MATERIALS SCIENCE↗
DOE OSTI2019

High-speed 3D shape measurement using the optimized composite fringe patterns and stereo-assisted structured light system

In this study, we propose a high-speed 3D shape measurement technique based on the optimized composite fringe patterns and stereo-assisted structured light system. Stereo phase unwrapping, as a new-fashioned method for absolute phase retrieval based on the multi-view geometric constraints, can eliminate the phase ambiguities and obtain a continuous phase map without projecting any additional patterns. However, in order to ensure the stability of phase unwrapping, the period of fringe is generally around 20, which limits the accuracy of 3D measurement. To solve this problem, we develop an optimized method for designing the composite pattern, in which the speckle pattern is embedded into the conventional 4-step phase-shifting fringe patterns without compromising the fringe modulation, and thus the phase measurement accuracy. We also present a simple and effective evaluation criterion for the correlation quality of the designed speckle pattern in order to improve the matching accuracy significantly. When the embedded speckle pattern is demodulated, the periodic ambiguities in the wrapped phase can be eliminated by combining the adaptive window image correlation with geometry constraint. Finally, some mismatched regions are further corrected based on the proposed regional diffusion compensation technique (RDC). These proposed techniques constitute a complete computational framework that allows to effectively recover an accurate, unambiguous, and distortion-free 3D point cloud with only 4 projected patterns. Experimental results verify that our method can achieve high-speed, high-accuracy, robust 3D shape measurement with dense (64-period) fringe patterns at 5000 frames per second.

42 ENGINEERING↗
DOE OSTI2020

Rapid Patterning and Advanced Device Structures for Low Cost Manufacturable Crystalline Si IBC Cells

Recent record efficiency Si cells have had an interdigitated back contact (IBC) design where both positive and negative contacts are fabricated on the back side of the Si wafer. Many industry groups have investigated IBC cells but used photolithography to pattern the rear contacts although it is considered impractical for low cost, high volume manufacturing. Alternative patterning methods using lasers and mechanical masking have been utilized in fabrication of patterned regions in IBC Si solar cells to replace photolithography. Another exciting advance in Si solar cell technology has been replacing the high temperature diffusion of doped regions inside the crystalline Si wafer with low temperature deposition of very thin layers of doped amorphous hydrogenated Si (a-Si:H) on the Si wafer. This is called a Si heterojunction (HJ) device. The a-Si:H provides excellent passivation of surface defects and has produced the highest open circuit voltages (VOC) of any Si solar cell device structure. The Institute of Energy Conversion (IEC) demonstrated the first IBC-HJ solar cell combining these two strategies in 2007 and has fabricated IBC-HJ cells with 20% efficiency using three photolithography steps. Despite the demonstrated efficiency potential of this device by industry groups (>26%) there is no commercial production because of the challenges of patterning and processing the structure in an industrial environment. Our work sought to address that challenge. The objective of this 3 year project was to develop the processing for the IBC-HJ Si solar cell using lasers for patterning and contact formation instead of photolithography. Laser patterning enables rapid, contactless manufacturing of patterned regions. We intensively studied laser fired contacts, laser patterning of the a-Si multi-layer stacks and metal layers and the use of plasma shadow masks. After an exhaustive focus in the first year on the laser fired emitter (LFE) and contact (LFC), we were unable to achieve VOC greater than 660 mV, compared to the 720 mV required to meet our milestones. We discovered that an additional issue with our original IBC structure was the presence of an inversion layer at the back surface connecting the p and n regions which reduced the VOC and fill factor (FF). We developed innovative methods for characterizing the inversion layer. These two limitations in the original design lead to development of a new IBC-HJ process sequence and device structure which we called Plasma Masked Laser Processed (PMLP). It retained the original high efficiency features including manufacturability. The LFC was replaced with a standard n-type a-Si HJ contact. The inversion layer was eliminated by replacing the previous p-type stack in the gap with an n-type or SiN stack. The PMLP used laser ablation of a multi-layer a-Si stack followed by chemical etching to open the n-contact. It required deposition of a patterned stack through a mask in the plasma deposition chamber. This turned out to be a source of significant problems due to inevitable unwanted deposition ‘leakage’ under the mask. This formed a blocking contact on the emitter which significantly reduced Voc and FF. Several iterations in PMLP device structure and chemical etching steps resulted in a large improvements, e.g. the efficiency increasing from 3 to 15% and Voc from 450 to 660 mV but they were unable to completely eliminate it. The best IBC-HJ device we fabricated had only 15% efficiency. For perspective, our standard FHJ devices had 20% efficiency.

14 SOLAR ENERGY↗