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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 991 records · Page 55

Nanosecond laser scribing of CIGS thin film solar cell based on ITO bottom contact

Cu(In,Ga)Se2 (CIGS) thin films, a promising photovoltaic architecture, have mainly relied on Molybdenum for the bottom contact. However, the opaque nature of Molybdenum (Mo) poses limitations in module level fabrication by laser scribing as a preferred method for interconnect. We examined the P1, P2, and P3 laser scribing processes on CIGS photovoltaic architecture on the indium tin oxide (ITO) bottom contact with a cost-effective nanosecond pulsed laser of 532 nm wavelength. Laser illuminated from the substrate side, enabled by the transparent bottom contact, facilitated selective laser energy deposition onto relevant interfaces towards high-quality scribing. Parametric tuning procedures are described in conjunction with experimental and numerical investigation of relevant mechanisms, and preliminary mini-module fabrication results are also presented.

Kuk, Seungkuk↗

Clear Sky Toolkit: Decision Support User Guide

The Clear Sky Decision Support Template is a Microsoft Excel-based resource that enables users to screen and prioritize critical facilities for the addition of solar + storage. The Decision Support Template consolidates and streamlines the most relevant resources from the emergency management discipline, the electric utility sector, and national energy research institutions to assist in further site analysis and decision-making. The Decision Support Template is intended for use by local government and private sector decision-makers who aim to mitigate the effects of power outages on critical infrastructure, understand the potential for deploying photovoltaic (PV) and storage solutions on critical facilities, and align emergency management planning processes and utility needs with community resilience objectives. The Decision Support Template is divided into five modules that provide a structured, step-by-step approach users can follow and apply to unique circumstances. This process guides a more thorough and accurate assessment of a site's potential to accommodate a solar + storage system, provide grid benefits to utilities, and support community resilience and disaster mitigation for the broader region. After identifying potentially viable and preferred sites for solar + storage using the Decision Support Template, users should conduct a more detailed evaluation and consultation with a solar professional.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

Photoinduced electron transfer kinetics of linked Ru-Co photocatalyst dyads

Two new supramolecular photocatalyst dyads based on the [Ru(2,2’-bipyridine)3]2+ photosensitizer linked to a macrocyclic Co(II)tetra(pyridyl) catalyst for proton reduction are reported. The dyads differ primarily in the bridging ligand which links the molecular modules; the first being a short and flexible linker, and the second a longer and electronically conjugated linker. Ultrafast transient optical spectroscopy was used to monitor the photoinduced kinetics of the dyads following visible excitation of the photosensitizer module. Direct comparison of transient spectra and kinetics indicates that there are indeed substantial differences between the ultrafast transient optical spectroscopy of the dyads, but there is no indication of oxidative quenching of the photosensitizer module by the catalyst module. These initial design and characterization studies of the linked Ru(II)—Co(II) dyads provide an important foundation for advanced designs of systems for efficient solar energy conversion by molecular architectures.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

Emissivity of solar cell cover glass calculated from infrared reflectance measurements

The thermal emissivity of solar cell cover glasses with differences in glass composition or manufacture and surface texture are evaluated using specular and specular+diffuse infrared reflectance at different angles of incidences. Non-textured and textured glasses all exhibit similar emissivity at all angles of incidence regardless of composition and patterning. Both diffuse and specular reflectance must be included for textured glass at any angle of incidence and may be needed for planar glass at a high angle of incidences to properly determine emissivity.

14 SOLAR ENERGY↗

Bifacial PV System Mismatch Loss Estimation

Nonuniform rear-irradiance on bifacial PV systems can cause additional mismatch loss, which may not be appropriately captured in PV energy production estimates and software. A simplified empirical relationship is presented that links the spatial variation of irradiance (to the resulting mismatch loss factor).

14 SOLAR ENERGY↗

Impact of Infrared Optical Properties on Crystalline Si and Thin Film CdTe Solar Cells

Photons with energies below the photovoltaic (PV) absorber band gap do not generate current and adversely impact performance when absorbed in other solar cell components to produce heat. Here we incorporate infrared (IR) optical response in simulations for understanding thermal losses. Spectroscopic ellipsometry is used to measure Al-Si interface optical properties in Si PV. Reflectance of an Si module has been analyzed to account for encapsulant and Al-Si interface contributions. IR extended quantum efficiency simulations calculate efficiency gains / losses arising from variations in current generated and total reflectance as functions of transparent front contact material in thin film CdTe PV.

14 SOLAR ENERGY↗

Impact of distributed power electronics on the lifetime and reliability of PV systems: Impact of distributed power electronics

Here, this paper quantifies the impact of distributed power electronics in photovoltaic (PV) systems in terms of end-of-life energy-capture performance and reliability. The analysis is based on simulations of PV installations over system lifetime at various degradation rates. It is shown how module-level or submodule-level power converters can mitigate variations in cell degradation over time, effectively increasing the system lifespan by 5-10 years compared with the nominal 25-year lifetime. An important aspect typically overlooked when characterizing such improvements is the reliability of distributed power electronics, as power converter failures may not only diminish energy yield improvements but also adversely affect the overall system operation. Failure models are developed, and power electronics reliability is taken into account in this work, in order to provide a more comprehensive view of the opportunities and limitations offered by distributed power electronics in PV systems. Lastly, it is shown how a differential power-processing approach achieves the best mismatch mitigation performance and the least susceptibility to converter faults.

14 SOLAR ENERGY↗

Relating Aerial Infrared Thermography Defects to Photovoltaic Performance: Preprint

In this research, we examine the relationship between aerial IR defect analysis and photovoltaic (PV) performance data for twelve utility- and commercial-scale solar sites in the United States. To do this, we fuse the site diagram geoJSON's, aerial infrared thermography (aIRT) defect analyses, and associated inverter time series, allowing for a direct comparison between site defects and time series data. Defect analyses were provided by Zeitview, under its Solar Insights platform. Following the data fusion process, we look at the relationship between system performance and aIRT defects. We investigate the relationship between degradation and hotspot defects, as well as the relationship between AC power data and offline strings and misaligned modules. In general, system degradation was not affected by long-term or balance-of-system (BoS) defects as they occurred infrequently in the data set. However, for one system, a near statistically significant relationship (p-value=0.057) was found when comparing the degradation of inverter blocks with several multi-hotspot defects to all other inverter blocks without this particular defect. There was strong alignment when comparing short-term recoverable module defects such as stuck trackers and offline strings to time series data. In general, we found that when an inverter block has more than 80% of modules flagged for one of these defects, its AC power time data is flat-lined and the inverter block is not producing.

aerial inspection↗

Cyberguardians Webinar

Robust solar industry growth is creating a shortage of U.S. workers who are knowledgeable in emerging Distributed Energy Resource (DER) technologies including networking, operational software, smart advanced inverters, smart advanced PV modules, and cybersecurity. Retraining military veterans and other qualified individuals to fill workforce gaps in those technologies is the project focus. The project leverages the experience and contributions of DER and cybersecurity experts, educational organizations offering accreditation, and groups serving our nation’s veterans to meet its goals. To bridge this workforce skills gap, the Cyberguardians and STEM Warriors project will establish a complete learning and career advancement system for veterans, transitioning military personnel and other qualified individuals into the DER workforce. The project will guide participants successfully through the process of program/vocation selection, curriculum enrollment, academic mentoring, degree or certificate attainment, job board enrollment, introduction to hiring managers at DER companies, and successful job acquisition. This webinar was used to promote the Cyberguardians program and to ensure ample news coverage to reach veterans, employers, and others that would benefit from this program.

14 SOLAR ENERGY↗

Carboxylating Elastomer via Thiol‐Ene Click Reaction to Improve Miscibility with Conjugated Polymers for Mechanically Robust Organic Solar Cells with Efficiency of 19%

Abstract Incorporating flexible insulating polymers is a straightforward strategy to enhance the mechanical properties of rigid conjugated polymers, enabling their use in flexible electronic devices. However, maintaining electronic characteristics simultaneously is challenging due to the poor miscibility between insulating polymers and conjugated polymers. This study introduces the carboxylation of insulating polymers as an effective strategy to enhance miscibility with conjugated polymers via surface energy modulation and hydrogen bonding. The carboxylated elastomer, synthesized via a thiol‐ene click reaction, closely matches the surface energy of the conjugated polymer. This significantly improves the mechanical properties, achieving a high crack‐onset strain of 21.48%, surpassing that (5.93%) of the unmodified elastomer:conjugated polymer blend. Upon incorporating the carboxylated elastomer into PM6:L8‐BO‐based organic solar cells, an impressive power conversion efficiency of 19.04% is attained, which top‐performs among insulating polymer‐incorporated devices and outperforms devices with unmodified elastomer or neat PM6:L8‐BO. The superior efficiency is attributed to the optimized microstructures and enhanced crystallinity for efficient and balanced charge transport, and suppressed charge recombination. Furthermore, flexible devices with 5% carboxylated elastomer exhibit superior mechanical stability, retaining ≈88.9% of the initial efficiency after 40 000 bending cycles at a 1 mm radius, surpassing ≈83.5% for devices with 5% unmodified elastomer.

Chemistry↗

Optimal net-load balancing in smart grids with high PV penetration

Mitigating mismatches in supply demand curve is critical for smooth power grid operation. Traditionally, load curtailment techniques such as Demand Response (DR) have been used for this purpose. However, smart grids with high PV penetration sometimes exhibit supply surplus causing over-voltages. Thus, load curtailment techniques cannot be the only component of a net-load balancing framework. Supply curtailment techniques such as Volt-Var Optimizations are complex and computationally expensive. This increases the complexity of net-load balancing systems used by the grid operator and limits their scalability. Recently, new technologies have been developed that enable the rapid and selective connection of PV modules of an installation to the grid. Taking advantage of these advancements, we develop a unified optimal net-load balancing framework which performs both load and solar curtailment. We show that when the available curtailment values are discrete, this problem is NP-hard and develop bounded approximation algorithms for minimizing the curtailment cost. Our algorithms produce fast solutions, given the tight timing constraints required for grid operation. We also incorporate the notion of fairness to ensure that curtailment is evenly distributed among all the nodes. Finally, we develop an online algorithm which performs net-load balancing using only data available for the current interval. Using both theoretical analysis and practical evaluations, we show that our net-load balancing algorithms provide solutions which are close to optimal in a small amount of time.

14 SOLAR ENERGY↗

Nishati Prototype 72-Cell Endurance Modules (Test Report)

US Manufacturer Nishati provided three prototype, 72-cell photovoltaic modules to Sandia for characterization under the US Department of Energy Small Business Voucher program. Nishati is developing the Endurance © product to address the stringent requirements associated with PV system installations sited near airports and military bases. These prototype modules are uniquely constructed of a polymeric matrix and an internal honeycomb structural element. Target features of the module design are reduced reflectivity from the front surface and reduced weight. Sandia applied a variety of in-house characterization methods to these modules with the goal of validating performance and identifying any areas for improvement. Reflectance testing revealed extremely low specular reflection, dramatically surpassing the performance of industry standard PV panels. Electrical performance testing validated performance in line with expectations for similar size and power class modules. Complimentary to reflection testing, outdoor angle of incidence testing indicated performance far exceeding expectations for industry standard PV panels. It is possible that the extremely low reflectance properties of these modules will convey an advantage in annual energy production in comparison to industry standard modules. Detailed performance modeling and experimental field validation would be required to verify this possible advantage. During the course of this testing, no obvious deficiencies in this module design were discovered. It is recommended that Nishati and Sandia proceed to the final Task associated with the SBV award. This final task will involve fielding modules at Sandia for reliability and energy production validation.

14 SOLAR ENERGY↗

Improving solar panel durability through novel panel designs and advanced manufacturing equipment

Work in the project was spread across 4 main themes:1) Improved Understanding of Why Cracks Form and Cause Degradation in Solar Cells: We developed a finite element model which correlated well with experimental determined deflection vs load profiles and which predicted stress profiles vs load level and temperature. These profiles helped to guide brace designs and showed the high stress levels seen in the silicon near the interconnect wire locations as the temperature is cooled below -30C, likely forming "invisible" microcracks. Experiments showed how for polymer backsheet modules, a brief exposure to such low temperatures made modules extremely sensitive to propagation of these microcracks at relatively low load levels, and how thicker and softer encapsulant helped to reduce this crack sensitivity. We showed for some modules that most cracks that are seen under loading had their origin at short, hard to see, V-cracks from soldering damage, and how the shunting from cells with high densities of cracks reduces energy delivery more than Pmax. 2) Improved Durability Testing Methods With Respect to Cracked Cells: We lobbied the PV community throughout the project that IEC 61215 was insufficient to probe the sensitivity of module Pmax degradation due to cracks in that in did not have a test leg that included a crack creation step (static loading) followed by a crack opening step (cyclic loading and/or thermal cycling). We published extensively on how pre- existing cracks opened up with cyclic loading. The new IEC TS 63209-1 ED1 test sequence now include our recommendations, and this should lead to improved module designs and reduced risk for investors. We also published recommendations for a new "Cold Climate Test" sequence to probe the sensitivity of modules to degradation from short microcracks formed when modules see temperatures below -30C followed by front side loading. We participated in several USTAG meetings related to cracked cells, EL testing, and mechanical load testing and provided input to the group to improve new standards under consideration. We also showed how the act of performing an EL test can affect the test results due to heating from the injected current. 3) New Module Designs and Related Manufacturing Methods & Equipment: We demonstrated reduced crack sensitivity on encapsulated cell coupons the benefits of building protective compressive stress into the cells by laminating them in a bent state and then allowing the coupon to flatten out after lamination. Our attempts to scale this to the module level with a more manufacturable sequence did not demonstrate the same positive effects, but we hope that others will follow up with other variations on this bent lamination or bent cooling concept to make more durable modules. 4) New Module Mounting Designs: We explored a range of bracing concepts which pressed on the backsheet to slightly bow the glass outward and place cells in a state of protective compressive stress and to reduce the deflection under front side loads. These successfully reduced cell cracking and crack opening, but high static loads permanently deformed cost-effective braces, after which they provided little benefit. We settled on an elegant & effective solution – the RailPad, where lightweight bracing elements are placed between the mounting rail(s) and the backsheet, and the existing strength of the rails is used to prevent module deflection under load. New construction and retrofit designs were made, and test sites were implemented in FL and MA. We applied for RailPad patent protection.

14 SOLAR ENERGY↗

Module-Level Thermal Interface Material Degradation in HALT

Abstract In this study, thermal interface material (TIM) degradation is driven through highly accelerated life test (HALT) using temperature cycling with a prescribed vibrational acceleration for two commercially available materials having thermal conductivities of 6.0 and 8.5 W/m K. HALT specimens were prepared by applying TIM through a 4-mil stencil over AlSiC baseplates in the shape of those used in Wolfspeed CAS325M12HM2 power electronics modules. Baseplates were mounted onto aluminum carrier blocks with embedded thermocouples to characterize the thermal resistance across the baseplate and TIM layer. Thermal dissipation into the top of the baseplates was provided by a custom heating block, which mimics the size and placement of the die junctions in CAS325 modules, applying power loads of 200, 300, and 400 W. After initial characterization, samples were transferred to the HALT chamber with one set of samples exposed to temperature cycling only (TCO) and the other temperature cycling and vibration (TCV). Both sample sets were cycled between temperature extremes of −40 °C and 180 °C with vibrations applied at a peak acceleration of 3.21 Grms. After hundreds of cycles, samples were reevaluated to assess changes in thermal resistance to provide an accelerated measure of TIM degradation. This allows for reliability prediction of useful lifetime (illustrated in a solar inverter case study herein), as well as to provide a basis for developing an accelerated testing method to related temperature cycling to faster methods of degradation. Such techniques provide a means to develop maintenance schedules for power modules for ensuring sufficient thermal performance over the operating lifetime.

Engineering↗

Dispersive Charge Transfer State Electroluminescence in Organic Solar Cells

Abstract The notion of quasi‐equilibrium is central to most solar cells; however, it has been questioned in organic photovoltaics (OPVs) owing to strong energetic disorder that frustrates efficient relaxation of electrons and holes within their respective density of states (DOS). Here, modulation electroluminescence (EL) spectroscopy is applied to OPVs and it is found that the frequency response of charge transfer (CT) state EL on the high energy side of the spectrum differs from that of the low energy side. This observation confirms that static disorder contributes substantially to the linewidth of the steady‐state EL spectrum and is unambiguous proof that the distribution of CT states formed by electrical injection in the dark is not in quasi‐equilibrium. These results emphasize the need for caution when analyzing OPV cells on the basis of reciprocity models that assume quasi‐equilibrium holds, and highlight a new method to study this unusual aspect of OPV operation.

14 SOLAR ENERGY↗

Modeling Tool Development and Validation for Solar Industry Process Heat Using Particle Thermal Energy Storage

U.S. industry sectors used 26.2 quadrillion Btu and accounted for 33% of total energy consumption in 2021 according to the Energy Information Agency. Industrial process heat accounts for 70% of industrial energy use with application temperatures ranging from 60 degrees -1100 degrees C. Industry processes, heavily relying on fossil fuels of cheap coal or natural gas, differ widely in operating conditions and load requirements which makes them difficult to standardize and imposes great challenges in decarbonization. Industry processes require reliable energy supply and vary widely in temperature ranges. Storing energy from renewable sources is necessary to improve reliability and to mitigate renewable intermittency when replacing carbon fuel-based heat supplies to achieve energy savings and reduce emissions. To this end, we have developed a particle-based thermal energy storage (TES) technology using low-cost and highly stable silica sand as a storage medium. The economic and performance-based analysis is key for renewable energy sources to reliably supply industry process heat and ultimately displace fossil fuels for decarbonization. The diversified industrial processes need case-by-case analysis and design. Therefore, an adaptive modeling tool is key for renewable power with energy storage to meet industry demands. Thus, a modeling tool to simulate a solar industry process heat system using the particle TES has been developed using the object-oriented equation-based language Modelica and the commercial platform of Modelon Impact. The Modelica-based software tool provides a general simulation environment for the design of reliable solar energy sources integrated with TES for various industrial process applications at different temperatures for economic competence with fossil fuels such as coal and natural gases. It uses both customized and standard component modeling modules in Modelon libraries for the flexibility to be adapted to a specific energy demand application. The particle TES system establishes a uniform energy supply platform with an efficient heat exchanger and particle thermal energy reservoir integrated with renewable powers. The particle TES system can provide a wide temperature range and can have a large storage temperature difference that increases storage energy density; therefore, it can be an adaptable energy storage system integrated with renewable power to supply 24/7 heat for industry decarbonization.

concentrated solar thermal↗

Q1-2024 Solar Cost Benchmarks

Each year, the U.S. Department of Energy’s (DOE) Solar Energy Technologies Office (SETO) and its national laboratory partners develop cost benchmarks for U.S. solar photovoltaic (PV) systems. These benchmarks track progress toward reducing solar costs and guide R&D priorities. Unlike typical studies that report only $/W, SETO uses intrinsic units (e.g., $/m² for mounting structures) to better capture how technology improvements such as module efficiency would impact system costs. This allows flexible modeling where inputs can vary significantly to assess cost sensitivity. Costs are reported in two ways: Minimum Sustainable Price (MSP): Long term, financially viable price under stable market conditions. Modeled Market Price (MMP): Actual market price, influenced by short term distortions such as tariffs or subsidies. Three national labs collect cost data from industry stakeholders, ensuring no duplication in outreach to stakeholders. Data reflects real transactions (primarily from Q1) and is weighted based on the number of sources per cost element. The PV System Cost Model (PVSCM) divides total installed system cost into eight categories: 1. Module (PV) 2. Inverter 3. Energy Storage System (ESS) 4. Structural BOS (SBOS) 5. Electrical BOS (EBOS) 6. Fieldwork 7. Office work 8. Other (developer/EPC costs) The first five are hardware costs, while the last three are soft costs. Each category includes fixed and variable cost components, where “size” depends on context (e.g., manufacturing capacity for modules vs. system capacity for installation costs). Variable costs are expressed using appropriate intrinsic units. The model reflects the owner’s upfront overnight capital cost, excluding tax credits. Tariffs and subsidies are treated as temporary market distortions affecting MMP but not MSP. PVSCM is implemented in Excel, where cost elements are aggregated into total system cost. Additional sheets handle unit conversions and operation & maintenance (O&M), with O&M costs levelized over the system’s lifetime.

14 SOLAR ENERGY↗