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Chapter 10.2: Encapsulant Materials for PV Modules

Encapsulant materials used in photovoltaic (PV) modules serve multiple purposes; it provides optical coupling of PV cells and protection against environmental stress. Polymers must perform these functions under prolonged periods of high temperature, humidity, and UV radiation. When PV panels were first developed in the 1960s and the 1970s, the dominant encapsulants were based on polydimethyl siloxane (PDMS). Ethylene-co-vinyl acetate (EVA) is currently the dominant encapsulant chosen for PV applications, not because it has the best combination of properties, but because it is an economical option with an established history of acceptable durability. Getting new products onto the market is challenging because there is no room for dramatic improvements, and one must balance the initial cost and performance with the unknowns of long-term service life. Recently, there has been renewed interest in using alternative encapsulant materials with some significant manufacturers switching from EVA to polyolefin elastomer-based (POE) alternatives.

14 SOLAR ENERGY↗

Modulation of Photoinduced Iodine Expulsion in Mixed Halide Perovskites with Electrochemical Bias

Hole trapping at iodine (I) sites in MAPbBr 1.5 I 1.5 mixed halide perovskites (MHP) is responsible for iodine migration and its eventual expulsion into solution. We have now modulated the photoinduced iodine expulsion in MHP through an externally applied electrochemical bias. At positive potentials, electron extraction at TiO 2 /MHP interfaces becomes efficient, leading to hole buildup within MHP films. This improved charge separation, in turn, favors iodine migration as evident from the increased apparent rate constant of iodine expulsion (k expulsion = 0.0030 s –1 ). Conversely, at negative potentials (-0.3 V vs Ag/AgCl) electron–hole recombination is facilitated within MHP, slowing down iodine expulsion by an order of magnitude (k expulsion = 0.00018 s –1 ). The tuning of the EFermi level through external bias modulates electron extraction at the TiO 2 /MHP interface and indirectly controls the buildup of holes, ultimately inducing iodine migration/expulsion. Suppressing iodine migration in perovskite solar cells is important for attaining greater stability since they operate under internal electrical bias.

14 SOLAR ENERGY↗

PHASE QUANTIZATION STUDY OF SPATIAL LIGHT MODULATOR FOR EXTREME HIGH-CONTRAST IMAGING

Direct imaging of exoplanets by reflected starlight is extremely challenging due to the large luminosity ratio to the primary star. Wave-front control is a critical technique to attenuate the speckle noise in order to achieve an extremely high contrast. We present a phase quantization study of a spatial light modulator (SLM) for wave-front control to meet the contrast requirement of detection of a terrestrial planet in the habitable zone of a solar-type star. We perform the numerical simulation by employing the SLM with different phase accuracy and actuator numbers, which are related to the achievable contrast. We use an optimization algorithm to solve the quantization problems that is matched to the controllable phase step of the SLM. Two optical configurations are discussed with the SLM located before and after the coronagraph focal plane mask. The simulation result has constrained the specification for SLM phase accuracy in the above two optical configurations, which gives us a phase accuracy of 0.4/1000 and 1/1000 waves to achieve a contrast of 10{sup -10}. Finally, we have demonstrated that an SLM with more actuators can deliver a competitive contrast performance on the order of 10{sup -10} in comparison to that by using a deformable mirror.

79 ASTRONOMY AND ASTROPHYSICS↗

15%-efficiency (Mg,Zn)CdTe solar cells with 1.7 eV bandgap for tandem applications

The overall objective of this project was to demonstrate a 15%-efficient Cd(Mg,Zn)Te solar cell with a bandgap of 1.7–1.9 eV. Such a cell would be a critical first step towards market-competitive flat-plate modules with efficiencies significantly higher than is achievable with single-junction silicon or thin-film modules. In particular, Cd(Mg,Zn)Te may be the optimum top cell for pairing with silicon in a tandem. It promises low cost and long-term stability not available with other top-cell candidates, and, while 1.5 eV polycrystalline CdTe cells have already achieved 22.1% efficiency, no serious efforts have been undertaken to demonstrate an efficient 1.7–1.9 eV Cd(Mg,Zn)Te cell. This project was the first such effort. To reach 15% efficiency, this project specifically aimed to develop (1) high-quality Cd(Mg,Zn)Te absorbers that minimize non-radiative recombination and thereby maximize the quasi-fermi level splitting, and (2) effective electron and hole (heterojunction) contacts that allow the full quasi-Fermi-level splitting (chemical potential) to be extracted at the metal electrodes (electrical potential). To this end, 1.7–1.9 eV Cd(Mg,Zn)Te absorber layers and heterojunction contacts were developed in parallel using molecular beam epitaxy (MBE) and close-space sublimation (CSS) growth; the former defines the upper bounds of performance and provides insight into material and device limitations, whereas the latter ensures that technology developed within the project is readily transferable to industry. Minority-carrier lifetime served as the primary metric for the first aim; open-circuit voltage (V oc ) and efficiency served as metrics for the second.

Holman, Zachary↗

Low Background kTon-Scale Liquid Argon Time Projection Chambers

We find that it is possible to increase sensitivity to low energy physics in a third or fourth DUNE-like module with careful controls over radiopurity and some modifications to a detector similar to the DUNE Far Detector design. In particular, sensitivity to supernova and solar neutrinos can be enhanced with improved MeV-scale reach. A neutrinoless double beta decay search with $^{136}$Xe loading appears feasible. Furthermore, sensitivity to Weakly-Interacting Massive Particle (WIMP) Dark Matter (DM) becomes competitive with the planned world program in such a detector, offering a unique seasonal variation detection that is characteristic for the nature of WIMPs.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

Young Leaders Workforce Training Program Overview and Impact

To support the Government of Colombia's plans to transform its power sector, the U.S. Agency for International Development (USAID) has assembled a cross-organizational team to develop and deliver a comprehensive workforce training program for young energy sector leaders in Colombia designed to enhance the efficient integration of growing volumes of variable renewable energy (VRE) to the energy sector. The team - which includes USAID's Colombia Mission, the National Renewable Energy Laboratory (NREL), USAID's Scaling Up Renewable Energy (SURE) program implemented by Tetra Tech, and the U.S. Energy Association (USEA) - collaboratively developed a series of seven capacity building modules designed to ready Colombia's energy sector workforce to participate in the construction, operation, and grid integration of VRE projects, such as wind and solar. This brochure highlights the program's objectives, results, and impacts to date.

Colombia↗

Activation Energy Determination for Photovoltaic Encapsulant Discoloration by Indoor Accelerated UV Testing

A novel methodology for determining the activation energy of photovoltaic encapsulant discoloration using an indoor accelerated ultraviolet (UV) stress test while simultaneously maintaining multiple module temperatures in a single weathering chamber is presented. The testing was performed on some fresh mini-modules with a glass/EVA/cell/EVA/backsheet construction. The short-circuit current degradation from individual cells was used to quantify transmittance losses due to discoloration. Activation energy determined using indoor accelerated UV test data and Modified Arrhenius model ranges from 26 to 44 kJ/mol (0.27 to 0.46 eV). Activation energy was also determined from the outdoor field degradation data by employing different physical models that consider the individual or combined effects of key environmental factors. The approach here is instrumental to evaluating the reliability studies on encapsulant degradation mechanisms using relatively less time and resources.

14 SOLAR ENERGY↗

High throughput CIGS solar cell fabrication via ultra-thin absorber layer with optical confinement and (Cd, CBD)-free heterojunction partner

The main objective of this proposal was to use several pathways to reduce the production cost of Cu(In,Ga)Se 2 (CIGS) PV modules and therefore the levelized cost of energy (LCOE) associated with this technology. Three high cost drivers were identified, nominally: 1) Materials cost and availability; 2) Large scale uniformity; 3) Improved throughput These three cost drivers were targeted using the following pathways: 1) Reducing the thickness of the CIGS layer while enhancing materials quality; 2) Developing and applying enhanced in-situ metrology via real time spectroscopic ellipsometry; 3) Looking into alternative heterojunction partner, back contact and anti-reflection (AR) coating Eleven main Tasks were then defined to achieve these goals (5 in Phase 1 and 6 in Phase 2), with 11 Milestones and 2 Go/No-go decision points at the end of Phase 1. The key results are summarized below

14 SOLAR ENERGY↗

Macroscopic Nonuniformities in Metal Grids Formed by Cracked Film Lithography Result in 19.3% Efficient Solar Cells

Cracked film lithography (CFL) is an emerging method for patterning transparent conductive metal grids. CFL can be vacuum- and Ag-free, and it forms more durable grids than nanowire approaches. In spite of CFL’s promising transmittance/grid sheet resistance/wire spacing tradeoffs, previous solar cell demonstrations have had relatively low performance. This work introduced macroscopic nonuniformities in the grids to improve the short-circuit current density/fill factor tradeoff in small area Cu(In,Ga)Se2 cells. Furthermore, the performance of optimized baseline grids was matched by CFL grids with microscopic openings and macroscopic patterns, culminating in a 19.3%-efficient cell. Simulations show that uniform CFL grids are enhanced by patterning because it leads to better balance among shadowing, grid resistance and transparent conductive oxide resistance losses. Thin-film module efficiency calculations were performed to highlight the performance gains that metal grids can enable by eliminating the transparent conductive oxide losses and widening monoliths. Adding the patterned CFL grids demonstrated in this work to CIGS modules is predicted to reach 0.7% higher efficiency (absolute) than screen-printed grids.

14 SOLAR ENERGY↗

Moisture ingress prediction in polyisobutylene-based edge seal with molecular sieve desiccant

Often photovoltaic modules are constructed with materials that are sensitive to water. This is most often the case with thin film technologies, including perovskite cells, where the active layers are a few microns thick and can be sensitive to moisture, liquid water or both. When moisture or liquid water can ingress, a small amount of water can lead to corrosion and depending on the resulting reactions, a larger local detrimental effect is possible. To prevent moisture from contacting photovoltaic components, impermeable frontsheets and backsheets are used with a polyisobutylene (PIB)-based edge seal material around the perimeter. Here, we evaluate the ability of a PIB-based edge seal using a molecular sieve desiccant to keep moisture out for the expected module lifetime. Moisture ingress is evaluated using test coupons where the edge seal is placed between 2 pieces of glass, one of which has a metallic calcium film on it, and monitoring the moisture ingress distance as a function of time. We expose samples to different temperature and humidity conditions to create permeation models useful for extrapolation to field use. This extrapolation indicates that this PIB material is capable of keeping moisture out of a module for the desired lifetime.

14 SOLAR ENERGY↗

Light Management in Bifacial Photovoltaics with Spectrally Selective Mirrors

Spectrally-selective mirrors that simultaneously provide above-bandgap anti-reflection and sub-bandgap light rejection are tested for their ability to provide passive cooling to partially sub-bandgap transparent bifacial photovoltaics. The optical and thermal benefits of both idealized and real, low-complexity spectrally-selective mirrors on single-axis tracking, bifacial PERC arrays under realistic conditions are tested via rigorous finite element simulations. Four- and six-layer mirror designs increased carrier generation beyond what traditional antireflection coatings can provide without the associated cell heating. Here, idealized mirrors were found to provide up to 2.4 °C of cooling when included on both air/glass interfaces of the bifacial module.

14 SOLAR ENERGY↗

Leaving in the lead: Priorities for perovskite photovoltaics

The need for moving electricity generation to a sustainable model requires the development of low cost ubiquitous photovoltaics (PVs) to harvest the planet’s primary energy source, the Sun. Building upon the successes of Si-based and CdTe-based PV technologies, PVs with lower-embodied energy and requiring lower carbon dioxide equivalent to produce will be required to meet long-term sustainability goals. In particular, thin-film technologies, such as high-efficiency metal halide perovskite (MHP) PV modules, provide avenues to reduced embodied energy, lower energy payback times, and enabling energy-dense tandems [H. M. Wikoff et al., Joule 6(7), 1710–1725 (2022) and V. Fthenakis, Renewable Sustainable Energy Rev. 13(9), 2746–2750 (2009)]. The ability to improve efficiency and lower energy payback time of next generation thin-film PV modules is a critical foundation for green H2 and electrification more broadly. In this regard, Pb-based MHP-PVs have separated themselves as a result of the high-efficiencies that can be realized across a range of electronic gaps. Questions regarding Pb-based MHP-PVs that are often asked, as the challenges of efficiency and reliability are met, revolve around the “problem” of the Pb content. Specifically, “does Pb toxicity preclude MHP-PV modules from being deployed at the TW scale?” To provide this sense of scale, in 2021, the United States burned 10.5 quads of coal, with 90% of that used for electricity generation. Given the energy content of coal of 29 MJ/kg and a residual lead content in that coal of 30 mg/kg, electricity generation from coal resulted in more lead emitted into the atmosphere than what would be required to produce over 2 TW of MHP-PV name plate capacity (assuming a 20% module efficiency and an ∼700 nm active layer). This amounts to more PV power than has been deployed across all PV technologies and geographies to date. This only includes US coal consumption; the rest of the world would be much larger. This example illustrates the scale of the material usage relative to the energy production. Imagine a power-generation technology that offsets these Pb emissions from coal and essentially sequesters this Pb content between two sheets of impermeable glass. Why should we let Pb’s history of misuse prevent it from being included in next generation PV modules that can enable a sustainable energy future?

14 SOLAR ENERGY↗

Assessment of Accelerated Stress Testing Data for Silicon Photovoltaics Using Tensor Decomposition Methods

In this work, we examine the use of high-order tensor decompositions to analyze degradation pathways emerging from accelerated stress testing of silicon photovoltaic (PV) modules. Matrix-based decompositions are powerful tools for studying two-dimensional data arrays and form the foundation of a host of classical data analysis techniques. Tensors are high-order extrapolations of matrices that are able to account for more parameter dimensions, and a variety of tensor decomposition methods have been developed that similarly seek to extend insights from matrix decompositions to higher dimensions. Applying and interpreting tensor decomposition methods to sequences of PV module image data, we seek to uncover and isolate different degradation modes occurring from accelerated stress testing procedures. Further, we consider the contributions of different modes to PV module performance degradations.

data analysis↗

Investigation of a Wedge Adhesion Test for Edge Seals

Many photovoltaic (PV) technologies have been found to be sensitive to moisture that diffuses into a PV package. Even with the use of impermeable frontsheets and backsheets, moisture can penetrate from the edges of a module. To limit this moisture ingress pathway from occurring, manufacturers often use a low permeability polyisobutylene (PIB) based edge seal filled with desiccant to further restrict moisture ingress. Moisture ingress studies have shown that these materials are capable of blocking moisture for the 25-year life of a module; but to do so, they must remain well-adhered and free of cracks. This work focuses on adapting the Boeing Wedge test for use with edge seals laminated using glass substrates as part of a strategy to assess the long-term durability of edge seals. The advantage of this method is that it duplicates the residual stresses and strains that a glass/glass module may have when the lamination process results in some residual glass bending that puts the perimeter in tension. Additionally, this method allows one to simultaneously expose the material to thermal stress, humidity, mechanical stress, and ultraviolet radiation. The disadvantage of this method generally is that we are limited by the fracture toughness of the glass substrates that the edge seal is adhered to. However, the low toughness of typical uncrosslinked or sparsely crosslinked PIB makes them suitable for this technique. We present data obtained during the development of the wedge test for use with PV edge seal materials. This includes development of the measuring techniques and evaluation of the test method with relevant materials. We find consistent data within a given experiment, along with the theoretical independence of fracture toughness measurements with wedge thickness. This indicates that the test methodology is reproducible. However, even though individual experimental sets are consistent, the reproducibility between experimental sets is poor. We believe this may be due to inconsistencies in sample history, sample batch, or small changes in sample preparation/assembly from one month to the next. Because the fracture strength of typical edge seal materials is so low, they cannot be relied upon for mechanical strength. A small stress or strain on the edge seal is capable of promoting delamination or tearing causing the edge seal to fail. Because of this, edge seals are very dependent on the processing and construction parameters in the full size PV module such that any long term evaluation of their durability must be conducted on full size modules to be accurate.

14 SOLAR ENERGY↗

Generalizable Mechanistic Understanding of Module-Level Light-Moisture and Thermal-Induced Instabilities in CIGS Photovoltaics (Final Report)

The objectives of this project are to identify the root causes of light, heat and humdity induced instabilities in the operation and accelerated testing of commercial Cu(In,Ga)Se 2 [CIGS] photovoltaic modules produced by major module manufacturers (e.g.: Solibro and MiaSolé), correlate them with module degradation/failure modes, and produce accurate service lifetime prediction models.

14 SOLAR ENERGY↗

PV module spectral response measurements - Data and Resources

"This dataset includes spectral response curves for 12 commercial silicon module types that are deployed at SNL in Albuquerque. The modules chosen for evaluation were originally purchased by SNL for the PV Lifetime project (renamed to Systems Long-Term Evaluation [SLTE]). The majority of those modules are deployed outdoors for long-term evaluation, but several modules of each type were placed in storage for future comparison purposes. One stored module of each type was sent to NREL for the spectral response measurements. NREL used the recently developed Module Quantum Efficiency (QE) test bed. What makes this system unique is that it scans the entire module automatically, taking one or more measurements on each cell. Using the mean of these measurements at each wavelength leads to improvements in spectral mismatch correction and module power measurements but having the individual measurements also makes it possible to identify outlier cells, which could be useful for investigating underperforming modules. All measurements were performed nominally at 25°C"

14 SOLAR ENERGY↗

Techno-economic analysis of hybrid PV/T systems for process heat using electricity to subsidize the cost of heat

Process heat applications make up a large potential market for renewable energy. Despite heating demand being approximately double that of electricity, relatively little work has been done to develop renewable energy for process heat applications. Concentrated solar thermal (CST) systems are capable of reaching temperatures necessary for industrial and commercial steam applications but are often overlooked due to the difficulty of competing with natural gas. Novel hybrid photovoltaic/thermal systems (PV/T) are capable of simultaneously generating electricity and heat. The electricity produced is of higher value and offsets the lifetime cost of the system by producing a cost savings to the facility, ultimately making solar heat competitive with natural gas, propane, coal, and other fuels. The design and economic feasibility of a dish concentrator PV/T (CPV/T) system utilizing a transmissive CPV array is explored through a techno-economic model including technical, financial, and geographical inputs. Through practical design choices, the levelized cost of heat (LCOH) is competitive with natural gas or could even be reduced to zero in some locations by factoring in the electricity savings from additional energy generated by the transmissive CPV module.

14 SOLAR ENERGY↗

Demonstration of GaInP2/Si Voltage Matched Tandem Solar Cells

Mechanically-stacked tandem solar cells combining existing photovoltaic technologies present a straightforward path toward higher conversion efficiencies. Voltage-matched configurations have been proposed as a simplified approach for fabricating two terminal modules, but they are subject to performance losses compared to four terminal configurations if voltage-matching conditions are not met. Here, we demonstrate a two terminal voltage-matched GaInP 2 /Si tandem with 23% efficiency. Through a combination of experimental measurement and simulation, we explore the impact of voltage and fill factor mismatches between the top and bottom sub-cell strings. Our results show that efficiency losses are minimized when voltage-mismatches are accommodated by designing the bottom strings to have a higher voltage. Fill factor mismatches due to differences in series resistance also lead to changes in the optimal ratio of the number of cells in the top and bottom sub-cell strings.

14 SOLAR ENERGY↗