Heterogeneously Integrated Photonic Modulators and High-Volume Manufacturing of Related Technologies.
Abstract not provided.
Boynton, Nick↗
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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↗
Design and verification of a novel hollow vibrating module for laser machining
If a vibration module is added on laser machining system, the quality of surface finish and aspect ratio on metals can be significantly enhanced. In this study, a single mobility model of vibrating laser along the path of laser beam was put forward. In order to realize the desired unidirectional motion, a resonance type vibration module with optical lens was designed and manufactured. This cylindrical module was composed of curved-beam flexure elements. The cylindrical coordinate system was established to describe the relationship of a curved-beam flexure element’s motion and deformation. In addition, the stiffness matrix of the curved-beam element was obtained. Finite element method and dynamical modeling were provided to analyze the resonance frequency and the displacement of the motion. The feasibility of the design was demonstrated with the help of experiments on frequency response. Experimental results show good agreement with theoretical analysis and simulation predictions.
46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
BACKFLIP: Identification of Materials and Changes Upon Aging of Emerging Fluoropolymer-Free and Industry-Benchmark PV Backsheets
Extending lifetimes of photovoltaic (PV) modules and decreasing manufacturing and decommissioning costs are motivating research of novel PV module backsheet materials. Backsheet integrity is critical to the safety and performance of a PV module, however, the polymeric materials are often vulnerable to environmental degradation. The long-term durability of emerging polyolefin (PO) materials is being examined to inform regarding the possible replacement of laminated backsheets containing polyethylene terephthalate (PET) cores and fluoropolymer protective inner/outer layers. This study compares traditional PET-based backsheets with novel, co-extruded, and recyclable PO-based backsheets after being subjected to hygrometric and UV photolytic accelerated weathering. A large set of characterization methods will compare physical, chemical, structural, mechanical, and insulating properties of these backsheets and the resulting mini-module (MiMo) PV performances. The study of chemical composition, glass- and phase-transition temperatures, degree of crystallinity, and crystalline structure are described here.
mini-module↗
The Role of Unit-Cell Topology in Modulating the Compaction Response of Additively Manufactured Cellular Materials using Simulations and Validation Experiments
Additive manufacturing has enabled a transformational ability to create cellular structures (or foams) with tailored topology. Compared to their monolithic polymer counterparts, cellular structures are potentially suitable for systems requiring materials with high specific energy-absorbing capability to provide enhanced damping. In this work, we demonstrate the utility of controlling unit-cell topology with the intent of obtaining a desired stress–strain response and energy density. Using mesoscale simulations that resolve the unit-cell sub-structures, we validate the role of unit-cell topology in selectively activating a buckling mode and thereby modulating the characteristic stress–strain response. Simulations incorporate a linear viscoelastic constitutive model and a hyperelastic model for simulating large deformation of the polymer under both tension and compression. Simulated results for nine different cellular structures are compared with experimental data to gain insights into three different modes of buckling and the corresponding stress–strain response.
36 MATERIALS SCIENCE↗
The role of unit cell topology in modulating the compaction response of additively manufactured cellular materials using simulations and validation experiments
Additive manufacturing has enabled a transformational ability to create cellular structures (or foams) with tailored topology. Compared to their monolithic polymer counterparts, cellular structures are potentially suitable for systems requiring materials with high specific energy-absorbing capability to provide enhanced damping. In this work, we demonstrate the utility of controlling unit-cell topology with the intent of obtaining a desired stress–strain response and energy density. Using mesoscale simulations that resolve the unit-cell sub-structures, we validate the role of unit-cell topology in selectively activating a buckling mode and thereby modulating the characteristic stress–strain response. Simulations incorporate a linear viscoelastic constitutive model and a hyperelastic model for simulating large deformation of the polymer under both tension and compression. Simulated results for nine different cellular structures are compared with experimental data to gain insights into three different modes of buckling and the corresponding stress–strain response.
36 MATERIALS SCIENCE↗
Generalized and Mechanistic PV Module Performance Prediction From Computer Vision and Machine Learning on Electroluminescence Images
Electroluminescence (EL) imaging of photovoltiac (PV) modules offers high-speed, high-resolution information about device performance, affording opportunities for greater insight and efficiency in module characterization across manufacturing, research and development, and power plant operations and management. Predicting module electrical properties from EL image features is a critical step toward these applications. In this article, we demonstrate quantification of both generalized and performance mechanism-specific EL image features, using pixel intensity-based and machine learning classification algorithms. From EL image features, we build predictive models for PV module power and series resistance, using time-series current-voltage (I-V) and EL data obtained stepwise on five brands of modules spanning three Si cell types through two accelerated exposures: damp heat (DH) (85°C/85% RH) and thermal cycling (TC) (IEC 61215). Overall, 195 pairs of EL images and I-V characteristics were analyzed, yielding 11700 individual PV cell images. A convolutional neural network was built to classify cells by the severity of busbar corrosion with high accuracy (95%). Generalized power predictive models estimated the maximum power of PV modules from EL images with high confidence and an adjusted-R 2 of 0.88, across all module brands and cell types in extended DH and TC exposures. Mechanistic degradation prediction was demonstrated by quantification of busbar corrosion in EL images of three module brands in DH, and subsequent modeling of series resistance using these mechanism-specific EL image features. For modules exhibiting busbar corrosion, we demonstrated series resistance predictive models with adjusted-R 2 of up to 0.73.
14 SOLAR ENERGY↗
On the Path to SunShot - Emerging Opportunities and Challenges in U.S. Solar Manufacturing
Innovation-driven cost and performance improvements, along with strong projected solar demand in the United States and across the Americas, could increase the attractiveness of U.S.-based solar manufacturing (see Chung et al. 2016). Although improvements to standard PV modules have produced deep cost reductions over the past 5 years, the returns on such incremental improvements appear to be diminishing, and more dramatic innovations in module design and manufacturing are required to continue along the path of rapid progress. At the same time, major opportunities exist for innovation to unlock the potential of CSP technologies. This need for innovation could benefit U.S. PV and CSP manufacturers. The United States has been rated one of the world’s most competitive and innovative countries as well as one of the best locations for PV manufacturing. It is a global leader in PV and CSP R&D and patent production, and U.S. PV manufacturers are already pursuing highly differentiated innovations.
14 SOLAR ENERGY↗
NEW CRYSTALLINE SILICON MODULE ARCHITECTURE TO REDUCE COSTS WITH IMPROVED MANUFACTURABILITY AND DURABILITY
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Solar, PV, Module, encapsulation↗
Overall Performance Losses and Activated Mechanisms in Double Glass and Glass-backsheet Photovoltaic Modules with Monofacial and Bifacial PERC Cells, under Accelerated Exposures
Commercial PV modules have various packaging choices nowadays, which influence their long-term reliability. This study compared the degradation behaviors of sixteen module variants from two brands with varying encapsulant materials (EVA or POE), encapsulant types, module architectures (GB or DG), and cell types (monofacial or bifacial) using null hypothesis testing to determine statistical significant findings. The modules were exposed for 2,520 hours under two accelerated exposures: modified damp heat (mDH) and modified damp heat with full-spectrum light (mDH+FSL). For both brands, two DG module variants with UV-Cutoff rear encapsulant are found to have significantly lower average power loss than the module variants of EVA+GB with opaque rear encapsulant after each accelerated exposure. Metallization interconnect corrosion is identified as the primary degradation mechanism. Furthermore, unsupervised hierarchical clustering finds that the degradation behaviors of modules from one brand with a more strict manufacturing quality control depends on module architectures only.
14 SOLAR ENERGY↗
A Manufacturing Cost and Supply Chain Analysis of SiC Power Electronics Applicable to Medium-Voltage Motor Drives
Wide bandgap (WBG) semiconductor devices are increasingly being considered for use in certain power electronics applications, where they can improve efficiency, performance, footprint, and, potentially, total system cost compared to systems using traditional silicon (Si) devices. Silicon carbide (SiC) devices in particular -- which are currently more mature than other WBG devices -- are poised for growth in the coming years. Today, the manufacturing of SiC wafers is concentrated in the United States, and chip production is split roughly equally between the United States, Japan, and Europe. Established contract manufacturers located throughout Asia typically carry out manufacturing of WBG power modules. We seek to understand how global manufacturing of SiC components may evolve over time by illustrating the regional cost drivers along the supply chain and providing an overview of other factors that influence where manufacturing is sited. We conduct this analysis for a particular case study where SiC devices are used in a medium-voltage motor drive.
71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
SiC Power Electronics in Medium Voltage Motor Drives: Trade and Manufacturing Analysis
Wide bandgap (WBG) semiconductor devices are increasingly being considered for use in certain power electronics applications, where they can improve efficiency, performance, footprint, and, potentially, total system cost compared to systems using traditional silicon (Si) devices. Silicon carbide (SiC) devices in particular -- which are currently more mature than other WBG devices -- are poised for growth in the coming years. Today, the manufacturing of SiC wafers is concentrated in the United States, and chip production is split roughly equally between the United States, Japan, and Europe. Established contract manufacturers located throughout Asia typically carry out manufacturing of WBG power modules. We seek to understand how global manufacturing of SiC components may evolve over time by illustrating the regional cost drivers along the supply chain and providing an overview of other factors that influence where manufacturing is sited. We conduct this analysis for a particular case study where SiC devices are used in a medium-voltage motor drive.
29 ENERGY PLANNING, POLICY, AND ECONOMY↗
Doping in Efficient Polycrystalline CdSeTe Solar Cells via AsCl 3 Vapor Annealing
Doping in cadmium telluride (CdTe) thin-film solar cells is a critical step in producing highly efficient CdTe solar modules. To date, copper (Cu) ex-situ diffusion doping and group V in situ doping (such as arsenic, As) have been effectively used in manufacturing CdTe solar modules. However, Cu doping is prone to rapid degradation, whereas the low activation ratio of the dopants constrains group V in situ doping. Recently, ex-situ group V doping has been developed, showing an improved doping activation ratio through a solution process. Here, in this study, we developed a vapor-based AsCl 3 doping method for diffusion doping of polycrystalline CdSeTe devices. AsCl 3 vapor annealing can promote the diffusion of As into the bulk CdSeTe through a surface chemical reaction between CdTe and AsCl 3 . This approach has led to a long carrier lifetime of over 72 ns, V oc of 850 mV, and power conversion efficiency of ~18% with Au metal electrodes. The vapor-based ex situ group V doping approach offers an effective means to perform group V diffusion doping into the CdSeTe device.
14 SOLAR ENERGY↗
Capital Intensity of Photovoltaics Manufacturing: Barrier to Scale and Opportunity for Innovation
Explore the source record for details and available documents.
14 SOLAR ENERGY↗
Ribbons Affect Movement of Cracked Solar Cells [Poster]
Cracking of crystalline silicon photovoltaic cells remains a challenging topic in accurately assessing the long-term reliability and performance of affected modules. Cells can be damaged in every stage throughout the lifetime of a photovoltaic module, ranging from manufacturing, transportation, and installation to operation. Initially, the metallization can be able to bridge the gap of fractured cells and keep individual cell fragments electrically connected. However, photovoltaic modules and cells experience thermo-mechanical stresses during operation from temperature changes and pressure cycles of wind and snow loads. This causes the cell fragments to move, which, in turn, can lead to the wear out of the metallization and, consequently, to power loss or a safety hazard. The rate at which this degradation mechanism proceeds is currently unknown. Hence, in this work, we quantify the cell fragment movement of polycrystalline and monocrystalline mini-modules. By using digital image correlation, we were able to extract the normal crack opening and tangential sliding distances of adjacent cell fragments during heating of the mini-modules. Those distances are essential to develop wear-out models for the metallization and determine the rate of the degradation mechanism. We found that the interconnect technology has a significant impact on the direction and quantity of the cell fragment movements.
14 SOLAR ENERGY↗
Bottom-Up Cost Analysis of a High Concentration PV Module; NREL (National Renewable Energy Laboratory)
We present a bottom-up model of III-V multi-junction cells, as well as a high concentration PV (HCPV) module. We calculate $0.65/Wp(DC) manufacturing costs for our model HCPV module design with today’s capabilities, and find that reducing cell costs and increasing module efficiency offer the promising pathways for future cost reductions. Cell costs could be significantly reduced via an increase in manufacturing scale, substrate reuse, and improved manufacturing yields. We also identify several other significant drivers of HCPV module costs, including the Fresnel lens primary optic, module housing, thermal management, and the receiver board. These costs could potentially be lowered by employing innovative module designs.
$/W↗
Indirect Liftoff Mechanism for High‐Throughput, Single‐Source Laser Scribing for Perovskite Solar Modules
A high‐throughput, single‐source laser scribing method exploiting a transparent conducting oxide (TCO) indirect liftoff mechanism is developed to produce serially interconnected perovskite solar modules. The TCO‐based indirect liftoff mechanism relies solely on laser absorption in the front transparent electrode material reducing thermal damage to the overlying layers and allowing for fast scribing speeds with low‐cost μs‐pulse duration fiber laser systems. Minimal resistive power losses are observed with the method compared to conventional ablative laser scribes, maintaining the power conversion efficiencies of small‐area devices (≈0.2 cm 2 ) across significantly larger deposition areas (≈1 cm 2 ). Finally, demonstrating > 3 m s −1 processing speeds, TCO‐based liftoff provides the highest throughput laser scribing method for thin‐film photovoltaic devices produced on glass/TCO substrates, capable of processing large‐area perovskite solar modules at a manufacturing scale.
14 SOLAR ENERGY↗
Integration of a real-time orientation measurement system for a real-time evaluator (RTE) to measure the position and orientation of crane-lifted components
Prefabrication of building components holds the potential to revolutionize the construction industry. Prefabrication consists of manufacturing building components, modules, and other elements in a factory to be shipped and installed on a construction site. Prefabricated components have been produced for various applications including precast concrete panels for new construction and exterior wall retrofits. The manufacturing process has seen much innovation in recent years; however, the installation process has seen minimal advancements. A real-time evaluator (RTE) was developed to reduce the installation cost of prefabricated components by reducing installation time, decreasing rework, and improving accuracy. The RTE uses off-the-shelf hardware and novel algorithms to assist erectors with component installation by measuring the real-time positions of connections and prefabricated components, providing installation guidance through a graphical user interface, and monitoring the accumulated installation errors. An overview of the RTE and the proposed workflow is presented. Previous on-site demonstrations provided valuable feedback from users on the potential areas for improvement of the system. One common request was real-time measurement of component orientation during lifting, a process that previously required that the component remain stationary while the laser tracker cycled through target prisms. This paper will present the incorporation and testing of a real-time orientation measurement system as it was implemented into the RTE, allowing for measurement of component orientation during movement.
Selvakumar, Balaji [ORNL]↗