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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 127 records · Page 7
All sourcesNASA NTRSDOE OSTI
NASA NTRS1984

Investigation of test methods, material properties, and processes for solar cell encapsulants

Photovoltaic (PV) modules consist of a string of electrically interconnected silicon solar cells capable of producing practical quantities of electrical power when exposed to sunlight. To insure high reliability and long term performance, the functional components of the solar cell module must be adequately protected from the environment by some encapsulation technique. The encapsulation system must provide mechanical support for the cells and corrosion protection for the electrical components. The goal of the program is to identify and develop encapsulation systems consistent with the PV module operating requirements of 30 year life and a target cost of $0.70 per peak watt ($70 per square meter) (1980 dollars). Assuming a module efficiency of ten percent, which is equivalent to a power output of 100 watts per square meter in midday sunlight, the capital cost of the modules may be calculated to be $70.00 per square meter. Out of this cost goal, only 20 percent is available for encapsulation due to the high cost of the cells, interconnects, and other related components. The encapsulation cost allocation may then be stated as $14.00 per square meter, included all coatings, pottant and mechanical supports for the cells.

Source record↗
DOE OSTI2012

National Center of Excellence for Energy Storage Technology 168.10 (Final Report for Period 10/1/2010-12/31/2011)

This report documents the performance of the Ohio State University (OSU) and Edison Welding Institute (EWI) in the period from 10/1/2010 to 12/31/2012. The objective of the project is to establish a Center of Excellence that leverages the strengths of the partners to establish a unique capability to develop and transfer energy storage industries to establish a unique capability in the development and transfer of energy storage system technology through a fundamental understanding of battery electrical and thermal performance, damage and aging mechanisms, and through the development of reliable, high-speed processes for joining substrates in battery cell, module and pack assemblies with low manufacturing variability. During this period, the OSU activity focused on procuring the equipment, materials and supplies necessary to conduct the experiments planned in the statement of project objectives. In detail, multiple laboratory setups were developed to enable for characterizing the open-circuit potential of cathode and anode materials for Li-ion batteries, perform experiments on calorimetry, and finally built multiple cell and module battery cyclers to be able to perform aging campaign on a wide variety of automotive grade battery cells and small modules. This suite of equipment feeds directly into the development, calibration of battery models ranging from first principle electrochemical models to electro-thermal equivalent circuit models suitable for use in control and xEV vehicle simulations. In addition, it allows to develop and calibrate ‘aging’ models for Li-ion batteries that enable the development of diagnostics and prognostics tools to characterize and predict battery degradation from automotive usage under a wide array of environmental and usage scenarios. The objective of the EWI work scope is to develop improved processes for making metal-tometal joints in advanced battery cells and packs. It will focus on developing generic techniques for making functional (electrically conductive and mechanically robust) metal-to-metal joints between thin substrates. Joints with multiple layers and bimetallic constituents will be investigated. During the current period of performance, EWI has defined the test matrix to evaluate the application of different welding technologies (laser welding, ultrasonic welding, resistance welding) to specific components of battery cells and modules, such as foils-to-tabs, tabs-to-tabs, and tabs-to-bus bars. The test matrix also includes a range of substrates (aluminum 1145 and 1100, copper 110 and nickel 200 as substrates). Furthermore, a set of procedures was defined to perform mechanical and electrical testing of the samples, including metallography, and non-destructive evaluations. Both on the OSU and EWI, this project enabled to leverage very significant industrial collaborations with a wide array of companies ranging from battery manufacturers and pack integrator all the ways to Tier 1 automotive suppliers and OEMs during the period of exercise of the project, and in the future for years to come.

25 ENERGY STORAGE↗
DOE OSTI2024

High-Efficiency and Low-Carbon Energy Storage and Power Generation System for Electric Aviation

This report summarizes the work performed by University of California San Diego (UCSD) – Honeywell Aerospace (Honeywell) team for the U.S. Department of Energy/Advanced Research Projects Agency-Energy (DOE/ARPA-E) under Phase 1 (April 2021 – October 2023) project, Cooperative Agreement DE-AR0001347 entitled “High-Efficiency and Low-Carbon Energy Storage and Power Generation System for Electric Aviation”. The main objective of this project is to develop and demonstrate an energy storage and power generation (ESPG) system operating on bio liquid natural gas (LNG) for electric aviation applications. The ESPG system concept in this project is a fuel cell, battery, and gas turbine hybrid system that incorporates an innovative solid oxide fuel cell (SOFC) technology. This SOFC technology has two main novel elements: (i) a lightweight and compact stack architecture that consists of cells and cell modules in electrical parallel and series connections (the module design) and (ii) exceptionally high performance, direct methane thin-film cells on porous substrate made by sputtering deposition process. This fuel cell has the specific power and volumetric power density suitable for electric aviation applications. Based on the current status of the SOFC technology, the Phase 1 work focused on the following activities: (i) ESPG System Modeling – to design and optimize an aircraft SOFC-based ESPG system concept that met the performance, weight and cost targets; (ii) Cell Material Development and Scaleup – to demonstrate scalability of the sputtering process for manufacture of thin-film SOFC cells of practical sizes, confirm the exceptional performance of sputtered cells, improve cell stability and durability for operation with hydrogen and methane fuel, and develop a suitable electrically conducting porous substrate to replace the current non-conducting ceramic substrate; (iii) Stack Development – to design and manufacture stack components for the stack architecture, evaluate and select a suitable sealant, and build and operate multi-cell stacks to demonstrate stack operation, and (iv) Technology to Market – to develop business models and commercialization plans, conduct various market and technology analysis and estimate SOFC and ESPG system costs.

25 ENERGY STORAGE↗
DOE OSTI2018

String-Level Modeling of Two, Three, and Four Terminal Si-Based Tandem Modules

III-V/Si tandem solar cells have demonstrated efficiencies exceeding the theoretical efficiency limit of silicon solar cells. On the cell level, device modeling shows that three-terminal tandem (3T) devices with rear contacted bottom Si cells perform as well as operating the subcells independently (4T). However, integrating these 3T devices in a module requires voltage matching of the top and the bottom cell. Here, we investigate the robustness of parallel/series-interconnected 3T III-V/Si tandem devices in comparison with series-interconnected two terminal (2T) and independently operated (4T) devices with respect to spectral, thermal, and resistive effects. Under most conditions, interconnected 3T devices are able to perform as well as those with independent operation of the top and bottom cell, and 3T devices significantly outperform 2T devices.

14 SOLAR ENERGY↗
DOE OSTI2012

Chapter III-2: Standards, Calibration and Testing of PV Modules and Solar Cells

This chapter covers common PV measurement techniques and shows how potential problems and sources of error are minimized through the development and use of common standards. Measurement uncertainty, however, remains a problem for some types of PV cells, and tests continue to be developed to address these issues.

14 SOLAR ENERGY↗
DOE OSTI2024

Monitoring of Photovoltaic (PV) Performance and Degradation: Integrated Renewable Energy Systems (IRES) - PV Monitoring Task

The Integrated Renewable Energy System (IRES) testbed demonstration at the Pacific Northwest National Laboratory (PNNL) Sequim campus includes development of a suite of capabilities for tracking the performance of photovoltaic (PV) renewable energy components located on a floating platform (floating PV) and on a shoreline building rooftop. The marine environment represents potentially harsh and corrosive conditions for PV modules. Compared to terrestrial PV, potential concerns for offshore PV arising from high humidity and occasional contact with saltwater, marine wildlife, and aquaculture. These environmental factors can reduce electricity generation efficiency and increase the risk of electrical faults, polymer insulation or jacketing degradation and hydrolysis of the PV cell encapsulant materials. Offshore PV modules may also be exposed to lower temperatures and buoyant and vibrating motions with a floating platform. It is not clear how the long-term performance of floating PV will be affected by these factors. To understand expected energy generation through solar cells on a floating platform, monitoring of the performance of PV modules in the marine environment is needed. This report outlines a plan for long-term testing of IRES PV components utilizing resources of the PNNL Material Aging and Detection (MAaD) Science team and the Marine and Coastal Research Laboratory (MCRL). Equipment applicable for onsite testing and real-time monitoring of the PV performance associated with environmental conditions including temperature, solar irradiance, shading and soiling is included. In case of performance loss, equipment for fault detection, failure analysis, material testing, and further troubleshooting are also available. Through establishment of this capabilities, the enabling IRES project sets the stage for future research to advance off-shore and near-shore energy options for businesses and communities.

14 SOLAR ENERGY↗
NASA NTRS1976

Photovoltaic test and demonstration project

The primary objectives of the Photovoltaic Test and Demonstration Project are: (1) to determine operating characteristics for different solar cell systems and subsystems, (2) to prove, through tests and demonstrations, that solar cell systems can satisfy the requirements of potentially attractive residential, commercial, industrial, and smaller terrestrial applications, (3) to devise and implement the methodology, techniques and equipment to make accurate and reproducible measurements of solar cell and array performance, and diagnostic measurements on solar cells, modules and arrays, and (4) to determine the endurance of solar cell modules, component parts, and materials under expected environmental conditions.

Forestieri, A. F.↗
NASA NTRS1979

Laboratory simulations of the Viking Labeled Release experiment - Kinetics following second nutrient injection and the nature of the gaseous end product

Injection of (C-14)-labeled nutrient onto Mars soil produced an evolution of C-14 gas in the Viking Labeled Release (LR) experiment. However, a second injection of nutrient seven days later was followed by an abrupt diminution of the amount of radioactive gas in the test cell. Simulation experiments performed in the LR Test Standards Module (TSM) have yielded a plausible explanation for this diminution. Radioactive carbon gases were injected into the TSM test cell in the presence and absence of two Mars analog soils. After equilibration, water was injected and its effect observed. The results indicate that the flight data following second nutrient injection can be explained on a physico-chemical basis involving a carbon dioxide/water/soil equilibrium in the test cell. The results also suggest that the gaseous end product of the Labeled Release reaction on Mars is more likely carbon dioxide than carbon monoxide.

Levin, G. V.↗
NASA NTRS1981

Cell module and fuel conditioner development

The results of pretesting and performance testing of Stack 564 are reported. The design features, progress in fabrication and plans for assembly of Stack 800 are given. The status of endurance testing of Stack 560 is reported. The design, fabrication, test procedures and preliminary tests of the 10 kW double counterflow reformer and the reformer test stand are described. Results of vendor contacts to define the performance and cost of fuel conditioning system components are reported. The results of burner tests and continuing development of the BOLTAR program are reported.

Hoover, D. Q., Jr.↗
NASA NTRS1981

The 19th Project Integration Meeting

The Flat-Plate Solar Array Project is described. Project analysis and integration is discussed. Technology research in silicon material, large-area silicon sheet and environmental isolation; cell and module formation; engineering sciences, and module performance and failure analysis. It includes a report on, and copies of visual presentations made at, the 19th Project Integration Meeting held at Pasadena, California, on November 11, 1981.

Mcdonald, R. R.↗
NASA NTRS1982

Flat Plate Solar Array Project: Proceedings of the 20th Project Integration Meeting

Progress made by the Flat-Plate Solar Array Project during the period November 1981 to April 1982 is reported. Project analysis and integration, technology research in silicon material, large-area silicon sheet and environmental isolation, cell and module formation, engineering sciences, and module performance and failure analysis are covered.

Mcdonald, R. R.↗
NASA NTRS1986

Accuracy and long-term stability of amorphous-silicon measurements

The measurement system requirements to obtain accurate electrical performance measurements of amorphous silicon cells and modules were described. The progress achieved in modifying the Jet Propulsion Laboratory (JPL) system toward that objective were reviewed.

Mueller, R.↗
DOE OSTI2015

Round-Robin Verification and Final Development of the IEC 62788-1-5 Encapsulation Size Change Test; NREL (National Renewable Energy Laboratory)

Polymeric encapsulation materials may a change size when processed at typical module lamination temperatures. The relief of residual strain, trapped during the manufacture of encapsulation sheet, can affect module performance and reliability. For example, displaced cells and interconnects threaten: cell fracture; broken interconnects (open circuits and ground faults); delamination at interfaces; and void formation. A standardized test for the characterization of change in linear dimensions of encapsulation sheet has been developed and verified. The IEC 62788-1-5 standard quantifies the maximum change in linear dimensions that may occur to allow for process control of size change. Developments incorporated into the Committee Draft (CD) of the standard as well as the assessment of the repeatability and reproducibility of the test method are described here. No pass/fail criteria are given in the standard, rather a repeatable protocol to quantify the change in dimension is provided to aid those working with encapsulation. The round-robin experiment described here identified that the repeatability and reproducibility of measurements is on the order of 1%. Recent refinements to the test procedure to improve repeatability and reproducibility include: the use of a convection oven to improve the thermal equilibration time constant and its uniformity; well-defined measurement locations reduce the effects of sampling size -and location- relative to the specimen edges; a standardized sand substrate may be readily obtained to reduce friction that would otherwise complicate the results; specimen sampling is defined, so that material is examined at known sites across the width and length of rolls; and encapsulation should be examined at the manufacturer’s recommended processing temperature, except when a cross-linking reaction may limit the size change. EVA, for example, should be examined 100 °C, between its melt transition (occurring up to 80 °C) and the onset of cross-linking (often at 100 °C).

14 SOLAR ENERGY↗
DOE OSTI2024

A thermotropic liquid crystal enables efficient and stable perovskite solar modules

Perovskite solar cells have seen impressive progress in performance and stability, yet maintaining efficiency while scaling area remains a challenge. Here we find that additives commonly used to passivate large-area perovskite films often co-precipitate during perovskite crystallization and aggregate at interfaces, contributing to defects and to spatial inhomogeneity. Here we develop design criteria for additives to prevent their evaporative precipitation and enable uniform passivation of defects. We explored liquid crystals with melting point below the perovskite processing temperature, functionalization for defect passivation and hydrophobicity to improve device stability. We find that thermotropic liquid crystals such as 3,4,5-trifluoro-4'-(trans-4-propylcyclohexyl)biphenyl enable large-area perovskite films that are uniform, low in defects and stable against environmental stress factors. We demonstrate modules with a certified stabilized efficiency of 21.1% at an aperture area of 31 cm 2 and enhanced stability under damp-heat conditions (ISOS-D-3, 85% relative humidity, 85 °C) with T 86 (the duration for the efficiency to decay to 86% of the initial value) of 1,200 h, and reverse bias with (ISOS-V-1, negative maximum-power-point voltage) and without bypass diodes.

14 SOLAR ENERGY↗
DOE OSTI2023

In-situ determination of moisture- and temperature-driven deflection of an encapsulated Si photovoltaic cell

Module reliability and service lifetime are critical factors in improving photovoltaic system performance and reducing the levelized cost of electricity (LCOE). Soldering and lamination of the cell impart residual stresses that persist over time and superimpose additional loads during operation. This paper demonstrates the use of X-ray Topography (XRT) to image in-situ the dynamic response of a glass/backsheet mini-module upon drying at elevated temperature after saturation at humidity levels compatible with accelerated testing. The local water content in the encapsulant is also determined in-situ over time via Water Reflectometric Detection (WaRD), with diffusion of water in the front (glass side) and rear (backsheet side) resolved. As water diffuses out from the back of the glass/backsheet module, the cell curves towards the backsheet concomitantly. Here we find that the cell edges deflect 40μm out-of-plane with respect to its center while the encapsulant dries, compared to ~100 μm deflection when heating from 25°C to 85°C. The local cell deflections (changes in cell orientation) are correlated with the dynamic loss of water in the backside encapsulant. We conclude that the observed cell deflections are the result of hygroscopic stress induced by the encapsulant upon moisture outdiffusion. Therefore, the cell experiences a continually changing stress state and curvature dependent on local humidity and temperature. Depending on cell architecture and interconnection, this “breathing” mode of the cell may induce wear out and fatigue of the interconnects, affect the electrical connection of cracked pieces or cause failure near the interconnected edges of two cells.

14 SOLAR ENERGY↗
DOE OSTI2018

Component Cell-Based Restriction of Spectral Conditions and the Impact on CPV Module Power Rating

One approach to consider the prevailing spectral conditions when performing CPV module power ratings according to the standard IEC 62670-3 is based on spectral matching ratios (SMRs) determined by the means of component cell sensors. In this work, an uncertainty analysis of the SMR approach is performed based on a dataset of spectral irradiances created with SMARTS2. Using these illumination spectra, the respective efficiencies of multijunction solar cells with different cell architectures are calculated. These efficiencies were used to analyze the influence of different component cell sensors and SMR filtering methods. The 3 main findings of this work are as follows. First, component cells based on the lattice-matched triple-junction (LM3J) cell are suitable for restricting spectral conditions and are qualified for the standardized power rating of CPV modules - even if the CPV module is using multijunction cells other than LM3J. Second, a filtering of all 3 SMRs with +/-3.0% of unity results in the worst case scenario in an underestimation of -1.7% and overestimation of +2.4% compared to AM1.5d efficiency. Third, there is no benefit in matching the component cells to the module cell in respect to the measurement uncertainty.

14 SOLAR ENERGY↗
DOE OSTI2023

Modulating the Mixing Gibbs Free Energy to Enhance Solid–Liquid Phase Separation for High–Performance Organic Solar Cells

Organic solar cells (OSC) feature a hierarchical structure with the electron donor/acceptor layer sandwiched by anode and cathode, which raises the importance of controlling the molecular crystal orientation, domain size, and vertical distribution to facilitate the charge collection at electrodes. However, the similar conjugated backbone of donor/acceptor material and fast film–formation kinetics have led to spinodal–decomposition–orientated phase separation that result in the film presenting an intimately mixed morphology and random molecular orientation. To solve the issue, the mixing Gibbs free energy–triggered solid–liquid phase separation during the film formation process is enhanced by solidifying one component and solvating the other based on a liquid additive. Following the liquid evaporation process, a favorable vertical distribution is obtained. Meanwhile, the prolonged solvation process enlarges the domain size and assists the molecules to diffuse and orient properly, enabling better exciton/charge dynamics during the power conversion processes. As a result, the fabricated devices exhibit a fill factor over 80% and an efficiency of 18.72%, which is one of the top efficiencies for binary OSCs. In conclusion, insights and a methodology is provided here to manipulate the organic donor/acceptor phase separation in terms of mixing Gibbs free energy.

14 SOLAR ENERGY↗
NASA NTRS1980

Three year performance of the NTS-2 solar cell experiment

Twelve different solar cell modules from the NTS 2 experiment are functioning after more than three years in a severe trapped radiation orbit of 20,367 km (10,990 nm) circular, 63 deg inclination. The rate of maximum power degradation may be fit to a predicted rate which is based on twice the value of 1 MeV electron equivalent damage fluence calculated from the space electron model AEI 7. The photovoltaic parameters of the cells are compared to their original values to demonstrate rank order of performance.

Statler, R. L.↗