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DOE OSTI2024

Photovoltaic Cable Connectors: A Comparative Assessment of the Present State of the Industry [Slides]

The consequences of failure for balance of systems (BoS) components (such as PV cable connectors) include offline module string(s); low system voltage; arc, ground, insulation, and over-temperature faults; triggered fuse(s); system shutdown; and fire. The degradation modes for connectors are studied here through an industry survey and its subsequent examination, which are compared to field-degraded specimens. 117 specimens were obtained from a variety of locations and climates or accelerated tests. A failure analysis for connectors from PV installations was developed (and applied to 54 specimens) including nondestructive examinations (photography, a custom resistance-current scan, and X-ray computed tomography) and destructive examinations (featuring milling of the external plastic, extraction of the internal convolute spring, and potting and polishing in cross-section). Surface and through-thickness composition of the metal pins and springs was quantified using scanning electron microscopy with energy-dispersive X-ray spectroscopy. Fourier-transform infrared spectroscopy was used to verify the base polymer materials and compare the chemical structure of the connector body, bushing, end nut, and o-ring. Thermogravimetric analysis and differential scanning calorimetry were used to further verify the degradation of the same polymeric components. Updated from 2023 NIST/UL Workshop on Photovoltaic Materials Durability (website: https://events.ul.com/WPMogn?rt=aAuoWsl4E0KaORLCMeOgfA) and 2024 PVRW workshop (https://pvrw.nrel.gov/past-proceedings).

14 SOLAR ENERGY↗

DOE OSTI2016

Plug and Play PV Systems for American Homes

The core objectives of the Plug & Play PV Systems Project were to develop a PV system that can be installed on a residential rooftop for less than $1.50/W in 2020, and in less than 10 hours (from point of purchase to commissioning). The Fraunhofer CSE team’s approach to this challenge involved a holistic approach to system design – hardware and software – that make Plug & Play PV systems: • Quick, easy, and safe to install • Easy to demonstrate as code compliant • Permitted, inspected, and interconnected via an electronic process Throughout the three years of work during this Department of Energy SunShot funded project, the team engaged in a substantive way with inspectional services departments and utilities, manufacturers, installers, and distributors. We received iterative feedback on the system design and on ideas for how such systems can be commercialized. This ultimately led us to conceiving of Plug & Play PV Systems as a framework, with a variety of components compatible with the Plug & Play PV approach, including string or microinverters, conventional modules or emerging lightweight modules. The framework enables a broad group of manufacturers to participate in taking Plug & Play PV Systems to market, and increases the market size for such systems. Key aspects of the development effort centered on the system hardware and associated engineering work, the development of a Plug & Play PV Server to enable the electronic permitting, inspection and interconnection process, understanding the details of code compliance and, on occasion, supporting applications for modifications to the code to allow lightweight modules, for example. We have published a number of papers on our testing and assessment of novel technologies (e.g., adhered lightweight modules) and on the electronic architecture.

14 SOLAR ENERGY↗

NASA NTRS1993

Flexible polycrystalline thin-film photovoltaics for space applications

Polycrystalline thin-film photovoltaics (PV), such as CIS and CdTe, have received considerable attention recently with respect to space power applications. Their combination of stability, efficiency, and economy from large-scale monolithic-integration of modules can have significant impact on cost and weight of PV arrays for spacecraft and planetary experiments. An added advantage, due to their minimal thickness (approximately 6 microns sans substrate), is the ability to manufacture lightweight, flexible devices (approximately 2000 W/kg) using large-volume manufacturing techniques. The photovoltaic effort at Martin Marietta and ISET is discussed, including large-area, large-volume thin-film deposition techniques such as electrodeposition and rotating cylindrical magnetron sputtering. Progress in the development of flexible polycrystalline thin-film PV is presented, including evaluation of flexible CIS cells. In addition, progress on flexible CdTe cells is presented. Finally, examples of lightweight, flexible arrays and their potential cost and weight impact is discussed.

Armstrong, J. H.↗

NASA NTRS1973

The NASA-Lewis terrestrial photovoltaics program

Research and technology efforts on solar cells and arrays having relevance to terrestrial uses are outline. These include raising cell efficiency, developing the FEP-covered module concept, and exploring low cost cell concepts. Solar cell-battery power systems for remote weather stations have been built to demonstrate the capabilities of solar cells for terrestrial applications.

Bernatowicz, D. T.↗

NASA NTRS1980

High efficiency compound semiconductor concentrator photovoltaics

Special emphasis was given to the high yield pilot production of packaged AlGaAs/GaAs concentrator solar cells, using organometallic VPE for materials growth, the demonstration of a concentrator module using 12 of these cells which achieved 16.4 percent conversion efficiency at 50 C coolant inlet temperature, and the demonstration of a spectral splitting converter module that achieved in excess of 20 percent efficiency. This converter employed ten silicon and ten AlGaAs cells with a dichroic filter functioning as the beam splitter. A monolithic array of AlGaAs/GaAs solar cells is described.

Borden, P.↗

DOE OSTI2023

CdTe-based thin film photovoltaics: Recent advances, current challenges and future prospects

Cadmium telluride (CdTe)-based cells have emerged as the leading commercialized thin film photovoltaic technology and has intrinsically better temperature coefficients, energy yield, and degradation rates than Si technologies. More than 30 GW peak (GWp) of CdTe-based modules are installed worldwide, multiple companies are in production, modules are shipping at up to 18.6% efficiency, and lab cell efficiency is above 22%. We review developments in the science and technology that have occurred over approximately the past decade. These achievements were enabled by manufacturing innovations and scaling module production, as well as maximizing photocurrent through window layer optimization and alloyed CdSe x Te 1-x (CST) absorbers. Improved chlorine passivation processes, film microstructure, and serendipitous Se defect passivation significantly increased minority carrier lifetime. Efficiencies >22% have been realized for both Cu and As doped CST-based cells. The path to further efficiency gains hinges primarily on increasing open circuit voltage (V oc ) and fill factor (FF) through innovations in materials, fabrication methods, and device stacks. Replacing the longstanding Cu doping with As doping is resulting in better module stability and is being translated to large-scale production. To realize 25% efficiency and >1 V V oc , research and development is needed to increase the minority carrier lifetime beyond 100 ns, reduce grain boundary and interface recombination, and tailor band diagrams at the front and back interfaces. Many of these goals have been realized separately however combining them together using scalable manufacturing approaches has been elusive to date. We review these achievements and outstanding opportunities for this remarkable photovoltaic technology.

14 SOLAR ENERGY↗

DOE OSTI2013

Comparison of Photovoltaic Models in the System Advisor Model: Preprint

The System Advisor Model (SAM) is free software developed by the National Renewable Energy Laboratory (NREL) for predicting the performance of renewable energy systems and analyzing the financial feasibility of residential, commercial, and utility-scale grid-connected projects. SAM offers several options for predicting the performance of photovoltaic (PV) systems. The model requires that the analyst choose from three PV system models, and depending on that choice, possibly choose from three module and two inverter component models. To obtain meaningful results from SAM, the analyst must be aware of the differences between the model options and their applicability to different modeling scenarios. This paper presents an overview the different PV model options and presents a comparison of results for a 200-kW system using different model options.

14 SOLAR ENERGY↗

DOE OSTI2025

Nature of innovations affecting photovoltaic system costs

Innovations improve technology costs through various kinds of engineering advancements, including changes to materials choices and device or process designs. Understanding how these innovations relate to cost change can reveal aspects of the process of technology evolution, yet developing such understanding is often not possible with a strictly quantitative approach due to data limitations. In this paper we develop a hybrid quantitative-qualitative framework for relating specific innovations to cost change by using the variables in a quantitative technology cost change model as an organizing principle. We demonstrate this framework by applying it to the cost decline in photovoltaic (PV) systems over the last five decades. This framework generates new understanding of a set of innovations that contributed to PV modules’ sustained cost decline and the more modest trends observed in balance-of-system (BOS) costs. The results show the great diversity of innovations that affected PV costs, drawing on wide-ranging fields of expertise within scientific research and practice. We find that there are differences in the characteristics of innovations that reduced the cost of PV modules compared to innovations influencing BOS costs. Numerous module innovations reduced costs by advancing manufacturing tools and processes that improved material quality. Many BOS innovations reduced costs through a combination of component design changes, integration, automation, digitalization, and standardization. Overall, most innovations in our sample affected PV hardware. However, some also target ‘soft technologies’ such as task durations through innovations like fast-track permitting, which require improved collaboration and process streamlining. This framework also provides insight into the nature of knowledge spillovers between technologies. Both module and BOS hardware innovations show the benefits of PV’s position within an ‘ecosystem’ of continuously advancing technologies in many industries, in particular semiconductors and electronics, and also point to the importance of public institutions for accelerating testing, permitting, and training.

14 SOLAR ENERGY↗

DOE OSTI2021

REopt Lite Geothermal Heat Pump Design Requirements

This document describes the design requirements for the geothermal heat pump (GHP) module being added to the existing REopt Lite web tool. This document describes the purpose, users, and functional requirements to which the modified web tool shall conform. This document will be revised, as required, throughout the development phase with consensus between the Department of Energy (DOE) Geothermal Technologies Office (GTO) and NREL. The GHP module will expand existing REopt Lite capabilities to include techno-economic optimization of GHP systems, either stand alone, or integrated with the other existing technology types, namely solar photovoltaics (PV), wind power, battery energy storage, thermal energy storage, combined hear and power (CHP), and absorption chiller. Included in this submission are links to the REopt Lite web tool and open-source Git-Hub page. The REopt Lite tool can also be accessed directly via the NREL Developer Network. A link is also provided for the REopt report that overviews the module's capabilities.

15 GEOTHERMAL ENERGY↗

DOE OSTI2019

Reduced Nonradiative Energy Loss Caused by Aggregation of Nonfullerene Acceptor in Organic Solar Cells

Abstract Reducing energy loss ( E loss ) is of critical importance to improving the photovoltaic performance of organic solar cells (OSCs). Although nonradiative recombination () is investigated in quite a few works, the method for modulating is seldom reported. Here, a new method of depressing E loss is reported for nonfullerene OSCs. In addition to ternary‐blend bulk heterojunction (BHJ) solar cells, it is proved that a small molecular material (NRM‐1) can be selectively dispersed into the acceptor phase in the PBDB‐T:IT‐4F‐based OSC, resulting in lower and , and hence a significant improvement in the open‐circuit voltage ( V OC ); under an optimal feed ratio of NRM‐1, an enhanced power conversion efficiency can also be gained. Moreover, the role of NRM‐1 in the method is illustrated and its applicability for several other representative OSCs is validated. This work paves a new pathway to reduce the E loss for nonfullerene OSCs.

Qin, Yunpeng↗

DOE OSTI2016

Dynamic Braking System of a Tidal Generator

Renewable energy generation has experienced significant cost reductions during the past decades, and it has become more accepted by the global population. In the beginning, wind generation dominated the development and deployment of renewable energy; however, during recent decades, photovoltaic (PV) generation has grown at a very significant pace due to the tremendous decrease in the cost of PV modules. The focus on renewable energy generation has now expanded to include new types with promising future applications, such as river and tidal generation. The input water flow to these types of resources is more predictable than wind or solar generation. The data used in this paper is representative of a typical river or tidal generator. The analysis is based on a generator with a power rating of 40 kW. The tidal generator under consideration is driven by two sets of helical turbines connected to each side of the generator located in between the turbines. The generator is operated in variable speed, and it is controlled to maximize the energy harvested as well as the operation of the turbine generator. The electrical system consists of a three-phase permanent magnet generator connected to a three-phase passive rectifier. The output of the rectifier is connected to a DC-DC converter to match the rectifier output to the DC bus voltage of the DC-AC inverter. The three-phase inverter is connected to the grid, and it is controlled to provide a good interface with the grid. One important aspect of river and tidal generation is the braking mechanism. In a tidal generator, the braking mechanism is important to avoid a runaway condition in case the connection to the grid is lost when there is a fault in the lines. A runaway condition may lead to an overspeed condition and cause extreme stresses on the turbine blade structure and eventual disintegration of the mechanical structure. In this paper, the concept of the dynamic braking system is developed and investigated for normal and abnormal operations. The main objective is to optimize the performance under emergency braking while designing the system to be as simple as possible to avoid overdesigning the power electronics or exceeding the target budget.

13 HYDRO ENERGY↗

DOE OSTI2021

Copper Electrode on Flexible Substrate by Intense Pulsed Light Sintering of Microsized Copper Particles

Metal electrodes deposited in a grid pattern onto flexible polymer substrates have been shown to be a viable alternative to replace indium tin oxide (ITO) as the transparent anode for organic photovoltaics. copper may be a better alternative in terms of cost and stability for large area low-cost solar modules, specifically on roll-to-roll platforms. These customized electrode patterns can be fabricated from copper nanoparticles through various printing techniques applicable to solution phase processing. The Intense Pulsed Light (IPL) technique has been used to sinter copper nanoparticles (~100nm) to fabricate conductive copper electrodes on flexible polymer substrates. However, compared to nanosized (~100 nm) copper particles, microsized (~2 um) copper is much cheaper. In this work, microsized (~2 um) copper is used to produce high conductive copper inks. The conductivity of the print can be adjusted through the use of surfactant. IPL sintering was optimized to obtain high conductivity copper films. In conclusion, several microscopic and electrical spectroscopic characterization techniques such as scanning electron microscopy (SEM), x-ray diffraction (XRD), 4-point probe resistivity measurements were employed to characterize the copper electrodes.

14 SOLAR ENERGY↗

NASA NTRS2005

n/p/n Tunnel Junction InGaAs Monolithic Interconnected Module (MIM)

The Monolithic Interconnected Module (MIM), originally introduced at the First NREL thermophotovoltaic (TPV) conference, consists of low-bandgap indium gallium arsenide (InGaAs) photovoltaic devices, series interconnected on a common semi-insulating indium phosphide (inP) substrate. An infrared reflector is deposited on the back surface of the substrate to reflect photons, which were not absorbed in the first pass through the structure. The single largest optical loss in the current device occurs int he heavily doped p-type emitter. A new MIM design (pat.pend.) has been developed which flips the polarity of the conventional MIM cell (i.e., n/p rather than p/n), eliminating the need for the high conductivity p-type emitter. The p-type base of the cell is connected to the n-type lateral conduction layer through a thin InGaAs tunnel junction. 0.58 eV and 0.74 eV InGaAs devices have demonstrated reflectances above 90% for wavelengths beyond the bandgap (greater than 95% for unprocessed structures). Electrical measurements indicate minimal voltage drops across the tunnel junction (less than mV/junction under 1200K-blackbody illumnination) and fill factors that are above 70% at current densities (J(sub sc)) above 8 Angstroms per square centimeters for the 0.74eV devices.

Wilt, David M.↗

DOE OSTI2025

Open data sets for assessing photovoltaic system reliability

Photovoltaic (PV) systems have become a cornerstone of renewable energy strategies, particularly due to the significant reduction in solar power costs over the past decade. However, the long-term reliability of PV installations presents a persistent challenge, requiring the development of advanced monitoring and predictive maintenance strategies. A wide range of data types is used to evaluate the health of PV systems, including environmental conditions, electrical performance, and inspection imagery. These data enable methodologies such as machine learning (ML) models for lifetime prediction and computer vision techniques for defect detection. However, the acquisition of high-quality and comprehensive data is difficult, particularly in terms of long-term consistency and data variety. Publicly available data sets serve as valuable resources for addressing these challenges, but they often suffer from fragmentation and are difficult to access. This paper presents a comprehensive review of existing open-source data sets related to PV degradation, analyzing their features, functionalities, and potential applications. We categorize these data sets based on the specific aspects of PV system information they cover, such as environmental conditions, operational monitoring, image inspection and module materials, and propose relevant tools and ML models for processing them. In addition, we propose practices for future data collection and usage, while also discussing potential directions in data-driven research. Our aim is to enhance data utilization and publication among researchers and industry professionals, promoting a deeper understanding of the role of data in enhancing the performance and durability of PV systems.

14 SOLAR ENERGY↗

DOE OSTI2022

Silicon Heterojunction Field Performance

The market share of silicon heterojunction (SHJ) modules are expected to increase in the following years. The presentation discusses field performance of SHJ and compares it to other high-efficiency modules. In-depth materials characterization is used to understand the origins of degradation in these type of modules.

ENGINEERING,SOLAR ENERGY↗

DOE OSTI2019

Albedo Data to Facilitate Bifacial PV System Planning

For mono-facial photovoltaic (PV) systems, the ground-reflected radiation typically comprises only 1% to 2% of the total radiation received by the PV module. Consequently, a rudimentary understanding of the ground albedo is adequate for predicting their performance. However, for bifacial PV modules where their benefit is determined by the additional radiation reflected by the ground to their backside, a better understanding of albedo values and characteristics is needed by both the PV and financial communities to better estimate performance and to reduce risk. This was identified as a key need at the 2018 Bifacial PV Workshop. Subsequently, the Department of Energy (DOE) has initiated work with the National Renewable Energy Laboratory (NREL) to provide albedo data for different locations and ground surfaces for both the simulation of bifacial PV systems and for summary information, including variations in albedo with respect to time of day, season, and year. This albedo data base will include data from measurement networks (SURFRAD and Ameriflux), and the PV industry is also asked to provide their albedo measurements and take part in a cooperative effort to provide an expansive and accurate data base of albedo values.

14 SOLAR ENERGY↗

NASA NTRS2002

Single Source Precursors for Thin Film Solar Cells

The development of thin film solar cells on flexible, lightweight, space-qualified substrates provides an attractive cost solution to fabricating solar arrays with high specific power, (W/kg). The use of a polycrystalline chalcopyrite absorber layer for thin film solar cells is considered as the next generation photovoltaic devices. At NASA GRC we have focused on the development of new single source precursors (SSP) and their utility to deposit the chalcopyrite semi-conducting layer (CIS) onto flexible substrates for solar cell fabrication. The syntheses and thermal modulation of SSPs via molecular engineering is described. Thin-film fabrication studies demonstrate the SSPs can be used in a spray CVD (chemical vapor deposition) process, for depositing CIS at reduced temperatures, which display good electrical properties, suitable for PV (photovoltaic) devices.

Banger, Kulbinder K.↗

DOE OSTI2018

Passive Cooling of Photovoltaics with Desiccants

As part of efforts to reduce photovoltaic (PV) costs and improve reliability/durability, temperature control needs to be closely examined in a number of ways including novel passive cooling technology. Modest PV module operating temperature reductions can increase PV power output by 10% or more. The higher the operating temperature of a typical PV device, the lower the overall PV conversion efficiency. Because some incident light is converted to heat in PV cells, the PV module heats up (typically 25 degrees C above ambient temperature in full sun), and the overall energy output of the PV system is reduced (typically a 10% power loss for every 20 degrees C to 30 degrees C increase in temperature). We are integrating material on the PV module that adsorbs water from the air at night when the PV module temperature is cool and the relative humidity in the air is typically high. This sorbed water evaporates as the PV module heats up during the day, taking the excess heat with it and thus effectively cooling the PV module (see Fig. 1). Initial experiments with this novel passive cooling have demonstrated that PV module operating temperatures may be reduced nearly 30 degrees C with evaporative cooling. In this paper, we describe 1) novel materials development, 2) initial modeling that predicts how the cooling will work in different environments, and 3) results demonstrating the PV operating temperature reductions achieved to date.

14 SOLAR ENERGY↗