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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 163 records · Page 9
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

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↗
DOE OSTI2024

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↗
DOE OSTI2024

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↗
NASA NTRS1966

Solar cell module assembly jig

The invention relates to the manufacture of solar cell modules and more particularly to a jig for assembling, positioning and maintaining the components under resilient pressure, while the entire assembly and the jig is subjected to heat for simultaneously soldering all of the various circuit connections; as well as structurally bonding the layers into a strong light weight structure which minimizes the tendency of the solar cells to crack and the other components and electrical connections to fracture.

Ofarrell, H. W.↗
DOE OSTI2020

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↗
DOE OSTI2016

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↗
NASA NTRS1978

A candidate low-cost processing sequence for terrestrial silicon solar cell panel

Manufacturing sequence for silicon solar cells using Czochralsky crystal growing techniques in order to produce at a rate of 20 MW per year on a 24-hour per day basis is discussed. Cost analysis of the manufacturing is presented and consideration is given to the following processing decision categories of the manufacturing of an unencapsulated solar cell from a silicon wafer: (1) treatment of the optical surface; (2) formation of the junction(s); and (3) metallization of electrical collectors. The manufacturing of encapsulated solar modules from solar cells, using two glass plates, a low iron front surface, and a standard float glass back plate, is described. Totaling the three major activities of wafer making, cell manufacturing, and module fabrication, the resulting contribution to module price will be 1.945 $/watt.

Bickler, D. B.↗
DOE OSTI2022

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↗
NASA NTRS2016

CubeSub - A CubeSat Based Submersible Testbed for Space Technology

This report is a Master's Thesis in Aerospace Engineering, performed at the NASA Ames Research Center. It describes the development of the CubeSub, a submersible testbed compatible with the CubeSat form factor. The CubeSub will be used to mature technology and operational procedures to be used in space exploration, and possibly also as a tool for exploration of Earthly environments. CubeSats are carried as payloads, either containing technology to be tested or experiments and sensors for scientific use. The CubeSub is designed to be built up by modules, which can be assembled in different configurations to fulfill different needs. Each module is powered individually and intermodular communication is wireless, reducing the need for wiring. The inside of the hull is flooded with ambient water to simplify the interaction between payloads and surrounding environment. The overall shape is similar to that of a conventional AUV, slender and smooth. This is to make for a low drag, reduce the risk of snagging on surrounding objects and make it possible to deploy through an ice sheet via a narrow borehole. Rapid prototyping is utilized to a large extent, with full-scale prototypes being constructed through 3D-printing and with COTS (Commercial Off-The-Shelf) components. Arduino boards are used for control and internal communication. Modules required for basic operation have been designed, manufactured and tested. Each module is described with regards to its function, design and manufacturability. By performing tests in a pool it was found that the basic concept is sound and that future improvements include better controllability, course stability and waterproofing of electrical components. Further development is needed to make the CubeSub usable for its intended purposes. The largest gains are expected to be found by developing the software and improving controllability.

Europa↗
DOE OSTI2017

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↗
DOE OSTI2018

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↗
NASA NTRS2018

An Overview of High Bandwidth Liquid Fuel Flow Modulators Developed for Active Combustion Control Research

This paper presents a description of the general construction of three high bandwidth liquid fuel modulators along with data corresponding to their respective modulation performance. These devices are a critical element of the National Aeronautics and Space Administration Glenn Research Center's (NASA GRC) Active Combustion Control (ACC) task. These devices are not commercially-off-the-shelf available, primarily due to a one kHz bandwidth requirement. Given their special nature, NASA GRC developed specifications for the modulation devices and then, through Small Business Innovative Research (SBIR) contracts, had vendors with expertise in valve design manufacture them. The modulators described in this paper are the Active Signal Modulator (ASM), the Jansen's Aircraft System Controls (JASC) modulator, and the WASK Engineering (WASK) modulator. These modulators utilize magnetostrictive, electric motor, or piezoelectric actuation, respectively. The specifications for these devices evolved over time to meet the needs of changing objectives in the ACC research task. This is primarily true with respect to flow number as their designs accommodate a range from one to eight (lbm./hr-psi0.5). These designs also exhibit relatively small volume, weight, and power consumption with an ability to modulate approximately +/- 30% from the mean on a pressure basis. The modulators have been characterized and have undergone laboratory performance tests by the vendors. Their data indicated suitability for continued use in ACC research testing.

Saus, Joseph R.↗
NASA NTRS1985

Thin film module development

The design of ARCO Solar, Inc.'s Genesis G100 photovoltaic module was driven by several criteria, including environmental stability (both electrical and mechanical), consumer aesthetics, low materials costs, and manufacturing ease. The module circuitry is designed as a 12 volt battery charger, using monolithic patterning techniques on a glass superstrate. This patterning and interconnect method proves amenable to high volume, low cost production throughput, and the use of glass serves the dual role of handling ease and availability. The mechanical design of the module centers on environmental stability. Packaging of the glass superstrate circuit must provide good resistance to thermal and humidity exposure along with hi-pot insulation and hailstone impact resistance. The options considered are given. Ethylene vinyl acetate (EVA) is chosen as the pottant material for its excellent weatherability.

Jester, T.↗
NASA NTRS1994

Acceleration recorder and playback module

The present invention is directed to methods and apparatus relating to an accelerometer electrical signal recorder and playback module. The recorder module may be manufactured in lightweight configuration and includes analog memory components to store data. Signal conditioning circuitry is incorporated into the module so that signals may be connected directly from the accelerometer to the recorder module. A battery pack may be included for powering both the module and the accelerometer. Timing circuitry is included to control the time duration within which data is recorded or played back so as to avoid overloading the analog memory components. Multiple accelerometer signal recordings may be taken simultaneously without analog to digital circuits, multiplexing circuitry or software to compensate for the effects of multiplexing the signals.

Bozeman, Richard J., Jr.↗
NASA NTRS1996

Acceleration Recorder and Playback Module

The present invention is directed to methods and apparatus relating to an accelerometer electrical signal recorder and playback module. The recorder module may be manufactured in lightweight configuration and includes analog memory components to store data. Signal conditioning circuitry is incorporated into the module so that signals may be connected directly from the accelerometer to the recorder module. A battery pack may be included for powering both the module and the accelerometer. Timing circuitry is included to control the time duration within which data is recorded or played back so as to avoid overloading the analog memory components. Multiple accelerometer signal recordings may be taken simultaneously without analog to digital circuits, multiplexing circuitry or software to compensate for the effects of multiplexing the signals.

Bozeman, Richard J., Jr.↗
NASA NTRS1985

Assembly-Line Manufacturing Industry Simulation

Assists in economic analysis of production line manufacturing. Originally developed to estimate product price received by hypothetical U.S. industry that manufactures silicon solar modules for use in electricity generation, SAMIS extended and generalized to extent that it simulates operation of many different production line manufacturing industries and/or companies.

Chamberlain, R. G.↗
NASA NTRS1986

Commerical module test program

The results are presented for a program of qualification testing of commercial crystalline silicon modules from nine manufacturers in five countries. The outcome demonstrated the effective role of the Block 5 Qualification Tests in the development of reliable modules.

Smokier, M. I.↗