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Elmer, Kevin

Publications and source records attributed to Elmer, Kevin.

High Temperature Copper Metallization: Demand, Hurdles and Reliability

As newer cells structures come online, the pressing need to replace silver in the metallization pastes has renewed interest in alternative technologies employing base metals. Copper typically leads the charge with its abundance and lower cost but has faced numerous obstacles from relatively higher oxidation and diffusion rates which can damage the lifetime of the devices. In this study, a low-cost alternative to silver metallization pastes has been shown on PERC cells. The screen printable copper paste can be fired in air at temperatures >500 degrees C, and the impact of processing conditions and equipment on the performance and reliability of 274 cm2 cells have been evaluated. Through damp heat testing of micro-modules using 16 cm2 cells, routes that can lead to both the failure and success of durable contacts have been demonstrated.

copper↗

Exploring the Performance and Reliability of Screen-Printable Fire-Through Copper Paste on PERC Solar Cells

In this work, we present the performance and reliability of a fire-through copper (Cu) paste which has been screen printed on c-Si solar cell with passivated emitter rear contact (PERC). The Cu paste is fired through silicon nitride (SiN) anti-reflection coating at a peak temperature of 630 degrees C . SEM images of the Cu paste show a Cu core with ~200 nm oxide shell around the particles. This conductive oxide layer acts as a diffusion barrier between Cu and Si and prevents the degradation of cell performance during accelerated aging conditions. An efficiency of 19.250% has been achieved with Voc=654mV,FF= 76.68%, Jsc=38.40 m.A/cm 2 for champion PERC cells. Accelerated testing of the PERC mini-modules in damp heat chamber with 85 degrees C and 85% humidity have demonstrated that the devices are operational even after 1,500 hours. Devices with screen printed Ag contacts on the front side have been studied in parallel to the Cu contacts for comparison.

copper↗

Evaluating the Performance and Reliability of Screen-Printable Fire-Through Copper Paste on PERC Solar Cells

A bifacial silicon heterojunction solar cell demands approximately 210 mg usage of silver paste (9 busbars, 24.5%, bifacial, M6 size wafer). Copper is an excellent alternative to silver: 100x cheaper, similar elecvtrical resistivities, and 1000x more abundant. Successful demonstration of large area selective emitter PERC solar cells using Cu fire-through paste with FF approximately 75% and approximately 19%. Paste chemistry results in oxide-based Cu diffusion barrier, leading to good reliability of the devices: 1000h DHT giving a 3.5% efficiency drop. The additional series resistance still needs to be lowered. Printed and fired cell performance is governed mostly by pFF, especially J02 ; same for DHT degradation. Further improvement in printing and firing optimization for lower series resistance and higher FF.

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Exploring the Performance and Reliability of Screen-Printable Fire-Through Copper Paste on PERC Solar Cells

For 40 TW of PV required to transition our planet to 100% renewables, the silver (Ag) should disappear from PV production. Advantages of copper (Cu) over silver (Ag) include 1) bulk Cu has a similar conductivity to Ag (1.7 mu O-cm for Cu, 1.6 mu O-cm for Ag) and 2) Cu is approximately 100 times cheaper than Ag, making it an excellent potential replacement. Problems associated with copper (Cu) contacts include 1) easy oxidation and 2) diffusion into the Si cell and recombination activity.

copper paste↗

Development and Reliability of Screen-Printable Fire-Through Cu Paste for Passivated Contact Solar Cells

We present the development of copper (Cu) paste which has been screen printed on Selective Emitter-Passivated Emitter Rear Contact (SE-PERC) solar cells. This paste can also be applied to Tunnel Oxide Passivated Contact (TOPCON) solar cells due to its fire-through nature. Champion PERC cells have achieved ....efficiency with ...parameters . Accelerated testing to investigate reliability performance of the SE- PERC mini-modules were carried out in damp heat chamber with 85oC and 85% humidity. The devices were found to be operational even after 1,500 hours. Devices with screen printed Ag contacts on the front side have been studied in parallel to the Cu contacts for comparison.

copper paste↗

Superboom Caustic Analysis and Measurement Program (SCAMP) Final Report

The objectives of the Superboom Caustic Analysis and Measurement (SCAMP) Program were to develop and validate, via flight-test measurements, analytical models for sonic boom signatures in and around focal zones as they are expected to occur during commercial aircraft transition from subsonic to supersonic flight, and to apply these models to focus boom prediction of low-boom aircraft designs. The SCAMP program has successfully investigated sonic boom focusing both analytically and experimentally, while gathering a comprehensive empirical flight test and acoustic dataset, and developing a suite of focused sonic boom prediction tools. An experimental flight and acoustic measurement test was designed during the initial year of the SCAMP program, with execution of the SCAMP flight test occurring in May 2011. The current SCAMP team, led by Wyle, includes partners from the Boeing Company, Pennsylvania State University, Gulfstream Aerospace, Eagle Aeronautics, and Central Washington University. Numerous collaborators have also participated by supporting the experiment with human and equipment resources at their own expense. The experiment involved precision flight of a McDonnell Douglas (now Boeing) F-18B executing different maneuvers that created focused sonic booms. The maneuvers were designed to center on the flight regime expected for commercial supersonic aircraft transonic transition, and also span a range of caustic curvatures in order to provide a variety of conditions for code validations. The SCAMP experiment was designed to capture concurrent F-18B on-board flight instrumentation data, high-fidelity ground-based and airborne acoustic data, and surface and upper air meteorological data. Close coordination with NASA Dryden resulted in the development of new experimental instrumentation and techniques to facilitate the SCAMP flight-test execution, including the development of an F-18B Mach rate cockpit display, TG-14 powered glider in-flight sonic boom measurement instrumentation and "Where's the Focus?" (WTF) software for near-real time way-point computation accounting for local atmospherics. In May 2011, 13 F-18B flights were conducted during 5 flying days over a 2 week period. A densely populated 10,000 ft-long ground acoustic array with 125-ft microphone spacing was designed to capture pre-, focus, and post-focus regions. The ground-based acoustic array was placed in a nominally east-west orientation in the remote Cuddeback lakebed region, north of Edwards AFB. This area was carefully selected to avoid placing focused booms on populated areas or solar power facilities. For the SCAMP measurement campaign, approvals were obtained to temporarily extend the Black Mountain supersonic corridor northward by three miles. The SCAMP flight tests successfully captured 70 boom events, with 61 focus passes, and 9 calibration passes. Seventeen of the focus passes and three of the calibration passes were laterally offset; with the others being centerline flights. Airborne incoming sonic boom wave measurements were measured by the TG-14 for 10 of the F-18B flight passes including one maximum focus signature, several N-u combinations, several overlapped N-u signatures, and several evanescent waves. During the 27-month program, the SCAMP team developed a suite of integrated computer codes with sonic boom focusing predictive capabilities: PCBoom, Lossy Nonlinear Tricomi Equation Method (LNTE) and the Nonlinear Progressive wave Equation (NPE) method. PCBoom propagates the rays through the atmosphere and, in addition to legacy focus signature prediction based on the Gill-Seebass method, provides input source characteristics and propagation parameters to LNTE and NPE. LNTE, a Tricomi solver that incorporates atmospheric losses, computes the focus signature at the focus, and computes the focus signature in the vicinity of the focal zone, including the evanescent and post-focus zones. LNTE signature auralization from low-boom vehicle designs has been demonstrated in the NASA Langley Interior Effects Room (IER). The NPE has also been validated for use in prediction of focused ground boom signatures in sonic boom focal zones. The NPE formulation has the capability to incorporate atmospheric turbulence in the predictions. This has been applied to sonic boom propagation in the past. Prediction of turbulence effects on focal zone signatures was not, however, explored during the SCAMP program.

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