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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 289 records · Page 16
All sourcesNASA NTRSDOE OSTI
NASA NTRS1986

Tests of Solar-Array Encapsulants

Materials tested for degradation by heat and light. Report presents early results of continuing series of photothermal aging tests of some candidate encapsulating materials for solar photovoltaic modules. Objectives of testing program: contribute to development of durable, low-cost encapsulants and predict lifetimes of encapsulated photovoltaic modules placed outdoors. Toward these ends, tests designed to reveal physical and chemical degradation mechanisms that affect encapsulants.

Liang, R. H.↗
NASA NTRS1985

Development of design criteria and qualification tests for bypass diodes in photovoltaic applications

Design criteria have been developed for bypass diodes in p-n and Schottky barrier in photovoltaic applications. A test method for assessing conformity to the design criteria is described. Junction temperatures are defined in terms of expected worst-case field conditions, including ambient temperature and solar irradiance on the photovoltaic module. The rating criteria address the maximum allowable current and heat-sink characteristics of diodes mounted inside or outside the photovoltaic module. The method establishes worst-case module-to-diode thermal interfaces and may be adapted for laboratory or field-site experiments. A list of the design criteria is given.

Otth, D. H.↗
DOE OSTI2022

Photovoltaic-assisted heat pump water heater system and method

A solar power system has a photovoltaic module that supplies electrical current derived from sunlight to a heater system of a hot water tank. The heater system uses the electrical energy from the photovoltaic module, and optionally also from a local power grid, to heat water up to a selected maximum stored hot water temperature. Control circuitry senses when the level of electrical power is below a threshold solar-power level, and in response sets the stored hot water temperature for the heater system to a first lower temperature value. The control circuitry also senses when the level of electrical power is above the threshold solar-power level, an in response sets the stored hot water temperature for the heater system to a second elevated temperature value higher than the lower temperature, making advantageous use of solar power when available. A mixing unit adds cold water to set the dispensed water temperature.

14 SOLAR ENERGY↗
DOE OSTI2020

Activation Energy for End-of-Life Solder Bond Degradation: Thermal Cycling of Field-Aged PV Modules

The longevity of solar photovoltaic modules depends on the durability and reliability of their components, one of which is the solder bonds in interconnect ribbons. The solder joints experience stresses from thermal cycling and constant elevated temperatures (40 °C-70 °C) in regular field operation leading to thermo-mechanical fatigue and intermetallic compound formation. To study the end-of-life wear-out mechanisms and to obtain activation energy of solder bond degradation, here two field-aged modules from Arizona-a 21-year-old Solarex MSX60 module (with Sn62Pb36Ag2 at the solder joints) and an 18-year-old Siemens M55 module (with Sn60Pb40 at the solder joints)-underwent 800 and 400 modified thermal cycles, respectively. Using three heating blankets, each module had three temperature zones maintained at 85, 95, and 105 °C during the 15-min hot dwell time of the thermal cycle. Cell-level series resistance data obtained from three temperature zones enabled the calculation of activation energy for solder bond degradation for the MSX60 and the M55 modules to be 0.12 eV and 0.35 eV, respectively. From each temperature zone in both modules, busbar-solder samples were obtained, imaged through SEM, and analyzed with energy-dispersive X-ray spectroscopy. In the MSX60 module with traces of Ag in the solder material, phase segregation and growth were primarily observed at high temperatures. For M55 modules without Ag in the solder material, major phase segregation was observed in all temperature zones. The IMC thickness for both modules increased with increasing module temperature. The beneficial effect of Ag in solder material on mitigating solder bond degradation is presented.

14 SOLAR ENERGY↗
NASA NTRS1984

Intermediate load modules for test and evaluation

Photovoltaic modules were tested for qualification. Tests involved the following: (1) delivery of 20 solar cells for use as reference cells; (2) module documentation and inspection plans specifying the 10 Group I modules; (3) design review of module documentation from Group I modules; (4) revise module documentation to overcome any problems of deficiencies associated with the Group I modules; (5) delivery of 10 Group II modules built to revised specifications; (6) testing of Group II modules to the criteria as outlined in qualification specification. It is found that the solarvolt MSP43E40B satisfies the design criteria of qualification specification for intermediate load modules. Design changes were made in the Group I modules to overcome the deficiencies which allowed Group II modules to pass the qualification tests.

Source record↗
NASA NTRS1978

Simulated hail impact testing of photovoltaic solar panels

Techniques used to simulate and study the effect of hail on photovoltaic solar panels are described. Simulated hail stones (frozen ice spheres projected at terminal velocity) or steel balls were applied by air guns, gravity drop, or static loading. Tests with simulated hail and steel balls yielded different results. The impact strength of 10 commercially available flat-plate photovoltaic modules was tested. It was found that none of the six panel designs incorporating clear potting silicone material as the outermost layer remained undamaged by 1-in. simulated hailstones, while a photovoltaic module equipped with a 0.188-in.-thick acrylic cover sheet would be able to withstand the impact of a 2-in.-diameter hailstone.

Moore, D.↗
NASA NTRS1982

Empirical testing of an analytical model predicting electrical isolation of photovoltaic models

A major design requirement for photovoltaic modules is that the encapsulation system be capable of withstanding large DC potentials without electrical breakdown. Presented is a simple analytical model which can be used to estimate material thickness to meet this requirement for a candidate encapsulation system or to predict the breakdown voltage of an existing module design. A series of electrical tests to verify the model are described in detail. The results of these verification tests confirmed the utility of the analytical model for preliminary design of photovoltaic modules.

Garcia, A., III↗
NASA NTRS1983

Design, analysis and test verification of advanced encapsulation systems

The analytical methodology for advanced encapsulation designs for the development of photovoltaic modules is presented. Analytical models are developed to test optical, thermal, electrical and structural properties of the various encapsulation systems. Model data is compared to relevant test data to improve model accuracy and develop general principles for the design of photovoltaic modules.

Garcia, A., III↗
NASA NTRS1984

Electrical research on solar cells and photovoltaic materials

The flat-plate solar cell array program which increases the service lifetime of the photovoltaic modules used for terrestrial energy applications is discussed. The current-voltage response characteristics of the solar cells encapsulated in the modules degrade with service time and this degradation places a limitation on the useful lifetime of the modules. The most desirable flat-plate array system involves solar cells consisting of highly polarizable materials with similar electrochemical potentials where the cells are encapsulated in polymers in which ionic concentrations and mobilities are negligibly small. Another possible mechanism limiting the service lifetime of the photovoltaic modules is the gradual loss of the electrical insulation characteristics of the polymer pottant due to water absorption or due to polymer degradation from light or heat effects. The mechanical properties of various polymer pottant materials and of electrochemical corrosion mechanisms in solar cell material are as follows: (1) electrical and ionic resistivity; (2) water absorption kinetics and water solubility limits; and (3) corrosion characterization of various metallization systems used in solar cell construction.

Orehotsky, J.↗
NASA NTRS1981

A quantitative method for photovoltaic encapsulation system optimization

It is pointed out that the design of encapsulation systems for flat plate photovoltaic modules requires the fulfillment of conflicting design requirements. An investigation was conducted with the objective to find an approach which will make it possible to determine a system with optimum characteristics. The results of the thermal, optical, structural, and electrical isolation analyses performed in the investigation indicate the major factors in the design of terrestrial photovoltaic modules. For defect-free materials, minimum encapsulation thicknesses are determined primarily by structural considerations. Cell temperature is not strongly affected by encapsulant thickness or thermal conductivity. The emissivity of module surfaces exerts a significant influence on cell temperature. Encapsulants should be elastomeric, and ribs are required on substrate modules. Aluminum is unsuitable as a substrate material. Antireflection coating is required on cell surfaces.

Garcia, A., III↗
DOE OSTI2022

Turn Your Half-Cut Cells for a Stronger Module

Here, we employ an existing model of crystalline silicon photovoltaic module cell fracture to explore the effect of cell size and orientation on their probability of fracture under module uniform loading. In addition, we also apply continuum damage mechanics to modify this model to consider the effect of cell fracture on the probability of subsequent cell fracture. We elucidate that cell fracture increases the probability of subsequent cell fracture and that rectangular modules containing half-cells aligned with the module's long orientation are much more robust against cell fracture than full-cell and half-cell short orientation modules.

14 SOLAR ENERGY↗
NASA NTRS1983

Breakdown of organic insulators

Solar cells and their associated electrical interconnects and leads were encapsulated in transparent elastomeric materials. Their purpose in a photovoltaic module, one of the most important for these elastomeric encapsulation materials, is to function as electrical insulation. This includes internal insulation between adjacent solar cells, between other encapsulated electrical parts, and between the total internal electrical circuitry and external metal frames, grounded areas, and module surfaces. Catastrophic electrical breakdown of the encapsulant insulation materials or electrical current through these materials or module edges to external locations can lead to module failure and can create hazards to humans. Electrical insulation stability, advanced elastomeric encapsulation materials are developed which are intended to be intrinsically free of in-situ ionic impurities, have ultralow water absorption, be weather-stable (UV, oxygen), and have high mechanical flexibility. Efforts to develop a method of assessing the life potential of organic insulation materials in photovoltaic modules are described.

Cuddihy, E. F.↗
NASA NTRS1982

Design, analysis and test verification of advanced encapsulation systems

An analytical methodology for advanced encapsulation designs was developed. From these methods design sensitivities are established for the development of photovoltaic module criteria and the definition of needed research tasks. Analytical models were developed to perform optical, thermal, electrical and analyses on candidate encapsulation systems. From these analyses several candidate systems were selected for qualification testing. Additionally, test specimens of various types are constructed and tested to determine the validity of the analysis methodology developed. Identified deficiencies and/or discrepancies between analytical models and relevant test data are corrected. Prediction capability of analytical models is improved. Encapsulation engineering generalities, principles, and design aids for photovoltaic module designers is generated.

Garcia, A., III↗
DOE OSTI2020

Clean Energy Manufacturing: Renewable Energy Technology Benchmarks

The manufacturing of clean energy technologies has become a global enterprise. An analysis of four clean energy technology manufacturing processes—wind turbine components, crystalline silicon solar photovoltaic modules, light-duty vehicle lithium-ion battery cells, and light-emitting diodes—was conducted to provide a reference point for comparison over time as this sector evolves. The manufacturing supply chain analysis included processing of raw materials, making required subcomponents, and assembling final products, using benchmarks that crossed 12 economies: Brazil, Canada, China, Germany, India, Japan, Malaysia, Mexico, South Korea, Republic of China (Taiwan), the United Kingdom, and the United States. Larger economies, with extensive manufacturing supply chains and high prevailing wages, tend to retain more value added from clean energy manufacturing than small economies. Manufacturing of clean energy technologies drives extensive trade among economies to support the widely distributed supply chain links. Production of wind turbine components and photovoltaic modules is more centralized than production of light-emitting diodes and lithium-ion battery cells. Across the four clean energy technologies evaluated, there was generally an excess of manufacturing capacity relative to global supply.

benchmarks↗
DOE OSTI2022

LeTID-Affected Cells from a Utility-Scale Photovoltaic System Characterized by Deep Level Transient Spectroscopy

Photovoltaic modules from a utility-scale field experienced power loss by light- and elevated temperature-induced degradation (LeTID). Samples of one of the affected monocrystalline silicon cells were cored and extracted from the module packaging and encapsulation. One of the cell fragments was processed using a regeneration cycle of applying short-circuit-rated current in forward bias at 85 degrees C for 2 weeks, while the other fragment was kept in its outdoor-degraded LeTID state. Both samples were scribed to form 2-mm diameter isolated areas using a femtosecond-pulse-width laser micromachining system. Both isolated areas contained front grid line segments which were wire bonded to larger contact pads, and the samples were probed in a cryostat linked to a deep-level transient spectroscopy (DLTS) system. Using DLTS, a majority-carrier, hole-trap defect was detected on each sample with an activation energy of 0.42 eV. The LeTID-degraded sample, however, had a larger signal corresponding to a trap density of 1.1x10^13 cm-3, which was about five times larger than the 2.1x10^12 cm-3 trap density of the regenerated sample.

charge carrier lifetime↗
DOE OSTI2020

Surface Modification of Backsheets Using Coupling Agents for Roll-To-Roll Processed Thin-Film Solar Photovoltaic (PV) Module Packaging Application

For many flexible electronic and photonic devices, moisture stability is one of the most important factors that affects its short- and long-term performance. To maintain the performance, the device should be packaged in such a way that it hermetically blocks moisture from the device; however, in practice, it is rather difficult to achieve. The more practical solution is to impede the moisture ingress to the device. In optoelectronic devices that will be outdoors like solar cells, the interfacial adhesion strength between the encapsulant layer (adhesive) and a moisture barrier layer is also a critical parameter. This paper presents surface modifications of poly(ethylene terephthalate) (PET) carrier films, one of the layers in the trilayer barrier film that directly adheres to an encapsulant, using chemical, UV/ozone, and both treatments to improve adhesion with the thermoset encapsulant polymer material. Whereas previous studies also utilized treatment methods to increase the wettability characteristics, in this paper, we not only present the results of the adhesion strength upon various techniques to achieve good adhesion but also screen their behavior upon exposure to a damp–heat (60 °C, 90% RH) environment. Here, we found that the combined treatment method increases the adhesion by up to 12.1-fold and demonstrates up to a 200% increase in adhesion strength even upon our severe damp–heat environmental condition.

36 MATERIALS SCIENCE↗
NASA NTRS1978

High efficiency solar photovoltaic power module concept

The investigation of a preliminary concept for high efficiency solar power generation in space is presented. The concept was a synergistic combination of spectral splitting, tailored bandgap cells, high concentration ratios, and cool cell areas.

Bekey, I.↗
NASA NTRS1986

Crystalline-silicon photovoltaics summary module design and reliability

The evolution of the design and reliability of solar modules was described. Design requirements involved 14 different considerations, including residential building and material electrical codes, wind-loading, hail impact, operating temperature levels, module flammability, and interfaces for both the array structure and the operation of the system. Reliability research involved in diverse investigations including glass-fracture strength, soiling levels, electrochemical corrosion, and bypass-diode qualification tests. Based on these internationally recognized studies, performance assessments, and failure analyses, the Flat-plate Solar Array Project in its 11-year duration served to nuture the development of 45 different solar module designs from 15 PV manufacturers.

Ross, R. G., Jr.↗