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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 343 records · Page 19
All sourcesNASA NTRSDOE OSTI
DOE OSTI2019

Thermomechanical residual stress evaluation in multi-crystalline silicon solar cells of photovoltaic modules with different encapsulation polymers using synchrotron X-ray microdiffraction

Photovoltaic (PV) module reliability issues, due to silicon cell cracking, are gaining more and more attention due to increasing demand for solar power and reduction of cell thickness to reduce cost. Recent reports show significant effect of encapsulation polymer material on cell cracks leading to the idea of tailoring encapsulation materials for more reliable PV modules. This paper investigates the effect of encapsulation modulus on the cell residual stress using Synchrotron scanning X-ray microdiffraction (µSXRD), which has been proven to be an effective technique to probe the stress in silicon solar cells, especially once they are encapsulated. The post lamination residual stress in the encapsulated multi-crystalline silicon (mc-Si) solar cells was reported for the first time using µSXRD in this manuscript and provide quantitative evaluation of the effect of encapsulation modulus on the cell residual stress. Further, simple approximate finite element (FE) model was also developed to evaluate the effect of the encapsulation polymer on the cell stress. The FE simulations predict the trend of the stress variation with encapsulation polymer modulus very well. Dynamic mechanical analysis and rheological testing of the encapsulation polymers was also performed to correlate the polymer behaviour with the experimental and simulated stresses. Both experimental and simulation results show a similar trend of significant cell stress variation with encapsulation polymer modulus. In the case of external loading, the temperature of load application is observed to be very significant as it dictates the elastic state of the encapsulant, leading to critical conclusion that the encapsulant needs to be selected based on elastic behaviour over the temperature history of the encapsulant during module fabrication and operation. Furthermore, the results and discussion presented are expected to be very useful for development of more reliable PV modules.

14 SOLAR ENERGY↗
NASA NTRS1986

Electrochemical aging effects in photovoltaic modules

Leakage currents were experimentally measured in PV modules undergoing natural aging outdoors, and in PV modules undergoing accelerated aging in laboratory environmental chambers. The significant contributors to module leakage current were identified with a long range goal to develop techniques to reduce or stop module leakage currents. For outdoor aging in general, module leakage current is relatively insensitive to temperature fluctuations, but is very sensitive to moisture effects such as dew, precipitation, and fluctuations in relative humidity. Comparing ethylene vinyl acetate (EVA) and polyvinyl butyral (PVB), module leakage currents are much higher in PVB as compared to EVA for all environmental conditions investigated. Leakage currents proceed in series along two paths, bulk conduction followed by interfacial (surfaces) conduction.

Mon, G. R.↗
DOE OSTI2023

Unfounded concerns about photovoltaic module toxicity and waste are slowing decarbonization

Unsubstantiated claims that fuel growing public concern over the toxicity of photovoltaic modules and their waste are slowing their deployment. Clarifying these issues will help to facilitate the decarbonization that our world depends on. Harnessing the potential of photovoltaic (PV) electricity generation is a key part of the transition to less carbon-intensive energy sources. The most recent energy production forecasts call for a massive 75 TW of global PV capacity by 2050 to have a chance of limiting global temperature rise to 1.5 °C and minimizing the impacts of climate change. This is more than a tenfold increase in the current manufacturing and deployment rate in less than 15 years. PV modules are new to many people, so increasing PV deployment has led to growing concerns about the quantity of waste that may arise from decommissioning them (if they are not recycled), and their potential to leach toxic metals. In conclusion, debunking misinformation about PV modules and PV module waste is the first step in addressing these concerns that are unnecessarily slowing PV deployment.

14 SOLAR ENERGY↗
DOE OSTI2014

Modeling the irradiance and temperature dependence of photovoltaic modules in PVsyst

In order to reliably simulate the energy yield of photovoltaic (PV) systems, it is necessary to have an accurate model of how the PV modules perform with respect to irradiance and cell temperature. Building on previous work that addresses the irradiance dependence, two approaches to fit the temperature dependence of module power in PVsyst have been developed and are applied here to recent multi-irradiance and -temperature data for a standard Yingli Solar PV module type. The results demonstrate that it is possible to match the measured irradiance and temperature dependence of PV modules in PVsyst. As a result, improvements in energy yield prediction using the optimized models relative to the PVsyst standard model are considered significant for decisions about project financing.

14 SOLAR ENERGY↗
NASA NTRS1989

Launch packaging options for the PV power module cargo element

NASA recently embarked on the Space Station Freedom program, which will utilize the Shuttle Orbiter for transportation to orbit. Each flight is unique in terms of the hardware that is manifested and the method by which it is integrated to form viable cargo elements. Various constraints determine the packaging options for the three PV power module combined assemblies. Several packaging options for the PV power module cargo element are presented. These options are discussed in terms of their impact on the overall flight hardware manifest as determined by the various constraints.

Hoberecht, Mark A.↗
DOE OSTI2019

Strong Attraction and Adhesion Forces of Dust Particles by System Voltages of Photovoltaic Modules

We report for the first time on direct measurements using atomic force microscopy (AFM) of electric field induced attraction and adhesion forces associated with soiling on photovoltaic (PV) modules. Real dust particles and silica spheres as surrogate to simulating dust particles were glued to AFM probe cantilevers. The electric field induced force (Fes) was measured via AFM force-distance (f-z) curves, where the electric field was generated by applying a voltage (Vs) to a simulated PV module. Fes and van der Waals (Fvw) force contributions could be separated with the f-z curves. The results show that Fes ~2.5 u N on dust particles is ~5 times larger than Fvw ~0.5 u N at even Vs = -100 V (i.e., similar to large-module operating voltages). Fes increases by an order of magnitude as the applied potential increases from Vs = -100 V to Vs = -500 V. These adhesion forces are by far the strongest that we have measured using the AFM technique for 'initial' contact of particles. Furthermore, unlike the more typical short-range forces of Fvw and liquid bridge, Fes extends sub-millimeters to a millimeter beyond the PV module surface, creating large attraction forces to even uncharged dust particles (i.e., via induced dipoles) in the air. These results indicate that the high voltages typically used with PV arrays today will attract more dust particles from the air, hold the dust particles to the surface very strongly, and potentially induce other PV module surface effects, all of which could increase the power production losses because of soiling.

14 SOLAR ENERGY↗
DOE OSTI2022

Technoeconomic Analysis of High-Value, Crystalline Silicon Photovoltaic Module Recycling Processes

Recycling is an important circular economy strategy, and for photovoltaics (PV), the one that has received the greatest research attention. Recycling of PV modules is required in Europe; everywhere else it competes in the market of end-of-life options, where cost is a primary decision factor. The vast majority of PV modules sold globally are crystalline-silicon (c-Si); most of the rest of the market are cadmium telluride thin film modules whose primary manufacturer runs its own commercial-scale recycling program. While many different c-Si recycling approaches and technologies have been proposed, they generally lack accompanying cost estimates or enough process information to model costs. Herein we develop detailed estimates of seven categories of capital and operating costs along with estimates of revenue from recovered materials for each step in two proposed recycling processes for c-Si PV modules. Using these results, we develop a hypothetical third recycling process merging process steps from the original two, estimate surcharges required to achieve minimum sustainable prices for each recycling process, as well as consider how economies of scale could reduce costs. Increasing the purity of and identifying higher-value markets for recovered materials are approaches to reducing costs and increasing recycling rates in voluntary markets.

crystalline silicon↗
DOE OSTI2022

Onymous early‐life performance degradation analysis of recent photovoltaic module technologies

Abstract The cost of photovoltaic (PV) modules has declined by 85% since 2010. To achieve this reduction, manufacturers altered module designs and bill of materials; changes that could affect module durability and reliability. To determine if these changes have affected module durability, we measured the performance degradation of 834 fielded PV modules representing 13 module types from 7 manufacturers in 3 climates over 5 years. Degradation rates ( Rd ) are highly nonlinear over time, and seasonal variations are present in some module types. Mean and median degradation rate values of −0.62%/year and −0.58%/year, respectively, are consistent with rates measured for older modules. Of the 23 systems studied, 6 have degradation rates that will exceed the warranty limits in the future, whereas 13 systems demonstrate the potential of achieving lifetimes beyond 30 years, assuming Rd trends have stabilized.

14 SOLAR ENERGY↗
DOE OSTI2024

Presenting a Model to Predict Changing Snow Albedo for Improving Photovoltaic Performance Simulation

As photovoltaic (PV) deployment increases worldwide, PV systems are being installed more frequently in locations that experience snow cover. The higher albedo of snow, relative to the ground, increases the performance of PV systems in northern and high-altitude locations by reflecting more light onto the PV modules. Accurate modeling of the snow’s albedo can improve estimates of PV system production. Typical modeling of snow albedo uses a simple two-value model that sets the albedo high when snow is present, and low when snow is not present. However, snow albedo changes over time as snow settles and melts and a binary model does not account for transitional changes, which can be significant. Here, we present and validate a model for estimating snow albedo as it changes over time. The model is simple enough to only require daily snow depth and hourly average temperature data, but can be improved through the addition of site-specific factors, when available. We validate this model to quantify its ability to more accurately predict snow albedo and compare the model’s performance against satellite imagery-based methods for obtaining historical albedo data. In addition, we perform modeling using the System Advisor Model (SAM) to show the impact of changes in albedo on energy modeling for PV systems. Overall, our albedo model has a significantly improved ability to predict the solar insolation on PV modules in real time, especially on bifacial PV modules where reflected irradiance plays a larger role in energy production.

Pike, Christopher (ORCID:0000000155888033)↗
DOE OSTI2015

PV Derived Data for Predicting Performance; NREL (National Renewable Energy Laboratory)

A method is described for providing solar irradiance data for modeling PV performance by using measured PV performance data and back-solving for the unknown direct normal irradiance (DNI) and diffuse horizontal irradiance (DHI), which can then be used to model the performance of PV systems of any size, PV array tilt, or PV array azimuth orientation. Ideally situated for using the performance data from PV modules with micro-inverters, the PV module operating current is used to determine the global tilted irradiance (GTI), and a separation model is then used to determine the DNI and DHI from the GTI.

14 SOLAR ENERGY↗
DOE OSTI2018

Photovoltaic Recycling Processes

Solar photovoltaic (PV) installations must be properly dismantled and any waste treated and disposed of at the end of project life. However, because most of the world's nearly 400 GW of PV systems have been built in the past decade - each expected to operate for between 20 and 30 years-current PV module waste volumes do not yet justify widespread operation of PV recycling facilities. In anticipation of increasing demand however, several recycling companies are evaluating the PV waste market to assess waste-volume growth. Others are pursuing research- and pilot-stage PV module recycling activities. The latter are mostly commercial laminated glass and metal recyclers that process batches of PV modules on a periodic basis. This report describes a recent survey-based evaluation of existing commercial and pilot-scale recycling processes in Europe, and associated life cycle inventory data.

14 SOLAR ENERGY↗
DOE OSTI2020

Durability of ionomer encapsulants in photovoltaic modules

Ethylene vinyl acetate (EVA) has for decades been the preferred material for photovoltaic (PV) module encapsulation. However, while it is relatively inexpensive and initially adheres well to module components, EVA discolors with age and - as interfacial adhesion degrades - becomes susceptible to delamination, ultimately resulting in reduced module efficiency and shortened service lifetimes. As potential replacements for EVA, ionomer thermoplastic materials cure faster, are more resistant to discoloration and potential induced degradation, and do not evolve corrosive acetic acid, making them compatible with new device materials such as perovskites. Since there is limited information on ionomer durability for PV module applications, a series of field and accelerated laboratory aging studies were conducted to assess ionomer interface stability in the presence of terrestrial environmental stressors. It is shown that adhesion to the glass and cell interfaces of PV modules is inferior to EVA, both before and after aging, rendering ionomers particularly susceptible to delamination after short timeframes. Potential solutions to improve ionomer adhesion are discussed.

14 SOLAR ENERGY↗
NASA NTRS1989

A definition study of the on-orbit assembly operations for the outboard photovoltaic power modules for Space Station Freedom

A concept is described for the assembly of the outboard PV modules for Space Station Freedom. Analysis of the on-orbit assembly operations was performed using CADAM design graphics software. A scenario for assembly using the various assembly equipment, as currently defined, is described in words, tables and illustrations. This work is part of ongoing studies in the area of space station assembly. The outboard PV module and the assembly equipment programs are all in definition and preliminary design phases. An input is provided to the design process of assembly equipment programs. It is established that the outboard PV module assembly operations can be performed using the assembly equipment currently planned in the Space Station Freedom Program.

Sours, Thomas J.↗
DOE OSTI2023

Modeling of the effectiveness of novel edge seal designs for fast, low‐Cap‐Ex manufacturing

Abstract In the manufacturing of photovoltaic (PV) modules, the lamination process can take up to 20 min to complete. In this work, new lamination processes are being developed, and have been prototyped, which hope to be able to cut this time down to as little as 30 s. This could provide significant savings in the cost of lamination equipment, floor space, and energy. PV modules are expected to have a lifespan exceeding 20 to 30 years. For moisture‐sensitive PV technologies, the edge seal between the two layers of glass can be the weakest point of its reliability. There is an inherent challenge when evaluating edge seal materials due to their low permeation rates. As part of Colorado State University's Photovoltaic Research and Development 2, work at the National Renewable Energy Laboratory has developed models to evaluate edge seal configurations in glass‐glass PV modules. Here, this new manufacturing process is evaluated for long‐term moisture durability. Different edge seal design options within glass–glass PV modules are explored. Most of these designs are targeting a superstrate on glass configuration, e.g CdTe, but some designs could be used on conventional crystalline Si cells. Using COMSOL finite element simulation software, we investigated the edge seal and interlayer design configurations containing silicone perimeter edge adhesive, desiccated polyisobutylene‐based edge seal, air, and polyolefin while integrating climate conditions equivalent to a hot and humid environment such as Miami, Florida. We found optimized configurations that will allow the module to prevent moisture ingress over 50 years minimizing the amount of time and material used while utilizing polymers that are easily dispensed.

14 SOLAR ENERGY↗
DOE OSTI2022

Results from an international interlaboratory study on light‐ and elevated temperature‐induced degradation in solar modules

Abstract This paper reports the results of an international interlaboratory comparison study on light‐ and elevated temperature‐induced degradation (LETID) on crystalline silicon photovoltaic (PV) modules. A large global network of PV module manufacturers and PV testing laboratories collaborated to design a protocol for LETID detection and screen a large and diverse set of prototype modules for LETID. Results across labs indicate the reproducibility of LETID testing is likely within ±1% of maximum power (P MP ). In intentionally engineered LETID‐sensitive modules, mean degradation after the prescribed detection stress is roughly 6% P MP . In other module types the LETID sensitivity is smaller, and in some we observe essentially negligible degradation attributable to LETID. In LETID‐sensitive modules, both open‐circuit voltage (V OC ) and short‐circuit current (I SC ) degrade by a roughly similar magnitude. We observe, as do previous studies, that LETID affects each cell in a module differently. An investigation of the potential mismatch losses caused by nonuniform LETID degradation found that mismatch loss is insignificant compared to the estimated loss of cell I SC , which drives loss of module I SC . Overall, this work has helped inform the creation of a forthcoming standard technical specification for LETID testing of PV modules, IEC TS 63342 ED1, and should aid in the interpretation of results from that and other LETID tests.

14 SOLAR ENERGY↗
DOE OSTI2018

Analyzing the Energy Performance, Wind Loading, and Costs of Photovoltaic Slat Modules on Commercial Rooftops

NREL studied a new type of photovoltaic (PV) module configuration wherein multiple narrow, tilted slats are mounted in a single frame. Each slat of the PV slat module contains a single row of cells and is made using ordinary crystalline silicon PV module materials and processes, including a glass front sheet and weatherproof polymer encapsulation. Compared to a conventional ballasted system, a system using slat modules offer higher energy production and lower weight at lower LCOE. The key benefits of slat modules are reduced wind loading, improved capacity factor and reduced installation cost. First, the individual slats allow air to flow through, which reduce wind loading. Using PV performance modeling software, we compared the performance of an optimized installation of slats modules to a typical installation of conventional modules in a ballasted rack mounting system. Based on the results of the performance modeling two different row tilt and spacing were tested in a wind tunnel. Scaled models of the PV Slat modules were wind tunnel tested to quantify the wind loading of a slat module system on a commercial rooftop, comparing the results to conventional ballasted rack mounted PV modules. Some commercial roofs do not have sufficient reserve dead load capacity to accommodate a ballasted system. A reduced ballast system design could make PV system installation on these roofs feasible for the first time without accepting the disadvantages of penetrating mounts. Finally, technoeconomic analysis was conducted to enable an economic comparison between a conventional commercial rooftop system and a reduced-ballast slat module installation.

14 SOLAR ENERGY↗
DOE OSTI2012

Lightweight PV Inverters: Dual Bi-Directional IGBTs Modules Enables Breakthrough PV Inverter Using Current Modulation Topology

Solar ADEPT Project: PV inverters convert DC power generated by modules into usable AC power. IPC’s initial 30kW 94lb. PV inverter reduces the weight of comparable 30kW PV inverters by 90%—reducing the cost of materials, manufacturing, shipping, and installation. With ARPA-E support, new bi-directional silicon power switches will be developed, commercialized, and utilized in IPC’s next-generation PV inverter. With these components, IPC will produce 100kW inverters that weight less than 100lb., reducing the weight of conventional 3,000lb. 100kW inverters by more than 95%. The new power switches will cut IPC’s $/W manufacturing cost in half, as well as further reduce indirect shipping and installation costs.

ARPA-E↗