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DOE OSTI2017

Crack detection in crystalline silicon solar cells using dark-field imaging

The high capital expenditure (capex) necessary to manufacture crystalline silicon PV modules negatively affects the levelized cost of electricity (¢/kWh) and critically impacts the rate at which the PV industry can scale up. Wafer, cell, and module fabrication with thin free-standing silicon wafers is one key to reduce capex. Thin wafers reduce capex associated with silicon refining and wafer fabrication, which together sum to 58% of the total capex of silicon module manufacturing. In addition, thin wafers directly and significantly reduce variable costs. However, introducing 50 μm thin free-standing wafers into today’s manufacturing lines result in cracking, creating a yield-based disincentive. Due to the brittle nature of silicon, wafer breakage is the major concern due to the high stress that is induced during processes in manufacturing lines. In this paper, we describe an improved method for edge micro-crack detection that can help enable low-capex, thin free-standing Si wafers. We present a method of detecting and measuring cracks along wafer edges by using a dark-field IR scattering imaging technique which enables detection of edge cracks at the micron scale.

14 SOLAR ENERGY↗

DOE OSTI2015

Life Cycle Inventories and Life Cycle Assessments of Photovoltaic Systems

Life Cycle Assessment (LCA) is a structured, comprehensive method of quantifying material- and energyflows and their associated impacts in the life cycles of products (i.e., goods and services). One of the major goals of IEA PVPS Task 12 is to provide guidance on assuring consistency, balance, transparency and quality of LCA to enhance the credibility and reliability of the results. The current report presents the latest consensus LCA results among the authors, PV LCA experts in North America, Europe and Asia. At this time consensus is limited to five technologies for which there are well-established and up-to-date LCI data: mono- and multi-crystalline Si, CdTe CIGS, and high concentration PV (HCPV) using III/V cells. The LCA indicators shown herein include Energy Payback Times (EPBT), Greenhouse Gas emissions (GHG), criteria pollutant emissions, and heavy metal emissions. Life Cycle Inventories (LCIs) are necessary for LCA and the availability of such data is often the greatest barrier for conducting LCA. The Task 12 LCA experts have put great efforts in gathering and compiling the LCI data presented in this report. These include detailed inputs and outputs during manufacturing of cell, wafer, module, and balance-of-system (i.e., structural- and electrical- components) that were estimated from actual production and operation facilities. In addition to the LCI data that support the LCA results presented herein, data are presented to enable analyses of various types of PV installations; these include operational data of rooftop and ground-mount PV systems and country-specific PV-mixes. The LCI datasets presented in this report are the latest that are available to the public describing the status in 2011 for crystalline Si, 2010-2011 for CdTe, 2010 for CIGS, and 2010 for HCPV technology. This report provides an update of the life cycle inventory data in Section 5 of the previous report: V. Fthenakis, H. C. Kim, R. Frischknecht, M. Raugei, P. Sinha, M. Stucki , 2011, Life Cycle Inventories and Life Cycle Assessment of Photovoltaic Systems, International Energy Agency(IEA) PVPS Task 12, Report T12-02:2011. Updates are provided for the crystalline silicon PV global supply chain (Section 5.1), thin film PV module manufacturing (Sections 5.2-5.3), PV mounting structures (Section 5.5), and country-specific electricity grid mixes (Section 5.9). Other sections of this report are the same as in the previous report. Electronic versions of the updated tables in Section 5 are available at IEA PVPS (http://www.iea-pvps.org; select Task 12 under Archive) and treeze Ltd (http://treeze.ch; under Publications).

14 SOLAR ENERGY↗

DOE OSTI2023

Novel Module Architecture for Lower CapEx and Improved Recyclability for c-Si PV Modules

Photovoltaic (PV) energy production is currently increasing at a rate at which recycling is becoming necessary. A novel module architecture has been demonstrated that has potential for high value recycling for c-Si PV. This architecture eliminates the vacuum lamination process and cross-linked en capsulants. Functioning prototypes of c-Si have been fabricated for stress testing in collaboration with NREL. These modules are being tested against traditionally manufactured modules. Based on preliminary results, this module architecture is a potentially viable solution for improving the manufacturing cost and recyclability of PV modules while retaining module performance.

computer architecture↗

DOE OSTI2018

Estimating the Effects of Module Area on Thin-Film Photovoltaic System Costs

We investigate the potential effects of module area on the cost and performance of photovoltaic systems. Applying a bottom-up methodology, we analyzed the costs associated with thin-film modules and systems as a function of module area. We calculate a potential for savings of up to 0.10/Wand0.13/W in module manufacturing costs for CdTe and CIGS respectively, with large area modules. We also find that an additional 0.04/W savings in balance-of-systems costs may be achieved. Sensitivity of the /W cost savings to module efficiency, manufacturing yield, and other parameters is presented. Lifetime energy yield must also be maintained to realize reductions in the levelized cost of energy; the effects of module size on energy yield for monolithic thin-film modules are not yet well understood. Finally, we discuss possible non-cost barriers to adoption of large area modules.

14 SOLAR ENERGY↗

DOE OSTI2018

Estimating the Effects of Module Area on Thin-Film Photovoltaic System Costs: Preprint

We investigate the potential effects of module area on the cost and performance of photovoltaic systems. Applying a bottom-up methodology, we analyzed the costs associated with thin-film modules and systems as a function of module area. We calculate a potential for savings of up to 0.10 dollars/W and 0.13 dollars/W in module manufacturing costs for CdTe and CIGS respectively, with large area modules. We also find that an additional 0.04 dollars/W savings in balance-of-systems costs may be achieved. Sensitivity of the dollar/W cost savings to module efficiency, manufacturing yield, and other parameters is presented. Lifetime energy yield must also be maintained to realize reductions in the levelized cost of energy; the effects of module size on energy yield for monolithic thin-film modules are not yet well understood. Finally, we discuss possible non-cost barriers to adoption of large area modules.

14 SOLAR ENERGY↗

DOE OSTI2015

The Capital Intensity of Photovoltaics Manufacturing

Factory capital expenditure (capex) for photovoltaic (PV) module manufacturing strongly influences the per-unit cost of a c-Si module. This provides a significant opportunity to address the U.S. DOE SunShot module price target through capex innovation. Innovation options to reduce the capex of PV manufacturing include incremental and disruptive process innovation with c-Si, platform innovations, and financial approaches. and financial approaches.

14 SOLAR ENERGY↗

DOE OSTI2015

Integrated Glass Coating Manufacturing Line

This project aims to enable US module manufacturers to coat glass with Enki’s state of the art tunable functionalized AR coatings at the lowest possible cost and highest possible performance by encapsulating Enki’s coating process in an integrated tool that facilitates effective process improvement through metrology and data analysis for greater quality and performance while reducing footprint, operating and capital costs. The Phase 1 objective was a fully designed manufacturing line, including fully specified equipment ready for issue of purchase requisitions; a detailed economic justification based on market prices at the end of Phase 1 and projected manufacturing costs and a detailed deployment plan for the equipment.

14 SOLAR ENERGY↗

DOE OSTI2018

Supply and Demand Constraints on Future PV Power in the USA

An economic analysis with a defined uncertainty range is presented that considers whether the future deployment of utility-scale PV (UPV) systems in the USA will be limited by the supply of PV modules or by market demand for these systems. An analysis of global PV module manufacturing growth and the fraction of modules produced that will be available for installation in the USA gives a plausible range of cumulative capacity for the UPV segment of 50 - 170 GW in 2030 and 60 - 500 GW in 2040. A parallel analysis of the future demand for UPV systems in the USA indicates a plausible range for cumulative capacity of 80 - 230 GW in 2030 and 150 - 530 GW in 2040. The plausible ranges for supply and demand substantially overlap in both 2030 and 2040, suggesting that neither supply nor demand is more likely to limit PV deployment in the USA. Consequently, mechanisms for enabling growth in both supply and demand can benefit efforts intended to increase the deployment of PV in the USA.

14 SOLAR ENERGY↗

DOE OSTI2018

Supply and Demand Constraints on Future PV Power in the USA: Preprint

14 SOLAR ENERGY↗

DOE OSTI2017

An Analysis of the Cost and Performance of Photovoltaic Systems as a Function of Module Area

We investigate the potential effects of module area on the cost and performance of photovoltaic systems. Applying a bottom-up methodology, we analyzed the costs associated with mc-Si and thin-film modules and systems as a function of module area. We calculate a potential for savings of up to $0.04/W, $0.10/W, and $0.13/W in module manufacturing costs for mc-Si, CdTe, and CIGS respectively, with large area modules. We also find that an additional $0.05/W savings in balance-of-systems costs may be achieved. However, these savings are dependent on the ability to maintain efficiency and manufacturing yield as area scales. Lifetime energy yield must also be maintained to realize reductions in the levelized cost of energy. We explore the possible effects of module size on efficiency and energy production, and find that more research is required to understand these issues for each technology. Sensitivity of the $/W cost savings to module efficiency and manufacturing yield is presented. We also discuss non-cost barriers to adoption of large area modules.

14 SOLAR ENERGY↗

DOE OSTI2021

Generalizable Mechanistic Understanding of Module-Level Light-Moisture and Thermal-Induced Instabilities in CIGS Photovoltaics (Final Report)

The objectives of this project are to identify the root causes of light, heat and humdity induced instabilities in the operation and accelerated testing of commercial Cu(In,Ga)Se 2 [CIGS] photovoltaic modules produced by major module manufacturers (e.g.: Solibro and MiaSolé), correlate them with module degradation/failure modes, and produce accurate service lifetime prediction models.

14 SOLAR ENERGY↗

DOE OSTI2022

Effect of Packing Nonuniformity at the Fiber Bundle–Case Interface on Performance of Hollow Fiber Membrane Gas Separation Modules

High-fidelity simulations of momentum and mass transfer within a hollow fiber gas separation membrane module are here reported. The simulations capture the potential detrimental effects of poor fiber packing at the bundle–case interface on fluid distribution and performance. Results are presented for both circular and planar fiber bundles. The length over which bundle–case gaps affects flow is determined. The length increases dramatically with increasing fiber packing fraction. As the packing fraction approaches 0.6, the impact extends over the entire bundle diameter for small modules (<1000 fibers). The results clearly demonstrate the detrimental effect of poor packing along the case and can be used to develop module manufacturing guidelines. To reduce computational costs, an equivalent planar bundle module approximation is developed. The approximate simulations agree well with results from full 3-D simulations and can reduce computational costs without sacrificing fidelity.

42 ENGINEERING↗

DOE OSTI2020

Information integrated glass module fabricated by integrated additive and subtractive manufacturing

In this Letter, we report a novel integrated additive and subtractive manufacturing (IASM) method to fabricate an information integrated glass module. After a certain number of glass layers are 3D printed and sintered by direct C O 2 laser irradiation, a microchannel will be fabricated on top of the printed glass by integrated picosecond laser, for intrinsic Fabry–Perot interferometer (IFPI) optical fiber sensor embedment. Then, the glass 3D printing process continues for the realization of bonding between optical fiber and printed glass. Temperature sensing up to 1000°C was demonstrated using the fabricated information integrated module. In addition, the long-term stability of the glass module at 1000°C was conducted. Enhanced sensor structure robustness and harsh temperature sensing capability make this glass module attractive for harsh environment structural health monitoring.

Zhang, Qi (ORCID:0000000268655981)↗

DOE OSTI2025

What Is a Polyolefin? A Critical Overview of Ethylene Copolymers Used as Solar Photovoltaic Module Encapsulants

In recent years, photovoltaic (PV) encapsulant films marketed as polyolefins (POs), more specifically as PO elastomers (POEs) and thermoplastic POs (TPOs), have gained significant market share and are projected to become the dominant encapsulation films by 2030. Relative to other industries, there are significant misconceptions about the term PO in the PV industry. Both in the scientific literature as well as in sales and advertising, the terms PO, POE, and TPO are often misused to describe the same type of material with comparable properties, while in reality these may each consist of separate material classes. This paper provides a comprehensive literature and market review, to showcase a broad range of PO and other ethylene copolymer encapsulants from recent studies, and discusses the materials' properties to clarify what constitutes a “polyolefin.” In addition, to promote a clearer comparison of encapsulant properties, we propose a two‐dimensional taxonomy to categorize polymers used in module manufacturing, including POs. In terms of improving the reliability of solar PV modules, PO‐based encapsulants have several advantages (including lower water uptake and ion diffusion), but might come with disadvantages too, such as a more complex processing and a higher sensitivity to the storage conditions and shelf life. All this might prospectively impact adhesion properties of the encapsulant to other materials' interfaces (glass, cells etc.) and end‐product quality. Because the track record of field‐deployed PV modules containing PO encapsulants is also limited, we hope to contribute to better material understanding and precision in communication in PV to secure quality.

14 SOLAR ENERGY↗

DOE OSTI2022

Motivation, benefits, and challenges for new photovoltaic material & module developments

Abstract In the last decade and longer, photovoltaic module manufacturers have experienced a rapidly growing market along with a dramatic decrease in module prices. Such cost pressures have resulted in a drive to develop and implement new module designs, which either increase performance and/or lifetime of the modules or decrease the cost to produce them. In this paper, the main motivations and benefits but also challenges for material innovations will be discussed. Many of these innovations include the use of new and novel materials in place of more conventional materials or designs. As a result, modules are being produced and sold without a long-term understanding about the performance and reliability of these new materials. This has led to unexpected new failure mechanisms occurring few years after deployment, such as potential induced degradation or backsheet cracking. None of these failure modes have been detected after the back then common single stress tests. New accelerated test approaches are based on a combination or sequence of multiple stressors that better reflect outdoor conditions. That allows for identification of new degradation modes linked to new module materials or module designs.

Oreski, G. (ORCID:0000000342239047)↗

DOE OSTI2026

Towards Commercialization of Low-Cost, Crack-Tolerant, Screen-Printable Metallization by Full-Size Module Testing and Field Characterization

This project is motivated by the need to develop a materials engineering solution to reduce solar module degradation caused by cell cracks. The cell-crack-induced power loss is a long-term degradation mechanism and one of the main causes of solar panel field failures. Cell cracks can occur during module fabrication, transportation, installation, and long-term operation due to thermomechanical stressors. Our team’s internal estimation – based on the national weather pattern, frequency of severe weather, and 39- GW asset survey by Heliolytics – reveals that the cell-crack-induced module degradation translates to lost revenues >$17B over an average 5-year period for solar farm owners and to reduced reliability (<25 years panel lifetime) for solar energy consumers. In response to this challenge, the prime recipient offers a metal matrix composite (MMC) silver paste that is tailor-engineered for screen-printing gridlines and busbars, which serve as the electrical contacts on solar cells. We formulate our MMC paste by adding low-cost (∼0.02¢/WDC for research grade), surface-engineered carbon nanotubes to commercially available silver paste. The MMC paste offers a drop-in, cost-effective solution to cell cracks for solar cell and module manufacturers. The main goal of this project was to conduct field-relevant, module-level analysis and qualification of MMC metallization.

14 SOLAR ENERGY↗

DOE OSTI2020

Stabilization of light-induced effects in Si modules for IEC 61215 design qualification

Standardized testing of commercial photovoltaic modules is widely used around the world and decreases risks of module failures. Such testing also reduces financial risks for module manufacturers and customers. This work examines the expected impact of certain defects in silicon (Si) modules during standardized accelerated testing. Specifically, the behavior of boron-oxygen (BO) light-induced degradation (LID) and light- and elevated temperature-induced degradation (LeTID) are simulated during some of the stress tests in IEC 61215. LID and LeTID reaction rates at qualification temperatures are estimated from earlier published data. It is demonstrated the BO-related LID may cause some false positives and false negatives when IEC 61215 tests are performed as prescribed in the 2016 published version. Possible stabilization steps to avoid these false results are suggested. State changes for the defects causing LeTID occur much more slowly than those causing BO LID, and therefore LeTID is predicted to have a lesser impact on the IEC 61215 stress tests results.

14 SOLAR ENERGY↗

DOE OSTI2023

Life-cycle costing assessment of back contact doping and encapsulation alternatives for increasing the life expectancy of CdTe PV modules (Final Report)

Contribution of Research to the State-of-Knowledge This research produced comparative sustainability evaluations of back contact doping and encapsulation alternatives considered by First Solar for decreasing degradation and increasing the life of the cadmium telluride (CdTe) photovoltaic (PV) modules. Technical Effectiveness and Economic Feasibility of Methods Investigated A holistic life-cycle-assessment of the alternatives considered for longer module operational lives, showed that they add between 0.2% and 2% to environmental impact indicators at the cradle-to-gate module level, but at the cradle-to-grave system level, alternative materials offer only benefits (i.e., environmental impact indicator decreases) to the public and the environment. Parallel experimental studies at First Solar showed that the use of the considered alternative materials did not impact the effectiveness of the current module recycling separations and material recovery processes. Furthermore, the increment on the module manufacturing cost due to using alternative materials was estimated to be negligible (i.e., >1%) and longer module lives more than compensate cost increases. Specifically, increase of the current warranted module life of 30 years to 50 years, would decrease the levelized cost of electricity (LCOE) from $40/MWh to $24/MWh for utility-scale installations in the US-SW, the economic feasibility of the considered alternatives is assured. Benefit to the Public With decreasing degradation from the current ~0.3%/year of Series 6 modules to less than 0.2%/year, the public will be benefited by longer photovoltaic operational lives, and therefore. In addition, the requirement for end-of-life management is shifted from 30 years to 40 or 50 years, with profound benefits to the public and the environment.

14 SOLAR ENERGY↗