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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 397 records · Page 22
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Measurement of Photovoltaic Module Deformation Dynamics During Hail Impact Using Digital Image Correlation

Stereo high-speed video of photovoltaic modules undergoing laboratory hail tests was processed using digital image correlation to determine module surface deformation during and immediately following impact. The purpose of this work was to demonstrate a methodology for characterizing module impact response differences as a function of construction and incident hail parameters. Video capture and digital image analysis were able to capture out-of-plane module deformation to a resolution of ±0.1 mm at 11 kHz on an in-plane grid of 10 × 10 mm over the area of a 1 × 2 m commercial photovoltaic module. With lighting and optical adjustments, the technique was adaptable to arbitrary module designs, including size, backsheet color, and cell interconnection. Furthermore, impacts were observed to produce an initially localized dimple in the glass surface, with peak deflection proportional to the square root of incident energy. Subsequent deformation propagation and dissipation were also captured, along with behavior for instances when the module glass fractured. Natural frequencies of the module were identifiable by analyzing module oscillations postimpact. Limitations of the measurement technique were that the impacting ice ball obscured the data field immediately surrounding the point of contact, and both ice and glass fracture events occurred within 100 μs, which was not resolvable at the chosen frame rate. Increasing the frame rate and visualizing the back surface of the impact could be applied to avoid these issues. Applications for these data include validating computational models for hail impacts, identifying the natural frequencies of a module, and identifying damage initiation mechanisms.

14 SOLAR ENERGY↗
DOE OSTI2018

Quantitative Study of the Effect of Non-Uniform Irradiance on Module Performance Combining EL and DLIT Imaging with Circuit Modeling

This paper presents a quantitative study of how the non-uniform irradiance from solar simulators and the often overlooked non-uniformities in modules (e.g. mismatched cell performance in a module, connection of cell strings, bypass diodes) affect the measurement accuracy in Si module power calibrations. By implementing spatial non-uniformity maps of solar simulators and experimental diode parameters of individual cells in a module to our circuit model, it enables a better understanding of the interaction of simulator irradiance non-uniformity with module imperfections in module power measurements. The comparison between simulation and experiment shows that with a nonuniform irradiance of 3%, the P MAX deviations could be as low as ~0.5 % for good-quality Si modules, and ~2% for poor-quality Si modules, confirming the sensitivity of module power calibrations to module properties.

14 SOLAR ENERGY↗
DOE OSTI2016

ITER Central Solenoid Module Fabrication

The fabrication of the modules for the ITER Central Solenoid (CS) has started in a dedicated production facility located in Poway, California, USA. The necessary tools have been designed, built, installed, and tested in the facility to enable the start of production. The current schedule has first module fabrication completed in 2017, followed by testing and subsequent shipment to ITER. The Central Solenoid is a key component of the ITER tokamak providing the inductive voltage to initiate and sustain the plasma current and to position and shape the plasma. The design of the CS has been a collaborative effort between the US ITER Project Office (US ITER), the international ITER Organization (IO) and General Atomics (GA). GA’s responsibility includes: completing the fabrication design, developing and qualifying the fabrication processes and tools, and then completing the fabrication of the seven 110 tonne CS modules. The modules will be shipped separately to the ITER site, and then stacked and aligned in the Assembly Hall prior to insertion in the core of the ITER tokamak. A dedicated facility in Poway, California, USA has been established by GA to complete the fabrication of the seven modules. Infrastructure improvements included thick reinforced concrete floors, a diesel generator for backup power, along with, cranes for moving the tooling within the facility. The fabrication process for a single module requires approximately 22 months followed by five months of testing, which includes preliminary electrical testing followed by high current (48.5 kA) tests at 4.7K. The production of the seven modules is completed in a parallel fashion through ten process stations. The process stations have been designed and built with most stations having completed testing and qualification for carrying out the required fabrication processes. The final qualification step for each process station is achieved by the successful production of a prototype coil. Fabrication of the first ITER module is in progress. The seven modules will be individually shipped to Cadarache, France upon their completion. This paper describes the processes and status of the fabrication of the CS Modules for ITER.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2016

SU-F-T-184: 3D Range-Modulator for Scanned Particle Therapy: Development, Monte Carlo Simulations and Measurements

Purpose: Active raster scanning in particle therapy results in highly conformal dose distributions. Treatment time, however, is relatively high due to the large number of different iso-energy layers used. By using only one energy and the so called 3D range-modulator irradiation times of a few seconds only can be achieved, thus making delivery of homogeneous dose to moving targets (e.g. lung cancer) more reliable. Methods: A 3D range-modulator consisting of many pins with base area of 2.25 mm2 and different lengths was developed and manufactured with rapid prototyping technique. The form of the 3D range-modulator was optimised for a spherical target volume with 5 cm diameter placed at 25 cm in a water phantom. Monte Carlo simulations using the FLUKA package were carried out to evaluate the modulating effect of the 3D range-modulator and simulate the resulting dose distribution. The fine and complicated contour form of the 3D range-modulator was taken into account by a specially programmed user routine. Additionally FLUKA was extended with the capability of intensity modulated scanning. To verify the simulation results dose measurements were carried out at the Heidelberg Ion Therapy Center (HIT) with a 400.41 MeV 12C beam. Results: The high resolution measurements show that the 3D range-modulator is capable of producing homogeneous 3D conformal dose distributions, simultaneously reducing significantly irradiation time. Measured dose is in very good agreement with the previously conducted FLUKA simulations, where slight differences were traced back to minor manufacturing deviations from the perfect optimised form. Conclusion: Combined with the advantages of very short treatment time the 3D range-modulator could be an alternative to treat small to medium sized tumours (e.g. lung metastasis) with the same conformity as full raster-scanning treatment. Further simulations and measurements of more complex cases will be conducted to investigate the full potential of the 3D range-modulator.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2015

Highly Sensitive Electro-Optic Modulators

There are very important diagnostic and communication applications that receive faint electrical signals to be transmitted over long distances for capture. Optical links reduce bandwidth and distance restrictions of metal transmission lines; however, such signals are only weakly imprinted onto the optical carrier, resulting in low fidelity transmission. Increasing signal fidelity often necessitates insertion of radio-frequency (RF) amplifiers before the electro-optic modulator, but (especially at high frequencies) RF amplification results in large irreversible distortions. We have investigated the feasibility of a Sensitive and Linear Modulation by Optical Nonlinearity (SALMON) modulator to supersede RF-amplified modulators. SALMON uses cross-phase modulation, a manifestation of the Kerr effect, to enhance the modulation depth of an RF-modulated optical wave. This ultrafast process has the potential to result in less irreversible distortions as compared to a RF-amplified modulator due to the broadband nature of the Kerr effect. Here, we prove that a SALMON modulator is a feasible alternative to an RFamplified modulator, by demonstrating a sensitivity enhancement factor greater than 20 and significantly reduced distortion.

42 ENGINEERING↗
DOE OSTI2026

Semi-Transparent Perovskite Solar Cells in a Stacked Tandem Module: Cooperative Research and Development Final Report, CRADA Number CRD-19-00810

This project seeks to develop device design, materials composition, and processing tools and parameters to fabricate semi-transparent perovskite solar cells and modules for application in stand-alone products or added to other solar cells in a mechanically stacked tandem configuration. This technology presents significant advanced manufacturing challenges and opportunities in getting to scale, including development of perovskite inks, scalable perovskite and heterojunction deposition and annealing processes, heterojunction composition, transparent electrode composition and deposition process, anti-reflection layer composition and deposition process, and cell to module integration processes. Modification 5: The proposed project seeks to develop device design, materials composition, and processing tools and parameters to fabricate semi-transparent perovskite solar cells and modules for application in stand-alone products or added to other solar cells in a mechanically-stacked tandem configuration. This technology presents significant advanced manufacturing challenges and opportunities in getting to scale, including development of perovskite inks, scalable perovskite and heterojunction deposition and annealing processes, heterojunction composition, transparent electrode composition and deposition process, passivation layers including in module scribes, anti-reflection layer composition and deposition process, and cell to module integration processes. Advanced metrology and characterization will be performed on perovskite films, cells and module. Furthermore, we will examine module or materials recycling for circular economy considerations. Modifcation 6: Gigahertz frequency microwave pump-probe spectroscopies are highly sensitive to thin film semiconductor photoconductivity of individual and stacks of layers that comprise perovskite solar cells. As such, these techniques will be used to qualify reproducibility and quality correlations during the manufacturing process. Modification 7: Mechanical adhesion of top contacts within perovskite modules significantly impacts the durability of the module when exposed to accelerated degradation testing. The adhesion between the perovskite/transport layer interface and the transport layer/top contact interface are both very sensitive small changes in processing. ALD processing conditions of the transport layer will be tuned to optimize the mechanical adhesion within the perovskite module stack.

14 SOLAR ENERGY↗
DOE OSTI2017

Integrated unaligned resonant modulator tuning

Methods and systems for tuning a resonant modulator are disclosed. One method includes receiving a carrier signal modulated by the resonant modulator with a stream of data having an approximately equal number of high and low bits, determining an average power of the modulated carrier signal, comparing the average power to a predetermined threshold, and operating a tuning device coupled to the resonant modulator based on the comparison of the average power and the predetermined threshold. One system includes an input structure, a plurality of processing elements, and a digital control element. The input structure is configured to receive, from the resonant modulator, a modulated carrier signal. The plurality of processing elements are configured to determine an average power of the modulated carrier signal. The digital control element is configured to operate a tuning device coupled to the resonant modulator based on the average power of the modulated carrier signal.

42 ENGINEERING↗
DOE OSTI2024

Towards 50 Year Lifetime PV Modules: Double Glass vs. Glass/Backsheet

This award aims to increase the lifetime of c-Si modules by lowering the power degradation rate to the goal of 0.2 %/year, while also increasing the harvested irradiance per module using bifacial cells to achieve the 2030 SunShot goal of $0.03/kWh. Increasing the durability and lifetime of modules requires improved module packaging material choices and module architectures to exploit new cell improvements. Bifacial PERC cells (with backside aluminum fingers) are becoming a primary PV technology due to their decreased rear surface recombination and increased light absorption compared to traditional monofacial Al-BSF cells. Bifacial modules with double glass architectures have been deployed to capture the rear-side irradiance thereby increasing the light captured. The choice of a double glass (DG) or glass/backsheet (GB) module leads to two very different chemical (e.g., O 2 , H 2 O) and mechanical environments (e.g., mechanical stress levels) inside the PV module that impact the cell’s operational conditions. The recipient will fabricate 4-cell DG and GB minimodules with various module architectures or constructions (mono- & bifacial cells, transparent & white encapsulants), and conduct stepwise accelerated exposures and characterization.

14 SOLAR ENERGY↗
DOE OSTI2022

Laser Welded Edge Seals for Glass/Glass Modules

Polymers used in module construction are often involved in degradation mechanisms and hamper recycling. This project explores femtosecond (fs) laser welding of glass/glass modules to enable polymer-free modules. We are utilizing the knowledge base of the industrial laser community to apply glass/glass fs laser welding technology to solar modules. Experimentally measured stress intensity factors for glass welds are input into a COMSOL model of a full-size module to test weld failure under static loading. If successful, fs laser welding could enable modules that are polymer-free that will extend module warrantees, allow hermetically sealed glass/glass modules for moisture-sensitive semiconductors, and improve module recyclability.

COMSOL finite element model↗
DOE OSTI2023

Perovskite Solar Module: Promise and Challenges in Efficiency, Meta‐Stability, and Operational Lifetime

Abstract Perovskite photovoltaics (PVs) are an emerging solar energy generation technology that is nearing commercialization. Despite the unprecedented progress in increasing power conversion efficiency (PCE) for perovskite solar cells (PSCs), up‐scaling lab‐made cells to solar modules remains a challenge. In this work, the recent progress of making perovskite mini‐modules is reviewed. In particular, a database summarizing the module size, performance, hysteresis, and operational lifetimes reported in the literature is built. After analyzing the performance losses from scaling PSCs to mini‐modules based on the data collected from the literature, the current key to high‐performance perovskite mini‐modules is found to be the coating method optimization. If the perovskite layer quality is well reserved, a >24% mini‐module efficiency is projected by only considering the losses from lateral resistivity and laser scribing area. Next, performance characteristics are explored including hysteresis and meta‐stable power outputs that must be overcome to correctly characterize perovskite modules. Finally, current challenges associated with the long‐term stability of perovskite modules are examined and the importance of such durability for commercialization is discussed. It is hoped that the findings in this review provide a bridge for the development of perovskite modules that will lead to commercialization in the near future.

36 MATERIALS SCIENCE↗
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 OSTI2023

Susceptibility to polarization type potential induced degradation in commercial bifacial p-PERC PV modules

Potential induced degradation (PID) is a reliability issue affecting photovoltaic (PV) modules, mainly when PV strings operate under high voltages in hot/humid conditions. Polarization-type PID (PID-p) has been known to decrease module performance quickly. PID-p can be reduced or recovered under the light in some cases, but this effect, as expected, would be less pronounced on the rear side of bifacial PV modules receiving lower irradiance. As bifacial PV modules are projected to dominate the PV market within the next 10 years, it is crucial to understand the PID-p issue in bifacial modules better. In this study, we performed indoor PID testing to induce PID-p on 14 commercial bifacial p-PERC modules with three different module constructions from three manufacturers. Here, four rounds (+ve and –ve polarities for front and rear sides) of PID testing are done at 25°C, 54% relative humidity (RH) for 168 h using the aluminum foil method. Each module side (front cell side and back cell side) is tested individually under both negative and positive voltage bias. The results show that the highest degradation of 32% in maximum power (Pmax) at standard test conditions (1000 W/m 2 ) and 51% at low irradiance (200 W/m 2 ) has been observed in some cases. Recovery under sunlight is also done, and outcomes show a near-complete recovery in Pmax. This study presents an extensive experimental methodology and a detailed analysis to systematically and simultaneously/sequentially evaluate multiple construction types of bifacial modules to the PID-p susceptibility and recovery.

14 SOLAR ENERGY↗
DOE OSTI2019

Imaging Lateral Drift Kinetics to Understand Causes of Outdoor Degradation in Silicon Heterojunction Photovoltaic Modules

Lateral drift currents caused by partial or patterned illumination of photovoltaic cells have important implications for laser-based screening methods and luminescence imaging of fielded and lab-stressed modules. This study investigates the kinetics of carrier drift and bulk recombination following patterned illumination in commercial silicon heterojunctions with intrinsic thin layer (HIT) modules, comparing the kinetics between a ten-year field-weathered module versus a control module that is stored indoors. The measurement of the microwave photoconductance decay (uPCD) transients in the modules, both coincident with the photoexcitation and in nonilluminated cell regions, reveals carrier drift on the 100 us timescale, followed by millisecond bulk lifetimes. Importantly, the uPCD transients are consistent with luminescence spreading over the cell, which is imaged using a time-gated InGaAs array camera. The weathered HIT module shows slower lateral drift and faster bulk lifetimes compared with the control, suggesting increased series resistance and accelerated nonradiative recombination in this module, attributable to degradation of the transparent conductive oxide and degradation of the passivation layer, respectively. These results provide a novel example of using time-resolved measurements directly on full photovoltaic modules to reveal causes of degradation, providing insight for further development of module imaging and screening capabilities.

14 SOLAR ENERGY↗
DOE OSTI2025

Impact of Different Thermal Gradients on the Dynamics of Cylindrical Lithium-ion Cells Subject to Accelerated Aging and on Module Performance

This study investigates the impacts of applying different thermal gradient patterns to cylindrical lithium-ion cells in a module on cell dynamics (temperatures, current flows, state of charge), module performance (evolution of resistance, capacity, and energy versus cycle number), and module lifetime. The thermal gradients were generated using cooling plates (CPs) with three different flow-field designs, namely, straight, perpendicular, and U-turn. The study uses computational fluid dynamics (CFD), the pseudo-two-dimensional (P2D) battery model, capacity loss and increased impedance due to the growth of a solid-electrolyte-interphase, and the electric current distribution from module terminals to cells that depends on the series-parallel electrical connections among the cells. The impact of the thermal gradient (resulting from the CP designs) on the variability in resistance, current, state of charge, and voltage among the cells was analyzed and linked to differences in the module's performance. Applying a thermal gradient to parallel-connected strings of series-connected cells led to variation in the current through each parallel string and an imbalance in the voltage of series-connected cells. Module performance is poorer when the thermal gradient causes a voltage imbalance than when it causes a current imbalance. Module performance becomes the worst when both current variation and voltage imbalance happen together. For instance, the module's lifetime (estimated as reaching 80% of its initial capacity) varied by 5% to 17.5%, depending on the magnitude and pattern of the imposed thermal gradient. As the relative orientation between thermal gradients and cells' electrical connectivity influences the module's performance, appropriate consideration should be given to the choice of the CP, especially if large thermal gradients are allowed.

Battery thermal management↗
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 OSTI2013

Compensator models for fluence field modulated computed tomography

Purpose: Fluence field modulated computed tomography (FFMCT) presents a novel approach for acquiring CT images, whereby a patient model guides dynamically changing fluence patterns in an attempt to achieve task-based, user-prescribed, regional variations in image quality, while also controlling dose to the patient. This work aims to compare the relative effectiveness of FFMCT applied to different thoracic imaging tasks (routine diagnostic CT, lung cancer screening, and cardiac CT) when the modulator is subject to limiting constraints, such as might be present in realistic implementations.Methods: An image quality plan was defined for a simulated anthropomorphic chest slice, including regions of high and low image quality, for each of the thoracic imaging tasks. Modulated fluence patterns were generated using a simulated annealing optimization script, which attempts to achieve the image quality plan under a global dosimetric constraint. Optimization was repeated under different types of modulation constraints (e.g., fixed or gantry angle dependent patterns, continuous or comprised of discrete apertures) with the most limiting case being a fixed conventional bowtie filter. For each thoracic imaging task, an image quality map (IQM{sub sd}) representing the regionally varying standard deviation is predicted for each modulation method and compared to the prescribed image quality plan as well as against results from uniform fluence fields. Relative integral dose measures were also compared.Results: Each IQM{sub sd} resulting from FFMCT showed improved agreement with planned objectives compared to those from uniform fluence fields for all cases. Dynamically changing modulation patterns yielded better uniformity, improved image quality, and lower dose compared to fixed filter patterns with optimized tube current. For the latter fixed filter cases, the optimal choice of tube current modulation was found to depend heavily on the task. Average integral dose reduction compared to a uniform fluence field ranged from 10% using a bowtie filter to 40% or greater using an idealized modulator.Conclusions: The results support that FFMCT may achieve regionally varying image quality distributions in good agreement with user-prescribed values, while limiting dose. The imposition of constraints inhibits dose reduction capacity and agreement with image quality plans but still yields significant improvement over what is afforded by conventional dose minimization techniques. These results suggest that FFMCT can be implemented effectively even when the modulator has limited modulation capabilities.

61 RADIATION PROTECTION AND DOSIMETRY↗
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

Module-Integrated Power Converters Based on Universal Dock

Solar power installations using alternating current photovoltaic (ACPV) modules have significant cost and performance advantages over systems using conventional solar modules and string inverters. ACPV modules have improved energy harvest due to module-level power point tracking and redundancy. More importantly, ACPV modules are easier and cheaper to install, lowering the total installed cost, indirect costs, and barriers to market entry. Furthermore, ACPV modules have communications and data logging capability, yielding module-level telemetry data that is useful in site diagnostics and other data applications. The products of these efforts were threefold. First, an advanced microinverter power topology was developed, modeled, simulated, and tested. Second, new microinverter enclosure concepts were developed and tested. Third, a new ACPV module prototype was constructed, combining the power topology and the enclosure concepts. SolarBridge filed for patents in each of these areas and is transitioning the project from a concept phase to full development.

14 SOLAR ENERGY↗