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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 469 records · Page 26
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Rapid Prototyping Techniques for Organic Direct-Bonded-Copper Power Modules

Organic Direct-Bonded-Copper (ODBC) is a novel packaging technology for power modules which allows higher flexibility in layout design. In this work, a set of rapid prototyping techniques are developed for ODBC modules based on a polyimide dielectric material. These techniques enable fast and low-cost fabrication of modules with 3-Dimensional (3D) layout features. An example half-bridge (HB) silicon carbide (SiC) metal oxide semiconductor field effect transistor (MOSFET) module is designed and prototyped using the proposed techniques aiming at ultra-low power loop inductance. Finite element analysis (FEA)-circuit co-simulations results and experimental results validate an approximately 0.71nH power loop inductance for the example module design.

36 MATERIALS SCIENCE↗
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↗
DOE OSTI2025

Sequential Stress Identifies Processing Defects in Bifacial Photovoltaic Modules That Limit Durability

Here, we use sequential stress to investigate hurdles to bifacial photovoltaic (PV) module durability from lamination defects. We test mini-modules with glass/glass (G/G) and glass/transparent-backsheet (G/TB) constructions using either ethylene vinyl acetate or polyolefin elastomer (POE) based encapsulants under a modified IEC 63209-2 sequential stress. This sequence includes multiple iterations of damp heat (DH200), full spectrum light exposure (A3), thermal cycling (TC50), and humidity/freeze (HF10). We compare indoor stress with outdoor exposure. Results show similar relative trends in degradation after a year outdoors compared to our first stress cycle. Subsequent stress cycles impart more severe damage than outdoor exposure for the short outdoor duration used here. Edge-pinch lamination defects in G/G mini-modules limit durability causing delamination and cell cracks. Conversely, we observe greater degradation in G/TB mini-modules compared to G/G in the later stages of the stress sequence when the backsheets are directly exposed to UV-containing light. Our results highlight: 1) the utility of sequential stress testing to uncover degradation modes in bifacial PV, 2) implications of using mini-modules for testing PV quality, and 3) the importance of lamination defects that must be avoided to ensure durability as the industry adopts G/G or G/TB packaging.

14 SOLAR ENERGY↗
DOE OSTI2021

Distribution of the Spectral Response of Cells in Silicon Modules - Mechanisms and Implications

Measurements of the spectral response of cells in a PV module can provide important insight into the physics of the device and are also needed for the accurate calibration of the performance of these devices using solar simulators. While techniques for measuring the spectral response of PV cells are well established, measurement of the spectral response of all cells in a module is not straightforward since in this case one has electrical access to a string of cells and not to cells individually. Here we present a new approach for testing the spectral response of individual cells in silicon modules that allows for the fast mapping of the response at different locations of the module. We show that in some cases the spectral response of different cells in a module can vary considerably and propose an underlying mechanism for this variation. We also discuss the implications of this observation for the uncertainty of the spectral correction and of the I SC calibration using a solar simulator.

modules↗
DOE OSTI2021

3-D Prismatic Packaging Methodologies for Wide Band Gap Power Electronics Modules

In a power module the parasitic inductance limits the dynamic high-frequency performance, and the area of the cooling surfaces limits the power capability. This paper presents a new 3D power electronic design methodology based on the concept of mutual inductance cancellation and multi-sided heat transfer. New 3D prismatic packaging concepts are proposed for Wide Band Gap (WBG) power devices, where the devices can be mounted at acute angles to adjacent interconnects or other devices. Discussion is given on electrical and thermal path optimization in a 3D space. To validate the 3D prismatic packaging methodology, a 1200V/50A SiC half-bridge power module is fabricated and tested for electrical and thermal performance and results are compared with simulations. The power density calculated for the module is 12 kW/in3 (including heatsink) and shows a 31.3% inductance reduction compared to a 2D planar module. Finally, design guidance suggested for utilizing prismatic structures is provided, together with suggested future work in the area. This paper presents the first reported true 3D power module.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2021

Characterization of Highly Thermally Conductive Organic Substrates for a Double-Sided Cooled Power Module

Abstract Silicon-Carbide (SiC) power devices have become a promising option for traditional Silicon (Si) due to the superior material properties. To fully take advantage of the SiC devices, a high-performance power device packaging solution is necessary. This study proposes a cost-effective double-sided cooled (DSC) 1.2 kV SiC half-bridge power module using organic epoxy-resin composite dielectric (ERCD) substrates. The high mechanical and thermal performance of the power module is achieved by the low-modulus, moderate thermal conductivity, and relatively thin (120 μm) layer of ERCD material compared with traditional metal-clad ceramic approaches. This novel organic dielectric can withstand high voltage (5 kV @ 120 μm) and operate up to 250°C continuously, which is indispensable for high power applications. The thermal modeling results show that the equivalent thermal resistance junction-to-case (Rjc_eq) of the DSC power module using dual direct bonded copper (DBC) is 17% higher than the dual ERCD configuration. Furthermore, a non-insulated DSC power module concept is proposed for maximizing thermal performance by considering thermal vias in the ERCD substrate and direct-soldered heat sink. A thought process for optimization of thermal via design is demonstrated and it shows up to 24% of improvement on thermal performance compared with the insulated DSC power module.

Double-sided cooling, epoxy-resin composite dielec↗
DOE OSTI2021

Thermal and Reliability Characterization of an Epoxy Resin-Based Double-Side Cooled Power Module

Wide-Band Gap (WBG) power devices have become a promising option for high-power applications due to the superior material properties over traditional Silicon. To not limit WBG devices’ mother nature, a rugged and high-performance power device packaging solution is necessary. This study proposes a Double-Side Cooled (DSC) 1.2 kV half-bridge power module having dual epoxy resin insulated metal substrate (eIMS) for solving convectional power module challenges and providing a cost-effective solution. The thermal performance outperforms traditional Alumina (Al2O3) Direct Bonded Copper (DBC) DSC power module due to moderate thermal conductivity (10 W/mK) and thin (120 mm) epoxy resin composite dielectric working as the IMS insulation layer. This novel organic dielectric can withstand high voltage (5 kVAC @ 120 μm) and has a Glass Transition Temperature (Tg) of 300°C, which is suitable for high-power applications. In the thermal-mechanical modeling, the organic DSC power module can pass the thermal cycling test over 1,000 cycles by optimizing the mechanical properties of the encapsulant material. In conclusion, this article not only proposes a competitive organic-based power module but also a methodology of evaluation for thermal and mechanical performance.

42 ENGINEERING↗
NASA NTRS1965

Electro-optic crystals and their use for light modulation

Several methods of modulating a beam of light, which have been described in the literature, utilizing the influence of an electrical signal on the birefringence of certain crystals, will be reviewed. These employ optics which respond to the state of polarization of a light beam, and include intensity modulation, position modulation, and the possibility of an electrically tuned optical filter. The influence of the piezo-optic, or strain contribution to the total electro-optic response in the design of an optoelectronic device will be discussed. Current experimental work in our laboratory in which the strain contribution is separated from the direct effect will be described. The strain-free effect is measured by applying a step voltage to the crystal, and observing the initial response. The electro-optical transient response can be observed with nanosecond time resolution. An electronic sampling technique is used to extract the desired response from photon noise. The stress-free or low-frequency effect is measured similarly but at low audio frequencies. Single crystal tetragonal BaT10 3 has been investigated in detail with the result that the strain-optic contribution to the low frequency effect r_(c) = r_(33)—r_(13) is about 80% of the total, where it is only 10% in KDP and 45% in ADP. The magnitudes of the electro-optic effect, dielectric constant, and other related properties are compared for several materials potentially useful as electro-optic modulators, and some comments are made about the practical problems of building a modulator.

ELECTRO-OPTICS↗
NASA NTRS1995

The Design and Implementation of NASA's Advanced Flight Computing Module

This paper describes a working flight computer Multichip Module developed jointly by JPL and TRW under their respective research programs in a collaborative fashion. The MCM is fabricated by nCHIP and is packaged within a 2 by 4 inch Al package from Coors. This flight computer module is one of three modules under development by NASA's Advanced Flight Computer (AFC) program. Further development of the Mass Memory and the programmable I/O MCM modules will follow. The three building block modules will then be stacked into a 3D MCM configuration. The mass and volume of the flight computer MCM achieved at 89 grams and 1.5 cubic inches respectively, represent a major enabling technology for future deep space as well as commercial remote sensing applications.

computer design space applications multichip modul↗
NASA NTRS2004

T/R module development for large aperture L-band phased array

This paper describes a transmit / receive (T/R) module for a large L-band space based radar active phased array being developed at JPL. Electrical performance and construction techniques are described, with emphasis on the former. The T/R modules have a bandwidth of more than 80 MHz centered at 1260MHz and support dual, switched polarizations. Phase and amplitude are controlled by a 6-bit phase shifter and a 6-bit attenuator, respectively. The transmitter power amplifier generates 2.4 W into a nominal 50 ohm load with 36% overall efficiency. The receiver noise figure is 4.4 dB including all front-end losses. The module weighs 32 g and has a footprint of 8 cm x 4.5 cm. Fourteen of these T/R modules were fabricated at the JPL Pick-and-Place Facility and were tested using a computer-controlled measurement facility developed at JPL. Calibrated performance of this set of T/R modules is presented and shows good agreement with design predictions.

transmit / receive (T/R) module↗
NASA NTRS2007

High-Reliability Pump Module for Non-Planar Ring Oscillator Laser

We propose and have demonstrated a prototype high-reliability pump module for pumping a Non-Planar Ring Oscillator (NPRO) laser suitable for space missions. The pump module consists of multiple fiber-coupled single-mode laser diodes and a fiber array micro-lens array based fiber combiner. The reported Single-Mode laser diode combiner laser pump module (LPM) provides a higher normalized brightness at the combined beam than multimode laser diode based LPMs. A higher brightness from the pump source is essential for efficient NPRO laser pumping and leads to higher reliability because higher efficiency requires a lower operating power for the laser diodes, which in turn increases the reliability and lifetime of the laser diodes. Single-mode laser diodes with Fiber Bragg Grating (FBG) stabilized wavelength permit the pump module to be operated without a thermal electric cooler (TEC) and this further improves the overall reliability of the pump module. The single-mode laser diode LPM is scalable in terms of the number of pump diodes and is capable of combining hundreds of fiber-coupled laser diodes. In the proof-of-concept demonstration, an e-beam written diffractive micro lens array, a custom fiber array, commercial 808nm single mode laser diodes, and a custom NPRO laser head are used. The reliability of the proposed LPM is discussed.

micro lens array↗
NASA NTRS2013

The Multi-purpose Crew Vehicle European Service Module: a European Contribution to Human Exploration

This paper provides an overview of the system and subsystem configuration of the MPCV European Service Module (ESM) at Preliminary Design Review (PDR) stage as well as its perspectives of utilisation within the global space exploration endeavour. The MPCV ESM is a cylindrical module with a diameter of 4500 mm and a total length - main engine excluded - of 2700 mm. It is fitted with four solar array wings with a span of 18.8 m. Its dry mass is 3.5 metric tons and it can carry 8.6 tons of propellant. The main functions of the European Service Module are to bring the structural continuity between the launcher and the crew module, to provide propulsion to the MPCV, to ensure its thermal control as well as electrical power and to store water, oxygen and nitrogen for the mission. The current agreement foresees the development and production by Europe of one flight model, with an option for a second one. This module will be assembled in Europe and delivered to NASA in 2016. It will be used for a flight of the MPCV Orion in December 2017.

Design↗
NASA NTRS2013

The Multi-purpose Crew Vehicle European Service Module: a European Contribution to Human Exploration

This paper provides an overview of the system and subsystem configuration of the MPCV European Service Module (ESM) at Preliminary Design Review (PDR) stage as well as its perspectives of utilisation within the global space exploration endeavour. The MPCV ESM is a cylindrical module with a diameter of 4500 mm and a total length – main engine excluded – of 2700 mm. It is fitted with four solar array wings with a span of 18.8 m. Its dry mass is 3.5 metric tons and it can carry 8.6 tons of propellant. The main functions of the European Service Module are to bring the structural continuity between the launcher and the crew module, to provide propulsion to the MPCV, to ensure its thermal control as well as electrical power and to store water, oxygen and nitrogen for the mission. The current agreement foresees the development and production by Europe of one flight model, with an option for a second one. This module will be assembled in Europe and delivered to NASA in 2016. It will be used for a flight of the MPCV Orion in December 2017.

European Service Module↗
NASA NTRS2018

In-Line Electromagnetic Actuator for Fuel Modulation

An in-line electromagnetic actuator with normally-open configuration has been developed for the purpose of exploring its application as a fuel modulator for the active control of combustor thermo-acoustic instabilities. The actuator is based on the spring-coil-plunger mechanism with the plunger designed to be suspended by crossed cantilever beam springs. Operational specification was set for a 1000 psi maximum inlet fuel pressure and modulation for a broad frequency bandwidth that encompasses frequencies that are typically associated with combustor thermo-acoustic instabilities. Various test results demonstrated fuel modulation up to 1200 Hz for coil excitation voltage between 2.3 and 4.6 V and current between 16 and 48 mA, respectively. The initial goal of this work was to demonstrate fuel modulation based on the concept of a normally-open fuel modulator with tethered plunger displacement.

Actuator↗
NASA NTRS1995

Radiation Effects in Photonic Modulator Structures

%T Radiation Effects in Photonic Modulator Structures%A Charles Barnes%A Roger Greenwell%J SPIE, Photonics for Space Environments%C Orlando, Florida, U.S.A.%D April 18-20, 1995%K Radiation%K Photonic Modulator Structures%U http://techreports.jpl.nasa.gov/1995/95-1057.pdfA review is given of the effects of radiation on various photonic modulator materials and devices including polymer-based structures, insulator-based devices, semiconductor-based devices and spatial light modulators. We conclude by providing recommendations for further work in the area of radiation effects in photonic modulators.!

Photonic↗
DOE OSTI2024

PV Modules Temperature Variation and Patterns in Medium and Utility-Scale Floating PV Systems

This paper presents the preliminary results and findings of the four operational Floating PV systems across the USA. At each site, temperature of five PV modules located at North-West, North-East, Middle, South-West, and, South-East have been monitored through the Resistant Temperature Detector (RTD) sensors. Three RTDs were attached to each PV module on the rear-side along the diagonal at top, middle and bottom cells. The preliminary results reveal wide temperature differences among the inter and intra PV modules. Besides this, wave pattern temperatures were observed in a few PV modules. The final results, findings, and, factors responsible will be investigated during the next few months. Index Terms - photovoltaic module, floating PV systems, string, array, temperature, mismatch, utility scale.

ENGINEERING,SOLAR ENERGY↗
DOE OSTI2025

Thermal Optimization and Experimental Demonstration of a Silicon Carbide, Half-Bridge Power Module

This paper describes modeling and experimental work to design and demonstrate a silicon carbide (SiC), single-side-cooled power module. Two SiC metal-oxide-semiconductor field-effect transistors (MOSFET) were used for each switch position and packaged on a metalized ceramic substrate. Thermal modeling was first conducted to optimize the module packaging to minimize junction-to-fluid thermal resistance and device temperature variations. This procedure identified the optimal device placement and baseplate thickness to maximize thermal performance. A heat exchanger - incorporating impinging jets of water-ethylene glycol - was designed to cool the module's baseplate to minimize thermal resistance and pumping power. The heat exchanger used relatively low fluid velocities (<1.5 m/s) to minimize erosion-corrosion effects and relatively large fluid channel sizes (>=1 mm) to prevent clogging. The power module concept was fabricated, and experiments were conducted to measure its thermal performance. Direct current was used to power the module devices, and junction temperatures were measured via device temperature-sensitive parameters. The experimental results were found to be in good agreement with model predictions (within 2%) and yielded junction-to-fluid thermal resistance values as low as about 15 mm2 K/W at relatively low pumping power values. The results demonstrate the improved performance associated with jet impingement cooling and represent an improvement over existing channel-flow-type cold plates, which can enable improvements to power density and reliability.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Solvent‐free Synthesis of Multi‐Module Pore‐Space‐Partitioned Metal‐Organic Frameworks for Gas Separation

Abstract Multi‐module design of framework materials with multiple distinct building blocks has attracted much attention because such materials are more amenable to compositional and geometrical tuning and thus offer more opportunities for property optimization. Few examples are known that use environmentally friendly and cost‐effective solvent‐free method to synthesize such materials. Here, we report the use of solvent‐free method (also modulator‐free) to synthesize a series of multi‐module MOFs with high stability and separation property for C 2 H 2 /CO 2 . The synthesis only requires simple mixing of reactants and short reaction time (2 h). Highly porous and stable materials can be made without any post‐synthetic activation. The success of solvent‐free synthesis of multi‐module MOFs reflects the synergy between different modules, resulting in stable pore‐partitioned materials, despite the fact that other competitive crystallization pathways with simpler framework compositions also exist.

Xiao, Yuchen↗