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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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NREL and NanoSpray will cooperate to perform testing of low-cost direct write contacts and interconnects for thin film solar applications.
The Boeing Company has evaluated the use of Tape Automated Bonding (TAB) and Surface Mount Technology (SMT) for a highly reliable, low cost interconnect for concentrator solar cell arrays. TAB and SMT are currently used in the electronics industry for chip interconnects and printed circuit board assembly. TAB tape consists of sixty-four 3-mil/1-oz tin-plated copper leads on 8-mil centers. The leads are thermocompression gang bonded to GaAs concentrator solar cell with silver contacts. This bond, known as an Inner Lead Bond (ILB), allows for pretesting and sorting capability via nondestruct wire bond pull and flash testing. Destructive wire pull tests resulted in preferred mid-span failures. Improvements in fill factor were attributed to decreased contact resistance on TAB bonded cells. Preliminary thermal cycling and aging tests were shown excellent bond strength and metallurgical results. Auger scans of bond sites reveals an Ag-Cu-Tin composition. Improper bonds are identified through flash testing as a performance degradation. On going testing of cells are underway at Lewis Research Center. SMT techniques are utilized to excise and form TAB leads post ILB. The formed leads' shape isolates thermal mismatches between the cells and the flex circuit they are mounted on. TABed cells are picked and placed with a gantry x-y-z positioning system with pattern recognition. Adhesives are selected to avoid thermal expansion mismatch and promote thermal transfer to the flex circuit. TAB outer lead bonds are parallel gap welded (PGW) to the flex circuit to finish the concentrator solar cell subassembly.
Twenty-four solar modules, half of which were 48 cells in an all-series electrical configuration and half of a six parallel cells by eight series cells were provided. Upon delivery of environmentally tested modules, low power outputs were discovered. These low power modules were determined to have cracked cells which were thought to cause the low output power. The cracks tended to be linear or circular which were caused by different stressing mechanisms. These stressing mechanisms were fully explored. Efforts were undertaken to determine the causes of cell fracture. This resulted in module design and process modifications. The design and process changes were subsequently implemented in production.
This report is part of the ongoing Solar Time-Based Residential Analytics and Cycle Time Estimator (SolarTRACE) project, led by the National Renewable Energy Laboratory (NREL). The SolarTRACE project utilizes time-stamped project-level data provided by installer-partners to assess nationwide and AHJ- and utility-level PI&I and other solar PV adoption timelines since 2017. Our dataset now covers 22% of residential solar and 33% of residential storage installs in the U.S. since 2017. This report provides an update to our previous 2022 report (Cruce et al., 2022b) and includes: updated 2017 2023 project timelines for residential rooftop solar PV up to 20kW; updated tracking of permitting process changes at nearly 4,000 AHJs nationwide; and first-ever reporting of timelines for residential PV+storage projects up to 20kW.
A program was conducted to develop technologies for welding interconnects to 50-micron thick, 2 by 2 cm solar cells obtained from three suppliers. The cells were characterized with respect to electrical performance, cell thickness, silver contact thickness, contact waviness, bowing, and fracture strength. Weld schedules were independently developed for each of the three cell types and were coincidentally identical. Thermal shock tests (100 cycles from 100 deg to -180 deg C) were performed on 16-cell coupons for each cell type without any weld joint failures or electrical degradation. Three 48-cell modules (one for each cell type) were assembled with 50-micron thick cells, frosted fused silica covers, silver clad Invar interconnectors, and Kapton substrates.
Interconnection tabs in a nine-solar-cell array have been soldered simultaneously with radiant heat. Cells and tabs are held in position for soldering by sandwiching them between compliant silicone-rubber vacuum platen and transparent polyimide sealing membrane. Heat lamps warm cells, producing smooth, flat solder joints of high quality.
The main objective of this research is to provide novel insights into the effects of permitting, inspection, and interconnection (PII) processes on PV system installations—and in particular, into the relationship between PII processes and adoption timelines. This research can then be used to clarify the potential effect of various process changes on reducing PII timelines, customer cancellation rates, and related costs nationwide. NREL completed this research by assembling a data set of distributed, largely residential rooftop solar systems less than 50 kilowatts in size from participating solar installers. NREL produced five publications describing the effects that PII processes can have on adoption timelines nationwide, in addition to publishing an interactive data viewer with five years of PII cycle time data. This tool can be used by stakeholders to identify potential adoption timelines by local government.
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Photovoltaic (PV) modules consist of a string of electrically interconnected silicon solar cells capable of producing practical quantities of electrical power when exposed to sunlight. To insure high reliability and long term performance, the functional components of the solar cell module must be adequately protected from the environment by some encapsulation technique. The encapsulation system must provide mechanical support for the cells and corrosion protection for the electrical components. The goal of the program is to identify and develop encapsulation systems consistent with the PV module operating requirements of 30 year life and a target cost of $0.70 per peak watt ($70 per square meter) (1980 dollars). Assuming a module efficiency of ten percent, which is equivalent to a power output of 100 watts per square meter in midday sunlight, the capital cost of the modules may be calculated to be $70.00 per square meter. Out of this cost goal, only 20 percent is available for encapsulation due to the high cost of the cells, interconnects, and other related components. The encapsulation cost allocation may then be stated as $14.00 per square meter, included all coatings, pottant and mechanical supports for the cells.
A long duration test is in progress for comparing various methods of attaching interconnects to solar cells for near-earth-orbit spacecraft. This JPL- and NASA-sponsored project has been cycling modules at between -80 C and + 80 C since June 1983. As of April 1984, 29,000 cycles have been completed, and the cycling is continuing. Modules include examples of parallel gap and ultrasonic welding and of soldering as fabricated by the Space and Communications Group, Hughes Aircraft Company and by Spectroblab. Evaluation of module integrity has been made at periodic intervals. No measurable degradation has been detected to date.
An investigation of the feasibility of a solar array panel subsystem which will produce 10,000 watts of electrical output at 1 A.U. with an overall beginning-of-life power-to-weight ratio of at least 110 watt/kg is reported. A description of the current baseline configuration which meets these requirements is presented. A parametric analysis of the single boom, two blanket planar solar array system was performed to arrive at the optimum system aspect ratio. A novel concept for the stiffening of a lightweight solar array by canting the solar cell blankets at a small angle to take advantage of the inherent in-plane stiffness to increase the symmetric out-of-plane frequency is introduced along with a preliminary analysis of the stiffening effect. A comparison of welded and soldered solar cell interconnections leads to the conclusion that welding is required on this ultralightweight solar array. The use of a boron/aluminum composite material in a BI-STEM type deployable boom is investigated as a possible advancement in the state-of-the-art.
The Whole Heliosphere Interval (WHI) is an internationally coordinated observing and modeling effort to characterize the 3-dimensional interconnected solar-heliospheric-planetary system - a.k.a. the "heliophysical" system. The heart of the WHI campaign is the study of the interconnected 3-D heliophysical domain, from the interior of the Sun, to the Earth, outer planets, and into interstellar space. WHI observing campaigns began with the 3-0 solar structure from solar Carrington Rotation 2068, which ran from March 20 - April 16, 2008. Observations and models of the outer heliosphere and planetary impacts extended beyond those dates as necessary; for example, the solar wind transit time to outer planets can take months. WHI occurs during solar minimum, which optimizes our ability to characterize the 3-D heliosphere and trace the structure to the outer limits of the heliosphere. A summary of some of the key results from the WHI first workshop in August 2008 will be given.
A high‐throughput, single‐source laser scribing method exploiting a transparent conducting oxide (TCO) indirect liftoff mechanism is developed to produce serially interconnected perovskite solar modules. The TCO‐based indirect liftoff mechanism relies solely on laser absorption in the front transparent electrode material reducing thermal damage to the overlying layers and allowing for fast scribing speeds with low‐cost μs‐pulse duration fiber laser systems. Minimal resistive power losses are observed with the method compared to conventional ablative laser scribes, maintaining the power conversion efficiencies of small‐area devices (≈0.2 cm 2 ) across significantly larger deposition areas (≈1 cm 2 ). Finally, demonstrating > 3 m s −1 processing speeds, TCO‐based liftoff provides the highest throughput laser scribing method for thin‐film photovoltaic devices produced on glass/TCO substrates, capable of processing large‐area perovskite solar modules at a manufacturing scale.
A spacecraft includes a plurality of solar panels interconnected with a power coupler and an electrically operated device to provide power to the device when the solar cells are insolated. The solar panels are subject to bending distortion when entering or leaving eclipse. Spacecraft attitude disturbances are reduced by mounting each of the solar panels to an elongated boom made from a material with a low coefficient of thermal expansion, so that the bending of one panel is not communicated to the next. The boom may be insulated to reduce its bending during changes in insolation. A particularly advantageous embodiment mounts each panel to the boom with a single mounting, which may be a hinge. The single mounting prevents transfer of bending moments from the panel to the boom.
A flight experiment was designed to determine the optimum design for gallium arsenide (GaAs) solar cell panels in a radiation environment. Elements of the experiment design include, different coverglass material and thicknesses, welded and soldered interconnects, different solar cell efficiencies, different solar cell types, and measurement of annealing properties. This experiment is scheduled to fly on the Combined Release and Radiation Effects Satellite (CRRES). This satellite will simultaneously measure the radiation environment and provide engineering data on solar cell degradation that can be directly related to radiation damage.
Energy storage has a unique and pivotal role to play in the transition to a low-carbon economy because it can help the electric grid accommodate more renewable energy. However, a number of barriers currently impede the process of connecting energy storage systems to the distribution grid. The Toolkit and Guidance for the Interconnection of Energy Storage and Solar-Plus-Storage (the “BATRIES Toolkit”), which is the publication subject to this Final Technical / Scientific Report, provides vetted solutions to eight regulatory and technical barriers to the interconnection of standalone storage and solar-plus-storage systems (referred to as “energy storage”) to the distribution grid. These recommendations are based on over a year of research and analysis by utility and industry experts. The BATRIES Toolkit also includes model language that utilities and utility regulators can use to update state interconnection rules to reduce the costs and time to safely interconnect energy storage and solar-plus-storage systems. The solutions are nationally applicable and can be applied in diverse states and markets across the U.S.
The increasing demand for solar energy faces significant barriers, including inefficient construction processes, high project costs limiting LCOE reductions, and diminishing availability of "good" sites with favorable interconnection. Conventional solar installations are often constrained by long construction timelines and the need for flat, large plots. Furthermore, the industry struggles with a shortage of skilled labor. Planted Solar aims to address these challenges by fundamentally transforming solar deployment from a construction project into a streamlined manufacturing process. Our novel approach combines high-density racking, integrated terrain-following design software, and installation automation. Unlike competing solutions that either assist with standard array assembly or offer dense packing without terrain adaptability or automation, Planted's technology uniquely brings together a new array product with in-place automated manufacturing to achieve the lowest possible cost, greater site flexibility, and accelerated deployment.
Two new models of negative-bias arcing on a solar cell power system in Low Earth Orbit are presented. One is an extended, analytical model and the other is a non-linear, numerical model. The models are based on an earlier analytical model in which the interactions between solar cell interconnects and the space plasma as well as the parameters of the power circuit are approximated linearly. Transient voltages due to arcs struck at the negative thermal of the solar panel are calculated in the time domain. The new models treat, respectively, further linear effects within the solar panel load circuit and non-linear effects associated with the plasma interactions. Results of computer calculations with the models show common-mode voltage transients of the electrically floating solar panel struck by an arc comparable to the early model but load transients that differ substantially from the early model. In particular, load transients of the non-linear model can be more than twice as great as those of the early model and more than twenty times as great as the extended, linear model.