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Each quarter, the National Laboratory of the Rockies conducts the Quarterly Solar Industry Update, a presentation of technical trends within the solar industry. Each presentation focuses on global and U.S. supply and demand, module and system price, investment trends and business models, and updates on U.S. government programs supporting the solar industry.
The IEC 62788-1-1 and IEC 63209-2 standards use aging sequences for durability of adhesion in photovoltaic (PV) modules, which may be evaluated using the single cantilever beam (SCB) test. Because the encapsulant forms critical interfaces with the front glass and solar cells, degradation at those interfaces under ultraviolet (UV) exposure, elevated temperature, and humidity can lead to interfacial delamination - compromising the long-term reliability. In this work, adhesion durability of UV-transmitting poly(ethylene-co-vinyl acetate) (EVA) encapsulant to glass and to silicon solar cells is evaluated after sequenced UV and damp heat aging (85C/85%RH). Laminates were prepared using StarPhire solar front glass with thin glass or PERC cells, and two EVA formulations with different concentrations of siloxane coupling agent. Adhesion was quantified by measuring critical debond energy using the SCB method. Both formulations exhibit similar qualitative trends, while different adhesion is observed at the periphery despite the use of low-shrink manufacturing. The results show that while glass/EVA adhesion remains stable or increases after UV exposure and shows only moderate changes after damp heat, the EVA/cell interface exhibits an irreversible loss of adhesion following UV and then damp heat exposure. Although glass/EVA interfaces generally exhibit lower debond energies, the EVA/cell interface is significantly more vulnerable to UV-driven degradation, identifying it as the dominant reliability risk location through early- and intermediate-module life. These results demonstrate that accelerated aging sequences can expose large, interface-specific losses in adhesion durability and underscore the importance of interface engineering for long-term PV module reliability.
Each quarter, the Nationa Laboratory of the Rockies conducts the Quarterly Solar Industry Update, a presentation of technical trends within the solar industry. Each presentation focuses on global and U.S. supply and demand, module and system price, investment trends and business models, and updates on U.S. government programs supporting the solar industry.
Module uses phase change heat absorbing wax to reduce peak temperatures, increasing electrical efficiency. Wax makes module more cost effective than conventional thermomodules by also storing thermal energy for air and water heating.
Antireflective coatings which may be suitable for use on the covers of photovoltaic solar modules can be easily produced by a dipping process. The coatings are applied to glass by drawing sheets of glass vertically out of dilute aqueous sodium silicate solutions at a constant speed, allowing the adherent liquid film to dry, then exposing the dried film to concentrated sulfuric acid, followed by a water rinse and dry. The process produces coatings of good optical performance (96.7 percent peak transmission at 0.540 mu M wavelength) combined with excellent stain and soil resistance, and good resistance to abrasion. The process is reproduceable and easily controlled.
The historical progression of efficiency improvements, cost reductions, and performance improvements in modules and photovoltaic systems are described. The potential for future improvements in photovoltaic device efficiencies and cost reductions continues as device concepts, designs, processes, and automated production capabilities mature. Additional step-function improvements can be made as today's simpler devices are replaced by more sophisticated devices.
The cost involved in the performance of the standard operations for the manufacture of silicon wafers is insignificant in the case of space photovoltaics applications. It is, however, a decisive factor with respect to terrestrial applications of silicon photovoltaic devices. In 1975, a program was, therefore, begun to develop low cost silicon solar arrays for terrestrial applications. The goal was silicon-based photovoltaic (PV) modules ready for installation at a selling price of $0.50/watt (1975 dollars). Sheet and ribbon silicon growth held out the promise of reduced cost through continuous operation, high material throughput, high material utilization efficiency, and a product whose shape lent itself to the assembly of high packing density modules. Attention is given to ribbon growth technologies, sheet technology generic problems, and ribbon cell and module technology status. It is concluded that the potential for crystalline ribbon silicon appears to be better today than ever before.
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.
Although the intrinsic strength of silicon dioxide glass is of the order of 10 to the 6th power lb/sq in, the practical strength is roughly two orders of magnitude below this theoretical limit, and depends almost entirely on the surface condition of the glass, that is, the number and size of flaws and the residual surface compression (temper) in the glass. Glass parts always fail in tension when these flaws grow under sustained loading to some critical size. Research associated with glass encapsulated crystalline-Si photovoltaic (PV) modules has greatly expanded our knowledge of glass breaking strength and developed sizeable data base for commercially available glass types. A detailed design algorithm is developed for thickness sizing of rectangular glass plates subject to pressure loads. Additional studies examine the strength of glass under impact loading conditions such as that caused by hail. Although the fundamentals of glass breakage are directly applicable to thin film modules, the fracture strength of typical numerical glass must be replaced with data that reflect the high temperature tin oxide processing, laser scribing, and edge processing peculiar to thin film modules. The fundamentals of glass breakage applicable to thin film modules and preliminary fracture strength data for a variety of 1 ft square glass specimens representing preprocessed and post processed sheets from current amorphous-Si module manufacturers are presented.
This is the third Flat-Plate Solar Array (FSA) Project document reporting on chemical bonding technology for terrestrial photovoltaic (PV) modules. The impetus for this work originated in the late 1970s when PV modules employing silicone encapsulation materials were undergoing delamination during outdoor exposure. At that time, manufacturers were not employing adhesion promoters and, hence, module interfaces in common with the silicone materials were only in physical contact and therefore easily prone to separation if, for example, water were to penetrate to the interfaces. Delamination with silicone materials virtually vanished when adhesion promoters, recommended by silicone manufacturers, were used. The activities related to the direct investigation of chemically bonded interfaces are described.
The Mast Material Test Program (MAMATEP) at NASA Lewis is discussed. Objectives include verifying the need for, and evaluating the performance of, various protection techniques for the Solar Array Assembly mast of the Space Station Photovoltaic Power Module. Mast material samples were evaluated in terms of mass and bending modulus, measured before and after environmental exposure. Test environments included atomic oxygen exposure (RF plasma asher), thermal cycling, and mechanical flexing. Protective coatings included CV-1144 silicon, a Ni/Au/InSn eutectic, and an open weave, Al braid. Results indicate that unprotected samples degrade in an atomic oxygen environment at a steady rate. Open weave, Al braid offers little protection for the fiberglass-epoxy sample in an asher environment. Ni/Au/InSn eutectic offers excellent protection in an asher environment prior to thermal cycling and mechanical flexing. Long duration asher results from unprotected samples indicate that, even though the fiberglass-epoxy degrades, a protection technique may not be necessary to ensure structural integrity. However, a protection technique may be desirable to limit or contain the amount of debris generated by the degradation of the fiberglass-epoxy.
Results are reported of studying the interaction of moisture with photovoltaic (PV) modules and custom-built test coupons in both laboratory and outdoor ambient environments. Characteristics measured included module cell-to-frame leakage currents, encapsulant bulk and surface currents, glass surface currents, and encapsulant/glass interface currents as functions of temperature and humidity. Using a computer model of interelectrode conduction, preferential conduction paths in PVB- and EVA-encapsulated modules are identified. In comparing the results of field and laboratory test environments on identical samples, comments are made about the greater severity of the outdoor environment. Several aspects of water-module interaction, including design strategies and continuing research, are discussed.
The MAMATEP program, which is aimed at verifying the need for and evaluating the performance of various protection techniques for the solar array assembly mast of the Space Station photovoltaic power module, is discussed. Coated and uncoated mast material samples have been environmentally tested and evaluated, before and after testing, in terms of mass and bending modulus. The protective coatings include CV-1144 silicone, a Ni/Al/InSn eutectic, and an open-weave Al braid. Long-term plasma asher results from unprotected samples indicate that, even though fiberglass-epoxy samples degrade, a protection technique may not be necessary to ensure structural integrity. A protection technique, however, may be desirable to limit or contain the amount of debris generated by the degradation of the fiberglass-epoxy.
This paper summarizes the Space Station program requirements for the Thermal Control System (TCS), and outlines the capabilities of the TCS for each assembly configuration. The TCS architecture for the completed assembly configuration is described, consisting of an active TCS (ATCS) and a passive TCS (PTCS). The four ATCS subsystems are described, including the two-phase ammonia central ATCS, photovoltaic power module, attached payload accommodation equipment and the single-phase water internal ATCS.
The results are detailed of follow-on availability analyses performed on the Space Station Freedom electric power system (EPS). The scope includes analyses of several EPS design variations, these are: the 4-photovoltaic (PV) module baseline EPS design, a 6-PV module EPS design, and a 3-solar dynamic module EPS design which included a 10 kW PV module. The analyses performed included: determining the discrete power levels that the EPS will operate at upon various component failures and the availability of each of these operating states; ranking EPS components by the relative contribution each component type gives to the power availability of the EPS; determining the availability impacts of including structural and long-life EPS components in the availability models used in the analyses; determining optimum sparing strategies, for storing space EPS components on-orbit, to maintain high average-power-capability with low lift-mass requirements; and analyses to determine the sensitivity of EPS-availability to uncertainties in the component reliability and maintainability data used.
A brief but comprehensive review is given of the technical accomplishments of the NASA Lewis Research Center during the past year. Topics covered include instrumentation and controls technology; internal fluid dynamics; aerospace materials, structures, propulsion, and electronics; space flight systems; cryogenic fluids; Space Station Freedom systems engineering, photovoltaic power module, electrical systems, and operations; and engineering and computational support.
The external induced contamination of Space Station Freedom's electrical power system surfaces is assessed using a molecular flow evaluation code, MOLFLUX. Outgassing rates are compared to available experimental data, and deposition to the midregion of both the solar array and the photovoltaic power module thermal control system radiator is calculated using a constant sticking coefficient. An estimate of annual deposition to the solar array due to outgassing is found to be 10 percent of the Space Station Freedom program requirement for maximum allowable deposition, while annual deposition to the radiator is approximately equal to the requirement.
Mispointing of the solar dynamic (SD) concentrator designed for use on Space Station Freedom (SSF) causes the optical axis of the concentrator to be nonparallel to the incoming rays from the Sun. This causes solar flux not to be focused into the aperture hole of the receiver and may position the flux on other SSF components. A Rocketdyne analysis has determined the thermal impact of off-axis radiation due to mispointing on elements of the SD module and photovoltaic (PV) arrays. The conclusion was that flux distributions on some of the radiator components, the two-axis gimbal rings, the truss, and the PV arrays could present problems. The OFFSET computer code was used at Lewis Research Center to further investigate these flux distributions incident on components. The Lewis study included distributions for a greater range of mispoint angles than the Rocketdyne study.