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At least 1,027 records · Page 57
All sourcesNASA NTRSDOE OSTI
NASA NTRS2023

Exploration Extra-Vehicular Mobility Unit (xEMU) Composite Hard Upper Torso (CHUT) Development

The xEMU is the Exploration Mobility Unity or space suit designed for microgravity (cislunar and low earth orbit (LEO)) and lunar surface operations. This suit design allows crewmembers to perform extravehicular exploration, science, construction, maintenance, and contingency operations while unattached to a vehicle for life support in pressure and thermal environments that exceed human capability. The xEMU provides life support, environmental protection, and communications capabilities to the EVA crewmember while allowing sufficient mobility and visibility to perform dexterous EVA tasks. The effort documented in this paper, addressed the design, analysis, manufacturing, full-scale test article testing and validation for a Composite Hard Upper Torso(CHUT)unit. Design and analysis of the CHUT was based on measured B-basis properties of the selected S-glass/epoxy composite, and established final geometry, composite layup and interface details that met requirements. A complete manufacturing and assembly protocol was established for the CHUT starting from composite layup in the tool, to final assembly of all interface metal hardware prior to delivery to NASA for suit integration. Full-scale CHUT test articles underwent static and fatigue pressure testing (2 lifetimes), impact testing at critical stress locations for tool drop/microgravity scenarios, followed by post-impact fatigue testing. Effect of manufacturing defects was evaluated by manufacturing a full-scale CHUT with 0.375”/0.5” defects at critical stress locations, followed by static and life-cycle fatigue testing. In all cases, the CHUT design met or exceeded mass, structural, interface and functional requirements. Two (2) complete CHUT articles were delivered to NASA for full-scale suit integration and testing.

spacesuit↗
NASA NTRSDate not supplied

NASA Advanced Space Suit Pressure Garment System Status and Development Priorities 2023

This paper discusses the current focus of NASA’s Advanced Space Suit Pressure Garment Technology Development team’s efforts, the status of that work, and a summary of longer term technology development priorities and activities. The Exploration Extra-vehicular Activity Mobility Unit (xEMU) has been the team’s primary effort over the past several years. ICES papers in 2022 detailed the design of the xEMU pressure garment components. This paper outlines the design updates to the xPGS since that time. More notably, this paper documents the various tests executed with the xPGS to evaluate its performance, durability, and acceptability for microgravity and Lunar missions. An overview of ongoing and planned xEMU testing and training is provided. The PGS team’s transition from xEMU development and testing, to supporting the Exploration Extravehicular Activity Services (xEVAS) vendors will also be discussed. In addition, technology development efforts in coordination with the EVA and Human Surface Mobility Program (EHP), the NASA Engineering Safety Council (NESC) and the Small Business Innovation Research (SBIR) Program will be discussed in the context of supporting sustaining EVA operations on the Lunar surface over the coming decade. Finally, a brief review of longer-term pressure garment challenges and technology gaps will be presented to provide an understanding of the advanced pressure garment team’s technology investment priorities and needs.

spacesuit↗
NASA NTRSDate not supplied

Exploration Helmet Permanent Anti-Fog Study

For the current Extravehicular Mobility Unit (EMU) spacesuit, an astronaut applies an antifog solution to the interior of the helmet bubble before each EVA. However, the anti-fog solution has been reported to cause eye discomfort during at least seven EMU EVAs when the anti-fog solution contacted the crew member’s eyes. During STS-100, astronaut Chris Hadfield reported the eye irritation temporarily blinded him during his spacewalk. In addition, the wipe on anti-fog solution is a consumable that needs to be accounted for and a supply launched for missions. To solve this, NASA has tested different permanent anti-fog coatings. However, major issues have arisen with Human in the Loop (HITL) testing with the coatings. Cleaning and removing Valsalva devices which use pressure sensitive adhesives have been challenges to avoid damaging the permanent anti-fog coating. Due to these issues, further investigation is being completed evaluating two solvent based anti-fog solutions: Exxene’s HCF-100 and FSI’s Visgard 106-94. Each coating will be evaluated on polycarbonate samples for application consistency, steam cycles (mimicking breath cycles), cleaning durability, haze, and light transmission. This study will determine if either coating is a viable option to pursue as a permanent anti-fog for spacesuit helmet applications.

spacesuit↗
NASA NTRSDate not supplied

NASA Advanced Space Suit Pressure Garment System Status and Development Priorities 2023

This paper discusses the current focus of NASA’s Advanced Space Suit Pressure Garment Technology Development team’s efforts, the status of that work, and a summary of longer term technology development priorities and activities. The Exploration Extra-vehicular Activity Mobility Unit (xEMU) has been the team’s primary effort over the past several years. ICES papers in 2022 detailed the design of the xEMU pressure garment components. This paper outlines the design updates to the xPGS since that time. More notably, this paper documents the various tests executed with the xPGS to evaluate its performance, durability, and acceptability for microgravity and Lunar missions. An overview of ongoing and planned xEMU testing and training is provided. The PGS team’s transition from xEMU development and testing, to supporting the Exploration Extravehicular Activity Services (xEVAS) vendors is discussed. In addition, technology development efforts in coordination with the EVA and Human Surface Mobility Program (EHP), the NASA Engineering Safety Council (NESC) and the Small Business Innovation Research (SBIR) Program will be discussed in the context of supporting sustaining EVA operations on the Lunar surface over the coming decade. Finally, a brief review of longer-term pressure garment challenges and technology gaps will be presented to provide an understanding of the advanced pressure garment team’s technology investment priorities and needs.

spacesuit↗
NASA NTRSDate not supplied

Exploration Helmet Permanent Anti-Fog Study

For the current Extravehicular Mobility Unit (EMU) spacesuit, an astronaut applies an antifog solution to the interior of the helmet bubble before each EVA. However, the anti-fog solution has been reported to cause eye discomfort during at least seven EMU EVAs when the anti-fog solution contacted the crew member’s eyes. During STS-100, astronaut Chris Hadfield reported the eye irritation temporarily blinded him during his spacewalk. In addition, the wipe on anti-fog solution is a consumable that needs to be accounted for and a supply launched for missions. To solve this, NASA has tested different permanent anti-fog coatings. However, major issues have arisen with Human in the Loop (HITL) testing with the coatings. Cleaning and removing Valsalva devices which use pressure sensitive adhesives have been challenges to avoid damaging the permanent anti-fog coating. Due to these issues, further investigation is being completed evaluating two solvent based anti-fog solutions: Exxene’s HCF-100 and FSI’s Visgard 106-94. Each coating will be evaluated on polycarbonate samples for application consistency, steam cycles (mimicking breath cycles), cleaning durability, haze, and light transmission. This study will determine if either coating is a viable option to pursue as a permanent anti-fog for spacesuit helmet applications.

spacesuit↗
NASA NTRS2023

Composite Hard Upper Torso (CHUT) for xEMU Space Suit

The xEMU is the Exploration Mobility Unity or space suit designed for microgravity (cislunar and low earth orbit (LEO)) and lunar surface operations. This suit design allows crewmembers to perform extravehicular exploration, science, construction, maintenance, and contingency operations while unattached to a vehicle for life support in pressure and thermal environments that exceed human capability. The xEMU provides life support, environmental protection, and communications capabilities to the EVA crewmember while allowing sufficient mobility and visibility to perform dexterous EVA tasks. The effort documented in this paper, addressed the design, analysis, manufacturing, full-scale test article testing and validation for a Composite Hard Upper Torso(CHUT)unit. Design and analysis of the CHUT was based on measured B-basis properties of the selected S-glass/epoxy composite, and established final geometry, composite layup and interface details that met requirements. A complete manufacturing and assembly protocol was established for the CHUT starting from composite layup in the tool, to final assembly of all interface metal hardware prior to delivery to NASA for suit integration. Full-scale CHUT test articles underwent static and fatigue pressure testing (2 lifetimes), impact testing at critical stress locations for tool drop/microgravity scenarios, followed by post-impact fatigue testing. Effect of manufacturing defects was evaluated by manufacturing a full-scale CHUT with 0.375”/0.5” defects at critical stress locations, followed by static and life-cycle fatigue testing. In all cases, the CHUT design met or exceeded mass, structural, interface and functional requirements. Two (2) complete CHUT articles were delivered to NASA for full-scale suit integration and testing.

spacesuit↗
NASA NTRSDate not supplied

Micrometeoroid and Orbital Debris (MMOD) Testing, Ballistic Limit Equation Definition and Risk Assessment of the Exploration Extravehicular Mobility Unit (XEMU)

A well-known hazard associated with exposure to the space environment is the risk of failure due to an impact from a micrometeoroid and orbital debris (MMOD) particle. As NASA prepares to return astronauts to the moon with the Artemis program, the next generation of spacesuit is in development to support future extravehicular activities (EVAs). An MMOD impact to the spacesuit is of great concern as a large leak could prevent an astronaut from safely reaching an airlock in time resulting in a loss of life. The exploration extravehicular mobility unit (xEMU) must meet MMOD requirements for multiple environments including those in low earth orbit (LEO) as well as the meteoroid and secondary lunar regolith ejecta environments found on the lunar surface. The subject of this paper is an MMOD risk assessment of the internal xEMU configuration design developed by NASA Johnson Space Center (JSC) personnel. Assessment of the MMOD risk for an 8-hour, 2-person EVA in both LEO and on the lunar surface showed that the xEMU spacesuit meets the program technical requirement of 1 in 2500 failure odds.

Micrometeoroid↗
DOE OSTI2017

Chapter 10.2: Encapsulant Materials for PV Modules

Encapsulant materials used in photovoltaic (PV) modules serve multiple purposes; it provides optical coupling of PV cells and protection against environmental stress. Polymers must perform these functions under prolonged periods of high temperature, humidity, and UV radiation. When PV panels were first developed in the 1960s and the 1970s, the dominant encapsulants were based on polydimethyl siloxane (PDMS). Ethylene-co-vinyl acetate (EVA) is currently the dominant encapsulant chosen for PV applications, not because it has the best combination of properties, but because it is an economical option with an established history of acceptable durability. Getting new products onto the market is challenging because there is no room for dramatic improvements, and one must balance the initial cost and performance with the unknowns of long-term service life. Recently, there has been renewed interest in using alternative encapsulant materials with some significant manufacturers switching from EVA to polyolefin elastomer-based (POE) alternatives.

14 SOLAR ENERGY↗
DOE OSTI2025

Chemically Recyclable and Tunable Polyolefin-Like Multiblock Copolymer Adhesives

Adhesives are important in creating multilayer products, such as in packaging and construction. Most current hot-melt adhesives such as poly(ethylene-co-vinyl acetate) (EVA) and polyurethanes lack chemical recyclability and do not easily de-bond, complicating recycling. Here, we achieved tunable adhesive properties of chemically recyclable polyolefin-like multiblock copolymers through regulating the incorporation of crystalline hard blocks, amorphous soft blocks, and ester content highlighted by adhesive strengths up to 6.80 MPa. We further demonstrated applications of these adhesives in multi-layer films and showed that the adhesives can be readily de-bonded, recovered, and chemically recycled. Overall, this study into structure-property relationships, including effects of crystallinity, soft-block incorporation, and ester content of the multiblock copolymers on adhesive properties, has resulted in a modular hot-melt adhesive platform that exhibits chemical recyclability for virgin-quality adhesive re-generation, reprocessability for repeated reuse of the recovered adhesive, and tunability for designing adhesives with a wide range of low to high (up to ~80% stronger than EVA) adhesion strengths.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Thermal behaviors of ethylene vinyl acetate encapsulants in fielded silicon photovoltaic modules

Aging of silicon photovoltaic (PV) module packaging is one of the greatest limiters of PV module service lifetimes. Module characterization typically focuses on power degradation metrics, which do not convey the complexities of often simultaneous degradation mechanisms. In this work, PV modules with pristine references and known fielding histories were investigated by non-destructive and destructive methods. Modules from Canadian Solar, Mission Solar, and Hanwha Q-Cells were fielded for up to three years; select modules were removed from fielding each year for coring to allow for characterization of the encapsulant. Modules are commonly encapsulated with two protective layers of partially-crystalline ethylene vinyl acetate (EVA) polymer that must undergo a crosslinking reaction to achieve desired properties. The extent of crystallinity of the encapsulants as studied by differential scanning calorimetry showed differences between manufacturers and over time. Some encapsulants showed different magnitudes of crystal sizes which changed after fielding; encapsulants with the monodisperse crystal sizes did not change with fielding. This is due to differences in thermal history. In conclusion, these results have implications for stress development during module aging, since EVA crystal melting and crosslinking reactions can result in encapsulant density changes.

36 MATERIALS SCIENCE↗
DOE OSTI2015

Field testing of thermoplastic encapsulants in high‐temperature installations

Abstract Recently there has been increased interest in using thermoplastic encapsulant materials in photovoltaic modules, but concerns have been raised about whether these would be mechanically stable at high temperatures in the field. Recently, this has become a significant topic of discussion in the development of IEC 61730 and IEC 61215. We constructed eight pairs of crystalline‐silicon modules and eight pairs of glass/encapsulation/glass thin‐film mock modules using different encapsulant materials, of which only two were formulated to chemically crosslink. One module set was exposed outdoors with thermal insulation on the back side in Mesa, Arizona, in the summer (hot‐dry), and an identical module set was exposed in environmental chambers. High‐precision creep measurements (±20 μ m) and electrical performance measurements indicate that despite many of these polymeric materials operating in the melt or rubbery state during outdoor deployment, no significant creep was seen because of their high viscosity, lower operating temperature at the edges, and/or the formation of chemical crosslinks in many of the encapsulants with age despite the absence of a crosslinking agent. Only an ethylene‐vinyl acetate ( EVA ) encapsulant formulated without a peroxide crosslinking agent crept significantly. In the case of the crystalline‐silicon modules, the physical restraint of the backsheet reduced creep further and was not detectable even for the EVA without peroxide. Because of the propensity of some polymeric materials to crosslink as they age, typical thermoplastic encapsulants would be unlikely to result in creep in the vast majority of installations.

14 SOLAR ENERGY↗
DOE OSTI2015

Adhesion and debonding kinetics of photovoltaic encapsulation in moist environments: Adhesion and debonding kinetics of photovoltaic encapsulation

Debonding of photovoltaic (PV) encapsulation in moist environments is frequently reported but presently not well understood or quantified. Temperature cycling, moisture, and mechanical loads often cause loss of encapsulation adhesion and interfacial debonding, initially facilitating back-reflectance and reduced electrical current, but ultimately leading to internal corrosion and loss of module functionality. To investigate the effects of temperature (T) and relative humidity (RH) on the kinetics of encapsulation debonding, we developed a mechanics-based technique to measure encapsulation debond energy and debond growth rates in a chamber of controlled environment. The debond energy decreased from 2.15 to 1.75 kJ m-2 in poly(ethylene-co-vinyl acetate) (EVA) and from 0.67 to 0.52 kJ m-2 in polyvinyl butyral when T increased from 25 to 50 degrees C and 20 to 40 degrees C, respectively. The debond growth rates of EVA increased up to 1000-fold with small increases of T (10 degrees C) and RH (15%). To elucidate the mechanisms of environmental debonding, we developed a fracture-kinetics model, where the viscoelastic relaxation processes at the debonding-tip are used to predict debond growth. The model and techniques constitute the fundamental basis for developing accelerated aging tests and long-term reliability predictions for PV encapsulation.

14 SOLAR ENERGY↗
DOE OSTI2021

Electrochemical Degradation Modes in Bifacial Silicon Photovoltaic Modules

Motivated by the rapidly rising deployment of bifacial monocrystalline-silicon photovoltaics (PV), we investigate the durability of various PV module packaging configurations with transparent coverings on both the front and rear sides of the module. We use a series of bifacial passivated emitter and rear cell (p-PERC) mini-modules with systematically varying outer cover materials (glass/glass, G/G, or glass/transparent backsheet, G/TB) and encapsulant chemistries (poly [ethylene-co-vinyl acetate], EVA; or polyolefin, POE). We study degradation modes over 1,000 hours of combined damp heat (DH) exposure and high system voltages that can cause potential-induced degradation (PID) under positive, zero, or negative 1,000 V cell-to-frame bias. We analyze the degradation modes using a combination of current-voltage measurements, impedance spectroscopy, external quantum efficiency, and spatially resolved luminescence and thermal imaging. Our results highlight various types of degradation including shunting, enhanced recombination, and series resistance increases, and we use spatially resolved characterization to separately identify the localized effects. We show that multiple PID and moisture-ingress degradation modes severely affect EVA-containing modules, with previously reported PID processes under negative-bias DH and a unique observation of rear-side surface recombination in G/EVA/G modules under positive-bias DH. We observe significantly less degradation in POE-containing modules, where the G/POE/G configuration exhibits minimal degradation under all stress conditions that we employ.

14 SOLAR ENERGY↗
DOE OSTI2022

Evaluation of bifacial module technologies with combined–accelerated stress testing

In view of the increasing interest and market share of bifacial cells and modules, suitable substrates such as glass and transparent backsheets along with ethylene vinyl acetate (EVA) and polyolefin elastomer (POE) encapsulants were examined in combined-accelerated stress testing (C-AST) to evaluate and compare degradation modes. Testing with both monofacial and bifacial cells, we found glass-glass modules with monofacial cells led to greater grid finger breakage than those with polymeric backsheets. Furthermore, this is attributed to previous X-ray topography and modeling work showing higher stress in cells and interconnections in glass-glass modules than glass-backsheet modules. Consistent with the objectives of C-AST, which stresses modules at levels corresponding to the limits seen in the natural environment, we observed the UV-fluorescence signatures of modules tested in C-AST (considering the degradation associated with developing chromophores, moisture penetration and photobleaching effects) to be like those in fielded modules, more so than other chamber stress testing implemented for comparison. We found light-induced degradation (LID) in module types with regenerated (inactive) cells with C-AST, suggesting the possibility of LID destabilization in some field conditions. We could also distinguish potential-induced degradation (PID) on the back of the bifacial passivated emitter and rear cells (PERC) in C-AST. Confirming with ex-situ tests, we found polarization-type PID most prevalent in glass-glass modules with EVA as would be anticipated considering the greater leakage current through such module encapsulation. Unlike PID tests performed in the dark, which can lead to false positive PID test results, field-representative illumination is experienced by the modules on the front and back side while –1200 V system voltage is applied in C-AST, supporting the conclusion that this module type with glass-glass construction would be susceptible to PID in the field.

14 SOLAR ENERGY↗
DOE OSTI2017

Recycled tetrahedron-like CuCl from waste Cu scraps for lithium ion battery anode

Highlights: • High EVA CuCl was recycled with 88.7% recovery from waste Cu craps. • The recycled CuCl displayed regular tetrahedron-like morphology. • The evolution mechanism of the recycled CuCl crystal was proposed. • The corresponding discharge capacity in LIB was 171.8 mAh/g after 50 cycles. • The results shed a new light on resource recovery and environmental protection. - Abstract: The wide applications of metal Cu inevitably resulted in a large quantity of waste Cu materials. In order to recover the useful Cu under the mild conditions and reduce the environmental emission, waste Cu scraps were recycled in the form of CuCl powders with high economic value added (EVA) via the facile hydrothermal route. The recycled CuCl powders were characterized in terms of scanning electron microscopy (SEM), energy dispersive X-ray spectroscopy (EDX) and X-ray diffraction (XRD). The results suggested that the recycled CuCl powders consisted of many regular tetrahedron-like micro-particles. Furthermore, in order to reduce the cost of lithium ion battery (LIB) anode and build the connection of waste Cu scraps and LIB, the recycled CuCl powders were evaluated as the anode active material of LIB. As expected, the reversible discharge capacity was about 171.8 mAh/g at 2.0 C even after 50 cycles, implying the satisfactory cycle stability. Clearly, the satisfactory results may open a new avenue to develop the circular economy and the sustainable energy industry, which would be very important in terms of both the resource recovery and the environmental protection.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2021

Lamination of transparent conductive adhesives for tandem solar cell applications

A transparent conductive adhesive (TCA) interlayer for mechanically stacked multijunction solar cells provides adhesive strength and electrical connection between sub-cells when stacked. The fabrication of TCA sheets from an ethyl-vinyl acetate (EVA) matrix and silver coated compliant conductive microspheres, similar to industry-standard EVA encapsulant sheets, compatible with a standard lamination process was developed. Blade coating TCA sheets using 3D printed blades and testing of vertical conduction through the interlayer with a TCA conductivity jig allowed for reproducible measurements and low-cost fabrication. The supplemental information provides design files to enable other researchers to produce their own blades and testing jigs. We identified 0.5 mm as an optimal blade height for producing lab-scale TCA sheets and 120 °C at 3 psi for 10 min as the optimal vacuum lamination process to minimize resistance and possible damage to samples. For TCA sheets with coverages between 0.75% and 9%, the series resistance was approximately 0.2 O cm2 which should result in minimal losses for one-sun photovoltaic applications.

14 SOLAR ENERGY↗
DOE OSTI2020

Damp Heat Induced Degradation of Silicon Heterojunction Solar Cells With Cu-Plated Contacts

Damp heat exposure is one of the most stringent environments for testing the durability of solar cells in packaged modules. Damp heat stresses and induces a variety of degradation modes in solar cells and modules: for example, moisture-induced corrosion of electrodes and interconnections, deterioration of polymeric materials, and/or thermally activated diffusion processes. To screen for these and other potential degradation modes, we subject one-cell modules containing silicon heterojunction (SHJ) solar cells with Cu-plated contacts to extended damp heat tests at 85 °C/85% relative humidity. SHJ cells were laminated with two common encapsulants: ethylene vinyl acetate (EVA) and polyolefin elastomer (POE), and two constructions: glass-backsheet and glass-glass. We observe degradation in all components of solar cell maximum power (PMP): current, voltage, and fill factor, and find evidence of increased carrier recombination and nonideal diode behavior with increasing stress. For glass-backsheet constructions, EVA samples generally degrade more than POE by a factor of approximately 1.5x PMP, and the different encapsulants produce different degradation patterns. Similar trends are observed in glass-glass modules, but to a lesser degree. In a different experiment, we observe a decrease in effective minority carrier lifetime of nonmetallized SHJ precursors measured after damp heat. This implies that some degradation unrelated to the contacts is to be expected and confirms the observation of increasing recombination.

14 SOLAR ENERGY↗
DOE OSTI2016

Degradation in PV Encapsulant Strength of Attachment: An Interlaboratory Study Towards a Climate-Specific Test

Reduced strength of attachment of the encapsulant resulting from the outdoor environment, including ultraviolet (UV) radiation, may decrease photovoltaic (PV) module lifetime by enabling widespread corrosion of internal components. To date, few studies exist showing how the adhesion of PV components varies with environmental stress. We have conducted an interlaboratory experiment to provide an understanding that will be used to develop climatic specific module tests. Factors examined in the study included the UV light source (lamp type), temperature, and humidity to be proposed for use in accelerated aging tests. A poly (ethylene-co-vinyl acetate) (EVA) formulation often used in veteran PV installations was studied using a compressive shear test - to quantify the strength of attachment at the EVA/glass interface. Replicate laminated glass/polymer/glass coupon specimens were weathered at 12 institutions using a variety of indoor chambers or field aging. Shear strength, shear strain, and toughness were measured using a mechanical load-frame for the compressive shear test, with subsequent optical imaging and electron microscopy of the separated surfaces.

14 SOLAR ENERGY↗