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At least 145 records · Page 8
All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Scalable Manufacturing of Efficient Perovskite/Silicon Tandem Modules

Crystalline-Si (c-Si) technology produces excellent solar cells with conversion efficiencies of up to 26.7%—nearly their practical limit of 27%—and has been commercialized extensively to produce panels below $\$0.40$/W. Techno-economic analysis shows that module efficiency will continue to be a primary cost driver because of high balance-ofsystems costs, and there is no path to higher efficiencies with single-junction silicon cells. In this project, three research teams from University of North Carolina, Arizona State University and National Renewable National Laboratory worked together to develop perovskite-silicon tandem cells with a high throughput process which can handle 5000 wafers per hour, enabled by very low added CAPEX of ~$20k for a doctor-blade coater. This can potentially increase the module efficiency to 30% (with grid) with small increase of cost, which will drive down the cost of silicon modules to be at least 16% cheaper than present silicon PERC modules. We also explored the alternative narrow bandgap perovskites as silicon replacement for all perovskite tandem cells. This project has substantially advanced the progress of solution-process perovskitessilicon tandem solar cells and perovskite-perovskite tandem solar cells with many inventions and discoveries, evidenced by 18 publications and 6 invention disclosures. Several notable examples include 1) we developed the new idea of small pyramid in combination with solution grown perovskites and demonstrated record-efficiency of 28.5% for 1 cm2 on textured silicon bottom cells and 25.2% for 24 cm2 on chemically etched silicon bottom cells for perovskite-silicon tandem cells. 2) We developed perovskite ink that can coat perovskites onto texture silicon without voids;, and new device structure to enhance the yield of fabrication by reducing shunting 3) We identified the origin of open circuit voltage on mixed halide wide bandgap perovskites, and came with a solution for this problem, reducing the voltage loss to a record small value, which can potentially push the perovskite-silicon tandem cell efficiency to over 31%; 4) We have developed efficient alternative low bandgap semiconductors, i.e. gradient-doped Sn based perovskites by Ba ions, new oxide hole transport layers which increase the efficiency of perovskite/perovskite tandem cells reached record efficiency of 26.3%; 5) We developed bifacial perovskite/perovskite tandem cells by overcoming contacts issues and regaining light absorption, further boosting the equivalent efficiency to 29.3% under 1 sun illumination with 30% albedo light; 6) We developed the first all perovskite tandem module fabricated in air by discovery a combination of oxidization and reduction couples, yield an aperture efficiency of 21.6% for all perovskite mininodules, exceeding that of single junction perovskite minimodules. These discoveries not only accelerate the commercialization of perovskite-silicon tandem solar cells, but also provide guidance in designing other type of perovskite solar cell technologies.

14 SOLAR ENERGY↗
DOE OSTI2014

Comparison of two data acquisition and processing systems of Moller polarimeter in Hall A of Jefferson Lab

Two data acquisition and processing systems are used simultaneously to measure electron beam polarization by Moller polarimeter in Hall A of Jefferson Lab (Newport News, VA, USA). The old system (since 1997) is fully functional, but is not repairable in case of malfunction (system modules arenot manufactured anymore). The new system (since 2010) based on flash-ADC is more accurate, but currently requires more detailed adjustment and further improvement. Description and specifications of two data acquisition and processing systems have been given. The results of polarization measurements during experiments conducted in Hall A from 2010 to 2012 are compared.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗
DOE OSTI2019

Nishati Prototype 72-Cell Endurance Modules (Test Report)

US Manufacturer Nishati provided three prototype, 72-cell photovoltaic modules to Sandia for characterization under the US Department of Energy Small Business Voucher program. Nishati is developing the Endurance © product to address the stringent requirements associated with PV system installations sited near airports and military bases. These prototype modules are uniquely constructed of a polymeric matrix and an internal honeycomb structural element. Target features of the module design are reduced reflectivity from the front surface and reduced weight. Sandia applied a variety of in-house characterization methods to these modules with the goal of validating performance and identifying any areas for improvement. Reflectance testing revealed extremely low specular reflection, dramatically surpassing the performance of industry standard PV panels. Electrical performance testing validated performance in line with expectations for similar size and power class modules. Complimentary to reflection testing, outdoor angle of incidence testing indicated performance far exceeding expectations for industry standard PV panels. It is possible that the extremely low reflectance properties of these modules will convey an advantage in annual energy production in comparison to industry standard modules. Detailed performance modeling and experimental field validation would be required to verify this possible advantage. During the course of this testing, no obvious deficiencies in this module design were discovered. It is recommended that Nishati and Sandia proceed to the final Task associated with the SBV award. This final task will involve fielding modules at Sandia for reliability and energy production validation.

14 SOLAR ENERGY↗
DOE OSTI2014

A 10-kW SiC Inverter with A Novel Printed Metal Power Module With Integrated Cooling Using Additive Manufacturing

With efforts to reduce the cost, size, and thermal management systems for the power electronics drivetrain in hybrid electric vehicles (HEVs) and plug-in hybrid electric vehicles (PHEVs), wide band gap semiconductors including silicon carbide (SiC) have been identified as possibly being a partial solution. This paper focuses on the development of a 10-kW all SiC inverter using a high power density, integrated printed metal power module with integrated cooling using additive manufacturing techniques. This is the first ever heat sink printed for a power electronics application. About 50% of the inverter was built using additive manufacturing techniques.

Inverter↗
DOE OSTI2015

Design and verification of a novel hollow vibrating module for laser machining

If a vibration module is added on laser machining system, the quality of surface finish and aspect ratio on metals can be significantly enhanced. In this study, a single mobility model of vibrating laser along the path of laser beam was put forward. In order to realize the desired unidirectional motion, a resonance type vibration module with optical lens was designed and manufactured. This cylindrical module was composed of curved-beam flexure elements. The cylindrical coordinate system was established to describe the relationship of a curved-beam flexure element’s motion and deformation. In addition, the stiffness matrix of the curved-beam element was obtained. Finite element method and dynamical modeling were provided to analyze the resonance frequency and the displacement of the motion. The feasibility of the design was demonstrated with the help of experiments on frequency response. Experimental results show good agreement with theoretical analysis and simulation predictions.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2011

Final Design And Manufacturing of the PEP II High Energy Ring Arc Bellows Module

A novel RF shield bellows module developed at SLAC has been successfully manufactured and installed in the PEP-II High Energy Ring (HER). Tests indicate that the module meets its performance and operational requirements. The primary function of the bellows module is to allow for thermal expansion of the chambers and for lateral, longitudinal and angular offsets due to tolerances and alignment, while providing RF continuity between adjoining chambers. An update on the Arc bellows module for the PEP-II High Energy Ring is presented. Final design, manufacturing issues, material and coating selection, and tribological and RF testing are discussed. Performance and operational requirements are also reviewed. The RF shield design has been proven during assembly to allow for large manufacturing tolerances without reducing the mechanical spring force below required values. In addition, the RF shield maintains electrical contact even with large misalignments across the module.

43 PARTICLE ACCELERATORS↗
DOE OSTI2021

BACKFLIP: Identification of Materials and Changes Upon Aging of Emerging Fluoropolymer-Free and Industry-Benchmark PV Backsheets

Extending lifetimes of photovoltaic (PV) modules and decreasing manufacturing and decommissioning costs are motivating research of novel PV module backsheet materials. Backsheet integrity is critical to the safety and performance of a PV module, however, the polymeric materials are often vulnerable to environmental degradation. The long-term durability of emerging polyolefin (PO) materials is being examined to inform regarding the possible replacement of laminated backsheets containing polyethylene terephthalate (PET) cores and fluoropolymer protective inner/outer layers. This study compares traditional PET-based backsheets with novel, co-extruded, and recyclable PO-based backsheets after being subjected to hygrometric and UV photolytic accelerated weathering. A large set of characterization methods will compare physical, chemical, structural, mechanical, and insulating properties of these backsheets and the resulting mini-module (MiMo) PV performances. The study of chemical composition, glass- and phase-transition temperatures, degree of crystallinity, and crystalline structure are described here.

mini-module↗
DOE OSTI2024

The Role of Unit-Cell Topology in Modulating the Compaction Response of Additively Manufactured Cellular Materials using Simulations and Validation Experiments

Additive manufacturing has enabled a transformational ability to create cellular structures (or foams) with tailored topology. Compared to their monolithic polymer counterparts, cellular structures are potentially suitable for systems requiring materials with high specific energy-absorbing capability to provide enhanced damping. In this work, we demonstrate the utility of controlling unit-cell topology with the intent of obtaining a desired stress–strain response and energy density. Using mesoscale simulations that resolve the unit-cell sub-structures, we validate the role of unit-cell topology in selectively activating a buckling mode and thereby modulating the characteristic stress–strain response. Simulations incorporate a linear viscoelastic constitutive model and a hyperelastic model for simulating large deformation of the polymer under both tension and compression. Simulated results for nine different cellular structures are compared with experimental data to gain insights into three different modes of buckling and the corresponding stress–strain response.

36 MATERIALS SCIENCE↗
DOE OSTI2024

The role of unit cell topology in modulating the compaction response of additively manufactured cellular materials using simulations and validation experiments

Additive manufacturing has enabled a transformational ability to create cellular structures (or foams) with tailored topology. Compared to their monolithic polymer counterparts, cellular structures are potentially suitable for systems requiring materials with high specific energy-absorbing capability to provide enhanced damping. In this work, we demonstrate the utility of controlling unit-cell topology with the intent of obtaining a desired stress–strain response and energy density. Using mesoscale simulations that resolve the unit-cell sub-structures, we validate the role of unit-cell topology in selectively activating a buckling mode and thereby modulating the characteristic stress–strain response. Simulations incorporate a linear viscoelastic constitutive model and a hyperelastic model for simulating large deformation of the polymer under both tension and compression. Simulated results for nine different cellular structures are compared with experimental data to gain insights into three different modes of buckling and the corresponding stress–strain response.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Generalized and Mechanistic PV Module Performance Prediction From Computer Vision and Machine Learning on Electroluminescence Images

Electroluminescence (EL) imaging of photovoltiac (PV) modules offers high-speed, high-resolution information about device performance, affording opportunities for greater insight and efficiency in module characterization across manufacturing, research and development, and power plant operations and management. Predicting module electrical properties from EL image features is a critical step toward these applications. In this article, we demonstrate quantification of both generalized and performance mechanism-specific EL image features, using pixel intensity-based and machine learning classification algorithms. From EL image features, we build predictive models for PV module power and series resistance, using time-series current-voltage (I-V) and EL data obtained stepwise on five brands of modules spanning three Si cell types through two accelerated exposures: damp heat (DH) (85°C/85% RH) and thermal cycling (TC) (IEC 61215). Overall, 195 pairs of EL images and I-V characteristics were analyzed, yielding 11700 individual PV cell images. A convolutional neural network was built to classify cells by the severity of busbar corrosion with high accuracy (95%). Generalized power predictive models estimated the maximum power of PV modules from EL images with high confidence and an adjusted-R 2 of 0.88, across all module brands and cell types in extended DH and TC exposures. Mechanistic degradation prediction was demonstrated by quantification of busbar corrosion in EL images of three module brands in DH, and subsequent modeling of series resistance using these mechanism-specific EL image features. For modules exhibiting busbar corrosion, we demonstrated series resistance predictive models with adjusted-R 2 of up to 0.73.

14 SOLAR ENERGY↗
DOE OSTI2016

On the Path to SunShot - Emerging Opportunities and Challenges in U.S. Solar Manufacturing

Innovation-driven cost and performance improvements, along with strong projected solar demand in the United States and across the Americas, could increase the attractiveness of U.S.-based solar manufacturing (see Chung et al. 2016). Although improvements to standard PV modules have produced deep cost reductions over the past 5 years, the returns on such incremental improvements appear to be diminishing, and more dramatic innovations in module design and manufacturing are required to continue along the path of rapid progress. At the same time, major opportunities exist for innovation to unlock the potential of CSP technologies. This need for innovation could benefit U.S. PV and CSP manufacturers. The United States has been rated one of the world’s most competitive and innovative countries as well as one of the best locations for PV manufacturing. It is a global leader in PV and CSP R&D and patent production, and U.S. PV manufacturers are already pursuing highly differentiated innovations.

14 SOLAR ENERGY↗
DOE OSTI2011

Grid-Competitive Residential and Commercial Fully Automated PV Systems Technology: Final technical Report, August 2011

Under DOE's Technology Pathway Partnership program, SunPower Corporation developed turn-key, high-efficiency residential and commercial systems that are cost effective. Key program objectives include a reduction in LCOE values to 9-12 cents/kWh and 13-18 cents/kWh respectively for the commercial and residential markets. Target LCOE values for the commercial ground, commercial roof, and residential markets are 10, 11, and 13 cents/kWh. For this effort, SunPower collaborated with a variety of suppliers and partners to complete the tasks below. Subcontractors included: Solaicx, SiGen, Ribbon Technology, Dow Corning, Xantrex, Tigo Energy, and Solar Bridge. SunPower's TPP addressed nearly the complete PV value chain: from ingot growth through system deployment. Throughout the award period of performance, SunPower has made progress toward achieving these reduced costs through the development of 20%+ efficient modules, increased cell efficiency through the understanding of loss mechanisms and improved manufacturing technologies, novel module development, automated design tools and techniques, and reduced system development and installation time. Based on an LCOE assessment using NREL's Solar Advisor Model, SunPower achieved the 2010 target range, as well as progress toward 2015 targets.

14 SOLAR ENERGY↗
DOE OSTI2022

Overall Performance Losses and Activated Mechanisms in Double Glass and Glass-backsheet Photovoltaic Modules with Monofacial and Bifacial PERC Cells, under Accelerated Exposures

Commercial PV modules have various packaging choices nowadays, which influence their long-term reliability. This study compared the degradation behaviors of sixteen module variants from two brands with varying encapsulant materials (EVA or POE), encapsulant types, module architectures (GB or DG), and cell types (monofacial or bifacial) using null hypothesis testing to determine statistical significant findings. The modules were exposed for 2,520 hours under two accelerated exposures: modified damp heat (mDH) and modified damp heat with full-spectrum light (mDH+FSL). For both brands, two DG module variants with UV-Cutoff rear encapsulant are found to have significantly lower average power loss than the module variants of EVA+GB with opaque rear encapsulant after each accelerated exposure. Metallization interconnect corrosion is identified as the primary degradation mechanism. Furthermore, unsupervised hierarchical clustering finds that the degradation behaviors of modules from one brand with a more strict manufacturing quality control depends on module architectures only.

14 SOLAR ENERGY↗
DOE OSTI2017

A Manufacturing Cost and Supply Chain Analysis of SiC Power Electronics Applicable to Medium-Voltage Motor Drives

Wide bandgap (WBG) semiconductor devices are increasingly being considered for use in certain power electronics applications, where they can improve efficiency, performance, footprint, and, potentially, total system cost compared to systems using traditional silicon (Si) devices. Silicon carbide (SiC) devices in particular -- which are currently more mature than other WBG devices -- are poised for growth in the coming years. Today, the manufacturing of SiC wafers is concentrated in the United States, and chip production is split roughly equally between the United States, Japan, and Europe. Established contract manufacturers located throughout Asia typically carry out manufacturing of WBG power modules. We seek to understand how global manufacturing of SiC components may evolve over time by illustrating the regional cost drivers along the supply chain and providing an overview of other factors that influence where manufacturing is sited. We conduct this analysis for a particular case study where SiC devices are used in a medium-voltage motor drive.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2018

SiC Power Electronics in Medium Voltage Motor Drives: Trade and Manufacturing Analysis

Wide bandgap (WBG) semiconductor devices are increasingly being considered for use in certain power electronics applications, where they can improve efficiency, performance, footprint, and, potentially, total system cost compared to systems using traditional silicon (Si) devices. Silicon carbide (SiC) devices in particular -- which are currently more mature than other WBG devices -- are poised for growth in the coming years. Today, the manufacturing of SiC wafers is concentrated in the United States, and chip production is split roughly equally between the United States, Japan, and Europe. Established contract manufacturers located throughout Asia typically carry out manufacturing of WBG power modules. We seek to understand how global manufacturing of SiC components may evolve over time by illustrating the regional cost drivers along the supply chain and providing an overview of other factors that influence where manufacturing is sited. We conduct this analysis for a particular case study where SiC devices are used in a medium-voltage motor drive.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗