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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 19 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Environmental Benefits of Closing the Solar Manufacturing and Recycling Loop: Preparation of Solar Manufacturing Inventories

The cumulative global solar panel waste stream is projected to reach between 60 and 78 million tonnes by 2050. Steps towards developing, demonstrating, and implementing processes that recover glass, metals, and semiconductor materials from end-of-life solar panels have already been taken. However, these processes result in the downcycling of most secondary solar materials. Critically, the costs and benefits of capturing these secondary materials for use in new solar panels are unknown. To evaluate the environmental benefit associated with solar material recycling and reuse in next generation panels, prior inventories must be updated and prepared for integration with recycling processes to examine the benefit of closing the material loop between solar panel end-of-life and new panel manufacturing. This current work describes steps taken to upgrade existing inventories that detail the manufacturing of cadmium-telluride (CdTe) panels from the Ecoinvent -v2.2 life cycle inventory database to Ecoinvent -v3. During this update, material inventories were modified to capture different realistic material supply chains within the constraints of Ecoinvent -v3. Materials discussed in detail in this work include primary flat glass, aluminum, steel, copper, and CdTe. This work demonstrated that environmental indicators such as embodied carbon, acidification, and terrestrial eutrophication associated with solar panel production can be reduced by 25% to over 40% through improved primary material sourcing.

CdTe solar panels↗
NASA NTRS2010

Solar cell circuit and method for manufacturing solar cells

The invention is a novel manufacturing method for making multi-junction solar cell circuits that addresses current problems associated with such circuits by allowing the formation of integral diodes in the cells and allows for a large number of circuits to readily be placed on a single silicon wafer substrate. The standard Ge wafer used as the base for multi-junction solar cells is replaced with a thinner layer of Ge or a II-V semiconductor material on a silicon/silicon dioxide substrate. This allows high-voltage cells with multiple multi-junction circuits to be manufactured on a single wafer, resulting in less array assembly mass and simplified power management.

Mardesich, Nick↗
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↗
NASA NTRSDate not supplied

Powering the Next Frontier: Manufacturing Solar Cells in Space

In support of NASA's Artemis program with the goal of a sustained human-lunar presence, there is a need for very large (>100kW) and high-voltage-capable solar arrays, estimated to cost over $150M. Perovskite-based thin-film photovoltaics offer substantial advantages over state-of-the-art solar arrays from the perspective of manufacturing large arrays. Many of the challenges perovskite solar cells experience in terrestrial operations, e.g degradation caused by moisture and oxygen exposure, are not applicable in long-term space applications. The future of implementing perovskite photovoltaics in space is promising, further so is manufacturing these solar cells in space. Here we provide an overview of NASA Glenn Research Center's progress towards validating perovskite solar cells for operation in space and we illuminate innovation opportunities to which the greater community can contribute so that we may realize in-space manufacturing of perovskite photovoltaics.

Solar Cells↗
DOE OSTI2016

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

This report provides insights into photovoltaic (PV) and concentrating solar power (CSP) manufacturing in the context of the U.S. Department of Energy's SunShot Initiative. Although global PV price reductions and deployment have been strong recently, PV manufacturing faces challenges. Slowing rates of manufacturing cost reductions, combined with the relatively low price of incumbent electricity generating sources in most large global PV markets, may constrain profit opportunities for firms and poses a potential challenge to the sustainable operation and growth of the global PV manufacturing base. In the United States, manufacturers also face a factors-of-production cost disadvantage compared with competing nations. However, the United States is one of the world's most competitive and innovative countries as well as one of the best locations for PV manufacturing. In conjunction with strong projected PV demand in the United States and across the Americas, these advantages could increase the share of PV technologies produced by U.S. manufacturers as the importance of innovation-driven PV cost reductions increases. Compared with PV, CSP systems are much more complex and require a much larger minimum effective scale, resulting in much higher total CAPEX requirements for system construction, lengthier development cycles, and ultimately higher costs of energy produced. The global lack of consistent CSP project development creates challenges for companies that manufacture specialty CSP components, and the potential lack of a near-term U.S. market could hinder domestic CSP manufacturers. However, global and U.S. CSP deployment is expected to expand beyond 2020, and U.S. CSP manufacturers could benefit from U.S. innovation advantages similar to those associated with PV. Expansion of PV and CSP manufacturing also presents U.S. job-growth opportunities.

14 SOLAR ENERGY↗
NASA NTRS1984

Solar-Cell-Manufacturing System

Cost of manufacturing solar arrays minimized by using polyimide-ribbed substrates together with silver-plated coils of low-expansion nickel/iron ribbon on solar cells. Polyimide taped to ribbon protects cell from abrasion or from sticking to other tooling.

Kelly, F. G.↗
NASA NTRS1980

Solar array manufacturing industry simulation

Solar Array Manufacturing Industry Simulation (SAMIS) program is a standardized model of industry to manufacture silicon solar modules for use in electricity generation. Model is used to develop financial reports that detail requirements, including amounts and prices for materials, labor, facilities, and equipment required by companies.

Chamberlain, R. G.↗
NASA NTRS1977

A review of the solar array manufacturing industry costing standards

The solar array manufacturing industry costing standards model is designed to compare the cost of producing solar arrays using alternative manufacturing processes. Constructive criticism of the methodology used is intended to enhance its implementation as a practical design tool. Three main elements of the procedure include workbook format and presentation, theoretical model validity and standard financial parameters.

Source record↗
NASA NTRS1976

SAMIS - A simulation of the solar array manufacturing industry

SAMIS is a continuing activity of the Project Analysis and Integration Task of the Low-cost Silicon Solar Array Project (LSSA). It provides a standardized procedure for producing reliable estimates of the cost of manufacturing solar arrays or their components. These estimates are based on descriptions of the manufacturing processes which are being studied and developed by LSSA subcontractors and will be used to assess the commercial viability of those processes and to set research priorities.

Chamberlain, R. G.↗
DOE OSTI2022

How Optical and Electrical Properties of ITO Coated Willow Glass Affect Photonic Curing Outcome for Upscaling Perovskite Solar Cell Manufacturing

Indium tin oxide (ITO) coated Willow® glass is an excellent substrate for roll-to-roll manufacturing of perovskite solar cells (PSCs) but can have large variability in its optical and electrical properties. Photonic curing uses intense light pulses instead of heat to process materials and can facilitate faster processing speeds in roll-to-roll manufacturing to upscale the production of PSCs. Since the entire film stack can absorb light and contributes to the photonic curing outcome, the substrate materials’ properties play an integral role. Furthermore, we present the effect of ITO transmittance on the photonic curing of nickel nitrate sol-gel precursors into nickel oxide and consequently the performance of PSCs fabricated with only photonic curing and no thermal annealing. Unexpectedly, ITO samples processed by photonic curing show improved optical and electrical properties.

14 SOLAR ENERGY↗
NASA NTRS1978

Product pricing in the Solar Array Manufacturing Industry - An executive summary of SAMICS

Capabilities, methodology, and a description of input data to the Solar Array Manufacturing Industry Costing Standards (SAMICS) are presented. SAMICS were developed to provide a standardized procedure and data base for comparing manufacturing processes of Low-cost Solar Array (LSA) subcontractors, guide the setting of research priorities, and assess the progress of LSA toward its hundred-fold cost reduction goal. SAMICS can be used to estimate the manufacturing costs and product prices and determine the impact of inflation, taxes, and interest rates, but it is limited by its ignoring the effects of the market supply and demand and an assumption that all factories operate in a production line mode. The SAMICS methodology defines the industry structure, hypothetical supplier companies, and manufacturing processes and maintains a body of standardized data which is used to compute the final product price. The input data includes the product description, the process characteristics, the equipment cost factors, and production data for the preparation of detailed cost estimates. Activities validating that SAMICS produced realistic price estimates and cost breakdowns are described.

Chamberlain, R. G.↗
NASA NTRS1988

Lunar production of space photovoltaic arrays

The advantages of manufacturing solar cells for use in space on the moon rather than on Earth are discussed. It is shown how solar cells manufactured on the moon could significantly reduce the cost of transportation of power systems to space destinations, including the moon, Mars, earth orbit, and transfer orbits. Silicon is abundant on the moon, and refining processes are demonstrated which do not depend on extensive use of reactants imported from Earth. Because of the lower requirements for refined silicon, the amorphous silicon process is preferred, despite lower efficiencies. Calculations show that the specific power of amorphous silicon cells can be adequate for most uses.

Landis, Geoffrey A.↗
DOE OSTI2014

Solion ion source for high-efficiency, high-throughput solar cell manufacturing

In this paper, we introduce the Solion ion source for high-throughput solar cell doping. As the source power is increased to enable higher throughput, negative effects degrade the lifetime of the plasma chamber and the extraction electrodes. In order to improve efficiency, we have explored a wide range of electron energies and determined the conditions which best suit production. To extend the lifetime of the source we have developed an in situ cleaning method using only existing hardware. With these combinations, source life-times of >200 h for phosphorous and >100 h for boron ion beams have been achieved while maintaining 1100 cell-per-hour production.

14 SOLAR ENERGY↗
DOE OSTI2023

Bottom-Up Costs and Market Analysis of the Horizontal Ribbon Growth (HRG) Technology (Final Report)

The American-Made Solar Prize is a prize competition from the U.S. Department of Energy that is designed to revitalize U.S. solar manufacturing. The competition aims to support the growth of U.S. solar manufacturing and reenergize American energy innovation by tapping into American's competitive spirit and the nation's unparalleled innovation ecosystem leveraging national labs, incubators, facilities and more. National Renewable Energy Lab (NREL) will provide technical and business advisement to the noted Solar Prize finalists. This CRADA will involve the development of a cost model of the CRADA Participant's horizontal ribbon growth (HRG) technology for making silicon wafers for solar cells.

14 SOLAR ENERGY↗
NASA NTRS2022

What would it take to manufacture perovskite solar cells in space?

Imagine, astronauts land on the moon. They verify their arrival with mission control, and perform system checks and validations. After the dust settles, they open the airlock of the landing vehicle and venture outside. A side hatch opens, and a flexible substrate slowly unfurls on a boom. A series of printer heads raster, hovering over the substrate and sequentially vapor-depositing the constituent layers of a perovskite solar module (Figure 1). In time, a 1-megawatt array has been manufactured on the moon and can now be connected to supply power to the Artemis Base Camp. This ambitious vision could someday become a reality. On August 29, 2021, a SpaceX Falcon 9 rocket launched a commercial resupply payload from Kennedy Space Center en route to the International Space Station (ISS). On board were perovskite solar cells that will fly for 6 months outside the ISS in low earth orbit (LEO) on the 15th Materials International Space Station Experiment (MISSE-15). This will be the first long duration flight of perovskite solar cell devices in LEO and a major step toward realizing the in-space operation and, potentially, manufacture of perovskite solar cells.

Lyndsey McMillon-Brown↗