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PV Module Reliability R&D Performing Organizations: National Renewable Energy Laboratory Sandia National Laboratories Key Technical Contacts: Roland Hulstrom (NREL, Primary Contact), 303-384-6420, roland_hulstrom@nrel.gov David King (SNL), 505-299-9184, dlking@sandia.gov DOE HQ Technology Manager: Jeffrey Mazer, 202-586-2455, jeffrey.mazer@hq.doe.gov FY 2004 Budgets: $2,544K (NREL), $965K (SNL) _____________________________________________________________________________________ Objectives • Isolate, scientifically understand, and help industry mitigate module failure and/or degradation mechanisms. • Gather and analyze outdoor, long-term, reliability/performance data for all candidate module technologies. • Use advanced indoor and outdoor accelerated exposure stress testing to discover and/or replicate observed outdoor failures and performance degradation. • Develop improved module packaging materials and designs that result in at least 25-year service lifetimes, lower costs, and acceptable long-term performance. • Assist industry with developing and implementing consensus standards and codes for module performance ratings and qualification testing. • Characterize and provide models for PV module performance and reliability for a range of field/application conditions. Accomplishments • Completed accelerated testing program (thermal cycling, UV exposure, humidity-freeze cycling, damp heat, and light-soaking) for several CdTe modules and provided results and conclusions to the manufacturer. • Completed accelerated testing program (thermal cycling, damp heat, and surface cuts) for a group of advanced prototype crystalline silicon modules and provided results and conclusions to the manufacturer. • Continued an intensive effort in support of NREL’s thin-film module hot and humid, long-term outdoor reliability testing program. NREL and SNL provided detailed baseline characterizations of more than 180 modules from 4 manufacturers prior to field deployment at the hot and humid test sites (Florida and Texas). • Completed an advanced indoor module light-soaking apparatus and used it to collect and publish data on a-Si and CdTe modules. Capabilities will be used, in collaboration with industry partners, to improve characterization of module light-soaking behavior. • Evaluated more than 20 module backsheet and encapsulant materials for their moisture barrier and adhesion properties. Several promising packaging material and design candidates were identified, and results were published in a report to industry. • Developed a new mathematical model to project the time-phased ingress of water vapor (moisture) into module backsheet and encapsulant materials, based on laboratory measurements of material diffusivity and solubility. This model can now be used to predict how long a given module packaging design will prevent moisture from reaching the PV material/absorber.PDF Image | FY 2004 ANNUAL REPORT DOE Solar
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