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3.2 Aluminized Mirrors Aluminized reflectors use a polished aluminum substrate, enhanced aluminum reflective layer, and a protective oxidized topcoat. The major concern has been poor durability of such materials in urban and industrialized (polluted) locations. An improved anodized aluminum mirror incorporated a protective polymeric overcoat onto aluminized aluminum. However, specularity degraded with outdoor exposure at Arizona, Florida, and NREL, and with accelerated exposure in the WOM. Recently, Alanod stopped selling this material for outdoor use because of problems associated with the delamination of the overcoat. The company is working to find a solution and to improve the abrasion resistance of the reflector. 3.3 Silvered Polymer Reflectors A polymeric solar reflector was developed through collaborative research with ReflecTech. In FY 2001, a small pilot run demonstrated that production could be achieved using standard commercial film converter equipment. This initial pilot-run material shows no significant loss in solar-weighted reflectance after 2.5 years of real- time outdoor exposure in Golden, CO. In addition, samples exposed in accelerated outdoor weathering tests (natural sunlight in Phoenix, AZ, concentrated 7 to 8 times with a Fresnel-reflector while samples are cooled with a fan to near ambient conditions and sprayed with deionized water 8 min per natural sun hour) are near a 10- year equivalent time period, and show no significant loss in solar-weighted reflectance. However, WOM results showed significant reflectance loss earlier than anticipated. Prototype materials to test modifications to the baseline construction were produced. These tests were successful in identifying changes to the baseline construction that dramatically improved the WOM durability of the reflective film. These improvements were then incorporated into a new pilot plant production run delivered late FY 2004; durability testing is ongoing and the material is being deployed. We expect the new reflector to considerably outperform the original material (which has maintained durability after 10 equivalent years of accelerated outdoor exposure), however testing has only recently been initiated, and further real time exposure will be needed to determine its actual lifetime. 3.4 Advanced Solar Reflective Mirror (ASRM) The ASRM developed under a subcontract with SAIC that ended 9/04, has a silvered specular substrate protected by an alumina coating several microns thick. The alumina hard coat is deposited by ion-beam-assisted deposition (IBAD). Samples of this “super thin glass technology” have been deposited at 20 nm/s both by batch and on a laboratory roll-coater. Many samples prepared have maintained 95% hemispherical reflectance after more than 3 years accelerated and outdoor exposure; testing is continuing. A new cost analysis shows the ASRM has the potential for a manufacturing cost lower than $10.76/m2, but the deposition rate must be increased to 30–50 nm/s. Although thin oxide coatings are routinely deposited at deposition rates greater than 100 nm/s, increasing the deposition rate while maintaining the optimized IBAD deposition conditions could be difficult. For long-term durability, edge protection will be necessary and the addition of adhesion-promoting layer should also improve durability. A short subcontract to evaluate different web materials, adhesion- promotion and anti-soiling layers, and use of a lower-purity alumina is warranted. To increase the deposition rate, the ASRM will need to be transitioned to a commercial roll-coating company (with SAIC’s consultation). However, NREL will need to establish this relationship. While positive progress has been made to develop an advanced solar reflector, work has been severely limited due to a lack of funding during the last few years. NREL remains the world leader in the research on the durability development of advanced solar reflectors but research has been limited to durability testing of reflectors supplied by industry, which is ongoing. The glass mirrors, ReflecTech, and ASRM may meet the 10-year lifetime goals based on accelerated exposure testing. However, predicting an outdoor lifetime based on accelerated exposure testing is risky. At this time, because all solar reflectors have recently changed their production considerably, none of the solar reflectors available have been in test long enough to demonstrate the 10- to 30-year lifetime goal, outdoors in real time.PDF Image | FY 2004 ANNUAL REPORT DOE Solar
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