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The project involves development of an extremely rugged and reliable DC-AC inverter/system that is compatible with utility interconnections and the full range of energy sources. The project incorporates packaging methodologies, interconnecting devices, and thermal management already used in space and weapons applications at Sandia National Laboratories, but not yet brought to the commercial market. Additionally, the automotive and telecommunications markets are using proven technologies that should be applied to this AC PV building block. Key Technical Challenges The success of the project relies on: I. Mass production of quality products using the latest technology J. All of the elements coming together into a rugged, reliable, and proven package. The development of this concept is based on mass production of consumer products, just as in the cellular telephone, personal computer, and automotive industries. Technology Approaches and Tasks Task 5, AC Building Block: Near-term work will include a first-year feasibility development for a system to demonstrate elements of power density, packaging, and preliminary thermal management. It will be pursued with key knowledgeable and experienced manufacturers through competitive, contracting and will be collaborative with key organizations at Sandia National Laboratories to tap technologies developed for space and weapons components for the commercial PV industry; specifically, provide proof of concept related to the microinverter, its power density, calculated mean-time-to-failure, and layout with a first-design prototype package. Additionally, the first year will focus on providing a report on materials study, lamination methods, and thermal management for the power bar. 4.4.2.2.2 Photovoltaic/Thermal Hybrid Status: Today, separate collector technologies (PV modules and flat-plate solar-thermal collectors) are used to produce electricity and thermal energy. With increased interest in zero- energy buildings, it is becoming more common for PV and thermal collectors to be installed on the same building, side-by-side on the roof. Because PV modules typically convert only 5% to 15% of the incident solar radiation to electricity, an obvious question is whether a combined PV/thermal collector would make sense. Potential advantages of PV/thermal collectors include: (1) cost savings due to dual use of components and labor, (2) reduced roof-space requirements, (3) fewer roof penetrations, and (4) integrated appearance. With lower-cost PV cells in the future, it becomes increasingly important to reduce the cost of other components in the PV module/array (e.g., superstrate/substrate, frame, mounting hardware, installation labor), and the beneficial impact of cost-sharing dual use in a PV/thermal collector increasing market. Beyond cost, there are practical advantages and the market appeal (to architects, sellers, installers, and consumers) of a single product that provides both electricity and thermal energy for applications such as zero-energy buildings. Challenges: Significant technical challenges must be overcome to develop practical PV/thermal collectors. Currently, few or no PV/thermal products are commercially available despite R&D efforts (some of which simply combined existing PV and solar-thermal collector designs). Potential problems include: K. Reduced PV efficiency due to elevated temperatures and optical losses L. Energy, temperature, and seasonality matching of PV waste heat with thermal end-uses Solar Energy Technologies Program Multi-Year Technical Plan 129PDF Image | Solar Energy Technologies Program
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