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• Research, technical reports, and industry collaborations on packaging formulations designed to eliminate module degradation and failure. • Selected collaborations with manufacturers to help resolve specific issues concerning module performance reliability. ____________________________________________________________________________________ 1. Introduction This joint NREL/SNL project has existed nearly as long as the National PV Program/Subprogram. Over the years, as PV module technologies have been investigated and developed, the PV Subprogram’s module reliability R&D activity has correspondingly changed to address a variety of candidate PV technologies and modules. As advanced, next-generation PV technologies are developed, the module reliability R&D scope and specific activities continue to evolve. The long- term (2020) goal of the DOE Solar Program Multi- Year Technical Plan (MYTP) is to commercialize PV modules having at least 30-year service lifetimes and less than 0.5% annual performance degradation rates, at a target cost (e.g., $1.50/Wp) that is consistent with market-required levelized costs of electricity (e.g., $0.06/kWhrAC). Achieving these module targets is critical to realizing the success of PV technologies and significant levels of deployment. 2. Technical Approach For FY 2005 (and beyond), this project’s technical approach (hence activities) consists of accelerated indoor environmental (e.g., temperature, humidity, high-voltage, ultraviolet radiation, and solar flux) stress testing of candidate module technologies; accelerated outdoor stress testing (e.g., high solar fluxes, module high-voltage environments); and long-term outdoor environmental analyses, characterization, modeling, failure/degradation analyses, and module packaging R&D to help mitigate failures/degradation and/or reduce module costs and improve performance. To conduct these activities, NREL and SNL develop and apply advanced measurement techniques, diagnostic methods, and instrumentation. A key aspect of the overall approach is close interaction and collaboration with PV module manufacturers. The intent is to optimize the time and funding applied to advancing module technologies from the prototype to the commercial production stage, with respect to meeting acceptable performance, reliability, and costing requirements. The three tasks comprising this project are: Task Title Exploratory Reliability & Performance R&D Module Packaging Research & Reliability Module Reliability Characterization 3. Results and Accomplishments FY 2005 Budget ($K) 1,092 1,102 701 61 For the three tasks, major results and accomplishments are as follows. 3.1 Exploratory Reliability and Performance R&D • • • • • • Assisted a major U.S. thin-film manufacturer with diagnosing a degradation problem that developed in the product line, pinpointing the cause, and recommending a solution. Completed a journal article that documents the implications of using fixed resistive loads for long-term PV module exposure testing; showed that identical degradation rates can be observed with resistive loads compared with maximum-power tracking loads, provided the resistance values are chosen correctly (helped to fulfill a milestone 01/05). Performed thermal cycling on a prototype CIGS thin-film roofing shingle product for a manufacturer, providing testing to a small manufacturer that would otherwise not be available. Initiated a cooperative testing program on SunPower’s high-efficiency crystalline-Si modules including light soaking, thermal cycling, and damp heat exposure indoors, and real-time outdoor exposure geared toward helping SunPower improve fabrication of its solar cells. Performed indoor stress testing of SBM Solar’s prototype crystalline silicon modules, including damp heat, thermal cycling, UV exposure, humidity-freeze, and standard module surface cut tests, helping to advance the company toward full qualification and eventually production. Assisted subcontractors in the hot and humid exposure project of the Thin-Film PV Partnership by making site visits and providing Photovoltaic R&D Advanced Materials and DevicesPDF Image | DOE Solar Energy Technologies Program
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