Crystalline-silicon reliability lessons for thin-film modules

The reliability of crystalline silicon modules has been brought to a high level with lifetimes approaching 20 years, and excellent industry credibility and user satisfaction. The transition from crystalline modules to thin film modules is comparable to the transition from discrete transistors to integrated circuits. New cell materials and monolithic structures will require new device processing techniques, but the package function and design will evolve to a lesser extent. Although there will be new encapsulants optimized to take advantage of the mechanical flexibility and low temperature processing features of thin films, the reliability and life degradation stresses and mechanisms will remain mostly unchanged. Key reliability technologies in common between crystalline and thin film modules include hot spot heating, galvanic and electrochemical corrosion, hail impact stresses, glass breakage, mechanical fatigue, photothermal degradation of encapsulants, operating temperature, moisture sorption, circuit design strategies, product safety issues, and the process required to achieve a reliable product from a laboratory prototype

An Algorithm for Synthesizing Mass and Stiffness Matrices from Experimental Vibration Modes

An algorithm is described for synthesizing the mass and stiffness matrices from experimentally derived modal data in a way that preserves the physical significance of the individual mass and stiffness elements. The mass and stiffness matrices are derived for a rollup solar array example, and are then used to define the modal response of a modified array

Long-term stability of amorphous-silicon modules

The Jet Propulsion Laboratory (JPL) program of developing qualification tests necessary for amorphous silicon modules, including appropriate accelerated environmental tests reveal degradation due to illumination. Data were given which showed the results of temperature-controlled field tests and accelerated tests in an environmental chamber

Vacuum oscillations of quasi degenerate solar neutrinos

The atmospheric neutrino oscillations and the vacuum oscillation solution of the solar neutrino problem can be consistently described by a doubly or triply degenerate neutrino spectrum as long as the high level of degeneracy required is not spoiled by radiative corrections. We show that this is the case for neutrino mass matrices generated by symmetries. This imposes a strong constraint on the mixing angles and requires the mixing should be close to bi-maximal. We briefly discuss the relevance of our results for the measurability of the neutrino spectrum.Comment: 6 pages. Final version, more clear presentatio

Interconnect fatigue design for terrestrial photovoltaic modules

The results of comprehensive investigation of interconnect fatigue that has led to the definition of useful reliability-design and life-prediction algorithms are presented. Experimental data indicate that the classical strain-cycle (fatigue) curve for the interconnect material is a good model of mean interconnect fatigue performance, but it fails to account for the broad statistical scatter, which is critical to reliability prediction. To fill this shortcoming the classical fatigue curve is combined with experimental cumulative interconnect failure rate data to yield statistical fatigue curves (having failure probability as a parameter) which enable (1) the prediction of cumulative interconnect failures during the design life of an array field, and (2) the unambiguous--ie., quantitative--interpretation of data from field-service qualification (accelerated thermal cycling) tests. Optimal interconnect cost-reliability design algorithms are derived based on minimizing the cost of energy over the design life of the array field

De-icing of the altitude wind tunnel turning vanes by electro-magnetic impulse

The Altitude Wind Tunnel at the NASA-Lewis facility is being proposed for a refurbishment and moderization. Two major changes are: (1) the increasing of the test section Mach number to 0.90, and (2) the addition of spray nozzles to provide simulation of flight in icing clouds. Features to be retained are the simulation of atmospheric temperature and pressure to 50,000 foot altitude and provision for full-scale aircraft engine operation by the exhausting of the aircraft combustion gases and ingestion of air to replace that used in combustion. The first change required a re-design of the turning vanes in the two corners downstream of the test section due to the higher Mach number at the corners. The second change threatens the operation of the turning vanes by the expected ice build-up, particulary on the first-corner vanes. De-icing by heat has two drawbacks: (1) an extremely large amount of heat is required, and (2) the melted ice would tend to collect as ice on some other surfaces in the tunnel, namely, the tunnel propellers and the cooling coils. An alternate de-icing method had been under development for three years under NASA-Lewis grants to the Wichita State University. This report describes the electro-impulse de-icing (EIDI) method and the testing work done to assess its applicability to wind tunnel turning vane de-icing. Tests were conducted in the structural dynamics laboratory and in the NASA Icing Research Tunnel. Good ice protection was achieved at lower power consumption and at a wide range of tunnel operations conditions. Recommendations for design and construction of the system for this application of the EIDI method are given

Electricity from photovoltaic solar cells: Flat-Plate Solar Array Project final report. Volume VI: Engineering sciences and reliability

The Flat-Plate Solar Array (FSA) Project, funded by the U.S. Government and managed by the Jet Propulsion Laboratory, was formed in 1975 to develop the module/array technology needed to attain widespread terrestrial use of photovoltaics by 1985. To accomplish this, the FSA Project established and managed an Industry, University, and Federal Government Team to perform the needed research and development. This volume of the series of final reports documenting the FSA Project deals with the Project's activities directed at developing the engineering technology base required to achieve modules that meet the functional, safety and reliability requirements of large-scale terrestrial photovoltaic systems applications. These activities included: (1) development of functional, safety, and reliability requirements for such applications; (2) development of the engineering analytical approaches, test techniques, and design solutions required to meet the requirements; (3) synthesis and procurement of candidate designs for test and evaluation; and (4) performance of extensive testing, evaluation, and failure analysis to define design shortfalls and, thus, areas requiring additional research and development. During the life of the FSA Project, these activities were known by and included a variety of evolving organizational titles: Design and Test, Large-Scale Procurements, Engineering, Engineering Sciences, Operations, Module Performance and Failure Analysis, and at the end of the Project, Reliability and Engineering Sciences. This volume provides both a summary of the approach and technical outcome of these activities and provides a complete Bibliography (Appendix A) of the published documentation covering the detailed accomplishments and technologies developed

Research of low cost wind generator rotors

A feasibility program determined that it would be possible to significantly reduce the cost of manufacturing wind generator rotors by making them of cast urethane. Several high modulus urethanes which were structurally tested were developed. A section of rotor was also cast and tested showing the excellent aerodynamic surface which results. A design analysis indicated that a cost reduction of almost ten to one can be achieved with a small weight increase to achieve the same structural integrity as expected of current rotor systems

Design and application of gas-gap heat switches

Gas-gap heat switches can serve as an effective means of thermally disconnecting a standby cryocooler when the primary (operating) cooler is connected and vice versa. The final phase of the development and test of a cryogenic heat switch designed for loads ranging from 2 watts at 8 K, to 100 watts at 80 K are described. Achieved heat-switch on/off conductance ratio ranged from 11,000 at 8 K to 2200 at 80 K. A particularly challenging element of heat-switch design is achieving satisfactory operation when large temperatures differentials exist across the switch. A special series of tests and analyses was conducted and used in this Phase-2 activity to evaluate the developed switches for temperature differentials ranging up to 200 K. Problems encountered at the maximum levels are described and analyzed, and means of avoiding the problems in the future are presented. A comprehensive summary of the overall heat-switch design methodology is also presented with special emphasis on lessons learned over the course of the 4-year development effort