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- All Subjects: solar
- Creators: Chemical Engineering Program
- Creators: Bowden, Stuart
- Resource Type: Text
Prior literature on Cu-contact reliability tended to focus on accelerated testing at the cell and wafer level that may not be entirely replicative of real-world environmental stresses in PV modules. This thesis is aimed at advancing the understanding of Cu-contact reliability from the perspective of quasi-commercial modules under more realistic stresses. In this thesis, c-Si solar cells with Cu-plated contacts are fabricated, made into PV modules, and subjected to environmental stress in an attempt to induce hypothesized failure modes and understand any new vulnerabilities that Cu contacts might introduce. In particular, damp heat stress is applied to conventional, p-type c-Si modules and high efficiency, n-type c-Si heterojunction modules. I present evidence of Cu-induced diode degradation that also depends on PV module materials, as well as degradation unrelated to Cu, and in either case suggest engineering solutions to the observed degradation. In a forensic search for degradation mechanisms, I present novel evidence of Cu outdiffusion from contact layers and encapsulant-driven contact corrosion as potential key factors. Finally, outdoor exposures to light uncover peculiarities in Cu-plated samples, but do not point to especially serious vulnerabilities.
The goal of this research was to identify why the federal government should invest in solar research and development, and which areas of solar improvement should be focused on. Motivation for this can be found in the pressing need to prevent and reverse the effects of climate change, the inevitability of fossil fuel resources eventually running out, and the economic and job creation potential which solar energy holds. Additionally, it is important to note that the best course of action will involve a split of funding between current solar rollout and energy grid updating, and the R&D listed in this research. Upon examination, it can be seen that an energy revolution, led by a federal solar jobs program and a Green New Deal, would be both an ethically and economically beneficial solution. A transition from existing fossil fuel infrastructure to renewable, solar-powered infrastructure would not only be possible but highly beneficial in many aspects, including massive job creation, a more affordable, renewable energy solution to replace coal-fired plants, and no fuel spending or negotiation required.<br/>When examining which areas of solar improvement to focus on for R&D funding, four primary areas were identified, with solutions presented for each. These areas for improvement are EM capture, EM conversion efficiency, energy storage capacity, and the prevention of overheating. For each of these areas of improvement, affordable solutions that would greatly improve the efficiency and viability of solar as a primary energy source were identified. The most notable area that should be examined is solar storage, which would allow solar PV panels to overcome their greatest real and perceived obstacle, which is the inconsistent power generation. Solar storage is easily attainable, and with enough storage capacity, excess solar energy which would otherwise be wasted during the day can be stored and used during the night or cloudy weather as necessary. Furthermore, the implementation of highly innovative solutions, such as agrivoltaics, would allow for a solar revolution to occur.