A New View of Microcrystalline Silicon: The Role of Plasma Processing in Achieving a Dense and Stable Absorber Material for Photovoltaic Applications

To further lower production costs and increase conversion efficiency of thin‐film silicon solar modules, challenges are the deposition of high‐quality microcrystalline silicon (μc‐Si:H) at an increased rate and on textured substrates that guarantee efficient light trapping. A qualitative model that explains how plasma processes act on the properties of μc‐Si:H and on the related solar cell performance is presented, evidencing the growth of two different material phases. The first phase, which gives signature for bulk defect density, can be obtained at high quality over a wide range of plasma process parameters and dominates cell performance on flat substrates. The second phase, which consists of nanoporous 2D regions, typically appears when the material is grown on substrates with inappropriate roughness, and alters or even dominates the electrical performance of the device. The formation of this second material phase is shown to be highly sensitive to deposition conditions and substrate geometry, especially at high deposition rates. This porous material phase is more prone to the incorporation of contaminants present in the plasma during film deposition and is reported to lead to solar cells with instabilities with respect to humidity exposure and post‐deposition oxidation. It is demonstrated how defective zones influence can be mitigated by the choice of suitable plasma processes and silicon sub‐oxide doped layers, for reaching high efficiency stable thin film silicon solar cells.     

Double helical laser beams based on interfering first-order Bessel beams

We demonstrate the generation of a nondiffracting double helical beam using axicons and ±1 vortex phase plates in a common-path interferometric system. Using linear diffraction theory, a simple analytical expression describing beam propagation is shown to agree with both experiments and Fresnel-diffraction-based simulations. Experiments are performed using continuous laser light in addition to ultrafast pulses, demonstrating that the common-path arrangement and the diffraction theory work equally well for both cases.     

Micro and nano cellular amorphous polymers (PMMA, PS) in supercritical CO2 assisted by nanostructured CO2-philic block copolymers - One step foaming process

Microcellular foaming of commodity amorphous polymers, poly(methyl methacrylate) (PMMA), and poly(styrene) (PS) was studied in supercritical CO₂ via a batch one-step process in the presence of block copolymers able to change their foaming behaviour and therefore the porous structures. Triblock (styrene-co-butadiene-co-methylmethacrylate SBM, methylmethacrylate-co-butylacrylate-co-methylmethacrylate MAM) terpolymers were blended to PS or PMMA by extrusion. They showed advantages compared to classical PS-PMMA polymer blends in terms of cell size control and reduction of cell size. Foaming is carried out on bulk injection molded samples which were saturated under high pressures of CO₂ (300 bars) at different temperatures (25° C to 80 °C) and different depressurization rates (pressure drop rates from 150 bar/min to 12 bar/min). Very distinct cellular structures and densities were controlled by varying either the copolymer type or the foaming conditions (T,P). Cell sizes ranged from 0.2 μm to 200 μm, and densities from 0.30 g/cm³ to 1 g/cm³ in the polymers considered. Particularly, when triblock copolymers were able to self organize (nanostructuring) in a polymer matrix, they became phase separated at a nanometer level, presenting nanostructured polymers matrixes. To conclude the study, a possible nanostructuring mechanism is suggested based on the interplay between rubbery and highly CO₂-philic blocks/rigid and less CO₂-philic blocks. It is demonstrated that block copolymer additives are a good pathway towards micro and ultra microcellular supercritical CO₂ foaming of amorphous polymers.     

High‐efficiency microcrystalline silicon single‐junction solar cells

This short communication highlights our latest results towards high‐efficiency microcrystalline silicon single‐junction solar cells. By combining adequate cell design with high‐quality material, a new world record efficiency was achieved for single‐junction microcrystalline silicon solar cell, with a conversion efficiency of 10.69%, independently confirmed at ISE CalLab PV Cells. Such significant conversion efficiency could be achieved with only 1.8 µm of Si. Copyright © 2013 John Wiley & Sons, Ltd.     

Does microstructure matter for statistical nanoindentation techniques?

In their paper, Trtik et al. (2009) identify spurious peaks in the application of statistical nanoindentation technique as a critical obstacle for mechanical phase identification. In this discussion, we show that Trtik et al.’s finding is a consequence of an unrealistic virtual 3-D checkerboard microstructure considered by the authors. These peaks are not a general feature of indentation on multiphase materials, nor can the presence of such peaks be attributed to an intrinsic shortcoming of the grid-indentation technique. We also show that the authors’ assertion of the absence of homogeneous material regions extending beyond 3 μm in cementitious materials is groundless.     

Development of a completely recyclable glass fiber-reinforced epoxy thermoset composite

Stimulated by the growing demand for more sustainable polymer systems, experiments were performed to develop completely recyclable epoxy-based thermoset composite materials involving the separation, recovery, and complete reuse of both components of the composite, the resin and the fibers. In this study, a possibility to design such composites by incorporation of reversible chemistry for dedicated repair and recycling is demonstrated. Relying on Diels–Alder (DA) adducts located on the cross-links between the polymeric chains, uncross-linking the thermoset via the reverse DA reactions becomes possible. The network breaks up at elevated temperatures in shorter segments, which can be solubilized in solvents like acetic acid, butan-1-ol, or toluene. Specific processes for each of these solvents were developed to recover the resin and fibers with virtually unchanged properties. Both components were used in a second manufacturing step to produce recycled composites which display properties comparable with the original composites.     

A classification approach to efficient global optimization in presence of non-computable domains

Gaussian-Process based optimization methods have become very popular in recent years for the global optimization of complex systems with high computational costs. These methods rely on the sequential construction of a statistical surrogate model, using a training set of computed objective function values, which is refined according to a prescribed infilling strategy. However, this sequential optimization procedure can stop prematurely if the objective function cannot be computed at a proposed point. Such a situation can occur when the search space encompasses design points corresponding to an unphysical configuration, an ill-posed problem, or a non-computable problem due to the limitation of numerical solvers. To avoid such a premature stop in the optimization procedure, we propose to use a classification model to learn non-computable areas and to adapt the infilling strategy accordingly. Specifically, the proposed method splits the training set into two subsets composed of computable and non-computable points. A surrogate model for the objective function is built using the training set of computable points, only, whereas a probabilistic classification model is built using the union of the computable and non-computable training sets. The classifier is then incorporated in the surrogate-based optimization procedure to avoid proposing new points in the non-computable domain while improving the classification uncertainty if needed. The method has the advantage to automatically adapt both the surrogate of the objective function and the classifier during the iterative optimization process. Therefore, non-computable areas do not need to be a priori known. The proposed method is applied to several analytical problems presenting different types of difficulty, and to the optimization of a fully nonlinear fluid-structure interaction system. The latter problem concerns the drag minimization of a flexible hydrofoil with cavitation constraints. The efficiency of the proposed method compared favorably to a reference evolutionary algorithm, except for situations where the feasible domain is a small portion of the design space.     

Effects of forearm and palm supports on the upper extremity during computer mouse use

The use of forearm and palm supports has been associated with lower neck and shoulder muscle activity as well as reduced musculoskeletal discomfort during keyboard use, however, few studies have investigated their effect during computer mouse use. Eight men and eight women completed several computer mousing tasks in six arm support conditions: Forearm Support, Flat Palm Support, Raised Palm Support, Forearm + Flat Palm Support, Forearm + Raised Palm Support, and No Support. Concurrently, an infrared three-dimensional motion analysis system measured postures, six-degree-of-freedom force-torque sensors measured applied forces & torques, and surface electromyography measured muscle activity. The use of forearm support compared to the no support condition was significantly associated with less shoulder muscle activity & torque, and the raised palm support was associated with less wrist extension. Forearm supports reduced shoulder flexion torque by 90% compared to no support. The use of either support also resulted in lower applied forces to the mouse pad. Participants reported less musculoskeletal discomfort when using a support. These results provide recommendations for office workstation setup and inform ergonomists of effective ways to reduce musculoskeletal exposures.     

Influence of elastomer distribution on the cryogenic microcracking of carbon fiber/epoxy composites

Carbon fiber/epoxy laminates containing three different types of rubber modifiers, separately and in combination, were developed for testing in a cryogenic environment. Preformed rubber particles, core shell rubber, and solid carboxyl‐functionalized rubber were chosen as additives to a model prepreg matrix to control the placement of the rubber within the resulting laminates. Cryogenic microcracking and mode I and II fracture toughness and interlaminar shear strength experiments were performed. Scanning electron microscopy was used to observe fracture surfaces of the rubber‐modified laminates. Fracture toughness properties were improved while the ILSS decreased because of the presence of these rubber modifiers. It was observed that the presence of these modifiers significantly reduced the microcrack density of the laminates exposed to cryogenic cycling, and in the case of one, even eliminated microcracking entirely. © 2003 Wiley Periodicals, Inc. J Appl Polym Sci 90: 2268–2275, 2003