THERMOPHOTOVOLTAIC SYSTEM
20250311449 ยท 2025-10-02
Inventors
Cpc classification
H10F10/17
ELECTRICITY
H10F77/703
ELECTRICITY
International classification
H10F10/17
ELECTRICITY
H10F77/42
ELECTRICITY
Abstract
A thermophotovoltaic device comprises an emitter for emitting photons towards a receiver. The thermophotovoltaic device also comprises an intermediate layer comprising a thermal insulating material with a low thermal conductivity of at most 1.4 W/m-K. The intermediate layer is positioned between the emitter and the receiver. The receiver comprising a photovoltaic cell configured to convert at least a portion of the photons into electric energy.
Claims
1. A thermophotovoltaic device comprising: an emitter for emitting photons towards a receiver; an intermediate layer comprising a thermal insulating material with a low thermal conductivity of at most 1.4 W/m-K, the intermediate layer positioned between the emitter and the receiver; and the receiver comprising a photovoltaic cell configured to convert at least a portion of the photons into electric energy.
2. The thermophotovoltaic device of claim 1, wherein the intermediate layer further comprises a reflective index of at least 1.4.
3. The thermophotovoltaic device of claim 2, wherein the intermediate layer comprises a substantially infrared and visible spectrum-transparent material.
4. The thermophotovoltaic device of claim 3, wherein the intermediate layer comprises glass.
5. The thermophotovoltaic device of claim 1, wherein a receiver interface between the intermediate layer and the receiver comprises optical epoxy.
6. The thermophotovoltaic device of claim 1, wherein a receiver interface between the intermediate layer and the receiver comprises a first nano-pattern fabricated on a surface of the receiver and a second interconnecting nano-pattern on a surface of the intermediate layer.
7. The thermophotovoltaic device of claim 1, wherein an emitter interface between the intermediate layer and the emitter comprises a surface with a nanometer-scale roughness.
8. A method for fabricating a thermophotovoltaic device with a zero-gap intermediate layer comprising: positioning an emitter for emitting photons towards a receiver; coupling an intermediate layer between the emitter and the receiver, the intermediate layer comprising a thermal insulating material with a thermal conductivity of at most 1.4 W/m-K; and positioning the receiver comprising a photovoltaic cell configured to convert at least a portion of the photons into electric energy.
9. The method of claim 8, wherein the intermediate layer further comprises a reflective index of at least 1.4.
10. The method of claim 9, wherein the intermediate layer comprises a substantially infrared and visible spectrum-transparent material.
11. The method of claim 10, wherein the intermediate layer comprises glass.
12. The method of claim 8, wherein coupling the intermediate layer between the emitter and the receiver comprises applying an optical epoxy to an interface between the intermediate layer and the receiver.
13. The method of claim 8, wherein coupling the intermediate layer between the emitter and the receiver comprises: fabricating a first nano-pattern on a surface of the receiver, and fabricating a second interconnecting nano-pattern on a surface of the intermediate layer.
14. The method of claim 8, wherein an emitter interface between the intermediate layer and the emitter comprises a surface with a nanometer-scale roughness.
15. The method of claim 14, further comprising applying a pressure between the intermediate layer and the surface of the emitter.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] In order to describe the manner in which the above-recited and other advantages and features can be obtained, a more particular description of the subject matter briefly described above will be rendered by reference to specific embodiments which are illustrated in the appended drawings. Understanding that these drawings depict only typical embodiments and are not therefore to be considered to be limiting in scope, embodiments will be described and explained with additional specificity and detail through the use of the accompanying drawings described below.
[0009]
[0010]
[0011]
[0012]
[0013]
[0014]
[0015]
[0016]
DETAILED DESCRIPTION
[0017] Zero-gap Thermophotovoltaics (zero-gap TPV), can address the long-standing challenges in waste heat harvesting by employing a fundamentally different physical principle from the existing technologies. Using zero-gap TPV disclosed embodiments eliminate the need of a vacuum or air gap in traditional gap-based TPVs, which is an obstacle that impedes the proliferation of TPVs and limited the large-scale cost-effective manufacturing. In at least one embodiment, an infrared-transparent intermediate layer is inserted between the thermal emitter and PV receiver as a functional component in the zero-gap TPVs.
[0018]
[0019] In at least one embodiment, the intermediate layer 120 may comprise a thermal insulating material with a low thermal conductivity of at most 1.4 W/m-K, the intermediate layer 120 positioned between the emitter and the receiver. Additionally or alternatively, the intermediate layer 120 further comprises a reflective index of at least 1.4. The intermediate layer 120 may comprise a substantially infrared and visible spectrum-transparent material. For example, the intermediate layer 120 comprises glass.
[0020] In at least one embodiment, the intermediate layer 120 comprises a transparency to the wavelength range of 0.5-2.5 m. Additionally or alternatively, the intermediate layer 120 comprises ability to withstand high temperatures (>1000 degree Celsius). Further, the intermediate layer 120 may comprise a low thermal conductivity (as low as possible, for example glass has 1.4 W/m.Math.K of thermal conductivity). The intermediate layer 120 may also comprise a high refractive index (as high as possible, glass is 1.5, GaAs is 3.3). Example materials for the intermediate layer 120 may comprise glass, GaAS, Si, InP, CdTe, CdS, or some other similar material. High-K propagating waves 122 and low-K propagating waves 124 may travel through the intermediate layer 120.
[0021] This new multilayer structure, serving as an effective IR waveguide, supports a much higher energy conversion efficiency and stable high-power generation. By replacing the vacuum or air gap with a solid-state layer, zero-gap TPV module 100 can be fabricated as a whole and easily scaled up without the difficulties of costly hermetic seal and packaging. This can bring down the single module cost significantly, as well as enable large system level installation and integration.
[0022] The intermediate layer 120 inserted between the thermal emitter 110 and PV receiver 130, replacing the vacuum or air gap, serves as a lossless waveguide for frustrated infrared photons. The loss effects, potentially from the material type, geometry, and optical transmission, could significantly affect the energy conversion performance. A zero-gap TPV module 100 is inherently a multi-layer optical structure that functions as a power generator. Interfaces between the layers within the zero-gap TPV determine at least some of the optical properties, and thus the energy conversion efficiency.
[0023] In order to calculate the power generation in a zero-gap TPV module 100, the first step is calculating the thermal radiation that reaches to the receiver 130 from emitter 110. Net radiation between emitter 110 and receiver 130 is obtained by solving Maxwell's equations, and then applying fluctuation-dissipation theorem to them. One of the methods that is useful for solving Maxwell's equations is using dyadic Green's functions. In this regard, because of the existence of several layers, the thermal radiation can be obtained by solving dyadic Green's functions in a multilayered structure by using scattering matrix method. Thus, based on this method, the radiation heat flux between emitter layer, with a temperature of T.sub.e and a thickness of Z.sub.s+1-Z.sub.s, and receiver layer with a temperature of T.sub.r at a location of Z.sub.c in a multilayered structure can be obtained by the following equation:
[0025] In order to predict the power generation in the PV cell, the carrier transport in a P-N junction 132 is modeled by solving the steady-state continuity equation numerically with finite difference method as follows:
[0026] where D.sub.(e,h) is a diffusion coefficient of electrons and holes, n.sub.(e,h) is electron and hole concentration, g.sub. is electron-hole pairs generation rate, and T.sub.(e,h) is lifetime of electron/hole. An is the difference between local carrier concentration (n.sub.(e,h)) and equilibrium carrier concentration (n.sub.(e,h)0). The equilibrium carrier concentration (n.sub.(e,h)0) depends on the intrinsic carrier concentration (n.sub.i) and can be calculated by n.sub.(e,h)0=n.sub.i.sup.2/N.sub.(a,d). The lifetime of electron/hole can be obtained by taking into account the photon recycling of radiative recombination lifetime .sub.PR.sub.RR, non-radiative Auger recombination lifetime .sub.Auger, and non-radiative Shockley-Read-Hall (SRH) recombination lifetime .sub.SRH as follows:
[0027] The electron-hole pairs generation rate (go) can be calculated by using the thermal radiation model as follows:
[0029] In order to solve the equation (2), four boundary conditions are needed. At the top and bottom sides of the PV cell, recombination of electron-hole pairs is happened. Therefore, by considering a recombination velocity in these surfaces, the following equation can be applied for the boundary conditions:
[0030] Moreover, at the top and bottom sides of the depletion region, it is assumed that all the generated electron-hole pairs are swept, so recombination does not happen at these two boundaries. The thickness of depletion region can be obtained by the following equation:
[0031] where, .sub.s represents the static relative permittivity, V.sub.0 represents the equilibrium voltage of the p-n junction that can be calculated by V.sub.0=(k.sub.bT/e)ln(N.sub.aN.sub.d/n.sub.i.sup.2).
[0032] After solving the equation (2) and obtaining the carrier distribution in the PV cell, in order to predict the power generation in the PV cell, first the generated current should be obtained. The generated current generation is a summation of generated currents in the depletion, P and N regions. It is assumed that all the generated electron-hole pairs in the depletion region generate current, so the generated current in the depletion region can be calculated as follows:
[0033] A lot of electron-hole pairs are generated in the P and N regions. However, because of the recombination in these regions, these generated electron-hole pairs can generate current only if they reach to the edges of depletion region. In this regard, the generated currents in P and N region depend on gradient of carrier concentration in the edges of depletion region and can be calculated as follows:
[0034] Thus, the total generated photocurrent is obtained as follows:
[0035] When there is no radiation on the PV cell, there is a current in the P-N junction that is called dark current (J.sub.0) because of applied voltage on the cell. When the photocurrent is generated in the PV cell due to the radiation, the generated photocurrent opposes the dark current. The dark current can be calculated by solving the equation (2) while the source term is zero (g=0). After obtaining the dark current, I-V curve of PV cell is obtained by using J(V.sub.f)=J.sub.phJ.sub.0(V.sub.f) and then the power generation can be calculated.
[0036] The power conversion efficiency of PV cell is defined as the ratio of power generation to the net radiation heat transfer form emitter to PV cell. However, the power conversion efficiency of the TPV system is defined as the ratio of power generation to the total heat transfer form emitter to PV cell which consists of radiation and conduction.
[0037] The optical properties of In.sub.0.18Ga.sub.0.82Sb, GaAs, ZrN, and Au is known to those having skill in the art. The Intrinsic Carrier Concentration of In.sub.0.18Ga.sub.0.82Sb is assumed to be 2.2210.sup.13 cm.sup.3. The electron and hole diffusion coefficients are assumed to be 35.2 cm.sup.2s.sup.1 and 18.3 cm.sup.2s.sup.1 respectively. The surface recombination velocity at the top and bottom of the PV cell is 210.sup.4 and 0 m.Math.s.sup.1. The non-radiative recombination lifetime of electron and hole of In.sub.0.18Ga.sub.0.82Sb are 9.8 ns and 31.1 ns respectively. Moreover, the radiative recombination lifetime of electron and hole of In.sub.0.18Ga.sub.0.82Sb are 13 ns and 1.27 s respectively.
[0038]
[0039]
[0040]
[0041] Moreover, according to
[0042] Furthermore, according to the
[0043]
[0044] Furthermore, by increasing the emitter temperature, the difference between power conversion efficiency of system with different TE module lengths is increased. This can be attributed to the fact that by increasing the emitter temperature, the efficiency of the TPV module 100 is increased significantly, so the gap between efficiency of TPV and TE is increased. Therefore, increasing the length of the TE modules 310 in higher emitter temperature, reduces the power conversion efficiency of the system more and more. Moreover, according to this figure, the power conversion efficiency is increased by increasing the emitter temperature. This can be attributed to the fact that by increasing the emitter temperature, the TPV power conversion efficiency is increased, so it causes the system to have higher efficiency. However, by increasing the emitter temperature, the contribution of side heat generation is decreased. This can be attributed to the fact that by increasing the emitter temperature, the radiation part of the incoming heat is increased. Because the radiation is absorbed by the PV cell, most of the radiation heat flux is absorbed by bottom heat collector 330. Thus, it causes the side heat collector 320 to absorb less part of incoming heat flux from the emitter when the emitter temperature is increased.
[0045] In at least one embodiment, the TPV module 100 comprises several different interfaces between the different layers. For example, an emitter interface 150 (shown in
[0046] Additionally or alternatively, in at least one embodiment, the emitter interface 150 between the intermediate layer 120 and the emitter 110 comprises a surface with nanometer-scale roughness. The emitter 110 and the intermediate layer 120 may then be bonded through a pressure connection where the two components are pressed together along the nanometer-scale roughness surfaces. In at least one embodiment, a pressure of 20 to 60 psi is sufficient for bonding the emitter 110 and the intermediate layer 120.
[0047] Additionally or alternatively, in at least one embodiment the emitter 110 comprises a film that is directly applied to the intermediate layer 120. For example, the film may have adhered to the intermediate layer 120 such that no additional pressure or action is needed to form the desired bond.
[0048] Additionally, in at least one embodiment, the receiver interface 152 between the intermediate layer 120 and the receiver 130 comprises a first nano-pattern fabricated on a surface of the receiver 130 and a second interconnecting nano-pattern on a surface of the intermediate layer 120. The second interconnecting non-pattern may comprise parallel lines that are configured to interconnect with parallel lines in the first nano-pattern. Various other patterns that provide some lateral friction may be utilized.
[0049] The following discussion now refers to a number of methods and method acts that may be performed. Although the method acts may be discussed in a certain order or illustrated in a flow chart as occurring in a particular order, no particular ordering is required unless specifically stated, or required because an act is dependent on another act being completed prior to the act being performed.
[0050]
[0051] Method 500 additionally includes an act 520 of coupling an intermediate layer. Act 510 comprises coupling an intermediate layer 120 between the emitter 110 and the receiver 130. The intermediate layer 120 comprises a thermal insulating material with a thermal conductivity of at most 1.4 W/m-K. For example, the emitter 110 may be coupled to the intermediate layer 120 through nano-scale course surfaces that are pressed together. Further, the intermediate layer 120 may be coupled to the receiver 130 through an optical epoxy.
[0052] Method 500 also includes an act 530 of positioning the receiver 130. Act 530 comprises positioning the receiver 130. The receiver 130 comprises a photovoltaic cell 140 configured to convert at least a portion of the photons into electric energy.
[0053] The present invention may be embodied in other specific forms without departing from its spirit or characteristics. The described embodiments are to be considered in all respects only as illustrative and not restrictive. The scope of the invention is, therefore, indicated by the appended claims rather than by the foregoing description. All changes which come within the meaning and range of equivalency of the claims are to be embraced within their scope.