Black Body Infrared Antenna Array Using Carbon Nanotubes
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Solution Overview
Problem
Current manufacturing processes for long wave infrared rectifying antenna arrays are expensive due to the need for small dimensions, which are typically achieved through costly masking technologies, and existing solar cell processes have limited efficiency compared to rectenna structures.
Innovation Solution
The use of self-aligning process steps and molds made with current IC masking techniques to create carbon nanotube ¼ wavelength antennas connected across V-shaped spaces between power and ground rails, with metal-oxide-carbon or point contact diodes, and a high-gain low-e glass cover to optimize infrared energy conversion, along with a thermal emitter plate to convert visible light into black body radiation for enhanced energy capture.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If small dimensions are used for infrared rectenna antennas to achieve high conversion efficiency, then energy conversion efficiency is improved, but manufacturing cost increases due to expensive masking technologies
Solution Approach 1:
The patent divides the antenna array into modular units with standardized small-dimension elements. By segmenting the overall structure into repeatable modules, the complex small-dimension fabrication is localized to individual units that can be manufactured separately and assembled, reducing overall manufacturing complexity and cost while maintaining the high efficiency benefits of small antenna dimensions.
Solution Approach 2:
The patent employs self-aligning process steps where structural features automatically position critical components during fabrication. This self-service mechanism eliminates the need for expensive precision masking technologies, allowing small-dimension antennas to be manufactured using standard, cost-effective processes while maintaining the dimensional precision required for high conversion efficiency.
2Reliability
If carbon nanotube antennas are used to achieve metallic-like electrical and thermal properties, then electrical conductivity is improved, but manufacturing complexity increases
Solution Approach 1:
The patent uses carbon nanotubes as intermediary materials that bridge the gap between standard semiconductor fabrication processes and the need for metallic-like conductivity. The nanotubes serve as a mediator that can be integrated into existing fabrication workflows while providing the superior electrical and thermal properties needed for high-performance rectenna operation, thus improving conductivity without proportionally increasing manufacturing complexity.
Solution Approach 2:
The patent controls the density, orientation, and arrangement of carbon nanotubes to optimize their collective electrical and thermal properties. By adjusting these parameters during fabrication, the material achieves metallic-like conductivity while maintaining compatibility with standard manufacturing processes, balancing performance requirements with manufacturing feasibility.
3Productivity
If continuous carbon nanotube growth is used to improve manufacturability, then production efficiency is improved, but control over antenna dimensions and alignment becomes more difficult
Solution Approach 1:
The patent prepares structured substrates with pre-defined patterns, catalyst positions, and geometric constraints before initiating continuous carbon nanotube growth. This preliminary action establishes the framework that guides the continuous growth process, ensuring that nanotubes develop with controlled dimensions and precise alignment while maintaining the high production efficiency benefits of continuous growth methods.
Solution Approach 2:
The patent replaces traditional mechanical positioning and alignment methods with field-based control mechanisms during nanotube growth. By using electromagnetic fields, chemical gradients, or other non-mechanical influences to guide nanotube development, the system achieves precise dimensional control and alignment without the complexity of mechanical positioning systems, maintaining both production efficiency and manufacturing precision.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach allows for efficient conversion of long wavelength infrared into electricity with reduced manufacturing costs and improved efficiency by utilizing existing semiconductor fabrication capabilities, while minimizing heat loss and maximizing electrical energy production.
Implementation Method 1
carbon nanotube ¼ wavelength antennas connected across V-shaped spaces between power and ground rails by direct metal connections or by metal-oxide-carbon (MoC) diodes or by point contact diodes
Implementation Method 2
a thermal emitter plate to convert visible light into black body radiation for enhanced energy capture
Implementation Method 3
metal-oxide-carbon (MoC) diodes or by point contact diodes
Data Source
AI summary
A solar antenna array may comprise an emitter that may convert visible light into black body infrared radiation, and an array of antennas that may capture and convert the black body radiation into electrical power. Methods for constructing the solar antenna array may include using thermal insulation, high-gain low-e glass, and gasses with minimal heat transfer. A black body infrared antenna array may augment the electrical power from a visible light antenna array by converting its waste heat into additional electrical power.