CNT Rectenna Arrays for Solar Energy Conversion
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Solution Overview
Problem
Current manufacturing processes for visible light rectenna arrays are expensive due to the need for deep submicron masking technology, which is costly and inefficient compared to traditional solar cell processes, and existing methods do not effectively utilize existing semiconductor fabrication capabilities for efficient conversion of solar energy.
Innovation Solution
The development of carbon nanotube (CNT) rectenna arrays using interdigitated aluminum lines and self-aligning process steps to achieve molecular-sized dimensions, with CNT antennas connecting between ground and negative voltage lines through geometric diodes, allowing for efficient conversion of sunlight into electricity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If deep submicron masking technology is used to manufacture visible light rectenna arrays, then the antenna dimensions can be reduced to tens of nanometers, but the manufacturing cost increases significantly
Solution Approach 1:
The patent employs self-aligned fabrication processes where subsequent layers automatically align to previous layers without requiring additional masking steps. The interdigitated electrode structure and dielectric layers are formed in a sequence where each layer's position is determined by the underlying layer, eliminating the need for expensive deep submicron masking while achieving the required tens of nanometer precision.
2Ease of manufacture
If traditional solar cell processes are used, then manufacturing cost is lower, but the conversion efficiency is insufficient compared to rectenna arrays
Solution Approach 1:
The patent changes the fundamental operating parameters by using rectifying diodes with specific electrical characteristics (non-linear I-V curves) that enable efficient rectification of optical frequencies. The interdigitated electrode geometry and dielectric material selection are optimized to achieve resonant enhancement at solar spectrum frequencies, improving conversion efficiency while using standard fabrication processes.
3Manufacturing precision
If CNT forests are grown between interdigitated aluminum lines, then molecular-sized antenna dimensions are achieved, but the process complexity increases
Solution Approach 1:
The patent segments the antenna structure into distinct functional layers: interdigitated aluminum electrode lines, dielectric layers, and CNT forest regions. Each segment is formed by a separate fabrication step that builds upon the previous segment, allowing independent optimization of each component while maintaining overall system integration through self-alignment.
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
Enables the efficient conversion of sunlight into electricity using existing IC manufacturing techniques, achieving high efficiency and reducing manufacturing costs by leveraging current semiconductor fabrication capabilities.
Implementation Method 1
visible light rectenna arrays for the conversion of solar energy to electricity
Implementation Method 2
conversion of solar energy to electricity
Data Source
AI summary
A method for constructing a solar rectenna array by growing carbon nanotube antennas between lines of metal, and subsequently applying a bias voltage on the carbon nanotube antennas to convert the diodes on the tips of the carbon nanotube antennas from metal oxide carbon diodes to geometric diodes. Techniques for preserving the converted diodes by adding additional oxide are also described.