CNT Rectenna Arrays via Stamping Fabrication
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current manufacturing processes for visible light rectenna arrays are expensive due to the need for deep submicron masking technology, which is costlier than traditional solar cell processes, and existing methods do not efficiently utilize existing semiconductor fabrication capabilities for carbon nanotube (CNT) structures.
Innovation Solution
The use of CNT rectenna arrays manufactured using current IC techniques and self-aligning process steps, with geometric diodes formed by carbon nanotube tips touching metal lines, and a stamping process to pattern metals for efficient CNT antenna array production, allowing for varying lengths and orientations to maximize sunlight reception, and the integration of bus bars for light reflection and collection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If deep submicron masking technology is used to manufacture visible light rectenna arrays, then the required nanometer-scale dimensions can be achieved, but the manufacturing cost increases significantly compared to traditional solar cell processes
Solution Approach 1:
The patent uses a stamp made from silicon nitride that replicates the antenna pattern onto each wafer. This stamp copying approach eliminates the need for expensive deep submicron photolithography while achieving the required nanometer-scale precision. The stamp is created once using precise fabrication, then reused many times to pattern subsequent wafers, dramatically reducing per-unit manufacturing cost while maintaining dimensional accuracy.
Solution Approach 2:
The patent performs preliminary actions by pre-fabricating the stamp structure and pre-patterning the metal layers before CNT growth. The metal lines are deposited and patterned in advance, and the stamp is prepared beforehand, so that when actual production occurs, only the CNT growth step is needed to create the functional antennas. This preliminary preparation eliminates costly real-time photolithography during mass production.
2Manufacturing precision
If traditional photolithographic operations are used for patterning, then precise metal line patterns can be achieved, but wafer handling complexity and production time increase
Solution Approach 1:
The patent extracts the patterning function from the wafer processing sequence and places it in a separate stamp structure. Instead of patterning each wafer individually through photolithography, the pattern is extracted into a reusable stamp that imprints the metal line locations. This separation allows the wafer to remain continuous and eliminates repeated photolithography cycles, dramatically improving throughput while maintaining pattern precision.
Solution Approach 2:
The patent merges multiple steps into a single CNT growth operation. The metal line patterning, antenna positioning, and rectenna formation are combined into one process where CNTs grow from pre-positioned catalyst sites on the metal lines. This consolidation eliminates separate photolithography, etching, and alignment steps, reducing both time and handling complexity while achieving precise patterns through the stamp-guided CNT growth.
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 enables the cost-effective production of CNT rectenna arrays with high efficiency in converting sunlight to electricity, leveraging existing semiconductor processing while reducing costs and improving volume production by minimizing wafer handling and photolithographic operations.
Implementation Method 1
CNT rectenna arrays manufactured using current IC techniques and self-aligning process steps, with geometric diodes formed by carbon nanotube tips touching metal lines, and a stamping process to pattern metals for efficient CNT antenna array production, allowing for varying lengths and orientations to maximize sunlight reception
Implementation Method 2
the integration of bus bars for light reflection and collection
Data Source
AI summary
A solar antenna array may comprise an array of carbon nanotube antennas that may capture and convert sunlight into electrical power. A method for constructing the solar antenna array from a glass top down to aluminum over a plastic bottom such that light passing through the glass top and/or reflected off the aluminum both may be captured by the antennas sandwiched between. Techniques for patterning the glass to further direct the light toward the antennas and techniques for continuous flow fabrication and testing are also described.