Fluid-Filled Membrane for Uniform Sub-Micrometer Gap in Near-Field Energy Conversion

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Solution Overview

Problem

Near-field energy transfer devices face challenges in maintaining uniformity of sub-micrometer gaps between emitter and receiver surfaces due to bowing or irregular surfaces and external forces, which affects the generation of commercially significant power levels.

Innovation Solution

The use of fluid-filled compliant membranes on the emitter and receiver surfaces to apply compensatory pressure and maintain a uniform sub-micrometer gap, resisting external mechanical pressure variations and accommodating surface irregularities.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If rigid structures are used to maintain gap separation, then structural strength is improved, but gap uniformity deteriorates due to surface bowing and external forces

Engineering Contradiction:

Improvestructural strengthVSAvoidgap uniformity

Core Design Contradiction:

StrengthVSManufacturing precision

Solution Approach 1:

The patent employs flexible membranes as compliant layers between the emitter and receiver substrates. These membranes can deform elastically to accommodate surface irregularities and maintain uniform gap separation, resolving the contradiction between structural strength and gap uniformity by providing both mechanical support and adaptability to surface variations

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The patent changes the mechanical parameters of the gap-maintaining structure by using compliant layers with specific elastic properties. By selecting materials and thicknesses that provide appropriate compliance, the system can adapt to surface bowing while maintaining structural integrity, thus achieving both strength and gap uniformity

Inventive Principle:

Principle #35Parameter changes

2Manufacturing precision

If compliant membranes are used to accommodate surface irregularities, then gap uniformity is improved, but resistance to external mechanical forces deteriorates

Engineering Contradiction:

Improvegap uniformityVSAvoidresistance to external forces

Core Design Contradiction:

Manufacturing precisionVSStrength

Solution Approach 1:

The patent combines rigid substrates with flexible membranes in a hybrid structure. The rigid substrates provide resistance to external mechanical forces, while the flexible membranes maintain gap uniformity by accommodating surface irregularities. This merging of rigid and compliant elements resolves the contradiction between gap uniformity and force resistance

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The compliant layers act as pre-configured cushioning elements that are built into the structure before operation. These layers are designed to deform under external forces, protecting the gap separation from damage while maintaining uniformity, thus providing beforehand cushioning against mechanical stresses

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

3Loss of energy

If sub-micrometer gap separation is achieved, then energy transfer efficiency is improved, but manufacturing precision requirements worsen

Engineering Contradiction:

Improveenergy transfer efficiencyVSAvoidgap separation precision

Core Design Contradiction:

Loss of energyVSManufacturing precision

Solution Approach 1:

The flexible membranes provide self-adjusting gap maintenance through their elastic compliance. As the substrates are brought into proximity, the membranes automatically deform to accommodate surface variations and maintain the optimal sub-micrometer gap, eliminating the need for ultra-precise manufacturing and assembly while achieving high energy transfer efficiency

Inventive Principle:

Principle #25Self-service

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 ensures consistent and efficient energy transfer by maintaining a uniform gap, enhancing power generation and reducing series resistance and heating losses in near-field energy conversion devices.

Implementation Method 1

a fluid-filled compliant membrane structure which exerts a compensatory pressure to either or both of the receiver and emitter

Methodology Applied

Scientific EffectFluid pressure: Pressure Increase

Implementation Method 2

appropriately compliant membranes, which preferably contain a fluid that applies compensatory pressure to the rear surface of the emitter, receiver, or both

Methodology Applied

Scientific EffectElastic deformation: Elasticity

Implementation Method 3

near-field energy transfer devices for the generation of electric current and power through transfer of energy from an emitter across a non-isothermal gap to a receiver

Methodology Applied

Scientific EffectThermal radiation: Thermal Radiation

Data Source

PatentUS8076569B2Method and structure, using flexible membrane surfaces, for setting and/or maintaining a uniform micron/sub-micron gap separation between juxtaposed photosensitive and heat-supplying surfaces of photovoltaic chips and the like for the generation of electrical power

Publication Date: 2011.12.13 MTPV POWER CORP

AI summary

A near-field energy conversion structure and method of assembling the same, utilizing a sub-micrometer “near field” gap between juxtaposed photocell infrared radiation receiver and heat emitter surfaces, wherein compliant membrane structures, preferably fluid-filled, are interposed in the structure.