MWCNT Rectenna Array Fabrication Without Deep Submicron Masks
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Solution Overview
Problem
Existing manufacturing processes for visible light rectennas are expensive due to the need for deep submicron masking technology, which is costlier than current solar cell processes, and there is a lack of efficient methods to construct carbon nanotube solar antennas for optimal solar energy conversion.
Innovation Solution
Utilizing IC manufacturing techniques and self-aligning process steps to construct multi-walled carbon nanotube (MWCNT) rectenna arrays with interdigitated conductive lines and geometric diodes, optimized for maximum sunlight reception and conversion efficiency, incorporating features like varying lengths, orientations, and connections to form half-wave or full-wave rectified structures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If deep submicron masking technology is used to manufacture visible light rectennas, then the antenna dimensions can be reduced to tens of nanometers, but the manufacturing cost increases significantly
Solution Approach 1:
The patent segments the rectenna structure into distinct functional components: carbon nanotube antennas, geometric diodes, and interdigitated conductive lines. This segmentation allows each component to be optimized and manufactured using appropriate processes, with the carbon nanotubes providing the necessary nanoscale dimensions without requiring deep submicron masking for the entire structure.
Solution Approach 2:
The patent introduces carbon nanotubes as an intermediary material that bridges the gap between macroscopic manufacturing processes and nanoscale antenna dimensions. The carbon nanotubes self-organize into vertical structures that provide the required tens-of-nanometers dimensions through their inherent physical properties rather than through costly lithographic patterning.
2Device complexity
If metal-oxide-metal rectifying diodes are used in the array core, then no semiconductor transistors are needed, but the manufacturing process complexity increases
Solution Approach 1:
The patent extracts the rectifying function from traditional semiconductor transistor structures and implements it using geometric diodes formed by metal-oxide-metal contacts. This extraction eliminates the need for complex transistor fabrication while maintaining the rectification functionality through simpler geometric configurations that can be integrated with the carbon nanotube antennas.
Solution Approach 2:
The patent changes the fundamental parameter of rectification from electronic (transistor-based) to geometric (shape-based metal-oxide-metal contacts). This parameter change allows the use of simpler manufacturing processes that rely on geometric configurations rather than complex semiconductor device fabrication, reducing overall process complexity.
3Loss of energy
If carbon nanotube structures are used for solar antennas, then conversion efficiency can be improved, but the manufacturing method must be developed
Solution Approach 1:
The patent employs self-aligned process steps where carbon nanotubes are grown in situ between interdigitated conductive lines, and geometric diodes are formed through sequential processing that automatically positions components relative to each other. This self-service approach eliminates the need for complex alignment procedures and makes the manufacturing process more accessible.
Solution Approach 2:
The patent performs preliminary actions by first depositing interdigitated conductive lines and catalyst patterns before growing the carbon nanotubes. This preliminary structuring provides a template that guides carbon nanotube growth and ensures proper positioning, simplifying the overall manufacturing process while achieving optimal antenna configurations for high conversion efficiency.
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
Achieves efficient conversion of sunlight into electricity using MWCNT rectenna arrays, leveraging existing semiconductor fabrication capabilities without high costs, and allowing control over light transmission and temperature regulation in building applications.
Implementation Method 1
Multi-walled carbon nanotube (MWCNT) rectenna arrays with interdigitated conductive lines and geometric diodes, optimized for maximum sunlight reception and conversion efficiency
Implementation Method 2
construct multi-walled carbon nanotube (MWCNT) rectenna arrays with interdigitated conductive lines and geometric diodes, optimized for maximum sunlight reception and conversion efficiency
Data Source
AI summary
Methods for constructing multi-walled carbon nanotube (MWCNT) antenna arrays, may include: variable doping of the MWCNTs, forming light pipes with layers of variable dielectric glass, forming geometric diodes on full-wave rectified devices that propagate both electrons and holes, using clear conductive ground plans to form windows that can control a building's internal temperature, and generating multiple lithographic patterns with a single mask.