Sol-Gel TPV Emitter Coating for High-Heat Surface Bonding

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Solution Overview

Problem

Conventional MgO—NiO emitter powders are difficult to integrate with high heat sources due to their powder form, leading to integration challenges and increased thermal losses.

Innovation Solution

A sol-gel emitter material, such as magnesium or zirconium doped nickel oxide, is used to provide a stable and flexible coating that can be applied to high heat surfaces, enhancing integration and reducing thermal conductivity losses.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If MgO-NiO emitter powder is used, then the material can be provided in a ready-to-use form, but it is difficult to integrate with high heat sources and exhibits poor bonding

Engineering Contradiction:

Improvereadiness of emitter materialVSAvoidintegration with high heat source

Core Design Contradiction:

Ease of manufactureVSEase of operation

Solution Approach 1:

The invention changes the physical state parameter of the emitter material from powder to sol-gel form. This parameter change enables the material to be applied as a coating on high heat sources, fundamentally resolving the integration difficulty while maintaining manufacturing readiness through standardized sol-gel preparation procedures

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention creates a composite sol-gel material combining MgO and NiO in a gel matrix structure. This composite approach provides both the desired emissivity properties of NiO-doped MgO and the coating applicability of sol-gel materials, simultaneously addressing integration and bonding issues

Inventive Principle:

Principle #40Composite materials

2Stability of the object's composition

If MgO-NiO emitter powder is used, then the material composition can be controlled, but thermal losses increase due to poor thermal conductivity

Engineering Contradiction:

Improveemitter material compositionVSAvoidthermal losses

Core Design Contradiction:

Stability of the object's compositionVSLoss of energy

Solution Approach 1:

The invention changes the physical state from powder to sol-gel coating, which fundamentally alters the thermal conductivity parameter. The sol-gel matrix provides continuous thermal pathways that reduce thermal losses while maintaining the controlled MgO-NiO composition through the gel structure

Inventive Principle:

Principle #35Parameter changes

3Ease of operation

If emitter material is laminated onto high heat source, then integration can be achieved, but bonding is poor and thermal conductivity is reduced

Engineering Contradiction:

Improveintegration capabilityVSAvoidbonding strength

Core Design Contradiction:

Ease of operationVSStrength

Solution Approach 1:

The invention replaces the mechanical lamination process with a chemical coating process using sol-gel. The sol-gel coating chemically bonds to the high heat source surface, substituting weak mechanical adhesion with strong chemical bonding, thereby significantly improving bonding strength while maintaining integration capability

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The sol-gel matrix acts as an intermediary between the high heat source and the MgO-NiO emitter particles. This intermediary provides both mechanical anchoring and chemical bonding, creating strong adhesion while maintaining the desired emitter material composition and thermal conductivity

Inventive Principle:

Principle #24Intermediary (Mediator)

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

The sol-gel emitter material offers better bonding and thermal conductivity, improving the integration with high heat sources and reducing thermal losses, thereby enhancing the efficiency of thermophotovoltaic systems.

Implementation Method 1

Thermal radiation produced by a surface heated by a heat source is used in a TPV cell to generate electricity

Methodology Applied

Scientific EffectThermal radiation: Thermal Radiation

Implementation Method 2

a tape casted Magnesium Oxide (MgO) doped with 2 mol % Nickel Oxide (NiO) exhibits an emissivity of 90% at a wavelength of 1.4 μm

Methodology Applied

Scientific EffectEmissivity:

Implementation Method 3

coating of a sol-gel emitter material onto a high heat surface provides a better bonding than laminating an oxide emitter material, which provides better thermal conductivity for a sol-gel emitter and reduces thermal losses

Methodology Applied

Scientific EffectThermal conductivity: Conduction (thermal)

Implementation Method 4

capable of being coated onto a high heat surface (for example by dip, spin, or spray coating)

Methodology Applied

Scientific EffectDip coating: Deposition (physical)

Implementation Method 5

capable of being coated onto a high heat surface (for example by dip, spin, or spray coating)

Methodology Applied

Scientific EffectSpin coating: Spin Coating

Implementation Method 6

capable of being coated onto a high heat surface (for example by dip, spin, or spray coating)

Methodology Applied

Scientific EffectSpray coating: Fluid Spray

Data Source

PatentUS12415735B2Sol-gel material, and use thereof

Publication Date: 2025.09.16 TECHCAL UNIV DUBLIN

AI summary

A thermophotovoltaic (TPV) system, comprises a substrate, an emitter material adhered to the substrate, and a thermophotovoltaic (TPV) cell. The emitter material is a typically a metal oxide doped nickel oxide sol-gel material, in which the metal is magnesium or zirconium, and in which the sol-gel material comprises 97-99 mol % metal oxide, and about 1-3 mol % nickel oxide dopant. Providing an emitter material as a sol-gel allows the material to be coated on to surfaces providing better adherence to the surface, and also provides excellent heat stability. A sol-gel material is also described.