Flexible Thermoelectric Generator Based on Polycrystalline SiGe Thin Films

Flexible and reliable thermoelectric generators (TEGs) will be essential for future energy harvesting sensors. In this study, we synthesized p- and n-type SiGe layers on a high heat-resistant polyimide film using metal-induced layer exchange (LE) and demonstrated TEG operation. Despite the low process temperature (<500 °C), the polycrystalline SiGe layers showed high power factors of 560 µW m−1 K−2 for p-type Si0.4Ge0.6 and 390 µW m−1 K−2 for n-type Si0.85Ge0.15, owing to self-organized doping in LE. Furthermore, the power factors indicated stable behavior with changing measurement temperature, an advantage of SiGe as an inorganic material. An in-plane π-type TEG based on these SiGe layers showed an output power of 0.45 µW cm−2 at near room temperature for a 30 K temperature gradient. This achievement will enable the development of environmentally friendly and highly reliable flexible TEGs for operating micro-energy devices in the future Internet of Things.

Design of a Scalable, Flexible, and Durable Thermoelectric Cooling Device for Soft Electronics Using Kirigami Cut Patterns

A flexible, soft thermoelectric cooling device is presented that shows potential for human cooling applications in wearable technologies and close-to-body applications. Current developments lack integration feasibility due to non-scalable assembly procedures and unsuitable materials for comfortable and durable integration into products. Our devices have been created and tested around the need to conform to the human body which we have quantified through the creation of a repeatable drape testing procedure, a metric used in the textile industry. Inspired by mass manufacturing constraints, our flexible thermoelectric devices are created using commercially available materials and scalable processing techniques. Thermoelectric legs are embedded in a foam substrate to provide flexibility, while Kirigami-inspired cuts are patterned on the foam to provide the drape necessary for mimicking the performance of textile and close to body materials. In total, nine different configurations, three different fill factors and three different Kirigami cut patterns were fabricated and inspected for thermal characterization, mechanical testing, flexibility and drape. Our studies show that adding Kirigami patterns can increase the durability of the device, improve the flexibility, decrease the drape coefficient, and have <1% of impact on cooling performance at higher fill factors (>1.5%), reaching temperature differences up to 4.39 ± 0.17°C between the hot and cold faces of the device. These thermoelectric cooling devices show great flexibility, durability, and cooling for integration into soft cooling products.

Flexible N-Type Thermoelectric Composites Based on Non-Conductive Polymer with Innovative Bi2Se3-CNT Hybrid Nanostructured Filler

This research is devoted to the fabrication of polyvinyl alcohol (PVOH) based n-type thermoelectric composites with innovative hybrid bismuth selenide-multiwalled carbon nanotube (Bi2Se3-MWCNT) fillers for application in flexible thermoelectric devices. Hybrid fillers were synthesized by direct deposition of Bi2Se3 on multiwalled carbon nanotubes using a physical vapor deposition method, thus ensuring direct electrical contact between the carbon nanotubes and Bi2Se3. The Seebeck coefficient of prepared PVOH/Bi2Se3-MWCNT composites was found to be comparable with that for the Bi2Se3 thin films, reaching −100 µV·K−1 for the composite with 30 wt.% filler, and fluctuations of the resistance of these composites did not exceed 1% during 100 repetitive bending cycles down to 10 mm radius, indicating the good mechanical durability of these composites and proving their high potential for application in flexible thermoelectrics. In addition, other properties of the fabricated composites that are important for the use of polymer-based materials such as thermal stability, storage modulus and linear coefficient of thermal expansion were found to be improved in comparison with the neat PVOH.

Linear Electron Beam Assisted Roll-to-Roll in-Vacuum Flexographic Patterning for Flexible Thermoelectric Generators

In this work, we investigated the use of in-line linear electron beam irradiation (LEB) surface treatment integrated into a commercially compatible roll-to-roll (R2R) processing line, as a single fluorocarbon cleaning step, following flexography oil masking used to pattern layers for devices. Thermoelectric generators (TEGs) were selected as the flexible electronic device demonstrator; a green renewable energy harvester ideal for powering wearable technologies. BiTe/BiSbTe-based flexible TEGs (f-TEGs) were fabricated using in-line oil patterned aluminium electrodes, followed by a 600 W LEB cleaning step, in which the duration was optimised. A BiTe/BiSbTe f-TEG using an oil-patterned electrode and a 15 min LEB clean (to remove oil prior to BiTe/BiSbTe deposition) showed similar Seebeck and output power (S~0.19 mV K−1 and p = 0.02 nW at ΔT = 20 K) compared to that of an oil-free reference f-TEG, demonstrating the success of using the LEB as a cleaning step to prevent any remaining oil interfering with the subsequent active material deposition. Device lifetimes were investigated, with electrode/thermoelectric interface degradation attributed to an aluminium/fluorine reaction, originating from the fluorine-rich masking oil. A BiTe/GeTe f-TEG using an oil-patterned/LEB clean, exceeded the lifetime of the comparable BiTe/BiSbTe f-TEG, highlighting the importance of deposited material reactivities with the additives from the masking oil, in this case fluorine. This work therefore demonstrates (i) full device architectures within an R2R system using vacuum flexography oil patterned electrodes; (ii) an enabling Electron beam cleansing step for removal of oil remnants; and (iii) that careful selection of masking oils is needed for the materials used when flexographic patterning during R2R.