AFOSR-MURI on Energy Harvesting and Storage Systems (EHSS)
Transcript of AFOSR-MURI on Energy Harvesting and Storage Systems (EHSS)
AFOSRAFOSR--MURI on Energy Harvesting and Storage Systems (EHSS)MURI on Energy Harvesting and Storage Systems (EHSS)
Period: May/2006-May/2011Funding: $6M
Dr. B. “Les” Lee (Air Force Office of Scientific Research), PMDr. Joan Fuller (Air Force Office of Scientific Research), Co-PMDr. Victor Giurgiutiu (Air Force Office of Scientific Research), Co-PM
Researchers: Minoru Taya, PI , UW
UW: Chunye Xu (ME), G. Cao(MSE), S. Jenekhe(ChemE), Y. Kuga(EE)
CU: M. Dunn, K. Maute, R. YangUCLA : T. Hahn, S JuVPI : D. Inman
Collaborating Industry, Boeing, etc.
Goal : To develop a set of energy harvesting materials and systems for future AF vehicles
Aug 25,2006
UW - Center for Intelligent Materials and Systems
Multi-scale approach to design ofenergy harvesting aircraft systems
a. system level
c. material level
micro-scale
antenna
PCB Power amplifier
TEC
Heat spreader
Polymer solar cells (PSC)
thermo-electric (TE)
antenna system under the wing with TE
Polymer matrix composite (PMC) cellBattery package layer (BPL)
separatorCathodeanode
Polymer solar cell
PMC BPL
macro-scale
nano-scale
d. nano-composite levelBinder polymerCarbon nano tube network
Porous Cu collector
p-type TEn-type TE
TEC
TIM
Thermal interface material (TIM)
b. component levelPolymer
battery cells
TECantenna
skin
PBC
Polymer solar cells
+
UW - Center for Intelligent Materials and Systems
A. Design Tools for Multifunctional Materials and Structures (Dunn, Maute and Taya)
B. Energy Harvesters based on thermoelectrics (Yang and Taya)
C. Energy harvester based on polymer solar cells (Jenekhe ,Xu, Nango)
D. Manufacturing and durability of energy harvesting structures(Ju and Hahn)
E. Design of Energy Storage System (Xu, Cao, Kuga)
F. Electric System Design (Kuga)
G. Multimode Energy Harvesting for ISR/MAV Missions (Inman)
H. Educational Programs (Taya and Dunn)
I. Validation of the Proposed EHSS (all)
MURI - EHSS Tasks
Tasks and MilestonesThe first 3 years The last 2 years Milestones and Deliverables
1st year 2nd year 3rd year 4th year 5thyear A Design Tool-component level A1 Electrochemo-mechanical coupling Model ▼ A2 Multi-scale, multi-physics constitutive Model ▼ A3 Design optimization model ▼ B TE energy harvester B1 Optimized TE materials ▼ B2 Processing of TE materials ▼ B3 Process TE unit ▼ B4 Process of TE models ▼ B5 Integration and testing with heat sources ▼ C Polymer solar cell harvester C1 Optimization of donor-acceptor copolymers by DFT ▼ C2 Process and characterization of molecular hetero junction PSC ▼ C3 Demo of PSC sheet with goal of 10% Efficiency ▼ C4 Process and demo of layer PSC About with 20% or more efficiency ▼ D Manufacturing and durability D1 Multifunctional manufacturing and integration schemes ▼ D2-1 Multifunctional characterization capability ▼ D2-2 Existing state-of-the art materials and material forms ▼ D2-3 1st generations of new materials ▼ D2-4 2nd generations of optimized new materials ▼ E Energy storage system E1 Cathode material system ▼ E2 Anodic material system ▼ E3 Environmentally storage electrolyte system ▼ E4 Demo of PBC ▼ E5 Demo of super capacity ▼ E6 Integration of PBC and PSC ▼F Electrical system design F1 Power conditioner ▼ F2 Hybrid power unit ▼ F3 Wireless system ▼ F4 Overall electrical system design ▼ G Multimode Energy Harvesting G1 System analysis of UAV ▼ G2 Design rules ▼ H Education Programs ▼ I Validations I1 components ▼ I2 UAV demonstrator ▼
MassDisplacementStressTemperature
Criteria
SQPMMASLP
Optimizer
DirectAdjointFD
Sensitivity
CurrentPower
2-D3-DHarmonic
Problem
CU – Multi-Physics Optimization Toolbox
GoldPolysiliconAluminum
MaterialMultiphysics
Thermo-mechanicalElectro-thermo-mechanical
piezo-electric
thermo-electric
system design
photovoltaic
component designphotovoltaic
storage
thermo-electric
antenna
skin
material design
collector
separator
+ electrode
- electrode
structure
• overall system design• placement of EHS systems• power storage management
• mechanical design• coupled analysis & design• integration
• structural battery design• multi-physics analysis
Electro-chemical-mech.
Computational Design Tool DevelopmentComputational Design Tool Development
Multiphysics Material & Micro Device DesignMultiphysics Material & Micro Device Design
Phononic Metamaterials DesignPhononic Metamaterials Design
Bandgap Metamaterials
Application-Specific Metamaterials
optimized material layout
wavefield in a the optimized material
surface wave guide
decomposed FE mesh
0
0.2
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1.2
-0.2 0 0.2 0.4 0.6 0.8 1
κbb (1/mm)
κ aa
(1/m
m)
a a
b b
0
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1.2
-0.2 0 0.2 0.4 0.6 0.8 1
κbb (1/mm)
κ aa
(1/m
m)
a a
b b
x
y
Photoelastic Metamaterials DesignPhotoelastic Metamaterials Design
uniaxial bending
ElectroElectro--Mechanical Microsystem DesignMechanical Microsystem Design
Design
Spa
ce
optimized gold pattern
Design
Space
optimized actuator
Design Tools for EH&S CompositesDesign Tools for EH&S Composites
MassDisplacementStressTemperature
Criteria
SQPMMASLP
Optimizer
DirectAdjointFD
Sensitivity
CurrentPower
2-D3-DHarmonic
Problem
CU - Topology Optimization Toolbox
GoldPolysiliconAluminum
MaterialMultiphysics
Thermo-mechanicalElectro-thermo-mechanical
Focus I: Design of Batteries with Load-Barring Capabilitiesmaximize energy storage & stiffness & strength
Collaboration with local companies & labs
ohmic load
Preliminary work: developed and implemented a micro-structural electrochemical-mechanical battery finite element model
Electro-chemo-mechanical
Design Tools for EH&S Enabled VehiclesDesign Tools for EH&S Enabled Vehicles
design with advanced EH&S materials
guidance for material &
device design
metamaterial design
system design system performancedemonstration and verification
component design
endu
ranc
e
range
application driven preference
component / material level criteria & parameter space
varia
ble
2
variable 1
crite
rion
2
criterion 1
system design space
Pareto optimal set
antennaPCB Power amplifier
TEC
Heat spreader
p-type TEn-type TE
TEC
TIM
Nanocomposites - Bulk Thermoelectric Materials with Embedded Nanostructures
• Cost-Effective• Mass Production• A Paradigm Shift on TE Research
Nanocomposite Thermoelectric Materials and Energy Harvesting System
Expectations• Reduced thermal conductivity.• Electrical conductivity comparable to or better than bulk.• Increased Seebeck Coefficient.• Overall Enhanced ZT by a factor of 2-5.
0.0
0.5
1.0
1.5
2.0
2.5
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1940 1960 1980 2000 2020
FIG
UR
E O
F M
ERIT
(ZT)
max
YEAR
Bi2Te3 alloyPbTealloy
Si0.8Ge0.2 alloy
Skutterudites(JPL)
PbSeTe/PbTeQuantum-dotSuperlattices(Lincoln Lab)
Bi2Te3/Sb2Te3Superlattices(RTI)
AgPbmSbTe2+m(Kanatzidis)
Dresselhaus
State-of-the-art Thermoelectrics
Statement of the Work (TE)- Materials, Devices, & System
Schematic drawing of silicon-based TE device (Pick & Place process, TE legs are made of nanocomposites)
P leg
Silicon substrate
SU-8
Ti/Cu /solder paste
Metal Interconnection
N leg
• Design and characterize thermoelectric nanocomposites• Design of TE devices• Testing TE devices and system integration
CU-Tasks on Thermoelectrics
ThermocoupleLeadsHeater
Leads
Conventional Four-Probe method Sub-ps Pump-Probe method
UW tasks – Nanocomposite synthesis & Device Fabrication
1. Develop atomic simulation tools to study the thermal conductivity, Seebeckcoefficient and electrical conductivity of nanocompositesand design nanocomposites
with effective ZT = 1.5-4.
2. Develop tools to measure the thermoelectric properties of
nanocomposite sample made in UW.
3. Develop tools to design thermoelectric devices and to predict the performance of TE-subsystem in AF environments 4. Assist UW to develop the fabrication process for nanocomposite TE devices and test TE devices.
Fabrication process for nanocomposite TE devices
Si wafer
Photoresist mask
(a) Photoresist masking
(b) Deep RIE
(c) Photoresist masking on opposite side
(d) Deep RIE
(e) Filling TE materials into the mold
(f) Polishing
(g) Connecting the P-N elements
(h) Final assembling and Si mold removal
P-type TE powder
N-type TE powder
Metal electrode
Substrate
Capsule
Si wafer
Photoresist mask
(a) Photoresist masking
(b) Deep RIE
(c) Photoresist masking on opposite side
(d) Deep RIE
(e) Filling TE materials into the mold
(f) Polishing
(g) Connecting the P-N elements
(h) Final assembling and Si mold removal
P-type TE powder
N-type TE powder
Metal electrode
Substrate
Capsule
Microfabricationprocesses to make micro/mini TE devices with the use of mechanical alloyed nanocomposite powder
Ref. : J.F. Li et al.Sensors and Actuators A 108 (2003) 97-102.
Effic
iency
(%)
Universityof Maine
Boeing
Boeing
Boeing
BoeingARCO
NREL
Boeing
Euro-CIS
200019951990198519801975
NREL/Spectrolab
NRELNREL
JapanEnergy
Spire
No. CarolinaState University
Multijunction ConcentratorsThree-junction (2-terminal, monolithic)Two-junction (2-terminal, monolithic)
Crystalline Si CellsSingle crystalMulticrystallineThin Si
Thin Film TechnologiesCu(In,Ga)Se2CdTeAmorphous Si:H (stabilized)
Emerging PVDye cells Organic cells(various technologies)
Varian
RCA
Solarex
UNSW
UNSW
ARCO
UNSWUNSW
UNSWSpire Stanford
Westing-house
UNSWGeorgia TechGeorgia Tech Sharp
AstroPower
NREL
AstroPower
Spectrolab
NREL
Masushita
Monosolar Kodak
Kodak
AMETEK
Photon Energy
UniversitySo. Florida
NREL
NREL
NRELCu(In,Ga)Se2
14x concentration
NREL
United Solar
United Solar
RCA
RCARCA
RCA RCARCA
Spectrolab
Solarex12
8
4
0
16
20
24
28
32
36
University ofLausanne
University ofLausanne
2005
Kodak UCSBCambridge
NREL
UniversityLinz
Siemens
ECN,The Netherlands
Princeton
UC Berkeley
Taken from a presentation by Baldwin “Energy Efficiency and Renewable Energy; Energy: A 21st Century Perspective; National Academy of Engineering; June 2, 2005”
Best Research-Cell Efficiencies
Task on Energy Harvesters Based on Polymer Solar Cells1. Design and Synthesis of D-A Copolymers
• Band structure engineering by DFT• Visible-NIR absorption to match solar spectrum• High carrier mobilities
2. Fabrication and Evaluation of Solar Cells• Layered Heterojuction (LH)• Bulk Heterojuction (BH)
3. Synthesis and Evaluation of Molecular Heterojuction(MH) Cells
NN
S
NN
N
NN
x y
x y
RR
R Rn
n
x y n
S
R R
S
R R
S
R R
R R
S
NN
S
N NS
NN
S
N N
R R
R R
R R
R R
A-BlockD-Block
SS
SS
R1 R1
R1 R1
R1 R1
R1 R1
... ...
LUMO
HOMO
LUMO
HOMO
D-Block
A-Block
S
NN
nS
DFT calculation
4. Fabrication and Evaluation of Hybrid Organic / Inorganic Solar Cells
5. Integration of Polymer Solar Cells with Other EHSS Components
Solar Spectrum
Nature: Purple Photosynthetic Bacteria
The antenna complexes efficiently realize various photosynthetic functions due to the presence of cofactors (BChl a and carotenoid) assembled into the apoproteins.
Photosynthetic Bacteria
AFM image of the LH1 complex on mica.
LH1-RC
e-
ITO
Bio-inspired Design of Dye-sensitized Solar Cell (DSSC)
NanotubeNano particles
TiO2
Dye
Ru complex Phthalocyanine
NH N
N HN
H
OOH
H
O
Chlorophyll
Redox, Electrolyte
Counter
LiI, CuI, KI,Ionic liquids,Solid Electrolyte
Pt, Au, C60, Carbon nanotubeFilm (PET, PEN)
Dye1 Dye2 Dye3
Energy harvesting and storage system-Development of efficient electrode and electrolyte for battery, supercapacitor and dye-sensitized solar cells
separator
cathode
anode
Lithium polymer battery (LPB)
Top
polymer matrix composite (PMC)
battery packaging layer (PBL)
mesoporous V2O5 •Li V3O8
porous Al current collector grid (+)
mesoporous polyolefin
Lithium polymer gel electrolyte
porous Cu current collector grid (-)
carbon nanotube anode
PBL
PMC
polymer solar cell
PolypropyleneAluminum
Toughened epoxy
Polypropylene
AluminumToughened epoxy
Toughened epoxy toughened epoxy adhesive layer for strong bonding
mesoporous polyolefin
parallel or series connected PBCs
Development of thin film lithium battery for energy storage from polymer solar cell
External Quantum Efficiency of Solar Cell
5-10%
Wing area of UAV 10.9 m2
Solar Energy at 50000 ft
~20 kWhm2/day
PSV harvested Electrical Energy
21.8 kWh/day
Battery Weight to store 2/3 of the energy for night fly
23.8 kg
D-A copolymer solar cell
Al current collector (+)
PET
mesoporousCarbon anode
mesoporousInsulator layerelectrolyte
Cu current collector (-)
mesoporous V2O5or MnO2, etc.
I
Battery goal: 600 Wh/kg
ITO nanorod
Cao’s research 1: Nanostructured Li battery electrodes
0.01 0.1 1 10 100 10001
10
100
1000
10000
100000
1000000
1E7
Spec
ific
Pow
er (W
/kg)
Specific Energy (Wh/kg)
Capacitor
ElectrochemicalCapacitor
BatteriesFuel Cell
0.01 0.1 1 10 100 10001
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100
1000
10000
100000
1000000
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Spec
ific
Pow
er (W
/kg)
Specific Energy (Wh/kg)
Capacitor
ElectrochemicalCapacitor
BatteriesFuel Cell
Capacitor
ElectrochemicalCapacitor
BatteriesFuel Cell
Ideal performance:
Large storage capacity: energy
Fast transport kinetics: power
UCLA Task
• Goal– Develop multifunctional design and
manufacturing methodologies for energy harvesting and storage structures.
AC Propulsion’s SoLong UAV
Multifunctional Characterization of Batteries and Thermoelectrics
• Mechanical Properties– Modulus, strength– Stress-strain relations– Failure mechanisms
• Interaction Between Performance and:– Deformation– Pressure– Temperature
Cathode
1/8” HD Rubber
Anode
Load
Cathode
1/8” HD Rubber
Anode
Load
1/8” HD Rubber
Anode
Load
1/8” HD Rubber
Anode
Load
Structural Integration of Batteries and Thermoelectrics
• Structural integration methods– Prepreg lay-up– Resin transfer molding
• Performance of integrated structures– Performance under
loading– Microstructure
analysis
Resin Resin
Vacuum 28” Hg
Photovoltaic Film
Thermal Collector
Composite Laminate
Thin Film Battery
Thermoelectric Fiber
Electric Wiring Not Shown Photovoltaic Film
Thermal Collector
Composite Laminate
Thin Film Battery
Thermoelectric Fiber
Electric Wiring Not Shown
H A Sodano
• Tasks included determining:– Available sources– Placement criteria– Key parameters– Design rules– Storage and power
management– Experimental
verification– Transitions to DOD
Design Rules for Multimode Harvesting
Formulate analysis tools for hybrid harvesting and storage
MAV Wing Cross Section
D. J. Inman
Electric System Design Using Supercapacitors and Battery
Goals-Integration of energy harvesting devices into electrical system.-Study of energy efficiency and how to improve it.-Initial design will be conducted with currently available energy harvesting devices including thermoelectric devices, photo-cells and super-capacitors.
Simplified diagram of the electrical system