High-performance dispenser printed MA p-type Bi(0.5)Sb(1.5)Te(3) flexible thermoelectric generators for powering wireless sensor networks

High-Performance W-Doped Bi0.5Sb1.5Te3 Flexible Thermoelectric Films and Generators

Bi-Sb-Te-based thermoelectric materials have the best room-temperature thermoelectric properties, but their inherent brittleness and rigidity limit their application in the wearable field. In this study, W-doped p-type Bi0.5Sb1.5Te3 (W-BST) thin films were prepared using magnetron sputtering on polyimide substrates to create thermoelectric generators (TEGs). Bending tests showed that the thin film has excellent flexibility and mechanical durability, meeting the flexible requirements of wearable devices. W doping can significantly increase the carrier concentration, Seebeck coefficient, and electrical conductivity of BST thin films. At 300 K, the power factor of the W-BST film is 2.25 times higher than that of the undoped film, reaching 13.75 μW cm-1 K-2. First-principles calculations showed that W doping introduces significant impurity peaks in the bandgap, in which W d electrons remarkably hybridize with the Sb and Te p electrons, leading to an improved electrical conductivity of BST films. Furthermore, W doping significantly reduces the work function of BST films, thereby improving the carrier mobility. A TEG module fabricated from four layers of W-BST thin films achieved a maximum output power density of 6.91 mW cm-2 at a temperature difference of 60 K. Application tests showed that the flexible TEG module could power a portable clock using the temperature difference between body temperature and room temperature. At a medium temperature of 439 K, the assembled TEG module can provide a stable output voltage of 1.51 V to power a LED. This study demonstrates the feasibility of combining inorganic thermoelectric materials with flexible substrates to create high-performance flexible TEGs.

Facile Fabrication of Flexible and High-Performing Thermoelectrics by Direct Laser Printing on Plastic Foil

The emerging fields of wearables and the Internet of Things introduce the need for electronics and power sources with unconventional form factors: large area, customizable shape, and flexibility. Thermoelectric (TE) generators can power those systems by converting abundant waste heat into electricity, whereas the versatility of additive manufacturing suits heterogeneous form factors. Here, additive manufacturing of high-performing flexible TEs is proposed. Maskless and large-area patterning of Bi2Te3-based films is performed by laser powder bed fusion directly on plastic foil. Mechanical interlocking allows simultaneous patterning, sintering, and attachment of the films to the substrate without using organic binders that jeopardize the final performance. Material waste could be minimized by recycling the unexposed powder. The particular microstructure of the laser-printed material renders the-otherwise brittle-Bi2Te3 films highly flexible despite their high thickness. The films survive 500 extreme-bending cycles to a 0.76 mm radius. Power factors above 1500 µW m-1K-2 and a record-low sheet resistance for flexible TEs of 0.4 Ω sq-1 are achieved, leading to unprecedented potential for power generation. This versatile fabrication route enables innovative implementations, such as cuttable arrays adapting to specific applications in self-powered sensing, and energy harvesting from unusual scenarios like human skin and curved hot surfaces.

Fully inkjet-printed Ag2Se flexible thermoelectric devices for sustainable power generation

Flexible thermoelectric devices show great promise as sustainable power units for the exponentially increasing self-powered wearable electronics and ultra-widely distributed wireless sensor networks. While exciting proof-of-concept demonstrations have been reported, their large-scale implementation is impeded by unsatisfactory device performance and costly device fabrication techniques. Here, we develop Ag2Se-based thermoelectric films and flexible devices via inkjet printing. Large-area patterned arrays with microscale resolution are obtained in a dimensionally controlled manner by manipulating ink formulations and tuning printing parameters. Printed Ag2Se-based films exhibit (00 l)-textured feature, and an exceptional power factor (1097 μWm-1K-2 at 377 K) is obtained by engineering the film composition and microstructure. Benefiting from high-resolution device integration, fully inkjet-printed Ag2Se-based flexible devices achieve a record-high normalized power (2 µWK-2cm-2) and superior flexibility. Diverse application scenarios are offered by inkjet-printed devices, such as continuous power generation by harvesting thermal energy from the environment or human bodies. Our strategy demonstrates the potential to revolutionize the design and manufacture of multi-scale and complex flexible thermoelectric devices while reducing costs, enabling them to be integrated into emerging electronic systems as sustainable power sources.

Advanced Thermoelectric Textiles for Power Generation: Principles, Design, and Manufacturing

Self-powered wearable thermoelectric (TE) devices significantly reduce the inconvenience caused to users, especially in daily use of portable devices and monitoring personal health. The textile-based TE devices (TETs) exhibit the excellent flexibility, deformability, and light weight, which fulfill demands of long-term wearing for the human body. In comparison to traditional TE devices with their longstanding research history, TETs are still in an initial stage of growth. In recent years, TETs to provide electricity for low-power wearable electronics have attracted increasing attention. This review summarizes the recent progress of TETs from the points of selecting TE materials, scalable fabrication methods of TE fibers/yarns and TETs, structure design of TETs and reported high-performance TETs. The key points to develop TETs with outstanding TE properties and mechanical performance and better than available optimization strategies are discussed. Furthermore, remaining challenges and perspectives of TETs are also proposed to suggest practical applications for heat harvesting from human body.

Tuning Thermoelectric Conversion Performance of BiSbTe/Epoxy Flexible Films with Dot Magnetic Arrays

Embedding of magnetic functional units into the thermoelectric (TE) materials has been demonstrated to be an effective way to enhance the TE conversion performance. However, the magnetic functional units in TE materials are all randomly distributed. In this paper, to explore the effect of the ordering of the magnetic functional units on TE conversion performance, a series of BiSbTe/epoxy flexible thermoelectromagnetic (TEM) films with dot magnetic arrays were successfully prepared by a two-step screen printing combined with a hot pressing process. TEM films with dot magnetic arrays can achieve high carrier mobility, while the carrier concentration increases due to large coercivity. Therefore, its electrical conductivities are significantly improved on the condition that it maintains a high Seebeck coefficient. The TEM film with hexagonal-dot magnetic arrays exhibits the best electrical transport properties, for which the room-temperature power factor reaches 1.51 mW·m^-1·K^-2, increased by 33.6 and 36.1% as compared with those of the pristine TE film and the TEM film with a continuous magnetic layer, respectively. This work provides a new way to enhance the TE conversion performance of flexible TEM films through the ordered magnetic arrays.

Wearable Thermoelectric Materials and Devices for Self-Powered Electronic Systems

The emergence of artificial intelligence and the Internet of Things has led to a growing demand for wearable and maintenance-free power sources. The continual push toward lower operating voltages and power consumption in modern integrated circuits has made the development of devices powered by body heat finally feasible. In this context, thermoelectric (TE) materials have emerged as promising candidates for the effective conversion of body heat into electricity to power wearable devices without being limited by environmental conditions. Driven by rapid advances in processing technology and the performance of TE materials over the past two decades, wearable thermoelectric generators (WTEGs) have gradually become more flexible and stretchable so that they can be used on complex and dynamic surfaces. In this review, the functional materials, processing techniques, and strategies for the device design of different types of WTEGs are comprehensively covered. Wearable self-powered systems based on WTEGs are summarized, including multi-function TE modules, hybrid energy harvesting, and all-in-one energy devices. Challenges in organic TE materials, interfacial engineering, and assessments of device performance are discussed, and suggestions for future developments in the area are provided. This review will promote the rapid implementation of wearable TE materials and devices in self-powered electronic systems.

Heat source free water floating carbon nanotube thermoelectric generators

Thermoelectric generators (TEGs) produce electric power from environmental heat energy and are expected to play a key role in powering the Internet of things. However, they require a heat source to create a stable and irreversible temperature gradient. Overcoming these restrictions will allow the use of TEGs to proliferate. Therefore, we propose heat source-free water-floating carbon nanotube (CNT) TEGs. Output voltage and power are generated by the temperature gradient in the CNT films in which water pumping via capillary action leads to evaporation-induced cooling in selected areas. Furthermore, the output voltage and power increase when the films are exposed to sunlight and wind flow. These water-floating CNT TEGs demonstrate a pathway for developing wireless monitoring systems for water environments.

Synthesis and Performance of Large-Scale Cost-Effective Environment-Friendly Nanostructured Thermoelectric Materials

Thermoelectricity is a promising technology that directly converts heat energy into electricity and finds its use in enormous applications. This technology can be used for waste heat recovery from automobile exhausts and industrial sectors and convert the heat from solar energy, especially in hot and humid areas such as Qatar. The large-scale, cost-effective commercialization of thermoelectric generators requires the processing and fabrication of nanostructured materials with quick, easy, and inexpensive techniques. Moreover, the methods should be replicable and reproducible, along with stability in terms of electrical, thermal, and mechanical properties of the TE material. This report summarizes and compares the up-to-date technologies available for batch production of the earth-abundant and ecofriendly materials along with some notorious works in this domain. We have also evaluated and assessed the pros and cons of each technique and its effect on the properties of the materials. The simplicity, time, and cost of each synthesis technique have also been discussed and compared with the conventional methods.

Origin of n type properties in single wall carbon nanotube films with anionic surfactants investigated by experimental and theoretical analyses

We investigated the origin of n-type thermoelectric properties in single-wall carbon nanotube (SWCNT) films with anionic surfactants via experimental analyses and first-principles calculations. Several types of anionic surfactants were employed to fabricate SWCNT films via drop-casting, followed by heat treatment at various temperatures. In particular, SWCNT films with sodium dodecylbenzene sulfonate (SDBS) surfactant heated to 350 °C exhibited a longer retention period, wherein the n-type Seebeck coefficient lasted for a maximum of 35 days. In x-ray photoelectron spectroscopy, SWCNT films with SDBS surfactant exhibited a larger amount of sodium than oxygen on the SWCNT surface. The electronic band structure and density of states of SWCNTs with oxygen atoms, oxygen molecules, water molecules, sulfur atoms, and sodium atoms were analyzed using first-principles calculations. The calculations showed that sodium atoms and oxygen molecules moved the Fermi level closer to the conduction and valence bands, respectively. The water molecules, oxygen, and sulfur atoms did not affect the Fermi level. Therefore, SWCNT films exhibited n-type thermoelectric properties when the interaction between the sodium atoms and the SWCNTs was larger than that between the oxygen molecules and the SWCNTs.

A Review on Thermoelectric Generators: Progress and Applications

A thermoelectric effect is a physical phenomenon consisting of the direct conversion of heat into electrical energy (Seebeck effect) or inversely from electrical current into heat (Peltier effect) without moving mechanical parts. The low efficiency of thermoelectric devices has limited their applications to certain areas, such as refrigeration, heat recovery, power generation and renewable energy. However, for specific applications like space probes, laboratory equipment and medical applications, where cost and efficiency are not as important as availability, reliability and predictability, thermoelectricity offers noteworthy potential. The challenge of making thermoelectricity a future leader in waste heat recovery and renewable energy is intensified by the integration of nanotechnology. In this review, state-of-the-art thermoelectric generators, applications and recent progress are reported. Fundamental knowledge of the thermoelectric effect, basic laws, and parameters affecting the efficiency of conventional and new thermoelectric materials are discussed. The applications of thermoelectricity are grouped into three main domains. The first group deals with the use of heat emitted from a radioisotope to supply electricity to various devices. In this group, space exploration was the only application for which thermoelectricity was successful. In the second group, a natural heat source could prove useful for producing electricity, but as thermoelectricity is still at an initial phase because of low conversion efficiency, applications are still at laboratory level. The third group is progressing at a high speed, mainly because the investigations are funded by governments and/or car manufacturers, with the final aim of reducing vehicle fuel consumption and ultimately mitigating the effect of greenhouse gas emissions.

Thermoelectric Performance Enhancement of Naturally Occurring Bi and Chitosan Composite Films Using Energy Efficient Method

This work presents an energy efficient technique for fabricating flexible thermoelectric generators while using printable ink. We have fabricated thermoelectric composite thick films using two different mesh sizes of n-type bismuth particles, various binder to thermoelectric material weight ratios, and two different pressures, 200 MPa and 300 MPa, in order to optimize the thermoelectric properties of the composite films. The use of chitosan dissolved in dimethylsulfoxide with less than 0.2 wt. % of chitosan, the first time chitosan has been used in this process, was sufficient for fabricating TE inks and composite films. Low temperature curing processes, along with uniaxial pressure, were used to evaporate the solvent from the drop-casted inks. This combination reduced the temperature needed compared to traditional curing processes while simultaneously increasing the packing density of the film by removing the pores and voids in the chitosan-bismuth composite film. Microstructural analysis of the composite films reveals low amounts of voids and pores when pressed at sufficiently high pressures. The highest performing composite film was obtained with the weight ratio of 1:2000 binder to bismuth, 100-mesh particle size, and 300 MPa of pressure. The best performing bismuth chitosan composite film that was pressed at 300 MPa had a power factor of 4009 ± 391 μW/m K2 with high electrical conductivity of 7337 ± 522 S/cm. The measured thermal conductivity of this same sample was 4.4 ± 0.8 W/m K and the corresponding figure of merit was 0.27 at room temperature.

Laser Treatment as Sintering Process for Dispenser Printed Bismuth Telluride Based Paste

Laser sintering as a thermal post treatment method for dispenser printed p- and n-type bismuth telluride based thermoelectric paste materials was investigated. A high-power fiber laser (600 W, 1064 nm) was used in combination with a scanning system to achieve high processing speed. A Design of Experiment (DoE) approach was used to identify the most relevant processing parameters. Printed layers were laser treated with different process parameters and the achieved sheet resistance, electrical conductivity, and Seebeck coefficient are compared to tube furnace processed reference specimen. For p-type material, electrical conductivity of 22 S/cm was achieved, compared to 15 S/cm in tube furnace process. For n-type material, conductivity achieved by laser process was much lower (7 S/cm) compared to 88 S/cm in furnace process. Also, Seebeck coefficient decreases during laser processing (40-70 µV/K and -110 µV/K) compared to the oven process (251 µV/K and -142 µV/K) for p- and n-type material. DoE did not yet deliver a set of optimum processing parameters, but supports doubts about the applicability of area specific laser energy density as a single parameter to optimize laser sintering process.

Flexible Thermoelectric Materials and Generators: Challenges and Innovations

The urgent need for ecofriendly, stable, long-lifetime power sources is driving the booming market for miniaturized and integrated electronics, including wearable and medical implantable devices. Flexible thermoelectric materials and devices are receiving increasing attention, due to their capability to convert heat into electricity directly by conformably attaching them onto heat sources. Polymer-based flexible thermoelectric materials are particularly fascinating because of their intrinsic flexibility, affordability, and low toxicity. There are other promising alternatives including inorganic-based flexible thermoelectrics that have high energy-conversion efficiency, large power output, and stability at relatively high temperature. Herein, the state-of-the-art in the development of flexible thermoelectric materials and devices is summarized, including exploring the fundamentals behind the performance of flexible thermoelectric materials and devices by relating materials chemistry and physics to properties. By taking insights from carrier and phonon transport, the limitations of high-performance flexible thermoelectric materials and the underlying mechanisms associated with each optimization strategy are highlighted. Finally, the remaining challenges in flexible thermoelectric materials are discussed in conclusion, and suggestions and a framework to guide future development are provided, which may pave the way for a bright future for flexible thermoelectric devices in the energy market.

Thermoelectric properties enhancement of p-type composite films using wood-based binder and mechanical pressing

Thermoelectric generators (TEGs) fabricated using additive manufacturing methods are attractive because they offer the advantages of scalability, lower cost, and potentially higher power density than conventional TEGs. Additive manufacturing of TEGs requires active thermoelectric particles to be dispersed in a polymer binder to synthesize printable slurries, and printed films to be subsequently subjected to a long and high temperature curing to enhance their thermoelectic properties. A large amount of polymer binder present in composite films results in a sizable loss in the electrical conductivity. In addition, a long and high-temperature film curing results is a slow and energy intensive fabrication process. In this work, we demonstrate the feasibility of using a small amount (≤10⁻³ wt ratio) of novel nanofiber cellulose (NFC) as a binder to provide sufficient adhesion strength to hold the TE particles together in the composite films. We also demonstrate a pressure induced densification process to enhance the thermoelectic properties of printed composite films. This novel approach has the potential to fundamentally transform the manufacting method for printing TEGs by eliminating the need of long-duration and high-temperature curing. A higher applied pressure leads to a compact packing and densification of films resulting in an improvement in the electrical conductivity. The highest power factor achieved for best performing p-type thermoelectric-NFC composite film subjected to pressure induced densification is 611 μW/m-K².

Materials and Wearable Devices for Autonomous Monitoring of Physiological Markers

Wearable devices are gaining considerable attention owing to the ease with which they can collect crucial information in real-time, both continuously and noninvasively, regarding a wearer's health. A concise summary is given of the three main elements that enable autonomous detection and monitoring of the likelihood or the existence of a health-risk state in continuous and real-time modes, with an emphasis on emerging materials and fabrication techniques in the relevant fields. The first element is the sensing technology used in the noninvasive detection of physiological markers relevant to the state of health. The second element is self-powered devices for longer periods of use by drawing energy from bodily movement and temperature. The third element is the self-healing properties of the materials used in the wearable devices to extended usage if they become scratched or cut. Promises and challenges of the separately reviewed parts and the combined parts are presented and discussed. Ideas regarding further improvement of skin-based wearable devices are also presented and discussed.

Realizing zT of 2.3 in Ge1-x-y Sbx Iny Te via Reducing the Phase-Transition Temperature and Introducing Resonant Energy Doping

GeTe with rhombohedral-to-cubic phase transition is a promising lead-free thermoelectric candidate. Herein, theoretical studies reveal that cubic GeTe has superior thermoelectric behavior, which is linked to (1) the two valence bands to enhance the electronic transport coefficients and (2) stronger enharmonic phonon-phonon interactions to ensure a lower intrinsic thermal conductivity. Experimentally, based on Ge_1-x Sb_x Te with optimized carrier concentration, a record-high figure-of-merit of 2.3 is achieved via further doping with In, which induces the distortion of the density of states near the Fermi level. Moreover, Sb and In codoping reduces the phase-transition temperature to extend the better thermoelectric behavior of cubic GeTe to low temperature. Additionally, electronic microscopy characterization demonstrates grain boundaries, a high-density of stacking faults, and nanoscale precipitates, which together with the inevitable point defects result in a dramatically decreased thermal conductivity. The fundamental investigation and experimental demonstration provide an important direction for the development of high-performance Pb-free thermoelectric materials.

High-Performance Screen-Printed Thermoelectric Films on Fabrics

Printing techniques could offer a scalable approach to fabricate thermoelectric (TE) devices on flexible substrates for power generation used in wearable devices and personalized thermo-regulation. However, typical printing processes need a large concentration of binder additives, which often render a detrimental effect on electrical transport of the printed TE layers. Here, we report scalable screen-printing of TE layers on flexible fiber glass fabrics, by rationally optimizing the printing inks consisting of TE particles (p-type Bi_0.5Sb_1.5Te₃ or n-type Bi₂Te_2.7Se_0.3), binders, and organic solvents. We identified a suitable binder additive, methyl cellulose, which offers suitable viscosity for printability at a very small concentration (0.45–0.60 wt.%), thus minimizing its negative impact on electrical transport. Following printing, the binders were subsequently burnt off via sintering and hot pressing. We found that the nanoscale defects left behind after the binder burnt off became effective phonon scattering centers, leading to low lattice thermal conductivity in the printed n-type material. With the high electrical conductivity and low thermal conductivity, the screen-printed TE layers showed high room-temperature ZT values of 0.65 and 0.81 for p-type and n-type, respectively.

Engineered Molecular Chain Ordering in Single-Walled Carbon Nanotubes/Polyaniline Composite Films for High-Performance Organic Thermoelectric Materials

Single-walled carbon nanotubes (SWNTs)/polyaniline (PANI) composite films with enhanced thermoelectric properties were prepared by combining in situ polymerization and solution processing. Conductive atomic force microscopy and X-ray diffraction measurements confirmed that solution processing and strong π-π interactions between the PANI and SWNTs induced the PANI molecules to form a highly ordered structure. The improved degree of order of the PANI molecular arrangement increased the carrier mobility and thereby enhanced the electrical transport properties of PANI. The maximum in-plane electrical conductivity and power factor of the SWNTs/PANI composite films reached 1.44×10(3)  S cm(-1) and 217 μW m(-1)  K(-2) , respectively, at room temperature. Furthermore, a thermoelectric generator fabricated with the SWNTs/PANI composite films showed good electric generation ability and stability. A high power density of 10.4 μW cm(-2)  K(-1) was obtained, which is superior to most reported results obtained in organic thermoelectric modules.