Recent advances in printable thermoelectric devices: materials, printing techniques, and applications

The Failure Mechanism of Micro Thermoelectric Devices under the Action of the Temperature Field

The micro thermoelectric device (m-TED) boasts features such as adjustable volume, straightforward structure, and precise, rapid temperature control, positioning it as the only current solution for managing the temperature of microelectronic systems. It is extensively utilized in 5G optical modules, laser lidars, and infrared detection. Nevertheless, as the size of the m-TED diminishes, the growing proportion of interface damages the device's operational reliability, constraining the advancement of the m-TED. In this study, we used commercially available bismuth telluride materials to construct the m-TED. The device's reliability was tested under various temperatures: -40, 85, 125, and 150 °C. By deconstructing and analyzing the devices that failed during the tests, we discovered that the primary cause of device failure was the degradation of the solder layer. Moreover, we demonstrated that encapsulating the device with polydimethylsiloxane (PDMS) could effectively delay the deterioration of its performance. This study sparks new insights into the service reliability of m-TEDs and paves the way for further optimizing device interface design and enhancing the device manufacturing process.

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.

Thermal Nanoimprint Lithography-A Review of the Process, Mold Fabrication, and Material

Micro- and nanopatterns perform unique functions and have attracted attention in various industrial fields, such as electronic devices, microfluidics, biotechnology, optics, sensors, and smart and anti-adhesion surfaces. To put fine-patterned products to practical use, low-cost patterning technology is necessary. Nanoimprint lithography (NIL) is a promising technique for high-throughput nanopattern fabrication. In particular, thermal nanoimprint lithography (T-NIL) has the advantage of employing flexible materials and eliminating chemicals and solvents. Moreover, T-NIL is particularly suitable for compostable and recyclable materials, especially when applying biobased materials for use in optics and electronics. These attributes make T-NIL an eco-friendly process. However, the processing time of normal T-NIL is longer than that of ultraviolet (UV) NIL using a UV-curable resin because the T-NIL process requires heating and cooling time. Therefore, many studies focus on improving the throughput of T-NIL. Specifically, a T-NIL process based on a roll-to-roll web system shows promise for next-generation nanopatterning techniques because it enables large-area applications with the capability to process webs several meters in width. In this review, the T-NIL process, roll mold fabrication techniques, and various materials are introduced. Moreover, metal pattern transfer techniques using a combination of nanotransfer printing, T-NIL, and a reverse offset are introduced.

Carbon Nanomaterials-Based Screen-Printed Electrodes for Sensing Applications

Electrochemical sensors consisting of screen-printed electrodes (SPEs) are recurrent devices in the recent literature for applications in different fields of interest and contribute to the expanding electroanalytical chemistry field. This is due to inherent characteristics that can be better (or only) achieved with the use of SPEs, including miniaturization, cost reduction, lower sample consumption, compatibility with portable equipment, and disposability. SPEs are also quite versatile; they can be manufactured using different formulations of conductive inks and substrates, and are of varied designs. Naturally, the analytical performance of SPEs is directly affected by the quality of the material used for printing and modifying the electrodes. In this sense, the most varied carbon nanomaterials have been explored for the preparation and modification of SPEs, providing devices with an enhanced electrochemical response and greater sensitivity, in addition to functionalized surfaces that can immobilize biological agents for the manufacture of biosensors. Considering the relevance and timeliness of the topic, this review aimed to provide an overview of the current scenario of the use of carbonaceous nanomaterials in the context of making electrochemical SPE sensors, from which different approaches will be presented, exploring materials traditionally investigated in electrochemistry, such as graphene, carbon nanotubes, carbon black, and those more recently investigated for this (carbon quantum dots, graphitic carbon nitride, and biochar). Perspectives on the use and expansion of these devices are also considered.

Hydrogel-based printing strategy for high-performance flexible thermoelectric generators

Flexible thermoelectric (TE) devices can utilize the slight temperature difference between curved surfaces and surroundings to generate TE potential, presenting great potential in microelectronic energy supply and wearable sensing. Printing method has been employed to fabricate high-performance flexible TE films by means of excellent capability of assembling nanomaterials, but the decrease in the electrical conductivity caused by organic matters in the thermoelectric pastes will significantly reduce the thermoelectric performance. Herein, we report a hydrogel-based printing strategy to deposit flexible TE generators on various flexible substrates. The hydrogel network formed by physical crosslinking and molecular chain entanglement at 0.498 wt% carboxylated cellulose nanofibers can effectively limit the fluidity of 1D nanorod dispersion, which produces only <5% decline in electrical conductivity and Seebeck coefficient compared to the pure inorganic nanorod films. The device with 72 couples constructed by printing presents a high power density of 1.278 W m^-2 under a temperature difference of 50 K. The advantages of hydrogel-based printing can broaden application prospects in the field of wearable electronics.

High Figure-of-Merit Telluride-Based Flexible Thermoelectric Films through Interfacial Modification via Millisecond Photonic-Curing for Fully Printed Thermoelectric Generators

The thermoelectric generator (TEG) shows great promise for energy harvesting and waste heat recovery applications. Cost barriers for this technology could be overcome by using printing technologies. However, the development of thermoelectric (TE) materials that combine printability, high-efficiency, and mechanical flexibility is a serious challenge. Here, flexible (SbBi)₂ (TeSe)₃ -based screen-printed TE films exhibiting record-high figure of merits (ZT) and power factors are reported. A high power factor of 24 µW cm^-1  K^-2 (ZT_max  ≈ 1.45) for a p-type film and a power factor of 10.5 µW cm^-1  K^-2 (ZT_max  ≈ 0.75) for an n-type film are achieved. The TE inks, comprised of p-Bi_0.5 Sb_1.5 Te₃ (BST)/n-Bi₂ Te_2.7 Se_0.3 (BT) and a Cu-Se-based inorganic binder (IB), are prepared by a one-pot synthesis process. The TE inks are printed on different substrates and sintered using photonic-curing leading to the formation of a highly conducting β-Cu_{2- δ} Se phase that connects "microsolders," the grains resulting in high-performance. Folded TEGs (f-TEGs) are fabricated using the materials. A half-millimeter thick f-TEG exhibits an open-circuit voltage (V_OC ) of 203 mV with a maximum power density (p_max ) of 5.1 W m^-2 at ∆T = 68 K. This result signifies that a few millimeters thick f-TEG could power Internet-of-Things (IoTs) devices converting low-grade heat to electricity.

Thermal management and control of wearable devices

The emergence of wearable devices over the recent decades has motivated numerous studies aimed at developing flexible or stretchable materials and structures for their electronic or optoelectronic functionalities. Like in conventional devices, electronic and optoelectronic components in wearable devices must be kept within certain temperature ranges to ensure reliability, performance, and/or functionality. But this must be accomplished without requiring any bulky heat sinks or other heat transfer augmentation elements. At the same time, the proximity of wearable devices to the human skin poses additional requirements of thermal comfort and safety. A growing body of literature is now focusing on the thermal management or control of wearable devices and related development of new materials and structures. The present article aims to provide a broad overview of such materials and structures and offer suggestions for future research directions.

Printed Thermoelectrics

The looming impact of climate change and the diminishing supply of fossil fuels both highlight the need for a transition to more sustainable energy sources. While solar and wind can produce much of the energy needed, to meet all our energy demands there is a need for a diverse sustainable energy generation mix. Thermoelectrics can play a vital role in this, by harvesting otherwise wasted heat energy and converting it into useful electrical energy. While efficient thermoelectric materials have been known since the 1950s, thermoelectrics have not been utilized beyond a few niche applications. This can in part be attributed to the high cost of manufacturing and the geometrical restraints of current commercial manufacturing techniques. Printing offers a potential route to manufacture thermoelectric materials at a lower price point and allows for the fabrication of generators that are custom built to meet the waste heat source requirements. This review details the significant progress that has been made in recent years in printing of thermoelectric materials in all thermoelectric material groups and printing methods, and highlights very recent publications that show printing can now offer comparable performance to commercially manufactured thermoelectric materials.

Extravascular Cooling of Blood Using a Concentrated Thermoelectric Cooling Probe

Thermal therapies have strong potential for improving outcomes for patients suffering from cardiac arrest, neonatal hypoxic-ischemic encephalopathy, or medically refractory intracranial hypertension. We propose a novel tool to manipulate blood temperature through extravascular thermoelectric heat exchange of blood vessel walls and flowing blood. This tool is a concentrated cooling probe with several thermoelectric units combined to focus cooling at the application site. Using this tool, we aim to achieve desired levels of temperature control and potentially reduce complications associated with traditional intravascular or systemic thermal therapies. Leveraging the feedback control, speed, and reversible operation of thermoelectric cooling modules, the device can adapt to cool or heat as desired. Pre-clinical testing on rodent models confirmed rapid, significant reduction of intravenous jugular blood temperature when a prototype device was brought in contact with the left carotid artery (change in blood temperature of -4.74 ± 2.9 °C/hr and -4.29 ± 1.64 °C/hr for 0 °C and -5 °C cooling trials respectively). Declines in rectal temperature were also noted, but at lesser magnitudes than for jugular blood (0 °C: -3.09 ± 1.29 °C/hr; -5 °C: -2.04 ± 1.08), indicating proof-of-concept of thermoelectric extravascular blood cooling within a relatively localized region of the body. With further improvements in the technique, there is potential for selective organ cooling via reduction in flowing blood temperature.

Printing thermoelectric inks toward next-generation energy and thermal devices

The ability of thermoelectric (TE) materials to convert thermal energy to electricity and vice versa highlights them as a promising candidate for sustainable energy applications. Despite considerable increases in the figure of merit zT of thermoelectric materials in the past two decades, there is still a prominent need to develop scalable synthesis and flexible manufacturing processes to convert high-efficiency materials into high-performance devices. Scalable printing techniques provide a versatile solution to not only fabricate both inorganic and organic TE materials with fine control over the compositions and microstructures, but also manufacture thermoelectric devices with optimized geometric and structural designs that lead to improved efficiency and system-level performances. In this review, we aim to provide a comprehensive framework of printing thermoelectric materials and devices by including recent breakthroughs and relevant discussions on TE materials chemistry, ink formulation, flexible or conformable device design, and processing strategies, with an emphasis on additive manufacturing techniques. In addition, we review recent innovations in the flexible, conformal, and stretchable device architectures and highlight state-of-the-art applications of these TE devices in energy harvesting and thermal management. Perspectives of emerging research opportunities and future directions are also discussed. While this review centers on thermoelectrics, the fundamental ink chemistry and printing processes possess the potential for applications to a broad range of energy, thermal and electronic devices.

Development of a schwarzite-based moving bed 3D printed water treatment system for nanoplastic remediation

The impact of micro and nanoplastic debris on our aquatic ecosystem is among the most prominent environmental challenges we face today. In addition, nanoplastics create significant concern for environmentalists because of their toxicity and difficulty in separation and removal. Here we report the development of a 3D printed moving bed water filter (M-3DPWF), which can perform as an efficient nanoplastic scavenger. The enhanced separation of the nanoplastics happens due to the creation of a charged filter material that traps the more surface charged nanoparticles selectively. Synthetic contaminated water from polycarbonate waste has been tested with the filter, and enhanced nanoplastic removal has been achieved. The proposed filtration mechanism of surface-charge based water cleaning is further validated using density function theory (semi-empirical) based simulation. The filter has also shown good structural and mechanical stability in both static and dynamic water conditions. The field suitability of the novel treatment system has also been confirmed using water from various sources, such as sea, river, and pond. Our results suggest that the newly developed water filter can be used for the removal of floating nanoparticles in water as a robust advanced treatment system.

The impact of micro and nanoplastic debris on our aquatic ecosystem is among the most prominent environmental challenges we face today.

Infinite Approaching Superlubricity by Three-Dimensional Printed Structures

The rapid development of three-dimensional (3D) printing technology opens great opportunities for the design of various multiscale lubrication structures. 3D printing allows high customization of arbitrary complex structures and rapid prototyping of objects, which provides an avenue to achieve effective lubrication. Current experimental observations on superlubricity are limited to atomically smooth clean surfaces, extreme operating conditions, and nano- or microscales. With the in-depth exploration of 3D printed lubrication, construction of multifunctional 3D structures with refined dimensions spanning from micronanoscale to macroscale is increasingly regarded as an important means to approach superlubricity and has aroused great scientific interest. To document recent advances in 3D printing for structural lubrication, a detailed literature review is provided. Emphasis is given on the design and lubrication performance of geometric and bioinspired lubrication structures with characteristic dimensions. The material requirements, merits, drawbacks, and representative applications of various 3D printing techniques are summarized. Potential future research trends aiming at the design strategy and manufacturing process of 3D printed lubrication structures are also highlighted.

Enhanced Output Performance of All-Solution-Processed Organic Thermoelectrics: Spray Printing and Interface Engineering

We report two organocompatible strategies to enhance the output performance of all-solution-processed poly(3,4-ethylenedioxythiophene):poly(styrenesulfonate) (PEDOT:PSS) thermoelectric generators (TEGs): introducing an additive spray printing process and functionalized polymer interlayers to reduce the module resistance. The spray printing enabled the deposition of 1-μm-thick PEDOT:PSS layers with a high degree of design freedom, resulting in a significantly reduced sheet resistance of 16 Ω sq^-1 that is closely related to the thermoelectric output performance. Also, by inserting an ultrathin silane-terminated polystyrene (PS) interlayer between the PEDOT:PSS thermoelectric layers and inkjet-printed Ag interconnects selectively, the contact resistivity extracted by the transmission line method was reduced from 6.02 × 10^-2 to 2.77 × 10^-2 Ω cm². We found that the PS interlayers behaved as a thin tunneling layer, which facilitated the carrier injection from the inkjet-printed Ag electrodes into the PEDOT:PSS films by field emission with an effectively lowered energy barrier. The activation energy was also extracted using the Richardson equation, resulting in a reduction of 2.59 ± 0.04 meV after the PS treatment. Scalable plastic-compatible processability and selective interface engineering enabled to demonstrate the flexible 74-leg PEDOT:PSS TEGs exhibiting the open-circuit voltage of 9.21 mV and the output power of 2.23 nW at a temperature difference of 10 K.