Abstract: A thermophotovoltaic generator uses conveniently available liquid hydrocarbon fuels. The fuels are controllably heated and vaporized before ignition to avoid residue and deposits as a result of liquid fuel being prematurely exposed to high temperatures of combustion causing unwanted breakdowns, producing power robbing residues and deposits. Heating fuel and air to right temperatures for ignition is accomplished by drawing combustion air over an exhaust chamber, through a regenerator and through a passage surrounding an IR filter. A separate cooling fan drives air through photovoltaic cell array fins over the recuperator and the exhaust in counterflow to the combustion air.

Abstract: Heterojunction GaSb Photocells for operating in wavelengths around 1.6 microns have P type GaSb wafers with backside P+ back metal contacts. Patterned active areas are created on the front side and receive a thin passivation film. A thin N+ transparent SnO2 or tin conductive oxide is deposited on the passivation film. A front contact grid is deposited. The thin passivating film is either amorphous silicon (a-Si:H) or TiO2 with a hydrogen plasma pretreatment. The deposited N+ transparent SnO2 or tin conductive oxide forms an N+/P Heterojunction cell. Front grid contacts and full back contacts are deposited. An antireflective coating is applied through the grids.

Abstract: A compact power supply and battery substitute has a cylindrical wall with combustion air and cooling air fans at opposite ends. Air and fuel vapor flows through a mixing tube and an Omega recuperator to a combustion chamber and heats IR emitters spaced from TPV cells. An emitter post array or a catalytic matched emitter are heated by combustion. Exhaust is conducted through the recuperator that heats secondary air and fuel vapors and air in a mixing tube. Cooling air flows over fins radially extending from the TPV cells and past the recuperator and, mixes with exhaust from the recuperators and flows out of the housing past the combustion air fan. Fans are self-powered, and resulting electric power replaces batteries.

Abstract: A one-axis azimuth sun-tracking carousel where the PV panels are mounted at a fixed tilt in operation can be mounted on a flat roof building without roof penetration and without risk of wind damage. The carousel is prefabricated and sized to carry the maximum power while still fitting in a standard shipping container. Panel support arms fold down for shipping or in the event of a hurricane to make the carousel less than 9 inches high. Because this carousel is prefabricated and compact, it can be easily hoisted up on a roof for rapid low-cost installation. Wind skirts provide low wind resistance in high wind situations during normal operation. In order to survive high winds without roof penetration, wire tether tie points allow several carousels in an array to be tethered together and to the building parapet walls.

Abstract: A solar PV panel has an array of primary mirrors that collects and reflects solar radiation toward an array of dichroic secondary elements. The dichroic secondary elements reflect near-visible solar radiation to an array of near-visible radiation sensitive solar cells and simultaneously transmit infrared radiation to an array of infrared sensitive solar cells. The array of near-visible radiation sensitive cells and the array of infrared sensitive cells are wired in series. The optical properties of the dichoic secondary element, near-visible radiation sensitive cell, and IR sensitive cell are chosen for simultaneous maximum power production from the panel.

Abstract: A planar concentrator solar power module has a planar base, an aligned array of linear photovoltaic cell circuits on the base and an array of linear Fresnel lenses or linear mirrors for directing focused solar radiation on the aligned array of linear photovoltaic cell circuits. The cell circuits are mounted on a back panel which may be a metal back plate. The cell circuit area is less than a total area of the module. Each linear lens or linear mirror has a length greater than a length of the adjacent cell circuit. The cell circuit may have cells mounted in shingle fashion to form a shingled-cell circuit. In an alternative module, linear extrusions on the circuit element have faces for mounting the linear mirrors for deflecting sun rays impinging on each mirror onto the shingled-cells. The linear extrusions are side-wall and inner extrusions with triangular cross-sections. The circuit backplate is encapsulated by lamination for weather protection.

Abstract: A planar concentrator solar power module has a planar base, an aligned array of linear photovoltaic cell circuits on the base and an array of linear Fresnel lenses or linear mirrors for directing focused solar radiation on the aligned array of linear photovoltaic cell circuits. The cell circuits are mounted on a back panel which may be a metal back plate. The cell circuit area is less than a total area of the module. Each linear lens or linear mirror has a length greater than a length of the adjacent cell circuit. The cell circuit may have cells mounted in shingle fashion to form a shingled-cell circuit. In an alternative module, linear extrusions on the circuit element have faces for mounting the linear mirrors for deflecting sun rays impinging on each mirror onto the shingled-cells. The linear extrusions are side-wall and inner extrusions with triangular cross-sections. The circuit backplate is encapsulated by lamination for weather protection.

Abstract: An emitter for use with a generator has a tube closed at one end, heated from its outside with a water-cooled photovoltaic converter array mounted inside for glass-melting application. Several TPV tubes may be inserted through holes in the insulation into the port sections between the glass-melting furnace and the regenerators. Any one of these tubes may be removed for maintenance at any time and replaced with a closure to close off the hole, without affecting the industrial process. The emitter tube may be a SiC or KANTHAL tube. The tube may be lines on its inside with AR coated tungsten foil or the tungsten may be deposited on the inner tube surface as a film followed by the AR coating. The photovoltaic converter array may comprise a polygonal array of shingle circuits where the circuits are fabricated using low bandgap GaSb cells.

Abstract: Our cylindrical TPV generator uses low bandgap PV cells mounted on circuits in a polygonal array around an IR emitter. The combustion gases are completely contained within the radiant tube burner. The PV array is mounted inside a leak-tight envelope cooled on its outer surface by either water or air flow. Flanges on either end of this PV array container allow for hermetic seals. A folded back coaxial emitter support tube provides a long path length limiting thermal conduction along its cylindrical wall from the very hot emitter section to the cooled seal flange. In our improved cylindrical TPV generator, we provide for a low temperature catalytic after-burn by providing a perforated turnaround plate coupling between the inner disk stack and the outer disk stack. This perforated turnaround plate provides a small amount of combustion air for the after-burn. A catalyst coating can be provided on the hotter surface of the outer finned disks. The after-burn occurs in the outer finned disk stack.

Abstract: A hydrocarbon thermophotovoltaic (TPV)electric generator insert has applications as a replacement burner to retrofit existing appliances. The retrofitted appliance is thus upgraded to either a cogeneration or self-powered unit. The design of the TPV burner insert is independent of the appliance to be retrofitted except for external adapters and can be easily retrofitted to any appliance design requiring a hydrocarbon burner. The burner uses fully premixed air and fuel near stoichiometry to attain a short duration, high intensity burn through optically dense porous ceramic emitters. The emitters attain temperatures between 1300° and 1500° C. The infrared radiation is collected by low bandgap photovoltaic cells with optical response at least out to a wavelength of 1.7 micrometers such as GaSb cells to produce DC power. The circuit cooling system uses fans or circulating water for cooling.

Abstract: Two-terminal circuit has top and bottom cells bonded to an insulating substrate with the top cells bonded on top of the bottom cells. Bottom cells are connected in series through ribbon bonds. Top cells are connected in parallel through ribbon bonds. The ribbon bonds connect to the topsides of the top and bottom cells. The substrate contains metal die bonding pads for the base contacts to the bottom cells. Metal traces are provided for ribbon bond connections to emitter contacts for the bottom cells. A metal trace becomes a positive terminal pad for the bottom cells and a negative terminal for a second pad for the bottom cells. Two cell assemblies may be series connected by connecting positive top cell output connectors with negative pads of top cells in adjacent cell assemblies, and by connecting positive bottom cell output connectors with negative pads of bottom cells in adjacent assemblies.

Abstract: A compact forced air cooled thermophotovoltaic generator includes a TPV converter assembly, a fan which is driven by electric power generated by the converter assembly and a housing for enclosing the assembly and fan. The assembly includes a fuel/air mixing tube, an infrared emitter positioned in the combustion chamber, a receiver positioned around the emitter and a heat shield positioned between the receiver and the emitter. The receiver includes a circuit having TPV cells connected to an inner surface and radial fins extending from an outer surface. A fuel source may be provided proximate (i.e. beneath) the mixing tube or may be remotely connected to the mixing tube by a fuel line. A housing encloses the TPV converter assembly and the fuel source, if provided as part of the unit. A fan or other updraft mechanism electrically connected to the cell circuit is provided at the bottom of the housing beneath the fuel source and/or converter assembly.

Abstract: A shingle circuit array and a method of assembling the shingle circuit is provided. The array has a shingle circuit with a substrate, an insulation film layer, a metal layer and TPV cells connected to the metal layer in series forming a shingle pattern with terraces. The substrate is of CTE matched material. The metal layer may be copper pads deposited on the terraces. The TPV cells are bonded to the copper pads and may be GaSb cells. Substrate materials include AlSiC or a Cu/Invar/Cu laminate sheet. The AlSiC material may be a microstructure having a continuous Al-metal phase with a discrete SiC particulate phase. The substrate may also be an enameled cast-iron substrate. The shingle circuit array may be provided in a TPV generator.

Abstract: The present invention is a hydrocarbon fired thermophotovoltaic furnace having a non-fused silica tube. In a preferred embodiment, the furnace has an infrared emitter tube having a top end and a bottom end and a substantially transparent non-fused silica window tube having a closed top end. The window tube is positioned concentrically around the infrared emitter tube, and the infrared emitter tube is in fluid communication with the window tube. The window tube is preferably composed of Lucalox (alumina or Chromolux), magnesia, yterria, titania, spinel, stablized zirconia or yterria alumina garnet. In another preferred embodiment, the furnace has a radiator tube having a top end and a bottom end and an infrared emitter tube having a closed top end. The infrared emitter tube is positioned concentrically around the radiator tube, and the radiator tube is in fluid communication with the infrared emitter tube. Fluid flows from the inner tube to the outer tube.

Abstract: Thermophotovoltaic (TPV) electric power generators have emitters with infrared (IR) outputs matched with usable wavelengths for converter cells. The emitters have durable substrates, optional refractory isolating layers, conductive refractory metal or inter-metallic emitter layers, and refractory metal oxide antireflection layers. SiC substrates have tungsten or TaSi2 emitter layers and 0.14 micron HfO2, ZrO2, Al2O3, Ta2O5 and TiO2 antireflection layers used as IR emitters for GaSb converter cells in TPV generators.

Abstract: A shingle circuit array and a method of assembling the shingle circuit is provided. The array has a shingle circuit with a substrate, an insulation film layer, a metal layer and TPV cells connected to the metal layer in series forming a shingle pattern with terraces. The substrate is of CTE matched material. The metal layer may be copper pads deposited on the terraces. The TPV cells are bonded to the copper pads and may be GaSb cells. Examples of substrate materials include AlSiC or a Cu/Invar/Cu laminate sheet. The AlSiC material may be a microstructure having a continuous Al-metal phase with a discrete SiC particulate phase. The shingle circuit array may be provided in a TPV generator.

Abstract: A small and light cylindrical thermophotovoltaic generator uses gaseous fuels, a counter flow heat exchanger, regenerator and low bandgap photovoltaic cells. In the fuel injection system, with preheated air from a recuperator, fuel combustion begins immediately when the fuel and air first meet. A hot and compact burn results from complete and rapid fuel and air mixing. A venturi necks down the air flow, and a chemically etched jet shim disk creates over 150 small fuel jet streams. The emitter geometric configuration provides good hot gas energy transfer to the IR emitter. Four alternate emitter configurations accomplish the good heat transfer. One emitter is a composite SiC with integrally formed internal fins which extend into the combustion chamber. The photovoltaic converter assembly has good spectral control, good high rate but lightweight heat removal and high current-carrying capability, while maintaining low parasitic IR absorption.

Abstract: Thermophotovoltaic (TPV) electric power generators have emitters with infrared (IR) outputs matched with usable wavelengths for converter cells. The emitters have durable substrates, optional refractory isolating layers, conductive refractory metal or inter-metallic emitter layers, and refractory metal oxide antireflection layers. SiC substrates have tungsten or TaSi2 emitter layers and 0.14 micron ZrO2 or Al2O3 antireflection layers used as IR emitters for GaSb converter cells in TPV generators.

Abstract: A three-layer solid infrared emitter having a spectral output matched to low bandgap TPV cells is provided. The three layers include inner and outer layers, and a core layer between the inner and outer layers. The core layer is of solid fiber reinforced undoped refractory oxide material. The inner layer of siC material absorbs radiation from the radiator, the core layer conducts heat from the inner layer to the outer layer. The core layer is a strengthening layer forming a diffuse reflector for stopping a shine-through of long wavelength radiation from the inner layer thereby preserving spectral selectivity in the outer layer. The emitter material may be cobalt doped, nickel doped, or combination of Ni or Co doped refractory oxides with erbia or a thin erbia selective emitter layer.

Abstract: A TPV cell apparatus with a base region of GaSb crystals. The GaSb crystals are of varying orientations and joined at grain boundaries. A surface region is provided on the GaSb crystals. The GaSb crystals are Tellurium doped N-type GaSb and the surface region is thin Zinc doped P-type GaSb cells. The surface region faces an infrared source. A bus region is connected to a metal grid connected which is in contact with the surface region of the cell. A continuous metal layer is in contact with the GaSb crystals. A multilayer coating is provided on a front side of the cell. The multilayer coating forms an infrared filter for transmitting convertible infrared energy to the cell and for reflecting as much of non-convertible infrared energy back to the IR source as possible. A TPV generator may be provided with the TPV cells.