Inverse Design of Photonic Surfaces via High throughput Femtosecond Laser Processing and Tandem Neural Networks.

This work demonstrates a method to design photonic surfaces by combining femtosecond laser processing with the inverse design capabilities of tandem neural networks that directly link laser fabrication parameters to their resulting textured substrate optical properties. High throughput fabrication and characterization platforms are developed that generate a dataset comprising 35280 unique microtextured surfaces on stainless steel with corresponding measured spectral emissivities. The trained model utilizes the nonlinear one-to-many mapping between spectral emissivity and laser parameters. Consequently, it generates predominantly novel designs, which reproduce the full range of spectral emissivities (average root-mean-squared-error < 2.5%) using only a compact region of laser parameter space 25 times smaller than what is represented in the training data. Finally, the inverse design model is experimentally validated on a thermophotovoltaic emitter design application. By synergizing laser-matter interactions with neural network capabilities, the approach offers insights into accelerating the discovery of photonic surfaces, advancing energy harvesting technologies.

Visualization of Porous Composite Battery Electrode Fabrication Dynamics for Different Formulations and Conditions Using Hard X-ray Microradiography.

Porous composite battery electrode performance is influenced by a large number of manufacturing decisions. While it is common to evaluate only finished electrodes when making process adjustments, one must then make inferences about the fabrication process dynamics from static results, which makes process optimization very costly and time-consuming. To get information about the dynamics of the manufacturing processes of these composites, we have built a miniature coating and drying apparatus capable of fabricating lab-scale electrode laminates while operating within an X-ray beamline hutch. Using this tool, we have collected the first radiography image sequences of lab-scale battery electrode coatings in profile, taken throughout drying processes conducted under industrially relevant conditions. To assist with interpretation of these image sequences, we developed an automated image analysis program. Here, we discuss our observations of battery electrode slurry samples, including stratification and long-term fluid flow, and their relevance to composite electrode manufacturing.

Nonintrusive thermal-wave sensor for operando quantification of degradation in commercial batteries.

Monitoring real-world battery degradation is crucial for the widespread application of batteries in different scenarios. However, acquiring quantitative degradation information in operating commercial cells is challenging due to the complex, embedded, and/or qualitative nature of most existing sensing techniques. This process is essentially limited by the type of signals used for detection. Here, we report the use of effective battery thermal conductivity (keff) as a quantitative indicator of battery degradation by leveraging the strong dependence of keff on battery-structure changes. A measurement scheme based on attachable thermal-wave sensors is developed for non-embedded detection and quantitative assessment. A proof-of-concept study of battery degradation during fast charging demonstrates that the amount of lithium plating and electrolyte consumption associated with the side reactions on the graphite anode and deposited lithium can be quantitatively distinguished using our method. Therefore, this work opens the door to the quantitative evaluation of battery degradation using simple non-embedded thermal-wave sensors.

High throughput, spatially resolved thermal properties measurement using attachable and reusable 3ω sensors.

The 3ω method is a well-established thermal technique used to measure the thermal conductivity of materials and the thermal resistance of interfaces. It has significant advantages over other steady state and transient thermal techniques in its ability to provide spatially resolved thermal property measurements over a wide range of thermal conductivity. Despite its advantages, it has been restricted to lab-scale use because of the difficulty involved in sample preparation and sensor fabrication and is limited to non-metallic substrates. High-throughput 3ω measurements with reusable sensors have not been realized yet. In this work, we demonstrate a method of applying reusable 3ω sensors fabricated on flexible polyimide films to measure bulk and spatially resolved thermal properties. We establish the limits of thermal conductivity measurement with the method to be 1 to 200 W/mK, and within the measurement limit, we verify the method by comparing the measured thermal conductivities of standard samples with established values. From the 3ω measurements, we also determine the thermal resistance of an interlayer of thermal grease as a function of pressure and compare it against the resistance calculated from direct thickness measurements to demonstrate the ability of this method to provide spatially resolved subsurface information. The technique presented is general and applicable to both metallic and non-metallic substrates, providing a method for high-throughput 3ω measurements with reusable sensors and without considerable sample preparation.

Extreme fast charging of commercial Li-ion batteries via combined thermal switching and self-heating approaches.

The mass adoption of electric vehicles is hindered by the inadequate extreme fast charging (XFC) performance (i.e., less than 15 min charging time to reach 80% state of charge) of commercial high-specific-energy (i.e., >200 Wh/kg) lithium-ion batteries (LIBs). Here, to enable the XFC of commercial LIBs, we propose the regulation of the battery's self-generated heat via active thermal switching. We demonstrate that retaining the heat during XFC with the switch OFF boosts the cell's kinetics while dissipating the heat after XFC with the switch ON reduces detrimental reactions in the battery. Without modifying cell materials or structures, the proposed XFC approach enables reliable battery operation by applying <15 min of charge and 1 h of discharge. These results are almost identical regarding operativity for the same battery type tested applying a 1 h of charge and 1 h of discharge, thus, meeting the XFC targets set by the United States Department of Energy. Finally, we also demonstrate the feasibility of integrating the XFC approach in a commercial battery thermal management system.

Using Thermal Interface Resistance for Noninvasive Operando Mapping of Buried Interfacial Lithium Morphology in Solid-State Batteries.

The lithium metal-solid-state electrolyte interface plays a critical role in the performance of solid-state batteries. However, operando characterization of the buried interface morphology in solid-state cells is particularly difficult because of the lack of direct optical access. Destructive techniques that require isolating the interface inadvertently modify the interface and cannot be used for operando monitoring. In this work, we introduce the concept of thermal wave sensing using modified 3ω sensors that are attached to the outside of the lithium metal-solid-state cells to noninvasively probe the morphology of the lithium metal-electrolyte interface. We show that the thermal interface resistance measured by the 3ω sensors relates directly to the physical morphology of the interface and demonstrates that 3ω thermal wave sensing can be used for noninvasive operando monitoring the morphology evolution of the lithium metal-solid-state electrolyte interface.

Distributed desalination using solar energy: A technoeconomic framework to decarbonize nontraditional water treatment.

Desalination using renewable energy offers a route to transform our incumbent linear consumption model to a circular one. This transition will also shift desalination from large-scale centralized coastal facilities toward modular distributed inland plants. This new scale of desalination can be satisfied using solar energy to decarbonize water production, but additional considerations, such as storage and inland brine management, become important. Here, we evaluate the levelized cost of water for 16 solar desalination system configurations at 2 different salinities. For fossil fuel-driven plants, we find that zero-liquid discharge is economically favorable to inland brine disposal. For renewable desalination, we discover that solar-thermal energy is superior to photovoltaics due to low thermal storage cost and that energy storage, despite being expensive, outperforms water storage as the latter has a low utilization factor. The analysis also yields a promising outlook for solar desalination by 2030 as solar generation and storage costs decrease.

Morphological Ordering of the Organic Layer for High-Performance Hybrid Thermoelectrics.

Inorganic-organic hybrids, such as Te-PEDOT:PSS core/shell nanowires, have emerged as a class of promising thermoelectric materials with combined attributes of mechanical flexibility and low cost. However, the poorly understood structure-property relationship calls for further investigation for performance enhancement. Here, through precise treatments of focused electron beam irradiation and thermal annealing on individual Te-PEDOT:PSS nanowires, new, nonchemical mechanisms are introduced to specifically engineer the organic phase, and the measured results provide an unprecedented piece of evidence, confirming the dominant role of organic shell in charge transport. Paired with the Kang-Snyder model and molecular dynamics simulations, this work provides mechanistic insights in terms of heating-enabled morphological ordering of the polymer chains. The measured results show that thermal annealing on the 42 nm nanowire results in a ZT value of 0.78 at 450 K. Through leveraging the interfacial self-assembly of the organic phase to construct a high electrical conductivity domain, this work lays out a clear framework for the development of next-generation soft thermoelectrics.

Ionocaloric refrigeration cycle.

Developing high-efficiency cooling with safe, low-global warming potential refrigerants is a grand challenge for tackling climate change. Caloric effect-based cooling technologies, such as magneto- or electrocaloric refrigeration, are promising but often require large applied fields for a relatively low coefficient of performance and adiabatic temperature change. We propose using the ionocaloric effect and the accompanying thermodynamic cycle as a caloric-based, all-condensed-phase cooling technology. Theoretical and experimental results show higher adiabatic temperature change and entropy change per unit mass and volume compared with other caloric effects under low applied field strengths. We demonstrated the viability of a practical system using an ionocaloric Stirling refrigeration cycle. Our experimental results show a coefficient of performance of 30% relative to Carnot and a temperature lift as high as 25°C using a voltage strength of ~0.22 volts.

Optical emissivity dataset of multi-material heterogeneous designs generated with automated figure extraction.

Optical device design is typically an iterative optimization process based on a good initial guess from prior reports. Optical properties databases are useful in this process but difficult to compile because their parsing requires finding relevant papers and manually converting graphical emissivity curves to data tables. Here, we present two contributions: one is a dataset of thermal emissivity records with design-related parameters, and the other is a software tool for automated colored curve data extraction from scientific plots. We manually collected 64 papers with 176 figures reporting thermal emissivity and automatically retrieved 153 colored curve data records. The automated figure analysis software pipeline uses Faster R-CNN for axes and legend object detection, EasyOCR for axes numbering recognition, and k-means clustering for colored curve retrieval. Additionally, we manually extracted geometry, materials, and method information from the text to add necessary metadata to each emissivity curve. Finally, we analyzed the dataset to determine the dominant classes of emissivity curves and determine the underlying design parameters leading to a type of emissivity profile.

Methods to stabilize aqueous supercooling identified by use of an isochoric nucleation detection (INDe) device.

Stable aqueous supercooling has shown significant potential as a technique for human tissue preservation, food cold storage, conservation biology, and beyond, but its stochastic nature has made its translation outside the laboratory difficult. In this work, we present an isochoric nucleation detection (INDe) platform for automated, high-throughput characterization of aqueous supercooling at >1 mL volumes, which enables statistically-powerful determination of the temperatures and time periods for which supercooling in a given aqueous system will remain stable. We employ the INDe to investigate the effects of thermodynamic, surface, and chemical parameters on aqueous supercooling, and demonstrate that various simple system modifications can significantly enhance supercooling stability, including isochoric (constant-volume) confinement, hydrophobic container walls, and the addition of even mild concentrations of solute. Finally, in order to enable informed design of stable supercooled biopreservation protocols, we apply a statistical model to estimate stable supercooling durations as a function of temperature and solution chemistry, producing proof-of-concept supercooling stability maps for four common cryoprotective solutes.

Thermal fluids with high specific heat capacity through reversible Diels-Alder reactions.

Thermal fluids are used as heat transfer fluids and thermal energy storage media in many energy technologies ranging from solar thermal heating to battery thermal management. The heat capacity of state-of-the-art thermal fluids remains ∼50% of that of water (which suffers from a limited operation range between 0°C and 100°C), and their viscosities are typically more than one order of magnitude higher than that of water. Our results demonstrate that the heat capacity of the proposed thermochemical fluid is significantly higher than that of state-of-the-art thermal fluids over a broad temperature range and is also higher than that of water between 60°C and 90°C. The viscosity of our liquid is only 3 times higher than that of water, and the operating temperature range is between -90°C and 135°C. Furthermore, a model was developed allowing for novel design of thermochemical thermal fluids in the future with even higher heat capacity.

Integrated cooling (i-Cool) textile of heat conduction and sweat transportation for personal perspiration management.

Perspiration evaporation plays an indispensable role in human body heat dissipation. However, conventional textiles tend to focus on sweat removal and pay little attention to the basic thermoregulation function of sweat, showing limited evaporation ability and cooling efficiency in moderate/profuse perspiration scenarios. Here, we propose an integrated cooling (i-Cool) textile with unique functional structure design for personal perspiration management. By integrating heat conductive pathways and water transport channels decently, i-Cool exhibits enhanced evaporation ability and high sweat evaporative cooling efficiency, not merely liquid sweat wicking function. In the steady-state evaporation test, compared to cotton, up to over 100% reduction in water mass gain ratio, and 3 times higher skin power density increment for every unit of sweat evaporation are demonstrated. Besides, i-Cool shows about 3 °C cooling effect with greatly reduced sweat consumption than cotton in the artificial sweating skin test. The practical application feasibility of i-Cool design principles is well validated based on commercial fabrics. Owing to its exceptional personal perspiration management performance, we expect the i-Cool concept can provide promising design guidelines for next-generation perspiration management textiles.

High thermoelectric figure of merit of porous Si nanowires from 300 to 700 K.

Thermoelectrics operating at high temperature can cost-effectively convert waste heat and compete with other zero-carbon technologies. Among different high-temperature thermoelectrics materials, silicon nanowires possess the combined attributes of cost effectiveness and mature manufacturing infrastructures. Despite significant breakthroughs in silicon nanowires based thermoelectrics for waste heat conversion, the figure of merit (ZT) or operating temperature has remained low. Here, we report the synthesis of large-area, wafer-scale arrays of porous silicon nanowires with ultra-thin Si crystallite size of ~4 nm. Concurrent measurements of thermal conductivity (κ), electrical conductivity (σ), and Seebeck coefficient (S) on the same nanowire show a ZT of 0.71 at 700 K, which is more than ~18 times higher than bulk Si. This ZT value is more than two times higher than any nanostructured Si-based thermoelectrics reported in the literature at 700 K. Experimental data and theoretical modeling demonstrate that this work has the potential to achieve a ZT of ~1 at 1000 K.

Decoupling electron and phonon transport in single-nanowire hybrid materials for high-performance thermoelectrics.

Organic-inorganic hybrids have recently emerged as a class of high-performing thermoelectric materials that are lightweight and mechanically flexible. However, the fundamental electrical and thermal transport in these materials has remained elusive due to the heterogeneity of bulk, polycrystalline, thin films reported thus far. Here, we systematically investigate a model hybrid comprising a single core/shell nanowire of Te-PEDOT:PSS. We show that as the nanowire diameter is reduced, the electrical conductivity increases and the thermal conductivity decreases, while the Seebeck coefficient remains nearly constant-this collectively results in a figure of merit, ZT, of 0.54 at 400 K. The origin of the decoupling of charge and heat transport lies in the fact that electrical transport occurs through the organic shell, while thermal transport is driven by the inorganic core. This study establishes design principles for high-performing thermoelectrics that leverage the unique interactions occurring at the interfaces of hybrid nanowires.

Solar Desalination Using Thermally Responsive Ionic Liquids Regenerated with a Photonic Heater.

Growing global water demand has brought desalination technologies to the forefront for freshwater production from nontraditional water sources. Among these, forward osmosis (FO) is a promising two-step desalination process (draw dilution and regeneration), but it is often overlooked due to the energy requirements associated with draw regeneration. To address this limiting factor, we demonstrate FO desalination using thermally responsive ionic liquids (ILs) that are regenerated using a renewable energy input, that is, solar heat. To efficiently harness sunlight, a simple photonic heater converts incoming irradiation into infrared wavelengths that are directly absorbed by IL-water mixtures, thereby inducing phase separation to yield clean water. This approach is markedly different as it uses radiative heating, a noncontact mode of heat transfer that couples to chemical functional groups within the IL for rapid energy transfer without a heat exchanger or secondary fluid. Overall, a solar-thermal separation efficiency of 50% is achieved under unconcentrated sunlight, which can be increased to 69% with the thermal design. Successful desalination of produced water from oil wells in Southern California highlights the potential of solar-powered IL-FO for energy-efficient and low-cost desalination of complex brines for beneficial water reuse.

Water Freezes at Near-Zero Temperatures Using Carbon Nanotube-Based Electrodes under Static Electric Fields.

Although static electric fields have been effective in controlling ice nucleation, the highest freezing temperature (Tf) of water that can be achieved in an electric field (E) is still uncertain. We performed a systematic study of the effect of an electric field on water freezing by varying the thickness of a dielectric layer and the voltage across it in an electrowetting system. Results show that Tf first increases sharply with E and then reaches saturation at -3.5 °C after a critical value E of 6 × 106 V/m. Using classical heterogeneous nucleation theory, it is revealed that this behavior is due to saturation in the contact angle of the ice embryo with the underlying substrate. Finally, we show that it is possible to overcome this freezing saturation by controlling the uniformity of the electric field using carbon nanotubes. We achieve a Tf of -0.6 °C using carbon nanotube-based electrodes with an E of 3 × 107 V/m. This work sheds new light on the control of ice nucleation and has the potential to impact many applications ranging from food freezing to ice production.

Aqueous Diels-Alder reactions for thermochemical storage and heat transfer fluids identified using density functional theory.

Thermal storage and transfer fluids have important applications in industrial, transportation, and domestic settings. Current thermal fluids have relatively low specific heats, often significantly below that of water. However, by introducing a thermochemical reaction to a base fluid, it is possible to enhance the fluid's thermal properties. In this work, density functional theory (DFT) is used to screen Diels-Alder reactions for use in aqueous thermal fluids. From an initial set of 52 reactions, four are identified with moderate aqueous solubility and predicted turning temperature near the liquid region of water. These reactions are selectively modified through 60 total functional group substitutions to produce novel reactions with improved solubility and thermal properties. Among the reactions generated by functional group substitution, seven have promising predicted thermal properties, significantly improving specific heat (by as much as 30.5%) and energy storage density (by as much as 4.9%) compared to pure water.

Far-field coherent thermal emission from polaritonic resonance in individual anisotropic nanoribbons.

Coherent thermal emission deviates from the Planckian blackbody emission with a narrow spectrum and strong directionality. While far-field thermal emission from polaritonic resonance has shown the deviation through modelling and optical characterizations, an approach to achieve and directly measure dominant coherent thermal emission has not materialised. By exploiting the large disparity in the skin depth and wavelength of surface phonon polaritons, we design anisotropic SiO2 nanoribbons to enable independent control of the incoherent and coherent behaviours, which exhibit over 8.5-fold enhancement in the emissivity compared with the thin-film limit. Importantly, this enhancement is attributed to the coherent polaritonic resonant effect, hence, was found to be stronger at lower temperature. A thermometry platform is devised to extract, for the first time, the thermal emissivity from such dielectric nanoemitters with nanowatt-level emitting power. The result provides new insight into the realisation of spatial and spectral distribution control for far-field thermal emission.

Enhanced thermal transport at covalently functionalized carbon nanotube array interfaces.

It has been more than a decade since the experimental demonstration that the thermal conductivity of carbon nanotubes can exceed that of diamond, which has the highest thermal conductivity among naturally occurring materials. In spite of tremendous promise as a thermal material, results have been disappointing for practical thermal systems and applications based on nanotubes. The main culprit for the dramatic shortfall in the performance of nanotubes in practical systems is high thermal interface resistance between them and other components because of weak adhesion at the interface. Here we report a sixfold reduction in the thermal interface resistance between metal surfaces and vertically aligned multiwall carbon nanotube arrays by bridging the interface with short, covalently bonded organic molecules. These results are also significant for single and multilayer graphene applications, since graphene faces similar limitations in practical systems.