Photoelectrosynthetically active heterostructures

• US 9,593,053 B1
• Filed: 11/14/2012
• Issued: 03/14/2017
• Est. Priority Date: 11/14/2011
• Status: Active Grant

• Current Assignee: Hypersolar, Inc.
• Original Assignee: Hypersolar, Inc.
• Inventors: Hussaini, Syed Mubeen Jawahar, McFarland, Eric, Young, Tim, Singh, Nirala
• Primary Examiner(s): Parker, Allen
• Assistant Examiner(s): Bradley, Stephen
• Application Number:
  US13/676,901
• Time in Patent Office: 1,581 Days
• US Class Current: 1/1
• CPC Class Codes: C07C 1/0495 Non-catalytic processes; Catalytic processes in which there is also another way of activation, e.g. radiation
• CPC Class Codes: C23C 14/24 Vacuum evaporation
• CPC Class Codes: C23C 14/5873 Removal of material
• CPC Class Codes: C23C 16/45525 Atomic layer deposition [ALD]
• CPC Class Codes: C25B 1/55 Photoelectrolysis
• CPC Class Codes: C25D 7/126 for solar cells
• CPC Class Codes: H01G 9/20 Light-sensitive devices
• CPC Class Codes: H01L 31/0236 Special surface textures
• CPC Class Codes: H01L 31/0336 in different semiconductor regions, e.g. Cu2X/CdX hetero- junctions, X being an element of Group VI of the Periodic Table
• CPC Class Codes: H01L 31/108 the potential barrier being of the Schottky type
• CPC Class Codes: H01L 31/186 Particular post-treatment for the devices, e.g. annealing, impurity gettering, short-circuit elimination, recrystallisation
• CPC Class Codes: Y02E 10/50 Photovoltaic [PV] energy
• CPC Class Codes: Y02P 20/133 Renewable energy sources, e.g. sunlight

Abstract

A two-step process, consisting of a photoelectrosynthetic process combined with a thermochemical process, is configured to produce a reduction product (e.g., methane gas, methanol, or carbon monoxide) from carbon dioxide and liquid waste streams. In a first step, photoelectrosynthetically active heterostructures (PAHs) and sunlight are used to drive oxidation/reduction reactions in which one primary product is hydrogen gas. In the second step, hydrogen generated in the first step is thermally catalytically reacted with carbon dioxide to form a reduction product from carbon dioxide (e.g., CO, formaldehyde, methane, or methanol). Synthesis gas (CO and H₂) can be further reacted to form alkanes. The methods and systems may employ PAHs known in the art or improved PAHs having lower costs, improved stability, solar energy conversion efficiency, and/or other desired attributes as disclosed herein.

Claims

1. A photoelectrosynthetically active heterostructure (PAH), comprising:

a continuous sheet-like material forming or supporting a protective structure having a plurality of cavities defining electrically insulating partitions;

a plurality of independent light absorbing units, each including one or more types or regions of n-type or p-type semiconductor material, each independent light absorbing unit being disposed entirely within a cavity of the protective structure such that the protective structure partially covers and protects the semiconductor material of each independent light absorbing unit from corrosion, and such that each independent light absorbing unit is separated from and independent of other light absorbing units of the PAH;

one or more cathodes coupled to the independent light absorbing units;

one or more anodes coupled to the independent light absorbing units and being isolated from the one or more cathodes so that each independent light absorbing unit is autonomous from other light absorbing units; and

a hydrogen permeable layer covering the one or more cathodes.

2. A photoelectrosynthetically active heterostructure as in claim 1, wherein the semiconductor material comprises one or more p-n junctions formed by one or more p-type semiconductor materials adjacent to one or more corresponding n-type semiconductor materials.

3. A photoelectrosynthetically active heterostructure as in claim 1, wherein the semiconductor material comprises one or more Schottky junctions formed by one or regions of p-type semiconductor material and/or n-type semiconductor material and one or more Schottky barriers.

4. A photoelectrosynthetically active heterostructure as in claim 1, wherein the semiconductor material comprises at least one p-type semiconductor material selected from the group consisting of intrinsic or p-doped SnS, ZnS, CdS, CdSe, CdTe, Cu₂S, WS₂, Cu_xO, Cu₂ZnSnS₄, CuIn_xGa_1-xSe₂, GaN, InP, or SiC;

doped (p-type) or undoped elemental Si or Ge; and

doped (p-type) or undoped compound semiconductors selected from metal sulfides, selenides, arsenides, nitrides, antinomides, phosphides, oxides, tellurides, and mixtures containing, respectively, sulfur (S) selenium (Se), arsenic (As), antimony (Sb), nitrogen (N), oxygen (O) tellurium (Te), and/or phosphorus (P) as one or more electronegative element(s) A, and one or more metals (M), of the form M_nA_x where M is one or a combination of elements selected from Cu, Ga, Ge, Si, Zn, Sn, W, In, Ni, Fe, Mo, Bi, Sb, or Mg.

5. A photoelectrosynthetically active heterostructure as in claim 1, wherein the semiconductor material comprises at least one n-type semiconductor material selected from the group consisting of intrinsic or n-doped InS, CdTe, CdS, CdSe, CdTe, Cu₂S, WS₂, Cu_xO, Cu₂ZnSnS₄, CuIn_xGa_1-xSe₂, GaN, InP, or SiC;

doped (n-type) or undoped elemental Si or Ge; and

doped (n-type) or undoped compound semiconductors selected from metal sulfides, selenides, arsenides, nitrides, antinomides, phosphides, oxides, tellurides, and their mixtures containing respectively, sulfur (S), selenium (Se), arsenic (As), antimony (Sb), nitrogen (N), oxygen (O), tellurium (Te), and/or phosphorus (P) as one or more electronegative element(s) (A), and one or more metals (M), of the form M_nA_x where M is one or a combination of elements selected from Cu, Ga, Ge, Si, Zn, Sn, W, In, Ni, Fe, Mo, Bi, Sb, or Mg.

6. A photoelectrosynthetically active heterostructure as in claim 1, wherein the one or more cathodes comprise at least one conductor material selected from the group consisting of platinum group metals, Pt, Au, transition metals, transition metal oxides, NiO, metal carbides, WC, metal sulfides, MoS₂, electrical conducting carbon containing materials, graphite, graphene, and carbon nanotubes.

7. A photoelectrosynthetically active heterostructure as in claim 1, wherein the one or more anodes comprise at least one conductor material selected from the group consisting of metals, oxides and mixtures of metals selected from Ru, Ag, V, W, Fe, Ni, Pt, Pd, Ir, Cr, Mn, Cu, or Ti;

metal sulfides;

MoS₂;

electrical conducting carbon containing materials;

graphite;

graphene; and

carbon nanotubes.

8. A photoelectrosynthetically active heterostructure as in claim 1, wherein the protective structure comprises at least one electrically insulating material selected from the group consisting of Al₂O₃, SiO₂, ZrO, AlF₃, TiF₂, ZnO, TiO₂, and oxides of n-type or p-type semiconductor materials.

9. A photoelectrosynthetically active heterostructure as in claim 1, wherein the hydrogen permeable layer comprises at least one material selected from the group consisting of chromium (III) oxide (Cr₂O₃), nafion membranes made from sulfonated tetrafluoroethylene-based fluoropolymer-copolymers, acrylics, mixtures of metal oxides, WCrO_x, and WZrCeO_x.

10. A photoelectrosynthetically active heterostructure as in claim 1, further comprising an interface between the semiconductor material and the protective structure that minimizes electron/hole recombination and/or surface electronic trap states.

11. A photoelectrosynthetically active heterostructure as in claim 10, wherein the interface between the semiconductor material and the protective structure comprises a thin layer of ZnO.

12. A photoelectrosynthetically active heterostructure as in claim 1, wherein:

at least one cathode is coupled to an independent light absorbing unit via an interface between the cathode and the semiconductor material that provides an electrically conductive pathway and minimizes resistance and charge recombination; and

at least one anode is coupled to an independent light absorbing unit via an interface between the anode and the semiconductor material that provides an electrically conductive pathway and minimizes resistance and charge recombination.

13. A photoelectrosynthetically active heterostructure as in claim 12, wherein:

the interface between the cathode and the semiconductor material comprises hydrogen terminated silicon, Si—

H, prepared by treating the Si in dilute buffered HF solution with a layer of Ti to serve as an ohmic contact, and

the interface between the anode and the semiconductor material comprises at least material selected from the group consisting of hydrogen terminated silicon (Si—

H) prepared by treating the Si in dilute buffered HF solution, 1 or 2 atomic layers of Al or Mg.

14. A photoelectrosynthetically active heterostructure as in claim 1, wherein each independent light absorbing unit of the PAH comprises multiple light absorbers connected in series by semiconductor contacts.

15. A photoelectrosynthetically active heterostructure as in claim 1, wherein the one or more cathodes and/or the one or more anodes are disposed at least partially within respective cavities of the protective structure.

16. A photoelectrosynthetically active heterostructure as in claim 15, wherein the one or more cathodes are formed as a plurality of separate cathodes electrically independent of one another, each being disposed at least partially within respective cavities of the protective structure, and wherein the one or more anodes are disposed adjacent to the protective structure, on an end of the protective structure opposite the cathodes.

17. A photoelectrosynthetically active heterostructure as in claim 15, wherein the one or more anodes are formed as plurality of separate anodes electrically independent of one another, each being disposed at least partially within respective cavities of the protective structure, and wherein the one or more cathodes are disposed adjacent to the protective structure, on an end of the protective structure opposite the anodes.

18. A photoelectrosynthetically active heterostructure as in claim 1, wherein the protective structure comprises a porous anodic aluminum oxide.

19. A photoelectrosynthetically active heterostructure (PAH), comprising:

a porous metal oxide protective structure having a honeycomb structure with a plurality of channels extending therethrough, each channel having a first opening and a second opening;

one or more semiconductor materials disposed in the channels and comprising independent light absorbing units, each independent light absorbing unit being disposed within a respective channel of the protective structure and not extending beyond a respective first opening or second opening of the channel such that a portion of the semiconductor material of each unit is protected from corrosion by the protective structure;

one or more cathodes, each disposed at a first opening and each coupled to a region of semiconductor material;

one or more anodes, each disposed at a second opening and each coupled to a region of semiconductor material, wherein the one or more anodes are isolated from the one or more cathodes so that each independent light absorbing unit is autonomous from other light absorbing units; and

a hydrogen permeable layer covering the one or more cathodes.

20. A photoelectrosynthetically active heterostructure (PAH), comprising:

a porous metal oxide protective structure having a honeycomb structure with a plurality of channels extending therethrough, each channel having a first opening and a second opening;

one or more semiconductor materials disposed in the channels and comprising independent light absorbing units, each independent light absorbing unit being disposed within a respective channel of the protective structure and not extending beyond a respective first opening or second opening of the channel such that a portion of the semiconductor material of each unit is protected from corrosion by the protective structure;

a plurality of cathodes, each disposed at a respective first opening and coupled to a region of semiconductor material of a respective independent light absorbing unit so as to be electrically isolated from and independent of other cathodes of the PAH;

a plurality of anodes, each disposed at a respective second opening and coupled to a region of semiconductor material of a respective independent light absorbing unit so as to be electrically isolated from and independent of other anodes of the PAH and so that each independent light absorbing unit is autonomous from other light absorbing units; and

a hydrogen permeable layer comprising chromium oxide covering the plurality of cathodes,

wherein each of the cathodes and/or each of the anodes is disposed at least partially within a respective cavity of the protective structure.