Methods for manufacturing photoelectrosynthetically active heterostructures
First Claim
1. A method of manufacturing a photoelectrosynthetically active heterostructure, comprising:
- forming or providing a plurality of nanosized cavities in an electrically insulating material;
forming or providing a layer of an electrically conductive metal on one side of the electrically insulating material;
depositing an electrocatalyst cathode layer in the plurality of cavities to form a plurality of cathodes;
depositing one or more layers of light-absorbing semiconductor material in the plurality of cavities;
depositing an electrocatalyst anode layer in the plurality of cavities to form a plurality of anodes;
removing the layer of electrically conductive metal; and
forming a hydrogen permeable layer over the electrocatalyst cathode layer,wherein the plurality of nanosized cavities are spaced so as to form a plurality of independent light absorbing units, andwherein the electrocatalyst anode layer is coupled to the independent light absorbing units and is isolated from the electrocatalyst cathode layer so that each independent light absorbing unit is autonomous from other light absorbing units.
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Accused Products
Abstract
A photoelectrosynthetically active heterostructure (PAH) is manufactured by forming or providing cavities in an electrically insulating material; forming or providing an electrically conductive layer on a side of the electrically insulating material; depositing an electrocatalyst cathode layer in the cavities; depositing one or more layers of light-absorbing semiconductor material in the cavities; depositing an electrocatalyst anode layer in the cavities; removing the layer of electrically conductive metal; and forming a hydrogen permeable layer over the electrocatalyst cathode layer. The one or more layers of light-absorbing semiconductor material can form a p-n junction or Schottky junction. The PAH can be used in photoelectrosynthetic processes to produce desired products, such as reduction product (e.g., methane gas, methanol, or carbon monoxide) from carbon dioxide and liquid waste streams.
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Citations
18 Claims
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1. A method of manufacturing a photoelectrosynthetically active heterostructure, comprising:
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forming or providing a plurality of nanosized cavities in an electrically insulating material; forming or providing a layer of an electrically conductive metal on one side of the electrically insulating material; depositing an electrocatalyst cathode layer in the plurality of cavities to form a plurality of cathodes; depositing one or more layers of light-absorbing semiconductor material in the plurality of cavities; depositing an electrocatalyst anode layer in the plurality of cavities to form a plurality of anodes; removing the layer of electrically conductive metal; and forming a hydrogen permeable layer over the electrocatalyst cathode layer, wherein the plurality of nanosized cavities are spaced so as to form a plurality of independent light absorbing units, and wherein the electrocatalyst anode layer is coupled to the independent light absorbing units and is isolated from the electrocatalyst cathode layer so that each independent light absorbing unit is autonomous from other light absorbing units. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15)
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16. A method of manufacturing a photoelectrosynthetically active heterostructure, comprising:
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forming or providing a protective membrane comprising an electrically insulating sheet and a plurality of cavities in the electrically insulating sheet; forming or providing an electrically conductive metal layer on one side of the electrically insulating sheet; depositing by electrodeposition, vapor deposition, chemical vapor deposition, or atomic layer vapor deposition an electrocatalyst cathode layer in the plurality of cavities; depositing by electrodeposition, vapor deposition, chemical vapor deposition, or atomic layer vapor deposition one or more layers of light-absorbing semiconductor material in the plurality of cavities; depositing by electrodeposition, vapor deposition, chemical vapor deposition, or atomic layer vapor deposition an electrocatalyst anode layer in the plurality of cavities; and removing the electrically conductive metal layer from the electrically insulating sheet, wherein the plurality of nanosized cavities are spaced so as to form a plurality of independent light absorbing units, and wherein the electrocatalyst anode layer is coupled to the independent light absorbing units and is isolated from the electrocatalyst cathode layer so that each independent light absorbing unit is autonomous from other light absorbing units. - View Dependent Claims (17)
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18. A method of manufacturing a photoelectrosynthetically active heterostructure, comprising:
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forming or providing a protective membrane comprising anodized aluminum oxide and a plurality of nanosized pores in the protective membrane; forming or providing an electrically conductive metal layer on one side of the protective membrane; electrodepositing an electrocatalyst cathode material in the plurality of nanosized pores; electrodepositing one or more layers of light-absorbing semiconductor material in the plurality of nanosized pores; electrodepositing an electrocatalyst anode material in the plurality of nanosized pores; and removing the electrically conductive metal layer from the protective membrane, wherein the plurality of nanosized pores are arranged so as to provide a plurality of independent light absorbing units, and wherein the electrocatalyst anode material is coupled to the independent light absorbing units and is isolated from the electrocatalyst cathode material so that each independent light absorbing unit is autonomous from other light absorbing units.
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Specification