Hafnia-plugged microcavities for thermal stability of selective emitters

Two-dimensional arrays of micro-cavities effectively control photon motion and selectively emit radiation tailored to the preferred bandgap of photovoltaic (PV) cells, thus enhancing the efficiency of thermophotovoltaic energy conversion. At the high operating temperatures, however, the micro- and nano-patterned structures of the selective emitters quickly lose their integrity––obliterating the tight tolerances required for precise spectral control. Even if oxidation, recrystallization, and grain growth could be avoided with single-crystal tungsten (W) selective emitters with vacuum packaging, surface diffusion, evaporation, and re-condensation are not avoidable in long-term operation at high temperatures. The concept of a planar array of plugged micro-cavities to suppress the curvature-dependent thermal degradation modes is proposed and tested. Based on scale-accelerated failure tests of silicon devices, the lifetime of W selective emitters operating at 1100 K is estimated to be at least 30 yr.