Silicon carbide increases energy efficiency

Illustration of the fill port of a silicon single crystal bar which has been prepared by the zone melting process. (Photo: TRUMPF Hüttinger)
To increase the efficiency of the power supply in industrial processes, thereby saving energy and CO2, the aim of the new joint "MMPSiC": Researchers at the Light Technology Institute (LTI) at the Karlsruhe Institute of Technology (KIT) examine together with the industrial partners TRUMPF Hüttinger and IXYS Semiconductor the use of power semiconductor switches of silicon carbide. The Federal Research Ministry is supporting the project with around 800,000 euros.

Of the semiconductor manufacturing over the coating of displays to processes in the automotive industry: Many industrial processes consume large amounts of electrical energy. Among these are technologies that will play an important role in the energy transition, as the zone melting method (float zone method) for producing high purity crystalline materials: The substance is electrically fused in a narrow zone; the melting zone is gradually continued. Behind the melting zone crystallized substance purer than before. The zone melting method provides, among other high-purity silicon single crystals for the manufacture of solar cells.

Power supply of zone melting systems based on tube technology systems are used to now having an electrical efficiency of up to 65 percent. By switching to power semiconductor silicon carbide, the efficiency of the process power supply could be increased to over 80 percent. This would save large amounts of electrical energy and reduce greenhouse gas emissions. For example, for a single float-zone scale plant would result consisting of 20 x 150 kW-process power supplies, with an annual duration of 4800 hours, a savings of more than 200,000 kWh of electrical energy and 109 tonnes of CO2 (Umweltbundesamt, as of July 2013).

The feasibility of such a process power supplies, researchers at the Light Technology Institute (LTI) of KIT together with the partners TRUMPF Hüttinger GmbH + Co. KG (Freiburg) and IXYS Semiconductor GmbH (Lampertheim) in the joint project "Modular medium frequency process power supply with silicon carbide semiconductor power switches" (MMPSiC) , As the semiconductor material Silicon Carbide offers several advantages: Thanks to the larger electronic band gap allows much higher operating temperatures than conventional semiconductors. Power electronics with silicon carbide is characterized by higher energy efficiency and compactness.

"When the power of energy-intensive industrial applications such as the zone melting method, it is necessary to switch at high frequencies," says the project director, Dr. Rainer Kling from LTI of KIT. "Silicon carbide is not yet tested for these high frequencies; so that we are breaking new ground. "In addition to examining the long-term stability include the control and the layout of the circuit to the tasks of the KIT researchers in the joint project MMPSiC.

The Federal Ministry of Education and Research (BMBF) supports MMPSiC project on the basis of the program "Information and Communication Technology 2020" (ICT 2020) as part of the funding program "Power electronics to increase energy efficiency" (LES 2) with around 800,000 euros. Of which receives the LTI KIT around 439,000 euros. Overall, the project volume is 1.3 million euros. The joint project started in 2014 and is planned for three years.

Source: KIT

Intelligent training with a fitness shirt and an e-bike

The FitnessSHIRT reads out physiological signals like pulse and breath continuously when worn. The interpreted data can be viewed on a smartphone or tablet PC, for example. Credit: © Fraunhofer IIS

Fabric manufacturers are experiencing a revolution at present: if clothing previously offered protection against the cold, rain, and snow, the trend now is toward intelligent, proactive, high-tech textiles like self-cleaning jackets, gloves that recognize toxins, and ski anoraks with integrated navigational devices to make life easier for those wearing them.

Most clever clothing is only at the prototype stage. It is by no means off-the-rack yet. Soon the FitnessSHIRT from the Fraunhofer Institute for Integrated Circuits IIS in Erlangen, Germany, will be ready for the mass market. It continuously measures physiological signals such as breathing, pulse, and changes in heart rate -- metrics of adaptability and stress load. The intelligent sports shirt is expected to be available sometime in the next year, as an investor is already on-board.

Smart electronics are hidden in the material

Conductive textile electrodes integrated into the shirt's material capture the wearer's cardio activity. In addition, an elastic band around the upper body senses the motion of the chest during breathing. A removable electronic unit attached with snaps digitizes the raw data and calculates additional parameters like pulse rate or breath rate with the help of algorithms. The data are transmitted via radio link to a smartphone or optionally to a PC, where they are evaluated further and can be stored. These parameters form the basis for judging vital functions like stress, performance, exertion, or relaxation.

"The FitnessSHIRT can be employed a number of ways. It offers completely new options for the pursuit of sports, leisure activities, and wellness, as well as options for the medical branch," says Christian Hofmann, an engineer at IIS. For example, it could act as a training partner to provide seniors or rehabilitation patients with feedback on their vital signs during exercises or bicycling, and protect them from overexertion. Athletes will also benefit: for one thing, the SHIRT is more comfortable to wear than a chest strap. For another, the integrated sensors deliver more detailed information. Besides pulse and respiration, accelerometers sense the movement of the user and carry out an analysis. "If the pulse rate is high, for example, while the breath rate and the exercise activity is low, it could be a sign of possible heart problems," according to Hofmann.

The developers of the MENTORbike are also persuaded by the high degree of comfort when worn and the possibilities for performance diagnostics. MENTORbike is a new type of training device consisting of a pedelec, a smartphone, and an intelligent user service site on the internet. The project partners, led by BitifEye Digital Test Solutions, want to use the pedelec in combination with the FitnessSHIRT from IIS in future. The SHIRT will have a wireless connection via smartphone to the pedelec and the user service site on the internet, where the data can be viewed, analyzed, and documented. The smartphone mounted on the bicycle handlebars collects the vital parameters it receives like pulse and breath rate as well as the physical data, for instance the energy expended and the speed, analyzes them, and cuts in the electric motor as needed.

"If the pulse rate exceeds a maximum value of 150, for example, the rider is supported by the motor taking some of the load. If the pulse rate falls below a value of 80 beats per minute, the electric motor is throttled back and the pedal loading increased again. The motor output adapts automatically to the fitness of the cyclist," explains Markus Gratzfeld, an engineer with BitifEye. In this way, users are assured of an optimal level of training at all times, with neither over- nor under-exertion. Rehabilitation patients, especially persons with cardiovascular disease, could monitor their performance limits better, exercise more confidently, and increase their range of movement.

Source: Fraunhofer-Gesellschaft

Defects in solar cells made of silicon identified

Sergio Castellanos wants continue researching, work in an industry and does not rule out to eventually move to another country. Credit: Image courtesy of Investigación y Desarrollo

Since he was a teenager, engineer Sergio Castellanos had the desire to study abroad to prepare and do research in the best laboratories, particularly on solar energy. With six years of stay in the United States, first at the University of Arizona and now at the Massachusetts Institute of Technology (MIT) in Boston, his dream has come true:

"Working on defects found on silicon and their impact on the efficiency of solar cells made with this material."

This research is carried out to obtain his doctorate from MIT.

"Dislocation is a defect that occurs at high temperatures, of 500 ° C onwards. In my research I analyze these defects and their impact on the efficiency of solar cells made from silicon, since this material is used in over 90 percent of solar panels worldwide ."

The Mexican researcher in Boston explains that the harmful part of the dislocation is interacting with other defects such as metallic impurities within the material of solar cells; they tend to reduce efficiency by -for example- interacting with electrons.

"When having a dislocation is very easy for impurities to settle into a defect in the material. Therefore, in my research I analyze at an early scale what kind of dislocations will be more harmful to the cells, meaning, which ones will interact more with impurities because not all do likewise, hence not all dislocations are equally harmful."

The proposal of Sergio Castellanos at the MIT is to apply a method in wafers of polycrystalline silicon before being processed into solar cells. This method involves using a chemical treatment in order to view the dislocations and analyze the geometric variation on the surface. After making crystallographic analysis as well as X-rays for determining the distribution and concentration of metal impurities, a correlation is made with the geometric appearance of the surface and then, just by looking at the surface, one can deduce what the electrical behavior within material will be.

"The goal is to identify which areas of the material will be more likely for electrons to recombine before being extracted by contacts, becoming less efficient cells."

A little bit of history

When the native of Hermosillo, Sonora (northern state of Mexico), was in high school, he applied for the Massachusetts Institute of Technology (MIT) and was not admitted. He told himself he would not be discouraged because surely the opportunity would could come later. He decided to study mechanical engineering at the Technological Institute of Hermosillo and two years in his parents supported him to finish his degree abroad.

He was transferred to the University of Arizona where he finished his degree. At the university, he became involved in several projects on the subject of energy, as was the case with hydrogen cells, a solar car and installing solar panels.

The Mexican says he enjoyed doing research and started looking for projects and teachers who worked in that area. He spotted four scientists, but wanted to go to MIT because "for any engineer to be in this school is a dream. I had practice in energy research during my bachelor's and for my doctorate I looked for subjects in this area. I applied at several universities and at last I was admitted at MIT in Boston."

His research in solar cells is in the last stage, and once completed in the next year he will make it available to other researchers. This work was presented at various conferences and has received good reviews in terms of utility.

To "finish the tale" on solar cells, the Mexican will complete his studies in six to eight months, and is more than satisfied with the subject that has developed during his research.

Sergio Castellanos wants continue researching, work in an industry and does not rule out to eventually move to another country. In the remaining months he will define his next step. (Agencia ID)

Source: Investigación y Desarrollo

Scientists get to the heart of fool's gold as a solar material

This crystal of iron pyrite shows the characteristic cubic crystals of 'fool's gold.' A new study led by Song Jin at the University of Wisconsin-Madison identifies defects in pyrite's crystal structure as a critical obstacle to building commercial solar cells from the cheap and abundant iron pyrite material. Credit: University of Wisconsin-Madison Geology Museum

As the installation of photovoltaic solar cells continues to accelerate, scientists are looking for inexpensive materials beyond the traditional silicon that can efficiently convert sunlight into electricity.

Theoretically, iron pyrite -- a cheap compound that makes a common mineral known as fool's gold -- could do the job, but when it works at all, the conversion efficiency remains frustratingly low. Now, a University of Wisconsin-Madison research team explains why that is, in a discovery that suggests how improvements in this promising material could lead to inexpensive yet efficient solar cells.

"We think we now understand why pyrite hasn't worked," says chemistry Professor Song Jin, "and that provides the hope, based on our understanding, for figuring out how to make it work. This could be even more difficult, but exciting and rewarding."

Although most commercial photovoltaic cells nowadays are based on silicon, the light-collecting film must be relatively thick and pure, which makes the production process costly and energy-intensive, says Jin.

A film of iron pyrite -- a compound built of iron and sulfur atoms -- could be 1,000 times thinner than silicon and still efficiently absorb sunlight.

Like silicon, iron and sulfur are common elements in Earth's crust, so solar cells made of iron pyrite could have a significant material cost advantage in large scale deployment. In fact, previous research that balanced factors like theoretical efficiency, materials availability, and extraction cost put iron pyrite at the top of the list of candidates for low-cost and large-scale photovoltaic materials.

In the current online edition of the Journal of the American Chemical Society, Jin and first author Miguel Cabán-Acevedo, a chemistry Ph.D. student, together with other scientists at UW-Madison, explain how they identified defects in the body of the iron pyrite material as the source of inefficiency. The research was supported by the U.S. Department of Energy.
In a photovoltaic material, absorption of sunlight creates oppositely charged carriers, called electrons and holes, that must be separated in order for sunlight to be converted to electricity. The efficiency of a photovoltaic solar cell can be judged by three parameters, Jin says, and the solar cells made of pyrite were almost totally deficient in one: voltage. Without a voltage, a cell cannot produce any power, he points out. Yet based on its essential parameters, iron pyrite should be a reasonably good solar material. "We wanted to know, why is the photovoltage so low," Jin says.

"We did a lot of different measurements and studies to look comprehensively at the problem," says Cabán-Acevedo, "and we think we have fully and definitively shown why pyrite, as a solar material, has not been efficient."

In exploring why pyrite was practically unable to make photovoltaic electricity, many researchers have looked at the surface of the crystals, but Cabán-Acevedo and Jin also looked inside. "If you think of this as a body, many have focused on the skin, but we also looked at the heart," says Cabán-Acevedo, "and we think the major problems lie inside, although there are also problems on the skin."

The internal problems, called "bulk defects," occur when a sulfur atom is missing from its expected place in the crystal structure. These defects are intrinsic to the material properties of iron pyrite and are present even in ultra-pure crystals. Their presence in large numbers eventually leads to the lack of photovoltage for solar cells based on iron pyrite crystals.
Science advances by comprehending causes, Jin says. "Our message is that now we understand why pyrite does not work. If you don't understand something, you must try to solve it by trial and error. Once you understand it, you can use rational design to overcome the obstacle. You don't have to stumble around in the dark."

Source: University of Wisconsin-Madison