Thermoelectric power generation offers a promising way to recover waste heat. The geometrical design of thermoelectric legs in modules is important to ensure sustainable power generation but cannot be easily achieved by traditional fabrication processes. Herein, we propose the design of cellular thermoelectric architectures for efficient and durable power generation, realized by the extrusion-based 3D printing process of Cu2Se thermoelectric materials. We design the optimum aspect ratio of a cuboid thermoelectric leg to maximize the power output and extend this design to the mechanically stiff cellular architectures of hollow hexagonal column- and honeycomb-based thermoelectric legs. Moreover, we develop organic binder-free Cu2Se-based 3D-printing inks with desirable viscoelasticity, tailored with an additive of inorganic Se82− polyanion, fabricating the designed topologies. The computational simulation and experimental measurement demonstrate the superior power output and mechanical stiffness of the proposed cellular thermoelectric architectures to other designs, unveiling the importance of topological designs of thermoelectric legs toward higher power and longer durability.

The mechanical flexibility of perovskite solar cells as well as high power conversion efficiency is attracting increasing attention. In addition to existing empirical approaches, such as cyclic bending tests, in this study we report the tensile properties of the perovskite materials themselves. Measuring the tensile properties of free-standing perovskite materials is critical because (1) tensile properties represent the realistic mechanical properties of the film-type perovskite layer in the solar cells including the effects of various defects, and (2) deformation behavior of the perovskite layer at any deformed state of the solar cells can be analyzed using solid mechanics with the tensile properties as input. Critical bending radius of MAPbI 3 -based flexible solar cells is found to be between 0.5 and 1.0 mm by the decrease in power conversion efficiency during cyclic bending deformation. This finding agrees well with the critical bending radius of 0.66 mm determined based on the elastic deformation limit of 1.17% for MAPbI 3 found by in situ tensile testing. Scanning electron microscopy observations and hole-nanoindentation tests suggest that the formation of coarse cracks in the perovskite layers is the primary cause of the decrease in power conversion efficiency observed in flexible perovskite solar cells.

The lack of highly impermeable and highly flexible encapsulation materials is slowing the development of flexible organic solar cells. Here, a transparent and lowtemperature synthetic alumina single layer is suggested as a highly impermeable and a highly flexible encapsulation material for organic solar cells. While the water vapor transmission rate (WVTR) is maintained up to 100,000 bending cycles for a 25 mm bending radius (corresponding to 8.1% of the elastic deformation limit), as measured by in situ tensile testing with free-standing 50 nm-thick alumina films, the WVTR degraded gradually depending on the bending radius and bending cycles for bending radii less than 25 mm. The degradation of the WVTR in cyclic deformation within the elastic deformation limit is investigated, and it is found to be due to the formation of pinholes by a bond-switching mechanism. Also, encapsulated organic solar cells with alumina films are found to maintain 80% of initial efficiency for 2 weeks even after cyclic bending with a 4 mm bending radius.

Aligned wavy-structured thermally grown silicon dioxide films are fabricated for stretchable encapsulation films. Uniaxial stretchability is investigated with micromechanics modeling, which can elucidate the stretchability arising from the wavy structure and the properties of the materials. The wavy-structured films with optimum combinations of film thickness and wavy structure show 20.1% of uniaxial stretchability and 1.11 × 10 −6 g m −2 day −1 of water vapor transmission rate (WVTR), simultaneously. It shows highly reliable barrier properties even after 1000 stretching cycles at 90% of their stretchability.

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