面向纳米机械能量采集的智能结构增材制造:综述

Reza Shamim

湖北工业大学,武汉 430068,中国

文章信息

关键词:

3D打印

能量采集智能结构

可持续能源

纳米机械系统

可再生能源

摘要

可穿戴设备和智能传感器等紧凑型微电子系统的快速增长,加剧了对可持续能源解决方案的需求,以应对其环境和经济影响。增材制造已发展成为纳米机械能量采集系统的一项变革性技术,能够制造出复杂、可定制且环境友好的器件,利用振动、风能、太阳能和生物力学运动等环境能源。本文探讨了增材制造在推动纳米机械能量采集方面的作用,涉及创新设计、材料优化以及压电、摩擦电、电磁和热电等转换机制的集成。主要进展包括仿生结构、纳米结构化表面和拓扑优化组件,这些组件提高了能量转换效率,例如3D打印摩擦电纳米发电机的功率密度高达2850 mW/m²,压电复合材料可达7.1 μW/cm²。尽管取得了进展,但在材料限制、表面优化和规模化生产方面仍存在挑战。文献计量分析(2020年–2025年7月)凸显了研究趋势,其中压电和摩擦电系统因其在物联网、可穿戴设备和结构监测中的应用而占据主导地位。未来方向涉及人工智能驱动的设计、高分辨率3D打印技术以及生物相容性聚合物和高塞贝克热电复合材料等先进材料,以提高耐用性和效率。本工作强调了其在推动可持续自供电技术方面的潜力,与全球可持续发展目标保持一致。

1. 智能结构与能量采集概述

紧凑型多功能微电子系统(如可穿戴设备和智能传感器)的快速普及,加剧了对可持续能源解决方案的需求。随着这些技术成为医疗保健、消费电子和基础设施监测不可或缺的组成部分,其累积的环境足迹显著增加[1–3]。即使是适度的效率提升,当扩展到数十亿台设备时,也能带来可观的环境和经济效益,包括减少温室气体排放和减少对集中式能源的依赖[4]。这些进展与联合国可持续发展目标7(SDG 7)相一致,该目标旨在确保到2030年人人获得负担得起、可靠和现代化的能源[5–7]。实现这些可持续性目标需要创新的能源使用策略和本地化可再生能源生产,其中环境能量采集为分散式低能耗设备提供了一种可行的供电方法。

增材制造(AM)因此成为实现可持续能源系统的主要推动力。凭借材料沉积的高精度和实现复杂几何形状同时低废料的能力,增材制造能够以最小的环境影响制造高功能性器件[8–11]。最重要的是,增材制造能够协同优化和制造机械组件与能量采集元件,这是向在战略性重要器件组件中直接嵌入能量采集功能迈出的渐进式一步。利用增材制造提供的灵活性,机械能量采集系统取得了显著发展,其应用已扩展到不同领域和侧重点。这些系统利用环境能源,越来越多地应用于生物医学传感器应用、结构健康控制和智能基础设施系统等领域,确保可持续、独立且近乎零能耗的服务,在整体性能分析中具有显著的自主性和可靠性[12]。

与传统电池相比——传统电池存在能量密度低、寿命短和处置成本高的问题[13]——风能[14]、海浪[15]、太阳能[16]、雨滴[17]、人体运动[18]、热能[19]、声音[20]、振动[21]、地热梯度[22]和温度波动[23]等环境能源提供了可再生替代方案。这些输入能量通过电磁、压电、摩擦电和热电等机制转化为可用电能,每种机制在低功耗应用中都具有独特的优势。

增材制造的结构创新能力进一步提升了能量采集系统的性能。例如,Yin等人[24]采用等几何优化方法对3D打印Mindlin板结构进行优化以拓宽声子带隙,实现了731.25 Hz的中心带隙。类似地,Lowell的全息三维光子晶体制造为弹性波能量采集引入了一种新方法[25]。

能量采集技术利用多种环境能源,包括振动、生物力学运动、降雨、风能、太阳能和海洋能,将环境能量转化为可用电能[26]。这些技术支持广泛的应用,如酒精传感、天气监测、心脏起搏器、可穿戴健康设备、结构健康监测、废水处理、导航系统以及专用能量采集平台,凸显了其广泛的工业相关性。如图1所示,其进步依赖于关键促成因素,包括仿真与实验验证、仿生设计方法、材料优化、缺陷与力学性能分析以及能效提升,反映了该领域固有的多学科性质。

流程图
graph TD
    A["仿生学"] --> B["测试"]
    B --> C["材料选择"]
    C --> D["应用"]
    D --> E["资源管理"]
    E --> F["制造"]
    F --> G["优化"]
    G --> H["仿真"]
    H --> I["质量控制"]
    I --> J["性能表征"]
    J --> K["能效"]
    K --> L["构建物理原型"]
    L --> M["基于仿真优化设计"]
    M --> N["设计"]
    N --> O["虚拟测试设计"]
    O --> P["解决3D打印缺陷"]
    P --> Q["分析性能"]
    Q --> R["关注可持续方法"]
    R --> S["从自然中汲取灵感"]
    S --> T["仿生学"]
    T --> U["评估原型问题"]
    U --> V["选择合适的材料"]
    V --> W["识别潜在用途"]
    W --> X["规划和调度资源"]

图1. 推动纳米机械能量采集进展的关键多学科要素。

这些进展对效率和可扩展性的结构性贡献。

尽管取得了这些进展,但若干挑战阻碍了增材制造能量采集系统的广泛采用。关键问题包括:

表面优化:在开发能够有效容纳多种采集机制(如摩擦电、压电)的集成表面结构方面面临挑战,因为不同的材料和几何要求使得实现单一高性能表面结构变得复杂[27,28]。 − 材料限制:用于3D打印的生物相容性和长寿命聚合物有限,严重制约了可植入或可穿戴器件的制造,这些器件需要医疗器械中的长期稳定性和安全性[29]。 − 电磁集成:受限于利用增材制造分辨率实现小型化高精度线圈和磁体的难度,而这对于在不影响小型化系统中高效能量转换和集成的前提下缩小器件尺寸是必要的[30]。 − 高温要求:在开发高性能稀土陶瓷方面面临挑战,因为涉及的高温过程难以控制和放大,影响了面向实际应用的耐用高效热电模块的制造[31]。 − 摩擦磨损:相变材料存在磨损和退化问题,而这些材料对于能量吸收和持续能量释放至关重要;因此需要开发更稳健的材料以延长在反复热循环下的工作寿命[32]。

在本综述中,研究了增材制造在纳米机械能量采集结构生产中整合材料和几何形状的作用。将评估基于增材制造技术的能量转换机制(包括压电、摩擦电、电磁及组合机制)的优势和局限性。此外,还将讨论该领域面临的关键可扩展性问题,并提出未来方向,例如基于人工智能(AI)的设计。

1.1. 增材制造在推动能量采集中的作用

通过使用3D打印,制造商可以制造功能集成、几何形状复杂的组件,从而提高能量转换和集成能力。增材制造在能量采集中的一些突出应用实例包括基于天然树结构的仿生太阳能聚光器[33]、为提高摩擦电输出而设计的纳米结构化表面[34]、用于风能转换的气动优化涡轮叶片外壳[35],以及用于嵌入具有高表面接触的压电材料的定制化衬底[36]。这些基于增材制造的进展提供了对形式和功能的精确控制,满足了优化能量采集器件性能所需的定制化程度。

能量采集技术被广泛应用于医疗保健领域的可穿戴生物传感器、结构健康监测领域的无线诊断传感器、环境监测领域的远程传感网络,以及面向低功耗应用(如LED照明和微功率水处理)的可持续能源系统。这些器件具有自维持、可扩展、轻量化和免维护的特点[37]。这些应用利用了能量采集器件的自给自足、可扩展性和轻量化特性,通常仅需极少维护。纳米机械能量采集系统通过四个模块运行:1)能量源(振动、风能、太阳能、波浪、运动、降水);2)转换机制(压电、摩擦电、电磁、静电);3)后处理/存储(整流后存储在超级电容器/微型电池中);4)应用特定设计(针对效率、适应性、耐用性进行优化),从而为医疗保健、结构监测、环境传感和可持续能源等领域提供轻量化、可扩展、低维护的器件[38–41]。

2. 3D打印能源研究的文献计量分析

为了对与增材制造能量采集相关的研究活动进行定量概述,我们进行了文献计量和基于关键词的趋势分析。选择Scopus数据库是因为其对工程和应用科学领域同行评审期刊的广泛覆盖。该分析涵盖了2020年1月至2025年的出版物。搜索策略结合了与增材制造相关的术语(例如3D打印、增材制造、熔融沉积成型、喷墨打印)和能量采集技术相关的术语(例如压电、摩擦电、热电、光伏、电磁、声学和生化能量采集)。仅考虑英文期刊文章,排除会议论文、社论和非研究文献,以确保一致性和可重复性。文献计量评估侧重于三个主要指标:(i) 不同能量采集机制的出版物分布,(ii) 关键词共现分析以识别主导研究主题及其相互关联,以及 (iii) 基于作者隶属机构的机构生产力。这些指标在文献计量研究中被广泛采用,以揭示研究趋势和主题演变。

图2展示了按能量采集机制划分的出版物分布,包括压电、摩擦电、热电、光伏、电磁、声学和生化能量采集。结果显示,压电和摩擦电能量采集领域的出版物明显集中,反映了它们与增材制造工艺的高度兼容性、材料多样性以及适用于小型化和柔性器件的特性。相比之下,生化能量采集和声能量采集的研究相对较少,表明这些领域在研究时段内在增材制造背景下仍较少被探索。

为了进一步探讨主题关系,使用VOSviewer进行了关键词共现分析。排除了”3D打印”、“增材制造”和”能量采集”等基础搜索词,以便更好地捕捉相关概念和应用驱动的研究方向。由此产生的网络可视化(图3)揭示了几个相互关联的主题集群。频繁出现的关键词包括压电、摩擦电纳米发电机、纳米材料、聚偏氟乙烯(PVDF)、柔性电子、印刷复合材料、喷墨打印、压电复合材料、可穿戴电子、太阳能和可持续性。材料(如PVDF和纳米材料)、赋能技术(如印刷和柔性电子)与应用领域之间的强共现联系,凸显了基于增材制造的能量采集研究的多学科性质。

流程图
graph TD
    A["3D打印"] --> B["能量采集"]
    A --> C["增材制造"]
    A --> D["熔融沉积成型"]
    A --> E["生物力学能量采集"]
    A --> F["摩擦电纳米发电机"]
    A --> G["压电效应"]
    A --> H["能量存储"]
    A --> I["3D打印技术"]
    A --> J["可持续性"]
    A --> K["纳米材料"]
    A --> L["太阳能"]
    A --> M["能量采集器"]
    A --> N["柔性能量器件"]
    A --> O["柔性电子"]

图2. 按能量采集机制划分的出版物分布。

3. 增材制造赋能能量收集技术

3.1. 静电能量收集与增材制造增强性能

静电能量收集通过带电表面或电极的相对运动产生电能,利用电容变化将机械能转化为电能。它特别适用于低频振动和小型应用,如可穿戴系统和无线传感器(图5a)。增材制造通过精确的电极配置和微型化结构改善了静电能量收集。Zhang等人[42]采用纳米石墨涂层纸作为环保高性能材料用于摩擦纳米发电机(TENG),实现了大于14 kW m⁻²的功率密度,促进了能量收集和运动传感。此外,Li等人[43]为自供电物联网开发了振动能量收集技术(摩擦电、压电、电磁),推动了智能监控、交通和医疗领域的发展。

树状图
类别数值
压电能量收集10,927
摩擦电能量收集5,031
光伏(太阳能)能量收集3,784
电磁能量收集3,608
热电能量收集3,463
声学能量收集724
生物化学能量收集318

图2. Scopus中能量收集类型分布(2020–2025年)。

文字图像
机构名称
纳米科学与技术研究所(INN),国家科学研究中心”德谟克利特”
曼彻斯特大学化学工程与分析科学系,曼彻斯特
青岛大学材料科学与工程学院,青岛,266071,中国
山东大学海洋学院,威海,264209,中国
迪肯大学工程学院,吉朗,3216,维多利亚州,澳大利亚
新加坡国立大学电气与计算机工程系,新加坡,1176
科学与创新研究学院(ACSIR),加济阿巴德,201002,印度
大邱庆北科学技术院机器人及机电一体化工程系
西北民族大学电气工程学院,甘肃,中国
中国科学院大学纳米科学与技术学院,北京,中国
坦佩雷大学增强技术组,Korkeakoulunkatu 3,坦佩雷,芬兰
佐治亚理工学院电气与计算机工程学院,85 5th St NW,亚特兰大
四川大学高分子研究所高分子材料工程国家重点实验室
新加坡国立大学电气与计算机工程系,4 Engineering Dr
全北国立大学柔性印刷电子学系,LANL-JBNU工程研究所
中国科学院大学,北京,100049,中国
北京大学材料科学与工程学院,北京,100871,中国
普渡大学机械工程学院,西拉法叶,47907,印第安纳州,美国
VOSviewer

图4. 纳米科学与工程领域的研究机构(VOSviewer)。

流程图
graph TD
    A["太阳能"] --> B["混合能量收集系统分类"]
    C["机械能"] --> D["振动"]
    E["静水压"] --> F["生物能"]
    G["工业废弃物"] --> H["林业作物"]
    I["农业作物"] --> J["城市固体废物"]
    K["绿色废物"] --> L["生物油"]
    M["PZT"] --> N["金属"]
    O["热源"] --> P["冷端"]
    Q["电极"] --> R["摩擦电层"]
    S["静水压"] --> T["振动"]
    U["(a)"] --> V["(b)"]
    W["(c)"] --> X["(d)"]
    Y["(e)"] --> Z["(f)"]
    AA["(g)"] --> AB["(h)"]

图5. 能量收集方法分类,包括 a. 静电式、b. 光伏式、c. 摩擦电式、d. 电磁式、e. 热电式、f. 压电式、g. 生物能源、h. 混合系统(图片经出版商许可使用)。

尽管稳定性和效率仍面临挑战,但人工智能物联网(AIoT)的集成为零排放未来提供了可持续的智能系统。

3.2. 光伏能量收集与增材制造增强性能

光伏能量收集利用半导体材料在光照下产生电荷载流子,通过光伏效应将太阳能转化为电能。该方法广泛应用于为远程传感器、便携式电子设备和环保基础设施供电(图5b)。增材制造通过提供定制化的太阳能电池几何结构和集成设计,推动了光伏能量收集的发展。Li等人[44]开发了通过绿色溶剂实现环保有机光伏的策略,克服了低溶解度和慢干燥等限制,改善了薄膜形貌和效率。此外,Kutsarov等人[45]综述了柔性钙钛矿太阳能电池的进展,强调了效率提升(>23%)和可扩展制造方法,如卷对卷加工。关键挑战包括基底限制、电极脆性以及低温沉积的墨水优化。界面工程、封装和绿色油墨的突破对商业化至关重要,其在可穿戴设备、物联网和空间光伏领域具有应用前景。

3.3. 摩擦电系统与增材制造增强的电极/表面设计

摩擦电增材制造将不同材料接触分离产生电荷的过程,与增材制造对表面和电极设计的精确控制相结合,用于能量收集。由摩擦电序列指导的摩擦引起的电荷转移,通过受控的表面化学和几何形状进行优化,已在增材制造金属粉末(如CpTi)中得到验证。粒径和湿度等附加参数也会影响摩擦充电,在TENG等器件中已展示出优化后的效率(图5c)。增材制造通过提供对表面特性和电极设计的精确控制来改进摩擦电系统。例如,对增材制造金属粉末(即CpTi、Ti6Al4V和SS 316 L)中摩擦充电的研究表明,表面化学和流速对摩擦充电行为有显著影响,为优化摩擦电能量收集表面提供了见解[46]。增材制造还通过为TENG制备纳米网格结构进一步推动了摩擦电系统的发展。例如,一种静电纺丝聚氨酯复合纳米网格,经富含氨基的石墨相氮化碳(g-C₃N₄)功能化,制成柔性PU封装的g-C₃N₄/Ecoflex器件。该器件实现了高输出(465 V,62.15 μA)和的功率密度,并在50,000次循环后保持稳定[47]。

3.4. 电磁系统与线圈/磁性元件制造

电磁能量收集依赖于法拉第感应定律,通过磁铁和线圈之间的相对运动产生电流。它是一种高效的振动或旋转源能量收集机制(图5d)。增材制造通过精确制造线圈和磁性元件,为电磁发电机(EMG)能量收集提供了支持。Son等人[48]评估了3D打印能量器件,报告称其可用于制造高性能复杂结构用于能量产生和存储。尽管提供了设计灵活性和材料多样性,但墨水配方和机械耐久性方面的额外问题仍需解决以实现大规模应用。同样,Jalali等人[49]制备了3D打印壳聚糖/MXene气凝胶用于增强摩擦电能量收集,其中2 wt%的MXene可将电压提升至110 V。MXene增强了极化和表面电荷密度、电荷转移效率以及电磁能量收集能力,这得益于增材制造对多孔结构的精确控制。

3.5. 热电能量收集与增材制造增强的模块架构

增材制造也推动了热电能量收集的发展。通过选区激光熔化和立体光刻制造的柔性Ag₂Se/Sb₂Te₃模块,在1000次机械弯曲后仍保持90%的功能性,同时在接近室温条件下产生超过的功率[50]。Baroutaji等人[51]评估了增材制造在热电材料中的应用,指出与传统技术相比,其在复杂几何结构、材料效率和成本节约方面的优势。尽管增材制造能够实现创新的热电器件几何结构,具有更好的热源贴合性,但材料性能、表面光洁度和各向异性特性仍需优化以实现大规模商业化(图5e)。热电能量收集依赖于塞贝克效应,利用热电材料将温度梯度转化为电能。该机制对于废热回收和远程供电应用至关重要。更进一步,Maduabuchi等人[52]优化了一种用于太阳能转换的两级分段热电发电机(TEG),通过几何参数优化实现了62.4%更高的功率输出(22.43 W)和27.5%更好的效率。该系统还使成本降低了14.6%,每年减少CO₂排放10.65 kg,显示了在实际可再生能源应用中的巨大潜力。

生物能源收获通过发酵和燃烧等过程,从有机材料(如生物质、生物燃料和微生物燃料电池)中提取能量(图5g)。这种方法对农村地区的可持续发电和废物管理系统具有重要价值。Mukherjee等人[55]展示了一种微生物燃料电池(MFC),利用新型细菌联合体(Kocuria rosea, Bacillus circulans, Corynebacterium vitaeruminis)实现芳烃生物修复和生物发电的同步进行。优化后的系统使用苯甲酸钠实现了0.8 V输出电压、81.81%的化学需氧量降低和18.15 mW/m²的功率密度,同时实现了盐桥的重复利用以降低成本。这突显了MFC在可持续废水处理和能源回收方面的潜力。值得注意的是,Begum等人[56]综述了混合热化学-生化生物质转化技术,展示了废物转化为能源系统在效率和成本效益方面的改进。集成方法在支持循环经济目标的同时提高了生物燃料产量,但规模化挑战依然存在。

3.8. 混合能量收集与增材制造驱动的集成

混合能量收集结合不同机制,从各种环境来源中最大限度地获取能量(图5h)。它在动态条件下提高了可靠性和效率。增材制造使得创建用于从低品位热源中收集能量的混合系统成为可能。例如,带有摩擦电和压电组件的斯特林发动机辅助模块在从低于100°C的温度收集能量时,已报道最高输出电压达74 V [57]。对于风能收集,Ravichandran [58]开发了一种使用3D打印文丘里结构的小型风力驱动摩擦纳米发电机(TENG)。该系统实现了创纪录的2850 mW/m²功率密度(峰值4.5 mW),性能优于更大型系统,可在20秒内为40个LED供电或为电容器充电。聚碳酸酯旗帜结构通过10,000次循环验证了其可靠性,展示了独立物联网应用的巨大潜力。同时,Han等人[59]优化了一种用于气流应用的3D打印小型电磁风能收集器,输出功率为0.305 W(效率6.59%),可为4个LED供电。叶片设计和气流路径的参数优化展示了自启动能力与转换效率之间的权衡,在暖通空调和城市能量收集方面具有潜在应用。

4. 先进的结构与材料创新

4.1. 增材制造驱动的拓扑优化与几何定制

各种增材制造实现的设计表明,性能高度依赖于几何排布和材料界面。例如,Kim等人[60]提出了一种带有滚动聚合物珠的风驱动摩擦纳米发电机(TENG),在20 m/s风速下产生1.36 mW/cm²的功率密度。该器件是一款自供能、全向的风速传感器,可为LED供电,展示了便携式应用的潜力;而Liu等人[61]设计了一种磁开关结构摩擦纳米发电机,用于连续稳定的风能收集,通过利用磁力而非风速来控制输出,产生4.82 mW的峰值功率——足以点亮500个LED或操作温度计。一种集成接触模式和滑动模式TENG与太阳能电池的混合能量模块被制造出来,可产生高达66.64 mW的功率,用于为小型电子设备供电,并为物联网和可穿戴设备提供了可持续的方法[62]。一项对小型光伏-热电混合系统的批判性综述比较了电气连接、控制策略和最大功率点跟踪方法,同时强调了改进电子接口和系统级设计对于提高未来物联网应用能量收集效率的必要性[63]。

4.2. 通过增材制造实现的功能材料与微/纳米结构

Chang等人[64]制造了一种3D打印压电聚合物复合材料,具有优化组成和拉胀几何结构,与平面结构相比电压提高了三倍。这种柔性传感器表现出强大的压电响应,适用于自供电触觉位置感知。Li等人制造了一种3D打印柔性压电复合材料,具有组合的传感和驱动能力,应变达1830 ppm,灵敏度达26.81 V/g。该器件可驱动微型机器人并检测关节运动,在机器人和可穿戴设备方面具有潜在应用[65]。反向电润湿系统也通过表面图案化和流体相互作用控制的进步,报告了高能量转换效率(3.3 V时高达40.2%)[66]。增材制造允许在微米和纳米尺度上对表面进行结构化,提高了能量收集器的表面积和电荷产生量。通过增材制造实现的表面功能化优化了材料相互作用,从而提升了器件性能。

图6展示了各种能量收集技术的综合示意图,围绕一个中心枢纽组织,以说明它们的互联潜力。图6a [67]展示了基于碳布上MoO₃的自集成结构超级电容TENG器件,用于双模式能量存储和摩擦电收集,电容为97.86 ,电压为55 V。图6b [68]展示了一种用于轻型卡车的压电能量收集减震器,将悬架振动转化为电能,最大输出功率为7.51 W。图6c [69]介绍了基于驻极体的能量收集器及其结构柔顺性和高电压输出,用于为小型系统供电。图6d [70]展示了存在微小温差时热电模块的阻抗响应,使用等效电路研究热接触电阻并优化能量收集性能。图6e [71]展示了一种用于振动除冰机器人的非线性电磁能量收集器,基于非线性磁芯模型,输出超过10 W。图6f [72]展示了通过ZnO-水纳米流体滤光器、石蜡-ZnO储热层和TiO₂-玻璃涂层层对光伏板进行光谱分割的效果,电效率提升%(ηel),CO₂减排5.3%。该面板由3.2 mm厚玻璃层(τ = 0.91,案例4为自清洁涂层TiO₂)、ZnO-水纳米流体滤光器(质量分数0.02,案例2–4)、硅层(0.3 mm,最佳范围700–1100 nm)和10 mm RT25-ZnO石蜡层组成。

流程图
graph TD
    A["Photovoltaic"] --> B["Triboelectric"]
    B --> C["Piezoelectric"]
    C --> D["Pyroelectric"]
    D --> E["Thermoelectric"]
    E --> F["Electromagnetic"]
    F --> G["Magnetic Core"]
    G --> H["Primary conductor"]
    H --> I["Transmission Line"]
    I --> J["Airga"]
    J --> K["Secondary winding"]
    K --> L["Cartridge heaters"]
    L --> M["Water circulation"]
    M --> N["Thermoelectric module"]
    style A fill:#f9f,stroke:#333
    style B fill:#ccf,stroke:#333
    style C fill:#cfc,stroke:#333
    style D fill:#fcc,stroke:#333
    style E fill:#cff,stroke:#333
    style F fill:#ffc,stroke:#333
    style G fill:#cfc,stroke:#333
    style H fill:#cfc,stroke:#333
    style I fill:#cfc,stroke:#333
    style J fill:#cfc,stroke:#333
    style K fill:#cfc,stroke:#333
    style L fill:#cfc,stroke:#333
    style M fill:#cfc,stroke:#333
    style N fill:#cfc,stroke:#333

图6. 能量收集技术的示意图,包括a. 摩擦电法、b. 压电法、c. 热释电法、d. 热电法、e. 电磁法和f. 光伏法(图片经出版商许可复用)。

4.3. 新兴设计与新型增材制造兼容材料

许多其他创新也增强了增材制造实现的收集系统的功能(表1)。例如,基于聚乙烯醇/层状双氢氧化物复合材料的3D打印纳米发电机电压可达60 V,耐温达,适用于自供电生理监测[78]。Xu等人[79]通过详细模拟对浮动式TENG进行了动力学分析,展示了波浪引发的运动和结构参数如何影响能量收集。通过六自由度跟踪和模拟,他们确定了提高蓝色能量转换效率的最佳结构。

5. NMEH:系统架构与集成

对自主传感器和可穿戴设备等无电池、微型化设备的需求推动了NMEH技术的采用,该技术收集环境能量并减少对电池的依赖[80,81]。增材制造和3D打印的进步使得利用微纳尺度换能器(压电、摩擦电、电磁和静电)构建更高效、更紧凑、多功能化的NMEH系统成为可能,这些系统通常产生微瓦级功率,且性能持续提升[82]。然而,商业化仍然受到诸多挑战的限制,包括开发高性能可打印材料、可扩展的纳米结构制造、优化的电荷生成与传输、与环境能源的谐振匹配,以及可靠、低成本的批量生产(表2)。

5.1. 面向间歇性增材制造输出的功率调节

由于能量收集器仅在环境激励下产生功率,因此高效的功率调节对于间歇性运行至关重要。所报道的系统通过换能器与存储单元之间的自主切换以及主动-休眠策略来解决不连续振动输入问题,从而将寄生功耗降至最低。实验结果表明,其日常能耗低于传统的电阻匹配接口,在非活动期间实现了0.75 J的节能,在活动期间实现了0.04 J的节能,且支持自启动[106,107]。Jung等人[108]通过实验评估了电路的功率流和效率,以确定调节需求。在收集器平均输出为501 的情况下,AC-DC级实现了66%的效率,提供331 µW。降压-升压转换器在使用存储能量运行时(案例2)效率达到82%,但在自启动操作期间(案例1)降至54%,表明冷启动期间存在效率损失。低损耗元件选择进一步降低了功耗,而控制器能耗在案例1(2.53 J对比2.57 J和4.10 J)和案例2(1.10 J对比1.85 J和30.88 J)中均低于先前设计。

NMEH的主要方向之一是将传感、发电和无线通信集成到紧凑平台上,例如使用TENG和电纺纳米纤维的3D打印步态分析系统,用于即时在线测量步幅和速度[109]。图7展示了微型化的低能量收集、存储和功率管理器件如何促进自维持无线传感器和可穿戴技术的发展,包括用于快速能量释放的电容器(0.22–100 μF)和超级电容器(0.22–100 F)、用于延长运行时间的锂离子和钠离子电池(80–550 mAh),以及用于最大化能量传输和可靠性的功率效率高达90%的功率管理器件(如降压转换器)。

5.2. 增材制造收集器片上集成的挑战

将环境能量收集直接集成到芯片平台上仍然在技术上具有挑战性,特别是在追求物联网边缘设备中自供电、无电池运行时。实现收集单元、存储块(如超级电容器或微型电池)以及微功率管理电路的功能性协同集成受到缩放极限的制约。对于半柔性和柔性混合器件,硅必须减薄至35 μm以实现弯曲半径为5 mm的形变,但这一减薄会增加破裂、分层和能量传输效率降低的风险。需要高精度装配来维持纳米级组件95%的转移印刷良率,但对于≤ 100 μm的芯片,粘附不稳定性变得显著,静电力和范德华力导致对准偏差和转移失败。硅与聚合物基底之间的热学和力学失配进一步限制了弯曲或可变形格式的可扩展性,而多源增材制造收集缺乏标准化接口,限制了超5G应用所需的高频射频波段的性能。

表1 增材制造材料在NMEH中的性能、应用和挑战概览。

材料组成3D打印方法关键功能性能NMEH应用主要挑战
半导体-聚合物纳米复合材料[73]Ga掺杂ZnO / 光固化树脂光聚合(LCD/DLP)柔性热电和压电薄膜;输出电压可达约3 V可穿戴热电与压电纳米发电机热稳定性;力学权衡;打印均匀性
聚合物基复合材料[74]MXene / P(VDF-TrFE)直写成型(DIW)压电输出(约5.5 V);柔韧可拉伸可穿戴纳米发电机和自供电传感器填料聚集;相位排列;可扩展性
聚合物-陶瓷纳米复合材料[75]PVDF / BaTiO3熔融沉积成型(FDM)高β相;d33 ≈ 28 pC/N;>30 V输出消费设备用压电收集器颗粒团聚;极化;翘曲
压电陶瓷[76]La掺杂PZT(PLZT)数字光处理(DLP)高压电性(d33 ≈ 279 pC/N)高效压电收集器脆性;浆料可打印性;烧结控制
无机半导体-有机复合材料[77]Bi₂Te₃基热电油墨材料挤出塞贝克系数约288 μV/K;微瓦级功率热电发电机和温度传感器低电导率;基底限制;油墨控制

表2 能量收集源、转换机制及效率概览。

来源能量转换效率参考文献
生物力学能量负关节功转化为电能5 W电功率,-8 W代谢功率[83]
电磁102.12 mW(220 Ω)(3.66 mW cm-3g-2)[84]
摩擦电171.13 μW(8 MΩ)(16.16 μW cm-3g-2)
摩擦电72 nW RMS(初始),96 nW RMS(200,000次循环后),20.7 μW cm-2峰值功率密度[85]
海浪介电弹性体发电机(小规模测试0.5–1.2 Hz,相当于全尺寸0.07–0.25 Hz)[86]
电磁(通过超材料缺陷)功率密度:81.1 W/m³(2 Hz时),99 W/m³(最大报道值)[87]
电磁机械效率:57%(最大),46.17%(平均)[88]
通过谐振介电弹性体发电机收集波浪能波浪能转换效率:18%[89]
摩擦电16.6 mW(弹簧辅助摆动结构)[90]
铁路轨道振动压电207.67 mW(环形结构)[91]
电磁250 mW(40–65%转换效率)[92]
电磁(三磁铁斥力配置)5 V/10 mA(50 mW)[93]
路面振动(轮廓)压电(PVDF/BaTiO₃/GP复合材料,十字形多孔结构)60.5 V(开路电压),654.2 nA(短路电流)[94]
摩擦电和电磁TENG:7.21 mW,EMG:0.74 mW(5 Hz激励时)[95]
混合电磁(直线式和旋转式)可变形黏壤土上54 km/h时高达48 W[数据截断]

表2(续)

来源能量转换效率参考文献
混合波浪/风能收集器:OWC + DE膜电压,40 μA短路电流(6 m/s风速)。风力涡轮机:通过整流电路将12 V DC升压至1.46 kV用于DE偏置。理论风能利用率:约为贝茨极限(59%)的50%。[105]

经济和可持续性方面的制约加剧了增材制造片上能量收集器集成的技术挑战。半导体行业已将其约20%的收入投入研发,而采用混合或柔性架构则会增加工艺复杂性,可能导致良率下降。可持续性考量进一步要求使用可回收、低温材料,大规模电子产品生产的环境影响(例如每年400亿个RFID标签产生100–500万吨温室气体排放)即为明证。尽管CMOS兼容的二维材料(如MoS₂)可以在下合成,但转移过程中的可扩展性和性能退化限制了其在工业中的应用。此外,对可变形、多功能系统的可靠性测试不足,阻碍了其与循环经济法规的对接。尽管2024年市场预计复苏17%,但可扩展的片上增材制造能量收集将需要在材料、标准以及产学研合作方面取得协调进展,并得到《欧洲芯片法案》[111]等倡议的支持。

6. 3D打印NMEH系统的资源与方法

6.1. NMEH的可再生能源

通过3D打印的NMEH器件根据能量来源和转换机制进行分类,因此可针对海洋、可穿戴或工业环境进行优化配置[112]。数值模拟是近期研究的重点,用于优化结构参数(如孔径形状和柔顺机构),以提高能量转换效率,特别是在平面波激励等动态加载条件下[113,114]。例如,3D打印惯性传感器在海洋应用中通过实验和数值验证,既可作为能量收集器,也可作为自主水下航行器的自持跟踪器[115]。

先进材料对于提升3D打印NMEH系统的性能至关重要。尽管有机太阳能电池为混合收集器提供了柔性,但若无光-机械转换,机械能量收集应用仍受到限制。Mahmud等人[116]证明,PVDF与BaTiO₃纳米颗粒及锆钛酸铅(PZT)的结合可极大地增强压电性能,从而在通过FDM和立体光刻(SLA)打印的3D打印压电纳米发电机(PENG)中实现高电荷输出。这些材料将用于传感器和生物医学植入体等应用,也可能受益于静电和电磁收集。此外,将基于石墨烯的微型超级电容器和电池集成到NMEH平台中,可实现器件上的电力存储,通过调节输出电压确保稳定的功率输送[117]。

6.2. NMEH制造的3D打印方法

增材制造能够实现NMEH纳米结构的制造,DLP提供高分辨率控制,而熔丝制造(FFF)等材料挤出方法支持聚合物复合材料,但缺乏亚微米级分辨率[118]。ASTM F2792标准化的其他增材制造技术包括用于多材料集成的喷墨打印和用于金属零件的粉末床熔融,但若不经后处理,纳米级细节仍受限[119]。压印光刻进一步增强了增材制造能力,可实现低成本、高通量的TENG制造;例如,木质素/PVA复合材料在传感和能量收集应用中的电性能优于纯PVA器件[120]。

流程图
graph TD
    A["Energy Harvesting + Energy Storage + Power Management"] --> B["Energy Harvesting"]
    B --> C["Self-Charging Power System"]
    C --> D["Energy Storage"]
    D --> E["Power Management"]
    
    subgraph A
        F1["Piezoelectric + Capacitor + MFPT"] --> G1["√"]
        F2["Piezoelectric + NiMH Battery + Voltage Regulator"] --> G2["√"]
        F3["Piezoelectric + NiMH Battery + Full Wave Rectifier"] --> G3["√"]
        F4["Piezoelectric + Li-Ion Battery + AC/DC Converter"] --> G4["√"]
        F5["Piezoelectric + Sodium-Ion Battery + PM Circuit"] --> G5["√"]

(Mermaid图中的英文标签保留原文,因为它们是技术术语/标签)

图7. 自供能无线传感器和可穿戴设备的能量收集、存储和功率管理集成架构示意图。

图7展示了集成能量收集传感器、电源管理和储能的低能量收集系统的研究示意图[110](图片已获得出版商许可重用)。

FDM是一种低成本、流行的3D打印NMEH制造方法,因其材料多样性和可扩展性而广受欢迎。然而,其较差的分辨率和表面粗糙度可能会影响其在能量收集应用中的性能[73]。本文描述了通过DLP(一种高分辨率、快速固化、低材料浪费的立体光刻技术)进行3D打印纳米材料增强收集器NMEH的3D打印和操作过程[121]。Yi等人[122]展示了DLP在制造柔性能源器件(如TENG和PENG)方面的应用,通过复杂结构实现了增强的输出,但存在材料生物相容性问题。FDM打印的ABS/碳黑复合材料具有强电磁干扰屏蔽(高达78 dB)和多功能性,如传感能力[123]。此外,经过机器学习优化的DLP打印光敏聚酰亚胺和聚四氟乙烯表面表现出卓越的摩擦学行为和热稳定性,适用于新一代自供电设备[124]。

选择性激光烧结(SLS)在生产由复合材料和陶瓷制成的压电元件方面也具有巨大潜力。Yang等人[125]利用PVDF/Ba-TiO₃/CNT复合材料制造了一种具有仿生结构的高功率收集器,实现了19.3 V电压和电容器在180秒内充电至5.03 V。Azam等人[126]在多壁碳纳米管(MWCNT)/PA12复合材料中实现了更好的压阻性能,但高MWCNT负载导致了加工问题。尽管SLS具有材料韧性和高分辨率,但在可穿戴技术或大规模应用方面受限于能耗和设备复杂性。FDM为非关键NMEH组件提供了一种经济、可扩展、快速原型制作的技术。Cao等人[127]展示了通过FDM制造的全封装微珠TENG阵列,其电荷密度为19.9 µC/m²,功率密度为13.8 W/m³,用于从风能、波浪能和运动中收集能量。

更通用的3D打印进展,如SLS、SLM和电子束熔化(EBM),使得复杂能源组件得以实现,并推动了4D打印等技术的发展,以及在燃料电池和储能中使用混合材料[128]。基于纺织品的能量收集也在推进中,Megdich等人[129–131]创建了一种具有3D打印负泊松比结构的PVDF/MWCNTs压电能量收集器,可提供高达28.2 V电压,可用于智能地板和安全系统。

Wei等人[132]综述了柔性可穿戴电子器件的制造方法,强调了对可扩展、精确和可再生工艺的需求。Hazarika等人[133]3D打印了一种结合辐射冷却和TENG功能的凯夫拉复合材料,可将皮肤冷却22.2°C,并输出1.37 mW/cm²的功率。Babu等人[134]通过聚丙烯在可拉伸织物上3D打印了高压T-TENG(~193 V),尽管聚二甲基硅氧烷(PDMS)的FDM兼容性断言仍需进一步确认。Patil等人[135]设计了一种FDM打印的RF收集器,采用可生物降解的聚乳酸(PLA),在2.4和5.2 GHz频率下具有高RF-DC转换效率,可用于为物联网设备供电。

Hu等人[136]通过FDM和热塑性聚氨酯(TPU)材料制造了拓扑优化的3D打印锂离子电池电极,具有增强的机械耐久性,并在50次拉伸循环后保持98%的容量。表面处理(如平行摩擦层)增强了TENG系统中的机电耦合,但操作条件需要更全面地报告以确保可重复性。总体而言,FDM在3D打印NMEH方面具有定制化、成本效益高和快速的优势,但受限于材料兼容性和分辨率。未来研究应侧重于比较研究,以建立增材制造技术之间的绝对性能基准[137]。Khan等人[138]制造了一种硅烷偶联的Linde A型沸石/聚二甲基硅氧烷TENG,输出为120 V、15 µA和42.6 µW/cm²,在超过30,000次循环中具有耐久性,并在极端条件下保持稳定。它可以有效为设备供电并监测人体运动,因此适用于可穿戴能量收集和生理监测。

多材料增材制造实现了复杂的内部架构,包括晶格和超材料启发结构,从而在航空航天和生物医学工程等领域实现了高功能密度和应用特定性能。然而,这些能力目前受到关键挑战的限制,包括界面结合不良、残余应力和表面应力、材料不相容性,以及热性能和机械性能不匹配引起的缺陷,特别是在金属-聚合物和金属-陶瓷系统中。此外,缺乏专用的多材料增材制造设计软件、经过验证的有限元框架、标准化设计规则和可扩展的后处理方法,限制了增材制造多材料和直写能力的充分发挥。因此,尽管增材制造在设计复杂性和功能性方面提供了明显的进步,但克服材料、工艺和软件限制仍然是实现全功能多材料组件的关键[139]。

6.3. NMEH专用3D打印组件

图8a[140]展示了用于电磁干扰屏蔽的3D打印蜂窝结构,由PLA与石墨烯纳米片和碳纳米管作为功能填料制成。多孔结构具有110.8 S/m的高电导率和53.5 dB的电磁干扰屏蔽效能,超过了商业目标。该设计具有轻量化特点(0.4–1.0 g/cm³),当孔径小于入射波长的1/5时,可实现可调电磁干扰屏蔽(35–45 dB)。图8b[141]展示了一种3D打印热电复合材料,其腿形几何结构针对放射性同位素热电发生器进行了优化。通过铜添加剂,该复合材料实现了p型材料ZT值为0.91,并提高了电导率,有助于深空任务的有效功率输出。图8c[142]描绘了一种通过浸没沉淀三维打印制造的薄型柔性压电-磁混合自传感执行器。通过核岭回归优化,该执行器实现了62.1%的结晶度,并提供13 mV/g的高电压传感输出和1.8 m/s²的磁阻尼,显著增强了生物医学应用中的振动控制。图8d[143]展示了一种用于压电能量收集器的三维打印双稳态非对称滚道,利用PLA收集超低频(1.6–6.2 Hz)能量,具有14.151–16.163 mW·cm⁻³·g⁻²·Hz⁻¹的高功率密度。图8e[144]展示了3D打印壳基铁电超材料,如Spinodoids和金刚石壳状结构,这些材料是使用压电陶瓷增材制造平台制造的。这些结构在相对密度为0.3时具有270 pC/N的压电常数(d33),而低介电常数增强了其在力和热传感应用中的灵敏度。图8f[145]展示了一种基于导电热塑性聚氨酯/聚乳酸/碳纳米管/石墨烯的长丝熔融制造3D打印TENG。


图8. 3D打印技术和结构示意图,包括a. 用于EMI屏蔽的3D打印蜂窝结构,b. 用于发电机的热电复合材料,c. 混合压电-磁自传感执行器,d. PVDF/ZnO压电能量收集器,e. 壳基铁电超材料,f. 采用FFF制造的3D打印TENG,以及g. 用于生物医学应用的PVDF基部件(图片已获得出版商许可重用)。

图9a[147]展示了一种具有四个折叠单元的3D打印TENG,实现了的功率密度,并实现自供电N₂还原为NH₃,产率为36.41 μg h⁻¹ mg⁻¹cat。图9b[148]详细介绍了使用Creality C-10打印机(配备0.8 mm硬化钢喷嘴,230°C,100°C热床温度,10 mm/s打印速度)对0.2 mm厚、30 mm方形压电测试样品进行长丝熔融制造打印的过程,以及纯TPU/CB传感器作为对比,展示了打印过程、修剪后的25 mm P1样品及其柔韧性。图9c[149]展示了一种箭术启发式弹射机构旋转能量收集器,用于超低频能量收集,在4 Hz频率下实现了转子速度提升3.6倍、输出功率提升3.0倍。图9d[150]展示了一个3D打印可穿戴能量手环(65 cm直径,12 cm宽度,1 mm厚度),配有锌离子微型电池和LED灯,通过Form3打印机上的立体光刻技术制造,包装光滑,输出电压2.72 V,可为1个或2个LED供电。图9e[75]展示了一个3D打印的PVDF/BT压电能量收集器,具有仿生3D结构,产生30.8 V的开路电压,可为智能鼠标供电。图9f[151]展示了一种使用3D打印正交平面弹簧的宽带电磁能量收集器,带宽为10–30 Hz,最大归一化功率密度为2.20 μW

图9 电磁[249]部分详细介绍了用于超低频振动的滚动-摆动电磁能量收集器,提供毫瓦级输出,并在0.4 g、1.4 Hz条件下为温度计/计算器供电161.3秒。图9 压电[250]展示了一种从公路交通中获取能量的高密度压电能量收集装置,能量密度为15.37 J/(m·pass·lane),具有用于智能公路应用的潜力。图9 摩擦电[251]展示了一种管状液-固TENG,带有耦合电极对,将短路电流提高90.9%至0.21 μA,输出功率提高4.82倍,用于高效波浪能量收集。图9 热电[252]综述了微型热电发生器,重点介绍了其在废热回收中的应用,在内燃机车辆中效率高达57%,并应用于生物工程领域。图9 热释电[253]提出了一种便携式电源概念,利用热释电发生器(PEG)能量转换与片上甲醇燃烧相结合,能量密度为48 mJ/cm³,在相变时功率提升2.5倍。图9 混合[254]展示了一种电磁-摩擦电混合能量收集器,具有振动到旋转的转换功能,在冲刺过程中可提供超过800 mW的功率,用于为便携式设备供电。

FDM打印的体心立方(BCC)及其他晶格结构(方形、FCC、组合式、金刚石立方、四面体立方)的SEM图像。图10a[152]展示了这些复杂晶格结构的表面形貌和力学性能,如弯曲刚度和能量吸收。图10b[153]展示了一个3D打印锥形梯度折射率声子晶体透镜的图像,该透镜使用VeroClear材料在Stratasys J750打印机上打印,位于225 mm锥体上,执行器部分

flowchart
graph TD
    A["Solar Energy"] --> B["Hydropower"]
    B --> C["Biomass Energy"]
    C --> D["Thermal Energy"]
    D --> E["Chemical Energy"]
    
    subgraph Solar_Energy
        F["Wind Energy"] --> G["Geothermal Energy"]
        H["Mechanical Energy"] --> I["Vibrational Energy"]
    end
    
    subgraph Hydropower
        J["Hydropower"] --> K["Geothermal Energy"]
        L["Geothermal Energy"] --> M["Mechanical Energy"]
        N["Vibrational Energy"] --> O["Chemical Energy"]
    end
graph TD

%% ── 能量类型子图示例 ──

subgraph Biomass_Energy[生物质能]
    P["水力发电"] --> Q["地热能"]
    R["机械能"] --> S["振动能"]
end

subgraph Thermal_Energy[热能]
    T["水力发电"] --> U["地热能"]
    V["机械能"] --> W["振动能"]
end

subgraph Chemical_Energy[化学能]
    X["水力发电"] --> Y["地热能"]
    Z["机械能"] --> AA["振动能"]
end

subgraph Electromagnetic_Energy[电磁能]
    AB["电磁"] --> AC["中心杆 线圈 支架 磁铁 线圈"]
    AC --> AD["轴承 内摆 外滚子"]
    AD --> AE["外滚子"]
    AE --> AF["线圈"]
    AF --> AG["螺栓"]
    AG --> AH["外滚子"]
    AH --> AI["外滚子"]
    AI --> AJ["外滚子"]
    AJ --> AK["外滚子"]
    AK --> AL["外滚子"]
    AL --> AM["外滚子"]
    AM --> AN["外滚子"]
    AN --> AO["外滚子"]
    AO --> AP["外滚子"]
    AP --> AQ["外滚子"]
    AQ --> AR["外滚子"]
    AR --> AS["外滚子"]
    AS --> AT["外滚子"]
    AT --> AU["外滚子"]
    AU --> AV["外滚子"]
    AV --> AW["外滚子"]
    AW --> AX["外滚子"]
    AX --> AY["外滚子"]
    AY --> AZ["外滚子"]
    AZ --> BA["外滚子"]
    BA --> BB["外滚子"]
    BB --> BC["外滚子"]
    BC --> BD["外滚子"]
    BD --> BE["外滚子"]
    BE --> BF["外滚子"]
    BF --> BG["外滚子"]
    BG --> BH["外滚子"]
    BH --> BI["外滚子"]
    BI --> BJ["外滚子"]
    BJ --> BK["外滚子"]
    BK --> BL["外滚子"]
    BL --> BM["外滚子"]
    BM --> BN["外滚子"]
    BN --> BO["外滚子"]
    BO --> BP["外滚子"]
    BP --> BQ["外滚子"]
    BQ --> BR["外滚子"]
    BR --> BS["外滚子"]
    BS --> BT["外滚子"]
    BT --> BU["外滚子"]
    BU --> BV["外滚子"]
    BV --> BW["外滚子"]
    BW --> BX["外滚子"]
    BX --> BY["外滚子"]
    BY --> BZ["外滚子"]
    BZ --> CA["外滚子"]
    CA --> CB["外滚子"]
    CB --> CC["外滚子"]
    CC --> CD["外滚子"]
    CD --> CE["外滚子"]
    CE --> CF["外滚子"]
    CF --> CG["外滚子"]
    CG --> CH["外滚子"]
    CH --> CI["外滚子"]
    CI --> CJ["外滚子"]
    CJ --> CK["外滚子"]
    CK --> CR["外滚子"]
    CR --> CS["外滚子"]
    CS --> CT["外滚子"]
    CT --> CU["外滚子"]
    CU --> CV["外滚子"]
    CV --> CW["外滚子"]
    CW --> CX["外滚子"]
    CX --> CY["外滚子"]
    CY --> CZ["外滚子"]
    CZ --> DA["外滚子"]
    DA --> DB["外滚子"]
    DB --> DC["外滚子"]
    DC --> DD["外滚子"]
    DD --> DE["外滚子"]
    DE --> DF["外滚子"]
    DF --> DG["外滚子"]
    DG --> DH["外滚子"]
    DH --> DI["外滚子"]
    DI --> DJ["外滚子"]
    DJ --> DK["外滚子"]
    DK --> DL["外滚子"]
    DL --> DV["外滚子"]
end

subgraph Renewable_Energy Sources[可再生能源来源]
E1["(a)"] & E2["(b)"] & E3["(c)"] & E4["(d)"] & E5["(e)"]
    subgraph Advanced_Harvesting_Technologies[先进收集技术]
    E1 & E2 & E3 & E4 & E5 & E6 & E7 & E8 & E9 & E10 & E11 & E12 & E13 & E14 & E15 & E16 & E17 & E18 & E19 & E20 & E21 & E22 & E23 & E24 & E25 & E26 & E27 & E28 & E29 & E30 & E31 & E32 & E33 & E34 & E35 & E36 & E37 & E38 & E39 & E40 & E41 & E42 & E43 & E44 & E45 & E46 & E47 & E48 & E49 & E50 & E51 & E52 & E53 & E54 & E55 & E56 & E57 & E58 & E59 & E60 & E61 & E62 & E63 & E64 & E65 & E66 & E67 & E68 & E69 & E70 & E71 & E72 & E73 & E74 & E75 & E76 & E77 & E78 & E79 & E80 & E81 & E82 & E83 & E84 & E85 & E86 & E87 & E88 & E89 & E90 & E91 & E92 & E93 & E94 & E95 & E96 & E97 & E98 & E99 & F00
    end
end

subgraph Advanced_Harvesting_Technologies[先进收集技术]
    subgraph Renewable_Energy Sources[可再生能源来源]
        subgraph Advanced_Harvesting_Technologies[先进收集技术]
        end
    end
end

subgraph Advanced_Harvesting_Technologies[先进收集技术]
    subgraph Advanced_Harvesting_Technologies[先进收集技术]
    end
end

subgraph Advanced_Harvesting_Technologies[先进收集技术]
    subgraph Advanced_Harvesting_Technologies[先进收集技术]
    end
end

片段6 翻译

文件内容为流程图/图表结构代码(Mermaid subgraph语法),包含大量重复的占位标签,无实际学术文本可供翻译。以下按照原始内容保留。

subgraph Advanced_Harvesting_Technologies
subgraph Advanced_Harvesting_Technologies
end

subgraph Advanced_Harvesting_Technologies
subgraph Advanced_Harvesting_Technifications
end

subgraph Advanced_Harvesting_Technifications
subgraph Advanced_Harvesting_Technifications
end

subgraph Advanced_Harvesting_Technifications
subgraph Advanced_Harvesting_Technifications
end

subgraph Advanced_Harvesting_Technifications
subgraph Advanced_Harvesting_Technifications
end

subgraph Advanced_Harvesting_Technifications
subgraph Advanced_Harvesting_Technolutions
end

subgraph Advanced_Harvesting_Technolutions
subgraph Advanced_Harvesting_Technolutions
end

subgraph Advanced_Harvesting_Technolutions
subgraph Advanced_Harvesting_Technolutions
end

subgraph Advanced_Harvesting_Technolutions
subgraph Advanced_Harvesting_Technolutions
end

subgraph Advanced_Harvesting_Technolutions
subgraph Advanced_Harvesting_Technifications
end

subgraph Advanced_Harvesting_Technifications
subgraph Advanced_Harvesting_Technifications
end

subgraph Advanced_Harvesting_Technifications
subgraph Advanced_Harvesting_Technifications
end

subgraph Advanced_Harvesting_Technifications
subgraph Advanced_Harvesting_Technologies
end

subgraph Advanced_Harvesting_Technifications
subgraph Advanced_Harvesting_Technifications
end

subgraph Advanced_Harvesting_Technifications
subgraph Advanced_Harvesting_Technifications
end

subgraph Advanced_Harvesting_Technifications
subgraph Advanced_Harvesting_Technifications
end

subgraph Advanced_Harvesting_Supercalculus_1_1_2_3_4_5_6_7_8_9_10_11_12_13_14_15_16_17_18_19_20_21_22_23_24_25_26_27_28_29_30_31_32_33_34_35_36_37_38_39_40_41_42_43_44_45_46_47_48_49_50_51_52_53_54_55_56_57_58_59_60_61_62_63_64_65_66_67_68_69_70_71_72_73_74_75_76_77_78_79_80_81_82_83_84_85_86_87_88_89_90_91_92_93_94_95_96_97_98_99
end

subgraph Advanced_Harvesting_Technifications
end

subgraph Advanced_Harvesting_Technifications
end

subgraph Advanced_Harvesting_Technifications
end

subgraph Advanced_Harvesting_Technifications
end

subgraph Advanced_Harvesting_Technifications
end

subgraph Advanced_Harvesting_Technifications
end

subgraph Advanced_Harvesting_Technifications
end

subgraph Advanced_Harvesting_Technifications
end

subgraph Advanced_Harvesting_Technifications
end

subgraph Advanced_Harvesting_Technifications
end

subgraph Advanced_Harvesting_Technifications
end

subgraph Advanced_Harvesting_Technifications
end

subgraph Advanced_Harvesting_Technifications
end

subgraph Intermediate_Energy Sources
  end

subgraph Intermediate_Technifications
  end

subgraph Intermediate_Technifications
  end

subgraph Intermediate_Technifications
  end

subgraph Intermediate_Technifications
      end
    
    subgraph Intermediate_Technifications
      end
    
    subgraph Intermediate_Technifications
      end
    
    subgraph Intermediate_Technifications
      end
    
    subgraph Intermediate_Technifications
      end

图9. 能量收集技术概览,包括:a. 可再生能源来源,b. 能量收集方法(电磁式、压电式、摩擦电式、热电式、热释电式、混合式),以及先进收集技术(a. 四折单元PE-TENG的基本结构与制备工艺,b. 结合炭黑和钛酸钡的3D打印PVDF/TPU传感器,c. 3D打印旋转式能量收集器,d. 集成3D打印的可穿戴能量手环,e. PVDF/BT PEH制备示意图,f. 基于正交平面弹簧的3D打印电磁能量收集器。(图片经出版商许可复用)。)

natural_image

一系列具有不同内部结构的3D打印白色泡沫立方体,从不同角度和表面纹理展示(无文字或符号)

text_image

(c) 3 cm 500 µm 8 µm 20 µm

(e)

text_image

UV Light Printing Platform 3D Prints Resin 3D Printing Anode Cathode Carbon film Flow layer Top layer Pt wire

(b)

natural_image

实验装置,GRIN-PC透镜设备置于测试台上,红色导线上安装有圆形元件网格(设备本身无可见文字或符号)

(d)

natural_image

两个相同的3D渲染机械部件在水中,带有彩色方向箭头指示运动或力的方向(无文字或符号)

(f)

natural_image

两个标有”Undried”的深灰色样本放置在尺子上方以显示比例(样本本身无文字或符号)

natural_image

具有3mm刻度指示的平行圆柱结构显微视图(无文字或符号)

图10. a. 未干燥的3D打印样品及其干燥后的对应样品,b. 3D打印扬声器和能量收集器,c. 3D打印叶状结构的微观结构分析,d. 水中的3D打印能量收集器,e. 紫外光3D打印过程示意图及打印微结构特写,f. 具有详细微观结构视图的3D打印晶格结构。(图片经出版商许可复用。)

以30 kHz L(0,1)模式激励,使用Polytec振动计在隔振台上测量速度。通过电场驱动微尺度3D打印制造的银网的结构表征,展示了宏观形貌、局部样品视图、银颗粒分布和微观形貌。图10c [154]展示了柔性透明薄膜的高光学透过率和电磁屏蔽效率。圆柱颗粒基TENG浮动模型的设计与优化,包括浮力稳定性、船体曲率和俯仰运动曲线。图10d [155]展示了利用导电3D打印优化波浪能量收集效率。光固化3D打印机示意图及多通道MFC分解图。图10e [156]展示了通过级联多通道结构增强可穿戴电子设备能量收集能力的新设计。未干燥和室温干燥样品的照片,以及使用100 μm针头打印的丝材。图10f [157]展示了直写3D打印在制备具有复杂结构的形状可控热电器件中的应用,通过最小化曲面热源的热损失来增强输出性能。

6.4. 增材制造纳米机械能量收集中的工艺-性能相关性

增材制造分辨率强烈影响纳米填料的分散性、表面质量和能量收集效率。高分辨率技术如

DLP、多光子聚合和连续液面生产能够实现均匀的纳米级特征,而基于挤出的方法则受限于较低的分辨率和较高的粗糙度。通过纳米位移光刻技术实现亚10 nm精度,增强了纳米填料的均匀性和能量转换效率 [158]。

表面功能化和金属化处理定量地加强了打印质量、粗糙度降低和器件性能之间的相关性。嵌入石墨烯或碳纤维的功能化热塑性塑料(如PLA和ABS)表现出改善的分散性,而以137 μm分辨率打印的多巴胺改性聚乙二醇二丙烯酸酯结构显示出更高的均匀性。丝网印刷的热电复合材料达到ZT值0.65(p型)和0.81(n型),在40 K温差下产生566 。金属化工艺(包括化学沉积)可保持50 μm分辨率,Ni线电阻率达到67 μΩ⋅cm,通过蒸汽处理将表面粗糙度从3.96 μm降至1.01 μm,使热电效率提升至24.79%。在压电和生物传感应用中,以40 μm分辨率打印、带有500 μm铜线的聚偏二氟乙烯-三氟乙烯P(VDF-TrFE)树脂,刻蚀后粗糙度低于0.19 μm,增强了对H₂O₂的机械能捕获和检测灵敏度,低至11.1 μM。优化增材制造参数——特别是分辨率、粗糙度和纳米填料分散性——可转化为纳米机械能量收集系统中可测量的性能提升。10–100 μm之间的平衡分辨率和受控填料负载(如ABS中5 wt%的CuC₂O₄)可改善导电性并减少损耗。具有40 μm特征的DLP打印PVDF-TrFE传感器和ELD-Cu电感器表现出稳定的功能,在2 MHz下插入损耗为0.26 dB/cm。丝网印刷的钙钛矿集成收集器在上达到22.6%的效率,短时间镀层后仍保持70%的电导率。电导率值从 ,功率输出高达,证实了…

6.5. 3D打印用于NMEH的优势与不足

为批判性地评估增材制造对NMEH系统的适用性,本节概述了主要优势、不足和性能基准,相关数据汇总于表3。

6.6. 用于NMEH的3D打印方法比较总结

表4概述了增材制造对NMEH制造的主要优势——设计灵活性、快速原型制作和更少的材料浪费——以及不足,如纳米级分辨率限制、表面粗糙度和材料兼容性问题。

7. 3D打印NMEH系统的应用

增材制造有助于可再生能源的可持续性,3D打印在风力涡轮机应用中将浪费、成本和CO₂排放降低约25%,主要支持SDG 7,而更广泛的SDG影响需要进一步的跨学科研究 [177]。在工业领域,3D打印NMEH系统可实现基于振动的轨道监测 [178]、自供电绿色海水淡化结构 [179] 以及通过混合电化学系统的自主制氢 [180]。

Yang等人 [181] 强调了DIW 3D打印如何通过增强集成和设计的灵活性,推动了可穿戴设备柔性聚合物复合电池的发展。关键进展包括具有高灵活性和容量的DIW打印电极、具有增强导电性的SLA打印电解质,以及具有高面积容量的DIW打印全电池 [182]。挑战在于墨水配方、纳米级分辨率以及力学性能与能量密度之间的权衡,未来研究趋势倾向于机器学习和先进模拟。Tan等人 [183] 描述称,利用柔性3D打印电子器件和聚合物基底上的功能墨水,可以实现低成本的穿戴式医疗设备(如心电贴片),但机械不匹配问题需要特殊的可拉伸墨水来保持变形下的性能。

在工业或环境场景中,3D打印的NMEH单元实现了能量自给型热传感器的选择性热冷变化检测 [184]。可对器件结构和打印材料进行优化,以最大化机械强度和导热性,从而使其能够在温度变化环境中可靠部署。为了实现自维持的健康与活动监测设备,以及将能量收集传感器与纺织品和柔性基底集成以延长佩戴舒适性和长期功能性,3D打印的NMEH器件提供了小巧、轻便且贴合人体的可穿戴电子设备 [185,186]。基于摩擦电材料以及同轴PTFE和石墨烯纤维的可拉伸电子纺织品可持续发电,从而制造出具有触觉感知能力的透气、可清洗电子皮肤 [187]。众多高灵敏度传感应用(如用于结构应变监测的能量自给型光学传感器 [188,189]、用于软体机器人的柔性压力与应变传感器 [190,191]、触觉界面,以及为基础设施中无线节点供电的无线结构健康监测)均采用了3D打印NMEH器件 [192]。DIW和DLP带来的增材制造技术使得柔性、生物相容的NMEH器件可用于无电池的生物医学监测 [193,194]。例如,Wang等人 [195] 利用废弃紫苏秸秆开发了一种柔性TENG,可产生5.7 V电压、为LED供电并检测人体运动,用于环保型能量收集与监测。一种集成了压电PVDF-TrFE薄膜和碲化铋合金块的柔性热电-压电发电机,用于收集体热和运动能量,在3 K温差下可产生17 V电压和3.8 μA电流,且在1000次弯折后性能稳定。将其佩戴在手指上时,可产生约8 V电压和约6 μA电流,具有在智能服装和生物医学监测中用作自供电可穿戴设备的巨大潜力 [196]。语音识别虽不在本文讨论范围内,但类似的柔性传感器未来可能实现语音交互式可穿戴设备。一种通过FDM制备的、基于聚二甲基硅氧烷和导电聚合物的低成本柔性压力传感器,展现出高灵敏度(在0–0.577 kPa范围内为160 kPa⁻¹)、长期机械稳定性(>4000次循环),以及用于脉搏和吞咽检测等生理监测应用的能力 [197,198]。同一平台还可实现机器人夹爪的可调刚度控制(15–44 N/m),支持软体机器人中的精细物体操作 [199]。如图11所示 [200,201],3D打印NMEH系统的未来发展方向包括自供电传感器、振动驱动智能照明、自主制造,以及集成能量收集与增材制造的可持续医疗设备。

将3D打印融入NMEH系统具有以下独特优势:它为复杂几何形状的设计提供了高度灵活性,促进了快速成型和定制化,并允许针对特定环境制造轻量化、小型化的定制器件。这些特性极大地拓宽了NMEH技术在众多领域的实际应用:

7.1. 自供电电子传感器

增材制造通过将压电和摩擦电材料集成到柔性、多功能器件中,改进了用于机器人、可穿戴设备和远程传感的自供电传感器 [202,203]。例如,3D打印的压电触觉传感器阵列可贴合不规则表面,实现机器人手部的精确力传感,但在分辨率和动态精度方面仍存在问题 [204]。4D打印的进步利用形状记忆聚合物制造出了自修复摩擦电传感器,其能量密度可达56 ,并具有同步关节传感功能,其中热编程促进了传感器恢复并提高了耐久性 [205,206]。混合3D/2D打印制造技术制备出了纳米纤维素纸基TENG,具有优异的电输出、耐磨性、机械柔韧性和环境可持续性,但其长期循环耐久性有待进一步研究 [207]。这些可穿戴、个性化、分布式的器件在偏远或恶劣环境(如太空)中具有潜在应用,但在部署前需进一步测试其耐辐射性、热稳定性和机械性能 [208]。

7.2. 噪声消除

TENG因将机械能量收集与降噪功能相结合而备受关注,可在嘈杂环境中提供多功能性 [209]。一种圆柱形设计采用图案化铝层和粗糙PDMS球体,可最大化电荷产生,并通过微结构散射实现被动消声 [210]。添加含有导电银纳米线的聚氨酯海绵基体可增强弹性及低频至中频的噪声吸收,可实现约20 dB的降噪效果(降至约50 dB),峰值功率为45 mW,适用于可穿戴电子设备 [211]。虽然相比传统消声器展现出更好的前景,但要在广泛应用中实现普及,仍需对频率响应、耐久性和噪声衰减进行更多研究 [212]。

7.3. 环保型粉尘吸附系统

研究者开发了一种3D打印的仿生绒毛结构TENG,用于自供电粉尘过滤和空气净化,将能量收集与颗粒物收集集成于单一器件中 [213]。使用PTFE粉末作为摩擦电材料极大地增强了电输出——在旋转模式下提高四倍,在垂直模式下提高五倍 [214]。PTFE–ABS界面处的静电荷通过静电吸引有效捕获空气中的粉尘 [215]。这种可重复使用的PTFE–ABS过滤器机械强度高,可耐受多次清洁循环,减少了废弃物并支持可持续发展,同时3D打印也减少了材料浪费 [216]。

7.4. 纤维脱胶、废水处理及智能纺织品应用

Li等人展示了一种水驱动和3D打印的TENG,用于纺织品加工和废水处理,实现了高污染物降解效率和自供电运行 [217–219,223]。集成到纺织机械和智能纺织品中的TENG基传感器可实现用于实时监测和可穿戴健康应用的机械能量收集,可提供高电压输出和可用的功率密度 [218–220,226]。这些进展说明了镍金属氢化物能量收集(NMEH)和先进制造作为实现可持续、自主纺织系统的重要使能技术的相关性。在这方面,增材制造,特别是环保型增材制造技术(如可生物降解的熔融沉积成型),适用于能量收集和传感系统的低碳制造 [221–226]。然而,将机械能量收集系统扩展到瓦特级以上仍然具有挑战性,需要在材料、打印技术和恶劣环境下的耐久性方面取得进一步进展 [227]。

flowchart
graph TD
    A["Application Domains"] --> B["Healthcare and sensor network applications that benefit from self-powered, sustainable energy solutions."]
    C["Core Enabling Technologies"] --> D["Additive manufacturing and sustainable printing techniques that enable complex designs and eco-friendly materials."]
    E["Multi-functional Platforms"] --> F["Hybrid systems that combine multiple energy sources for efficient and versatile energy collection."]
    G["Energy Harvesting Mechanisms"] --> H["Mechanical and fluidic energy harvesting methods that convert environmental energy into usable power."]
    I["3D Printed NMEH Systems"] --> A & C & E & F & G

7.5. 增材制造-纳米机械能量采集器可持续性的生命周期评估

生命周期评估表明,使用碳纤维增强尼龙试样 通过FFF进行增材制造,当用回收碳纤维替代原始纤维时,可带来显著的生命周期环境效益。原始碳纤维生产每千克排放420 kg CO₂当量,而基于溶剂分解的回收将其降低至:等离子体增强法每千克143 kg CO₂当量(减少66%),超临界溶剂分解法每千克75.7 kg CO₂当量(减少82%),碳纤维回收率达90%。寿命终结阶段的负担也显著降低:填埋处理每千克复合材料产生0.11 kg CO₂当量,而等离子体增强法产生净信用−37.4 kg CO₂当量,超临界溶剂分解法则为46.5 kg CO₂当量。对于PA6试样,生命周期排放从1.87 kg 当量(原始碳纤维,填埋)降至0.98 kg CO₂当量(使用75%回收碳纤维且功能无损失,减少48%),或1.45 kg CO₂当量(功能损失50%,减少22%),PA12呈现类似趋势。工艺电力消耗仍然是主要贡献因素,FFF期间每个试样消耗353瓦时。优化五个试样的打印可将气候变化影响从每个试样0.93 kg降至0.82 kg CO₂当量(减少12%)。总体而言,基于溶剂分解的回收实现了循环性,并将全球变暖潜能相对于原始碳纤维基线降低了48%以上,展示了增材制造组件清晰的生命周期净环境优势 [228]。

8. 挑战与未来展望

尽管在将增材制造与纳米机械能量采集器集成方面取得了进展,但局限性依然存在,例如制造具有高能量转换效率的可打印材料 [229]、应对循环和环境应力的长期耐久性 [230],以及可扩展、高性价比的大规模可生产性 [231]。实际应用还需要解决能量管理、用户接受度和系统兼容性等问题。增材制造的高分辨率进步促进了复杂几何形状和微结构的创建 [232],同时在打印过程中进行材料功能化——例如注入导电纳米颗粒如碳纳米管或石墨烯——可将电导率提高多达70%,并增强机械强度 [233,234]。此外,表面处理和后处理可将摩擦电性能提高多达30% [235]。

创建新型可打印材料是提升热电发电机性能的核心。Tran等人展示了使用等离子喷涂的TiO₂−ₓ和Li:Co₃O₄材料,用于适用于废热回收的大规模、复杂几何形状TEG,效率高达2.39% [236]。高塞贝克系数热电聚合物在环境能量采集方面前景广阔 [237],而丝素蛋白和PLA等生物相容性材料为环保型生物医学器件奠定了基础 [238]。可打印陶瓷和混合复合材料是额外的3D打印纳米机械能量采集器功能。

纳米机械能量采集器的最佳3D打印方法取决于机械鲁棒性、表面分辨率、可扩展性、材料兼容性和电输出。针对TENG、PENG和混合采集器,评估了SLS、FDM、DLP和直接金属打印方法。性能通过几何优化得到提升——例如悬臂梁在振动源±2 Hz范围内进行优化 [239],以及微图案化等表面处理以改善电荷2–3 [240]。蜂窝或螺旋形填充等内部几何结构可将能量转换效率提高多达50% [241]。未来,AI辅助设计和多物理场模拟将允许针对特定应用优化纳米机械能量采集器器件。

纳米机械能量采集器研究的关键优先事项之一是将能量采集器与微纳电子器件集成,用于自主传感器、生物医学植入物和物联网设备。这需要利用超紧凑能量调节电路(例如高效率整流器(>90%转换效率)、DC-DC转换器和超级电容器接口(专为打印机械能量采集器的不规则交流输出而设计))将机械能量采集器间歇性、非线性的输出与电子器件恒定的低功率需求相匹配 [242]。阻抗匹配、自适应电源管理、片上集成、保形封装和无线能量传输对于确保采集器与电子器件之间的无故障运行也至关重要。

8.1. 增材制造-纳米机械能量采集器的可靠性指标与失效机制

纳米机械能量采集器的可靠性评估需要理解循环载荷如何引发材料和结构退化。在基于PVDF/多壁碳纳米管的采集器中,填料分散不良(尤其在接近1 wt%时)会引入孔隙和表面不规则性,这些缺陷充当应力集中点,削弱基体并在重复加载下加速失效。接触粘附层特性的数值模拟进一步阐明了界面强度的变化如何影响分层风险和层状增材制造复合材料的整体机械完整性,从而指导增强纳米机械能量采集器系统循环耐久性的设计 [243]。通过延长循环压缩对可靠性进行了评估,在超过1400次循环中维持了稳定的输出,开路电压无损失,表明在该工作窗口内无可观测的退化,并显示出良好的短期重复使用耐久性。

延长寿命进一步取决于最小化缺陷的萌生和扩展,而通过受控3D打印进行封装已被证明在这方面是有效的。精细调节FDM工艺可为活性材料提供保护性的均匀封装。研究发现,喷嘴温度为 时可实现最佳的层间融合和结构完整性,而降至280°C会导致弱粘接和孔隙形成,升至 则造成过度挤出,产生凸块和表面不规则性,从而危及可靠性 [75]。

8.2. AI驱动增材制造优化的硬件约束

基于AI的拓扑优化正越来越多地与增材制造相结合,以自动化开发复杂几何形状,包括提高性能和材料效率的拉胀结构。这些方法加速了设计-测试周期,如一种面向3D微打印的主动学习策略所证明的,该策略仅需数百个训练点即可快速收敛,经过四次迭代后将打印误差降低至公差范围内。数据驱动设计在工艺特定优化中也被证明是有效的:在FDM中,随机森林模型相比传统技术将预测精度提高了40%以上,支持制造拉伸强度约41 MPa的零件。这些结果展示了AI驱动优化在生成功能改进结构的同时显著减少设计和校准工作的潜力。尽管取得了这些进展,硬件相关的局限性限制了更广泛的采用和实时部署。例如,基于视觉的校准可达到平均几何偏差0.047 mm,但依然对环境变化高度敏感;而线弧增材制造中的预测控制,尽管将零件高度波动降低了400%并将焊道宽度一致性提高了50%,却说明了硬件集成智能的脆弱性。模型性能也因数据和可迁移性差距而出现平台期:即使缺陷检测达到了~72 fps下91.7%的平均精度均值,粉末床分类超过99%,人工神经网络在性能预测中相关性达 ,卷积神经网络在拉伸强度预测中达到 ,但跨不同机器的鲁棒性尚未得到验证,且仿真到现实的差距依然存在。未来的进展将依赖于减少计算负载、扩展高质量数据集,以及推进基于物理信息的和可解释的方法,以…

为克服PENG的限制,包括纳米纤维直径的变异性和PVDF薄膜中β相含量的欠优化,人工智能通过基于PENG参数训练的机器学习算法辅助PENG的精确优化。人工神经网络在确定M形PENG的共振频率和相应采集电压方面达到了超过94%的精度,通过优化梁长和验证质量重量等参数来降低共振频率(使用深度神经网络-遗传算法从169 Hz降至110.5 Hz,同时在0.25 g下将输出电压从2.5 V提高到3.4 V)。对于纳米纤维静电纺丝,ANN模型预测聚丙烯腈纳米纤维直径的精度 表明溶液浓度和施加电压对生产直径均匀的纳米纤维具有主导意义,满足可穿戴器件的标准。模糊逻辑技术在预测旋涂PVDF的β相方面展示了最高效率(R² = 0.9942,误差 = 1.32%),通过优化旋涂速度和退火温度(≤60°C)来改善器件响应。通过纳入有限元方法数据和遗传算法,这些策略克服了PVDF/6H-SiC纳米复合器件极化不完善的问题,展示了240%的电压提升(高达28.94 V)。这些策略共同促进了PENG的大规模生产,在自供能传感器和物联网器件中显示出371%更高的能量密度,同时减少了实验室实验次数 [245]。

9. 结论与展望

实现完全功能化的3D打印纳米微能量采集(NMEH)系统是一条跨学科路径,连接了材料科学、增材制造(AM)、电子学和能源系统。多方面的技术和系统挑战必须通过四大支柱的同步进展来解决:(1) 具有可调机电性能的可打印先进材料;(2) 增材制造过程中的嵌入式材料功能化方法;(3) 面向几何特异性能量转换优化的智能设计;(4) 通过定制化能量管理电路实现微/纳系统无缝集成。考虑这些相互依赖关系的整体策略将推动可扩展、鲁棒且面向特定应用的NMEH技术在下一代表自供电系统中的实施。

9.1. 当前进展总结

先进的制造方法通过实现复杂、特定应用形状的制备并提高能量转换效率,彻底改变了纳米材料和能量采集智能结构的设计。精密的增材制造技术,如熔融沉积成型(FDM)和直写成型(DIW),提供了精确几何微调和材料优化的潜力,包括掺入导电纳米颗粒(如碳纳米管),从而实现了高达70%的电导率提升和机械强度的改善。例如,Tran等人采用等离子喷涂TiO₂₋ₓ基热电发电机在723 K下实现了0.85%的效率和2.43 mW的输出功率,而Li: p型材料进一步将性能提升至2.39%的效率。生物相容性材料(如PLA)的开发以及微图案化摩擦电层(可将表面电荷密度提升)等策略,进一步推动了用于可穿戴电子设备、生物医学植入物和物联网节点的NMEH系统的发展。尽管取得了这些进展,但仍然存在挑战,包括开发可扩展、耐用的可打印材料以及解决微/纳系统集成中的阻抗失配问题。

9.2. 3D打印NMEH系统的未来展望

3D打印NMEH系统的未来进展将重点关注可打印功能材料、高分辨率增材制造和高效的电能调理电子器件,以实现实际部署。Seebeck系数超过200 μV/K的热电聚合物、生物相容性材料(如丝素蛋白)、改进的SLS和DIW分辨率以及AI辅助几何优化等发展,预计将显著增强机械能到电能的转换以及物联网集成。剩余的挑战包括循环耐久性、材料可重复性和可扩展制造。超声场辅助金属增材制造在生产可靠的NMEH结构组件方面展现出巨大潜力,实现了孔隙率的大幅降低、晶粒细化、裂纹消除,以及在AZ31镁合金、Ti-6Al-4V、NiTi和AA7075等合金中强度、延展性、硬度和热调控性能的显著改善。优化的超声参数和多场耦合进一步支持了性能提升,通过增强机械可靠性和可持续制造,使这些技术符合可持续发展目标SDG 9和SDG 12的商业化要求。

风花(WB)采集器[246]、摩擦纳米发电机(TENG)[247]和柔性压电材料[248]展示了多功能方法,这些方法通过发挥各自在不同可持续驱动领域的优势,同时克服商业化的主要障碍,正趋于融合以实现商业化。值得注意的是,WB融合了风载荷减缓(效率49.11%)、自感知()和高电功率输出(电磁发电机3.63 W,摩擦纳米发电机143 V),因此在高速铁路系统(如中国庞大的45,000公里铁路网)中具有大规模实施的巨大潜力。同时,这种集成为无电池机器人物联网节点的潜在成本降低提供了机会,但仍需在强风环境下进行现场概念验证测试,并需要进一步的增材制造策略以降低成本。这些趋势和思路也反映了对摩擦纳米发电机提出的严格要求——尽管面临环境挑战,其中防湿设计(例如微图案化PDMS可在80%的高相对湿度下仍保持85%的效率)和热复合材料(例如PH-SA可将性能提升三倍,直至 )必须共存——其仍然在海洋应用(例如从波浪中采集高达 的功率)和汽车检测(工作温度范围为 )中提供鲁棒的解决方案。因此,需要投入更多的商业化辅助努力,包括推进二维材料(如石墨烯和MXenes)的当前技术状态,以及制定降解敏感性的标准化测量方法。此外,柔性压电材料展现出与生物系统和可持续发展目标的兼容性,这在其驱动……的能力中得到了充分体现。

基金资助

作者未因本文的研究、撰写和/或发表获得任何财务资助。

利益冲突声明

作者声明,本研究报告的工作不存在已知的潜在竞争性财务利益或个人关系。

数据可用性

本文所述研究未使用任何数据。

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