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Abstract

A composite emitter (100) for a thermophotovoltaic cell and other applications, and a method of forming the composite emitter. The composite emitter includes a substrate (102) and a selective emitter layer (104) composed of at least one substantially pure ceramic oxide selective emitter material applied to the substrate using a thermal spraying method. The substrate is preferably made of a durable material such as a silicon-based material or a refractory metal oxide. In one embodiment, the selective emitter layer may be composed of two or more selective emitter materials. In another embodiment, the composite emitter may further include a reflective metal layer (106). The method includes providing a substrate and plasma spraying one or more selective emitter materials onto the substrate to a thickness of between about 10 microns and about 400 microns to form the selective emitter layer. Preferably, the selective emitter layer has an in situ density of between 80% and 95% of the bulk density of the selective emitter material used.

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First Claim