Thermoelectric flexible composites for harvesting energy from aircraft environments and aircraft manufacturing environments

Abstract

The invention relates to thermoelectric flexible composites for harvesting energy from aircraft environments and aircraft manufacturing environments. The present apparatus, system, and method relate to conserving energy that is consumed, powering devices, components, systems, and the like onboard an aircraft, and using highly flexible thermoelectric composite devices, generating electrical current by converting waste heat into electrical energy, powering aircraft manufacturing components used in aircraft manufacturing facilities for manufacturing aircrafts.

Description

[0001] Related Applications

[0002] This application claims priority to U.S. Provisional Application Serial No. 63 / 540,741, filed on September 27, 2023, the contents of which are incorporated by reference in their entirety. Technical Field

[0003] The present disclosure generally relates to the field of thermoelectric devices. Specifically, the present disclosure relates to the field of highly flexible thermoelectric devices. Background Art

[0004] Many component and subassembly surfaces on an aircraft can dissipate heat because heat generated by the component and / or subassembly itself migrates to the component and / or subassembly surface, or because such surfaces of aircraft components and / or subassemblies that do not themselves generate heat can absorb heat from the environment (e.g., including the environment external to the aircraft component and / or subassembly, etc.) and then dissipate the absorbed heat from the surface. In certain aircraft components and / or subassemblies, the generated heat is redirected from the heat generating source and reused to provide heat to another location in the aircraft (e.g., redirecting exhaust air from an engine, etc.). In other cases, the heat that leaves the surface of the aircraft structure is released to the surrounding environment (e.g., areas outside the aircraft, etc.) as "waste heat." In aircraft environments, including, for example, aircraft operating environments, aircraft manufacturing environments, etc., a large amount of waste heat is generated during operation and manufacturing, and the waste heat is released to the surrounding aircraft environment.

[0005] Unless explicitly stated otherwise, no statement herein is admitted to be prior art merely by virtue of its inclusion in the Technical Field and / or Background sections. Summary of the invention

[0006] The present aspect relates to collecting thermal energy, which may be in the form of waste heat, from aircraft component surfaces and / or from aircraft subassembly surfaces (referred to equivalently herein as "aircraft component surfaces" and "aircraft environment surfaces") in an aircraft environment. Further aspects of the present aspect relate to collecting thermal energy, which may be in the form of waste heat, from surfaces present in an aircraft manufacturing facility (referred to equivalently herein as "aircraft manufacturing environment surfaces").

[0007] The present aspect includes an aircraft component and / or an aircraft subassembly (herein equivalently referred to as an "aircraft component"), which includes an aircraft component surface configured for heat dissipation and at least one highly flexible thermoelectric composite device, the highly flexible thermoelectric composite device including at least one wire connected to the highly flexible thermoelectric composite device, the at least one wire further connected to the circuit, and wherein the at least one highly flexible thermoelectric device is placed adjacent to the aircraft component surface.

[0008] In another aspect, at least one highly flexible thermoelectric device is in direct contact with a surface of an aircraft component.

[0009] In another aspect, the highly flexible thermoelectric composite device is exposed to a temperature gradient, and the highly flexible thermoelectric composite device is configured to maintain the temperature gradient during operation of the aircraft component.

[0010] In a further aspect, an aircraft component surface is configured to dissipate heat during operation of the aircraft.

[0011] In a further aspect, an aircraft component surface is configured to generate heat during aircraft operation.

[0012] On the other hand, the aircraft component surface is configured to dissipate heat during aircraft operation, and the aircraft component surface further includes at least one of an aircraft engine surface, an air duct surface, a heater surface, an electrical equipment compartment surface, and an aircraft cabin component surface and / or an aircraft cabin sub-component surface (herein equivalently referred to as "aircraft cabin component surface").

[0013] In another aspect, an aircraft cabin assembly includes at least one of a sidewall, a passenger seat, an electronics unit, a duct, and combinations thereof.

[0014] Another aspect of the present invention relates to an aircraft, comprising an aircraft component and / or an aircraft subassembly (referred to herein equivalently as an "aircraft component"), the aircraft component comprising an aircraft component surface configured for heat dissipation, and at least one highly flexible thermoelectric composite device, the highly flexible thermoelectric composite device comprising at least one wire connected to the highly flexible thermoelectric composite device, the at least one wire further connected to the circuit, and wherein the at least one highly flexible thermoelectric device is placed adjacent to the aircraft component surface.

[0015] In another aspect, a highly flexible thermoelectric composite device is in direct contact with a surface of an aircraft component.

[0016] In another aspect, the highly flexible thermoelectric composite device is in direct contact with a surface of an aircraft component configured to dissipate heat.

[0017] In another aspect, a highly flexible thermoelectric composite device is incorporated into an aircraft component surface configured to dissipate heat.

[0018] Further, the present aspect relates to a method for collecting waste energy in an aircraft, the method comprising placing at least one highly flexible thermoelectric composite device adjacent to an aircraft component surface of the aircraft, the aircraft component surface being configured to dissipate a certain amount of heat, the highly flexible thermoelectric composite device comprising at least one wire connected to the flexible thermoelectric composite device, the at least one wire further connected to a circuit, converting a certain amount of heat transferred from the aircraft component surface to the highly flexible thermoelectric composite device into electrical energy, the highly flexible thermoelectric composite device being placed on the aircraft component surface, and directing the electrical energy from the highly flexible thermoelectric composite device to the circuit.

[0019] In another aspect, the method further includes powering an electrically powered aircraft component with electrical energy from the highly flexible thermoelectric composite device, the electrically powered aircraft component being in communication with the electrical circuit.

[0020] In another aspect, the method further includes charging an energy storage device, such as an energy storage battery, with at least a portion of the electrical energy directed from the highly flexible thermoelectric composite device to the energy storage device, wherein the energy storage device is connected to the circuit.

[0021] In another aspect, the aircraft component surface includes at least one of an aircraft engine surface, a bleed air duct surface, a heater surface, an electrical equipment bay surface, and an aircraft cabin component surface.

[0022] In another aspect, an aircraft cabin component surface includes at least one of a sidewall surface, a passenger seating surface, an electronics bay surface, a duct surface, and combinations thereof.

[0023] In another aspect, the method further includes positioning a plurality of highly flexible thermoelectric composite devices adjacent to the aircraft component surface.

[0024] In another aspect, the method further includes placing at least one highly flexible thermoelectric composite device in direct contact with a surface of an aircraft component.

[0025] In another aspect, the method further includes incorporating at least one highly flexible thermoelectric composite device into a surface of an aircraft component.

[0026] In another aspect, the electrically powered aircraft component includes at least one of a temperature sensor, a power sensor, a lighting array, safety lighting, LED lighting, an ambient light sensor, a cockpit instrument panel, emergency equipment, communication equipment, an auxiliary power unit, a fire extinguishing device, and combinations thereof.

[0027] On the other hand, highly flexible thermoelectric composite devices are solely responsible for powering electrically powered aircraft components.

[0028] On the other hand, highly flexible thermoelectric composite devices are specifically responsible for powering electrically powered aircraft components.

[0029] In another aspect, the highly flexible thermoelectric composite device is an auxiliary power source provided to electrically powered aircraft components.

[0030] In another aspect, the method further includes powering an electrically powered aircraft component from the energy storage device, the electrically powered aircraft component including at least one of a temperature sensor, a power sensor, a lighting array, an ambient light sensor, a cockpit instrument panel, emergency equipment, communication equipment, an auxiliary power unit, a fire extinguishing device, and combinations thereof.

[0031] In another aspect, a voltage booster is connected to the circuit.

[0032] In a further aspect, the energy storage device is a rechargeable battery.

[0033] In a further aspect, the energy storage device is a rechargeable lithium-ion battery.

[0034] Another aspect of the present invention relates to a method of manufacturing an aircraft in an aircraft manufacturing environment, which may be an aircraft manufacturing facility, which may be a "shop" of the aircraft manufacturing facility, the method comprising providing an aircraft manufacturing environment surface configured for heat dissipation, the aircraft manufacturing environment surface configured for dissipating a certain amount of heat. The method further comprises placing at least one highly flexible thermoelectric composite device adjacent to the aircraft manufacturing environment surface, the highly flexible thermoelectric composite device comprising at least one wire in communication with the highly flexible thermoelectric composite device, the at least one wire further in communication with an electrical circuit, converting a certain amount of heat from the aircraft manufacturing environment surface into electrical energy, and directing the electrical energy from the highly flexible thermoelectric composite device to the electrical circuit.

[0035] In another aspect, the method further includes powering an electric drive component with electrical energy directed from at least one highly flexible thermoelectric composite device to the electric drive component, the electric drive component being in communication with at least one highly flexible thermoelectric composite device and further in communication with the circuit.

[0036] In another aspect, the method further includes charging an energy storage device with electrical energy from the at least one flexible thermoelectric composite device, the energy storage device being in communication with the circuit during a battery charging cycle.

[0037] In another aspect, the method further includes placing at least one highly flexible thermoelectric composite device in direct contact with an aircraft manufacturing environment surface.

[0038] In another aspect, the method further includes incorporating at least one highly flexible thermoelectric composite device into an aircraft manufacturing environment surface.

[0039] In another aspect, the method further includes placing a plurality of highly flexible thermoelectric composite devices in direct contact with an aircraft manufacturing environment surface.

[0040] In another aspect, the method further includes placing at least one highly flexible thermoelectric composite device in direct contact with an aircraft manufacturing environment surface.

[0041] In another aspect, at least one highly flexible thermoelectric composite device is solely responsible for powering the electric drive component.

[0042] In another aspect, at least one highly flexible thermoelectric composite device is an auxiliary power source provided to an electric drive component.

[0043] In another aspect, the method further includes powering the electric drive component with electrical energy directed from the energy storage device to the electric drive component.

[0044] Another aspect of the present invention relates to an electric drive component that is at least partially driven by electrical energy directed to the electric drive component from a highly flexible thermoelectric composite device according to a method, the method comprising providing an aircraft manufacturing environment surface, the aircraft manufacturing environment surface being configured to dissipate heat. The method further comprises placing at least one highly flexible thermoelectric composite device adjacent to the aircraft manufacturing environment surface, the highly flexible thermoelectric composite device comprising at least one wire in communication with the highly flexible thermoelectric composite device, the at least one wire further in communication with an electrical circuit, converting a certain amount of heat from the aircraft manufacturing environment surface into electrical energy, and directing the electrical energy from the highly flexible thermoelectric composite device to the electrical circuit.

[0045] Further, the present aspect relates to an electric drive component that is at least partially driven by electrical energy directed to the electric drive component from a highly flexible thermoelectric composite device according to a method, the method comprising providing an aircraft manufacturing environment surface, the aircraft manufacturing environment surface being configured to dissipate heat. The method further comprises placing at least one highly flexible thermoelectric composite device adjacent to the aircraft manufacturing environment surface, the highly flexible thermoelectric composite device comprising at least one wire in communication with the highly flexible thermoelectric composite device, the at least one wire further in communication with an electrical circuit, converting a certain amount of heat from the aircraft manufacturing environment surface into electrical energy, and directing the electrical energy from the highly flexible thermoelectric composite device to the electrical circuit. The method further comprises directly charging an energy storage device with electrical energy directed from at least one flexible thermoelectric composite device, the energy storage device being in communication with the electrical circuit during a battery charging cycle, and powering the electric drive component with electrical energy directed from the energy storage device.

[0046] Further aspects of the present invention relate to an aircraft manufactured according to a manufacturing method, the manufacturing method comprising providing a structure configured to dissipate heat during operation, the structure comprising a structure surface, and the structure surface is configured to dissipate a certain amount of heat during operation of the structure. The method further comprises placing at least one highly flexible thermoelectric composite device adjacent to the structure, the highly flexible thermoelectric composite device comprising at least one wire in communication with the highly flexible thermoelectric composite device, the at least one wire further in communication with an electrical circuit, converting a certain amount of heat from the structure surface into electrical energy, and directing the electrical energy from the highly flexible thermoelectric composite device to the electrical circuit.

[0047] Further aspects of the present invention relate to an aircraft manufactured according to a method of manufacturing an aircraft in an aircraft manufacturing facility (the method may include, for example, collecting energy from a "shop floor" of an aircraft manufacturing environment, etc.), the method including providing an aircraft manufacturing environment surface, the aircraft manufacturing environment surface configured to dissipate heat. The method further includes placing at least one highly flexible thermoelectric composite device adjacent to the aircraft manufacturing environment surface, the highly flexible thermoelectric composite device including at least one wire in communication with the highly flexible thermoelectric composite device, the at least one wire further in communication with an electrical circuit, converting a certain amount of heat from the aircraft manufacturing environment surface into electrical energy, and directing the electrical energy from the highly flexible thermoelectric composite device to the electrical circuit.

[0048] In another aspect, the method further includes powering an electric drive component with electrical energy directed from at least one highly flexible thermoelectric composite device to the electric drive component, the electric drive component being in communication with at least one of the highly flexible thermoelectric composite device and the circuit.

[0049] In another aspect, the method further includes directly charging the energy storage device with electrical energy from at least one flexible thermoelectric composite device, and during a battery charging cycle, the energy storage device is connected to the circuit and the electrical drive component is powered with electrical energy directed from the energy storage device to the electrical drive component.

[0050] The features, functions, and advantages that have been discussed may be achieved independently in various aspects or may be combined in yet other aspects, further details of which may be seen with reference to the following description and drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0051] Having described various variations of the present disclosure in general terms, reference will now be made to the accompanying drawings, which are not necessarily drawn to scale, and in which:

[0052] Figure 1 is an illustration of a vehicle in the form of an aircraft according to the present invention;

[0053] Figure 1Ais an illustration of a vehicle in the form of an aircraft according to the present invention, placed in an aircraft manufacturing environment in the form of an aircraft manufacturing facility;

[0054] Figure 2 is an illustration of an aircraft component in the form of an aircraft engine according to the present invention, which includes a highly flexible thermoplastic composite device located in direct contact with an engine surface;

[0055] Figure 3 is an illustration of an aircraft assembly in the form of an auxiliary power unit according to the present invention, comprising a highly flexible thermoplastic composite device located in direct contact with a surface of the auxiliary power unit;

[0056] Figure 4 is an illustration of an aircraft component in the form of an avionics bay according to the present invention, comprising a highly flexible thermoplastic composite material device located in direct contact with a surface of the avionics bay;

[0057] Figure 5A is a circuit diagram including a highly flexible thermoplastic composite device according to the present aspect;

[0058] Figure 5B is a circuit diagram including a highly flexible thermoplastic composite device according to the present aspect;

[0059] Fig. 6A is a block diagram illustrating an aircraft component having an aircraft component surface and including a highly flexible thermoelectric composite device according to the present invention;

[0060] Figure 6B is a block diagram illustrating an aircraft component having an aircraft component surface according to the present invention, which includes a highly flexible thermoelectric composite device in communication with an electrical circuit and an aircraft component;

[0061] Figure 6C is a block diagram of an aircraft component of an aircraft according to the present invention, comprising a highly flexible thermoelectric composite device configured to provide electrical power to the aircraft component;

[0062] Fig.6D is a block diagram illustrating an aircraft component of an aircraft according to the present invention, which includes a highly flexible thermoelectric composite device configured to power the aircraft component;

[0063] Fig. 6E is a block diagram illustrating an aircraft including an aircraft component according to the present invention, the aircraft component including a highly flexible thermoelectric composite device configured to power the aircraft component and charge an energy storage device;

[0064] Fig. 6Fis a block diagram illustrating an aircraft including an aircraft component according to the present invention, the aircraft component including a highly flexible thermoelectric composite device configured to power a first aircraft component, charge an energy storage device, and direct electrical energy to a second aircraft component;

[0065] Figure 6G is a block diagram illustrating an aircraft component of an aircraft according to the present invention, which includes a highly flexible thermoelectric composite device configured to power an aircraft component used to manufacture an aircraft in an aircraft manufacturing environment, which may be an aircraft manufacturing facility;

[0066] Figure 6H is a block diagram illustrating an aircraft component of an aircraft according to the present invention, which includes a highly flexible thermoelectric composite device configured to power the aircraft component and charge an energy storage device;

[0067] Fig.6I is a block diagram illustrating an aircraft component of an aircraft according to the present invention, comprising a highly flexible thermoelectric composite device configured to power a first aircraft component, charge an energy storage device, and direct power to a second aircraft manufacturing component;

[0068] Figure 7 is a view of a manufacturing process for a highly flexible thermoelectric composite material device according to the present invention;

[0069] Figure 8 is an exploded view of a highly flexible thermoelectric composite device according to the present invention;

[0070] Fig. 9 is a perspective view of a highly flexible thermoelectric composite device according to the present invention;

[0071] Fig.10 is a perspective view of a highly flexible thermoelectric composite device according to the present invention;

[0072] Fig.11 is a perspective view of a highly flexible thermoelectric composite device according to the present invention in a highly deformed state;

[0073] Fig.12 is a perspective view of a highly flexible thermoelectric composite device according to the present invention in a highly deformed state;

[0074] Fig.13 is a view of a plurality of highly flexible thermoelectric composite devices placed in series according to the present invention;

[0075] Fig.14 is a schematic diagram of a plurality of highly flexible thermoplastic composite devices placed in series according to the present invention;

[0076] Fig.15is a schematic diagram of a plurality of highly flexible thermoplastic composite devices placed in series according to the present invention;

[0077] Fig.16 is a flow chart outlining a method according to the present aspect;

[0078] Fig.17 is a flow chart outlining a method according to the present aspect;

[0079] Fig.18 is a flow chart outlining a method according to the present aspect;

[0080] Fig.19 is a flow chart outlining a method according to the present aspect;

[0081] Fig. 20 is a flow chart outlining a method according to the present aspect;

[0082] Fig.21 is a flow chart outlining a method according to the present aspect;

[0083] Fig. 22 is a flow chart outlining a method according to the present aspect;

[0084] Fig.23 is a flow chart outlining a method according to the present aspect;

[0085] Fig.24 is a flow chart outlining a method according to the present aspect; and

[0086] Fig.25 is a flow chart outlining a method according to the present aspect. DETAILED DESCRIPTION

[0087] Aircraft structures may include aircraft components, aircraft sub-assemblies, and equipment on and within an aircraft (structures, components, sub-assemblies, and equipment within and / or on an aircraft are referred to herein as "aircraft components"), and aircraft structures may themselves generate heat and dissipate heat from aircraft component surfaces, or they may be located adjacent to various heat-generating aircraft components, such that surfaces of non-heat-generating components may still include surfaces that may dissipate absorbed heat. Aircraft component surfaces may dissipate significant amounts of heat and experience significant temperature gradients during operation. Aircraft components include aircraft component surfaces that may dissipate significant amounts of heat, such as, for example, during operation of the aircraft and / or operation of the aircraft components.

[0088] For example, aircraft engines generate a large amount of heat during operation, which heat can be partially redirected and / or reused as exhaust air, which can help heat the aircraft cabin, and / or other heating functions. In addition, other heat-generating aircraft components may include, for example, auxiliary power units, electronic equipment bays / panels, passenger seats (e.g., seat cushions, armrests, side walls, etc.). According to the present aspect, such heat-generating aircraft components include surfaces that dissipate heat.

[0089] Additionally, areas within an aircraft, as well as some aircraft components, that do not themselves generate heat during operation, may include surfaces that can absorb or reflect heat and then dissipate or reflect the heat. For example, such component surfaces may experience thermal gradients as they absorb heat from adjacent structures during operation. Still further, various aircraft component surfaces, such as passenger seat surfaces, aircraft window surfaces, sidewall surfaces, etc., may dissipate heat (e.g., while the aircraft is in an operational state, including, for example, in flight, during taxiing, at rest on the tarmac or at a gate, etc.).

[0090] The present aspect is directed to collecting, capturing and / or reusing at least a portion of heat transferred (e.g., dissipated) from heat-generating and / or heat-dissipating aircraft component surfaces, e.g., "waste heat," and converting such waste heat into electricity by placing and positioning a highly flexible thermoelectric composite device (herein equivalently referred to as a "TE device") in close proximity to, adjacent to, in direct contact with and / or incorporated into an aircraft component surface that is capable of dissipating the collected, absorbed, reflected and / or generated heat.

[0091] According to the present aspect, a highly efficient and flexible thermoelectric composite device is placed in contact with an aircraft component surface configured for heat dissipation, and a certain amount of thermal energy (e.g., "waste heat") emitted from such aircraft component surface (which would previously be lost to the surrounding environment) is now utilized, collected, "scavenged", and otherwise converted into electrical energy, which can be: 1) directed to directly power electrical components; 2) directed to a circuit to power electrical components connected to the circuit; and / or 3) directed to and stored in a rechargeable battery directly connected to the TE device or connected to the circuit. The converted electricity can then be delivered, for example, on demand, such as to power aircraft components in an aircraft environment, which environment may include components on the aircraft, and / or to power electric drive devices and / or systems in an aircraft manufacturing facility.

[0092] That is, the highly flexible thermoelectric composite device can directly or indirectly deliver converted electrical energy (which is converted from heat on the surface of an aircraft component or the surface of an aircraft environment) to power electrically powered aircraft environment components. The highly flexible thermoelectric composite device can further deliver the electrical energy converted from the heat dissipation surface to a rechargeable energy storage device, for example, to directly or indirectly power electrically powered aircraft components on an aircraft or electrically powered components and systems in an aircraft manufacturing facility (also referred to herein as the "aircraft environment").

[0093] Directly powering a component with electrical energy converted from thermal energy by a TE device contemplates that the TE device is in direct communication with an electrically powered aircraft component (e.g., in direct contact with an aircraft component surface or an aircraft environment surface). For example, an electrically powered aircraft component may itself include a TE device, or the component may include an energy storage device that is charged with electricity generated by the TE device. In other examples, the "indirectly powered" electrically powered component may be in communication with a circuit that is further in communication with at least one of the TE device and the energy storage device, and the energy storage device may be charged with electricity generated by the heat dissipated from the surface of the TE device.

[0094] Moreover, in accordance with further aspects of the present invention, a highly efficient and highly flexible thermoelectric composite device is placed in contact with a heat-dissipating aircraft manufacturing facility surface (equivalently referred to herein as an "aircraft environment surface"), such as during aircraft manufacturing. Such aircraft environment surfaces may include, for example, facility windows, roofs, lamps, machinery, ovens, heaters, and any physical structure having a surface that can dissipate heat. Such aircraft manufacturing facility surfaces present in an aircraft manufacturing facility are configured to collect heat and / or dissipate heat during which previously dissipated thermal energy (e.g., "waste heat") was previously lost to the surrounding environment. In accordance with this aspect, by associating a highly flexible thermoelectric composite device with a heat-dissipating aircraft manufacturing facility surface, the "waste heat" can now be utilized, collected, "scavenged," and otherwise converted into electrical energy, which can be directed to, for example, power aircraft manufacturing facility components or systems that are placed in communication with the highly flexible thermoelectric device or placed in communication with a circuit that is in communication with the highly flexible thermoelectric device. In a further aspect of the present invention, the converted electrical energy can be directed to and stored in a rechargeable energy storage device that is connected to the TE device (directly or through a circuit, etc.), and the stored electrical energy is then delivered to the aircraft manufacturing facility components to power the aircraft manufacturing facility components in the aircraft manufacturing facility as needed.

[0095] In a further aspect, the highly flexible thermoelectric composite device itself is incorporated (e.g., integrally incorporated) into an aircraft manufacturing facility component having a surface configured to dissipate heat during aircraft manufacturing in the aircraft manufacturing facility, such that heat generated during operation of the aircraft manufacturing facility component is converted by the TE device into electrical current, which can be delivered back to the aircraft manufacturing component to power the component, or to power features of the component (e.g., lights or power indicators associated with the component, etc.), or to charge a battery that can be incorporated into the component to power the component.

[0096] According to this aspect, the heat dissipation surface of an aircraft component and / or an aircraft manufacturing facility surface (which may support and include and may directly contact the present TE device) may be planar, non-planar, contoured (e.g., regular or irregular geometric shapes, etc.), and the highly flexible TE device is configured to be flexible enough to conform to the heat dissipating aircraft component surface or the heat dissipating aircraft environment surface and maintain contact therewith while maintaining direct contact between the highly flexible TE device and the heat dissipating surface.

[0097] In one example, the TE device includes wires connected to an electrical circuit. When the surface of an aircraft component (and / or an aircraft manufacturing facility surface) dissipates heat, an associated TE device placed adjacent to the heat dissipation surface (e.g., in direct contact with the heat dissipation surface, integrated with the heat dissipation surface, etc.) experiences or "maintains" a temperature gradient (herein equivalently referred to as a "thermal gradient", and / or "and / or "heat flux") across the TE device structure, and the TE device converts a certain amount of "waste heat" from the surface of the aircraft component into an electrical charge. When the TE device is located in communication with the electrical circuit, the TE device transfers the generated charge to the electrical circuit.

[0098] According to this aspect, the circuit in communication with the TE device may be an existing circuit that is part of a typical aircraft electrical architecture. In further examples, the circuit in communication with the TE device may be a circuit dedicated to the TE device. That is, according to this aspect, in addition to being an auxiliary power source for the TE device, the circuit may also include or otherwise be connected to a conventional power source. In this example, the TE device may be an auxiliary power source in the circuit, and in the absence of a conventional power source (for example, when the conventional power source on the aircraft is interrupted, etc.), the TE device continues to supply electrical energy to the circuit. In other examples, the circuit may be an additional circuit dedicated to the TE device, and the TE device serves as an exclusive power source for the circuit.

[0099] According to the present aspect, an aircraft component or system, which may be an electrically powered aircraft component or system, may be in communication with a TE device via a circuit and powered by the TE device. If the aircraft experiences a power outage, the power provided to the circuit by the TE device may continue to power the aircraft component / system in communication with the TE device via the circuit, e.g., the electrically powered aircraft component / system remains in uninterrupted operation during such an unplanned aircraft power outage. In this example, the TE device may provide a continuous source of power, thereby eliminating the need to convert aircraft power (e.g., in the form of a "backup power source" or the like) to operate the aircraft component / system in communication with the TE device via the circuit.

[0100] In addition, according to further aspects of the present invention, an energy storage device (e.g., a rechargeable energy storage device such as a lithium-ion battery) can be connected to a circuit, and the TE device delivers charge to the energy storage device and the TE device supplies power to the electrical components. In further examples, when the aircraft is not operating (e.g., when the aircraft structure is not experiencing a thermal gradient to operate the TE device), the electrical energy stored in the energy storage device can be delivered to the aircraft components. In further examples, the energy storage device can be connected to further circuits to operate additional aircraft components / systems, etc. Electrically driven aircraft components / systems may include, for example, sensors, indicators, lighting groups, emergency equipment, communication equipment, navigation equipment, ventilation systems, etc.

[0101] The circuit in communication with the present TE device may further be in communication with an indicator powered by the circuit, the indicator indicating, for example, power generated by the TE device, or indicating that electrical energy is being delivered from, or has been supplied to, an energy storage device.

[0102] As described herein, the TE device can be a dedicated power source for an aircraft component. In addition, the TE device can be configured (e.g., connected to a circuit) to be used as an auxiliary power source, and the TE device is configured in either mode to direct the charge (converted from heat) to a rechargeable energy storage device, which can be adjusted as needed to deliver electrical energy from the energy storage device.

[0103] Figure 1 A vehicle is shown in the form of an aircraft 10 having an aircraft engine 12 providing propulsion. Figure 1A An aircraft 10 is shown in an aircraft manufacturing facility 11 in accordance with the present invention. Figure 2 1 is a partially exploded view of an aircraft component 14 having an aircraft component surface for dissipating heat during operation, the aircraft component 14 having an aircraft component surface 14a (in the form of an aircraft engine 12 having an aircraft engine surface 12a). Figure 2As shown, a highly flexible thermoelectric composite device (herein equivalently referred to as a "TE device") 18 is placed in contact with, adjacent to, and further in direct contact with respective aircraft component surfaces 12a, 14a that dissipate heat during operation. Figure 2 As shown, the aircraft component surface may be or may otherwise include a non-planar surface, and may present a contoured (eg, non-planar) surface upon which the TE device 18 is incorporated.

[0104] Figure 3 FIG. 1 is a partially exploded view of an auxiliary power unit 13 as another type of aircraft component 14 having a surface that can dissipate heat during operation and having an aircraft component surface 14a (in FIG. 1 ) that can dissipate heat and on which a TE device 18 can be placed, for example, in direct contact. Figure 3 In another example, Figure 4 As a further type of aircraft component 14, an electrical equipment compartment 15 is shown, which has an aircraft component surface 14a (in Figure 4 The electronic equipment compartment surface 16 is also shown in the figure, which can dissipate heat and on which the TE device 18 can be placed, for example, in direct contact.

[0105] According to the present aspect, an aircraft component includes an aircraft component surface, and at least one TE device is in direct contact with the aircraft component surface. The aircraft component surface can be planar, and in addition, the aircraft structure surface can be contoured (e.g., non-planar), and the highly flexible TE device is configured to be sufficiently flexible (e.g., bendable) to conform to the contour of the aircraft structure surface, maintaining the TE device in direct contact with the contour of the aircraft component surface.

[0106] As described herein, the circuitry in communication with the present TE device may be further in communication with an indicator powered by the circuitry that indicates power generated by the TE device, or that electrical energy is being delivered from, or supplied to, an energy storage device. Figure 5A and Figure 5B is a circuit diagram illustrating this aspect.

[0107] Figure 5A shows that, for example, it is possible to exist and be located Figure 1 Electrical circuitry 30 within the electrical architecture of an aircraft of the type shown. Figure 5AAs shown, the electrical circuit 30 includes at least one highly flexible thermoelectric composite device ("TE device") 18 in communication with an indicator 32 and a booster 36 along the circuit 30. When the TE device 18 operates, converts heat into electricity and generates current, the TE device 18 experiences a thermal gradient; it is an indication that a temperature change / increase is occurring across the area, and indicates that a temperature change / increase is occurring in an area in or near the aircraft structure that is in contact with the TE device. The booster 36 in the circuit 30 can further enhance the voltage generated by the TE device in the circuit 30.

[0108] Figure 5B An optional circuit 40 according to the present aspect is shown, in which the TE device 18 is connected to the circuit 40, and the circuit 40 further includes a booster 36, which can be placed in the circuit 40 between, for example, the TE device 18 and a rechargeable energy storage device 42 (for example, it can be a rechargeable lithium-ion battery, etc.), and the circuit 40 is further connected to the electrical component 34, which can be, for example, a temperature sensor.

[0109] In furtherance of this aspect, the TE device can be placed in contact with or in proximity to aircraft component surfaces that are not typically configured for heat dissipation and in aircraft locations that facilitate rapid detection of undesirably detected temperature changes (e.g., rapid detection of a temperature increase, such as real-time detection, with real-time being defined herein as a duration ranging from about 5 seconds to about 30 seconds). In these aircraft structure locations that are not expected to experience a temperature increase, when the TE device experiences even a minimal thermal gradient from about 3°C ​​to about 5°C, the TE device will begin to convert heat into an electrical current that can be directed to, for example, a circuit that includes an electrically powered indicator. The power generated by the TE device can be detected and indicated by an indicator, for example, as an alert that a particular aircraft structure or an area proximate to an aircraft structure is experiencing a temperature increase that may be undesirable. In this mode, the TE device itself can act as a temperature sensor.

[0110] Fig. 6A , 6B and 6C are diagrams outlining further aspects of the present invention. Fig. 6A is a block diagram illustrating an aircraft component surface that includes or otherwise incorporates the present TE device 18 . Figure 6B Shown Fig. 6A The aircraft structure 60 (including the TE device 18), the TE device 18 is connected to the circuit 30, and the aircraft structure 60 (including the TE device 18) is shown as described herein and as shown in FIG. Figure 5A Components shown in communication with circuit 30. When energy storage device 42 is placed in communication with the circuit, the circuit may be designated as circuit 40, which illustrates components as described herein and as Figure 5B Components shown are in communication with circuit 40.

[0111] like Figure 6C As shown, the present invention further relates to an electric drive component 34, which may be, for example, a temperature sensor, etc. Figure 6C As shown, electrically powered aircraft components may be in direct contact with the present TE device 18, for example, to directly power component 34. As mentioned herein, the TE device may be a dedicated power source for an aircraft component, and the TE device may also be configured in a circuit as an auxiliary power source for an aircraft component, the TE device being configured in either mode to direct the charge generated by the TE device to a (re)chargeable energy storage device that may be adjusted to deliver electrical energy from the energy storage device as needed.

[0112] The present TE device can be manufactured as an extremely thin device having an overall thickness ranging from about 2 mm to about 2.4 mm, facilitating placement of the present TE device in various locations on an aircraft and contacting aircraft component surfaces on an aircraft that was previously impossible (e.g., inaccessible locations, etc.), and / or placement between structures that exhibit significant spatial constraints and / or tolerances between structures, where the available space (e.g., "gap") between structures is only a little or only a few millimeters wide. According to this aspect, the width of the present TE device (having a width ranging from about 10 mm for a TE tensile test specimen to about 32 mm for a TE device), for example, allows such a present TE device to occupy previously unoccupied space between closely and adjacently placed aircraft components.

[0113] Further aspects of the present invention relate to an aircraft comprising an aircraft component, the aircraft component further comprising a highly flexible thermoelectric composite device (TE device). Fig.6D A block diagram 70a is shown including an aircraft 72, which includes an aircraft component 74, and the aircraft component 74 includes a TE device 76, or is otherwise in communication with the TE device 76, such as by circuits, etc. According to the present aspect, when the aircraft component 74 is in operation, the surface of the aircraft component may experience a temperature change, which may be an increase in temperature (e.g., the surface of the component may maintain a temperature gradient from an initial temperature to an "operating" temperature, the initial temperature when the component is in a stationary state, the "operating" temperature when the component itself is in operation and dissipates heat, or when the surrounding of the component experiences an increase in heat and the temperature of the surface of the component increases so that the surface of the component can dissipate heat).

[0114] That is, the aircraft component 74 may further be a non-operating component that may not generate heat itself, but may absorb a certain amount of heat from the surrounding environment or from a heat source inside or outside the aircraft (e.g., the sun), and then radiate or otherwise dissipate at least a portion of the heat from the surface of the component, or otherwise transfer a portion of the absorbed heat (e.g., passenger seats, armrests, headrests that can absorb heat from passers-by occupying the seats; windows or sidewalls that can absorb radiant energy from solar energy; fixed aircraft components or aircraft cabin components placed in areas that are subject to temperature changes and / or temperature increases when other components or structures are in operation and dissipating heat, etc.). Fig.6D As shown, the TE device is placed adjacent to or in direct contact with an aircraft component surface of an aircraft component 74 such that the TE device responds to temperature changes on the aircraft component surface and experiences a temperature gradient across the TE device, thereby enabling the TE device to convert thermal energy removed from waste heat at the aircraft component surface of the aircraft component into electrical current. Fig.6D As shown, according to one example, if the aircraft component itself is or includes an electrically powered aircraft component, the current generated by the TE device may be directed through an electrical circuit back to the aircraft component.

[0115] Fig. 6E A block diagram 70b is shown relating to another example, wherein the TE device 76 is further connected to the energy storage device 78, for example, via a circuit. Fig. 6E As shown, the TE device is placed adjacent to or in direct contact with the aircraft component surface of the aircraft component 74, so that the TE device responds to temperature changes on the aircraft component surface and experiences a temperature gradient across the TE device, so that the TE device can convert thermal energy from waste heat removed from the aircraft component surface of the aircraft component into electric current. According to one present example, in FIG. 70 b , if the aircraft component itself is or includes an electrically driven aircraft component, 1) the current generated by the TE device can be directed from the TE device back into the aircraft component through a circuit; and / or 2) the current generated by the TE device can be directed from the TE device through a circuit to an energy storage device (e.g., which can be a rechargeable lithium-ion battery); and 3) the charge stored in the energy storage device can be released as needed and directed to power the electrically driven aircraft component.

[0116] Fig. 6FAnother block diagram 70c of this example is shown, wherein a first aircraft component 74 includes a TE device 76 configured to remove and redirect energy in the form of thermal energy from a surface of the first aircraft component to converted electrical energy, the electrical energy being directed from the TE device 76 through an electrical circuit: 1) to an energy storage device 78 in communication with the TE device; and / or 2) to a second aircraft component 75 also in communication with the electrical circuit; and / or to the energy storage device 78. In this example, the surface of the first aircraft component may experience a temperature change that activates the TE device 76, and the TE device 76 is configured to convert the thermal energy into electrical current, which may be delivered to power at least one of the first aircraft component that may be an electrically driven component and the second aircraft component that may be an electrically driven component.

[0117] Similar to the arrangement outlined in Figure 70b, as shown in Figure 70c, current can be drawn from the energy storage device as needed, for example, to power one or both of the first and second aircraft components 74, 75 as needed. The release of stored power from the energy storage device can be selectively performed when the TE device is in an operating state or when the TE device is not in an operating state.

[0118] As described herein, according to further aspects, a highly flexible thermoelectric composite device can be associated with and otherwise placed adjacent to or in direct contact with a surface of an aircraft manufacturing facility component associated with aircraft manufacturing, such as in an aircraft manufacturing facility. According to these aspects, the TE device can utilize, remove, etc. "waste heat" that would otherwise be lost to the manufacturing environment, and convert the waste heat into electrical energy that can be directed to power an aircraft manufacturing facility component in communication with the thermoelectric device.

[0119] In other present examples, the energy storage device can be connected to the TE device in a circuit, and the energy storage device is charged by the current generated by the TE device. When there is no thermal gradient and the TE device is not operating, the energy from the energy storage device can be directed from the charged energy storage device to power the electrically driven aircraft manufacturing components in the aircraft manufacturing facility (herein equivalently referred to as the "aircraft manufacturing environment"). The energy storage device (which can be, for example, a rechargeable lithium-ion battery) can be removed from the circuit and contacted with the remotely located aircraft manufacturing component to power the remotely located component. In other examples, the energy storage device can release charge to the circuit (e.g., a central circuit), and other manufacturing components can be "plugged into" the circuit to receive electrical energy from the energy storage device or the operating TE device.

[0120] Figure 6GFIG. 80a of an aircraft manufacturing facility 82 is shown, which includes an associated aircraft manufacturing component 84, which further includes a TE device 86 positioned adjacent to or in direct contact with a surface of the aircraft manufacturing component. According to this example, the aircraft manufacturing component surface dissipates heat during operation, or is located in the aircraft manufacturing facility and positioned adjacent to or in contact with a heat source, such that the component surface absorbs heat and then radiates and / or dissipates a portion of the absorbed heat from the component surface, such that the component surface maintains a temperature change (e.g., an increase in temperature), causing a temperature gradient within the associated TE device. In the presence of a temperature gradient, the TE device is configured to utilize, remove, etc. "waste heat" that would otherwise be lost to the manufacturing environment, and the TE device is configured to convert the waste heat into electrical energy, which can be used to power the aircraft manufacturing component, or can be stored in, for example, an energy storage device and directed from the energy storage device to power the aircraft manufacturing component.

[0121] Figure 6H FIG. 80b is shown in relation to another example, wherein the TE device 86 is further connected to the energy storage device 88, for example, via a circuit. Figure 6H As shown, the TE device 86 is placed adjacent to or in direct contact with an aircraft manufacturing component surface of an aircraft manufacturing component 84 within an aircraft manufacturing facility 82, such that the TE device responds to temperature changes on the aircraft manufacturing component surface and experiences a temperature gradient across the TE device, which enables the TE device to convert thermal energy from waste heat removed from the aircraft manufacturing component surface of the aircraft manufacturing component into electrical current.

[0122] According to one present example, in FIG. 80b, if the aircraft manufacturing component itself is or includes an electrically powered aircraft manufacturing component, 1) the current generated by the TE device can be directed from the TE device back to the aircraft manufacturing component through a circuit; and / or 2) the current generated by the TE device can be directed from the TE device through a circuit to an energy storage device 88 (for example, which can be a rechargeable lithium-ion battery); and 3) the charge stored in the energy storage device 88 can be released as needed and directed to power the electrically powered aircraft manufacturing component.

[0123] Fig.6IAnother block diagram 80c of this example is shown, wherein a first aircraft manufacturing component 84 within an aircraft manufacturing facility 82 includes a TE device 86 configured to remove and redirect energy in the form of thermal energy from a surface of the first aircraft manufacturing component to converted electrical energy, the electrical energy being directed from the TE device 86 through an electrical circuit 87: 1) to an energy storage device 88 in communication with the TE device; and / or 2) to a second aircraft manufacturing component 85 also in communication with the electrical circuit 87; and / or 3) to the energy storage device 88. In this example, the first aircraft manufacturing component may experience a temperature change that activates the TE device 86, which is configured to convert the thermal energy into electrical current that may be delivered to power a second aircraft manufacturing component, which may be an electrically powered manufacturing component.

[0124] Similar to the arrangement outlined in Figure 80b, as shown in Figure 80c, current can be drawn from the energy storage device as needed, for example, to power one or both of the first and second aircraft components 84, 85 as needed. The stored power can be released from the energy storage battery when the TE device is in operation or when the TE device is not in operation.

[0125] As described herein, with respect to another example, an energy storage device (which may be, for example, a rechargeable lithium-ion battery) may be removed from a circuit and contacted with an aircraft manufacturing component remotely located within an aircraft manufacturing facility to power an electrically powered aircraft manufacturing component (e.g., a cordless component). In other examples, the energy storage device may release charge to a circuit (e.g., a central circuit) and other manufacturing components may be "plugged into" the circuit to receive power from the energy storage device or an operating TE device.

[0126] According to the present apparatus, system and method, a "self-sustaining" power generation device is disclosed to reduce weight and energy consumption, and to facilitate autonomous sensing, thereby improving safety and reliability. The highly flexible thermoelectric composite device (herein equivalently referred to as "TE device") of the present disclosure is well suited for generating electrical energy from aircraft components, and for powering temperature sensors of aircraft structures (herein equivalently referred to as "aircraft parts" and "aircraft components"), because during aircraft operation, energy conversion / power generation occurs continuously due to heat flux provided by the aircraft structure, and heat flux generated to areas close to such aircraft structure.

[0127] That is, according to the present aspect, heat can be collected from, for example, an engine casing or other heat-generating aircraft structures (for example, during aircraft operation) by the TE devices of the present disclosure, which can, for example, power microelectromechanical system (MEMS) sensors or monitor changes in temperature gradients while withstanding structural deformations caused by repeated mechanical loads and / or repeated thermal expansion.

[0128] The present power generation / energy collection application is achieved by the highly flexible TE device of the present disclosure, which provides a conformable thermal contact between the highly flexible TE device and the heat source. The present highly flexible TE device provides a repeatable and reliable scalable TE device that avoids the limitations of typical semiconductors welded to non-flexible electrodes, and instead provides a TE device with high efficiency and is not prone to mechanical and electrical failure. The present highly flexible thermoelectric composite device includes soft multifunctional composite materials, the synthesis of which can provide enhanced thermal transfer and have excellent conformability in the contact area between the device and the heat source. The present TE device can generate record high power; at ΔT equal to 60°C, it produces an open circuit voltage of 440mV and approximately 550μW / cm -2 The power density is 2.3W while being able to stretch to more than 30% tensile strain for at least about 15,000 load cycles.

[0129] The present aspect contemplates incorporating a highly flexible thermoelectric (TE) composite device of the present disclosure into an aircraft environment, which itself acts as a thermal sensor. In an optional aspect of the present aspect, the highly flexible TE composite device is placed in a circuit connected thereto and configured to power the thermal sensor in the event of a power outage on the aircraft. The "high flexibility" of the present highly flexible TE composite device is defined as the ability of the TE composite device to maintain power generation capabilities and structural integrity (e.g., by converting thermal gradients into electrical energy) while being able to withstand structural deformation in the form of stretching the area of ​​the TE composite device by 30% (e.g., 30% strain) within 15,000 cycles while achieving a slight change in resistance magnitude. The property of the present TE composite device to withstand repeated structural deformation without affecting performance is referred to herein as the "stretchability" of the present highly flexible TE composite device; "stretchability" includes deformations such as stretching, twisting, and bending.

[0130] The present TE composite devices may include printed liquid metal electrodes, which may be self-healing electrodes that can withstand, for example, punctures, yet still maintain the ability to efficiently convert thermal gradients into electrical energy.

[0131] The present highly flexible TE composite device comprises an elastomer-based substrate material, which further comprises a conductive material, which not only has high flexibility, but also significantly improves the performance and durability of the TE composite device by maintaining a high level of thermal gradient to electrical energy performance during a selected life of the TE composite device, thereby enabling the TE composite device to surpass the known structural deformation tests described herein.

[0132] The present TE composite device overcomes previous problems with the use of elastomers that exhibit undesirably low thermal conductivity, which previously resulted in inefficient conduction across thermal gradients. The present TE composite device overcomes previously unacceptable TE device architectures by incorporating new functional filler materials into the TE composite device structure. Such functional filler materials include liquid metal alloys of gallium (e.g., eutectic gallium indium (EGaIn)) for forming flowable electrical interconnects within the TE composite device.

[0133] According to this aspect, the selected liquid metal incorporated into the TE composite device structure includes high thermal conductivity (20-30 Wm - 1 K -1 ) to enhance selected thermal management. According to this aspect, liquid metal droplets are provided as a dispersion in an elastomeric composite to provide selected thermal conductivity and electrical insulation, in addition to providing selected physical properties, enabling the present TE composite device to be used for the first time in selected applications and selected locations for selected applications that were not previously possible.

[0134] According to the present invention, the liquid metal elastomer composite liquid metal can be used as both a thermal interface material and an electrical interconnect layer, and their surface can be selectively patterned to create conductive traces. In some examples, the improved TE composite device can produce a peak open circuit voltage of 440mV and a power of 550μW cm at a temperature gradient of about 60°C. -2 power density.

[0135] According to this aspect, in some examples, 3D printing technology is incorporated to manufacture the present TE composite device, and the printed TE device includes multiple layers, in one example, including two thermal interface elastomer layers separated by an insulating layer, which can, for example, encapsulate bismuth telluride (Bi2Te3) thermoelectric semiconductors. According to this example, a printed liquid metal elastomer composite with high thermal conductivity is used as a thermal interface material, the insulating layer is printed with hollow microspheres embedded in the elastomer to reduce density and thermal bypass around the TE semiconductor, and the sprayed liquid metal (using a template and applying L:M by a spray gun) is used as a stretchable electrical interconnect layer between the semiconductors.

[0136] According to the present aspect, the highly flexible TE composite device exhibits significantly high steady-state voltage, and the high heat sink performance achievable is believed to be due to the increased surface area resulting in enhanced heat dissipation on the side not directly connected to the aircraft component surface, ie, the "cold side".

[0137] Example 1 demonstrates an exemplary method for fabricating the present TE composite device.

[0138] Example 1

[0139] An additive manufacturing printing step is performed on the TE particle array. Inorganic p / n-type thermoelectric semiconductors are arranged in pairs, such as diagonally within the mold, and assembled in an alternating sequence to form a complete circuit after printing electrical interconnects. Bismuth telluride (Bi2Te3) is selected as the TE material due to its low lattice thermal conductivity and high electrical conductivity at room temperature. After the Bi2Te3 particles are arranged, a thermal insulation layer is printed to fill the gaps between the particles. The thermal insulation layer (e.g., interlayer) is selected using an ink containing uniformly dispersed hollow thermoplastic microspheres (e.g., Nouryon Chemicals, Chicago, IL). The embedded microspheres reduce the thermal density and hollow microsphere elastomer composites (HMECs) with low thermal conductivity help transfer most of the heat passing through the thermoelectric semiconductor to the cold side of the thermoelectric device. The increased heat flux thus contributes to higher power generation of the TE composite device.

[0140] After the insulating layer is cured, liquid metal (eutectic indium gallium) is sprayed on the TE particles using an air brush to form interconnections between the P-type and N-type TE particles. An electrically insulating liquid metal-elastomer composite with high thermal conductivity is printed on it as a stretchable thermal interface layer. The liquid metal inclusions embedded in this layer are very small (less than 8μm in diameter) to ensure electrical insulation, eliminate LM leakage and improve the durability of the device. The same steps are then applied to the other side to complete the fabrication of this highly flexible, highly deformable and stretchable TE composite device.

[0141] This representative TE composite device includes 120 TE particles with a final size of 51.5x32x2.2mm 3 , the calculated fill factor is 14.27%; indicating the area fraction filled by the TE material. The highly flexible TE composite device has a selected flexibility, can be directly in contact with a contoured surface, has a fill factor of about 14%, has high energy harvesting performance and structural integrity, and does not sacrifice the desired and selected stretchability. In further examples, even if a certain degree of stretchability is sacrificed, the energy harvesting capability can be improved.

[0142] Functional elastomer composites can be formulated to print components of TE devices, for example, including: 1) 50% volume fraction of hollow microsphere elastomer composite (incorporated into the TE device as a thermal insulation layer between the hot and cold sides of the final TE composite device); 2) 50% volume fraction of liquid metal elastomer composite with inclusions less than 5μm. Ecoflex00-30 is used as the matrix phase, while fillers and processing parameters are adjusted to make two composites in order to tailor selected properties and achieve the desired uniformity within the printed layer (e.g., avoiding dispersion sedimentation, etc.).

[0143] According to this aspect, the high flexibility of the highly flexible TE composite device enables the use of the present TE device for energy harvesting in areas and locations on the structure, such as contoured structures located in areas that were previously difficult to access and / or difficult to install non-highly flexible, high-efficiency thermoelectric devices. As described herein, when the present highly flexible TE composite device survives and completes 15,000 cycles at a maximum strain of 30% as the present device does, and remains fully functional without suffering significant electrical or mechanical failure, the device is considered to have a suitable lifespan and a period of use. Tensile sample V of the present highly flexible TE composite device before (32 mV before test) and after (approximately 32 mV after test) testing for 15,000 cycles at 30% strain (mechanical load) at ΔT = 40°C OC Electrical stability was demonstrated; the TE composite device was further shown to be fully intact after 15,000 load cycles.

[0144] Furthermore, regarding the structural integrity of the stretchable and highly flexible TE composite devices, the printed TE devices remained functional over time, with the internal resistance and open-circuit voltage measured three months after fabrication showing no change compared to the initial measurements.

[0145] Examples of this TE device include Figure 7 , 8 , 9, 10, 11 and 12. Figure 7 The present TE device "stack" 90 of the present TE device 18 is shown layer by layer. In one example, as Figure 7 As shown, in step "A" of the process, TE particles are arranged and a hollow microsphere elastomer composite (HMEC) is printed as a thermal insulation layer 90a. In step "B", a liquid metal interconnect 90b is formed on the layer by screen printing. In step "C", a printed liquid metal elastomer composite (LMEC) thermal interface layer 90c is formed. Figure 8 is an exploded view of the TE device stack 80 of the TE device 18 , showing the stacking direction of the molded / printed layers 90 a , 90 b , 90 c of the present TE device 18 .

[0146] Fig. 9 and Fig.10 A TE device 18 is shown that includes an electrical wire 20 that may be positioned and otherwise formed into the TE device 18 and has non-limiting dimensions selected based on end-use constraints, the electrical wire 20 being configured to contact an electrical circuit (not shown). Fig. 9 and Fig.10 ), the purpose of which is to direct the power generated by the TE device 18 to such a circuit. Fig. 9 and Fig.10Further illustrated (although not necessarily drawn to scale) are various sizes of TE devices made and used in accordance with the present invention; Fig. 9 The TE device 18 shown in FIG. 1 has a significantly greater length than width (e.g., a length:width ratio greater than about 5:1, and as shown, about 7:1). Fig.10 As shown, Fig.10 The TE device 18 shown in FIG. 1 is presented as having a length:width ratio of less than about 2:1, and for non-limiting illustrative purposes only, is presented as about 1.5:1.

[0147] like Fig.11 and Fig.12 As shown, the highly flexible thermoelectric composite device 18 incorporating the wire 20 is configured to be used in a case where the following Fig.11 and Fig.12 The ability to deform significantly of the type shown while maintaining its power generation capability and functionality makes the present TE device very useful and capable of being incorporated into and onto complex aircraft component surfaces, which may include curved surfaces, surfaces with irregular and / or complex geometries, and the like.

[0148] Fig.13 , 14 15 depicts the present TE device array, which includes a plurality of TE devices 18 connected in series via wires 20. Fig.13 As shown, the TE devices 18 are configured to be connected in series and are interconnected with each other through electrical wires 20 to form a TE device array 18a. Fig.14 The TE devices 18 connected in series to form the TE device array 18a are shown to be deployed at a position facing the aircraft component surface 14a of the aircraft component 14, which surface may be a heat-generating aircraft component / aircraft component surface. When the aircraft component 14 dissipates heat, a thermal gradient is formed on the TE devices 18, so that the TE devices 18 constituting the TE device array 18a convert the heat energy emitted from the component 14 into electrical energy, and the TE device array 18a generates more electricity than a single TE device 18 generates.

[0149] According to this aspect, the flexibility achieved within the present TE device is achieved at least in part by composite material components within the composite material layer exhibiting fluid-like behavior, allowing such TE devices to withstand a certain degree of damage (e.g., puncture), which can be "self-healed" as the liquid phase conductors within the composite material layer rearrange to reform and maintain the ability to conduct electricity. In addition, connecting the TE devices in series can further ensure that if one TE device is damaged, the entire TE device array can continue to operate and continue to convert heat into electricity and maintain uninterrupted delivery of manufactured charge from the TE device to, for example, a circuit. Fig.15As shown, the TE device array 18a includes a plurality of TE devices 18 placed in series, and the "shadow" TE device in the middle is damaged to a certain extent, but the TE device array 18a can still operate normally.

[0150] Figures 16 to 25 is a flow chart outlining a method according to the present aspect. Fig.16 A method 100 of manufacturing an aircraft in an aircraft manufacturing facility according to the present invention (which includes, for example, harvesting energy from a "shop floor" environment, etc.) is shown, the method 100 including providing an aircraft component, the aircraft component including an aircraft structural surface, and the aircraft component surface being configured to dissipate an amount of heat from the aircraft component surface during component operation. The method 100 further includes placing 102 at least one highly flexible thermoelectric composite device adjacent to the aircraft component surface, the highly flexible thermoelectric composite device including at least one wire in communication with the highly flexible thermoelectric composite device, and the at least one wire further in communication with an electrical circuit. The method 100 further includes converting 104 heat from the aircraft component surface into electrical energy, and directing 106 the electrical energy from the highly flexible thermoelectric composite device to the electrical circuit.

[0151] Fig.17 2 is a flowchart outlining a method 200 according to the present aspect, the method 200 including aspects of the method 100 and additionally including powering an electric drive component 208 with electrical energy derived from at least one highly flexible thermoelectric composite device, the electric drive component being in communication with at least one of the highly flexible thermoelectric composite device and the circuit.

[0152] Fig.18 300, the method 300 comprising placing 302 a highly flexible thermoelectric composite device in direct contact with an aircraft structure surface, the highly flexible thermoelectric composite device comprising at least one electrical wire in communication with the highly flexible thermoelectric composite device, and the at least one electrical wire further in communication with an electrical circuit. The method 300 further comprises converting 104 heat from the aircraft structure surface into electrical energy, and directing 106 the electrical energy from the highly flexible thermoelectric composite device to the electrical circuit.

[0153] Fig.19 4 is a flow chart outlining a further method 400 according to the present aspect, the method 400 comprising placing 402 a plurality of highly flexible thermoelectric composite devices adjacent to an aircraft component surface of an aircraft component, the highly flexible thermoelectric composite devices comprising at least one electrical wire in communication with the highly flexible thermoelectric composite devices, and the at least one electrical wire further in communication with an electrical circuit. The method 100 further comprises converting 104 heat from the aircraft structure surface into electrical energy, and directing 106 the electrical energy from the highly flexible thermoelectric composite devices to the electrical circuit.

[0154] Fig. 2010 is a flow chart outlining a method 500 according to the present aspect, the method 500 comprising placing 102 at least one highly flexible thermoelectric composite device adjacent to an aircraft component surface of an aircraft component, the highly flexible thermoelectric composite device comprising at least one wire in communication with the highly flexible thermoelectric composite device, and the at least one wire further in communication with an electrical circuit. The method 500 further comprises converting 104 heat from the aircraft component surface into electrical energy, directing 502 the converted electrical energy from the TE device to an energy storage device, and charging 504 the energy storage device with an electrical charge, the energy storage device being a chargeable and / or rechargeable energy storage device (e.g., a lithium-ion battery).

[0155] Fig.21 is a flow chart outlining a method 600 according to the present aspect, the method 600 including aspects of the method 500 and further including powering 602 an electrically powered aircraft component with electrical power delivered to the electrically powered aircraft component from an energy storage device.

[0156] Fig. 22 700 is a flow chart outlining a method 700 according to the present aspect, the method 700 comprising providing 702 an aircraft manufacturing facility structure surface or an aircraft manufacturing component surface configured to dissipate heat in an aircraft manufacturing facility (e.g., an aircraft manufacturing environment), for example, during operation of the aircraft manufacturing component, and placing 704 at least one highly flexible thermoelectric composite device adjacent to at least one of the aircraft manufacturing facility structure surface that dissipates heat and the aircraft manufacturing component surface that dissipates heat in the aircraft manufacturing facility, for example, during operation of the aircraft manufacturing component. The method 700 further comprises converting 706 heat dissipated from at least one of the aircraft manufacturing facility structure and the aircraft manufacturing component during operation of the aircraft manufacturing component into electrical energy, and directing 708 the electrical energy to an electrical circuit, the TE device being in communication with the electrical circuit.

[0157] Fig.23 is a flow chart outlining a method 800 according to the present aspect, the method 800 including aspects of the method 700 and further including powering 802 electric drive components in an aircraft manufacturing facility with electrical energy generated by a TE device.

[0158] Fig.24 900 includes aspects of method 700 and further includes charging 902 an energy storage device (which may be, for example, a chargeable or rechargeable energy storage device, which may be, for example, a battery, which may be a lithium-ion battery) with electrical energy generated by the TE device.

[0159] Fig.25is a flow chart outlining a method 1000 according to the present aspect, the method 1000 including aspects of the method 900 and further comprising powering 1002 the electric drive component with electrical energy directed from the energy storage device to the electric drive component.

[0160] Figure 1 , 2 , 3, 4, 5A, 5B, 6A-6I, 7, 8, 9, 10, 11, 12, 13, 14 and 15. The equipment and system shown in any of the figures can be Fig.16 , 17 , 18, 19, 20, 21, 22, 23, 24 and 25.

[0161] Furthermore, the present disclosure includes embodiments according to the following clauses:

[0162] 1. An aircraft component (14) [a structure to which a TE device is attached; hence structure + TE device], comprising:

[0163] an aircraft component surface (14a) of an aircraft component, the aircraft component surface being configured to dissipate heat;

[0164] At least one highly flexible thermoelectric composite device (18), the highly flexible thermoelectric composite device comprising at least one wire (20) in communication with the highly flexible thermoelectric composite device; the at least one wire further in communication with an electrical circuit (30); and

[0165] Wherein the at least one highly flexible thermoelectric device is positioned adjacent to the aircraft component surface.

[0166] 2. An aircraft structure according to clause 1, wherein the at least one highly flexible thermoelectric device is in direct contact with a surface of the aircraft structure.

[0167] 3. The aircraft structure of clause 1, wherein the highly flexible thermoelectric composite device is configured to maintain a temperature gradient during operation of the aircraft component.

[0168] 4. An aircraft structure according to clause 1, wherein the aircraft component is configured to generate heat.

[0169] 5. An aircraft component according to clause 1, wherein the aircraft component is configured for heat dissipation, the aircraft component comprising at least one of an aircraft engine (12), a bleed air duct, a heater, an electrical equipment compartment (15), and an aircraft cabin component (74).

[0170] 6. The aircraft structure according to clause 5, wherein the aircraft cabin component (74) includes at least one of a side wall, a passenger seat, an electronic unit, a duct, and combinations thereof.

[0171] 7. An aircraft (10) comprising an aircraft assembly as claimed in clause 1.

[0172] 8. A method of collecting (100) waste energy in an aircraft, the method comprising:

[0173] placing (102) at least one highly flexible thermoelectric composite device adjacent to an aircraft component surface of an aircraft component of an aircraft, the aircraft component surface configured to dissipate a certain amount of heat, the highly flexible thermoelectric composite device comprising at least one wire in communication with the flexible thermoelectric composite device, the at least one wire further in communication with an electrical circuit;

[0174] converting (104) an amount of heat transferred from the aircraft component surface to the highly flexible thermoelectric composite device into electrical energy; and

[0175] The electrical energy is directed (106) from the highly flexible thermoelectric composite device to the circuit.

[0176] 9. The method (200) of clause 8, further comprising:

[0177] An electrically powered aircraft component is powered (208) with electrical energy directed from the highly flexible thermoelectric composite device, the electrically powered aircraft component being in communication with the circuit.

[0178] 10. The method (500) of clause 8, further comprising:

[0179] A battery is charged (504) using at least a portion of the electrical energy directed from the highly flexible thermoelectric composite device to a battery, the battery being in communication with the circuit.

[0180] 11. The method of clause 8, wherein the aircraft component surface comprises at least one of an aircraft engine surface, a bleed air duct surface, a heater surface, an electrical equipment bay surface, and an aircraft cabin component surface.

[0181] 12. The method of clause 11, wherein the aircraft cabin component surface comprises at least one of a sidewall surface, a passenger seat surface, an electronics bay surface, a duct surface, and combinations thereof.

[0182] 13. The method (400) of clause 8, further comprising:

[0183] A plurality of highly flexible thermoelectric composite devices are placed (402) adjacent to the aircraft component surface.

[0184] 14. The method (300) of clause 8, further comprising:

[0185] At least one highly flexible thermoelectric composite device is placed (302) in direct contact with a surface of the aircraft component.

[0186] 15. The method of clause 9, wherein the electrically powered aircraft component comprises at least one of a temperature sensor, a power sensor, a lighting array, safety lighting, LED lighting, an ambient light sensor, a cockpit instrument panel, emergency equipment, communication equipment, an auxiliary power unit, a fire extinguishing device, and combinations thereof.

[0187] 16. The method of clause 9, wherein the highly flexible thermoelectric composite device is solely responsible for powering the electrically powered aircraft component.

[0188] 17. The method of clause 9, wherein the highly flexible thermoelectric composite device is an auxiliary power source provided to the electrically powered aircraft component.

[0189] 18. The method (600) of clause 10, further comprising:

[0190] Power is supplied from the battery to electrically powered aircraft components (602), the electrically powered aircraft components including at least one of a temperature sensor, a power sensor, a lighting array, an ambient light sensor, a cockpit instrument panel, emergency equipment, communication equipment, an auxiliary power unit, a fire suppression device, and combinations thereof.

[0191] 19. The method of clause 10, wherein a voltage booster is coupled to the circuit.

[0192] 20. The method of clause 10, wherein the battery is a rechargeable lithium-ion battery.

[0193] 21. A method of manufacturing an aircraft in an aircraft manufacturing environment [harvesting energy from a "shop floor"], the method comprising:

[0194] providing an aircraft manufacturing environment surface, the aircraft manufacturing environment surface configured to dissipate heat;

[0195] placing at least one highly flexible thermoelectric composite device adjacent to the aircraft manufacturing environment surface, the highly flexible thermoelectric composite device comprising at least one wire in communication with the highly flexible thermoelectric composite device, the at least one wire further in communication with an electrical circuit;

[0196] converting a quantity of heat dissipated from a surface of the aircraft manufacturing environment into electrical energy; and

[0197] Electrical energy is directed from the highly flexible thermoelectric composite device to the circuit.

[0198] 22. The method according to clause 21, further comprising:

[0199] The electric drive component is powered by electric energy from the at least one highly flexible thermoelectric composite device, and the electric drive component is connected to the at least one highly flexible thermoelectric composite device and further connected to the circuit.

[0200] 23. The method according to clause 21, further comprising:

[0201] A battery is charged with electrical energy directed from the at least one flexible thermoelectric composite device, the battery being in communication with the circuit during a battery charging cycle.

[0202] 24. The method of clause 21, further comprising placing the at least one highly flexible thermoelectric composite device in direct contact with the aircraft manufacturing environment surface.

[0203] 25. The method of clause 21, further comprising incorporating the at least one highly flexible thermoelectric composite device into the aircraft manufacturing environment surface.

[0204] 26. The method of clause 21, further comprising placing a plurality of highly flexible thermoelectric composite devices in direct contact with the aircraft manufacturing environment surface.

[0205] 27. The method of clause 21, further comprising incorporating a plurality of highly flexible thermoelectric composite devices into the aircraft manufacturing environment surface.

[0206] 28. The method of clause 21, wherein the at least one highly flexible thermoelectric composite device is solely responsible for powering the electric drive component.

[0207] 29. The method of clause 21, wherein the at least one highly flexible thermoelectric composite device is an auxiliary power source provided to the electric drive component.

[0208] 30. The method according to clause 23, further comprising:

[0209] The electric drive components are powered by electrical energy directed from the battery to the electric drive components.

[0210] 31. An electric drive component powered at least in part by electrical energy directed from the highly flexible thermoelectric composite device to the electric drive component according to the method of clause 22.

[0211] 32. An electric drive component powered at least in part by electrical energy directed from the battery to the electric drive component according to the method of clause 30.

[0212] 33. An aircraft manufactured according to the method of clause 22.

[0213] 34. An aircraft manufactured according to the method of clause 30.

[0214] Of course, without departing from the essential features of the present disclosure, the present invention may be implemented in other ways than those specifically described herein. The present invention should be considered illustrative and non-restrictive in all aspects, and all changes within the meaning and equivalent range of the claims should be included therein.

Claims

1. An aircraft component (14) [a structure to which a TE device is attached; Therefore, it is a structure + TE device], the aircraft assembly includes: an aircraft component surface (14a) of an aircraft component, the aircraft component surface being configured to dissipate heat; At least one highly flexible thermoelectric composite device (18), the highly flexible thermoelectric composite device comprising at least one wire (20) in communication with the highly flexible thermoelectric composite device; the at least one wire further in communication with an electrical circuit (30); and Wherein the at least one highly flexible thermoelectric device is positioned adjacent to the aircraft component surface. 2 . The aircraft structure of claim 1 , wherein the at least one highly flexible thermoelectric device is in direct contact with a surface of the aircraft structure. 3 . The aircraft structure of claim 1 , wherein the highly flexible thermoelectric composite device is configured to maintain a temperature gradient during operation of the aircraft component. The aircraft structure of claim 1 , wherein the aircraft component is configured to generate heat.

5. The aircraft component of claim 1, wherein the aircraft component is configured for heat dissipation, the aircraft component comprising at least one of an aircraft engine (12), a bleed air duct, a heater, an electrical equipment bay (15), and an aircraft cabin component (74).

6. The aircraft structure of claim 5, wherein the aircraft cabin component (74) includes at least one of a side wall, a passenger seat, an electronics unit, a duct, and combinations thereof.

7. An aircraft (10) comprising the aircraft assembly of claim 1.

8. A method of collecting (100) waste energy in an aircraft, the method comprising: placing (102) at least one highly flexible thermoelectric composite device adjacent to an aircraft component surface of an aircraft component of an aircraft, the aircraft component surface configured to dissipate a certain amount of heat, the highly flexible thermoelectric composite device comprising at least one wire in communication with the flexible thermoelectric composite device, the at least one wire further in communication with an electrical circuit; converting (104) an amount of heat transferred from the aircraft component surface to the highly flexible thermoelectric composite device into electrical energy; and The electrical energy is directed (106) from the highly flexible thermoelectric composite device to the circuit.

9. The method (200) of claim 8, further comprising: An electrically powered aircraft component is powered (208) with electrical energy directed from the highly flexible thermoelectric composite device, the electrically powered aircraft component being in communication with the circuit.

10. The method (500) of claim 8, further comprising: A battery is charged (504) using at least a portion of the electrical energy directed from the highly flexible thermoelectric composite device to a battery, the battery being in communication with the circuit.

Images