Thermionic Energy Harvester with Gradient Thermal Expansion Layer

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Solution Overview

Problem

Existing electrochemical technologies, such as lithium-ion, lead-acid, and nickel-cadmium batteries, face limitations in operational duration, energy storage capacity, and are burdened by hazardous materials requiring onerous handling, shipping, and disposal, as well as constraints due to electrochemical degradation under mechanical stress and limited charge and discharge rates.

Innovation Solution

A thermal energy harvesting thermionic device integrated with electronic components, featuring a cathode, an anode, and nanoparticles in a medium between them, along with an intermediate layer of gradient thermal expansion material, to generate electrical output and power electronic components efficiently.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Quantity of substance

If electrochemical battery technology is used, then energy storage capacity can be achieved, but operational duration is limited and hazardous materials are required

Engineering Contradiction:

Improveenergy storage capacityVSAvoidoperational duration

Core Design Contradiction:

Quantity of substanceVSDuration of action of moving object

Solution Approach 1:

The patent replaces electrochemical battery systems with a thermionic energy conversion system that uses thermal energy to generate electricity through electron emission from a cathode to an anode, eliminating the need for electrochemical reactions and hazardous battery materials while providing continuous operational duration limited only by heat supply

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The invention changes the fundamental energy conversion parameter from electrochemical to thermionic, using temperature differential as the driving force rather than chemical potential difference, thereby achieving unlimited operational duration as long as thermal energy is supplied to the cathode

Inventive Principle:

Principle #35Parameter changes

2Power

If electrochemical battery technology is used, then power delivery can be achieved, but charge and discharge rates are limited

Engineering Contradiction:

Improvepower deliveryVSAvoidcharge and discharge rates

Core Design Contradiction:

PowerVSProductivity

Solution Approach 1:

The patent substitutes electrochemical charge/discharge processes with direct thermionic energy conversion, where thermal energy continuously drives electron emission and current flow without the rate limitations inherent in chemical reaction kinetics, enabling sustained high-power output

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Ease of manufacture

If uniform thermal expansion material is used, then manufacturing simplicity is maintained, but mechanical stress-related degradation occurs

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidresistance to mechanical stress degradation

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent applies a gradient thermal expansion material where the thermal expansion coefficient varies spatially through the material thickness, with the surface near the heater having different properties than the far surface, allowing each region to accommodate local thermal stresses and preventing catastrophic failure from uniform expansion constraints

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The invention uses a composite thermal expansion material with spatially varying composition or structure that provides different thermal expansion characteristics at different locations, combining the benefits of thermal management with enhanced mechanical reliability under thermal cycling conditions

Inventive Principle:

Principle #40Composite materials

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The solution enhances energy harvesting and extends operational lifetime by leveraging thermal energy conversion, reducing material hazards, and mitigating mechanical stress-related degradation, thus providing a more sustainable and efficient power source.

Implementation Method 1

a thermal energy harvesting thermionic device configured to receive thermal energy and generate an electrical output

Methodology Applied

Scientific EffectThermionic emission: Thermionic Emission

Implementation Method 2

The intermediate layer comprises a gradient thermal expansion material (TEM), and has a first surface with a first coefficient of thermal expansion (CTE) facing the thermal energy harvesting thermionic device, and a second surface with a second CTE facing the electronics layer

Methodology Applied

Scientific EffectThermal expansion: Thermal Expansion

Data Source

PatentUS11417506B1Apparatus including thermal energy harvesting thermionic device integrated with electronics, and related systems and methods

Publication Date: 2022.08.16 BIRMINGHAM TECHNOLOGIES INC

AI summary

Embodiments relate to an apparatus that includes an electronics layer with at least one electronic component, and a thermal energy harvesting thermionic device to receive thermal energy and generate an electrical output for powering the electronic component. The thermionic device includes a cathode, an anode spaced from the cathode, and a plurality of nanoparticles in at least one medium contained between the cathode and the anode to permit electron transfer between the cathode and the anode. An intermediate layer is positioned between the thermionic device and the electronics layer. The intermediate layer is made of a gradient thermal expansion material (TEM). Related systems and methods are also provided.