Thermocouple-Embedded Screw for Battery-Free Sensor Power
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Solution Overview
Problem
Existing sensor systems, particularly those in mobile or stationary applications, face challenges with battery-powered solutions that require frequent maintenance or replacement, leading to high costs due to limited battery lifespan and the inability to use batteries in high-temperature or rotating environments.
Innovation Solution
Integration of thermocouples within screws or fasteners to harness energy from temperature differences between the screw head and tip, eliminating the need for batteries and cables by converting thermal energy into electrical energy for powering sensors and electronics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a battery is used to power the sensor, then the sensor can operate wirelessly, but the battery has limited lifespan requiring frequent maintenance or replacement
Solution Approach 1:
The thermocouple embedded in the screw generates electrical energy autonomously by exploiting the temperature difference between the screw head and screw tip during normal operation. This self-powered mechanism eliminates the need for external battery replacement or recharging, allowing the sensor to operate indefinitely without maintenance.
2Adaptability or versatility
If a battery is used to power the sensor, then the sensor can function independently, but high costs are incurred due to compliance with maintenance intervals and replacement
Solution Approach 1:
The thermoelectric energy harvesting system converts the temperature gradient present in the application environment into electrical energy, enabling the sensor to power itself without external battery intervention. This eliminates all costs associated with battery maintenance, replacement, and compliance with maintenance intervals.
3Use of energy by moving object
If cables are used to supply power to the sensor, then continuous power is available, but installation complexity and wiring effort increase
Solution Approach 1:
The patent extracts the power supply function from external sources (batteries or cables) and integrates it directly into the screw itself through an embedded thermocouple. This eliminates the need for separate power supply components and wiring, simplifying both installation and the overall system structure.
4Power
If batteries are used in high-temperature or rotating environments, then power supply is provided, but batteries cannot be used due to high temperatures and environmental constraints
Solution Approach 1:
The patent replaces the chemical energy storage system (battery) with a thermoelectric energy conversion system (thermocouple). This substitution allows the sensor to operate in high-temperature and rotating environments where batteries would fail, as the thermocouple directly converts thermal gradients into electrical energy without chemical reactions or moving parts.
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
This solution provides a cost-effective, maintenance-free power supply for sensor systems, enabling continuous operation without cables or batteries, even in environments where traditional power sources are impractical, and enhances energy harvesting efficiency by leveraging temperature gradients.
Implementation Method 1
Energy supply means in the form of thermocouples enable the use of a temperature difference to generate electricity
Data Source
Figure 1
Figure 2a~2b
Figure 3a
AI summary
The invention relates to a connecting means (10, 10', 10'', 10''', 10'''') having the following features: a power supply means in the form of at least one thermocouple (18, 18'), the at least one thermocouple (18, 18') being recessed into the connecting means (10, 10', 10'', 10''', 10'''') or a shaft (14) of the connecting means (10, 10', 10'', 10''', 10'''').