Methods for fabrication, manufacture and production of an autonomous electrical power source

Patent metadata

Field	Value
Publication number	US-11069848-B2
Application number	US-202016774710-A
Country	US
Kind code	B2
Filing date	Jan 28, 2020
Priority date	Apr 10, 2017
Publication date	Jul 20, 2021
Grant date	Jul 20, 2021

Abstract

A method for forming a unique, environmentally-friendly micron scale autonomous electrical power source is provided in a configuration that generates renewable energy for use in electronic systems, electronic devices and electronic system components. The configuration includes a first conductor with a facing surface conditioned to have a low work function, a second conductor with a facing surface having a comparatively higher work function, and a dielectric layer, not more than 200 nm thick, sandwiched between the respective facing surfaces of the first conductor and the second conductor. The autonomous electrical power source formed according to the disclosed method is configured to harvest minimal thermal energy from any source in an environment above absolute zero. An autonomous electrical power source component is also provided that includes a plurality of autonomous electrical power source constituent elements electrically connected to one another to increase a power output of the autonomous electrical power source.

First claim

I claim:

1. A method for forming an electrical power source element, comprising:
forming a first conductor of a first conductive material on a support surface, the first conductor having a first facing surface facing away from the support surface and a second surface opposite the first surface facing the support surface;
surface conditioning the first facing surface of the first conductor to have a comparatively low work function value measured in electron volts (eV);
providing a second conductor formed of a second conductive material, the second conductor having a first facing surface and a second surface opposite the first facing surface, the first facing surface of the second conductor having a work function value in a range of at least 1.0 eV greater than the work function value of the surface conditioned first facing surface of the first conductor; and
arranging the second conductor such that the first facing surface of the second conductor faces the first facing surface of the first conductor, the second conductor being arranged to form a gap between the first facing surface of the first conductor and the first facing surface of the second conductor, the gap being in a range of 200 angstroms or less in thickness, such that a resultant structure of the electrical power source element promotes electron migration between said first conductor and said second conductor through quantum tunneling effects, causing the electrical power source element to generate an electric potential between the first conductor and the second conductor at any temperature above absolute zero.

2. The method of claim 1 , the conditioning of the first facing surface of the first conductor comprising surface treating the first facing surface of the first conductor to lower the work function of the first surface to be in the range of 1.0 eV or less.

3. The method of claim 1 , the conditioning of the first surface of the first conductor comprising forming a separate material layer having a work function in the range of 1.0 eV or less on the first facing surface of the first conductor.

4. The method of claim 3 , the separate material layer being in a range of 1 nm or less in thickness.

5. The method of claim 4 , the separate material layer being a separate physical layer in intimate contact with the first facing surface of the first conductor.

6. The method of claim 1 , the first conductor and the second conductor each having a thickness in a range of 10 nm or less.

7. The method of claim 1 , the conductive material from which the first conductor is formed being graphene.

8. The method of claim 1 , further comprising forming a layer of a dielectric material in the gap between the first facing surface of the first conductor in the first facing surface of the second conductor.

9. The method of claim 8 , the dielectric layer being formed to have a thickness in a range of 100 angstroms or less and being sandwiched between the first facing surface of the first conductor and the first facing surface of the second conductor.

10. The method of claim 9 , the dielectric layer being formed to have a thickness in a range of 20 angstroms to 60 angstroms.

11. The method of claim 9 , the dielectric layer being formed to have a varying thickness across a planform of the dielectric layer between the first facing surface of the first conductor and the first facing surface of the second conductor.

12. The method of claim 8 , the dielectric layer being formed at least in part of a plurality of tapered shapes, each of the plurality of tapered shapes having a tapered structure in which a cross-sectional area of the each of the plurality of tapered shapes is comparatively larger at an and facing the first facing surface of the second conductor and comparatively smaller at an end facing the first facing surface of the first conductor.

13. The method of claim 8 , the dielectric layer being formed of a porous material, a plurality of pores in the porous material being filled at least in part with a metal cation.

14. The method of claim 1 , forming an insulating layer in contact with at least one of the second surface of the first conductor and the second surface of the second conductor.

15. The method of claim 1 , further comprising placing a first electric lead in electrical contact with the second surface of the first conductor and a second electrical lead in electrical contact with the second surface of the second conductor,
the first electrical lead and the second electrical lead being configured to electrically connect the electrical power source element to a load.

16. A method for forming an electrical power source component, comprising:
forming an insulating layer on a supporting surface;
forming an electrical power source element on the insulating layer by,
arranging a first conductor of a conductive material on the insulating layer, the first conductor having a first facing surface facing away from the insulating layer and a second surface opposite the first surface facing the insulating layer,
surface conditioning the first facing surface of the first conductor to have a work function value in a range of 1.0 eV or less,
forming a dielectric layer having a thickness in a range of 200 angstroms or less over the surface conditioned first facing surface of the first conductor,
arranging a second conductor having a first facing surface and a second surface opposite the first facing surface over the dielectric layer, the first facing surface of the second conductor having a work function value in a range of 2.0 eV or greater, and facing the dielectric layer, the second conductor being arranged to form a gap between the first facing surface of the first conductor and the first facing surface of the second conductor, the gap being in a range of 100 Angstroms or less in thickness, such that a resultant structure of the electrical power source element promotes electron migration between said first conductor and said second conductor through quantum tunneling effects, causing the electrical power source element to generate an electric potential between the first conductor layer and the second conductor layer at any temperature above absolute zero;

forming another insulating layer on the electrical power source element;
repeating the forming the electrical power source element and the forming the another insulating layer steps until a desired stack of a number of electrical power source elements, each sandwiched between opposing insulating layers, is formed as a stacked structure;
electrically interconnecting the stacked number of electrical power source elements; and
encasing the stacked structure of the number of electrical power source elements in an outer insulating material structure.

17. The method of claim 16 , each of the electrical power source elements being formed to be less than 300 nm thick.

18. The method of claim 16 , each of the another insulating layers being formed to have a thickness of less than 10 μm.

19. The method of claim 16 , the dielectric layer being formed to have a thickness in a range of 20 angstroms to 60 angstroms, and to be sandwiched between the first facing surface of the first conductor and the first facing surface of the second conductor.

20. The method of claim 16 , the repeating the forming of the electrical power source element and the forming the another insulating layer steps continuing until at least 50 electrical power source elements separated by the another insulating layers is provided in the stacked structure,
an over

Assignees

• Face Int Corp

Inventors

• Boyd Clark D

Classifications

• H01J45/00 Primary

  Discharge tubes functioning as thermionic generators {(structural combination of fuel element with thermoelectric element G21C3/40; nuclear power plants using thermionic converters G21D7/04; structural combination of a radioactive source with a thermionic converter, e.g. radioisotope batteries G21H1/10; generators in which thermal or kinetic energy is converted into electrical energy by ionisation of a fluid and removal of the charge therefrom H02N3/00)} · CPC title

• H01L35/32

  Electricity · mapped topic

• H01L35/34 Primary

  Electricity · mapped topic

• H10N10/17

  characterised by the structure or configuration of the cell or thermocouple forming the device · CPC title

• H10N10/01 Primary

  Manufacture or treatment · CPC title