Structurally embedded and inhospitable environment systems and devices having autonomous electrical power sources

Patent metadata

Field	Value
Publication number	US-9893261-B1
Application number	US-201715484054-A
Country	US
Kind code	B1
Filing date	Apr 10, 2017
Priority date	Apr 10, 2017
Publication date	Feb 13, 2018
Grant date	Feb 13, 2018

Abstract

A method for producing an electrically-powered device and/or component that is embeddable in a solid structural component is provided. The electrically powered device includes an attached autonomous electrical power source in a form of a unique, environmentally-friendly structure that is configured to transform thermal energy at any temperature above absolute zero to an electric potential without any external stimulus including physical movement or deformation energy. The autonomous electrical power source component provides a mechanism for generating renewable energy as primary for the electrically-powered device and/or component once an integrated structure including the electrically-powered device is deployed in an environment that restricts future access to the electrical power source for servicing, recharge, replacement, replenishment or the like. The structure of the autonomous electrical power source component converts minimal thermal energy to a usable electrical power potential over a sustained period of time without external disturbance to the power source.

First claim

We claim:

1. A method for forming an embeddable integrated electrical package, comprising:
providing at least one electrically-driven component;
forming an electrical power source component configured to provide an electrical energy source for the at least one electrically-driven component by
arranging a first conductor, formed of a first conductive material and having a first surface and a second surface, on a build surface with the first surface of the first conductor facing away from the build surface,
conditioning the first surface of the first conductor to have a work function in a range of 1.0 electron volts (eV) or less,
forming a dielectric layer with a thickness of 200 nm or less over the conditioned first surface of the first conductor, and
arranging a second conductor, formed of a second conductive material and having a first surface with a work function in a range of 2.0 eV or greater, and a second surface, over the formed dielectric layer such that the first surface of the second conductor faces the dielectric layer,
the first conductor, the dielectric layer and the second conductor forming a layered structure of an electrical power source component element;

connecting a first electrical lead and a second electrical lead between the at least one electrically-driven component and the electrical power source component to electrically connect the electrically driven component and the electrical power source component; and
encasing the at least one electrically-driven component and the electrical power source component in a common outer shell to provide the embeddable integrated electrical package.

2. The method of claim 1 , a structure of the electrical power source component having a thickness in a range of less than 5 mils.

3. The method of claim 1 , the conditioning of the first surface of the first conductor comprising surface treating the first 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.

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

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

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 , the dielectric layer having a thickness in a range of 100 nm or less and being sandwiched between the first surface of the first conductor and the first surface of the second conductor.

9. The method of claim 8 , the dielectric layer having a thickness in a range of 20 nm to 60 nm.

10. The method of claim 8 , the dielectric layer varying in thickness across a planform of the dielectric layer between the first surface of the first conductor and first surface of the second conductor.

11. The method of claim 1 , 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 end facing the first surface of the second conductor and comparatively smaller at an end facing the first surface of the first conductor.

12. The method of claim 1 , the dielectric layer being a porous layer, pores in the porous layer being filled at least in part with a metal cation.

13. The method of claim 1 , the electrical power source component being comprised of a plurality of electrical power source component elements and a plurality of insulating layers arranged in a stacked structure,
the plurality of electrical power source component elements being separated by the plurality of insulating layers in the stacked structure, and
the plurality of electrical power source component elements being electrically interconnected with one another.

14. The method of claim 13 , each of the plurality of insulating layers having a thickness of less than 10 μm.

15. The method of claim 13 , the electrical power source component further comprising an outer insulating layer substantially encasing the stacked structure.

16. The method of claim 13 , the first electrical lead being electrically connected to an uppermost electrical power source component element in the stacked structure and the second electrical lead being electrically connected to a lowermost electrical power source component element in the stacked structure.

17. The method of claim 1 , further comprising embedding the embeddable integrated electrical package as an integral portion of a structural member.

18. The method of claim 17 , the structural member substantially fully encasing the embeddable integrated electrical package.

19. The method of claim 17 , the structural member being one of a portion of a building structure or a portion of a vehicle structure.

20. The method of claim 1 , the at least one electrically-driven component comprising one or more of an environmental sensor, a seismic sensor, a wireless communicating component, and a haptic alert/warning device.

Assignees

• Face Int Corp

Inventors

• Boyd Clark D
• Face Bradbury R
• Shepard Jeffrey D

Classifications

• H01J45/00

  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

• G01V1/16

  Receiving elements for seismic signals; Arrangements or adaptations of receiving elements · CPC title

• H02J50/001

  Energy harvesting or scavenging · CPC title

• H02J7/34

  Parallel operation in networks using both storage and other DC sources, e.g. providing buffering (H02J7/14 takes precedence) · CPC title

• H10W42/00

  Arrangements for protection of devices (arrangements for thermal protection H10W40/00) · CPC title