Abstract: A multi-layer superlattice quantum well thermoelectric material comprising at least 10 alternating layers has a layer thickness of each less than 50 nm, the alternating layers being electrically conducting and barrier layers, wherein the layer structure shows no discernible interdiffusion leading to a break-up or dissolution of the layer boundaries upon heat treatment at a temperature in the range from 50 to 150° C. for a time of at least 100 hours and the concentration of doping materials in the conducting layers is 1018 to 1023 cm?3 and in the barrier layers is 1013 to 1018 cm?3.

Abstract: A self-powered food heater. The food heater includes a burner with an electric fuel pump and an electric blower, a fire box, a water tank and electronic controls. The food heater also includes a set of thermoelectric modules compressed against a heat transfer surface of the tank. Hot exhaust leaving the burner enters the fire box. Some of the heat from the fire box passes through the thermoelectric modules generating sufficient electric power to power the fuel pump and the blower. Water in the tank is heated to its boiling temperature. Heat from the boiling water heats food also contained in the tank. In a preferred embodiment special compression frames provide substantially uniform compression, within desired ranges, of the modules between a portion of the heat transfer surface of the tank and a module cover plate.

Abstract: A quickly attachable electric generator device for producing electric power from surfaces of hot or cold pipes. The invention provides a thermoelectric unit which includes a pedestal comprised of a material with high thermal conductivity on which a thermoelectric module is located. The pedestal includes a heat transfer element made to conform to a hot or cold cylindrical surface. The module also includes a module-to-air heat transfer element and the thermoelectric module is compressed between the air-to-module element and the pedestal. This element is referred to as a heat sink when energy is extracted from a hot surface and is referred to as a heat source when energy is flowing from the air and a cold surface. In preferred embodiments the heat transfer element is a thin flexible heat conductor that conforms to the hot or cold surface of various shapes and serves as a heat transfer conduit to transfer heat to or from a rigid portion of the pedestal.

Abstract: A quantum well thermoelectric module providing very high conversion of heat energy in to electrical energy. In prefered embodiments the module provides electric power for monitoring, measuring or detecting any of a variety of things (such as temperature, smoke, other pollution, flow, fluid level and vibration) and a transmitter for transmitting information measured or detected. In a preferred embodiment wireless monitor systems are utilized to monitor conditions at various locations aboard a ship and to wirelessly transmit information about those conditions to a central location. Preferably, a finned unit is provided to efficiently transfer heat from a module surface to the environment. A preferred quantum well choice is p type B9C/B4C and n-type Si/SiGe legs. Another preferred choice is n-doped Si/SiGe for the n-legs and p-doped Si/SiGe for the p-legs.

Abstract: A super-lattice thermoelectric device. The device is comprised of p-legs and n-legs, each leg being comprised of a large number of very thin alternating layers of two materials with differing electron band gaps. The n-legs in the device are comprised of alternating layers of Si and SiC. The p-legs are comprised of alternating layers of B4C and B9C. In preferred embodiments the layers are about 100 angstroms thick. Thermoelectric modules made according to the present invention are useful for both cooling applications as well as electric power generation. This preferred embodiment is a thermoelectric 10×10 egg crate type module about 6 cm×6 cm×0.76 cm designed to produce 70 Watts with a temperature difference of 300 degrees C. with a module efficiency of about 30 percent. The module has 98 active thermoelectric legs, with each leg having more than 3 million super-lattice layers.

Abstract: A super-lattice thermoelectric device. The device includes p-legs and n-legs, each leg having a large number of alternating layers of two materials with differing electron band gaps. The n-legs in the device are comprised of alternating layers of silicon and silicon germanium. The p-legs includes alternating layers of B4C and B9C. In preferred embodiments the layers are about 100 angstroms thick. Applicants have fabricated and tested a first Si/SiGe (n-leg) and B4C/B9C (p-leg) quantum well thermocouple. Each leg was only 11 microns thick on a 5 micron Si substrate. Nevertheless, in actual tests the thermocouple operated with an amazing efficiency of 14 percent with a Th of 250 degrees C. Thermoelectric modules made according to the present invention are useful for both cooling applications as well as electric power generation. This preferred embodiment is a thermoelectric 10×10 egg crate type module about 6 cm×6 cm×0.

Abstract: A tracking device for tracking a vehicle in which a radio transmitter is powered by heat energy of the exhaust system of an engine propelling the vehicle. A thermoelectric module is attached to a hot portion of the exhaust system. Electrical power generated by the thermoelectric module is used to power the transmitter. A preferred tracking device consists of one thermoelectric module, one transmitter, a flexible finned plate for dissipating heat, and two high Curie temperature magnets for attaching the device to the vehicle's tail pipe. The transmitter is mounted on the flexible finned plate with a thermal insulator in-between them.

Abstract: An electric generator system for producing electric power from the environmental temperature changes such as occur during a normal summer day on Earth or Mars. In a preferred embodiment a phase-change mass is provided which partially or completely freezes during the relatively cold part of a cycle and partially or completely melts during the relatively hot part of the cycle. A thermoelectric module is positioned between the phase-change mass and the environment. The temperature of the phase-change mass remains relatively constant throughout the cycle. During the hot part of the cycle heat flows from the environment through the thermoelectric module into the phase change mass generating electric power which is stored in an electric power storage device such as a capacitor or battery. During the cold part of the cycle heat flows from the phase change mass back through the module and out to the environment also generating electric power that also is similarly stored.

Abstract: A superlattice thermoelectric device. The device includes p-legs and n-legs, each leg includes a large number of at least two different very thin alternating layers of elements. The n-legs in the device includes alternating layers of silicon and silicon carbide. In preferred embodiments p-legs include a superlatice of B-C layers, with alternating layers of different stoichiometric forms of B-C. This preferred embodiment is designed to produce 20 Watts with a temperature difference of 300 degrees C. with a module efficiency of about 30 percent. The module is about 1 cm thick with a cross section area of about 7 cm2 and has about 10,000 sets of n and p legs each set of legs being about 55 microns thick and having about 5,000 very thin layers (each layer about 10 nm thick).

Abstract: A heat of fusion thermoelectric generator. A heat source is in thermal contact with a phase change material, wherein the heat source is capable of providing sufficient heat so as to be able to melt the phase change material. The phase change material is in thermal contact with a hot side heat sink. At least one thermoelectric module is disposed between and in thermal contact with the hot side heat sink and a cold side heat sink. Electric power is generated by the thermoelectric module from a temperature difference between the hot side heat sink and the cold side heat sink.

Abstract: A self-powered space heater. At least one thermoelectric module is sandwiched between a hot surface of a combustion chamber of a fluid fired space heater and a room air-cooled heat exchanger for transferring heat from the space heater to room air. A blower circulates room air through the heat exchanger for the dual purpose of heating the room air and also removing heat from the heat exchanger. In a preferred embodiment two thermoelectric modules are utilized in a diesel fuel fired space heater to provide heated air for the cab of a diesel truck. Spherical self-alignment washers are used in a compression frame to apply uniform compression force to both hot and cold sides of the thermoelectric modules. The two modules provide about 25 Watts output that is more than sufficient power to operate the heater that requires about 20 Watts. Extra power can be used for other purposes such as battery charging.

Abstract: A low-cost thermoelectric module utilizing a greatly reduced quantity of thermoelectric material as compared to similar prior art thermoelectric modules. An egg crate design containing thermoelectric elements is utilized in the present invention. However, the walls of the egg crate in the parts of the module separating the thermoelectric elements are made thick so that the total cross sectional area of the elements is less than 75 percent of the total module cross sectional area. The spaces above and below the elements are filled with a high heat and electric conducting material such as aluminum. This produces funnel-shaped conductors funneling heat and electric current into and out of each of the thermoelectric elements. The payoff to this approach is that the heat flux through the hot and cold module surfaces can be maintained while producing the same power output with about half the thermoelectric material or less.

Abstract: A powder injection molding and infiltration process. A powder of a skeleton material having a relatively high melting point is mixed with a composite binder to form a mold mixture. The composite binder is comprised of at least two binder materials. The mold mixture is molded into a desired shape in a mold device to produce a molded part. The composite binder is then removed to produce voids in the molded part and the voids are filled by infiltrating an infiltrant comprised of an infiltrant material having a relatively low melting point to produce a composite molded part. In a preferred embodiment the skeleton material is TiB2 and the infiltrant material is aluminum and the composite binder is comprised of a plastic and a wax. In this embodiment the wax portion of the composite binder is removed using a solvent and the plastic is removed during the infiltration step. The resulting composite part has a TiB2 skeleton with voids substantially filled with aluminum.

Abstract: A combustion heat powered portable electronic device. At least one thermoelectric module is sandwiched between a hot block heated by a combustion heat source and a cold-side heat sink and provides electric power to a portable electronic device from the temperature difference. An electric circuit provides power for purposes of operating the portable electronic device either directly or indirectly by charging a rechargeable battery which in turn provides power to the electronic device. In a preferred embodiment the combustion heat source is a catalytic combustion unit. The hot block and/or cold side heat sink can be integrated into a single unit with the thermoelectric module. In a preferred embodiment the cold side heat sink is cooled by fins cooled by air driven by a forced air fan powered by the thermoelectric module.

Abstract: Thermoelectric elements for use in a thermoelectric device. The thermoelectric elements have a very large number of alternating layers of semiconductor material deposited on a very thin flexible substrate. The layers of semiconductor material alternate between barrier semiconductor material and conducting semiconductor material creating quantum wells within the thin layers of conducting semiconductor material. The conducting semiconductor material is doped to create conducting properties. The substrate preferably should be very thin, a very good thermal and electrical insulator with good thermal stability and strong and flexible. In a preferred embodiment, the thin organic substrate is a thin polyimide film (specifically Kapton.RTM.) coated with an even thinner film of crystalline silicon. The substrate is about 0.3 mills (127 microns) thick. The crystalline silicon layer is about 0.1 micron thick. This embodiment includes on each side of the thin Kapton.RTM.

Abstract: Thermoelectric elements for use in a thermoelectric device. The thermoelectric elements have a very large number of alternating layers of semiconductor material deposited on a very thin organic substrate. The layers of semiconductor material alternate between barrier semiconductor material and conducting semiconductor material creating quantum wells within the thin layers of conducting semiconductor material. The conducting semiconductor material is doped to create conducting properties. The substrate preferably should be very thin, a very good thermal and electrical insulator with good thermal stability and strong and flexible.

Abstract: A stovepipe thermoelectric generator. The unit fits in a stovepipe of a coal or wood stove. At least one thermoelectric module is sandwiched between a hot side fin unit with fins extending into the flow of exhaust gases and a cold side fin unit with fins cooled by forced room air. A damper controls exhaust gas flow through a heat chamber, directing the exhaust gas through a generating side and a bypass side depending on a temperature indication. This prevents heat damage to the thermoelectric module. At least one fan is provided to force room air through cooling fins of the cold side fin unit An electric circuit is described for providing power for the fan and providing additional electric power for purposes such as charging a battery.

Abstract: A self-powered combustion furnace unit. A combustion furnace providing circulating hot fluid heating is equipped with a thermoelectric generator comprised of a plurality of thermoelectric modules mounted on the furnace. The heat from the combustion provides a high temperature hot side heat source for the thermoelectric modules and the fluid of the circulating hot fuid system provides the cold side heat sink for the thermoelectric modules. Electric power produced by the thermoelectric modules powers a motor driving a pump which circulates the circulating hot fluid. In a preferred embodiment low cost, high temperature thermoelectric modules are provided which comprise thermoelectric elements installed in injection molded eggcrates. The thermoelectric modules are held in close contact with the hot side heat exchanger and the cold side heat sink with a spring force such as that provided by Belville springs.

Abstract: A method for fabricating a thermoelectric module with thermoelectric elements installed in an gapless eggcrate. This gapless eggcrate provides insulated spaces for a large number of p-type and n-type thermoelectric elements. The absence of gaps in the walls of the spaces virtually eliminates the possibility of interwall shorts between the elements. Thermoelectric elements, both p-type and n-type, are inserted into the insulated spaces in the gapless eggcrate to provide the desired thermoelectric effects . Electrical connections are established on both the hot and cold sides of the module to connect the thermoelectric elements in series or parallel as desired. Normally, most or all of the elements will be connected in series. In a preferred embodiment the gapless eggcrate is formed from a high temperature plastic. P-type thermoelectric material is extruded and then sliced to form p-type thermoelectric elements, and n-type thermoelectric material is extruded and sliced to form n-type thermoelectric elements.

Abstract: An aspirated wick atomizer nozzle device having a nozzle body and a screen wire wick sandwiched between the an outlet surface of the nozzle body and the inside surface of a nozzle cap. A liquid entering the nozzle body through a fuel inlet passes by a wicking action of the screen wire wick to a fuel and air exit port where it is entrained and atomized by a gas exiting the nozzle body through an air outlet orifice.