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 thermoelectric generator system. The thermoelectric generator has at least one hot side heat exchanger and at least one cold side heat exchanger and at least one thermoelectric module with thermoelectric elements installed in an injection molded eggcrate. The thermoelectric modules are held in close contact with the hot side heat exchanger and the cold side heat sink with a spring force. A preferred embodiment contains eight modules held in compression between the hot and cold heat exchangers with Belville springs. The eggcrate is molded from a high temperature plastic with ridges provided for extra strength and tapered walls to permit ease of installation of the thermoelectric elements and stop tabs assure correct positioning of the elements. Electrical connections at hot and cold surfaces are preferably made by thermal spraying metallize coatings on the surfaces and then surface finishing the module to expose the walls of the eggcrate.

Abstract: A thermoelectric module having a gapless insulating eggcrate providing 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. Electrical connections on both the hot and cold sides of the module electrically connect the elements in series or in parallel as desired. Usually, 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. In a preferred embodiment, two lead wires are added before adding the hot and cold side electrical connections. In this embodiment, electrical connections on the hot and cold sides comprise a thin layer of molybdenum and a coating of aluminum over the molybdenum. The surfaces are ground down to expose the insulating eggcrate walls except where connections between the elements are desired.

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: A thermoelectric generator for producing electric power for a motor vehicle from the heat of the exhaust gasses produced by the engine of the motor vehicle. The exhaust gasses pass through a finned heat transfer support structure which has seat positions on its outside surface for the positioning of thermoelectric modules. A good contact cylinder provides a framework from which a spring force can be applied to the thermoelectric modules to hold them in good contact on their seats on the surface of the heat transfer support structure.

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.

Abstract: A combustion device for producing predetermined radiation spectral output and heat for a variety of applications including lighting, cooking, heating water, electric power generation, and providing inexpensive photons to enhance chemical and physical reactions.A process for the preparation of a porous ceramic burner is described which comprises drawing a solution which contains metal oxide fibers onto a burner skeleton by use of a vacuum to form a base fiber layer. The base fiber layer is dried, after which an additional metal oxide fiber layer, the outer fiber layer, is added over the base fiber layer. In another embodiment of the invention, an intermediate fiber layer is placed over the base layer, prior to the addition of the outer fiber layer.

Abstract: Embodiments of gas-fired appliances which generate sufficient electricity to be self-powered include water heaters, space heaters, air conditioning units, and electric power and steam cogeneration systems. In such apparatus, gas is burned in a porous ceramic surface combustion burner. The high temperature surface of the burner includes a narrow band quantum emitting substance such as a rare earth metal oxide and preferably ytterbium oxide. Relatively shorter wavelength radiation from this quantum emitting surface illuminates photovoltaic cells having an absorption spectrum matched to the emission spectrum of the burner surface for generating sufficient electricity for powering the appliance. An infrared absorbing filter removes relatively longer wavelength radiation which would otherwise heat the photovoltaic cells. The cells are cooled, preferably by a portion of the utility fluid heated by the appliance.

Abstract: A cell for using solar radiation to generate electrical power comprises a direct band gap (or high absorption coefficient) substrate which is formed with at least one hole that extends from one side of the substrate to the other side of the substrate. A p-n junction formed with an emitter and a base is joined to one side of the substrate with the hole allowing means to make electrical contact with the base. A metallic layer is extended through the hole into electrical contact with the base to establish a low resistance path between the base of the p-n junction and the back side of the substrate.

Abstract: A thermoelectric conversion system including a burner assembly and a number of thermoelectric conversion modules for converting thermal energy resulting from the operation of the burner assembly into electrical energy. The burner assembly includes a central combustion chamber and a number of longitudinally extending heat pipes each having an evaporator section and a condenser section with the evaporator sections positioned at spaced locations around the combustion chamber. The system also includes flow means for causing the hot gases provided by the combustion chamber to flow past the evaporator sections. The heat pipes and the conversion modules correspond in number, with each of the modules connected in heat transfer relationship with a corresponding heat pipe condenser section.

Abstract: A thermoelectric converter includes a heat source having a mating face and a heat sink also having a mating face. The converter also includes a thermoelectric conversion module positioned between these faces. The module includes an electrically insulative holder having a first side positioned adjacent the heat source and a second side disposed adjacent the heat sink. The holder includes spaced parallel first walls and spaced parallel second walls extending normal to the first wall so that these first and second walls define an array of compartments with each compartment containing a thermoelectric element. The module further includes a compressed resilient, thermally conductive pad positioned in each compartment.