United States Patent 10,756,248

Bellezza August 25, 2020

Energy conversion apparatus and method of manufacture

Abstract

A new class of thermoelectric and energy conversion apparatus, that enhances the efficiency of converting one form of energy to another using a wide range of energy conversion materials. The new method of stimulating greater electrical conversion using polymers and thermoelectric composite materials that have unique properties similar to commercial superconductors. The invention entails processes that create and interconnect the superconducting polymer layers through an assembly lowering internal resistance, impeding phonon conduction and stimulating increase in electron flow through the device with increased electrical power. The invention includes the use of dopants that are mixed with a polymer solution to build superconducting polymer connections between the thermoelectric device layers.

Inventors: Bellezza; Anthony Paul (Parkesburg, PA)
Applicant Name: Bellezza; Anthony Paul
Family ID: 72140874
Appl. No.: 15/144,630
Filed: May 2, 2016

Related U.S. Patent Documents

Application Number 12547222, Aug 25, 2009
Application Number 61092929, Aug 29, 2008

Current U.S. Class: 1/1

Current CPC Class: H01L 35/32 (20130101); H01L 35/34 (20130101); H01L 35/30 (20130101); H01L 35/06 (20130101); H01L 35/225 (20130101)

Current International Class: H01L 35/32 (20060101); H01L 35/30 (20060101); H01L 35/34 (20060101); H02H 1/00 (20060101)

Field of Search: ;136/248

References Cited [Referenced By]

U.S. Patent Documents

5023230 June 1991 Cheng
2002/0166673 November 2002 Polan
2003/0217766 November 2003 Schroeder
0246650 December 2004 Grigorov

Primary Examiner: Mershon; Jayne L
Attorney, Agent or Firm: Bower; Kenneth Smith; Lyman Patent Services Associates

Claims

I claim:

1. A device for converting a heat to an electrical energy, comprising: a heat source; a heat sink; an electrical load; a solder-less thermoelectric assembly formed from a stack of layers, comprising: one or more copper layers for conducting the heat from the heat source to the stack and the electrical energy from the stack to the load; one or more P-Type semiconductor layers for converting the heat to the electrical energy; one or more copper layers for conducting the heat from the stack to the heat sink and the electrical energy from the stack to the load; one or more N-Type semiconductor layers for converting the heat to the electrical energy; and a coating of superconducting polymer covering each of the copper layers, the one or more P-Type semiconductor layers, and the one or more N-Type semiconductor layers, wherein the coating is carbonized after assembly of the stack of layers; a switching mechanism connecting one or more electrical paths from the stack to the electrical load; and pressure applying member for maintaining the plurality of adjoining layers in an intimate contact.

2. The device of claim 1, wherein a second electrical path from the stack to the electrical load is established before a first electrical path from the stack to the electrical load is severed.

3. The device of claim 2, wherein a quiescent period separates a severing of the first electrical path from the stack to the electrical load and a establishment of the second electrical path to the electrical load.

4. The device of claim 1, wherein one or more of the copper layers or the P-Type semiconductor layers or the N-Type semiconductor layers are formed by a sintering process or a casting process.

5. The device of claim 4, wherein one or more surfaces of one or more of the P-Type semiconductor layers or the N-Type semiconductor layers has an as-cast surface.

6. The device of claim 1, wherein all or part of one or more of the layers in the stack is coated with a metal ion diffusion barrier.

7. The device of claim 1, wherein the coating of superconducting polymer carries the electrical energy between the adjoining layers with one or more superconducting polymer threads for an interconnection while impeding a flow of phonons through the superconducting polymer threads to the adjoining layers.

8. The device of claim 7, wherein the coating of the superconducting polymers is of a sufficient thickness for bridging a gap between one or more irregularities in the adjoining layers.

9. The device of claim 7, wherein the coating of superconducting polymers is resilient for maintaining a flow of the electrical energy between the adjoining layers during a change in a dimension due to different thermal properties and a temperature gradients causing a expansion and a contraction.

10. The device of claim 7, wherein the coating of superconducting polymer prevents an oxidation of the layer during and after formation.

11. The device of claim 7, wherein one or more of the layers in the stack contains a high temperature material for aiding a formation of a superconducting polymer threads in a layered coating.

12. The device of claim 11, wherein the superconducting polymer is a high temperature superconducting polymer derivative.

13. The device of claim 1, wherein one or more of the layers in the stack contains a carbonized hydrocarbon superconducting polymer derivative.

14. The device of claim 1, wherein all or part of one or more layers in the stack are coated with a superconducting material that confirms to a space between the layers that are adjoining.

15. The device of claim 14, wherein the superconducting material is a superconducting polymer paste.

16. The device of claim 15, wherein the superconducting polymer paste contains a metal and a binder.

17. The device of claim 16, wherein the metal is bismuth or copper and the binder includes propylene and a dopant.

18. The device of claim 1, wherein the pressure applying member is a cryogenically conditioned metallic member.

19. The device of claim 1, wherein the pressure applying member is a spring.

20. The device of claim 19, wherein the spring contains a nickel or chromium or iron alloy.

21. The device of claim 1, wherein one or more of a Peltier, a magneto-caloric or an electro-caloric or a superconducting polymer effect reduces a temperature of one or more of the copper layers for producing a greater flow of the electrical energy than can be explained by a temperature difference between the heat source and the heat sink.

22. A device for converting a heat to an electrical energy, comprising: a heat source; a heat sink; an electrical load; a solder-less thermoelectric assembly formed from a stack of layers comprising: one or more first copper layers for conducting the heat from the heat source to the stack and the electrical energy from the stack to the load; one or more P-Type semiconductors for converting the heat to the electrical energy; or more second copper layers for conducting the heat from the stack to the heat sink and the electrical energy from the stack to the electrical load; and one or more N-Type semiconductors for converting the heat to the electrical energy; a switching mechanism connecting one or more electrical paths from the stack to the electrical load; and a pressure applying member for maintaining the layers in a intimate contact; wherein a second electrical path to the electrical load is established before a first electrical path is severed; wherein one or more of the copper layers or the P-Type semiconductor layers or the N-Type semiconductor layers are formed by a sintering process or a casting process; wherein a surface of one or more of the copper layers or the P-Type semiconductor layers or the N-Type semiconductor layers remain in an as cast; wherein a coating of superconducting polymer covers each of the first and second copper layers, the one or more P-Type semiconductor layer and the one or more N-Type semiconductor layers, wherein the coating is carbonized after assembly of the stack of layers, the coating being disposed between at least two components of the stack of layers, the coating carrying the electrical energy between the layers with the superconducting polymer threads interconnected while impeding a flow of photons through the superconducting polymer threads to the layers; wherein the coating of superconducting polymers is of a sufficient thickness for bridging a gap between an irregularity between the layers; wherein the coating of superconducting polymers is resilient for maintaining an electron flow between the layers during changes in a dimension due to a thermal properties of a expansion and a contraction.

Future Patent Applications of parent patent 10,756,248

COMMENT SUMMARY OF THE INVENTION In Part for defining the patent text and possible continuation applications for highly conductive electrical devices

Patent Disclosure Reference:

Laboratory experiments have also shown that superconducting polymer coatings maintain their superconducting properties after being carbonized due to operation at elevated temperatures. For purposes of clarity in this patent application the term superconducting polymer will be used to refer to the as coated and carbonized condition of the superconducting polymer.

Comment: Carbonized Polymers are Graphene. Graphene is resilient and it is widely known now that it repairs itself instantly within electrical interfaces and can be used in high temperature applications without circuit failure. The carbon produced within the interface is Tubostatic and high-purity Graphene. During the production of Bellezza’ thermoelectric device process, high temperature in the operation and production creates very high current within the interface of polymer coated semiconductor and substrate-creating superconducting Tubostatic Graphene.

Patent Disclosure Reference:

The interconnecting superconducting polymer coatings are ajoined together by “cooper paired” electrons that can be of infinite lengths through layers of multiple size thermoelectric devices. The polymers that are the subject of this invention include but are not limited to the non-conjugated, conjugated and saturated polymers, having unique magnetic and electrical properties with cooper pairing electrons as conventional super conductors. The polymers of this invention are superconductive at room temperatures. The superconductive polymer survive high temperatures of a thermoelectric device as a carbonized polymer between the tightly pressed layers of the thermoelectric device.

Comment: Bismuth Tellurium wafers impede the phonon conduction while under high pressure, claim already in filed continuation patent. When pressure is released phonon conduction returns to norm. Tunable heat conduction

Patent Disclosure Reference:

It is also an object of the present invention to develop high temperature thermoelectric devises that operate at the highest theoretical temperatures that can be achieved using carbonized superconducting polymer threads of this invention.

Comment: Possible continuation application used in high temperature electrical devices or furnaces where electrical wires cannot be used.

Patent Disclosure Reference:

It is also an object of the present invention to develop thermoelectric devices that can expand and contract without damaging the interconnecting superconducting polymer threads. The flexing and stretching super conducting polymers of this invention, will tolerate different thermo expansion coefficients of materials used within a thermoelectric device.

Comment: Graphene is resilient and it is widely known now that it repairs itself instantly within electrical interfaces, and can be used in high temperature applications without circuit failure.

Patent Disclosure Reference:

It is still a further object of the present invention to provide a similarly inexpensive, repeatable, forgiving and reliable method of assembly of a Seebeck thermoelectric generator or Peltier device for cooling, heating or atmospheric water harvesting.

Comment: My patents use Pulse Width Modulators to energize the Seebeck and Peltier units. In my patent teachings, I’m the first to operate a Seebeck or Peltier device with a Pulse Width Modulator. Seebeck thermoelectric devices use a switching power supply to generate 200% more power than steady state electrical conduction from the source to the load. The square wave duty cycle has a shorted overlapping wave form.

Patent Disclosure Reference:

It is still a further object of the present invention to provide a light weight, small, inexpensive and reliable replacement for the Sterling engines that are currently used to convert solar radiation gathered by concentrated solar collectors into electrical energy.

Patent Disclosure Reference:

It is still a further object of the present invention to provide a light weight, small, inexpensive and reliable replacement for the Sterling engines in combination with any non-solar heat source

Comment: I have filed a separate patent application in spring 2021 that generates electrical power as a Solar Thermoelectric Generator. The size of the foot print per electrical power generated is fractional in comparison to conventional Photovoltaic solar applications for home or business. My Thermoelectric generator would replace the sterling heat engine in space travel and weigh much less, and can be used in combination of any heat source.

Patent Disclosure Reference:

It is still a further object of the present invention to provide a light weight, small, inexpensive and reliable device for co-generation of power from waste heat of power plants or where ever heat is being discarded.

Comment: Used in combination of any industrial waste heat application.

Patent Disclosure Reference:

It is still a further object of the present invention to provide a light weight, small, inexpensive and reliable device for conversion of vehicle exhaust gas heat into electrical power for accessories or to increase the vehicle’s overall efficiency.

Comment: The beltless auto engine as everything is operated by electric from the Thermoelectric Generator. Auto exhaust wastes 30% of the fuel consumed. Alternator, water pump, AC, fan, heater fan, power steering, radio, battery charging etc.

Patent Disclosure Reference:

It is still a further object of the present invention to provide a light weight, small, inexpensive and reliable system for conversion of heat from geothermal sources to electrical energy

Comment: Sub ground temperatures are 50 degrees F and surface temperature vary. Small geothermal sensors could be used for earth quake seismic activity in remote areas. Power generation under blacktop road surfaces as sub temperatures are 50 degrees F creating a perfect delta T thermoelectric power generator with battery backup for night time use. Street lights, traffic lights est.

Patent Disclosure Reference:

It is still a further object of the present invention to provide a light weight, small, inexpensive and reliable system for generating electrical energy from the temperature difference from one body of water or between water at different depths in the same body of water.

Patent Disclosure Reference:

It is still a further object of the present invention to provide a light weight, small, inexpensive and reliable system for generating electrical energy from the temperature difference between air that is unsaturated and saturated with water vapor.

Comment: Water temperatures varying from cold at the bottom depth to the surface temperature create a perfect delta T. No batteries required or daylight solar to operate. Used for LED navigation lights, warning beacons ect.

Patent Disclosure Reference:

It is still a further object of the present invention to provide a light weight, small, inexpensive and reliable system for generating electrical energy from the temperature difference between living organisms and the ambient conditions.

Comment: Medical body sensors, Watches, Pulse and Temperature monitors, Heart monitor in real time with no wires or batteries. There are many companies marketing and researching different uses.

Patent Disclosure Reference:

It is still a further object of the present invention to provide a light weight, small, inexpensive and reliable system for generating electrical energy from the temperature difference between air that is unsaturated and saturated with water vapor.

Comment: Fast-moving air generates low pressure and results in a temperature decline which could be used in a thermoelectric device.

Patent Disclosure Reference:

It is still a further object of the present invention to provide a solder-less assembly of state of the art devices that convert various forms of energy into electrical power.

Comment: Used in the carbon circuits, as solder does not bond with carbon.

Patent Disclosure Reference:

BACKGROUND OF THE INVENTION

Besides the low Zt factor for converting of power, the constant expanding and contracting of the hot and cold layers of a thermoelectric device create cracks in the soldered layers that results in efficiencies dropping off and eventual failure to the device. The operating temperature of today’s devices is also limited below optimum operating temperatures by the use of low temperature solders. Lower temperatures within the interface layers results in a lower electric power output from the generator assembly. The low temperature solders Tin (Sn) 95% Antimony (Sb) 5% commonly used in today’s devices, re-melt at 235 degrees C., much below the melting point of Bismuth Tellurium Alloys of 650 degrees C. The low operating temperatures with consequent lower interface temperatures make thermoelectric device efficiencies lower.

Comment: My solderless thermoelectric seebeck device can operate at higher temperatures than a soldered Bismuth Tellurium thermoelectric generator. Low temperature solder melts at 235 degrees C. I can use much higher temperatures up to 600 degrees C which increases my delta T, creating more electrical power.

Patent Disclosure Reference:

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT OF THE PRESENT INVENTION

Hot layer 107 as well as cold layers 109 and 111 are made of materials that are good conductors of heat and electricity. The material for making hot and cold layers of the preferred embodiment of the present invention is, but is not limited to copper. Block diagrams of process steps for forming the hot and cold layers of the preferred embodiment of the present invention are found in but not limited to FIG. 2, FIG. 3 and FIG. 4. The process of FIG. 4 forms semiconductor layers that are integral with the hot and cold layers. Other combinations of materials and processes that can be utilized but are not limited to in the formation of hot and cold layers include electrically conducting, semi-conducting and non-conducting materials, thermally conducting, refractory or insulating materials or materials having physical properties of solid, crystaline, lattice structure, amorphous, non-porous, granular, micro-particulate, nano-particulate, porous metal and non-metal structures and are bound together by sintering, cohesive bonds, adhesive bonds, cementitious materials, polymers and epoxies and any one or any combination of the aforementioned materials or processes.

Comment: I have discovered that any material can be used as a substrate of thermoelectric systems after being carbonized as found in the teachings of Bellezza. Cost reduction in producing thermoelectric devices can eliminate the need for costly metals (Copper). Conductive refractory material and cement could be used as ice and snow melting surfaces in conjunction with Bellezza high frequency switching electronic topography that uses low voltage and high current minimizing electric shock of prior art. A polymer/ceramic substrate of electronic circuits using carbonized polymers would be a good replacement for copper laminated circuits est.

Patent Disclosure Reference:

The cold layers 109 and 111 as well as the hot layer 107 are optionally coated with a diffusion barrier to prevent metal ions from migrating into the adjoining layers. The ion diffusion barrier coating of the present invention is but is not limited to Nickel that can be applied with any of the processes well known in the art.

Comment: Bellezza uses Graphene coating process in place of Nickel diffusion barrier. Graphene is the world’s best diffusion barrier known and Bellezza uses Nickel as an option to carbonized polymer.

Patent Disclosure Reference:

The fifth breakthrough of the preferred embodiment of the present invention is a cooling affect of the cold thermo conductive layers during the conversion of heat to electrical energy. This effect shows that the inventive thermoelectric process herein described produce a device that will operate at a higher efficiency than can be explained exclusively by the temperature difference between the heat source and the heat sink.

Comment: Bellezza discovered that while operating a Seebeck device at high frequencies (switching shorted power supply), the Delta T is much different than in the steady state electrical operation. The cold side of the thermoelectric generator is staying near room temperature, while the hot side is hundreds of degrees in temperature (claim 21). This anomaly can only be explained by a Peltier, a magneto-caloric or an electro-caloric or a superconducting polymer effect. This could be used in compressorless refrigeration and air conditioning using no Freon.