Energy converter system, method of fabrication, and method of operation
AssigneeSpark Thermionics, Inc.
InventorsLucas Heinrich Hess, Felix T. Schmitt, Jared William Schwede
Life of this patent
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Abstract
An energy converter system, preferably including one or more thermionic energy converters and optionally including an electrical power converter. A method of fabrication for an energy converter system, preferably including placing braze material, heating the system, and cooling the system. A method of operation for an energy converter system, preferably including providing a heat source, converting thermal energy to electrical energy, and providing one or more electrical energy outputs.
Claims20
A thermionic energy converter (TEC) comprising:
- an emitter body comprising:
- a first electrical output;
- and
- an emitter face electrically coupled to the first electrical output;
- a collector body comprising:
- a second electrical output;
- and
- a collector face opposing the emitter face across a gap defined between the collector face and the emitter face;
- and
- a seal that mechanically connects the emitter body to the collector body, wherein the seal does not electrically connect the emitter body to the collector body, the seal comprising:
- an insulator arranged between the collector body and the emitter body, the insulator bonded to the emitter body, wherein the TEC defines an interfacial volume between the insulator and the collector body;
- and
- a braze material;
- wherein:
- the collector body defines:
- an interior surface;
- and
- an exterior surface separate from the interior surface;
- the TEC defines a chamber interior bounded by the emitter body, the seal, and the interior surface of the collector body;
- the braze material substantially fills the interfacial volume, thereby bonding the insulator to the collector body;
- and
- the braze material extends beyond the interfacial volume to conformally coat a portion of the exterior surface of the collector body, thereby functioning as a protective coating for the portion of the exterior surface.
A method for fabricating a thermionic energy converter (TEC), the method comprising:
- arranging an assembly, comprising:
- arranging a first active braze alloy (ABA) portion between an emitter body and an insulator;
- and
- arranging a second ABA portion between a collector body and the insulator, wherein the emitter body and the collector body are electrically conductive, wherein the insulator is electrically insulating;
- and
- after arranging the assembly, brazing the assembly such that:
- the assembly defines a chamber interior bounded by the emitter body, the first ABA portion, the insulator, the second ABA portion, and an interior surface of the collector body;
- the first ABA portion substantially fills a first interfacial volume defined between the insulator and the emitter body such that the first interfacial volume does not fluidly couple the chamber interior to an ambient environment surrounding the assembly, thereby mechanically bonding the insulator to the emitter body;
- the second ABA portion substantially fills a second interfacial volume defined between the insulator and the collector body such that the second interfacial volume does not fluidly couple the chamber interior to the ambient environment, thereby mechanically bonding the insulator to the collector body;
- the second ABA portion extends beyond the second interfacial volume to conformally coat a portion of an exterior surface of the collector body, thereby functioning as a protective coating for the portion of the exterior surface, wherein the exterior surface is separate from the interior surface;
- and
- the first ABA portion does not contact the second ABA portion and does not contact the emitter body.
Dependencies are inferred from the claim text.